Patient specific alignment guide with cutting surface and laser indicator

• US 10,426,492 B2
• Filed: 09/25/2015
• Issued: 10/01/2019
• Est. Priority Date: 02/27/2006
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Metzger, Robert, Schoenefeld, Ryan John, Belcher, Nathan Emick, Uthgenannt, Brian
• Primary Examiner(s): Ku, Si Ming
• Application Number:
  US14/865,762
• Publication Number:
  US 20160008013A1
• Time in Patent Office: 1,467 Days
• CPC Class Codes: A61B 17/15 Guides therefor arrangements for guiding straight saw blades in general B23D51/025
• CPC Class Codes: A61B 17/154 for preparing bone for knee prosthesis
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1675 for the knee
• CPC Class Codes: A61B 17/1703 using imaging means, e.g. by X-rays
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: A61B 2090/3945 Active visible markers, e.g. light emitting diodes
• CPC Class Codes: A61B 2560/0443 Modular apparatus
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• CPC Class Codes: A61B 90/13 guided by light, e.g. laser pointers
• CPC Class Codes: A61F 2002/30617 Visible markings for adjusting, locating or measuring
• CPC Class Codes: A61F 2002/4662 for measuring penetration depth
• CPC Class Codes: A61F 2002/4668 for measuring angles
• CPC Class Codes: A61F 2002/4687 Mechanical guides for implantation instruments
• CPC Class Codes: A61F 2250/0097 Visible markings, e.g. indicia

Abstract

A patient-specific guiding system for guiding an instrument relative to a portion of an anatomical feature of a patient. The patient-specific guiding system includes a patient-specific guide. The guide includes a first portion having a first patient-specific inner surface that conforms to a first surface of the anatomical feature and an outer surface opposite the first patient-specific inner surface. The first portion also includes a guide surface for use in guiding the instrument relative to the anatomical feature. The guide also includes a second portion having a second patient-specific inner surface that conforms to a second surface of the anatomical feature and an outer surface opposite the second patient-specific inner surface. The second portion is removably connected to the first portion.

Claims

1. A patient-specific guiding system for guiding an instrument relative to a portion of an anatomical feature of a patient, the patient-specific guiding system comprising:

a patient-specific guide having;

a first portion having a first patient-specific inner surface that is configured to conform to and mate with a first surface of the anatomical feature in only one position and an outer surface opposite the first patient-specific inner surface, the first portion including a guide surface for use in guiding the instrument relative to the anatomical feature and a fixation feature for coupling the first portion to the first surface of the anatomical feature; and

a second portion having a second patient-specific inner surface that is configured to conform to and mate with a second surface of the anatomical feature in only one position and an outer surface opposite the second patient-specific inner surface, the second portion being removably connected to the first portion;

wherein the first and second patient-specific inner surfaces each have a three dimensional contour that is configured to nest and closely conform to the first and second surfaces, respectively, of the anatomical features, to align the guide relative to the anatomical feature; and

wherein the first and second portions are non-adjustably conformable with the first and second surfaces when the first and second portions are connected to each other to facilitate engagement in a single desired orientation; and

wherein the guide surface is an opening in the first patient-specific inner surface that is configured to receive the instrument.

2. The patient-specific guiding system of claim 1, further comprising a coupling mechanism that couples the first portion directly to the anatomical feature, and wherein the second portion is coupled to the anatomical feature only through the coupling mechanism, by non-adjustably coupling with the first portion.

3. The patient-specific guiding system of claim 1, further comprising a laser coupled to the guide that emits a light that identifies a reference plane for use in aligning the guide surface relative to the anatomical feature.

4. The patient-specific guiding system of claim 3, wherein the reference plane is substantially perpendicular to a cutting plane of the instrument, the instrument cutting the portion of the anatomical feature along the cutting plane.

5. The patient-specific guiding system of claim 3, wherein the reference plane lies in a cutting plane of the instrument, the instrument cutting the portion of the anatomical feature along the cutting plane.

6. The patient-specific guiding system of claim 1, further comprising a cutting guide having a cutting surface that guides a cutting tool for cutting the anatomical feature, the guide surface removably supporting the cutting guide to align the cutting guide relative to the anatomical feature.

7. The patient-specific guiding system of claim 6, wherein the cutting guide is removably connected to the first portion by at least one of a dovetail coupling, a pinned coupling, a scored coupling, a magnetic coupling, and a snap-fit coupling.

8. The patient-specific guiding system of claim 6, further comprising a spacer that is removably interposed between the cutting guide and the first portion to space the cutting guide and the first portion apart at a predetermined distance.

9. The patient-specific guiding system of claim 1, further comprising a secondary cutting guide that guides a cutting tool for cutting the anatomical feature, and a secondary coupling mechanism that couples the secondary cutting guide to the anatomical feature, the guide surface removably supporting the secondary cutting guide to align the secondary cutting guide relative to the anatomical feature, the first portion being removable from the anatomical feature while the secondary cutting guide is coupled to the anatomical feature.

10. A guiding system comprising:

a first component configured to extend along a surface of a bone, the first component comprising;

at least one fixation feature disposed on the first component;

a first coupling feature;

a cutting guide surface located between the at least one fixation feature and the first coupling feature; and

a first interior surface that is patient-specific so as to be configured to conform to the surface of the bone; and

a second component configured to engage a portion of the bone to be resected, the second component comprising;

a second coupling feature configured to interface with the first coupling feature; and

a second interior surface that is patient-specific so as to be configured to conform to an anatomical surface of the portion of the bone to be resected, wherein the second component does not include any fixation features;

wherein the second interior surface is configured to engage the anatomic surface to position the at least one fixation feature at a patient-specific location on the bone when the first component and the second component are coupled together; and

wherein the second component separable from the first component at the interface between the first and second coupling features;

wherein the first and second interior surfaces each have a three-dimensional contour that is configured to nest and closely conform to the surface and the anatomical surface, respectively, of the bone, to align the guide relative to the anatomical surface;

wherein the surface comprises an anterior surface of a distal portion of a femur and the anatomical surface comprises an inferior surface of the distal portion of the femur.

11. The guiding system of claim 10, wherein the first component is patient-specific so as to be configured to conform to the surface of the bone.

12. The guiding system of claim 10, wherein the first cutting guide feature comprises an opening positioned to engage a portion of the bone to be cut.

13. The guiding system of claim 12, wherein the second component is separable from the first component such that the portion of the bone to be resected is visible when a cutting tool is inserted in the first cutting guide feature.

14. The guiding system of claim 10, further comprising a third component comprising:

a third coupling feature configured to join with the first coupling feature; and

a second cutting guide feature extending through the third portion;

wherein the second cutting guide feature extends beyond an outer perimeter of the first portion when the first and third coupling features are engaged.

15. The guiding system of claim 10, further comprising a spacer positioned between the first coupling feature and the second coupling feature.

16. The guiding system of claim 10, further comprising a pin, wherein the at least one fixation feature comprises a through-bore configured to receive the pin to fixedly couple the first component to the bone.

20. The guiding system of claim 10, wherein the first coupling feature and the second coupling feature are configured to mate in only a single orientation.

17. A guiding system comprising:

a first portion having a first interior surface including a first three-dimensional contour that is configured to nest and closely conform to an anterior surface of a femur, the first portion comprising;

at least one through-bore extending through the first portion;

a distal side surface;

a pin extending through the through-bore to form a fixation feature; and

a cutting guide slot defined by an opening extending through the first portion and disposed between the at least one through-bore and the distal side surface; and

a second portion having a second interior surface including a second three-dimensional contour that is configured to nest and closely conform to a distal end of the femur, the second portion comprising;

a proximal side surface configured to join with the distal side surface;

wherein the second portion is separable from the first portion along a joint formed by a coupling feature and configured to extend along the anterior surface of the femur;

wherein the first and second portions are configured to position the cutting guide slot at a patient-specific location on the anterior surface of the femur, and wherein the second portion does not include any fixation features.

18. The guiding system of claim 17, wherein the second portion is couplable to the femur only through joining of the distal side surface and the proximal side surface.

19. The guiding system of claim 17, wherein the second portion is removable from the first portion in a posterior-to-anterior direction at a dovetail coupling.