Patient-Customizable Device and System for Performing an Orthopaedic Surgical Procedure

• US 20090088761A1
• Filed: 09/29/2008
• Published: 04/02/2009
• Est. Priority Date: 09/30/2007
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Inventors: Rhodes, Matt, Roose, Jeffrey R.
• Granted Patent: US 8,361,076 B2
• Time in Patent Office: Days
• US Class Current: 606/87
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• 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: Y10T 409/30084 with regulation of operation by templet, card, or other replaceable information supply

Abstract

A number of orthopaedic surgical instruments are also disclosed. A method, apparatus, and system for fabricating such instruments are also disclosed.

Claims

1. A customized patient-specific cutting block, comprising:

a cutting block body that comprises (i) a bone-facing surface, (ii) an outer surface opposite the bone-facing surface, (iii) a plurality of guide pin holes formed in the body of the cutting block, and (iv) a cutting guide extending through the cutting block body,

a plurality of guide pins each of which is respectively positioned in one of the plurality of guide pin holes, wherein (i) each of the plurality of guide pins includes a bone-contacting end that extends out of the bone-facing surface of the cutting block body, and (ii) each of the plurality of guide pins is movable relative to the cutting block body such that the bone-contacting ends of the plurality of guide pins collectively create a customized patient-specific negative contour configured to receive a portion of a bone of a patient that has a corresponding contour, and

a securing device operable to lock each of the plurality of guide pins in a desired position so as to create the customized patient-specific negative contour.

2. The customized patient-specific cutting block of claim 1, wherein the customized patient-specific cutting block comprises a customized patient-specific femoral cutting block.

3. The customized patient-specific cutting block of claim 1, wherein the customized patient-specific cutting block comprises a customized patient-specific tibial cutting block.

4. The customized patient-specific cutting block of claim 1, wherein each of the plurality of guide pins is independently movable relative to each other.

5. The customized patient-specific cutting block of claim 1, wherein each of the plurality of guide pins also includes an outer end that extends out of the outer surface of the cutting block body.

6. A customized patient-specific orthopaedic instrument, comprising:

a customized patient-specific cutting block having (i) a body with a cutting guide extending therethrough, and (ii) a plurality of guide pins each of which includes a bone-contacting end that extends out of the body of the cutting block, wherein each of the plurality of guide pins is movable relative to the body of the cutting block such that the bone-contacting ends of the plurality of guide pins collectively create a customized patient-specific negative contour configured to receive a portion of a bone of a patient that has a corresponding contour, and an electronic programming device having (i) a housing having an aperture formed therein, the aperture being configured to receive the customized patient-specific cutting block therein, (ii) and one or more electrically-operated actuators operable to position each of the plurality of guide pins in a desired position so as to create the customized patient-specific negative contour.

7. The customized patient-specific orthopaedic instrument of claim 6, wherein:

the customized patient-specific cutting block further includes a securing device operable to lock each of the plurality of guide pins in the desired position, and

the electronic programming device further includes a coupler configured to operate the securing device of the customized patient-specific cutting block.

8. The customized patient-specific orthopaedic instrument of claim 6, wherein:

the electronic programming device further includes a plurality of holes each of which is configured to receive one of the plurality of guide pins of the customized patient-specific cutting block,

one of a plurality of push rods is located in each of the holes, and

the one or more electrically-operated actuators is operable to position the plurality of push rods in a respective position so as to position each of the plurality of guide pins in the desired position.

9. The customized patient-specific orthopaedic instrument of claim 6, wherein:

the electronic programming device further includes (i) a processor, and (ii) a memory device electrically coupled to the processor, the memory device having stored therein a plurality of instructions which, when executed by the processor, cause the processor to operate the one or more electrically-operated actuators to position each of the plurality of guide pins in the desired position.

10. The customized patient-specific orthopaedic instrument of claim 9, wherein the electronic programming device further includes an input port electrically coupled to the memory device.

11. The customized patient-specific orthopaedic instrument of claim 6, wherein the customized patient-specific cutting block comprises a customized patient-specific femoral cutting block.

12. The customized patient-specific orthopaedic instrument of claim 6, wherein the customized patient-specific cutting block comprises a customized patient-specific tibial cutting block.

13. The customized patient-specific orthopaedic instrument of claim 6, wherein each of the plurality of guide pins is independently movable relative to each other.