Method of Cranial Repair and Cranial Repair Implant Molding Device

• US 20120265313A1
• Filed: 04/02/2012
• Published: 10/18/2012
• Est. Priority Date: 04/01/2011
• Status: Active Grant

• Current Assignee: KLS-Martin, L.P.
• Original Assignee: KLS-Martin, L.P.
• Inventors: Burke, Shawn, Teague, Michael, Lemoyne, Pat
• Granted Patent: US 8,673,014 B2
• Time in Patent Office: Days
• US Class Current: 623/17.19
• CPC Class Codes: A61F 2/2875 Skull or cranium A61F2/2803 and A61F2/3099 take precedence
• CPC Class Codes: A61F 2/30942 for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques
• CPC Class Codes: A61F 2002/30324 differing in thickness
• CPC Class Codes: B29C 33/308 Adjustable moulds for injection moulding B29C45/376
• CPC Class Codes: B29L 2031/7532 Artificial members, protheses

Abstract

A method of cranial repair and the cranial implant molding device used therein, the device having a frame or base that receives a bottom or convex molding plate and a top or concave molding plate in a manner whereby the two plates are separated a distance to receive a settable or curable implant forming material therebetween. The plates are separated by a compressible member such that by the use of threaded mechanical fasteners or similar members the distance between the two plates can be adjusted by tightening or loosening the mechanical members. The thickness of the implant is varied by varying the separation distance on different sides of the frame.

Claims

1. A cranial implant molding device comprising:

a bottom plate comprising a mold cavity bottom wall, a first and a second bottom plate flange positioned to either side of said mold cavity bottom wall, and a depending wall connecting each of said bottom plate flanges to said mold cavity bottom wall;

a top plate comprising a mold cavity top wall, a first and a second top plate flange positioned to either side of said mold cavity top wall, a depending wall connecting each of said top plate flanges to said mold cavity top wall, and a vent port disposed in said mold cavity top wall;

a base comprising a recess, said bottom plate and said top plate being positioned on said base such that said mold cavity bottom wall and said mold cavity top wall are disposed within said recess and such that said mold cavity bottom wall is separated from said mold cavity top wall to form a mold cavity adapted to receive implant forming material;

at least one mechanical adjustment member extending through said first top plate flange and said first bottom plate flange and into said base, and at least one other mechanical adjustment member extending through said second top plate flange and said second bottom plate flange and into said base, whereby manipulation of said mechanical adjustment members adjusts the distance between said first top plate flange and said first bottom plate flange and between said second top plate flange and said second bottom plate flange, thereby adjusting the distance between said mold cavity top wall and said mold cavity bottom wall.

2. The device of claim 1, wherein said mechanical adjustment members may be independently manipulated, such that the distance between said first top plate flange and said first bottom plate flange may be different from the distance between said second top plate flange and said second bottom plate flange.

3. The device of claim 1, further comprising at least one compressible resilient member disposed between said first top plate flange and said first bottom plate flange, and at least one resilient member disposed between said second top plate flange and said second bottom plate flange.

4. The device of claim 1, wherein said mold cavity bottom wall is generally convex and said mold cavity top wall is generally concave.

5. The device of claim 1, wherein said top plate nests within said bottom plate.

6. The device of claim 1, wherein said recess is four-sided such that said recess retains excess implant forming material therein.

7. The device of claim 1, further comprising a plurality of said top mold plates and a plurality of said bottom mold plates, wherein the configuration of said mold cavity top wall of each said top mold plate is different and wherein the configuration of said mold cavity bottom wall of each said bottom mold plate is different.

8. A cranial implant molding device comprising:

a bottom plate comprising a generally convex mold cavity bottom wall, a first and a second bottom plate flange positioned to either side of said mold cavity bottom wall, and a depending wall connecting each of said bottom plate flanges to said mold cavity bottom wall;

a top plate comprising a generally concave mold cavity top wall, a first and a second top plate flange positioned to either side of said mold cavity top wall, a depending wall connecting each of said top plate flanges to said mold cavity top wall, and a vent port disposed in said mold cavity top wall;

a base comprising a recess, said bottom plate and said top plate being positioned on said base such that said mold cavity bottom wall and said mold cavity top wall are disposed within said recess and such that said mold cavity bottom wall is separated from said mold cavity top wall to form a mold cavity adapted to receive implant forming material;

at least one compressible resilient member disposed between said first top plate flange and said first bottom plate flange, and at least one resilient member disposed between said second top plate flange and said second bottom plate flange;

at least one mechanical adjustment member extending through said first top plate flange and said first bottom plate flange and into said base, and at least one other mechanical adjustment member extending through said second top plate flange and said second bottom plate flange and into said base, whereby manipulation of said mechanical adjustment members adjusts the distance between said first top plate flange and said first bottom plate flange and between said second top plate flange and said second bottom plate flange, thereby adjusting the distance between said mold cavity top wall and said mold cavity bottom wall;

wherein said mechanical adjustment members may be independently manipulated, such that the distance between said first top plate flange and said first bottom plate flange may be different from the distance between said second top plate flange and said second bottom plate flange.

9. The device of claim 8, further comprising a plurality of said top mold plates and a plurality of said bottom mold plates, wherein the configuration of said mold cavity top wall of each said top mold plate is different and wherein the configuration of said mold cavity bottom wall of each said bottom mold plate is different.

10. The device of claim 8, wherein said top plate depending walls are received within said bottom plate depending walls.

11. The device of claim 8, wherein said recess is four-sided such that said recess retains excess implant forming material therein.

12. A method of cranial repair comprising the steps of:

removing a portion of cranial bone to create a defined opening in the cranium;

measuring the removed portion or the remaining cranial edges to determine the dimensions, shape and edge thicknesses of the removed portion;

providing a cranial implant molding device comprising a bottom plate comprising a generally convex mold cavity bottom wall, a first and a second bottom plate flange positioned to either side of said mold cavity bottom wall, and a depending wall connecting each of said bottom plate flanges to said mold cavity bottom wall;

a top plate comprising a generally concave mold cavity top wall, a first and a second top plate flange positioned to either side of said mold cavity top wall, a depending wall connecting each of said top plate flanges to said mold cavity top wall, and a vent port disposed in said mold cavity top wall;

a base comprising a recess, said bottom plate and said top plate being positioned on said base such that said mold cavity bottom wall and said mold cavity top wall are disposed within said recess and such that said mold cavity bottom wall is separated from said mold cavity top wall to form a mold cavity adapted to receive implant forming material;

at least one compressible resilient member disposed between said first top plate flange and said first bottom plate flange, and at least one resilient member disposed between said second top plate flange and said second bottom plate flange;

at least one mechanical adjustment member extending through said first top plate flange and said first bottom plate flange and into said base, and at least one other mechanical adjustment member extending through said second top plate flange and said second bottom plate flange and into said base, whereby manipulation of said mechanical adjustment members adjusts the distance between said first top plate flange and said first bottom plate flange and between said second top plate flange and said second bottom plate flange, thereby adjusting the distance between said mold cavity top wall and said mold cavity bottom wall;

wherein said mechanical adjustment members may be independently manipulated, such that the distance between said first top plate flange and said first bottom plate flange may be different from the distance between said second top plate flange and said second bottom plate flange;

creating a cranial implant by delivering said implant forming material into said mold cavity;

adjusting the separation distance between said bottom mold plate and said top mold plate;

allowing said implant to cure and removing said implant from said cranial implant molding device; and

positioning said implant in said cranial defined opening and securing said implant.

13. The method of claim 12, further comprising the steps of providing a plurality of said top mold plates and a plurality of said bottom mold plates, wherein said mold cavity top wall of each said top mold plate is different and wherein said mold cavity bottom wall of each said bottom mold plate is different;

and

choosing one of said bottom mold plates and one of said top mold plates that best matches said defined opening.

14. The method of claim 12, wherein said step of adjusting the separation distance between said bottom mold plate and said top mold plate is performed prior to said step of creating a cranial implant by delivering said implant forming material into said mold cavity.

15. The method of claim 12, wherein said step of adjusting the separation distance between said bottom mold plate and said top mold plate is performed after said step of creating a cranial implant by delivering said implant forming material into said mold cavity.

16. The method of claim 12, wherein said step of adjusting the separation distance between said bottom mold plate and said top mold plate comprises manipulating said mechanical adjustment member such that the separation distance between said first top plate flange and said first bottom plate flange is different from the distance between said second top plate flange and said second bottom plate flange.

17. The method of claim 12, wherein said step of adjusting the separation distance between said bottom mold plate and said top mold plate comprises manipulating said mechanical adjustment member such that the separation distance between said first top plate flange and said first bottom plate flange is the same as the distance between said second top plate flange and said second bottom plate flange.