SYSTEMS AND METHODS FOR PROVIDING PROSTHETIC COMPONENTS

• US 20160228255A1
• Filed: 04/20/2016
• Published: 08/11/2016
• Est. Priority Date: 08/27/2007
• Status: Active Grant

• Current Assignee: Alec C. Samuelson, Connor E. Samuelson, Kent M. Samuelson, Marcus F. Samuelson
• Original Assignee: Alec C. Samuelson, Connor E. Samuelson, Kent M. Samuelson, Marcus F. Samuelson
• Inventors: Samuelson, Connor E, Samuelson, Marcus F., Samuelson, Alec C., Samuelson, Kent M.
• Granted Patent: US 10,213,826 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61F 2/30965 Reinforcing the prosthesis by embedding particles or fibres during moulding or dipping
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/3877 Patellae or trochleae
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2002/30014 differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2002/30028 differing in tissue ingrowth capacity, e.g. made from both ingrowth-promoting and ingrowth-preventing parts
• CPC Class Codes: A61F 2002/30116 partial circles, i.e. circular segments
• CPC Class Codes: A61F 2002/30245 Partial spheres
• CPC Class Codes: A61F 2002/30604 modular
• CPC Class Codes: A61F 2002/30934 Special articulating surfaces
• CPC Class Codes: A61F 2002/3863 Condyles fitted on an anchored base
• CPC Class Codes: A61F 2002/3895 unicompartimental
• CPC Class Codes: A61F 2310/00011 Metals or alloys
• CPC Class Codes: A61F 2310/00179 Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00329 Glasses, e.g. bioglass
• CPC Class Codes: A61F 2310/00353 Bone cement, e.g. polymethylmethacrylate or PMMA
• CPC Class Codes: B22C 9/10 Cores; Manufacture or installation of cores breaker cores B22C9/084
• CPC Class Codes: B22C 9/22 Moulds for peculiarly-shaped castings
• CPC Class Codes: B22D 23/00 : Casting processes not provided for in groups B22D1/00 - B22D21/00 making metallic powder by casting B22F9/08; alumino-thermic welding B23K23/00; remelting metals C22B9/16
• CPC Class Codes: B22D 23/02 : Top casting
• CPC Class Codes: B22D 25/00 : Special casting characterised by the nature of the product B22D15/02, B22D17/16, B22D19/00 take precedence; casting stereotype plates B41D3/00
• CPC Class Codes: B22D 25/02 : by its peculiarity of shape; of works of art cylinders, pistons B22D15/02

Abstract

Methods for forming prosthetic implants, including femoral implants, are discussed. While the methods can include any suitable step, in some cases, they include providing a master negative mold defining an internal space shaped to form a femoral component configured to replace a distal portion of a femur, wherein the femoral component comprises at least one of: an anterior flange that is disposed at an anterior proximal end of the femoral component, and a proximal extension disposed at a proximal portion of a posterior condyle of the femoral component, the proximal extension comprising a concave articulation surface that is configured to articulate against at least one of: a tibial prosthetic component and a tibia; filling the master negative mold with a molding material to form a molded femoral component; and removing at least one of: the anterior flange, and the proximal extension from the molded femoral component to form a modified molded femoral component. Other implementations are described.

Claims

1. A method for forming a prosthetic femoral implant, the method comprising:

providing a master negative mold defining an internal space shaped to form a femoral component configured to replace a distal portion of a femur, wherein the femoral component comprises at least one of;

(i) an anterior flange that is disposed at an anterior proximal end of the femoral component, and (ii) a proximal extension disposed at a proximal portion of a posterior condyle of the femoral component, the proximal extension comprising a concave articulation surface that is configured to articulate against at least one of;

(i) a tibial prosthetic component and (ii) a tibia;

filling the master negative mold with a molding material to form a molded femoral component; and

removing at least one of;

(i) the anterior flange, and (ii) the proximal extension from the molded femoral component to form a modified molded femoral component.

2. The method of claim 1, wherein the modified molded femoral component comprises an implantable, biocompatible femoral component.

3. The method of claim 1, comprising removing the anterior flange to form the modified molded femoral component.

4. The method of claim 1, comprising removing the proximal extension to form the modified molded femoral component.

5. The method of claim 1, comprising removing the proximal extension and the anterior flange to form the modified molded femoral component.

6. The method of claim 1, further comprising:

coating the modified molded femoral component with an investment;

removing the modified molded femoral component from the investment; and

filling the investment with a biocompatible material to form an implantable, biocompatible femoral component.

7. A method for implanting a tibial component, the method comprising:

resecting a proximal portion of a tibia to provide a resected surface that slopes distally at an angle between about 4° and

about 20°

from being perpendicular with a longitudinal axis of a portion of the tibia; and

seating the tibial component on the proximal end of the tibia, such that an undersurface of the tibial component slopes distally at the angle between about 4° and

about 20°

from being perpendicular with the longitudinal axis of the tibia.

8. The method of claim 7, wherein the undersurface of the tibial component slopes distally from an anterior edge of the undersurface of the tibial component to a posterior edge of undersurface of the tibial component.

9. The method of claim 7, wherein the undersurface of the tibial component slopes distally from a posterior edge of the undersurface of the tibial component to an anterior edge of undersurface of the tibial component.

10. The method of claim 7, wherein the tibial component further comprises a stem attached to the undersurface of the tibial component, and wherein the stem is configured to contact an inner surface of a tibial anterior cortex of the tibia when the stem is in the tibia and the undersurface is in contact with the resected proximal portion of the tibia.

11. The method of claim 10, wherein the stem is curved to approximate a contour of the inner surface of the tibial anterior cortex.

20. The guide block of claim 11, wherein the cutting guide block comprises a medial and a lateral component that are configured to be selectively coupled together and decoupled from each other.

12. A femoral component for replacing a distal portion of a femur, the femoral component comprising:

a lateral condyle,

wherein the lateral condyle comprises a first articular surface that is substantially flat in an medial to lateral dimension.

13. The component of claim 12, further comprising a medial condyle,

wherein the medial condyle comprises a second articular surface that is rounded in the medial to lateral dimension.

14. The component of claim 12, wherein a width of the first articular surface is between about 20% and about 99% of a width of a widest portion, medial to laterally, of the lateral condyle.

15. A cutting guide block for resection of a proximal portion of a posterior condyle of a femur, the guide block comprising:

an inner surface configured to sit on a distal end of a femur; and

a first guide configured to align a cutting tool with a proximal portion of a posterior condyle of the femur.

16. The guide block of claim 15, wherein the first guide is configured direct the cutting tool into the proximal portion of the posterior condyle at an angle between about 20°

and about 65°

with respect to a longitudinal axis of a distal portion of the femur.

17. The guide block of claim 16, wherein the first guide is configured direct the cutting tool into the proximal portion of the posterior condyle at an angle between about 35°

and about 55°

with respect to a longitudinal axis of a distal portion of the femur.

18. The guide block of claim 15, wherein the first guide is configured to prevent the cutting tool from cutting a popliteal portion of the femur.

19. The guide block of claim 15, further comprising a second guide that is configured to align the cutting tool with the proximal portion of the posterior condyle of the femur, wherein the first guide is configured to resect a first portion of the proximal portion of the posterior condyle of the femur to prepare the femur for implantation of a first femoral component, wherein the second guide is configured to resect a second portion of the proximal portion of the posterior condyle to prepare the femur for implantation of a second femoral component, wherein the second portion is larger than the first portion, and wherein the second femoral component cannot properly be seated on the femur until the second portion has been resected.