Method of design of human joint prosthesis

• US 4,822,365 A
• Filed: 09/11/1987
• Issued: 04/18/1989
• Est. Priority Date: 05/30/1986
• Status: Expired due to Fees

• Current Assignee: Frederick C. Ewald, Walker, Peter S.
• Original Assignee: Frederick C. Ewald, Walker, Peter S.
• Inventors: Walker, Peter S., Ewald, Frederick C.
• Primary Examiner(s): Apley, Richard J.
• Assistant Examiner(s): Cannon, Alan W.
• Application Number:
  US07/097,286
• Time in Patent Office: 585 Days
• Field of Search: 623/18, 623/20-23, 623/66, 364/468, 364/474, 364/475, 364/512
• US Class Current: 128/898
• 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 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3886 for stabilising knees against anterior or lateral dislocations
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2310/00017 Iron- or Fe-based alloys, e.g. stainless steel
• CPC Class Codes: A61F 2310/00023 Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/35012 Cad cam
• CPC Class Codes: G05B 2219/45172 Prosthesis
• CPC Class Codes: G05B 2219/49008 Making 3-D object with model in computer memory
• CPC Class Codes: Y10S 623/914 Bone

Abstract

A method of designing a prosthesis having convex male and concave female mating portions is provided for a human joint comprising a condylar male portion the surface of which is generated by the piecewise analysis of an anatomical condyle, which can be an average condyle or a selected condyle, or a distortion of an average condyle to fit the observed general dimensions of a specific patient, and the female portion having at least flexion and laxity surfaces, the flexion surfaces of which are generated by plotting the path of articulation of substantial points of contact between said male portion and a corresponding anatomical female component for said joint through the full normal extension-flexion range plus normal rotation and posterior-anterior displacement for that joint, and the laxity surfaces of said female member comprising raised guide-bearing surfaces for resisting dislocation of the condylar portion, the height and angle, and therefore, the resistance to dislocation, of which guide bearing surfaces increases as a function of deviation from the central motion path of said male portion and as a function of the flexion angle, and which at full laxity for any given angle of flexion corresponds substantially to the forces of anatomical ligamentous restraint of said anatomical joint at the limits of laxity.

Claims

1. A method of making a prosthesis for the replacement of the male and female articular surfaces of a human joint having a male articular surface bearing portion and a female articular surface bearing portion respectively adapted to be affixed to the anatomical bone structure adjacent said joint subsequent to the surgical resection of said bone structure for the removal of the anatomical male and female articular surfaces thereof such that the male and female articular surfaces of said prosthesis are disposed in pressure receiving relation to each other and adapted for articulating movement through a path between extreme positions of extension and flexion, said method comprising:

generating and storing in a computer a mathematical model of a male articular surface contour, said model contour representing an average of a preselected number of actual anatomical male articular surface contours of said joint derived from mathematical analogues of empirical measurements of the anatomical surface geometries of said preselected number of actual anatomical male articular surface contours;

generating a first set of computer numerical control signals corresponding to said model male articular surface contour;

machining said model male articular surface contour onto a first workpiece in direct response to said first set of computer numerical control signals;

forming said male articular surface bearing portion of said prosthesis utilizing said first machined workpiece;

generating and storing in a computer a model female articular surface contour for receiving said model male articular surface contour in articulating relation, said model female articular surface contour corresponding to the surface described by sweeping said model male articular surface contour through the average motion path of said joint;

superimposing laxity parameters upon said model female articular surface contour in said computer to account for the partially restrained motion in a specified direction before substantial ligamentious restraint takes place at the extremes of motion in a normal anatomical human joint of the type to be replaced by the prosthesis, thereby creating a resultant model female articular surface contour in said computer;

generating a second set of computer numerical control signals corresponding to said resultant model female articular surface contour;

machining said resultant female articular surface onto a second workpiece in direct response to said second set of computer numerical control signals; and

forming said female articular surface bearing portion of said prosthesis utilizing said second machined workpiece.

2. The method of claim 1 further characterized by further machining the first and second machined workpieces respectively to form the male and female articular surface bearing portions of said prosthesis respectively.

3. The method of claim 1 wherein the first and second machined workpieces respectively comprise the male and female articular surface defining walls of the cavity portion of molds adapted for the molding of the male and female articular surface bearing portions of said prosthesis respectively.