Apparatus and method for sculpting the surface of a joint

• US 7,115,131 B2
• Filed: 05/29/2002
• Issued: 10/03/2006
• Est. Priority Date: 06/14/2001
• Status: Expired due to Fees

• Current Assignee: Cayenne Medical Incorporated (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Alexandria Research Technologies, LLC
• Inventors: Engh, Gerard A., Johnson, Wesley D.
• Primary Examiner(s): Philogene, Pedro
• Application Number:
  US10/159,147
• Publication Number:
  US 20020198528A1
• Time in Patent Office: 1,588 Days
• Field of Search: 606/79, 606/80, 606/82, 606/86, 606/88, 623/20.11, 623/20.14, 623/20.15, 623/20.21, 623/20.3, 623/20.31, 623/20.32, 623/20.34, 623/20.35, 623/20.33, 623/20.29, 623/20.23, 623/20.16, 623/16.11, 623/13.12, 623/18.11, 623/20.18, 623/20.19, 623/20.2
• US Class Current: 606/79
• CPC Class Codes: A61B 17/00234 for minimally invasive surgery A61B17/0218, A61B17/0469, A61B17/12013, A61B17/1285, A61B17/29, A61B17/320016 take precedence
• CPC Class Codes: A61B 17/0206 with antagonistic arms as supports for retractor elements
• CPC Class Codes: A61B 17/025 Joint distractors
• CPC Class Codes: A61B 17/1628 Motors; Power supplies
• CPC Class Codes: A61B 17/1631 Special drive shafts, e.g. flexible shafts A61B17/1642, A61B17/164 take precedence
• CPC Class Codes: A61B 17/1666 for the acetabulum
• CPC Class Codes: A61B 17/1675 for the knee
• CPC Class Codes: A61B 17/32002 with continuously rotating, oscillating or reciprocating cutting instruments
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00539 hydraulically
• CPC Class Codes: A61B 2017/00557 inflatable A61B2017/22051 takes precedence
• CPC Class Codes: A61B 2017/0268 for the knee
• CPC Class Codes: A61B 2017/0275 for the hip
• CPC Class Codes: A61B 2017/1602 Mills
• CPC Class Codes: A61F 2/30724 Spacers for centering an implant in a bone cavity, e.g. in a cement-receiving cavity
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• 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 2/34 Acetabular cups
• CPC Class Codes: A61F 2/3662 Femoral shafts
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3859 : Femoral components
• CPC Class Codes: A61F 2/3872 : Meniscus for implantation between the natural bone surfaces
• 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 2/4603 : for insertion or extraction of endoprosthetic joints or of accessories thereof
• CPC Class Codes: A61F 2/461 : of knees
• CPC Class Codes: A61F 2/4684 : Trial or dummy prostheses
• CPC Class Codes: A61F 2002/30092 : using shape memory or superelastic materials, e.g. nitinol
• CPC Class Codes: A61F 2002/30604 : modular
• CPC Class Codes: A61F 2002/30616 : Sets comprising a plurality of prosthetic parts of different sizes or orientations
• CPC Class Codes: A61F 2002/30884 : Fins or wings, e.g. longitudinal wings for preventing rotation within the bone cavity
• CPC Class Codes: A61F 2002/30894 : inclined obliquely with respect to each other
• CPC Class Codes: A61F 2002/3895 : unicompartimental
• CPC Class Codes: A61F 2002/4631 : the prosthesis being specially adapted for being cemented
• CPC Class Codes: A61F 2002/4635 : using minimally invasive surgery
• CPC Class Codes: A61F 2002/4681 : by applying mechanical shocks, e.g. by hammering
• CPC Class Codes: A61F 2002/4693 : hydraulic
• CPC Class Codes: A61F 2002/4694 : pneumatic
• CPC Class Codes: A61F 2210/0014 : using shape memory or superelastic materials, e.g. nitinol
• 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: A61F 2310/00952 : Coating, pre-coating or prosthesis-covering structure made of bone cement, e.g. pre-applied PMMA cement mantle

Abstract

The present invention provides a method and device for restoring individual patient joint kinematics using minimally invasive surgical procedures. The instrumentation of the invention sculpts the articular surface of a first bone that normally articulates in a predetermined manner with a second bone. The instrumentation includes a bone sculpting tool and a mount for attaching the tool to the second bone. The implant system is comprised of implants that provide intraoperative surgical options for articular constraint and facilitate proper alignment and orientation of the joint to restore kinematics as defined by the individual patient anatomy.

Claims

1. An apparatus for replacing the surfaces of a joint between a first bone and a second bone, the first bone articulating in a predetermined manner with a second bone, the apparatus comprising:

a first bone implant including a plurality of individual components for mimicking and replacing the bearing surface of the first bone, each of said plurality of individual components having an inner surface adapted to be secured to the first bone and an outer surface; and

a second bone implant for mimicking and replacing respective bearing surfaces of the second bone;

wherein the outer surface of said plurality of individual components of the first bone implant contacts said second bone implant and further wherein each of said plurality of individual components of the first bone implant are structured to be aligned, oriented and engaged one to the other within the confines of the joint cavity during surgical placement therewithin and the resulting configuration of the first bone implant and second bone implant articulate in a predetermined manner to restore proper kinematics; and

further wherein the material used to construct the plurality of individual components of the first bone implant is of a similar material.

2. The apparatus of claim 1 wherein the components of the first bone implant and the second bone implant are aligned and oriented to each other within the confines of the joint cavity during surgical placement therewithin.

3. The apparatus of claim 1 wherein the second bone implant is configured as a unitary piece.

4. The apparatus of claim 1 wherein the second bone implant further comprises a fixed bearing attachment and a bearing attached thereto, and a mobile bearing attachment and a bearing attached thereto.

5. The apparatus of claim 1 wherein the second bone implant further comprises a plurality of components.

6. The apparatus of claim 5 wherein at least one of the second bone components is fixed bearing.

7. The apparatus of claim 5 wherein at least one of the second bone components is mobile bearing.

8. The apparatus of claim 5 wherein the second bone components are a combination of fixed bearing and mobile bearing components.

9. The apparatus of claim 1 wherein the first bone implant comprises two bearing-surface components.

10. The apparatus of claim 1 wherein the first bone implant comprises three bearing-surface components.

11. The apparatus of claim 1 wherein each of the plurality of individual components of the first bone implant further comprises a fin longitudinally disposed along an axis of said each of said plurality of individual components for driving the components into the first bone.

12. The apparatus of claim 1 wherein the first bone implant is a femoral implant and the second bone implant is a tibial implant.

13. The apparatus of claim 1 wherein the first bone implant and second bone implant are each sized for insertion through a minimally invasive incision.

14. The apparatus of claim 1 wherein the plurality of individual components of the first bone implant are flexible components.

15. The apparatus of claim 1 wherein the plurality of individual components of the first bone implant are rigid components.

16. The apparatus of claim 1 wherein the plurality of individual components of the first bone implant are a combination of rigid components and flexible components.

17. An apparatus for replacing the surfaces of a joint between a first bone and a second bone, the first bone normally articulating in a predetermined manner with a second bone, the apparatus comprising a first bone implant including a plurality of individual components for mimicking and replacing the bearing surface of the first bone, each of said plurality of individual components having an inner surface and an outer surface, the inner surface adapted to be secured to the first bone and including a plurality of spacers thereon;

and a second bone implant for mimicking and replacing the bearing surface of the second bone;

wherein the outer surface of said plurality of individual components of said first bone implant contacts the second bone implant, and further wherein the components of the first bone implant are joined within the confines of the joint cavity during surgical placement therewithin and the first bone implant and the second bone implant articulate in a predetermined manner.

18. The apparatus of claim 17 further including a hardenable fluid for cementing the spacers.

19. The apparatus of claim 17 wherein the first bone implant and second bone implant are each sized for insertion through a minimally invasive incision.

20. The apparatus of claim 17 wherein the plurality of individual components of the first bone implant are flexible components.

21. The apparatus of claim 17 wherein the plurality of individual components of the first bone implant are rigid components.

22. The apparatus of claim 17 wherein the plurality of individual components of the first bone implant are a combination of rigid components and flexible components.

23. A method of replacing the articular surfaces of a first bone that normally articulates in a predetermined manner with a second bone and replacing the articular surfaces of the second bone, comprising:

a) resecting a portion of the second bone to provide the second bone with a resected cavity;

b) providing an apparatus comprising a bone-sculpting tool attached to a bone mount;

c) attaching the mount rigidly in the cavity;

d) sculpting the articular surfaces of the first bone by articulating one of the bones with respect to the other;

e) providing a first bone implant comprising a plurality of individual components and a second bone implant;

f) placing the components of the first bone in the first bone resections;

g) placing the second bone implant in the second bone resection; and

h) joining the components of the first bone implant and the second bone implant within the confines of the joint cavity.

24. The method of claim 23 wherein the step of joining further comprises aligning and orienting the components of the first bone implant and the second bone implant within the confines of the joint cavity.

25. The method of claim 23 further comprising the step of adjusting the position and orientation of the tool to bring the tool into bone-sculpting engagement with the articular surface of the first bone.

26. The method of claim 23 wherein the second bone resection is formed by advancing a cutting mill into the second bone.

27. The method of claim 23 wherein the femoral implant comprises a first component for resurfacing the medial condyle and a second component for resurfacing the lateral condyle.

28. The method of claim 27 wherein the second component also resurfaces the patellofemoral groove.

29. The method of claim 23 wherein the femoral implant comprises a first component for resurfacing the medial condyle, a second component for resurfacing the lateral condyle and a third component for resurfacing the patellofemoral groove.

30. The method of claim 23 wherein fins are provided centrally on each component of the femoral implant for support.

31. The method of claim 23 wherein each component further comprises a fin for driving into the femur for implantation.

32. The method of claim 23 wherein each component has an inner surface and an outer surface and wherein the inner surface is comprised of a plurality of spacers.

33. The method of claim 32 wherein the a plurality of segments are bonded to an articular surface.

34. The method of claim 32 wherein the outer surface is a thin sheet of implant grade material.

35. The method of claim 32 wherein the each component is coated with a hardenable fluid.

36. An apparatus for replacing the surfaces of a femur and a tibia, where the tibia normally articulates in a predetermined manner with the femur, the apparatus comprising:

a femoral implant including a plurality of individual components sized for insertion through a minimally invasive incision, each of said plurality of individual components having an inner surface and an outer surface, the inner surface adapted to be secured to the femur; and

a tibial implant including a plurality of individual components sized for insertion through a minimally invasive incision;

wherein the outer surface of said plurality of individual components of the femoral implant contact the tibial implant; and

further wherein each of the plurality of individual components of the femoral implant are structured to be aligned, oriented and joined one to the other within the confines of the joint cavity during surgical placement therewithin, and each of the plurality of individual components of the tibial implant are structured to be aligned, oriented and joined to each other within the confines of the joint cavity during surgical placement therewithin, and the femoral implant and tibial implant articulate in a predetermined manner to restore proper kinematics.

37. The apparatus of claim 36 wherein the tibial implant comprises separate tibial components for the medial and lateral compartments of the tibia.

38. The apparatus of claim 36 wherein at least one of the tibial implant components is fixed bearing.

39. The apparatus of claim 36 wherein at least one of the tibial implant components is mobile bearing.

40. The apparatus of claim 37 wherein the tibial implant components are a combination of fixed bearing and mobile bearing.

41. The apparatus of claim 36 wherein the plurality of individual components of the femoral implant are flexible components.

42. The apparatus of claim 36 wherein the plurality of individual components of the femoral implant are rigid components.

43. The apparatus of claim 36 wherein the plurality of individual components of the femoral implant are a combination of rigid components and flexible components.

44. An apparatus for replacing the articulating surfaces of a femur and a tibia, where the tibia normally articulates in a predetermined manner with a femur, the apparatus comprising:

a femoral implant including a plurality of individual components sized for insertion through a minimally invasive incision each of said plurality of individual components having an inner surface adapted to be secured to the femur and an outer surface; and

a tibial implant comprising a plurality of individual components sized for insertion through a minimally invasive incision, the tibial implant components comprising a fixed bearing attachment and a bearing attached thereto, and a mobile bearing attachment and a bearing attached thereto;

wherein the outer surface of said plurality of individual components of the femoral implant contact the tibial implant; and

further wherein each of said plurality of individual components of said femoral implant are structured to be aligned, oriented and engaged one to the other within the confines of the joint cavity during surgical placement therewithin, and the components of the tibial implant are structured to be aligned, oriented and engaged one to the other within the confines of the joint cavity during surgical placement therewithin; and

further wherein the resulting femoral implant and the tibial implant articulate in a predetermined manner to restore proper kinematics.

45. The apparatus of claim 44 wherein the plurality of individual components of the femoral implant are flexible components.

46. The apparatus of claim 44 wherein the plurality of individual components of the femoral implant are rigid components.

47. The apparatus of claim 44 wherein the plurality of individual components of the femoral implant are a combination of rigid components and flexible components.

48. A method of replacing the articular surfaces of a first bone that normally articulates in a predetermined manner with a second bone and replacing the articular surfaces of the first bone, comprising:

a) resecting a portion of the second bone to provide a second bone resection;

b) providing an apparatus comprising a bone-sculpting tool attached to a bone mount;

c) attaching the mount rigidly to the second bone resection;

d) sculpting the articular surface to provide first bone resections of the first bone by articulating one of the bones with respect to the other;

e) providing a hardenable fluid along the sculpted surface;

f) providing a first bone implant comprising a plurality of individual components wherein each component has an inner surface and an outer surface and wherein the inner surface is comprised of a plurality of spacers;

g) providing a second bone implant;

h) placing the components of the first bone in the first bone resections;

i) allowing the hardenable fluid to cure;

j) placing the second bone implant in the second bone resection; and

k) joining the components of the first bone implant within the confines of the joint cavity and joining the components of the second bone implant within the confines of the joint cavity.

49. The method of claim 48 further including articulating the second bone with respect to the first bone such that the second bone implant moulds the plurality of spacers along the shape of the resected surface.

50. An apparatus for partially replacing the surfaces of a femur, the apparatus comprising a plurality of individual bearing-surface components sized for insertion through a minimally invasive incision, said plurality of individual bearing-surface components having an inner surface adapted to be secured to the femur and an outer surface adapted to contact a second bone implant;

wherein each of the plurality of individual bearing-surface components are structured to be individually placed into the joint cavity, and structured to be aligned, oriented and joined one to the other within the confines of the joint cavity during surgical placement therewithin to restore proper kinematics; and

further wherein the material used to construct the plurality of individual bearing-surface components is of a similar material.

51. The apparatus of claim 50 wherein the plurality of bearing-surface components replace a medial and lateral femoral condyle.

52. The apparatus of claim 50 wherein the plurality of bearing-surface components replace a patellofemoral groove and lateral femoral condyle.

53. The apparatus of claim 50 wherein the plurality of bearing-surface components replace a patellofemoral groove and a medial femoral condyle.

54. The apparatus of claim 50 wherein the plurality of individual bearing-surface components are flexible components.

55. The apparatus of claim 50 wherein the plurality of individual bearing-surface components are rigid components.

56. The apparatus of claim 50 wherein the plurality of individual bearing-surface components are a combination of rigid components and flexible components.

57. An apparatus for partially replacing the surfaces of a femur, the apparatus comprising a plurality of individual bearing-surface components sized for insertion through a minimally invasive incision wherein the plurality of individual bearing-surface components have an inner surface adapted to be secured to the femur and an outer surface adapted to contact a second bone implant, and further wherein each of the plurality of individual bearing-surface components are designed to be individually placed into the joint cavity and structured to be aligned, oriented and engaged one to the other within the confines of the joint cavity during surgical placement therewithin to restore proper kinematics;

and further wherein the material used to construct the plurality of individual bearing-surface components is of a similar material.

58. The apparatus of claim 57 wherein the plurality of bearing-surface components replace a medial and lateral femoral condyle of the femur.

59. The apparatus of claim 57 wherein the plurality of bearing-surface components replace a patellofemoral groove and lateral femoral condyle of the femur.

60. The apparatus of claim 57 wherein the plurality of bearing-surface components replace a patellofemoral groove and medial femoral condyle of the femur.

61. The apparatus of claim 57 wherein the plurality of individual bearing-surface components are flexible components.

62. The apparatus of claim 57 wherein the plurality of individual bearing-surface components are rigid components.

63. The apparatus of claim 57 wherein the plurality of individual bearing-surface components are a combination of rigid components and flexible components.

64. A bicompartmental prosthesis configured for implantation within a joint cavity comprising medial tibial and medial femoral components and lateral tibial and lateral femoral components, each of said components having an inner surface and an outer surface, wherein the inner surface of said medial femoral component and lateral femoral component are adapted to be secured to a femur and the inner surface of said medial tibial component and said lateral tibial component are adapted to be secured to a tibia, and further wherein the outer surface of said medial femoral component and lateral femoral component contact the outer surface of said medial tibial and lateral tibial components, and further wherein the medial femoral component and lateral femoral component are structured to be individually placed into the joint cavity, and structured to be aligned, oriented and joined one to the other within the confines of the joint cavity during surgical placement therewithin to restore proper kinematics and the medial tibial component and lateral tibial component are designed to be individually placed into the joint cavity, and structured to be aligned, oriented and joined one to the other within the confines of the joint cavity during surgical placement therewithin to restore proper kinematics.

65. The bicompartmental prosthesis of claim 64 wherein the medial femoral and lateral femoral components are flexible components.

66. The bicompartmental prosthesis of claim 64 wherein the medial femoral and lateral femoral components are rigid components.

67. The bicompartmental prosthesis of claim 64 wherein the medial femoral and lateral femoral components are a combination of rigid components and flexible components.

68. A bicompartmental prosthesis for implantation within a joint cavity comprising medial tibial and medial femoral components and lateral tibial and lateral femoral components, each of said components having an inner surface and an outer surface, wherein the inner surface of said medial femoral component and lateral femoral component are adapted to be secured to a femur and the inner surface of said medial tibial component and said lateral tibial component are adapted to be secured to a tibia, and further wherein the outer surface of said medial femoral component and lateral femoral component contact the outer surface of said medial tibial and lateral tibial components, and further wherein the medial femoral component and lateral femoral component are structured to be individually placed into the joint cavity, and structured to be aligned, oriented, and engaged one to the other within the confines of the joint cavity during surgical placement therewithin to restore proper kinematics and the medial tibial component and lateral tibial component are designed to be individually placed into the joint cavity, and structured to be aligned, oriented and engaged one to the other within the confines of the joint cavity during surgical placement therewithin to restore proper kinematics.

69. The bicompartmental prosthesis of claim 68 wherein the medial femoral and lateral femoral components are flexible components.

70. The bicompartmental prosthesis of claim 68 wherein the medial femoral and lateral femoral components are rigid components.

71. The bicompartmental prosthesis of claim 68 wherein the medial femoral and lateral femoral components are a combination of rigid components and flexible components.

72. An apparatus for replacing the bearing-surface of a first bone comprising a plurality of individual bearing-surface first bone components sized for insertion through a minimally invasive incision and including an inner surface adapted to be secured to said first bone and an outer surface adapted to contact a second bone implant, wherein each of the individual bearing-surface first bone components are structured to be individually placed into the joint cavity, and structured to be aligned and oriented one to the other within the joint cavity during surgical placement therewithin to restore proper kinematics;

and further wherein the material used to construct the plurality of individual bearing-surface first bone components is of a similar material.

73. The apparatus of claim 72 wherein the first bone components are femoral components.

74. The apparatus of claim 73 wherein the femoral components are joined within the confines of the joint cavity during surgical placement therewithin.

75. The apparatus of claim 73 wherein the femoral components are engaged within the confines of the joint cavity during surgical placement therewithin.

76. The apparatus of claim 72 wherein the plurality of individual bearing-surface first bone components are flexible components.

77. The apparatus of claim 72 wherein the plurality of individual bearing-surface first bone components are rigid components.

78. The apparatus of claim 72 wherein the plurality of individual bearing-surface first bone components are a combination of rigid components and flexible components.