Orthognathic implant and methods of use

• US 8,435,270 B2
• Filed: 04/01/2011
• Issued: 05/07/2013
• Est. Priority Date: 04/29/2010
• Status: Active Grant

• Current Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Original Assignee: Synthes USA LLC (Johnson & Johnson)
• Inventors: Furrer, Andre, Wilde, Frank, Zillig, Timo
• Primary Examiner(s): Truong, Kevin T
• Assistant Examiner(s): SEVILLA, CHRISTIAN ANTHONY
• Application Number:
  US13/078,250
• Publication Number:
  US 20120029574A1
• Time in Patent Office: 767 Days
• Field of Search: 606/280, 606/281, 606/283, 606/284, 606/285, 606/903, 700/98, 294/071
• US Class Current: 606/280
• CPC Class Codes: A61B 17/151 for corrective osteotomy
• CPC Class Codes: A61B 17/1728 for holes for bone plates or plate screws
• CPC Class Codes: A61B 17/176 for the jaw guiding dental drills A61C1/082
• CPC Class Codes: A61B 17/8061 specially adapted for particular bones A61B17/70 and A61B17/74 take precedence
• CPC Class Codes: A61B 17/8071 for the jaw
• CPC Class Codes: A61B 17/808 Instruments for holding or positioning bone plates, or for adjusting screw-to-plate locking mechanisms
• CPC Class Codes: A61B 17/8085 with pliable or malleable elements or having a mesh-like structure, e.g. small strips A61B17/8071, A61B17/8076 take precedence
• 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: Y10T 29/4978 Assisting assembly or disassembly

Abstract

An implant for use in orthognathic surgery of a mandible may include a longitudinal plate member and a plurality of pre-configured guides coupled to the plate member. The longitudinal plate member is pre-bent to correspond to the post-operative shape of the mandible; and the guides are pre-configured to align the plate member with the mandible when the implant is positioned against the mandible after the mandible has been separated.

Claims

1. A method of customizing a pre-shaped implant configured to fix at least a first mandibular bone part relative to a second mandibular bone part that is separated from the first mandibular bone part by a bone gap, the method comprising:

obtaining a pre-operative 3-D model of a patient'"'"'s mandible in a computer, so as to define a first modeled part of the mandible and a second modeled part of the mandible that define a first position relative to each other;

manipulating the pre-operative 3-D model of the mandible into a planned post-operative shape whereby the first modeled part of the mandible and the second modeled part of the mandible define a second position relative to each other; and

custom constructing a bone fixation implant to match the planned post-operative shape of the mandible such that the bone fixation implant is configured to attach to the first and second mandibular bone parts when the first and second mandibular bone parts define the second position relative to each other, the implant including a plate member and at least one guide coupled to the plate member, the custom constructing step comprising;

prior to segmenting the second mandibular bone part from the first mandibular bone part, bending the plate member so as to attach to the first and second mandibular bone parts after the second mandibular bone part has been segmented from the first mandibular bone part; and

prior to segmenting the second mandibular bone part from the first mandibular bone part, configuring the at least one guide to align the plate member with the mandible when the implant is positioned against the mandible after the second mandibular bone part has been separated from the first mandibular bone part.

2. The method of claim 1, wherein the at least one guide includes a guide body and the configuring step comprises pre-shaping the guide body to correspond to the post-operative shape of the mandible so as to align the plate member with the mandible when the implant is positioned against the mandible after the mandible has been separated.

3. The method of claim 2, further comprising over molding the guide body onto the plate member.

4. The method of claim 2, wherein the guide body is made from a biocompatible material.

5. The method of claim 1, wherein the at least one guide includes a guide body, a pusher aperture that extends transversely through the guide body, and a pusher that is disposed within the pusher aperture, the configuring step comprising positioning the pusher pre-operatively so as to abut a bottom of the mandible when the implant is positioned against the mandible after the mandible has been separated.

6. The method of claim 5, the configuring step further comprising pre-operatively adjusting the pusher within the transverse aperture.

7. The method of claim 1, wherein the second position is different than the first position.

8. The method of claim 1, wherein the first position is the same as the second position.