Intramedullary rod implantation system

• US 8,444,653 B2
• Filed: 08/30/2010
• Issued: 05/21/2013
• Est. Priority Date: 08/30/2010
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Nycz, Jeffrey H., Salyer, Brian D., Serbousek, Jon C.
• Primary Examiner(s): Sweet, Thomas J
• Assistant Examiner(s): Shah, Krutanjali M
• Application Number:
  US12/871,432
• Publication Number:
  US 20120053585A1
• Time in Patent Office: 995 Days
• Field of Search: 623/22.11, 623 2226- 2327, 623/22.12, 606 62- 68, 606/86.R, 606 96- 98, 606/104, 606/102, 606/916
• US Class Current: 606/98
• CPC Class Codes: A61B 17/1707 using electromagnetic effects, e.g. with magnet and external sensors
• CPC Class Codes: A61B 17/1725 for applying transverse screws or pins through intramedullary nails or pins
• CPC Class Codes: A61B 8/0841 for locating instruments
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/3607 including proximal or total replacement of the femur
• CPC Class Codes: A61F 2002/3067 for data transfer
• CPC Class Codes: A61F 2002/368 with lateral apertures, bores, holes or openings, e.g. for reducing the mass, for receiving fixation screws or for communicating with the inside of a hollow shaft

Abstract

A system for implanting a prosthetic device with an opening into a bone includes a plug that is removably received within the opening of the prosthetic device. The system also includes a bone removal tool that advances into the bone from outside the bone and that removes a portion of the bone while advancing into the bone to reveal the plug. The bone removal tool includes a plug engaging portion that engages with the plug. The bone removal tool at least partially removes the plug from the opening of the prosthetic device while engaged with the plug. Moreover, the system includes an alignment system that detects whether the bone removal tool and the plug are substantially axially aligned.

Claims

1. A system for implanting a prosthetic device into a bone, the prosthetic device having an opening that is disposed in the bone, the system comprising:

a plug that is removably received within the opening of the prosthetic device;

a bone removal tool that advances into the bone from outside the bone and that removes a portion of the bone while advancing into the bone to reveal the plug, the bone removal tool including a plug engaging portion that engages with the plug, the bone removal tool at least partially removing the plug from the opening of the prosthetic device while engaged with the plug; and

an alignment system that detects whether the bone removal tool and the plug are substantially axially aligned,

wherein the alignment system includes a receiver and a signal generator, one of the receiver and the signal generator being positioned within the plug.

2. The system of claim 1, wherein the plug is threadably engaged to the prosthetic device in the opening in a first rotational direction, and wherein the bone removal tool includes a drill bit that removes the portion of the bone by rotating in a second rotational direction, the second rotational direction being opposite the first rotational direction.

3. The system of claim 1, wherein the bone removal tool includes a drill bit that advances into the bone in a first direction to remove the portion of the bone, the drill bit engaging with the plug as the drill bit advances in the first direction, the plug being removable from the opening of the prosthetic device in a second direction, the second direction being opposite the first direction.

4. The system of claim 1, wherein the plug engaging portion includes a barb that embeds within the plug to engage with the plug.

5. The system of claim 1, wherein the alignment system includes an ultrasound system that is operatively coupled to the bone removal tool, and wherein the plug includes an ultrasonically detectable material that is detectable with an ultrasound signal generated by the ultrasound system, the ultrasound system distinguishing between the ultrasonically detectable material and an area adjacent the ultrasonically detectable material to detect whether the bone removal tool and the plug are substantially axially aligned.

6. The system of claim 1, wherein the alignment system includes a signal generator that generates and emits a radio frequency (RF) signal and a receiver that receives the RF signal, the signal generator being operably coupled to one of the plug and the bone removal tool, the receiver being operably coupled to the other of the plug and the bone removal tool, the alignment system also including a processor that detects whether the bone removal tool and the plug are substantially axially aligned based on the RF signal received by the receiver.

7. The system of claim 1, wherein the bone removal tool includes a drill bit, and further comprising a power generator that generates power from rotation of the drill bit to power the alignment system.

8. The system of claim 1, wherein the alignment system includes a feedback device that indicates that the bone removal tool is substantially axially aligned with the plug.

9. The system of claim 8, wherein the feedback system includes at least one of a visual feedback system, an audible feedback system, and a tactile feedback system.

10. The system of claim 1, further comprising the prosthetic device, and wherein the prosthetic device includes an intramedullary rod that is received within an intramedullary canal of the bone.

11. The system of claim 1, wherein the plug is axially tapered.

12. The system of claim 1, wherein the plug includes a deformable outer surface that deforms against an inner surface of the opening of the prosthetic device upon insertion of the plug into the opening of the prosthetic device.

13. The system of claim 12, wherein the deformable outer surface plastically deforms upon insertion of the plug into the opening.

14. A system for implanting a prosthetic device into a bone comprising:

an intramedullary (IM) rod that is operable to be implanted in an IM canal of one of a femur, a tibia, and a humerus, the IM rod having a longitudinal axis and a through hole that extends transverse to the longitudinal axis;

a plug that is threadably engaged to the IM rod within the through hole in a first rotational direction;

a bone removal tool that rotates in a second rotational direction, the second rotational direction being opposite the first rotational direction, the bone removal tool advancing into the bone from outside the bone in a first linear direction, the bone removal tool removing a portion of the bone while rotating in the second rotational direction and while advancing through the bone in the first linear direction to reveal the plug, the bone removal tool including a barb that embeds within and engages with the plug, the bone removal tool at least partially threadably disengaging the plug from the through hole of the IM rod while rotating in the second rotational direction and while embedded within the plug;

an alignment system that detects whether the bone removal tool and the plug are substantially axially aligned, the alignment system including at least one of an ultrasound system and a proximity sensor system, the alignment system including a power generating device that generates power from rotation of the bone removal tool to power the alignment system;

a feedback device that indicates that the bone removal tool is substantially axially aligned with the plug; and

a fastener that extends into the bone and into the opening to secure the intramedullary rod to the bone.

15. The system of claim 14, wherein the proximity sensor system is a radio frequency system.

16. The system of claim 15, wherein the plug further includes a passive signal generator and the bone removing tool includes a transceiver that emits a field to cause the passive signal generator to emit a radio frequency signal.

17. The system of claim 14, wherein the feedback device provides a feedback signal selected from the group comprising visual feedback, an audible feedback, a tactile feedback, and combinations thereof.

18. A system for implanting a prosthetic device into a bone, the prosthetic device having an opening that is disposed in the bone, the system comprising:

a plug configured to be removably received within the opening of the prosthetic device, the plug including a signal generator positioned within the plug and configured to emit a radio frequency signal;

a bone removal tool configured to pass into the bone relative to the plug, the bone removal tool including a plug engaging portion configured to engage the plug to at least partially remove the plug from the opening of the prosthetic device while engaging the plug; and

an alignment system that detects whether the bone removal tool and the plug are substantially axially aligned, the alignment system including a receiver that receives the radio frequency signal from the signal generator associated with the plug and a processor that detects whether the bone removal tool and the plug are substantially axially aligned based on the radio frequency signal received by the receiver.

19. The system of claim 18, wherein the plug is threadably engaged to the prosthetic device in the opening in a first rotational direction, and wherein the bone removal tool includes a drill bit that removes a portion of the bone by rotating in a second rotational direction, the second rotational direction being opposite the first rotational direction.

20. The system of claim 18, wherein the bone removal tool includes a drill bit that advances into the bone in a first direction to remove a portion of the bone, the drill bit engaging with the plug as the drill bit advances in the first direction, the plug being removable from the opening of the prosthetic device in a second direction, the second direction being opposite the first direction.

21. The system of claim 18, wherein the alignment system includes a feedback device that indicates that the bone removal tool is substantially axially aligned with the plug.

22. The system of claim 18, further comprising the prosthetic device, and wherein the prosthetic device includes an intramedullary rod that is received within an intramedullary canal of the bone.

23. The system of claim 18, wherein the plug engaging portion includes a barb that embeds within the plug to engage with the plug.

24. The system of claim 18, wherein the signal generator is a passive signal generator and the receiver is a transceiver that emits a field that causes the signal generator to emit the radio frequency signal.

25. The system of claim 18, wherein the alignment system further includes a feedback device having an indicator that provides a feedback signal if the bone removal tool is substantially axially aligned with the plug selected from the group consisting of a visual feedback, an audible feedback, a tactile feedback, and combinations thereof.