Surgical tools for arthroplasty

• US 8,657,827 B2
• Filed: 11/22/2011
• Issued: 02/25/2014
• Est. Priority Date: 05/25/2001
• Status: Expired due to Term

• Current Assignee: Conformis Incorporated
• Original Assignee: Conformis Incorporated
• Inventors: Fitz, Wolfgang, Lang, Philipp, Bojarski, Raymond A., Steines, Daniel, Burdulis, Albert G. Jr., Vargas-Voracek, Rene
• Primary Examiner(s): Philogene, Pedro
• Application Number:
  US13/302,833
• Publication Number:
  US 20120143197A1
• Time in Patent Office: 826 Days
• Field of Search: 606/88, 606/87, 606/84, 606/86.A, 606/86.R, 606/85, 606/82, 606/80, 606/102, 606/79
• US Class Current: 606/87
• CPC Class Codes: A61B 17/154 for preparing bone for knee prosthesis
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/158 Cutting patella
• CPC Class Codes: A61B 17/1666 for the acetabulum
• CPC Class Codes: A61B 17/1668 for the upper femur A61B17/164 takes precedence
• CPC Class Codes: A61B 17/1675 for the knee
• CPC Class Codes: A61B 17/1739 specially adapted for particular parts of the body
• CPC Class Codes: A61B 17/1746 for the acetabulum
• CPC Class Codes: A61B 17/1767 for the patella
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: A61B 2034/102 Modelling of surgical devices, implants or prosthesis
• CPC Class Codes: A61B 2034/105 Modelling of the patient, e.g. for ligaments or bones
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: A61B 2034/2055 Optical tracking systems
• CPC Class Codes: A61B 2090/063 for measuring volume
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• CPC Class Codes: A61B 34/20 Surgical navigation systems; Devices for tracking or guiding surgical instruments, e.g. for frameless stereotaxis
• CPC Class Codes: A61B 5/103 Detecting, measuring or recording devices for testing the shape, pattern, colour, size or movement of the body or parts thereof, for diagnostic purposes A61B5/08 takes precedence; measuring aids for tailors A41H1/00; measuring instruments specially adapted for dentistry A61C19/04
• CPC Class Codes: A61B 5/4504 Bones A61B5/4547 takes precedence
• CPC Class Codes: A61B 5/4514 : Cartilage
• CPC Class Codes: A61B 5/4523 : Tendons
• CPC Class Codes: A61B 5/4528 : Joints A61B5/4533, A61B5/4538 take precedence
• CPC Class Codes: A61B 5/4533 : Ligaments
• CPC Class Codes: A61B 90/06 : Measuring instruments not otherwise provided for
• CPC Class Codes: A61F 2/30756 : Cartilage endoprostheses A61F2/3603 takes precedence
• 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 2/3877 : Patellae or trochleae
• CPC Class Codes: A61F 2002/3895 : unicompartimental
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing

Abstract

Disclosed herein are methods, compositions and tools for repairing articular surfaces repair materials and for repairing an articular surface. The articular surface repairs are customizable or highly selectable by patient and geared toward providing optimal fit and function. The surgical tools are designed to be customizable or highly selectable by patient to increase the speed, accuracy and simplicity of performing total or partial arthroplasty.

Claims

1. A patient-specific surgical instrument for use in surgically repairing a diseased or damaged joint of a patient, the instrument comprising:

a patient-specific surface for engaging a corresponding portion of the diseased or damaged joint, the patient-specific surface including cartilage information derived from image data of the diseased or damaged joint, wherein the corresponding portion of the diseased or damaged joint includes an osteophyte, wherein the patient-specific surface references the osteophyte when the patient-specific surface is engaged and aligned with the corresponding portion of the diseased or damaged joint; and

a guide sized and shaped to accommodate a surgical tool, wherein the guide has a position and orientation relative to the patient-specific surface to provide a predetermined path for the surgical tool.

2. The surgical instrument of claim 1, wherein the patient-specific surgical instrument is configured such that the patient-specific surface extends over but does not engage a second osteophyte of the diseased or damaged joint when the patient-specific surface is engaged and aligned with the corresponding portion of the diseased or damaged joint.

3. The surgical instrument of claim 1, wherein the patient-specific surgical instrument is configured such that the patient-specific surface extends over but substantially does not engage a second osteophyte of the diseased or damaged joint when the patient-specific surface is engaged and aligned with the corresponding portion of the diseased or damaged joint.

4. The surgical instrument of claim 1, wherein the patient-specific surface is configured to substantially engage the osteophyte.

5. The surgical instrument of claim 1, wherein the patient-specific surface is configured to substantially engage a portion of the osteophyte.

6. The surgical instrument of claim 1, wherein the surgical tool is a drill.

7. The surgical instrument of claim 1, wherein the surgical tool is a saw.

8. The surgical instrument of claim 1, wherein the surgical tool is a reamer.

9. The surgical instrument of claim 1, wherein the surgical tool is a k-wire, curette or screw.

10. The surgical instrument of claim 1, wherein the instrument is comprised of multiple components.

11. The surgical instrument of claim 1, wherein the patient-specific surface and the guide are contained in a single component.

12. The surgical tool of claim 1, wherein the patient-specific surface is a continuous surface.

13. The surgical instrument of claim 1, wherein the diseased or damaged joint is a knee joint of the patient.

14. The surgical instrument of claim 13, wherein the corresponding portion of the diseased or damaged joint is a femoral surface of the knee joint of the patient and the guide is configured to define a cutting or drilling path through the femoral surface when the patient-specific surface is engaged and aligned with the corresponding portion of the diseased or damaged joint.

15. The surgical instrument of claim 14, wherein the cutting or drilling path is configured to extend through a distal portion of a femoral condyle of the knee joint of the patient when the patient-specific surface is engaged and aligned with the corresponding portion of the diseased or damaged joint.

16. The surgical instrument of claim 14, wherein the cutting or drilling path is configured to extend through an anterior portion of a femoral condyle of the knee joint of the patient when the patient-specific surface is engaged and aligned with the corresponding portion of the diseased or damaged joint.

17. The surgical instrument of claim 14, wherein the cutting or drilling path is configured to extend through a posterior portion of a femoral condyle of the knee joint of the patient when the patient-specific surface is engaged and aligned with the corresponding portion of the diseased or damaged joint.

18. The surgical instrument of claim 14, wherein the cutting or drilling path is configured to extend through a portion of two femoral condyles of the knee joint of the patient when the patient-specific surface is engaged and aligned with the corresponding portion of the diseased or damaged joint.

19. The surgical instrument of claim 13, wherein the corresponding portion of the diseased or damaged joint is a portion of the tibia of the knee joint of the patient and the guide defines a cutting or drilling path through a tibial plateau of the tibia.

20. The surgical instrument of claim 19, wherein the cutting path has a predetermined slope relative to the tibial plateau.

21. The surgical instrument of claim 20, wherein the predetermined slope is between 0 and 7 degrees.

22. The surgical instrument of claim 19, wherein the cutting or drilling path is at a predetermined orientation relative to at least one of a mechanical axis and an anatomic axis of the knee joint of the patient.

23. The surgical instrument of claim 19, wherein the cutting or drilling path is at a predetermined distance relative to a cartilage surface of the tibial plateau.

24. The surgical instrument of claim 13, further comprising a spacer sized to fit in a space between a femoral surface and a tibial surface of the knee joint of the patient and configured to balance ligaments associated with the knee joint of the patient.

25. The surgical instrument of claim 24, wherein the patient-specific surface and the guide are contained in a single component, wherein the spacer is not connected to the single component.

26. The surgical instrument of claim 24, wherein the patient-specific surface and the guide are contained in a single component, wherein the spacer is connected to the single component.

27. The surgical instrument of claim 26, further comprising an attachment mechanism allowing the spacer to be connected to the single component.

28. The surgical instrument of claim 1, wherein the diseased or damaged joint is a knee joint, the instrument further comprising an adjustment mechanism to balance ligaments associated with the knee joint of the patient.

29. The surgical instrument of claim 28, wherein the patient-specific surface and the guide are contained in a single component, wherein the adjustment mechanism is not connected to the single component.

30. The surgical instrument of claim 28, wherein the patient-specific surface and the guide are contained in a single component, wherein the adjustment mechanism is connected to the single component.

31. The surgical instrument of claim 30, further comprising an attachment mechanism allowing the adjustment mechanism to be connected to the single component.

32. The surgical instrument of claim 1, further comprising a plurality of guides.

33. The surgical instrument of claim 1, further comprising a second guide, wherein the second guide is configured at an angle relative to the guide.

34. The surgical instrument of claim 1, further comprising at least one stabilizer on a surface of the instrument oriented to engage a surface portion of the diseased or damaged joint when the patient-specific surface engages the corresponding portion of the diseased or damaged joint.

35. The surgical instrument of claim 34, wherein the stabilizer is selected from the group consisting of pin, peg, post, and nub.

36. The surgical instrument of claim 1, wherein the instrument is configured to resist movement when the patient-specific surface is placed against the corresponding portion of the diseased or damaged joint.

37. The surgical instrument of claim 1, wherein the instrument is configured to resist rotation in at least one axis when the patient-specific surface is placed against the corresponding portion of the joint.

38. The surgical instrument of claim 1, wherein the diseased or damaged joint is selected from the group consisting of a hip, a knee, an ankle, a shoulder, an elbow and a wrist joint.

39. The surgical instrument of claim 1, wherein the instrument is configured to be oriented along a mechanical axis of the diseased or damaged joint when the patient-specific surface is placed against and aligned with the corresponding portion of the diseased or damaged joint.

40. The surgical instrument of claim 1, wherein the instrument is configured to be oriented along an anatomical axis of the diseased or damaged joint when the patient-specific surface is placed against and aligned with the corresponding portion of the diseased or damaged joint.

41. The surgical instrument of claim 13, wherein the corresponding portion of the diseased or damaged joint includes portions of at least one of a medial condyle and a lateral condyle of the knee joint of the patient.

42. The surgical instrument of claim 41, wherein the corresponding portion of the diseased or damaged joint includes at least a portion of the medial condyle and at least a portion of the lateral condyle of the knee joint of the patient.

43. The surgical instrument of claim 13, wherein the corresponding portion of the diseased or damaged join includes portions of at least one of a medial tibial plateau and a lateral tibial plateau of the knee joint of the patient.

44. The surgical instrument of claim 1, wherein the guide includes a stop to restrict the movement of the surgical tool.

45. The surgical instrument of claim 1, wherein the guide includes a metal insert.

46. The surgical instrument of claim 45, wherein the metal insert is a bushing.

47. The surgical instrument of claim 1, further comprising an adjustment mechanism for adjusting the position of the guide relative to the diseased or damaged joint.

48. The surgical instrument of claim 47, wherein the adjustment mechanism includes at least one of a tensiometer, a spacer, a shim, a hinge device, a jack device, and a ratchet device.

49. The surgical instrument of claim 47, wherein the adjustment mechanism includes adjustment means for optimizing balance of the diseased or damaged joint.

50. A surgical instrument for use in surgically repairing a diseased or damaged joint of a patient, comprising:

a cutting block having a patient-specific surface and a guide;

the patient-specific surface having a first portion configured to have a shape that is substantially a negative of a cartilage surface of the diseased or damaged joint and a second portion configured to have a shape that is substantially a negative of a cortical bone surface of the diseased or damaged joint, wherein the patient-specific surface is configured to reference an osteophyte of the diseased or damaged joint;

the guide being sized and shaped to accommodate a surgical tool and have a position and orientation relative to the patient-specific surface to provide a predetermined path for the surgical tool that is aligned through a portion of the diseased or damaged joint.

51. The surgical instrument of claim 50, wherein the patient-specific surface is configured to engage at least a portion of the osteophyte of the diseased or damaged joint.

52. The surgical instrument of claim 50, wherein the patient-specific surface is configured to substantially engage at least a portion of the osteophyte of the diseased or damaged joint.

53. A surgical instrument for use in surgically repairing a diseased or damaged joint of a patient, comprising:

a cutting block having a patient-specific surface and a guide;

the patient-specific surface having a first portion configured to have a shape that is substantially a negative of a subchondral bone surface of the diseased or damaged joint and a second portion configured to have a shape that is substantially a negative of a cortical bone surface of the diseased or damaged joint, wherein the patient-specific surface is configured to reference an osteophyte of the diseased or damaged joint;

the guide being sized and shaped to accommodate a surgical tool and have a position and orientation relative to the patient-specific surface to provide a predetermined path for the surgical tool that is aligned through a portion of the diseased or damaged joint.

54. The surgical instrument of claim 53, wherein the patient-specific surface is configured to engage at least a portion of the osteophyte of the diseased or damaged joint.

55. The surgical instrument of claim 53, wherein the patient-specific surface is configured to substantially engage at least a portion of the osteophyte of the diseased or damaged joint.

56. A surgical instrument for use in surgically repairing a diseased or damaged joint of a patient, comprising:

a cutting block having a patient-specific surface and a guide;

the patient-specific surface having a first portion configured to have a shape that is substantially a negative of a cartilage surface of the diseased or damaged joint, a second portion configured to have a shape that is substantially a negative of a cortical bone surface of the diseased or damaged joint, and a third portion configured to have a shape that is substantially a negative of a subchondral bone surface of the diseased or damaged joint, wherein the patient-specific surface is configured to reference an osteophyte of the diseased or damaged joint;

the guide being sized and shaped to accommodate a surgical tool and have a position and orientation relative to the patient-specific surface to provide a predetermined path for the surgical tool that is aligned through a portion of the diseased or damaged joint.

57. The surgical instrument of claim 56, wherein the patient-specific surface is configured to engage at least a portion of the osteophyte of the diseased or damaged joint.

58. The surgical instrument of claim 56, wherein the patient-specific surface is configured to substantially engage at least a portion of the osteophyte of the diseased or damaged joint.

59. A surgical instrument for use in surgically repairing a diseased or damaged joint of a patient, comprising:

a block having a patient-specific surface and a guide sized and shaped to accommodate a surgical tool,

the patient-specific surface having at least a portion configured to have a shape that is substantially a negative of a corresponding surface portion of the diseased or damaged joint, wherein the corresponding surface portion includes cartilage and an osteophyte, wherein the patient-specific surface is configured to reference the osteophyte;

the guide having a position and orientation relative to the patient-specific surface to provide a predetermined path for the surgical tool when the patient-specific surface is placed against the corresponding surface portion of the diseased or damaged joint such that the guide has a predetermined alignment relative to an anatomical or biomechanical axis of the diseased or damaged joint.

60. The surgical instrument of claim 59, wherein the corresponding surface portion further includes a bone surface.

61. The surgical instrument of claim 59, wherein the corresponding surface portion further includes a subchondral bone surface.

62. The surgical instrument of claim 59, wherein the corresponding surface portion further includes a cortical bone surface.

63. The surgical instrument of claim 59, wherein the patient-specific surface is configured to engage at least a portion of the osteophyte of the diseased or damaged joint.

64. The surgical instrument of claim 59, wherein the patient-specific surface is configured to substantially engage at least a portion of the osteophyte of the diseased or damaged joint.