Methods of articular cartilage implants

• US 8,876,902 B2
• Filed: 04/13/2012
• Issued: 11/04/2014
• Est. Priority Date: 03/06/2008
• Status: Active Grant

• Current Assignee: Moirai Orthopaedics, LLC
• Original Assignee: Moirai Orthopaedics, LLC
• Inventors: Strzepa, Peter, Cook, Stephen D.
• Primary Examiner(s): Willse, David H
• Assistant Examiner(s): BLANCO, JAVIER G
• Application Number:
  US13/447,009
• Publication Number:
  US 20120203343A1
• Time in Patent Office: 935 Days
• US Class Current: 623/14.12
• CPC Class Codes: A61F 2/30756 Cartilage endoprostheses A61F2/3603 takes precedence
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3804 for elbows
• CPC Class Codes: A61F 2/40 for shoulders
• CPC Class Codes: A61F 2/4261 for wrists
• CPC Class Codes: A61F 2002/30112 Rounded shapes, e.g. with rounded corners
• CPC Class Codes: A61F 2002/30125 elliptical or oval
• CPC Class Codes: A61F 2002/30299 umbrella-shaped or mushroom-shaped
• CPC Class Codes: A61F 2002/30822 Circumferential grooves
• CPC Class Codes: A61F 2002/30878 with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
• CPC Class Codes: A61F 2230/0008 elliptical or oval
• CPC Class Codes: A61F 2230/0093 Umbrella-shaped, e.g. mushroom-shaped
• CPC Class Codes: A61F 2310/00011 Metals or alloys
• CPC Class Codes: A61F 2310/00161 Carbon; Graphite
• CPC Class Codes: A61F 2310/00173 Graphite
• CPC Class Codes: A61F 2310/00179 Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00574 Coating or prosthesis-covering structure made of carbon, e.g. of pyrocarbon
• CPC Class Codes: A61F 2310/00796 Coating or prosthesis-covering structure made of a phosphorus-containing compound, e.g. hydroxy(l)apatite
• CPC Class Codes: Y10S 623/908 Bone

Abstract

Methods of utilizing implant devices for the repair of articular cartilage defects are provided herein. The implant devices have circular, or oblong, articular ends. The articular ends have a convex upper face and a concave lower face, the convex upper face blending to the concave lower face, and the concave lower face having a curvature less than the curvature of the convex upper face. The implant devices further have a stem extending from the concave lower face away from the upper face, the stem having a maximum radius at the convex lower face and tapering to lesser radius along the length of the stem.

Claims

1. A method of repair of articular cartilage comprising:

locating articular cartilage having a lesion;

utilizing an implant of having dimensions compatible with the lesion, wherein the articular cartilage implant comprises;

an articular end for repair of articular cartilage defects, the articular end having a perimeter, a convex upper face, and a concave lower face, the convex upper face having a first circular pitch radius and a first circular roll radius, at least a portion of the concave lower face having a spherical radius, the convex upper face blending into a rim, wherein at least a first and second portion of the rim extends at least a first distance along a vertical axis and a third and fourth portion of the rim tapers inward along the vertical axis, the rim blending into the concave lower face;

wherein the first circular pitch radius ranges from about 15 to about 30 millimeters,

wherein the first circular roll radius ranges from about 20 to about 40 millimeters; and

a stem extending from the concave lower face away from the convex upper face along the vertical axis, the stem having a plurality of stem perimeters along the vertical axis;

wherein the stem has a first stem portion having a maximum stem perimeter extending at least one millimeter from the concave lower face away from the convex upper face along the vertical axis, the maximum stem perimeter being less than the articular end perimeter, and a second stem portion extending from the first stem portion away from the convex upper face along the vertical axis, the second stem portion having a plurality of second stem portion perimeters decreasing in stem diameter from the maximum stem perimeter of the first stem portion to a lesser second stem portion stem perimeter along the vertical axis of the stem; and

wherein the stem has a plurality of circumferential grooves, wherein each circumferential groove extends continuously around at least one of the plurality of second stem portion perimeters, wherein at least one circumferential groove is defined between two adjacent second stem portion perimeters and has a shape of a partial, non-planar torus extending radially inward of the adjacent second stem portion perimeters, wherein the at least one circumferential groove blends into at least one of the two adjacent second stem portion perimeters,

wherein the stem blends into the concave lower face, and

wherein the articular end and the stem each consist essentially of;

a graphite core and a pyrocarbon coating,

forming a cavity in the cartilage and subchondral bone and cancellous bone; and

engaging the implant with the cavity so that the lower surface abuts against the prepared subchondral bone and the stem abuts against the prepared cancellous bone.

2. The method of claim 1, wherein forming the cavity includes placement of autograft, allograft bone, or various bone graft substitute material into the lesion.

3. The method of claim 1, wherein the first portion tapers inward along its horizontal axis in the vertical direction and has a uniform length along its depth axis in the vertical direction, the second portion tapers inward along its horizontal axis and its depth axis in the vertical direction, the first and second portion blend into each other, the length of the first portion along the vertical ranges from about 2 millimeters to about 10 millimeters, the length of the second portion along the vertical ranges from about 2 millimeters to about 25 millimeters.

4. The method of claim 1, wherein the pyrocarbon coating has an elastic modulus from about 15 GPa to about 22 GPa, and the pyrocarbon coating has an average thickness ranging from about 100 to about 1000 microns.

5. The method of claim 4, wherein the pyrocarbon coating has an elastic modulus of about 20 GPa and a strength of at least 400 MPa.

6. The method of claim 1, wherein the convex upper face and perimeter of the articular end are polished, and the concave lower face and stem are coated with hydroxyapatite.

7. The method of claim 1, wherein the first circular pitch radius and the first circular roll radius are about the same.

8. The method of claim 1, wherein the perimeter is oval.

9. The method of claim 8, wherein the maximum stem perimeter of the first stem portion is oval and the plurality of second stem portion perimeters of the second stem portion are oval.

10. The method of claim 1, wherein forming the cavity comprises drilling, punching, or broaching through the cartilage and the subchondral bone into the cancellous bone.

11. The method of claim 1, wherein the perimeter of the articular end is circular.

12. The method of claim 11, wherein the first stem portion is cylindrical and the second stem portion is conical.

13. The method of claim 1, wherein the partial, non-planar torus of the grooves has a tubular radius of from about 0.25 millimeters to about 1.5 millimeters, and the grooves are spaced apart at a distance of from about 1 millimeter to about 3 millimeters from each other.