Patient-adapted and improved articular implants, designs and related guide tools

• US 8,926,706 B2
• Filed: 11/11/2011
• Issued: 01/06/2015
• Est. Priority Date: 05/25/2001
• Status: Expired due to Term

• Current Assignee: Conformis Incorporated
• Original Assignee: Conformis Incorporated
• Inventors: Bojarski, Raymond A., Chao, Nam, Slamin, John, Lang, Philipp, Fitz, Wolfgang, Steines, Daniel
• Primary Examiner(s): Philogene, Pedro
• Application Number:
  US13/294,579
• Publication Number:
  US 20120232669A1
• Time in Patent Office: 1,152 Days
• Field of Search: 623 2014- 2036, 623/18.11, 606/86.R, 606/102
• US Class Current: 623/20.3
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 2034/107 Visualisation of planned trajectories or target regions
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• 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 2/384 hinged, i.e. with transverse axle restricting the movement
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/3886 for stabilising knees against anterior or lateral dislocations
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/5046 for designing or making customized prostheses, e.g. using templates, finite-element analysis or CAD-CAM techniques
• CPC Class Codes: A61F 2002/30324 differing in thickness
• CPC Class Codes: A61F 2002/30327 differing in diameter
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/3895 unicompartimental
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

Methods and devices are disclosed relating improved articular models, implant components, and related guide tools and procedures. In addition, methods and devices are disclosed relating articular models, implant components, and/or related guide tools and procedures that include one or more features derived from patient-data, for example, images of the patient'"'"'s joint. The data can be used to create a model for analyzing a patient'"'"'s joint and to devise and evaluate a course of corrective action. The data also can be used to create patient-adapted implant components and related tools and procedures.

Claims

1. A knee implant system for repairing a knee joint of a patient comprising:

a femoral implant component having one or more patient-adapted features and one or more standard features, wherein the one or more patient-adapted features include an M-L dimension of a joint-facing condylar portion of the femoral implant that matches a corresponding M-L dimension of a femoral condyle of the knee joint of the patient; and

a tibial implant component.

2. The knee implant system of claim 1, wherein the femoral implant includes a medial condylar portion and a lateral condylar portion, wherein the one or more standard features include an intercondylar M-L dimension of the femoral implant that is designed to be of a standard length.

3. The knee implant system of claim 1, wherein the tibial implant component includes one or more patient-adapted tibial features.

4. The knee implant system of claim 1, wherein the tibial implant component includes only standard tibial features.

5. The knee implant system of claim 2, wherein the tibial implant component includes a medial insert and a lateral insert, wherein the distance between the medial and lateral inserts is standard and configured to match the intercondylar M-L dimension of the femoral implant.

6. The knee implant system of claim 5, wherein the tibial implant component further includes one or more patient-adapted tibial features.

7. The knee implant system of claim 5, wherein the tibial implant component further includes at least one additional standard tibial feature.

8. The knee implant system of claim 3, wherein the one or more patient-adapted tibial features include a perimeter of the tibial implant component that matches a corresponding perimeter of cortical bone of the patient'"'"'s tibia.

9. The knee implant system of claim 3, wherein the one or more patient-adapted tibial features include a M-L dimension, an A-P dimension, or both that match a corresponding M-L dimension, an A-P dimension, or both of the patient'"'"'s tibia.

10. The knee implant system of claim 3, wherein the tibial implant component further includes one or more standard tibial features.

11. The knee implant system of claim 10, wherein the one or more standard tibial features include a standard configuration of an insert of the tibial implant component.

12. The knee implant system of claim 11, wherein the standard configuration includes one or more standard dimensions of the insert configured to fit into a standard tibial tray.

13. The knee implant system of claim 1, wherein the one or more patient-adapted features are derived from patient-specific data obtained from the patient, wherein the patient-specific data includes one or more parameters of the patient'"'"'s biological features selected from the group consisting of:

one or more anatomical structures, anatomical axes, alignment, biomechanical axes, kinematics, soft tissue balance, soft tissue impingement of the knee joint of the patient, one or more bone properties of the patient, demographic data of the patient, and any combination thereof.

14. The knee implant system of claim 13, wherein the one or more patient-adapted features are designed based on the patient-specific data.

15. The knee implant system of claim 13, wherein the one or more patient-adapted features are engineered from one or more corresponding standard features based on the patient-specific data.

16. The knee implant system of claim 3, wherein the one or more patient-adapted tibial features are derived from patient-specific data obtained from the patient, wherein the patient-specific data includes one or more parameters of the patient'"'"'s biological features selected from the group consisting of:

one or more anatomical structures, anatomical axes, alignment, biomechanical axes, kinematics, soft tissue balance, soft tissue impingement of the knee joint of the patient, one or more bone properties of the patient, demographic data of the patient, and any combination thereof.

17. The knee implant system of claim 1, wherein the femoral implant includes a bone-facing surface having two or more facet portions configured to abut a resected surface of a corresponding femoral condyle of the knee joint of the patient.

18. The knee implant system of claim 17, wherein the resected surface of the corresponding femoral condyle is prepared with a predetermined resectioning strategy selected or designed for the patient.

19. The knee implant system of claim 1, further including one or more surgical tools that facilitate the placement of the femoral implant in the patient'"'"'s knee joint.

20. The knee implant system of claim 18, further including one or more surgical tools created for the patient, wherein the one or more surgical tools are created based on the predetermined resectioning strategy.

21. The knee implant system of claim 1, further including one or more surgical tools that facilitate the placement of the tibial implant in the patient'"'"'s knee joint.

22. The knee implant system of claim 1, wherein the femoral implant includes a medial condylar portion and a lateral condylar portion, and further includes a patient-adapted intercondylar M-L notch dimension that matches the patient'"'"'s intercondylar M-L notch dimension.

23. The knee implant system of claim 22, wherein the tibial implant component includes a medial insert and a lateral insert, wherein the distance between the medial and lateral inserts is patient-adapted and configured to match the intercondylar M-L notch dimension of the femoral implant.

26. The knee implant system of claim 1, wherein the one or more patient-adapted features include one or more patient-adapted curvatures configured to match one or more corresponding curvatures of the knee joint of the patient.

27. The knee implant system of claim 26, wherein the one or more patient-adapted curvatures are engineered based on one or more corresponding curvatures of the knee joint of the patient.

28. The knee implant system of claim 27, wherein the one or more patient-adapted curvatures are engineered to improve an existing feature of the patient'"'"'s biology.

29. The knee implant system of claim 28, wherein the one or more patient-adapted curvatures are engineered to correct an abnormality in the existing feature of the patient'"'"'s biology.

30. The knee implant system of claim 26, wherein the one or more patient-adapted curvatures are in a sagittal plane.

31. The knee implant system of claim 1, wherein the joint-facing condylar portion of the femoral implant includes a medial condylar portion and a lateral condylar portion, wherein the femoral condyle of the knee joint of the patient includes both medial and lateral condyles of the knee joint of the patient.

24. A knee implant system for repairing a knee joint of a patient comprising:

a femoral implant component having two or more patient-adapted features and one or more standard features, wherein the two or more patient-adapted features include an M-L width of a joint-facing surface of the femoral implant that matches a corresponding M-L width of a femoral condyle of the knee joint of the patient and a sagittal curvature of an articular surface portion of the femoral implant that is derived from an articular shape of a femoral condyle of the knee joint of the patient; and

a tibial implant component.

25. A knee implant system for repairing a knee joint of a patient comprising:

a femoral implant component having one or more patient-adapted features and one or more standard features, wherein the one or more patient-adapted features include an M-L width of a joint-facing surface of the femoral implant that matches a corresponding M-L width of a femoral condyle of the knee joint of the patient;

a tibial implant component; and

one or more surgical tools created for the patient for the placement of the femoral and tibial implant components in the patient'"'"'s knee joint.