Marking template for installing a custom replacement device for resurfacing a femur and associated installation method

• US 8,961,529 B2
• Filed: 03/12/2014
• Issued: 02/24/2015
• Est. Priority Date: 03/17/2000
• Status: Expired due to Term

• Current Assignee: Kinamed Inc (VME Acquisition Corp)
• Original Assignee: Kinamed Inc (VME Acquisition Corp)
• Inventors: Carignan, Roger, Pratt, Clyde R.
• Primary Examiner(s): STEWART, ALVIN J
• Application Number:
  US14/205,840
• Publication Number:
  US 20140189993A1
• Time in Patent Office: 349 Days
• Field of Search: 623/20.35, 623 203- 2032, 623/20.18, 623/20.14, 623/20.15, 623/20.11, 623/18.11, 623/16.11, 623/20.19, 623/20.21, 606/80, 606/96, 606/53, 606 85- 88, 606/99, 606/101
• US Class Current: 606/96
• CPC Class Codes: A61B 17/00491 Surgical glue applicators surgical adhesives A61L24/00; two-component delivery syringes A61M5/19
• CPC Class Codes: A61B 17/1764 for the knee
• 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 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• 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 2/3859 Femoral components
• CPC Class Codes: A61F 2/3877 Patellae or trochleae
• CPC Class Codes: A61F 2/461 of knees
• CPC Class Codes: A61F 2/4657 Measuring instruments used for implanting artificial joints for surgical instruments A61B90/06
• CPC Class Codes: A61F 2002/30125 elliptical or oval
• CPC Class Codes: A61F 2002/30594 slotted, e.g. radial or meridian slot ending in a polar aperture, non-polar slots, horizontal or arcuate slots
• CPC Class Codes: A61F 2002/30685 Means for reducing or preventing the generation of wear particulates
• CPC Class Codes: A61F 2002/30892 parallel
• CPC Class Codes: A61F 2002/30948 using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/4658 for measuring dimensions, e.g. length
• CPC Class Codes: A61F 2230/0008 elliptical or oval
• CPC Class Codes: A61F 2310/00017 Iron- or Fe-based alloys, e.g. stainless steel
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 : Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: A61F 2310/00203 : containing alumina or aluminium oxide
• CPC Class Codes: A61F 2310/00239 : containing zirconia or zirconium oxide ZrO2
• CPC Class Codes: A61F 2310/00407 : Coating made of titanium or of Ti-based alloys
• 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 623/901 : Method of manufacturing prosthetic device
• CPC Class Codes: Y10T 29/49764 : with testing or indicating

Abstract

A replacement device for resurfacing a joint surface of a femur and a method of making and installing such a device is provided. The custom replacement device is designed to substantially fit the trochlear groove surface, of an individual femur, thereby creating a “customized” replacement device for that individual femur and maintaining the original kinematics of the joint. The top surface is designed so as to maintain centrally directed tracking of the patella perpendicular to the plane established by the distal end of the femoral condyles and aligned with the center of the femoral head.

Claims

1. A method of manufacturing a surgical instrument, the method comprising:

receiving pre-operative data related to a particular patient defining at least a portion of a three-dimensional tissue contacting geometry of a surgical instrument, the surgical instrument including a surgical tool guide,

wherein the received pre-operative data is based on three-dimensional geometry of a distal-anterior portion of a femur and a pre-operatively planned spatial arrangement of the surgical tool guide relative to the distal-anterior portion; and

manufacturing the surgical instrument using the received pre-operative data, thereby configuring the surgical instrument based on the received pre-operative data to mount to the particular patient'"'"'s femur in a pre-defined spatial arrangement, wherein manufacturing the surgical instrument includes manufacturing the three-dimensional tissue contacting geometry and the surgical tool guide, such that the surgical tool guide is in a pre-defined spatial arrangement relative to the three-dimensional tissue contacting geometry.

2. The method of claim 1, wherein manufacturing the surgical instrument comprises manufacturing the surgical instrument such that it is configured to mount to the particular patient'"'"'s femur in a single pre-defined position.

3. The method of claim 1, wherein manufacturing the surgical instrument comprises manufacturing the three-dimensional tissue contacting geometry such that it is matched to at least a portion of a cartilage surface of the femur.

4. The method of claim 1, wherein manufacturing the surgical instrument comprises manufacturing the three-dimensional tissue contacting geometry such that it is matched to at least a portion of a subchondral bone surface of the femur.

5. The method of claim 4, wherein manufacturing the surgical instrument comprises shaping the three-dimensional tissue contacting geometry to match a shape of at least a portion of an uncut subchondral bone surface.

6. The method of claim 1, wherein receiving the pre-operative data comprises receiving imaging data concerning at least one cartilage surface of the particular patient'"'"'s femur.

7. The method of claim 1, wherein manufacturing the surgical instrument comprises using a computer controlled machine to build the surgical instrument.

8. The method of claim 1, wherein the received pre-operative data is further based on a pre-operatively planned spatial arrangement of the femoral implant relative to an axis of the particular patient'"'"'s femur passing through a femoral head and a knee joint of the particular patient.

9. The method of claim 1, wherein the received pre-operative data is further based on at least one cartilage surface of the femur.

10. A method of manufacturing a surgical instrument, the method comprising:

receiving pre-operative data related to a particular patient defining at least a portion of a three-dimensional tissue contacting geometry of a surgical instrument, the surgical instrument including a surgical tool guide,

wherein the received pre-operative data is based on (i) three-dimensional geometry of a distal-anterior portion of a femur, (ii) at least one cartilage surface, and (iii) a pre-operatively planned spatial arrangement of the surgical tool guide relative to the distal-anterior portion; and

manufacturing the surgical instrument using the received pre-operative data, thereby configuring the surgical instrument based on the received pre-operative data to mount to the particular patient'"'"'s distal femur in a pre-defined spatial arrangement, wherein manufacturing the surgical instrument includes manufacturing the three-dimensional tissue contacting geometry and the surgical tool guide, such that the surgical tool guide is in a pre-defined spatial arrangement relative to the three-dimensional tissue contacting geometry.

11. The method of claim 10, wherein manufacturing the surgical instrument comprises manufacturing the surgical instrument such that it is configured to mount to the particular patient'"'"'s femur in a single pre-defined position.

12. The method of claim 10, wherein manufacturing the surgical instrument comprises manufacturing the three-dimensional tissue contacting geometry such that it is matched to at least a portion of a cartilage surface of the femur.

13. The method of claim 10, wherein manufacturing the surgical instrument comprises manufacturing the three-dimensional tissue contacting geometry such that it is matched to at least a portion of a subchondral bone surface of the femur.

14. The method of claim 13, wherein manufacturing the surgical instrument comprises shaping the three-dimensional tissue contacting geometry to match a shape of at least a portion of an uncut subchondral bone surface.

15. The method of claim 10, wherein receiving the pre-operative data comprises receiving imaging data concerning at least one cartilage surface of the particular patient'"'"'s femur.

16. The method of claim 10, wherein manufacturing the surgical instrument comprises using a computer controlled machine to build the surgical instrument.

17. The method of claim 10, wherein the received pre-operative data is further based on a pre-operatively planned spatial arrangement of the femoral implant relative to an axis of the particular patient'"'"'s femur passing through a femoral head and a knee joint of the particular patient.