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

• US 8,974,539 B2
• Filed: 11/11/2011
• Issued: 03/10/2015
• 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:
  US13/294,573
• Publication Number:
  US 20120232671A1
• Time in Patent Office: 1,215 Days
• Field of Search: 623 2014- 2036, 623/18.11, 606/86.R
• US Class Current: 623/20.35
• 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 femoral implant for repairing a knee joint of a patient, comprising:

a condylar portion having an articulating surface and a bone-facing surface, wherein the articulating surface has a sagittal curvature derived from patient-specific image data of the knee joint of the patient.

2. The femoral implant of claim 1, wherein the sagittal curvature is partially patient-engineered from patient-specific data to improve an existing feature of the patient'"'"'s biology.

3. The femoral implant of claim 2, wherein the patient-engineered portion is configured to correct an abnormality in an existing sagittal J-curve of a corresponding femoral condyle of the patient.

4. The femoral implant of claim 3, wherein the abnormality is an abnormality selected from the group consisting of an arthritic flattening of the patient'"'"'s corresponding femoral condyle, one or more subchondral cysts, one or more osteophyte formations, and any combination thereof.

5. The femoral implant of claim 1, wherein at least a portion of the sagittal curvature is derived from the patient-specific image data to match an existing feature of the patient'"'"'s biology.

6. The femoral implant of claim 1, wherein at least a portion of a coronal curvature of the articulating surface of the condylar portion of the femoral implant is derived from the patient-specific image data.

7. The femoral implant of claim 1, wherein a coronal curvature of the articulating surface of the condylar portion of the femoral implant is substantially constant along at least a portion of the articulating surface.

8. The femoral implant of claim 2, 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, biomechanical axes, alignment, 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.

9. The femoral implant of claim 2, wherein the existing feature of the patient'"'"'s biology includes one or more of a deformity of the knee joint, an alignment of the knee joint, a trochlear shape of the knee joint, a ligament of the knee joint, kinematics of the knee joint, biomechanics of the knee joint, joint-line location of the knee joint, and joint-gap width of the knee joint.

10. The femoral implant of claim 1, wherein the bone-facing surface substantially opposes the articulating surface, and wherein the bone-facing surface includes two or more facets configured to abut a resected surface of a corresponding femoral condyle of the knee joint of the patient.

11. The femoral implant of claim 10, wherein the resected surface of the corresponding femoral condyle is prepared with a predetermined resectioning strategy selected or designed for the patient.

12. The femoral implant of claim 1, wherein the femoral implant is configured to replace both medial and lateral femoral condyles of the knee joint of the patient, and includes a corresponding medial condylar portion and a corresponding lateral condylar portion.

13. The femoral implant of claim 1, wherein the femoral implant is configured to replace a medial or a lateral femoral condyle of the knee joint of the patient, and includes a corresponding medial condylar portion or a corresponding lateral condylar portion.

22. The femoral implant of claim 1, wherein the sagittal curvature of the articulating surface of the condylar portion of the femoral implant is adapted based on patient-specific measurements to improve a feature of the femoral implant relative to the knee joint of the patient.

23. The femoral implant of claim 22, wherein the feature of the femoral implant is a feature selected from the group consisting of an A-P dimension, an M-L dimension, an S-I dimension and any combination thereof.

14. An implant system for repairing a knee joint of a patient, comprising:

a femoral implant, wherein an articulating surface of a condylar portion of the femoral implant comprises a sagittal curvature derived from patient-specific image data of the knee joint of the patient; and

a tibial implant having a joint-facing surface, wherein at least a portion of the joint-facing surface of the tibial implant has a shape based on the articulating surface of the condylar portion of the femoral implant.

15. The implant system of claim 14, wherein a coronal curvature of the articulating surface of the condylar portion of the femoral implant is substantially constant at least a portion of the articulating surface.

16. The implant system of claim 15, wherein a coronal curvature of at least a portion of the joint-facing surface of the tibial implant is substantially constant.

17. The implant system of claim 14, wherein the femoral implant is configured to replace both medial and lateral femoral condyles of the knee joint of the patient, and includes a corresponding medial condylar portion and a corresponding lateral condylar portion.

18. The implant system of claim 14, wherein the femoral implant is configured to replace a medial or a lateral femoral condyle of the knee joint of the patient, and includes a corresponding medial condylar portion or a corresponding lateral condylar portion.

19. The implant system of claim 17, wherein the tibial implant includes a single insert having the joint-facing surface, wherein at least a portion of the joint-facing surface of the single insert has a shape based on the articulating surface of both medial and lateral condylar portions of the femoral implant.

20. The implant system of claim 17, wherein the tibial implant includes dual inserts having the joint-facing surface, wherein at least a portion of the joint-facing surface of the dual inserts has a shape based on the articulating surface of both medial and lateral condylar portions of the femoral implant.

21. The implant system of claim 17, wherein the tibial implant includes an all polyethylene implant having the joint-facing surface, wherein at least a portion of the joint-facing surface of the all polyethylene implant has a shape based on the articulating surface of both medial and lateral condylar portions of the femoral implant.

24. An articular repair system for repairing a joint of a patient, comprising:

an articular surface that includes variable radii in a first plane, wherein the varying radii are derived from patient-specific image data of the joint of the patient, and wherein at least a portion of the articular surface includes a single radius in a second plane.

25. The articular repair system of claim 24, wherein the first plane is an anteroposterior plane.

26. The articular repair system of claim 24, wherein the second plane is an anteroposterior plane.

27. The articular repair system of claim 24, wherein the first plane is a mediolateral plane.

28. The articular repair system of claim 24, wherein the second plane is a mediolateral plane.

29. The articular repair system of claim 24, wherein the first plane is a superoinferior plane.

30. The articular repair system of claim 24, wherein the second plane is a superoinferior plane.

31. The articular repair system of claim 24, wherein the single radius is not derived from patient-specific image data.