Patient specific surgical guide locator and mount

• US 9,089,342 B2
• Filed: 05/07/2012
• Issued: 07/28/2015
• Est. Priority Date: 02/24/2009
• Status: Active Grant

• Current Assignee: MicroPort Orthopedics Holdings, Inc. (MicroPort Scientific Corp.)
• Original Assignee: MicroPort Orthopedics Holdings, Inc. (MicroPort Scientific Corp.)
• Inventors: Carroll, Michael, Obert, Richard, Stemniski, Paul
• Primary Examiner(s): Yang, Andrew
• Assistant Examiner(s): Chang, Olivia C
• Application Number:
  US13/465,547
• Publication Number:
  US 20120221008A1
• Time in Patent Office: 1,177 Days
• Field of Search: 606 86 R- 90
• US Class Current: 1/1
• CPC Class Codes: A61B 17/151 for corrective osteotomy
• 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 2017/0023 disposable
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: A61B 2034/104 Modelling the effect of the tool, e.g. the effect of an implanted prosthesis or for predicting the effect of ablation or burring
• 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: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture
• CPC Class Codes: Y10T 29/49863 with prestressing of part

Abstract

A resection guide locator includes a bone engagement portion with surfaces that are complementary to the surface topographies of a bone to be resected during surgery. A housing includes a socket defined by a resilient annular wall that is sized and arranged so to accept a resection guide by press-fit to thereby position and hold the resection guide within he socket. The resection guide is maintained in a predetermined, preferred position while the surfaces are releasably locked in position on the bone. A method is disclosed for forming and using the resection guide locator.

Claims

1. A resection guide locator for use in resecting a bone having a surface topography comprising:

a bone engagement portion having a surface that is complementary to said surface topography of said bone to be resected; and

a socket sized to receive a resection guide so as to maintain said resection guide in position while said surface of said one engagement portion is arranged in contacting relation with the bone,

wherein an elongate slot and a pair of through holes are defined within the socket, the elongate slot and pair of through holes are positioned within the socket such that they respectively align with an elongate slot and a pair of through holes defined by the resection guide when the resection guide is received within the socket, and

wherein the elongate slot and pair of through holes defined within the sockets are disposed at a distance from one another such that they do not intersect.

2. A resection guide locator according to claim 1 wherein said surface of said bone engagement portion comprises a surface topography wherein one or more localized prominences have a location, shape, and size that complement the location, shape, and size of a corresponding one or more localized concavities that define a portion of said surface topography of said bone.

3. A resection guide locator according to claim 1 wherein said surface of said bone engagement portion comprises a surface topography wherein one or more localized concavities have a location, shape, and size that complement the location, shape, and size of a corresponding one or more localized prominences that define a portion of said surface topography of said bone.

4. A resection guide locator according to claim 2 or 3 wherein said surface of said bone comprises a condylar surface.

5. A resection guide locator according to claim 2 or 3 wherein said surface of said bone comprises an articular surface.

6. A resection guide locator according to claim 2 or 3 wherein said surface of said one comprises a cortical surface.

7. A resection guide locator according to claim 1 wherein said surface of said bone engagement portion comprises a complementary, substantially mirror image of the anatomic surface features of a selected region of said bone.

8. A resection guide locator according to claim 2 wherein said one or more localized prominences of said bone engagement portion and said one or more corresponding localized concavities of said bone securely engage one another so as to releasably interlock said surface of said bone engagement portion of said resection guide with said surface of said bone.

9. A resection guide locator according to claim 3 wherein mating of at least one of said bone surface prominences with a corresponding complementary concavity defined in a bone engaging surface of said resection guide locator impedes relative movement therebetween.

10. A resection guide locator according to claim 2 wherein mating of at least one of said bone surface concavity with a corresponding complementary prominence defined in a bone engaging surface of said resection guide locator impedes relative movement therebetween.

11. A resection guide locator for use in resecting a boric having a surface topography comprising:

a bone engagement portion having a surface that is complementary to said surface topography of said bone to be resected; and

a socket defined by a resilient wall arranged for storing energy when a resection guide is press-fit in said socket and operatively engages a portion of said wall so as to maintain said resection guide in position while said surface of said bone engagement portion is arranged in contacting relation with the bone,

wherein an elongate slot and a pair of through holes are defined within the socket, the elongate slot and pair of through holes are positioned within the socket such that they respectively align with an elongate slot and a pair of through holes defined by the resection guide when the resection guide is received within the socket, and

wherein the elongate slot and pair of through holes defined within the socket are disposed at a distance from one another such that they do not intersect.

12. A resection guide locator according to claim 11 wherein said surface of said bone engagement portion comprises a surface topography wherein one or more localized prominences have a location, shape, and size that complement the location, shape, and size of a corresponding one or more localized concavities that define a portion of said surface topography of said bone, and further wherein said surface of said bone engagement portion comprises a surface topography wherein one or more localized concavities have a location, shape, and size that complement the location, shape, and size of a corresponding one or more localized prominences that defines a portion of said surface topography of said bone.

13. A resection guide locator according to claims 11 wherein said surface of said bone comprises at least one of a condylar surface, an articular surface, and a cortical surface.

14. A resection guide locator according to claim 11 wherein said surface of said bone engagement portion comprises a complementary, substantially mirror image of the anatomic surface features of a selected region of said bone.

15. A resection guide locator according to claims 12 wherein said one or more localized prominences and said one or more corresponding localized concavities securely engage one another so as to releasably interlock said surface of said bone engagement portion of said resection guide with said surface of said bone.

16. A resection guide locator according to claims 12 wherein mating of at least one of said bone surface prominences with a corresponding complementary concavity defined in a bone engaging surface of said resection guide locator impedes relative movement therebetween.

17. A resection guide locator according to claims 12 wherein mating of at least one of said bone surface concavity with a corresponding complementary prominence defined in a bone engaging surface of said resection guide locator impedes relative movement therebetween.

18. A resection guide locator for use in resecting to bone having a surface topography comprising:

a bone engagement portion having a surface that is complementary to the surface topography of said bone to be resected; and

a socket sized to receive by press-fit a resection guide having a resection slot so as to maintain said resection slot defined by the resection guide in a substantially fixed orientation relative to the bone engagement portion while said surface of said bone engagement portion is arranged in secure interlocking relation with said bone surface,

wherein an elongate slot and a pair of through holes are defined within the socket, the elongate slot and the pair of through holes are positioned within the socket that they respectively align with the resection slot and a pair of through holes defined by the resection guide when the resection guide is received within the socket, and

wherein the elongate slot and pair of through holes defined within the socket are disposed at a distance from one another such that they do not intersect.

19. A resection guide locator according to claim 18 wherein said surface of said bone engagement portion comprises a surface topography wherein one or more localized prominences have a location, shape, and size that complement the location, shape, and size of a corresponding one or more localized concavities that define a portion of said surface topography of said bone, and further wherein said surface of said bone engagement portion comprises a surface topography wherein one or more localized concavities have as location, shape, and size that complement the location, shape, and size of a corresponding one or more localized prominences that define a portion of said surface topography of said bone.

20. A resection guide locator according to claims 18 wherein said surface of said bone comprises at least one of a condylar surface, an articular surface, and a cortical surface.

21. A resection guide locator according to claim 18 wherein said surface of said bone engagement portion comprises a complementary, substantially mirror image of the anatomic surface features of a selected region of said bone.

22. A resection guide locator according to claims 19 wherein said one or more localized prominences and said one or more corresponding localized concavities securely engage one another so as to releasably interlock said surface of said bone engagement portion of said resection guide with said surface of said bone.

23. A section guide locator according to claims 19 wherein mating of at least one of said bone surface prominences with a corresponding complementary concavity defined in a bone engaging surface of said resection guide locator impedes relative movement therebetween.

24. A resection guide locator according to claims 19 wherein mating of at least one of said bone surface concavity with a corresponding complementary prominence defined in a bone engaging surface of said resection guide locator impedes relative movement therebetween.

25. A resection guide mount comprising:

a bone engagement portion having two surfaces that are complementary to respective separate surface topographies of a bone to be resected; and

a housing portion attached to said bone engaging portion having a socket defined by a resilient annular wall that is sized and arranged so to accept a resection guide by press-fit, to thereby position and hold said resection guide within said socket and thereby maintain said resection guide in a predetermined position while said two surfaces of said bone engagement portion is arranged in secure interlocking relation with said two separate surfaces of bone to be resected,

wherein the housing portion defines an elongate slot, and a pair of through holes within the socket, the elongate slot and pair of through holes are positioned within the socket such that they respectively align with an elongate slot and a pair of through holes defined by the resection guide when the resection guide is received within the socket, and

wherein the elongate slot and the pair of through holes defined within the socket are disposed at a distance from one another such that they do not intersect.

26. A resection guide locator comprising:

a base sized to engage a portion of a bone to be resected having a surface that is topographically complementary to the surface topography of said bone; and

a housing attached to said base comprising a socket defined by a resilient peripheral wall arranged for storing energy when a resection guide is press-fit in said socket so as to operatively engage said wall thereby maintaining said guide in a predetermined position relative to said one while said topographically complementary surface of said bone engagement portion is arranged in secure interlocking relation with said bone surface,

wherein the housing portion defines an elongate slot and a pair of through holes within the socket, the elongate slot and pair of through holes are positioned within the socket such that they respectively align with an elongate slot and a pair of through holes defined by the resection guide when the resection guide is received within the socket, and

wherein the elongate slot and the pair of through holes defined within the socket are disposed at a distance from one another such that they do not intersect.

27. A method for forming a resection guide locator comprising the steps of:

(A) generating an anatomically accurate image of a bone that includes surface topographies;

(B) converting said anatomically accurate image to a digital model;

(C) adding a digital representation of a resection guide locator to said digital model so as to form a composite digital model;

(D) mapping one of said surface topographies complementarily onto a bone engagement portion of said resection guide locator; and

(E) manufacturing said resection guide locator based upon said composite digital model so that a manufactured resection guide locator is formed including said complementary surface topography on a bone engagement portion and a receptacle pocket sized to receive a resection guide with a press-fit, the resection guide locator defining an elongate slot and a pair through holes within the receptacle pocket, the elongate slot and pair of through holes are positioned within the receptacle pocket such that they respectively align with an elongate slot and a pair of through holes defined by the resection guide when the resection guide is received within the receptacle pocket,

wherein the elongate slot and the pair of through holes defined within the receptacle pocket are disposed at a distance from one another such that they do not intersect.

28. A method comprising the steps of:

(A) generating an anatomically accurate image of a bone that includes surface topographies;

(B) converting said anatomically accurate image to a digital model;

(C) adding a digital representation of a resection guide locator to said digital model so as to form a composite digital model;

(D) mapping one of said surface topographies complementarily onto a bone engagement portion of said resection guide locator;

(E) manufacturing said resection guide locator based upon said composite digital model so that a manufactured resection guide locator is formed including said complementary surface topography on a bone engagement portion and a receptacle pocket sized to receive a resection guide with a press-fit, the resection guide locator defining an elongate slot and a pair of through holes within the receptacle pocket, the elongate slot and pair of through holes are positioned within the receptacle pocket such that they respectively align with an elongate slot and a pair of through holes defined by the resection guide when the resection guide is received within the receptacle pocket; and

(F) applying said resection guide locator to said bone such that said complementary surface topography locks said bone engagement portion to a corresponding portion of said bone,

wherein the elongate slot and the pair of through holes defined within the receptacle pocket are disposed at a distance from one another such that they do not intersect.

29. The method of claim 28 further comprising inserting a resection guide in said receptacle pocket of said reception guide locator such that the elongate slot and the pair of through holes defined by the resection guide respectively align with the elongate slot and pair of through holes defined by the resection guide locator within the receptacle pocket.

30. The method of claim 29 further comprising pinning said resection guide to the one by inserting a pin into each through hole of the pair of through holes define by the resection guide such that said resection guide locator is sandwiched between said resection guide and the bone.