Joint arthroplasty devices and surgical tools

• US 9,125,673 B2
• Filed: 11/05/2013
• Issued: 09/08/2015
• Est. Priority Date: 05/25/2001
• Status: Expired due to Term

• Current Assignee: Conformis Incorporated
• Original Assignee: Conformis Incorporated
• Inventors: Fitz, Wolfgang, Lang, Philipp, Steines, Daniel, Tsougarakis, Konstantinos, Vargas-Voracek, Rene
• Primary Examiner(s): Philogene, Pedro
• Application Number:
  US14/072,754
• Publication Number:
  US 20140058396A1
• Time in Patent Office: 672 Days
• Field of Search: 606/86, 606/87, 606/96, 606/89, 606/79, 606/86.R, 623/21.18, 623/14.12, 623/20.32, 623/20.34, 623/20.14, 294/070.1, 295/57, 295/271
• US Class Current: 1/1
• CPC Class Codes: A61B 17/15 Guides therefor arrangements for guiding straight saw blades in general B23D51/025
• 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 17/158 Cutting patella
• CPC Class Codes: A61B 17/16 Bone cutting, breaking or removal means other than saws, e.g. Osteoclasts; Drills or chisels for bones; Trepans arthroscopic bone cutters A61B17/320016; dental implant drills potentially for other surgical use A61C8/0089; bone grinders A61F2/4644, A22C17/06; A61B17/1662 takes precedence over all other subgroups except A61B17/17
• CPC Class Codes: A61B 17/1666 for the acetabulum
• CPC Class Codes: A61B 17/1668 for the upper femur A61B17/164 takes precedence
• CPC Class Codes: A61B 17/1671 for the spine
• CPC Class Codes: A61B 17/1675 for the knee
• CPC Class Codes: A61B 17/1739 specially adapted for particular parts of the body
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 17/7098 wherein the implant is permeable or has openings, e.g. fenestrated screw hollow surgical screws A61B17/864
• CPC Class Codes: A61B 17/8805 for introducing fluid filler into bone or extracting it A61B17/7097, A61B17/8833 take precedence
• CPC Class Codes: A61B 2034/102 Modelling of surgical devices, implants or prosthesis
• CPC Class Codes: A61B 2034/105 Modelling of the patient, e.g. for ligaments or bones
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: A61B 2034/256 having a database of accessory information, e.g. including context sensitive help or scientific articles
• CPC Class Codes: A61B 2090/061 for measuring dimensions, e.g. length
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• CPC Class Codes: A61B 34/20 : Surgical navigation systems; Devices for tracking or guiding surgical instruments, e.g. for frameless stereotaxis
• CPC Class Codes: A61B 5/4504 : Bones A61B5/4547 takes precedence
• CPC Class Codes: A61B 5/4514 : Cartilage
• CPC Class Codes: A61B 5/4528 : Joints A61B5/4533, A61B5/4538 take precedence
• CPC Class Codes: A61B 6/508 : for non-human patients
• CPC Class Codes: A61F 2/30756 : Cartilage endoprostheses A61F2/3603 takes precedence
• CPC Class Codes: A61F 2/30767 : Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/30771 : applied in original prostheses, e.g. holes or grooves
• 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 2/36 : Femoral heads ; Femoral endoprostheses
• CPC Class Codes: A61F 2/3859 : Femoral components
• CPC Class Codes: A61F 2/4657 : Measuring instruments used for implanting artificial joints for surgical instruments A61B90/06
• CPC Class Codes: A61F 2002/30062 : (bio)absorbable, biodegradable, bioerodable, (bio)resorbable, resorptive
• CPC Class Codes: A61F 2002/30677 : Means for introducing or releasing pharmaceutical products, e.g. antibiotics, into the body
• CPC Class Codes: A61F 2002/30787 : inclined obliquely with respect to each other
• CPC Class Codes: A61F 2002/30841 : Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes
• CPC Class Codes: A61F 2002/30894 : inclined obliquely with respect to each other
• CPC Class Codes: A61F 2002/3092 : having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30948 : using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/30957 : using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30962 : using stereolithography
• CPC Class Codes: A61F 2002/3097 : using laser
• CPC Class Codes: A61F 2002/4631 : the prosthesis being specially adapted for being cemented
• CPC Class Codes: A61F 2210/0004 : bioabsorbable
• CPC Class Codes: A61F 2310/00011 : Metals or alloys
• 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 2310/00047 : Aluminium or Al-based alloys
• CPC Class Codes: A61F 2310/00065 : Manganese or Mn-based alloys
• CPC Class Codes: A61F 2310/00071 : Nickel or Ni-based alloys
• CPC Class Codes: A61F 2310/00077 : Copper or Cu-based alloys
• CPC Class Codes: A61F 2310/00083 : Zinc or Zn-based alloys
• CPC Class Codes: A61F 2310/00107 : Palladium or Pd-based alloys
• CPC Class Codes: A61F 2310/00113 : Silver or Ag-based alloys
• CPC Class Codes: A61F 2310/00119 : Tin or Sn-based alloys
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00143 : Iridium or Ir-based alloys
• CPC Class Codes: A61F 2310/00149 : Platinum or Pt-based alloys
• CPC Class Codes: A61F 2310/00155 : Gold or Au-based alloys
• CPC Class Codes: A61F 2310/00293 : containing a phosphorus-containing compound, e.g. apatite
• CPC Class Codes: A61F 2310/00383 : Gelatin
• CPC Class Codes: A61F 2310/00395 : Coating or prosthesis-covering structure made of metals or of alloys
• CPC Class Codes: A61F 2310/00592 : Coating or prosthesis-covering structure made of ceramics or of ceramic-like compounds
• CPC Class Codes: B23Q 17/00 : Arrangements for observing, indicating or measuring on machine tools for automatic control or regulation of feed movement, cutting velocity or position of tool or work B23Q15/00
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49 : Method of mechanical manufacture
• CPC Class Codes: Y10T 29/49764 : with testing or indicating
• CPC Class Codes: Y10T 29/49778 : with aligning, guiding, or instruction

Abstract

Disclosed herein are methods, compositions and tools for repairing articular surfaces repair materials and for repairing an articular surface. The articular surface repairs are customizable or highly selectable by patient and geared toward providing optimal fit and function. The surgical tools are designed to be customizable or highly selectable by patient to increase the speed, accuracy and simplicity of performing total or partial arthroplasty.

Claims

1. A system for surgically repairing a joint of a patient, comprising:

a surgical tool having;

a first mold including an internal surface that substantially conforms to the shape of a surface of the joint of the patient; and

a cutting guide to guide a surgical instrument, wherein the first mold and the cutting guide each includes one or more holes that include anatomical information of the joint to facilitate the placement of an articular repair system when the internal surface of the first mold is aligned with and substantially conforms to the shape of the surface of the joint, wherein the joint of the patient is an ankle joint of the patient.

2. The system of claim 1, wherein the first mold has a shape that substantially conforms to a portion of a tibia.

3. The system of claim 1, wherein the first mold has a shape that substantially conforms to a portion of cortical bone of the ankle joint of the patient.

4. The system of claim 1, wherein the first mold has a shape that substantially conforms to a portion of an articular surface of the ankle joint of the patient.

5. The system of claim 1, wherein the first mold has a shape that substantially conforms to a portion of cartilage of the ankle joint of the patient.

6. The system of claim 1, wherein the first mold has a shape that substantially conforms to a portion of subchondral bone of the ankle joint of the patient.

7. The system of claim 1, wherein the first mold includes one or more holes to guide one or more pins, wherein the one or more guide holes of the cutting guide is configured to accommodate the one or more pins.

8. The system of claim 1, wherein the tool is a first tool, and further comprising:

a second surgical tool having;

a second mold including an internal surface that substantially conforms to the shape of a second surface of the ankle joint of the patient; and

a second cutting guide, wherein the second guide includes anatomical information of the joint to facilitate the placement of a second component of an ankle repair system when the internal surface of the second mold is aligned with and substantially conforms to the shape of the second surface of the ankle joint.

9. The system of claim 8, wherein the first mold has a shape that substantially conforms to a portion of a tibia.

10. The system of claim 8, wherein the first mold has a shape that substantially conforms to a portion of cortical bone of the ankle joint of the patient.

11. The system of claim 8, wherein the first mold has a shape that substantially conforms to a portion of an articular surface of the ankle joint of the patient.

12. The system of claim 8, wherein the first mold has a shape that substantially conforms to a portion of cartilage of the ankle joint of the patient.

13. The system of claim 8, wherein the first mold has a shape that substantially conforms to a portion of subchondral bone of the ankle joint of the patient.

14. The system of claim 8, further comprising an ankle implant.

15. The system of claim 8, further comprising an articular implant.

16. The system of claim 1, further comprising an ankle implant.

17. The system of claim 1, wherein the anatomical information is information regarding an axis associated with the ankle joint of the patient.

18. The system of claim 1, wherein the anatomical information is information regarding a tibial axis of the patient.

19. The system of claim 1, wherein the anatomical information is information regarding a deformity of the joint of the patient.

20. The system of claim 1, wherein the anatomical information is information regarding an alignment of the joint of the patient.

21. The system of claim 1, wherein the guide defines at least in part a rotation of an ankle implant.

22. The system of claim 1, wherein the guide defines at least in part an axial rotation of an ankle implant.

23. The system of claim 1, wherein the guide defines a cut plane extending into the joint.

24. The system of claim 1, wherein the mold and the cutting guide are integrally formed.

25. The system of claim 1, wherein the mold and the cutting guide are separate components.

26. A system for surgically repairing a joint of a patient, comprising:

a mold having an internal surface that substantially conforms to the shape of a surface of the of a joint of the patient; and

a guide to guide a surgical instrument, wherein the guide includes rotational information of the joint to facilitate the placement of an articular repair system when the internal surface of the mold is aligned with and substantially conforms to the shape of the surface of the joint, wherein the joint of the patient is an ankle joint of the patient.

27. A system for surgically repairing a joint of a patient, comprising:

a mold having an internal surface that substantially conforms to the shape of an articular surface of a joint of the patient; and

a guide to guide a surgical instrument, wherein the guide includes rotational information of the joint to facilitate the placement of an articular repair system when the internal surface of the mold is aligned with and substantially conforms to the shape of the articular surface of the joint, wherein the joint of the patient is an ankle joint of the patient.

28. A system for surgically repairing a joint of a patient, comprising:

a first surgical tool having a first mold having an internal surface that substantially conforms to the shape of a first surface of a joint of the patient; and

a first guide configured to guide a surgical instrument, wherein the guide includes first anatomical information of the joint to facilitate the placement of an articular repair system when the internal surface of the mold is aligned with and substantially conforms to the shape of the bone surface of the joint; and

a second surgical tool having a second mold having an internal surface that substantially conforms to the shape of a second surface of the joint of the patient; and

a second guide configured to guide a surgical instrument, wherein the guide includes second anatomical information of the joint to facilitate the placement of an articular repair system when the internal surface of the mold is aligned with and substantially conforms to the shape of the bone surface of the joint, wherein the joint of the patient is an ankle joint of the patient.

29. The surgical instrument of claim 28, further comprising an articular implant.

30. The surgical instrument of claim 29, wherein the first anatomical information includes rotational information of the articular implant.