Surgical templates

• US 9,265,511 B2
• Filed: 11/03/2014
• Issued: 02/23/2016
• Est. Priority Date: 03/23/2007
• Status: Active Grant

• Current Assignee: Xiros Limited
• Original Assignee: Xiros Limited
• Inventors: White, Derrick, Seedhom, Bahaa, Chelule, Kenneth Langat
• Primary Examiner(s): WOODALL, NICHOLAS W
• Application Number:
  US14/531,825
• Publication Number:
  US 20150112350A1
• Time in Patent Office: 477 Days
• US Class Current: 1/1
• 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 17/17 Guides or aligning means for drills , mills, pins or wires
• CPC Class Codes: A61B 17/1703 using imaging means, e.g. by X-rays
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 17/56 Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor
• 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 90/94 coded with symbols, e.g. text
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/461 of knees
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A surgical template system for use in working on a bone comprises: a tool guide block comprising at least one guide aperture for receiving and guiding a tool to work on a bone; locating means comprising a plurality of locating members, each member having a respective end surface for positioning against a surface of the bone; and attachment means for non-adjustably attaching the tool guide block to the locating means such that, when attached, the member end surfaces are secured in fixed position with, respect to each other, for engaging different respective portions of the surface of the bone, and the at least one guide aperture is secured in a fixed position with respect to the end surfaces. Corresponding methods of manufacturing a surgical template system, methods of manufacturing locating means for a surgical template system, methods of fitting a prosthesis to a bone, surgical methods, and surgical apparatus are described.

Claims

1. A surgical template system for use in working on a bone, comprising:

at least one tool guide block comprising at least one guide aperture for receiving and guiding a tool to work on a bone; and

a patient-specific component comprising a plurality of locating members, each member having a respective bone-engaging surface adapted to conform to a respective portion of a predetermined surface of a specific bone of a patient,

wherein the tool guide block is non-adjustably attached to the patient-specific component such that the member bone-engaging surfaces are secured in fixed position with respect to each other, for engaging the different respective portions of said surface of the bone, and the at least one guide aperture is secured in a fixed position with respect to the bone-engaging surfaces, with the bone-engaging surfaces of the locating member configured to conform to said predetermined surface so as to enable the attached patient-specific component and tool guide block to be seated in a defined position with respect to the specific bone, with each member bone-engaging surface in contact with its respective portion of the bone surface, and wherein the tool guide block is formed from a first material and the patient-specific component is formed from a second, different material;

wherein the patient-specific component comprises a bore and a pin adapted to extend through the bore and be drivable into a bone surface to assist in securing the patient-specific component to the patient'"'"'s bone.

2. The system of claim 1, wherein the patient-specific component and the tool guide block is adapted to key together in a defined position.

3. The system of claim 2, wherein the tool guide block comprises a protrusion that is received by a recess of the patient-specific component.

4. The system of claim 2, wherein the tool guide block comprises a tenon that is received by a slot of the patient-specific component.

5. The system of claim 2, wherein the tool guide block comprises a first locking element and the patient-specific component comprises a second locking element, and wherein the tool guide block can be attached to the patient-specific component by relative rotation between the tool guide block and the patient-specific component to cause the first locking element and the second locking element to mate with each other.

6. The system of claim 1, wherein the tool guide block is non-releasably attached to the patient-specific component.

7. The system of claim 1, wherein the tool guide block is attached to the patient-specific component by a snap-fit mechanism.

8. The system of claim 1, further comprising a sleeve lining the bore.

9. The system of claim 1, wherein the guide aperture comprises at least one slot for guiding a saw blade.

10. The system of claim 1, wherein the patient-specific component comprises a body portion and the plurality of locating members are integral with and extend from the body portion, the tool guide block being attached to the body portion the patient-specific component.

11. The system of claim 10, wherein the locating members are spaced apart from each other so as to define a gap therebetween and such that locating members can contact respective, spaced apart, predetermined surface portions of the bone with surface portions between adjacent locating members not being in contact with the patient-specific component.

12. The system of claim 11, wherein the locating members are adapted to contact an articular surface of a tibia or a femur.

13. The system of claim 11, wherein the locating members are adapted to contact a non-articular surface of a tibia or a femur.

14. The system of claim 11, wherein one of the locating members is adapted to contact an articular surface of the bone and one of the locating members is adapted to contact a non-articular surface of the bone.

15. The system of claim 1, wherein the at least one tool guide block comprises first and second tool guide blocks, the first tool guide block having a guide aperture in the form of a slot for guiding a saw blade, and the second tool guide block having a guide aperture in the form of a bore for guiding a drill bit.

16. The system of claim 1, wherein the guide aperture comprises at least one slot for guiding a saw blade and at least one of the locating members comprises a slit to allow unhindered movement of the saw blade when guided by the slot.

17. The system of claim 1, wherein the patient-specific component comprises a body portion and the plurality of locating members are integral with and extend from the body portion, the at least one tool guide block comprising a plurality of tool guide blocks, each tool guide block being adapted to key together with the patient-specific component in a defined position.

18. The system of claim 17, wherein the guide aperture of each tool guide block comprises a bore for guiding a drill bit.

19. A surgical template system for use in working on a bone, comprising:

at least one tool guide block comprising at least one guide aperture for receiving and guiding a tool to work on a bone; and

a patient-specific component comprising a plurality of locating members, each member having a respective bone-engaging surface adapted to conform to a respective portion of a predetermined surface of a specific bone of a patient,

wherein the tool guide block is non-adjustably attached to the patient-specific component such that the member bone-engaging surfaces are secured in fixed position with respect to each other, for engaging the different respective portions of said surface of the bone, the at least one guide aperture is secured in a fixed position with respect to the bone-engaging surfaces, and the bone-engaging surfaces of the locating members conform to said predetermined surface so as to enable the attached patient-specific component and tool guide block to be seated in a defined position with respect to the specific bone, with each member bone-engaging surface in contact with its respective portion of the bone surface, and wherein the tool guide block is formed from a first material and the patient-specific component is formed from a second, different material;

wherein the patient-specific component comprises a plurality of bores, a plurality of sleeves lining the bores, and a plurality of pins adapted to extend through respective bores and be drivable into a bone surface to assist in securing the patient-specific component to the patient'"'"'s bone.

20. The system of claim 19, wherein the plurality of bores comprises first and second bores, each extending through one of the locating members.