Patient selectable knee arthroplasty devices

• US 9,333,085 B2
• Filed: 09/30/2013
• Issued: 05/10/2016
• 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
• Primary Examiner(s): STEWART, JASON-DENNIS NEILKEN
• Application Number:
  US14/040,890
• Publication Number:
  US 20140029814A1
• Time in Patent Office: 953 Days
• Field of Search: 623/16.11, 623/18.11, 623/11.11
• US Class Current: 1/1
• 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: A61F 2/30756 Cartilage endoprostheses A61F2/3603 takes precedence
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• 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 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 2002/30962 using stereolithography
• CPC Class Codes: A61F 2002/4635 using minimally invasive surgery
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G06T 2207/30052 Implant; Prosthesis
• CPC Class Codes: G06T 7/0014 using an image reference approach

Abstract

Disclosed herein are methods and devices for repairing articular surfaces in a knee joint. The articular surface repairs are customizable or highly selectable for each patient and geared toward providing optimal fit and function. Kits are also provided to enable customized repairs to be performed.

Claims

1. A method of generating an articular repair system including an articular implant having an inner surface for attachment to a bone of a patient'"'"'s joint at an implantation site and an outer surface for providing an articular surface, the method comprising:

deriving a shape of cartilage and/or subchondral bone surface from electronic image data of the patient'"'"'s joint;

determining a desired shape for at least a portion of the outer surface of the articular implant at least in part from the derived shape of the cartilage;

selecting the articular implant from a library of implants such that at least a portion of the outer surface of the articular implant approximates the desired shape, wherein at least a portion of the inner surface of the articular implant is configured to engage with a chamfer cut on the bone of the patient'"'"'s joint; and

providing a surgical tool in the articular repair system, wherein the surgical tool is created based, at least in part, on the derived shape of the cartilage and/or subchondral bone surface, and configured to facilitate the implantation of the articular implant into the patient'"'"'s joint.

2. The method of claim 1, wherein the patient'"'"'s joint is a knee joint, wherein the articular implant is a tibial implant.

3. The method of claim 1, wherein the patient'"'"'s joint is a knee joint, wherein the articular implant is a femoral implant that has only one condylar portion.

4. The method of claim 3, wherein the condylar portion is a first condylar portion and the articular implant further comprises a second condylar portion, wherein the first and second condylar portions are disposed on opposite sides of the trochlear portion.

5. The method of claim 4, wherein a bone-facing implant surface of the trochlear portion bone is configured to abut at least a portion of uncut trochlear bone upon implantation of the implant.

6. The method of claim 4, wherein the bone-facing implant surface of the trochlear portion bone is configured to abut at least a portion of cut trochlear bone upon implantation of the implant.

7. The method of claim 1, wherein the library includes implants of various sizes, shapes and/or thicknesses.

8. The method of claim 1, wherein the selected articular implant is further manipulated to match the patient'"'"'s joint.

9. The method of claim 8, wherein the selected articular implant is further manipulated by mechanical abrasion.

10. The method of claim 8, wherein the selected articular implant is further manipulated by, at least in part, an automated process.

11. The method of claim 8, wherein the selected articular implant is further manipulated by, at least in part, a manual process.

12. A method of generating an articular repair system including an articular implant having an inner surface for attachment to a bone of a patient'"'"'s joint at an implantation site and an outer surface for providing an articular surface, the method comprising:

deriving an articular shape from electronic image data of the patient'"'"'s joint;

determining a desired shape for at least a portion of the outer surface of the articular implant at least in part from the derived articular shape of the patient'"'"'s joint;

selecting the articular implant from a library of implants such that at least a portion of the outer surface of the articular implant approximates the desired shape, wherein at least a portion of the inner surface of the articular implant is configured to engage with a prepared bone surface of the patient'"'"'s joint; and

providing a surgical tool in the articular repair system, wherein the surgical tool is created based, at least in part, on the derived articular shape of the patient'"'"'s joint.

13. The method of claim 12, wherein the derived articular shape of the patient'"'"'s joint includes a shape of subchondral bone of an articular surface of the patient'"'"'s joint.

14. The method of claim 12, wherein the derived articular shape of the patient'"'"'s joint includes a shape of cartilage of an articular surface of the patient'"'"'s joint.

15. The method of claim 12, wherein the derived articular shape of the patient'"'"'s joint includes a shape of subchondral bone and cartilage of an articular surface of the patient'"'"'s joint.

16. The method of claim 12, wherein the derived articular shape of the patient'"'"'s joint includes a shape of normal and diseased or damaged cartilage of an articular surface of the patient'"'"'s joint.

17. The method of claim 12, wherein the derived articular shape of the patient'"'"'s joint includes a projected shape of an articular surface of the patient'"'"'s joint.

18. The method of claim 12, wherein the prepared bone surface of the patient'"'"'s joint includes a chamfer cut.

19. The method of claim 12, wherein the library includes implants of various sizes, shapes and/or thicknesses.

20. The method of claim 12, wherein the selected articular implant is further manipulated to match the patient'"'"'s joint.