Spacer molds for orthopedic implants

• US 9,433,506 B2
• Filed: 05/02/2013
• Issued: 09/06/2016
• Est. Priority Date: 05/03/2012
• Status: Active Grant

• Current Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Inventors: Lomicka, Matthew J., Barfield, Charlie, Cordonnier, Michael, Protopsaltis, Dimitri, Lingeman, Stephen, Daniel, William, Strohkirch, Terrance, Lenz, Amber
• Primary Examiner(s): Heitbrink, Jill
• Application Number:
  US13/875,744
• Publication Number:
  US 20130295213A1
• Time in Patent Office: 1,223 Days
• Field of Search: 425/577, 425/451.9, 425/DIG.221
• US Class Current: 1/1
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/3872 Meniscus for implantation between the natural bone surfaces
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2002/30537 adjustable
• CPC Class Codes: A61F 2002/30556 for adjusting thickness
• CPC Class Codes: A61F 2310/00353 Bone cement, e.g. polymethylmethacrylate or PMMA

Abstract

A prosthetic mold for forming a prosthesis is disclosed. The prosthesis can include a bone mating surface, an articulating surface, and an intermedullary post. The prosthetic mold can include a first portion, a second portion engageable with the first portion, and an injection portion. The first portion can be configured to form the articulating surface. The second portion can be configured to form the bone mating surface and define an intermedullary post cavity. Engagement between the first and second portions can define a mold cavity. The injection port can be axially aligned, and in communication, with the intermedullary post cavity. The injection port can engage an injection assembly. In one embodiment, the prosthetic mold is configured to form a tibial prosthesis. In another embodiment, the prosthetic mold is configured to form a femoral prosthesis.

Claims

1. A prosthetic mold for forming a prosthesis having a bone mating surface, an articulating surface, and an intermedullary post, the mold comprising:

a first portion configured to form the articulating surface;

a second portion engageable with the first portion to define a mold cavity therebetween, the second portion configured to form the bone mating surface and define an intermedullary post cavity; and

an injection port configured to engage an injection assembly, the injection port extending outwardly from the second portion such that the injection port is axially aligned, and in communication, with the intermedullary post cavity.

2. The prosthetic mold of claim 1, further comprising a post-injection assembly configured to be removably coupled to the injection port, the post-injection assembly including a handle and a stem having at least one channel in fluid communication with the mold cavity, the at least one channel configured to permit a fluid to flow from the mold cavity into a hollow portion of the post-injection assembly.

3. The prosthetic mold of claim 1, further comprising at least one locking member configured to contemporaneously engage at least one first protrusion, disposed on the first portion, and at least one second protrusion, disposed on the second portion, to secure the first and second portions to each other.

4. The prosthetic mold of claim 3, the first and second portions further including a first and a second disengagement member, respectively, the at least one locking member configured to separately engage the first and the second disengagement member.

5. The prosthetic mold of claim 3, wherein the at least one locking member is configured to provide a planar surface for positioning the mold in an upright position.

6. The prosthetic mold of claim 1, wherein the second portion comprises:

a plunger configured to form the bone mating surface and define the intermedullary post cavity; and

a cover configured to fit over the plunger and engage the first portion.

7. The prosthetic mold of claim 6, wherein a position of the plunger, relative to the first portion, is adjustable among a plurality of positions between a predetermined maximum distance and a predetermined minimum distance.

8. The prosthetic mold of claim 7, further comprising an adjustment mechanism engaged with the plunger and configured to continuously adjust the plunger among the plurality of positions.

9. The prosthetic mold of claim 8, wherein the adjustment mechanism comprises a dial having a threaded surface configured to cooperate with a threaded surface of the plunger.

10. The prosthetic mold of claim 7, wherein the plunger further comprises a plurality of indicia corresponding to a plurality of dimensions of the mold cavity, as measured when the plunger is in one of the plurality of adjustable positions.

11. The prosthetic mold of claim 10, wherein the plurality of dimensions correspond to a plurality of distances between the bone mating surface and a region of the first portion corresponding to a low point in the articular surface of the prosthesis.

12. A prosthetic mold for forming a prosthesis having a bone mating surface and an articulating surface, the mold comprising:

a cavity member configured to form the articulating surface; and

a plunger having a surface configured to form the bone mating surface and a portion configured to form an intermedullary post having an injection port.

13. The prosthetic mold of claim 12, wherein the plunger comprises a plurality of vents in communication with the mold cavity.

14. The prosthetic mold of claim 12, further comprising an adjustment mechanism engaged with the plunger and configured to continuously adjust the plunger among a plurality of positions.

15. The prosthetic mold of claim 14, wherein the adjustment mechanism comprises a dial having a threaded surface configured to cooperate with a threaded surface of the plunger.

16. The prosthetic mold of claim 12, wherein the plunger further comprises a plurality of indicia corresponding to a plurality of dimensions of the mold cavity, as measured when the plunger is in one of a plurality of positions.

17. The prosthetic mold of claim 16, wherein the plurality of dimensions correspond to a plurality of distances between the bone mating surface and a region of the cavity member corresponding to a low point in the articular surface of the prosthesis.

18. The prosthetic mold of claim 12, further comprising a stop mechanism configured to engage the plunger to fix the position of the plunger within the mold cavity.

19. The prosthetic mold of claim 12, further comprising a compression mechanism engaged with the plunger, the cavity member, or both, and configured to press the plunger into the cavity member.

20. The prosthetic mold of claim 19, wherein the compression mechanism comprises a cover, an adjustment dial, or a compression rod.