Acetabular cup prosthesis alignment system and method

• US 9,585,768 B2
• Filed: 03/15/2013
• Issued: 03/07/2017
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Inventors: Sherman, Jason T., Birkbeck, Alec A., Freeman, Robert R.
• Primary Examiner(s): LAWSON, MATTHEW JAMES
• Application Number:
  US13/834,993
• Publication Number:
  US 20140276871A1
• Time in Patent Office: 1,453 Days
• US Class Current: 1/1
• CPC Class Codes: A61B 2034/2048 using an accelerometer or inertia sensor
• 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 34/25 User interfaces for surgical systems
• CPC Class Codes: A61F 2/34 Acetabular cups
• CPC Class Codes: A61F 2/4609 of acetabular cups
• CPC Class Codes: A61F 2/4657 Measuring instruments used for implanting artificial joints for surgical instruments A61B90/06
• CPC Class Codes: A61F 2002/4629 connected to the endoprosthesis or implant via a threaded connection
• CPC Class Codes: A61F 2002/4632 using computer-controlled surgery, e.g. robotic surgery
• CPC Class Codes: A61F 2002/4668 for measuring angles

Abstract

Technologies for aligning an acetabular prosthetic component in a patient'"'"'s surgically prepared acetabulum include a reference sensor module securable to the patient'"'"'s bony anatomy, an inserter sensor module securable to an acetabular prosthetic component inserter, and a display module. Each sensor module generates sensor data indicative of the orientation of the sensor module and/or structures to which the sensor module is coupled. The display module receives the sensor data from the sensor modules, determines the orientation of the acetabular prosthetic component relative to the patient'"'"'s bony anatomy, and displays indicia of the determined orientation on a display.

Claims

1. A system for aligning an acetabular prosthetic component in a patient'"'"'s surgically prepared acetabulum, the system comprising:

a reference sensor module securable to the patient'"'"'s bony anatomy and including (i) a housing having a first keyed structure, (ii) a first orientation sensor configured to generate first sensor data indicative of the orientation of the patient'"'"'s bony anatomy in three-dimensions, and (iii) a first communication circuit to transmit the first sensor data;

an inserter sensor module securable to an acetabular prosthetic component inserter, the inserter sensor module including (i) a housing having a second keyed structure, (ii) a second orientation sensor configured to generate second sensor data indicative of the orientation of the acetabular prosthetic component inserter in three-dimensions, (iii) a second communication circuit to transmit the second sensor data, and (iv) an alignment indicator;

a display module separate from the reference sensor module and the inserter sensor module, the display module including (i) a display, (ii) a third communication circuit configured to receive the first sensor data and the second sensor data, and (iii) a processing circuit to determine an orientation of an acetabular prosthetic component coupled to the acetabular prosthetic component inserter relative to the patient'"'"'s bony anatomy based on the first sensor data and the second sensor data, display indicia of the determined orientation of the acetabular prosthetic component on the display, and communicate with the inserter sensor module to activate the alignment indicator in response to the determined orientation being within threshold amount of a reference orientation;

wherein the first keyed structure and the second keyed structure are keyed to each other such that the reference sensor module and the inserter sensor module can be coupled to each other in a single orientation in which the first keyed structure and the second keyed structure are mated; and

wherein the first keyed structure comprises a raised platform extending upwardly from a top surface of the housing of the reference sensor module and the second keyed structure comprises a recess defined in a top surface of the housing of the inserter sensor module, wherein the raised platform is received in the recess when the reference sensor module and the inserter sensor module are coupled to each other in the single orientation.

2. The system of claim 1, wherein the first orientation sensor comprises a first three-axis gyroscope and a first three-axis accelerometer, and

wherein the second orientation sensor comprises a second three-axis gyroscope and a second three-axis accelerometer.

3. The system of claim 1, wherein each of the reference sensor module and the inserter sensor module includes a power button selectable to turn on the corresponding sensor module, and wherein each of the reference sensor module and the inserter sensor module is incapable of being turned off by selection of the power button after the corresponding sensor module has been turned on.

4. The system of claim 1, wherein the alignment indicator comprises a first alignment indicator and a second alignment indicator, and

wherein the processing circuit of the display module is configured to (i) communicate with the inserter sensor module to activate the first alignment indicator in response to the determined orientation being within a first threshold amount of the reference orientation and (ii) communicate with the inserter sensor module to activate the second alignment indicator in response to the determined orientation being within a second threshold amount of the reference orientation that is less than the first threshold amount.

5. The system of claim 4, wherein the second alignment indicator is bounded by the first alignment indicator.

6. The system of claim 1, wherein the processing circuit of the display module is configured to determine an inclination angle and an anteversion angle of the acetabular prosthetic component relative to the patient'"'"'s bony anatomy and display the inclination angle and the anteversion angle on the display.

7. The system of claim 6, wherein the processing circuit of the display module is configured to display a graphical representation of the acetabular prosthetic component inserter on the display in a position based on the determined inclination angle and anteversion angle.

8. The system of claim 1, wherein the processing circuit of the display module is configured to determine a coordinate system conversion factor to convert the second sensor data from a coordinate system of the inserter sensor module to a patient coordinate system of the patient'"'"'s bony anatomy and determine the orientation of the acetabular prosthetic component inserter relative to the patient'"'"'s bony anatomy using the coordinate system conversion factor.

9. The system of claim 1, further comprising an alignment frame having a frame body, a plurality of contact feet, and cradle, wherein the contact feet are movable relative to the frame body and the cradle is sized to receive the inserter sensor module.

10. A system for aligning an acetabular prosthetic component in a patient'"'"'s surgically prepared acetabulum, the system comprising:

a reference sensor module securable to the patient'"'"'s bony anatomy, the reference sensor module including (i) a housing having a first keyed structure, (ii) a first orientation sensor positioned in the housing and configured to generate first sensor data indicative of the orientation of the patient'"'"'s bony anatomy in three-dimensions, and (iii) a first communication circuit to transmit the first sensor data; and

an inserter sensor module securable to an acetabular prosthetic component inserter, the inserter sensor module including (i) a housing having a second keyed structure (ii) a second orientation sensor configured to generate second sensor data indicative of the orientation of the acetabular prosthetic component inserter in three-dimensions, (iii) a second communication circuit to transmit the second sensor data, and (iv) an alignment indicator,

wherein the first keyed structure and the second keyed structure are keyed to each other such that the reference sensor module and the inserter sensor module can be coupled to each other in a single orientation in which the first keyed structure and the second keyed structure are mated;

wherein the first keyed structure comprises one of a raised platform extending upwardly from a top surface of the housing of the reference sensor module and a recess defined in a top surface of the housing of the reference sensor module and the second keyed structure comprises the other of a raised platform extending upwardly from a top surface of the housing of the inserter sensor module and a recess defined in a top surface of the housing of the inserter sensor module, wherein the raised platform is received in the recess when the reference sensor module and the inserter sensor module are coupled to each other in the single orientation.