Trochlear implants and methods of use

• US 9,668,865 B2
• Filed: 09/16/2014
• Issued: 06/06/2017
• Est. Priority Date: 08/25/2009
• Status: Active Grant

• Current Assignee: Fellowship of Orthopaedic Researchers, LLC
• Original Assignee: Fellowship of Orthopaedic Researchers, LLC
• Inventors: Cook, Stephen D, Strzepa, Peter, Bajaj, Shoib
• Primary Examiner(s): SCHILLINGER, ANN M
• Application Number:
  US14/487,558
• Publication Number:
  US 20150005895A1
• Time in Patent Office: 994 Days
• CPC Class Codes: A61F 2/30756 Cartilage endoprostheses A61F2/3603 takes precedence
• CPC Class Codes: A61F 2/3877 Patellae or trochleae
• CPC Class Codes: A61F 2310/00173 Graphite
• CPC Class Codes: A61F 2310/00574 Coating or prosthesis-covering structure made of carbon, e.g. of pyrocarbon

Abstract

Implant devices, and method of using the same, are provided. The implant devices have an articular end and a stem, the stem having an oval-shaped cross-section. The articular end has an upper surface, a side surface, and a lower surface. The upper surface and lower surface each intersect the side surface. The upper surface has a first surface curvature, a central surface curvature, and a second surface curvature. The stem extends from the lower surface in a direction away from the upper surface of the articular end.

Claims

1. An implant comprising:

(a) an articular end having an upper surface, a side surface, and a lower surface;

wherein the upper surface and lower surface each intersect the side surface, the upper surface has a first surface curvature, a central surface curvature, and a second surface curvature;

wherein the central surface curvature is formed along a partial torus and has a saddle point;

wherein the upper surface blends into the side surface, the side surface blends into the upper surface and the lower surface, and the lower surface blends into the side surface; and

wherein each blend has an edge radius of from about 0.1 millimeters to about 2 millimeters; and

(b) a stem that extends from the lower surface in a direction away from the upper surface of the articular end and has a central axis;

wherein the location of the saddle point is offset along a horizontal direction from the location of the central axis by a distance ranging from between about 1 to about 5 millimeters; and

wherein the stem has at least one groove about its perimeter, the at least one groove defined by a partial torus having a tubular radius ranging from about 0.25 millimeters to about 2 millimeters.

2. The implant of claim 1, wherein the first surface curvature is formed along a partial right circular cone having an aperture ranging from between about 20°

to about 80°

.

3. The implant of claim 2, wherein the aperture of the partial right circular cone ranges from between about 40°

to about 60°

.

4. The implant of claim 1, wherein the central surface curvature is formed along a partial torus having a minor radius ranging from between about 8 millimeters to about 40 millimeters and a major radius ranging from about 25 millimeters to about 70 millimeters.

5. The implant of claim 4, wherein the minor radius of the partial torus is about 12 millimeters and the major radius of the partial torus is about 48 millimeters.

6. The implant of claim 1, wherein the second surface curvature is formed along a partial right circular cone having an aperture ranging from between about 20°

to about 80°

.

7. The implant of claim 6, wherein the aperture of the partial right circular cone ranges from between about 30°

to about 50°

.

8. The implant of claim 1, wherein the first surface curvature is formed along a partial right circular cone having an aperture ranging from between about 20°

to about 80°

, the central surface curvature is formed along a partial torus having a minor radius ranging from between about 8 millimeters to about 40 millimeters and a major radius ranging from about 25 millimeters to about 70 millimeters, and the second surface curvature is formed along a partial right circular cone having an aperture ranging from between about 20°

to about 80°

.

9. The implant of claim 8, wherein the first surface curvature is formed along a partial right circular cone having an aperture ranging from between about 40°

to about 60°

, the central surface curvature is formed along a partial torus having a minor radius of about 12 millimeters and a major radius of about 48 millimeters, and the second surface curvature is formed along a partial right circular cone having an aperture ranging from between about 30°

to about 50°

, wherein the first surface aperture is between about 5°

to about 15°

greater than the second surface aperture.

10. The implant of claim 1, wherein the at least one groove extends continuously about the perimeter of the stem.

11. The implant of claim 1, wherein the location of the saddle point is offset along a horizontal direction towards a medial side of the implant.

12. The implant of claim 11, wherein a length along a vertical axis parallel to the central axis of the stem, from the saddle point to a lower surface of the articular end, ranges from between about 1 millimeter to about 6 millimeters.

13. The implant of claim 12, wherein the side surface of the articular end is generally cylindrical, and has a diameter ranging from between about 10 millimeters to about 40 millimeters.

14. The implant of claim 13, wherein the diameter is about 20 millimeters, the offset is either 1 millimeter or 3 millimeters, the first surface curvature is formed along a partial cone having an aperture selected from the group consisting of about 40°

, about 50°

, and about 60°

, and the second surface curvature is formed along a partial cone having an aperture angle selected from the group consisting of about 30°

, about 40°

, and about 50°

, and wherein the first surface aperture is about 10°

greater than the second surface aperture.

15. The implant of claim 13, wherein the diameter is about 25 millimeters, the offset is either about 1 millimeter or about 3 millimeters, the first surface curvature is formed along a partial cone having an aperture selected from the group consisting of about 40°

and about 50°

, and the second surface curvature is formed along a partial cone having an aperture selected from the group consisting of about 30° and

about 40°

, and wherein the first surface aperture is about 10°

greater than the second surface aperture.

16. The implant of claim 1, wherein the stem has a width distance ranging from between about 1 millimeter to about 6 millimeters and a depth distance ranging from between about 5 millimeters and about 40 millimeters.

17. The implant of claim 1, wherein each blend has an edge radius of about 0.8 millimeters.

18. The implant of claim 1, wherein the lower surface of the articular end blends into the stem with a corner fillet, the corner fillet having a radius of about 1.5 millimeters.

19. The implant of claim 1, wherein the articular end and the stem are formed from graphite and pyrocarbon.

20. The implant of claim 19, wherein the articular end and the stem comprise a graphite core and a pyrocarbon coating.

21. The implant of claim 20, wherein the pyrocarbon coating has an elastic modulus from about 15 GPa to about 22 GPa.

22. The implant of claim 21, wherein the pyrocarbon coating has an elastic modulus of about 20 GPa.

23. The implant of claim 21, wherein the pyrocarbon coating has a strength of at least about 400 MPa.

24. The implant of claim 20, wherein the pyrocarbon coating has an average thickness ranging from about 100 to about 1000 microns.

25. The implant of claim 20, wherein the pyrocarbon coating is harder than the graphite core.

26. The implant of claim 1, wherein the upper surface and the blends are polished, and the lower surface and stem are coated with hydroxyapatite.

27. The implant of claim 1, wherein the stem has at least one groove that blends into the stem with a groove blend having an edge radius ranging from about 0.1 millimeters to about 1 millimeter.

28. An implant comprising:

(a) an articular end having an upper surface, a side surface, and a lower surface;

wherein the upper surface and lower surface each intersect the side surface, the upper surface has a first surface curvature, a central surface curvature, and a second surface curvature;

wherein the central surface curvature is formed along a partial torus and has a saddle point;

(b) a stem that extends from the lower surface in a direction away from the upper surface of the articular end and has a central axis;

wherein the location of the saddle point is offset along a horizontal direction from the location of the central axis by a distance ranging from between about 1 to about 5 millimeters; and

wherein the stem has at least one groove about its perimeter, the at least one groove defined by a partial torus having a tubular radius ranging from about 0.25 millimeters to about 2 millimeters.

29. The implant of claim 28, wherein the upper surface blends into the side surface, the side surface blends into the upper surface and the lower surface, and the lower surface blends into the side surface.

30. The implant of claim 29, wherein the blend of the upper surface into the side surface, the blend of the side surface into the upper surface, the blend of the side surface into the lower surface, and the blend of the lower surface into the side surface each has an edge radius of from about 0.1 millimeters to about 2 millimeters.

31. The implant of claim 29, wherein each blend has an edge radius of about 0.8 millimeters.

32. The implant of claim 28, wherein the first surface curvature is formed along a partial right circular cone having an aperture ranging from between about 20°

to about 80°

.

33. The implant of claim 32, wherein the aperture of the partial right circular cone ranges from between about 40°

to about 60°

.

34. The implant of claim 28, wherein the central surface curvature is formed along a partial torus having a minor radius ranging from between about 8 millimeters to about 40 millimeters and a major radius ranging from about 25 millimeters to about 70 millimeters.

35. The implant of claim 34, wherein the minor radius of the partial torus is about 12 millimeters and the major radius of the partial torus is about 48 millimeters.

36. The implant of claim 28, wherein the second surface curvature is formed along a partial right circular cone having an aperture ranging from between about 20°

to about 80°

.

37. The implant of claim 36, wherein the aperture of the partial right circular cone ranges from between about 30°

to about 50°

.

38. The implant of claim 28, wherein the first surface curvature is formed along a partial right circular cone having an aperture ranging from between about 20°

to about 80°

, the central surface curvature is formed along a partial torus having a minor radius ranging from between about 8 millimeters to about 40 millimeters and a major radius ranging from about 25 millimeters to about 70 millimeters, and the second surface curvature is formed along a partial right circular cone having an aperture ranging from between about 20°

to about 80°

.

39. The implant of claim 38, wherein the first surface curvature is formed along a partial right circular cone having an aperture ranging from between about 40°

to about 60°

, the central surface curvature is formed along a partial torus having a minor radius of about 12 millimeters and a major radius of about 48 millimeters, and the second surface curvature is formed along a partial right circular cone having an aperture ranging from between about 30°

to about 50°

, wherein the first surface aperture is between about 5°

to about 15°

greater than the second surface aperture.

40. The implant of claim 28, wherein the at least one groove extends continuously about the perimeter of the stem.

41. The implant of claim 28, wherein the location of the saddle point is offset along a horizontal direction towards a medial side of the implant.

42. The implant of claim 41, wherein a length along a vertical axis parallel to the central axis of the stem, from the saddle point to a lower surface of the articular end, ranges from between about 1 millimeter to about 6 millimeters.

43. The implant of claim 42, wherein the side surface of the articular end is generally cylindrical, and has a diameter ranging from between about 10 millimeters to about 40 millimeters.

44. The implant of claim 43, wherein the diameter is about 20 millimeters, the offset is either 1 millimeter or 3 millimeters, the first surface curvature is formed along a partial cone having an aperture selected from the group consisting of about 40°

, about 50°

, and about 60°

, and the second surface curvature is formed along a partial cone having an aperture angle selected from the group consisting of about 30°

, about 40°

, and about 50°

, and wherein the first surface aperture is about 10°

greater than the second surface aperture.

45. The implant of claim 43, wherein the diameter is about 25 millimeters, the offset is either about 1 millimeter or about 3 millimeters, the first surface curvature is formed along a partial cone having an aperture selected from the group consisting of about 40°

and about 50°

, and the second surface curvature is formed along a partial cone having an aperture selected from the group consisting of about 30° and

about 40°

, and wherein the first surface aperture is about 10°

greater than the second surface aperture.

46. The implant of claim 28, wherein the stem has a width distance ranging from between about 1 millimeter to about 6 millimeters and a depth distance ranging from between about 5 millimeters and about 40 millimeters.

47. The implant of claim 28, wherein the lower surface of the articular end blends into the stem with a corner fillet, the corner fillet having a radius of about 1.5 millimeters.

48. The implant of claim 28, wherein the articular end and the stem are formed from graphite and pyrocarbon.

49. The implant of claim 48, wherein the articular end and the stem comprise a graphite core and a pyrocarbon coating.

50. The implant of claim 49, wherein the pyrocarbon coating has an elastic modulus from about 15 GPa to about 22 GPa.

51. The implant of claim 50, wherein the pyrocarbon coating has an elastic modulus of about 20 GPa.

52. The implant of claim 50, wherein the pyrocarbon coating has a strength of at least about 400 MPa.

53. The implant of claim 49, wherein the pyrocarbon coating has an average thickness ranging from about 100 to about 1000 microns.

54. The implant of claim 49, wherein the pyrocarbon coating is harder than the graphite core.

55. The implant of claim 28, wherein the upper surface and the blends are polished, and the lower surface and stem are coated with hydroxyapatite.

56. The implant of claim 28, wherein the stem has at least one groove that blends into the stem with a groove blend having an edge radius ranging from about 0.1 millimeters to about 1 millimeter.