Patient specific surgical guide locator and mount

• US 9,901,353 B2
• Filed: 05/08/2015
• Issued: 02/27/2018
• Est. Priority Date: 02/24/2009
• Status: Active Grant

• Current Assignee: Microport Holdings Incorporated
• Original Assignee: Microport Holdings Incorporated
• Inventors: Carroll, Michael, Obert, Richard, Stemniski, Paul
• Primary Examiner(s): Bates, David
• Assistant Examiner(s): Chang, Olivia C
• Application Number:
  US14/707,617
• Publication Number:
  US 20150238201A1
• Time in Patent Office: 1,026 Days
• CPC Class Codes: A61B 17/151 for corrective osteotomy
• 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 2017/0023 disposable
• 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 2034/104 Modelling the effect of the tool, e.g. the effect of an implanted prosthesis or for predicting the effect of ablation or burring
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture
• CPC Class Codes: Y10T 29/49863 with prestressing of part

Abstract

A resection guide locator includes a bone engagement portion with surfaces that are complementary to the surface topographies of a bone to be resected during surgery. A housing includes a socket defined by a resilient annular wall that is sized and arranged so to accept a resection guide by press-fit to thereby position and hold the resection guide within he socket. The resection guide is maintained in a predetermined, preferred position while the surfaces are releasably locked in position on the bone. A method is disclosed for forming and using the resection guide locator.

Claims

1. A surgical locator device, comprising:

a body having opposed first and second sides, the first side including a conformal surface that is shaped to be complementary to a shape of a natural anatomical surface of a patient, the body including a base having a surface that is recessed relative to a surface of the second side such that the surface of the base is disposed between the conformal surface and the surface of the second side,

wherein the surface of the base defines a plurality of slots each of which extends through the body and each slot being sized and configured to receive a surgical instrument therein, and further wherein a first slot of the plurality of slots extends in a first direction, a second slot of the plurality of slots extends in a second direction, and a third slot of the plurality of slots extends in a third direction.

2. The surgical locator device of claim 1, wherein each of the first, second, and third directions are different from one another.

3. The surgical locator device of claim 1, wherein the body includes a post that extends away from the base, and wherein a pair of arms extend in opposite directions away from the post.

4. The surgical locator device of claim 3, wherein the base includes a pair of pylons disposed on opposed sides of a support block between which the recessed surface is formed.

5. The surgical locator device of claim 4, wherein the first slot is positioned between the support block and a pilot block that extends from the post.

6. The surgical locator device of claim 4, wherein the second slot is positioned between the support block and a first pylon of the pair of pylons, and the third slot is positioned between the support block and a second pylon of the pair of pylons.

7. A system, comprising:

a surgical locator including

a body having opposed first and second sides, the first side including a conformal surface that is shaped to be complementary to a shape of a natural anatomical surface of a patient, the body including a base having a surface that is recessed relative to a surface of the second side such that the surface of the base is disposed between the conformal surface and the surface of the second side,

wherein the surface of the base defines a first slot extending in a first direction, a second slot extending in a second direction, and a third slot extending in a third direction, and wherein each of the first, second, and third slots extend through the body.

8. The system of claim 7, further comprising

a resection guide sized and configured to be at least partially received within the recessed surface defined by the surgical locator, the resection guide defining first, second, and third slots,

wherein, when the resection guide is positioned properly within the recessed surface of the surgical locator, the first, second, and third slots of the resection guide respectively align with the first, second, and third slots of the surgical locator.

9. The system of claim 8, wherein each of the first, second, and third directions are different from one another.

10. The system of claim 9, wherein the body of the surgical locator includes a post that extends away from the base, and wherein a pair of arms extend in opposite directions away from the post.

11. The system of claim 10, wherein the base of the surgical locator includes a pair of pylons disposed on opposed sides of a support block between which the recessed surface is formed.

12. The system of claim 11, wherein the first slot of the surgical locator is positioned between the support block and a pilot block that extends from the post.

13. The system of claim 12, wherein the second slot of the surgical locator is positioned between the support block and a first pylon of the pair of pylons, and the third slot of the surgical locator is positioned between the support block and a second pylon of the pair of pylons.

14. The system of claim 8, wherein the resection guide includes a bridge beam and a pair of divergent arms that extend away from the bridge beam.

15. The system of claim 14, wherein the first slot of the resection guide is positioned along the bridge beam, the second slot of the resection guide is positioned along a first arm of the pair of divergent arms, and the third slot of the resection guide is positioned along a second arm of the pair of divergent arms.

16. The system of claim 15, wherein the first and second arms of the resection guide extend beyond the body of the surgical locator when the resection guide is positioned properly within the recessed surface defined by the surgical locator.

17. The system of claim 16, wherein the bridge beam is disposed between a pilot block that extends from the post of the surgical locator and a support block of the surgical locator when the resection guide is positioned properly within the recessed surface.

18. The system of claim 8, wherein the surgical locator is formed from a first material and the resection guide is formed from a second material that is different from the first material.

19. A system, comprising:

a locating device including a body having opposed first and second sides, the first side including a conformal surface that is shaped to be complementary to a shape of a natural anatomical surface of a patient, the body of the locating device including a base having a surface that is recessed relative to a surface of the second side such that the surface of the base is disposed between the conformal surface and the surface of the second side, wherein the surface of the base defines a first plurality of slots, each slot of the first plurality of slots extends through the body of the locating device and is sized and configured to receive a surgical instrument therein; and

a resection guide sized and configured to be at least partially received within the recessed surface defined by the locating device, the resection guide defining a second plurality of slots, each slot of the second plurality of slots is configured to align with a respective one of the first plurality of slots when the resection guide is positioned properly within the recessed surface of the locating device such that a surface of the resection guide abuts the surface of the base, wherein the resection guide includes

(i) a bridge beam disposed between a pilot block that extends from a post of the locating device and a support block of the locating device when the resection guide is positioned properly within the recessed surface, and

(ii) a pair of divergent arms that extend away from the bridge beam such that the first and second arms of the resection guide extend beyond the body of the locating device when the resection guide is positioned properly within the recessed surface defined by the locating device.

20. A system, comprising:

a locating device including a body having opposed first and second sides, the first side including a conformal surface that is shaped to be complementary to a shape of a natural anatomical surface of a patient, the second side including a base having a first block, a second block, and a pair of pylons that collectively define a recess therebetween, wherein the body defines a first plurality of slots within the recess; and

a resection guide sized and configured to be at least partially received within the recess defined by the locating device, the resection guide defining a second plurality of slots, wherein each of the second plurality of slots aligns with a respective one of the first plurality of slots when the resection guide is positioned properly within the locating device, wherein the resection guide includes a bridge beam and a pair of divergent arms that extend away from the bridge beam such that the first slot of the resection guide is positioned along the bridge beam, the second slot of the resection guide is positioned along a first arm of the pair of divergent arms, and the third slot of the resection guide is positioned along a second arm of the pair of divergent arms.

21. A system, comprising:

a locating device including a body having opposed first and second sides, the first side including a conformal surface that is shaped to be complementary to a shape of a natural anatomical surface of a patient, the second side including a base having a plurality of surfaces that collectively define a recess, wherein the body defines a first plurality of slots within the recess, each of the plurality of slots extending through the base and being sized and configured to receive a surgical instrument therein; and

a resection guide including a bridge beam, a first arm coupled to a first end of the bridge beam, and a second arm coupled to a second end of the bridge beam, the resection guide defining a second plurality of slots,

wherein, when the resection guide is received properly within the recess of the locating device, the first and second arms of the resection guide extend beyond the body of the locating device, and each of the second plurality of slots aligns with a respective one of the first plurality of slots, and

wherein the first slot of the resection guide is positioned along the bridge beam, the second slot of the resection guide is positioned along a first arm of the pair of divergent arms, and the third slot of the resection guide is positioned along a second arm of the pair of divergent arms.

22. The system of claim 21, wherein the body of the locating device includes a post extending away from the base and a pair of arms extending in opposite directions away from the post.

23. The system of claim 22, wherein the locating device is formed from a first material and the resection guide is formed from a second material.