Surgical templates

• US 9,974,551 B2
• Filed: 04/19/2017
• Issued: 05/22/2018
• Est. Priority Date: 03/23/2007
• Status: Active Grant

• Current Assignee: Xiros Limited
• Original Assignee: Xiros Limited
• Inventors: White, Derrick, Seedhom, Bahaa, Cheulule, Kenneth Langat
• Primary Examiner(s): Boles, Sameh
• Application Number:
  US15/491,853
• Publication Number:
  US 20170215895A1
• Time in Patent Office: 398 Days
• 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 17/17 Guides or aligning means for drills , mills, pins or wires
• CPC Class Codes: A61B 17/1703 using imaging means, e.g. by X-rays
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 17/56 Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor
• 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 90/94 coded with symbols, e.g. text
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/461 of knees
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A surgical template system for use in working on a bone comprises: a tool guide block comprising at least one guide aperture for receiving and guiding a tool to work on a bone; locating means comprising a plurality of locating members, each member having a respective end surface for positioning against a surface of the bone; and attachment means for non-adjustably attaching the tool guide block to the locating means such that, when attached, the member end surfaces are secured in fixed position with, respect to each other, for engaging different respective portions of the surface of the bone, and the at least one guide aperture is secured in a fixed position with respect to the end surfaces. Corresponding methods of manufacturing a surgical template system, methods of manufacturing locating means for a surgical template system, methods of fitting a prosthesis to a bone, surgical methods, and surgical apparatus are described.

Claims

1. A method of preparing a femur to receive a prosthetic knee using an assembly comprising at least one tool guide comprising at least one guide aperture for receiving and guiding a tool to work on the femur, and a patient-specific component comprising a plurality of locating members, each member having a respective bone-engaging surface adapted to conform to a respective portion of a predetermined surface of the femur, wherein the tool guide is secured in a fixed position with respect to the patient-specific component, the tool guide being formed of metal and the patient-specific component being formed of a polymeric material, the at least one guide aperture comprising a saw guide slot, the patient-specific component comprising a plurality of bores and a plurality of metal sleeves lining the bores, the method comprising:

mounting the assembly on the femur such that the member bone-engaging surfaces are secured in a fixed position with respect to each other, and engage different respective portions of the surface of the femur, the at least one guide aperture is secured in a fixed position with respect to the bone-engaging surfaces, and the bone-engaging surfaces of the locating members conform to said predetermined surface;

inserting first and second pins through respective metal sleeves and into non-articular surfaces of the femur to secure the assembly in place against the femur;

drilling first and second locating holes in an articular surface of the femur with a drill inserted through metal drill guides on the assembly;

inserting a saw through the saw guide slot and cutting off a portion of the articular surface of the femur with the saw to form a first, flat surface on the end of the femur;

removing the assembly from the femur;

mounting another tool guide on the first flat surface of the femur by inserting locating protrusions of the another tool guide into the locating holes; and

using the another tool guide to perform further work on the femur, wherein performing further work on the femur comprises inserting a saw through a saw guide slot of the another tool guide and cutting off another portion of the femur to form a second flat surface on the femur.

2. The method according to claim 1, wherein the second flat surface intersects the first flat surface on the femur.

3. The method according to claim 1, wherein the another tool guide comprises a plurality of guide apertures that correspond to internal surfaces of a prosthetic device.

4. The method according to claim 1, wherein the act of performing further work on the femur further comprises inserting a saw through another saw guide slot of the another tool guide and cutting off another portion of the femur to form a third flat surface on the femur.

5. The method according to claim 4, wherein the saw guide slot of the another tool guide is substantially parallel to the another saw guide slot of the another tool guide.

6. The method according to claim 4, further comprising mounting a prosthetic device on the femur, wherein the prosthetic device is positioned so that one or more internal surfaces of the prosthetic device contact one or more of the flat surfaces formed on the femur.

7. The method according to claim 1, wherein the first and second pins are inserted parallel to one another.

8. The method according to claim 1, wherein the first and second pins are inserted parallel to the saw guide slot of the tool guide.

9. The method according to claim 1, wherein the first and second pins are inserted parallel to one another and parallel to the saw guide slot of the tool guide.

10. The method according to claim 1, wherein each of the first and second pins is inserted in a direction that is substantially perpendicular to the bone surface at the point where it is inserted.

11. The method according to claim 1, wherein the act of mounting another tool guide on the first flat surface further comprises inserting another pin through the another tool guide and the first flat surface to secure the another tool guide to the femur.

12. The method according to claim 1, wherein the act of mounting another tool guide on the first flat surface further comprises inserting a plurality of pins through the another tool guide and the first flat surface to secure the another tool guide to the femur.

13. A method of preparing a bone to receive a prosthetic device using an assembly comprising at least one tool guide comprising at least one guide aperture for receiving and guiding a tool to work on the bone, and a patient-specific component comprising a plurality of locating members, each member having a respective bone-engaging surface adapted to conform to a respective portion of a predetermined surface of the bone, wherein the tool guide is secured in a fixed position with respect to the patient-specific component, the tool guide being formed of metal and the patient-specific component being formed of a polymeric material, the at least one guide aperture comprising a saw guide slot, the patient-specific component comprising a plurality of bores and a plurality of metal sleeves lining the bores, the method comprising:

mounting the assembly on the bone such that the member bone-engaging surfaces are secured in a fixed position with respect to each other, and engage different respective portions of the surface of the bone, the at least one guide aperture is secured in a fixed position with respect to the bone-engaging surfaces, and the bone-engaging surfaces of the locating members conform to said predetermined surface;

inserting first and second pins through respective metal sleeves and into non-articular surfaces of the bone to secure the assembly in place against the bone;

inserting a saw through the saw guide slot and cutting off a portion of the articular surface of the bone with the saw to form a flat surface on the end of the bone;

removing the assembly from the bone;

mounting another tool guide on the cut flat surface of the bone; and

inserting a tool through a tool guide aperture of the another tool guide to perform additional work on the bone.

14. The method according to claim 13, wherein the act of inserting a tool comprises inserting a drill through the tool guide aperture of the another tool guide and drilling a hole in the cut flat surface of the bone.

15. The method according to claim 13, wherein the act of inserting a tool comprises inserting a saw blade through the tool guide aperture of the another tool guide and making an additional cut that intersects the cut flat surface of the bone.

16. The method according to claim 13, wherein the act of mounting another tool guide on the cut flat surface further comprises inserting another pin through the another tool guide and into the bone to secure the another tool guide to the bone.

17. The method according to claim 13, wherein the act of mounting another tool guide on the cut flat surface further comprises inserting a plurality of pins through the another tool guide and into the bone to secure the another tool guide to the bone.

18. The method according to claim 13, further comprising drilling first and second locating holes in an articular surface of the bone with a drill inserted through metal drill guides on the assembly prior to removing the assembly from the bone.

19. The method according to claim 18, wherein the act of mounting another tool guide on the cut flat surface of the bone comprises inserting first and second locating protrusions of the another tool guide into the first and second locating holes, respectively.