Patient-specific fracture fixation instrumentation and method

• US 10,251,690 B2
• Filed: 04/26/2017
• Issued: 04/09/2019
• Est. Priority Date: 04/19/2011
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Katrana, Nicholas J., Winslow, Nathan A., McDaniel, John M.
• Primary Examiner(s): Coley, Zade
• Application Number:
  US15/497,384
• Publication Number:
  US 20170258508A1
• Time in Patent Office: 713 Days
• CPC Class Codes: A61B 17/282 Jaws
• CPC Class Codes: A61B 17/8061 specially adapted for particular bones A61B17/70 and A61B17/74 take precedence
• CPC Class Codes: A61B 17/8866 for gripping or pushing bones, e.g. approximators joint distractors A61B17/025
• CPC Class Codes: A61B 2017/00407 Ratchet means
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient

Abstract

An instrument for internal bone fracture fixation includes a shaft having a distal portion and a patient-specific bone holder coupled to the distal portion. The bone holder has a three-dimensional curved and patient-specific bone engagement surface designed during a preoperative plan based on a medical scan of a patient to match and conform to an outer surface of a bone fragment of the patient in only one position.

Claims

1. A method for internal bone fracture fixation comprising:

engaging an inner three-dimensional surface of a bone holder with an outer surface of a first bone fragment of a fractured bone of a patient, the inner surface designed preoperatively to match the first bone fragment of the fractured bone based on a medical scan of the patient;

carrying the first bone fragment in the bone holder attached to a reduction instrument;

moving the first bone fragment with the reduction instrument to engage a fractured surface of the fractured bone using a shaft connected to the bone holder;

passing a pin through a hole of the bone holder into the fractured bone;

removing the bone holder;

attaching a patient-specific bone-engagement surface of an implant to an outer surface of a first bone portion of the fractured bone and the first bone fragment; and

fixing the first bone fragment to the fractured bone.

2. The method of claim 1, wherein the shaft is a first shaft of a forceps-like instrument comprising the reduction instrument that includes a second shaft.

3. The method of claim 2, further comprising engaging an outer surface of a second bone portion of the fractured bone with a patient-specific inner surface of a second bone holder coupled to the second shaft.

4. The method of claim 3, wherein the second bone portion comprises a second bone fragment of the fractured bone.

5. The method of claim 2, further comprising locking the first shaft relative to the second shaft of the forceps-like instrument to reduce the bone fragment and the fractured bone.

6. The method of claim 1, further comprising removably coupling the bone holder to the shaft.

7. The method of claim 6, wherein removably coupling the bone holder to the shaft comprises actuating a ball detent mechanism.

8. The method of claim 1, further comprising extending a stabilizer from the bone holder to engage the fractured bone.

9. The method of claim 1, further comprising telescoping the shaft relative to a handle to adjust a length of the bone holder.

10. The method of claim 1, wherein the bone holder comprises a cup-like body configured to cap the first bone fragment.

11. A method of designing a patient-specific fracture fixation device, the method comprising:

producing a reconstructed bone by positioning a bone component onto a fracture surface of a fractured bone where a bone fragment has been separated from a remaining portion of the fractured bone, the bone component comprising a prosthetic implant comprising;

an inner surface configured to mate with the fracture surface; and

an outer surface defining an anatomic extension of the remaining portion of the fractured bone comprising a three-dimensionally contoured surface configured to match an outer surface portion of the bone fragment;

obtaining images of the reconstructed bone, the images including three-dimensional curved surfaces of the bone component and the remaining portion of the fractured bone; and

modeling a patient-specific bone holder for the fracture fixation device, the modeled bone holder including an engagement surface configured to match as an inverse surface to the outer surface of the bone component.

12. The method of claim 11, further comprising:

generating medical scan data to construct three-dimensional imaging from which the images are obtainable; and

using a CAD program to generate a CAD file when modeling the patient-specific bone holder.

13. The method of claim 11, further comprising manufacturing the patient-specific bone holder.

14. The method of claim 11, wherein the engagement surface comprises a three-dimensionally curved patient-specific holding surface configured as a mirror image of the outer surface of the bone component.

15. A method for internal bone fracture fixation comprising:

obtaining bone images of a fractured bone and a bone fragment;

obtaining a patient-specific bone holder having a patient-specific surface comprising a mirror image of an outer surface of the bone fragment derived from the bone images of the bone fragment;

attaching the patient-specific bone holder to a reduction instrument;

carrying the bone fragment in the patient-specific bone holder attached to the reduction instrument;

moving the bone fragment with the reduction instrument to engage a fractured surface of the fractured bone;

holding the bone fragment against the fractured surface using the patient-specific bone holder and the reduction instrument; and

attaching the bone fragment to the fractured bone.

16. The method of claim 15, wherein attaching the bone fragment to the bone comprises inserting a pin through the bone fragment and into the fractured bone.

17. The method of claim 16, wherein the pin is inserted through the patient-specific bone holder.

18. The method of claim 16, wherein attaching the bone fragment to the bone further comprises attaching a patient-specific plate to the fractured bone and the bone fracture.

19. The method of claim 18, wherein the patient-specific plate comprises bone-contacting surfaces that are mirror images of the outer surface of the bone fragment and an outer surface of the fractured bone derived from the bone images of the bone fragment and the fractured bone, respectively.

20. The method of claim 18, further comprising removing the patient-specific bone holder after inserting the pin and before attaching the patient-specific plate.

21. The method of claim 15, wherein the reduction instrument comprises:

a first telescoping shaft having a first arm with a first distal portion coupled to the patient-specific bone holder;

a second telescoping shaft having a second arm with a second distal portion, the second telescoping shaft pivotably coupled to the first telescoping shaft; and

a second bone holder coupled to the second distal portion.