Modular implant system with fully porous coated sleeve

• US 20050107883A1
• Filed: 04/02/2004
• Published: 05/19/2005
• Est. Priority Date: 11/18/2003
• Status: Active Grant

• Current Assignee: Depuy Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Products Incorporated (Johnson & Johnson)
• Inventors: Hazebrouck, Stephen A., Brown, Scott C., Goodfried, Gary P., Lester, Mark B.
• Granted Patent: US 7,799,085 B2
• Time in Patent Office: Days
• US Class Current: 623/20.150
• CPC Class Codes: A61F 2/30734 Modular inserts, sleeves or augments, e.g. placed on proximal part of stem for fixation purposes or wedges for bridging a bone defect
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/384 hinged, i.e. with transverse axle restricting the movement
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/4684 Trial or dummy prostheses
• CPC Class Codes: A61F 2002/30215 Stepped cones, i.e. having discrete diameter changes
• CPC Class Codes: A61F 2002/30233 Stepped cylinders, i.e. having discrete diameter changes
• CPC Class Codes: A61F 2002/30329 Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2002/30332 Conically- or frustoconically-shaped protrusion and recess
• CPC Class Codes: A61F 2002/30339 Double cones, i.e. connecting element having two conical connections, one at each of its opposite ends
• CPC Class Codes: A61F 2002/30433 using additional screws, bolts, dowels, rivets or washers e.g. connecting screws
• CPC Class Codes: A61F 2002/30574 with an integral complete or partial collar or flange
• CPC Class Codes: A61F 2002/30604 modular
• CPC Class Codes: A61F 2002/30607 Kits of prosthetic parts to be assembled in various combinations for forming different prostheses
• CPC Class Codes: A61F 2002/30616 Sets comprising a plurality of prosthetic parts of different sizes or orientations
• CPC Class Codes: A61F 2002/3069 Revision endoprostheses
• CPC Class Codes: A61F 2002/30738 Sleeves
• CPC Class Codes: A61F 2002/30774 internally-threaded
• CPC Class Codes: A61F 2002/308 oblong
• CPC Class Codes: A61F 2002/30827 Plurality of grooves
• CPC Class Codes: A61F 2002/30878 : with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
• CPC Class Codes: A61F 2002/30925 : etched
• CPC Class Codes: A61F 2002/30968 : Sintering
• CPC Class Codes: A61F 2002/4641 : for disconnecting
• CPC Class Codes: A61F 2220/0025 : Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2220/0033 : made by longitudinally pushing a protrusion into a complementary-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2220/0041 : using additional screws, bolts, dowels or rivets, e.g. connecting screws
• CPC Class Codes: A61F 2230/0067 : conical
• CPC Class Codes: A61F 2230/0069 : cylindrical
• CPC Class Codes: A61F 2250/0062 : Kits of prosthetic parts to be assembled in various combinations for forming different prostheses
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 : Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium

Abstract

A modular knee implant system allows a surgeon to select between several different styles of distal femoral implant components and several different styles of stem extensions while also allowing for use of a metaphyseal component. The metaphyseal component can be a universal one that is usable with all of the styles of distal femoral implant components through use of an adapter. A second adapter allows for use of stem extensions with different types of connectors with the metaphyseal component. A separate metaphyseal component could also be provided with a distal Morse taper post to mate with a distal femoral component having a proximal Morse taper bore. The metaphyseal component may have an outer surface that is configured to maximize contact area with the patient'"'"'s bone, and may have a surface finish over a substantial part of its overall length that is conducive to bone ingrowth.

Claims

1. A modular orthopaedic implant system comprising:

a first component having an articulating surface and an interior surface defining a tapered bore and an exterior surface spaced from the articulating surface, at least a portion of the exterior surface surrounding the tapered bore, the portion of the exterior surface surrounding the tapered bore being asymmetrical in at least one cross-section; and

a tapered metaphyseal component mountable to the distal femoral component.

2. The modular orthopaedic implant system of claim 1 wherein the first component comprises a distal femoral component that is sized and shaped to replace more than the distal 3 cm. of the native femur.

3. The modular orthopaedic implant system of claim 1 further comprising a plurality of orthopaedic components having tapered bores sized and shaped to be received in and frictionally lock with the tapered bore of the first component.

4. The modular orthopaedfc implant system of claim 3 wherein at least one of the plurality of orthopaedic components comprises a segment sized and shaped to replace a portion of the shaft of a long bone.

5. The modular orthopaedic implant system of claim 1 wherein the tapered metaphyseal component includes a tapered post sized and shaped to be receivable within the tapered bore of the first component and to create a frictional lock between the first component and the tapered metaphyseal component.

6. The modular orthopaedic implant system of claim 1 wherein the tapered metaphyseal component has an interior surface defining a distal tapered bore, the system further comprising an adapter for connecting the tapered metaphyseal component to the first component, the adapter having a tapered post sized and shaped to be receivable within the tapered bore of the first component and to create a frictional lock between the first component and the adapter, the adapter further comprising a tapered post sized and shaped to be receivable within the tapered bore of the tapered metaphyseal component and to create a frictional lock between the adapter and the tapered metaphyseal component.

7. The modular orthopaedic implant system of claim 6 wherein the two tapered posts of the adapter are different from each other in size or shape.

8. The modular orthopaedic implant system of claim 1 wherein the tapered metaphyseal component has an interior surface defining an opening, the system further comprising:

a first stem extension having a distal end and a proximal end, the distal end being shaped and sized to be received in and mate with the opening of the tapered metaphyseal component;

a second stem extension having a distal end and a proximal end, the distal end of the second femoral stem extension being different from the distal end of the first femoral stem extension shape in size or shape;

an adapter for connecting the second femoral stem extension to the tapered metaphyseal component, the adapter having an end sized and shaped to be received in and mate with the opening of the tapered metaphyseal component, and the adapter opposite end having an opening sized and shaped to receive and mate with the distal end of the second femoral stem extension.

9. The modular orthopaedic implant system of claim 8 wherein the distal end of the second stem extension is threaded.

10. An orthopaedic implant system comprising:

a first orthopaedic component; and

a metaphyseal component mountable to the first orthopaedic component;

wherein the metaphyseal component has a wide end, a narrow end, an overall length between the wide end and narrow end, and a tapered outer surface;

wherein the tapered outer surface of the metaphyseal component includes a plurality of steps and is porous over a majority of the overall length of the metaphyseal component.

11. The orthopaedic implant system of claim 10 wherein the tapered outer surface of the metaphyseal component is porous over at least 75% of its overall length.

12. The orthopaedic implant system of claim 10 wherein the tapered outer surface of the metaphyseal component is smooth at the narrow end.

13. The orthopaedic implant system of claim 10 wherein the entire tapered outer surface of the metaphyseal component is porous.

14. The orthopaedic implant system of claim 13 wherein the metaphyseal component has a distal surface that is non-porous and a proximal surface that is non-porous.

15. The orthopaedic implant system of claim 10 wherein the metaphyseal component has an average of at least five steps per inch of overall length of the metaphyseal component.

16. The orthopaedic implant system of claim 10 wherein the outer surface of the metaphyseal component has at least 10 steps.

17. The orthopaedic implant system of claim 16 wherein the outer surface of the metaphyseal component has at least 15 steps.

18. The orthopaedic implant system of claim 17 wherein the outer surface of the metaphyseal component has at least 19 steps.

19. The orthopaedic implant system of claim 10 further comprising a plurality of orthopaedic components.

20. An orthopaedic knee implant system comprising:

a distal femoral component having an articulating surface and a non-articulating surface; and

a metaphyseal component mountable to the non-articulating surface of the distal femoral component;

wherein the metaphyseal component has a wide end, a narrow end, an overall length between the wide end and narrow end, and a tapered outer surface;

wherein the tapered outer surface of the metaphyseal component includes at least five steps per inch of the overall length of the metaphyseal component.

21. The orthopaedic implant system of claim 20 wherein the system further comprising a stem extension

22. An orthopaedic knee implant system comprising:

a distal femoral component having an articulating surface and a non-articulating surface; and

a metaphyseal component mountable to the non-articulating surface of the distal femoral component;

wherein the metaphyseal component has a wide end, a narrow end, an overall length between the wide end and narrow end, and a tapered outer surface;

wherein the tapered outer surface of the metaphyseal component includes a plurality of adjacent steps extending from the wide end to the narrow end, each step being spaced from the adjacent step by a distance of less than 0.2 inches.

23. The orthopaedic implant system of claim 22 wherein each step is spaced from the adjacent step by a distance of about 0.12-0.16 inches.

24. An orthopaedic implant system comprising:

a first implantable component having an articulating surface to replace a portion of a patient'"'"'s bone;

a second implantable component;

the first implantable component having a tapered bore;

the second implantable component having a tapered bore differing from the tapered bore of the first implantable component in at least one characteristic;

an adapter for connecting the first implantable component to the second implantable component, the adapter including two tapered posts, one of said tapered posts being sized and shaped to be received in and frictionally lock with the tapered bore of the first implantable component and the other of said tapered posts being sized and shaped to be received in and frictionally lock with the tapered bore of the second implantable component.

25. The system of claim 24 wherein the first implantable component comprises a distal femoral component and the second implantable component comprises a tapered metaphyseal component.

26. The system of claim 25 further comprising an implantable segment sized and shaped to replace a diaphyseal portion of a long bone, the implantable segment having a tapered post sized and shaped to be received in and frictionally lock with the tapered bore of the distal femoral component.

27. A modular orthopaedic knee implant system comprising:

a distal femoral component having a distal articulating surface;

a tapered metaphyseal component having a distal end and a proximal end with an opening at the proximal end, the tapered metaphyseal component being mountable to the distal femoral component;

a first femoral stem extension having a distal end and a proximal end, the distal end being shaped and sized to be received in and mate with the opening at the proximal end of the tapered metaphyseal component;

a second femoral stem extension having a distal end and a proximal end, the distal end of the second femoral stem extension being different from the distal end of the first femoral shape in size or shape;

an adapter for connecting the second femoral stem extension to the tapered metaphyseal component, the adapter having a proximal end and a distal end, the adapter distal end being sized and shaped to be received in and mate with the opening at the proximal end of the tapered metaphyseal component, and the adapter proximal end having an opening sized and shaped to receive and mate with the distal end of the second femoral stem extension.

28. The modular orthopaedic knee implant system of claim 27 wherein the opening at the adapter proximal end is threaded.

29. The modular orthopaedic knee implant system of claim 27 wherein the distal end of the adapter comprises a post.

30. An orthopaedic knee implant kit comprising:

a first distal femoral component having a distal articulating surface and a post;

a second distal femoral component having a distal articulating surface and a proximal end and with a bore at the proximal end;

a tapered metaphyseal component having a proximal end and a distal end and having an interior surface defining a bore at the distal end, the bore of the tapered metaphyseal component being shaped and sized to receive a portion of the post of the first distal femoral component for mounting the tapered metaphyseal component on the first distal femoral component;

an adapter having a distal end comprising a post shaped and sized to be received in the bore at the proximal end of the second femoral component, the adapter having a proximal end comprising a post shaped and sized to be received in the bore at the distal end of the tapered metaphyseal component;

wherein the tapered metaphyseal component may be selectively used with the first distal femoral component and the second distal femoral component.

31. The orthopaedic knee implant kit of claim 30 wherein the proximal end of the tapered metaphyseal component has an interior surface defining a bore, the kit further comprising a second adapter having a proximal end and a distal end, the distal end of the second adapter having an outer surface shaped to define a post receivable and frictionally engageable with the bore at the proximal end of the tapered metaphyseal component.

32. The orthopaedic knee implant kit of claim 31 further comprising a first stem extension having a proximal end and a distal end, wherein the distal end of the first stem extension has an outer surface defining a post sized and shaped to be receivable and frictionally engageable with the bore at the proximal end of the tapered metaphyseal component.

33. The orthopaedic knee implant kit of claim 32 further comprising a second stem extension having a proximal end and a distal end, wherein the distal end of the second stem extension differs from the distal end of the first stem extension in size or shape.

34. The orthopaedic knee implant kit of claim 33 wherein the distal end of the second stem extension is threaded and the proximal end of the second adapter is threaded.