U.S. patent application number 14/315714 was filed with the patent office on 2015-01-29 for patient-adapted and improved orthopedic implants, designs and related tools.
The applicant listed for this patent is ConforMIS, Inc.. Invention is credited to Raymond A. Bojarski, Nam T. Chao, Wolfgang Fitz, Philipp Lang, Thomas Minas, John Slamin, Daniel Steines.
Application Number | 20150032217 14/315714 |
Document ID | / |
Family ID | 43527756 |
Filed Date | 2015-01-29 |
United States Patent
Application |
20150032217 |
Kind Code |
A1 |
Bojarski; Raymond A. ; et
al. |
January 29, 2015 |
Patient-Adapted and Improved Orthopedic Implants, Designs and
Related Tools
Abstract
Methods and devices are disclosed relating improved articular
models, implant components, and related guide tools and procedures.
In addition, methods and devices are disclosed relating articular
models, implant components, and/or related guide tools and
procedures that include one or more features derived from
patient-data, for example, images of the patient's joint. The data
can be used to create a model for analyzing a patient's joint and
to devise and evaluate a course of corrective action. The data also
can be used to create patient-adapted implant components and
related tools and procedures.
Inventors: |
Bojarski; Raymond A.;
(Attleboro, MA) ; Lang; Philipp; (Lexington,
MA) ; Chao; Nam T.; (Marlborough, MA) ; Fitz;
Wolfgang; (Sherborn, MA) ; Slamin; John;
(Wrentham, MA) ; Steines; Daniel; (Lexington,
MA) ; Minas; Thomas; (Dover, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ConforMIS, Inc. |
Bedford |
MA |
US |
|
|
Family ID: |
43527756 |
Appl. No.: |
14/315714 |
Filed: |
June 26, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12821301 |
Jun 23, 2010 |
8771365 |
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14315714 |
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12660529 |
Feb 25, 2010 |
8480754 |
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12821301 |
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61269405 |
Jun 24, 2009 |
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61220726 |
Jun 26, 2009 |
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61273216 |
Jul 31, 2009 |
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61275174 |
Aug 26, 2009 |
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61280493 |
Nov 4, 2009 |
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61284458 |
Dec 18, 2009 |
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61155362 |
Feb 25, 2009 |
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Current U.S.
Class: |
623/20.32 |
Current CPC
Class: |
A61B 17/155 20130101;
A61F 2250/0036 20130101; A61F 2002/30327 20130101; A61F 2002/30324
20130101; A61F 2/389 20130101; A61B 17/1764 20130101; A61F
2250/0039 20130101; B33Y 80/00 20141201; A61F 2002/30952 20130101;
A61F 2/3886 20130101; A61B 17/157 20130101; A61F 2/30942 20130101;
B33Y 70/00 20141201 |
Class at
Publication: |
623/20.32 |
International
Class: |
A61F 2/30 20060101
A61F002/30; A61F 2/38 20060101 A61F002/38 |
Claims
1. A tibial implant for repairing a knee joint of a patient,
comprising: a tibial tray for placement on a prepared proximal
surface of a tibia of the knee joint of the patient, and an insert
having a bottom surface for engaging the tibial tray and an
articular surface generally opposite the bottom surface, wherein
the articular surface has a shape derived from electronic image
data of the knee joint of the patient and, includes a medial
portion and a lateral portion, wherein the medial portion and the
lateral portion have different shapes, wherein a medial thickness
extending in a generally perpendicular direction between the bottom
surface and the medial portion is different from a lateral
thickness extending in a generally perpendicular direction between
the bottom surface and the lateral portion; wherein the tibial
implant is configured to avoid interference with a ligament
associated with the knee joint of the patient.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No.
12/821,301 entitled "Patient-Adapted and Improved Orthopedic
Implants, Designs, and Related Tools," filed Jun. 23, 2010, which
in turn claims the benefit of: U.S. Ser. No. 61/269,405, entitled
"Patient-Specific Orthopedic Implants And Models" filed Jun. 24,
2009; U.S. Ser. No. 61/220,726, entitled "Patient-Specific
Orthopedic Implants And Models," filed Jun. 26, 2009; U.S. Ser. No.
61/273,216, entitled "Patient-Specific Orthopedic Implants And
Models" filed Jul. 31, 2009; U.S. Ser. No. 61/275,174, entitled
"Patient-Specific Orthopedic Implants And Models" filed Aug. 26,
2009; U.S. Ser. No. 61/280,493, entitled "Patient-Adapted and
Improved Orthopedic Implants, Designs and Related Tools" filed Nov.
4, 2009; U.S. Ser. No. 61/284,458, entitled "Patient-Adapted And
Improved Orthopedic Implants, Designs And Related Tools" filed Dec.
18, 2009.
[0002] U.S. Ser. No. 12/821,301 is also a continuation in part of
U.S. Ser. No. 12/660,529, entitled "Patient-Adapted and Improved
Orthopedic Implants, Designs, and Related Tools" filed Feb. 25,
2010, which claims priority to and the benefit of U.S. Ser. No.
61/155,362, entitled "Patient-Adapted and Improved Orthopedic
Implants, Designs, and Models" filed Feb. 25, 2009.
[0003] Each of the above-described applications is hereby
incorporated by reference in its entirety and for all purposes, and
this application claims priority to each of the applications listed
above.
TECHNICAL FIELD
[0004] This application relates to improved and/or patient-adapted
(e.g., patient-specific and/or patient-engineered) orthopedic
implants and guide tools, as well as related methods, designs and
models.
BACKGROUND
[0005] Generally, a diseased, injured or defective joint, such as,
for example, a joint exhibiting osteoarthritis, has been repaired
using standard off-the-shelf implants and other surgical devices.
Specific off-the-shelf implant designs have been altered over the
years to address particular issues. However, in altering a design
to address a particular issue, historical design changes frequently
have created one or more additional issues for future designs to
address. Collectively, many of these issues have arisen from one or
more differences between a patient's existing or healthy joint
anatomy and the corresponding features of an implant component.
SUMMARY
[0006] The patient-adapted (e.g., patient-specific and/or
patient-engineered) implant components described herein can be
selected (e.g., from a library), designed (e.g., preoperatively
designed including, optionally, manufacturing the components or
tools), and/or selected and designed (e.g., by selecting a blank
component or tool having certain blank features and then altering
the blank features to be patient-adapted). Moreover, related
methods, such as designs and strategies for resectioning a
patient's biological structure also can be selected and/or
designed. For example, an implant component bone-facing surface and
a resectioning strategy for the corresponding bone-facing surface
can be selected and/or designed together so that an implant
component's bone-facing surface matches the resected surface in one
or more aspects.
[0007] In certain embodiments, patient-adapted features of an
implant component, guide tool or related method can be achieved by
analyzing imaging test data and selecting and/or designing (e.g.,
preoperatively selecting from a library and/or designing) an
implant component, a guide tool, and/or a procedure having a
feature that is matched and/or optimized for the particular
patient's biology. The imaging test data can include data from the
patient's joint, for example, data generated from an image of the
joint such as x-ray imaging, cone beam CT, digital tomosynthesis,
ultrasound, MRI or CT scan, or a PET or SPECT scan, is processed to
generate a varied or corrected version of the joint or portions of
the joint or surfaces within the joint. Certain embodiments provide
methods and devices to create a desired model of a joint or
portions or surfaces of a joint based on data derived from the
existing joint. For example, the data also can be used to create a
model that can be used to analyze the patient's joint and to devise
and evaluate a course of corrective action. The data and/or model
also can be used to design an implant component having one or more
patient-specific features, such as a surface or curvature.
[0008] In one aspect, certain embodiments provide a tibial implant
for a knee arthroplasty that includes (a) a tibial tray sized and
shaped generally for placement on a proximal surface of a tibia of
a patient with at least one insert locking mechanism, and (b) a
first insert, a second insert, or both a first and second tibial
insert. The first insert can include a first reciprocal locking
mechanism, a first bottom surface for engaging a surface of the
tibial tray, a first articular surface portion generally opposite
the first base surface, and a first thickness extending in a
generally perpendicular direction between the first bottom surface
and the first articular surface. The second insert can include a
second reciprocal locking mechanism, a second bottom surface for
engaging a surface of the tibial tray, a second articular surface
portion generally opposite the second base surface, and a second
thickness extending in a generally perpendicular direction between
the second bottom surface and the second articular surface. In some
embodiments, the first thickness of the first insert can be greater
than the second thickness of the second insert. The first and
second thicknesses can be measured, for example, from geographic
centers of the first and second contact areas of the first and
second articular surfaces, respectively, and/or from corresponding
edges of first and second contact areas of the first and second
articular surfaces, respectively, and/or from central points of the
first and second articular surfaces, respectively, and/or from the
point of the first and second articular surfaces that are closest
to the first and second bottom surfaces, respectively, and/or from
the point of the first and second articular surfaces that are
furthest from the first and second bottom surfaces, respectively.
In some embodiments, the first and second thicknesses can be
average thicknesses of the first and second inserts,
respectively.
[0009] In some embodiments, the first thickness of the first insert
can be substantially greater than the second thickness of the
second insert. For example, the difference in the thickness of the
first and second thicknesses can be a statistically significant
difference. Alternatively or in addition, the first and second
thicknesses can be a clinically significant difference, such as a
difference in thickness that is sufficient to induce a clinical
effect. A clinical effect can include an alignment of at least a
portion of the knee and/or balancing of at least a portion of the
knee. In addition, in some embodiments, the first and second
inserts of the tibial implant can have different curvatures on
respective articular surface portions and/or different slopes on
respective articular surface portions.
[0010] In another aspect, certain embodiments provide a tibial
implant for knee arthroplasty that can include a medial tibial
insert comprising (i) a substantially planar inner surface for
engaging a medial tibial tray face and (ii) an articular surface
comprising an articular surface plateau and disposed therein a
curved portion for opposing an articular surface of a medial
femoral condyle. Alternatively or in addition, the tibial implant
can include a lateral tibial insert comprising (i) a substantially
planar inner surface for engaging a lateral tibial tray face and
(ii) an articular surface comprising an articular surface plateau
and disposed therein a curved portion for opposing an articular
surface of a lateral femoral condyle. In some embodiments, the
distance from the inner surface to the articular surface of the
medial tibial insert can be different from the distance from the
inner surface to the articular surface of the lateral tibial
insert.
[0011] In some embodiments, the minimum distance from the inner
surface to the articular surface of the medial tibial insert can be
different from the minimum distance from the inner surface to the
articular surface of the lateral tibial insert, and/or the maximum
distance from the inner surface to the articular surface of the
medial tibial insert can be different from the maximum distance
from the inner surface to the articular surface of the lateral
tibial insert, and/or the average distance from the inner surface
to the articular surface of the medial tibial insert can be
different from the average distance from the inner surface to the
articular surface of the lateral tibial insert.
[0012] In some embodiments, the distance from the inner surface to
the articular surface of the medial tibial insert can be
substantially different and/or significantly different from the
distance from the inner surface to the articular surface of the
lateral tibial insert. For example, the distance from the inner
surface to a central point of the articular surface of the medial
tibial insert can be different from the distance from the inner
surface to a central point of the articular surface of the lateral
tibial insert. Alternatively or in addition, the distance from the
inner surface to a central point of a contact area of the articular
surface of the medial tibial insert is different from the distance
from the inner surface to a central point of a contact area of the
articular surface of the lateral tibial insert. Alternatively or in
addition, the distance from the inner surface to an edge of the
articular surface of the medial tibial insert is different from the
distance from the inner surface to an edge the articular surface of
the lateral tibial insert.
[0013] In some embodiments, the medial and lateral tibial inserts
can have different curvatures in the respective curved portions,
and/or different articular surface plateau slopes. In some
embodiments, the slope for the articular surface plateau of the
medial tibial insert can be patient-matched to the patient's medial
tibial plateau slope, or it can be patient-matched to the patient's
lateral tibial plateau slope. Similarly, in some embodiments, the
slope for the articular surface plateau of the lateral tibial
insert can be patient-matched to the patient's lateral tibial
plateau slope, or it can be patient-matched to the patient's medial
tibial plateau slope. In some embodiments, the tibial implant can
have a first tibial tray that includes a medial tibial tray face
and a second tibial tray that includes a lateral tibial tray
face.
[0014] In another aspect, certain embodiments provide a method for
making a tibial implant for use in repairing or replacing a knee of
a patient. The method can include one or both of the steps of (a)
electronically evaluating at least a portion of the knee based on
image data of the of the knee, and (b) specifying one or more
parameters of the tibial implant based at least in part on the
evaluation. The specified parameters can define, at least in part,
a tibial implant having a first articular surface higher than a
second articular surface relative to a proximal end of a tibia of
the knee when the tibial implant is implanted on the proximal end
of the tibia. In some embodiments, the method can further include
the step of planning a surgical result based on the electronic
image data of a patient's knee and, optionally, the specified
parameters can define, at least in part, a configuration of a
tibial implant to substantially achieve a planned surgical result.
The surgical result can be knee balancing during a surgical
procedure and, optionally, the knee balancing can include knee
balancing during extension and/or knee balancing during flexion.
Alternatively or in addition, the surgical result can be knee
alignment and, optionally, the knee alignment can include knee
alignment of anatomical axes and/or knee alignment of biomechanical
axes. In some embodiments, the knee alignment can include knee
alignment of the patient's femur and tibia, for example, linear
alignment and/or rotational alignment of the patient's femur and
tibia. In some embodiments, the surgical result can include
establishment or reestablishment of a particular joint line for the
patient, for example, establishment of the joint-line of a medial
compartment relative to a lateral compartment of the patient's
knee.
[0015] In some embodiments, the method's step of electronically
evaluating at least a portion of the knee can include determining a
difference in the relative position of at least a portion of first
and second articular surfaces of the knee. Alternatively and/or in
addition, the step of electronically evaluating at least a portion
of the knee can include determining a joint line of the knee, for
example, pre-surgically determining a joint line of the knee and/or
post-surgically determining a joint line of the knee.
[0016] In another aspect, certain embodiments provide a method for
making a tibial implant having at least one of a medial tibial
insert and a lateral tibial insert that substantially matches a
patient's biological feature in one or more measurements, or as a
predetermined percentage thereof. The method can include one or
both of the steps of (a) preoperatively identifying a feature
measurement of the patient's joint, and (b) designing at least one
of the medial tibial insert and the lateral tibial insert to
include substantially the same feature measurement or a
predetermined percentage of the feature measurement identified in
step (a). In certain embodiments, step (b) can include designing at
least one of the medial tibial insert and lateral tibial insert
using computer-aided design (CAD), and/or using computer-aided
manufacturing (CAM), and/or cutting a blank insert or an insert
having a blank feature to yield substantially the same feature
measurement or a predetermined percentage of the feature
measurement from step (a).
[0017] In some embodiments of the method, the substantially
matching feature measurement can be selected from the group
consisting of an insert mediolateral dimension substantially
matching a corresponding patient mediolateral dimension or a
predetermined percentage thereof, an insert thickness substantially
matching a corresponding thickness of resected patient tissue or a
predetermined percentage thereof, an insert perimeter shape
substantially matching a corresponding patient perimeter shape or a
predetermined percentage thereof, an insert surface slope
substantially matching a corresponding patient slope or a
predetermined percentage thereof, and an insert surface curvature
substantially matching a corresponding patient curvature or a
predetermined percentage thereof.
[0018] In some embodiments, designing a substantially matching or
same feature measurement can include smoothing a line or curve of
the patient's biological feature to derive the implant's
substantially same feature measurement or a predetermined
percentage of the feature measurement.
[0019] In another aspect, certain embodiments provide a method for
implanting a knee implant in a patient's knee that includes one or
both of the steps of (a) preparing a proximal end of a tibia to
receive an implant; and (b) inserting at least one tibial implant
onto the prepared proximal end of the tibia such that a first
articular surface of the at least one implant engages a first
articular surface of a femur or femoral implant and a second
articular surface of the at least one implant engages a second
articular surface of the femur or femoral implant. The first
articular surface can be higher than the second articular surface
relative to an anatomical axis of the tibia. In some embodiments,
the tibial implant includes a single tibial implant tray,
optionally with a single tibial insert, or alternatively, with dual
tibial inserts. In other embodiments, the tibial implant includes
dual tibial implant trays, optionally with a single tibial insert,
or alternatively, with dual tibial inserts, for example, a single
tibial insert for each of the two tibial implant trays.
[0020] In some embodiments, the method can further include
adjusting a height of a first articular surface relative to second
articular surface. In some embodiments, the method can further
include one or more of aligning the patient's joint, assessing the
alignment of the patient's joint, and adjusting alignment of the
patient's joint. Adjusting the alignment of a patient's joint can
include, for example, one or more of adjusting rotational alignment
of the patient's joint, adjusting linear alignment of the patient's
joint, and adjusting alignment of the patient's femur and tibia. In
some embodiments, the method can include adjusting a biomechanical
axis of the patient's joint and/or adjusting an anatomical axis of
the patient's joint. In some embodiments, the method can further
include one or more of balancing a patient's joint, assessing the
balance of the patient's joint, and adjusting the balance of the
patient's joint. Balancing can include, for example, balancing of
the patient's joint in extension and/or in flexion.
[0021] In some embodiments, the method can further include planning
a surgical procedure based on electronic image data of the
patient's knee, for example, to achieve a predetermined surgical
result and optionally performing the surgical procedure. In some
embodiments, the method's step (b) can substantially achieve the
predetermined surgical result. The surgical result can include, for
example, one or more of joint balancing, joint alignment, inserting
a first insert, adjusting balance with a second insert or trial
insert, adjusting alignment with a second insert or trial insert,
inserting a second insert, replacing a second insert or trial
insert with a third insert or trial insert, adjusting balance with
the third insert or trial insert, and adjusting alignment with a
third insert or trial insert.
[0022] In another aspect, certain embodiments provide a method for
balancing or optimizing ligament tension during implantation of a
knee implant in a patient that includes one or more of the steps of
(a) assessing the patient's medial joint gap distance and tension,
(b) assessing the patient's lateral joint gap distance and tension,
and (c) selecting independent medial and lateral tibial inserts to
provide proper gap distance and tension. In some embodiments, the
selected medial and lateral tibial inserts can have different
thicknesses. In some embodiments, the selected medial tibial insert
in step (c) is selected from among two or more medial tibial
inserts having different thicknesses and/or the selected lateral
tibial insert in step (c) is selected from among two or more
lateral tibial inserts having different thicknesses. The selection
of one or both medial and lateral tibial inserts can be used to
substantially restore the patient's natural medial and/or lateral
joint gaps, and/or it can be used to substantially restore the
patient's natural kinematics.
[0023] In another aspect, certain embodiments provide a kit for
implanting a tibial implant in a patient in need of knee
replacement that includes (a) a tibial tray having a first surface
for affixing the tray to the patient's tibia and an opposing second
surface for engaging a medial tibial insert, and (b) two or more
medial tibial inserts having different thicknesses from which to
select one medial tibial insert for engaging with the tibial tray.
In another aspect, certain embodiments provide a kit for implanting
a tibial implant in a patient in need of knee replacement that
includes (a) a tibial tray having a first surface for affixing the
tray to the patient's tibia and an opposing second surface for
engaging a lateral tibial insert; and (b) two or more lateral
tibial inserts having different thicknesses from which to select
one lateral tibial insert for engaging with the tibial tray.
[0024] It is to be understood that the features of the various
embodiments described herein are not mutually exclusive and may
exist in various combinations and permutations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The foregoing and other objects, aspects, features, and
advantages of embodiments will become more apparent and may be
better understood by referring to the following description, taken
in conjunction with the accompanying drawings, in which:
[0026] FIG. 1 is a flow chart illustrating a process that includes
selecting and/or designing an initial patient-adapted implant;
[0027] FIG. 2A is a photograph showing an exemplary knee
replacement using a patient-specific bicompartmental device and a
patient-specific unicompartmental device; FIGS. 2B and 2C are x-ray
images showing the device of FIG. 2A in the coronal plane and in
the sagittal plane, respectively;
[0028] FIG. 3 illustrates a coronal plane of the knee with
exemplary resection cuts that can be used to correct lower limb
alignment in a knee replacement;
[0029] FIG. 4 illustrates perimeters and areas of two bone surface
areas for two different bone resection cut depths;
[0030] FIG. 5 is a distal view of the femur in which two different
resection cuts are applied;
[0031] FIGS. 6A and 6B depict the posterior margin of an implant
component selected and/or designed using imaging data or shapes
derived from imaging data so that the implant component does not
interfere with and stays clear of the patient's PCL;
[0032] FIGS. 7A and 7B show exemplary unicompartmental medial and
lateral tibial implant components used together without (FIG. 7A)
and with (FIG. 7B) a polyethylene layer or insert;
[0033] FIGS. 8A-C depict three different types of step cuts
separating medial and lateral resection cut facets on a patient's
proximal tibia;
[0034] FIGS. 9A and 9B show exemplary flow charts for deriving a
medial tibial component slope (FIG. 9A) and/or a lateral tibial
component slope (FIG. 9B) for a tibial implant component;
[0035] FIGS. 10A-O show exemplary tibial implants designs that
include a tibial tray with dual inserts; FIGS. 10P-AD show
exemplary tibial implants designs that include a tibial tray with a
single inserts, with a range of insert surface shapes;
[0036] FIGS. 11A-C depict exemplary medial and lateral gliding
paths for tibial implant components and related single and dual
piece insert surfaces;
[0037] FIG. 12 depicts an embodiments of a tibial implant component
that is ligament retaining;
[0038] FIGS. 13A and 13B depict embodiments of a tibial implant
component that are ligament retaining;
[0039] FIGS. 14A and 14B depict embodiments of a tibial implant
component impinge (FIG. 14A) and that do not impinge (FIG. 14B)
ligaments;
[0040] FIG. 15A-C depict steps in a process for designing a
PCL-retaining tibial insert;
[0041] FIG. 16A-C depict three perspectives of an exemplary tibial
implant component that includes a stabilizing fin (e.g., a
PCL-sacrificing patient-specific tibial implant component);
[0042] FIGS. 17A and 17B depict exemplary cross-sections of tibial
implant components having a post (or keel or projection) projecting
from the surface of the implant component;
[0043] FIG. 18 shows proximal tibial resection cut depths of 2 mm,
3 mm and 4 mm;
[0044] FIG. 19 shows exemplary small, medium and large blank tibial
trays;
[0045] FIGS. 20A-C depict three exemplary combinations of a tibial
tray and tibial tray insert manufactured and/or machined to include
matching perimeters;
[0046] FIG. 21A-C depict exemplary A-P and peg angles for tibial
trays;
[0047] FIG. 22A shows six exemplary tool tips for making a polymer
(e.g., polyethylene) insert for a tibial implant component; FIG.
22B shows a sagittal view of two exemplary tools sweeping from
different distances into the polyethylene insert;
[0048] FIG. 23A shows an embodiment in which the shape of the
concave groove on the medial side of the joint-facing surface of
the tibial insert is matched by a convex shape on the opposing
surface of the insert and by a concavity on the engaging surface of
the tibial tray; FIG. 23B illustrates two exemplary concavity
dimensions for the bearing surface of a tibial implant
component;
[0049] FIGS. 24A and B illustrates two embodiments of tibial
implant components having sloped sagittal J-curves;
[0050] FIG. 25 is a flow chart for adapting a blank implant
component for a particular patient;
[0051] FIG. 26 illustrates various tibial cuts and corresponding
surface features;
[0052] FIG. 27 depicts a resected proximal tibial surface perimeter
and a smoothed perimeter line for designing a tibial implant
perimeter;
[0053] FIGS. 28 to 33 illustrate an exemplary design of a knee
implant, including a femoral component and a patella component;
[0054] FIG. 34A illustrates a tibial proximal resection cut that
can be selected and/or designed to be a certain distance below a
particular location on the patient's tibial plateau; FIG. 34B
illustrates anatomic sketches (e.g., using a CAD program to
manipulate a model of the patient's biological structure) overlaid
with the patient's tibial plateau; FIG. 34C illustrates sketched
overlays used to identify the centers of tubercles and the centers
of one or both of the lateral and medial plateaus;
[0055] FIGS. 35A to 35C illustrate one or more axes that can be
derived from anatomic sketches;
[0056] FIG. 36A depicts a proximal tibial resection made at 2 mm
below the lowest point of the patient's medial tibial plateau with
a an A-P slope cut that matched the A-P slope; FIGS. 36B and 36C
illustrate an implant selected and/or designed to have 90% coverage
of the patient's cut tibial surface;
[0057] FIGS. 37A to 47C describe exemplary steps for performing
resection cuts to the tibia using the anatomical references
identified above;
[0058] FIGS. 48A to 48E illustrate various aspects of an embodiment
of a tibial implant component, including a view of the tibial tray
bottom (FIG. 48A), a view of the tibial tray top (FIG. 48B), a view
of the tibial insert bottom (FIG. 48C), a top-front (i.e.,
proximal-anterior) perspective view of the tibial tray (FIG. 48D),
and a bottom front (i.e., distal anterior) perspective view of the
tibial insert (FIG. 48E);
[0059] FIGS. 49A-C show aspects of an embodiment of a tibial
implant component that includes a tibial tray and a one-piece
insert;
[0060] FIGS. 50A-C show aspects of an embodiment of a tibial
implant component that includes a tibial tray and a one-piece
insert;
[0061] FIGS. 51A-C show exemplary steps for altering a blank tibial
tray and a blank tibial insert to each include a patient-adapted
profile, for example, to substantially match the profile of the
patient's resected tibial surface;
[0062] FIGS. 52A-C show exemplary strategies for establishing
proper tibial rotation for a patient;
[0063] FIG. 53 illustrates exemplary stem design options for a
tibial tray;
[0064] FIGS. 54A and B show an approach in certain embodiments for
identifying a tibial implant perimeter profile based on the depth
and angle of the proximal tibial resection, which can applied in
the selection and/or design of the tibial tray perimeter profile
and/or the tibial insert perimeter profile;
[0065] FIGS. 55A and B show the same approach as described for
FIGS. 54A and B, but applied to a different patient having a
smaller tibia (e.g., smaller diameter and perimeter length);
[0066] FIGS. 56A-D show four different exemplary tibial implant
profiles, for example, having different medial and lateral condyle
perimeter shapes;
[0067] FIGS. 57A and B illustrate a first femur jig used to
establish peg holes and pin placements for a subsequent jig used
for a distal cut;
[0068] FIGS. 58A and B illustrate a distal femoral resection cut
performed with a second femur jig;
[0069] FIG. 59A illustrates an anterior cut, posterior cut, and
chamfer cut performed with a third femur jig; FIG. 59B illustrate
an additional femoral jig for making additional resection cuts;
[0070] FIGS. 60A and 60B illustrate and exemplary tibial jig;
[0071] FIG. 61 illustrates and exemplary balancing chip;
[0072] FIGS. 62A and B illustrate an exemplary balancing chip
attached to a tibial jig;
[0073] FIG. 63 illustrates a first jig used to establish placement
and alignment of femoral implant peg holes;
[0074] FIG. 64 illustrates a second jig used to establish placement
pins for the distal cut jig;
[0075] FIG. 65 illustrates a distal cut jig positioned based on the
placement established by the previous jig; and
[0076] FIG. 66 illustrates remaining resection cuts performed with
a chamfer cut jig.
[0077] Additional figure descriptions are included in the text
below. Unless otherwise denoted in the description for each figure,
"M" and "L" in certain figures indicate medial and lateral sides of
the view; "A" and "P" in certain figures indicate anterior and
posterior sides of the view, and "S" and "I" in certain figures
indicate superior and inferior sides of the view.
DETAILED DESCRIPTION
Introduction
[0078] When a surgeon uses a traditional off-the-shelf implant to
replace a patient's joint, for example, a knee joint, hip joint, or
shoulder joint, certain features of the implant typically do not
match the particular patient's biological features. These
mismatches can cause various complications during and after
surgery. For example, surgeons may need to extend the surgery time
and apply estimates and rules of thumb during surgery to address
the mismatches. For the patient, complications associated with
these mismatches can include pain, discomfort, soft tissue
impingement, and an unnatural feeling of the joint during motion,
e.g., so-called mid-flexion instability, as well as an altered
range of movement and an increased likelihood of implant failure.
In order to fit a traditional implant component to a patient's
articular bone, surgeons typically remove substantially more of the
patient's bone than is necessary to merely clear diseased bone from
the site. This removal of substantial portions of the patient's
bone frequently diminishes the patient's bone stock to the point
that only one subsequent revision implant is possible.
[0079] Certain embodiments of the implants, guide tools, and
related methods of designing (e.g., designing and making), and
using the implants and guide tools described herein can be applied
to any joint including, without limitation, a spine, spinal
articulations, an intervertebral disk, a facet joint, a shoulder,
an elbow, a wrist, a hand, a finger, a hip, a knee, an ankle, a
foot, or a toe joint. Furthermore, various embodiments described
herein can apply to methods and procedures, and the design of
methods and procedures, for resectioning the patient's anatomy in
order to implant the implant components described herein and/or to
using the guide tools described herein.
[0080] In certain embodiments, implant components and/or related
methods described herein can include a combination of
patient-specific and patient-engineered features. For example,
patient-specific data collected preoperatively can be used to
engineer one or more optimized surgical cuts to the patient's bone
and to design or select a corresponding implant component having or
more bone-facing surfaces or facets (i.e., "bone cuts") that
specifically match one or more of the patient's resected bone
surfaces. The surgical cuts to the patient's bone can be optimized
(i.e., patient-engineered) to enhance one or more parameters, such
as: (1) deformity correction and limb alignment (2) maximizing
preservation of bone, cartilage, or ligaments, or (3) restoration
and/or optimization of joint kinematics or biomechanics. Based on
the optimized surgical cuts and, optionally, on other desired
features of the implant component, the implant component's
bone-facing surface can be designed or selected to, at least in
part, negatively-match the shape of the patient's resected bone
surface.
Improved Implants, Guide Tools and Related Methods
[0081] Certain embodiments are directed to implants, guide tools,
and/or related methods that can be used to provide to a patient a
pre-primary procedure and/or a pre-primary implant such that a
subsequent, replacement implant can be performed with a second
(and, optionally, a third, and optionally, a fourth)
patient-adapted pre-primary implant or with a traditional primary
implant. In certain embodiments, the pre-primary implant procedure
can include 3, 4, 5, 6, 7, or more resection or surgical cuts to
the patient's bone and the pre-primary implant can include on its
corresponding bone-facing surface a matching number and orientation
of bone-cut facets or surfaces.
[0082] In one illustrative embodiment, a first pre-primary
joint-replacement procedure includes a patient-adapted implant
component, guide tool, and/or related method. The patient-adapted
implant component, guide tool, and/or related method can be
preoperatively selected and/or designed from patient-specific data,
such as one or more images of the patient's joint, to include one
or more features that are patient-specific or patient-engineered.
The features (e.g., dimensions, shape, surface contours) of the
first pre-primary implant and, optionally, patient-specific data
(e.g., features of the patient's resected bone surfaces and
features of the patient's contralateral joint) can be stored in a
database. When the first pre-primary implant fails, for example,
due to bone loss or osteolysis or aseptic loosening at a later
point in time (e.g., 15 years after the original implantation) a
second implant can be implanted. For the second implant procedure,
the amount of diseased bone can be assessed. If the amount of
diseased bone to be resected is minimal, the patient-specific data
can be used to select and/or design a second pre-primary procedure
and/or a pre-primary implant. If the amount of diseased bone to be
resected is substantial, a traditional primary procedure and a
traditional implant can be employed.
[0083] Alternatively, certain embodiments are directed to implants,
guide tools, and/or related methods that can be used to provide to
a patient a primary procedure and/or a primary implant such that a
subsequent replacement implant can be used as part of a traditional
revision procedure. Certain embodiments are directed to implants,
guide tools, and/or related methods that can be used to provide a
patient-adapted revision implant. For example, following a
traditional implant, a subsequent revision can include a
patient-adapted procedure and/or a patient-adapted implant
component as described herein.
[0084] FIG. 1 is a flow chart illustrating a process that includes
selecting and/or designing a first patient-adapted implant, for
example, a pre-primary implant. First, using the techniques
described herein or those suitable and known in the art,
measurements of the target joint are obtained 210. This step can be
repeated multiple times, as desired. Optionally, a virtual model of
the joint can be generated, for example, to determine proper joint
alignment and the corresponding resection cuts and implant
component features based on the determined proper alignment. This
information can be collected and stored 212 in a database 213. Once
measurements of the target joint are obtained and analyzed to
determine resection cuts and patient-adapted implant features, the
patient-adapted implant components can be selected 214 (e.g.,
selected from a virtual library and optionally manufactured without
further design alteration 215, or selected from a physical library
of implant components). Alternatively, or in addition, one or more
implant components with best-fitting and/or optimized features can
be selected 214 (e.g., from a library) and then further designed
(e.g., designed and manufactured) 216. Alternatively or in
addition, one or more implant components with best-fitting and/or
optimized features can be designed (e.g., designed and
manufactured) 218, 216 without an initial selection from a library.
Using a virtual model to assess the selected or designed implant
component(s), this process also can be repeated as desired (e.g.,
before one or more physical components are selected and/or
generated). The information regarding the selected and/or designed
implant component(s) can be collected and stored 220, 222 in a
database 213. Once a desired first patient-adapted implant
component or set of implant components is obtained, a surgeon can
prepare the implantation site and install the first implant 224.
The information regarding preparation of the implantation site and
implant installation can be collected and stored 226 in a database
213. In this way, the information associated with the first
pre-primary implant component is available for use by a surgeon for
subsequent implantation of a second pre-primary or a primary
implant.
[0085] Exemplary patient-adapted (i.e., patient-specific and/or
patient-engineered) features of the implant components described
herein are identified in Table 1. One or more of these implant
component features can be selected and/or designed based on
patient-specific data, such as image data.
TABLE-US-00001 TABLE 1 Exemplary implant features that can be
patient-adapted based on patient- specific measurements Category
Exemplary feature Implant or implant or One or more portions of, or
all of, an external implant component (applies knee, component
curvature shoulder, hip, ankle, or One or more portions of, or all
of, an internal implant other implant or implant dimension
component) One or more portions of, or all of, an internal or
external implant angle Portions or all of one or more of the ML,
AP, SI dimension of the internal and external component and
component features An outer locking mechanism dimension between a
plastic or non-metallic insert and a metal backing component in one
or more dimensions Component height Component profile Component 2D
or 3D shape Component volume Composite implant height Insert width
Insert shape Insert length Insert height Insert profile Insert
curvature Insert angle Distance between two curvatures or
concavities Polyethylene or plastic width Polyethylene or plastic
shape Polyethylene or plastic length Polyethylene or plastic height
Polyethylene or plastic profile Polyethylene or plastic curvature
Polyethylene or plastic angle Component stem width Component stem
shape Component stem length Component stem height Component stem
profile Component stem curvature Component stem position Component
stem thickness Component stem angle Component peg width Component
peg shape Component peg length Component peg height Component peg
profile Component peg curvature Component peg position Component
peg thickness Component peg angle Slope of an implant surface
Number of sections, facets, or cuts on an implant surface Tibial
implant or implant Slope of an implant surface component Condylar
distance, e.g., between tibial joint-facing surface concavities
that engage femoral condyles Coronal curvature (e.g., one or more
radii of curvature in the coronal plane) of one or both
joint-facing surface concavities that engage each femoral condyle
Sagittal curvature (e.g., one or more radii of curvature in the
sagittal plane) of one or both joint-facing surface concavities
that engage each femoral condyle
[0086] The term "implant component" as used herein can include: (i)
one of two or more devices that work together in an implant or
implant system, or (ii) a complete implant or implant system, for
example, in embodiments in which an implant is a single, unitary
device. The term "match" as used herein is envisioned to include
one or both of a negative-match, as a convex surface fits a concave
surface, and a positive-match, as one surface is identical to
another surface.
[0087] Traditional implants and implant components can have
surfaces and dimensions that are a poor match to a particular
patient's biological feature(s). The patient-adapted implants,
guide tools, and related methods described herein improve upon
these deficiencies. The following two subsections describe two
particular improvements, with respect to the bone-facing surface
and the joint-facing surface of an implant component; however, the
principles described herein are applicable to any aspect of an
implant component.
Bone-Facing Surface of an Implant Component
[0088] In certain embodiments, the bone-facing surface of an
implant can be designed to substantially negatively-match one more
bone surfaces. For example, in certain embodiments at least a
portion of the bone-facing surface of a patient-adapted implant
component can be designed to substantially negatively-match the
shape of subchondral bone, cortical bone, endosteal bone, and/or
bone marrow. A portion of the implant also can be designed for
resurfacing, for example, by negatively-matching portions of a
bone-facing surface of the implant component to the subchondral
bone or cartilage. Accordingly, in certain embodiments, the
bone-facing surface of an implant component can include one or more
portions designed to engage resurfaced bone, for example, by having
a surface that negatively-matches uncut subchondral bone or
cartilage, and one or more portions designed to engage cut bone,
for example, by having a surface that negatively-matches a cut
subchondral bone.
[0089] In certain embodiments, the bone-facing surface of an
implant component includes multiple surfaces, also referred to
herein as bone cuts. One or more of the bone cuts on the
bone-facing surface of the implant component can be selected and/or
designed to substantially negatively-match one or more surfaces of
the patient's joint, including one or more of a resected surface, a
resurfaced surface, and an unaltered surface, including one or more
of bone, cartilage, and other biological surfaces. For example, in
certain embodiments, one or more of the bone cuts on the
bone-facing surface of the implant component can be designed to
substantially negatively-match (e.g., the number, depth, and/or
angles of cut) one or more resected surfaces of the patient's bone.
The bone-facing surface of the implant component can include any
number of bone cuts, for example, two, three, four, less than five,
five, more than five, six, seven, eight, nine or more bone cuts. In
certain embodiments, the bone cuts of the implant component and/or
the resection cuts to the patient's bone can include one or more
facets on corresponding portions (e.g., medial and lateral
portions) of an implant component. For example, the facets can be
separated by a space or by a step cut connecting two corresponding
facets that reside on parallel or non-parallel planes. These
bone-facing surface features can be applied to various joint
implants, including knee, hip, spine, and shoulder joint
implants.
[0090] Any one or more bone cuts can include one or more facets. In
some embodiments, medial and lateral facets of a bone cut can
coplanar and contiguous, for example, as exemplified by coplanar
and contiguous medial and lateral sections and/or anterior and
posterior sections of a surface of a tibial implant component.
Alternatively or in addition, facets can be separated by a space
between corresponding regions of an implant component.
Alternatively or in addition, facets of a bone cut can be separated
by a transition such as a step cut, for example, a vertical or
angled cut connecting two non-coplanar or non facets of a bone cut.
In certain embodiments, one or more bone cut facets, bone cuts,
and/or the entire bone-facing surface of an implant can be
non-planar, for example, substantially curvilinear.
[0091] In certain embodiments, corresponding sections of an implant
component can include different thicknesses (e.g., distance between
the component's bone-facing surface and joint-facing surface),
surface features, bone cut features, section volumes, and/or other
features. For example, corresponding lateral and medial or sections
of a tibial implant component surface can include different
thicknesses, section volumes, bone cut angles, and bone cut surface
areas. One or more of the thicknesses, section volumes, bone cut
angles, bone cut surface areas, bone cut curvatures, numbers of
bone cuts, peg placements, peg angles, and other features may vary
between two or more sections (e.g., corresponding sections on
lateral and medial condyles) of an implant component. Alternatively
or in addition, one, more, or all of these features can be the same
in corresponding sections of an implant component. An implant
design that allows for independent features on different sections
of an implant allows various options for achieving one or more
goals, including, for example, (1) deformity correction and limb
alignment (2) preserving bone, cartilage, and/or ligaments, (3)
preserving and/or optimizing other features of the patient's
anatomy, such as trochlea and trochlear shape, (4) restoring and/or
optimizing joint kinematics or biomechanics, and/or (5) restoring
and/or optimizing joint-line location and/or joint gap width.
[0092] Alternatively or in addition, corresponding sections of an
implant component can be designed to include the same features, for
example, the same thickness or at least a threshold thickness. For
example, when the corresponding implant sections are exposed to
similar stress forces, similar minimum thicknesses can be used in
response to those stresses. Alternatively or in addition, an
implant design can include a rule, such that a quantifiable feature
of one section is greater than, greater than or equal to, less
than, or less than or equal to the same feature of another section
of the implant component. For example, in certain embodiments, an
implant design can include a lateral portion that is thicker than
or equal in thickness to the corresponding medial portion.
Similarly, in certain embodiments, an implant design can include a
lateral height that is higher than or equal to the corresponding
medial height.
[0093] In certain embodiments, one or more of an implant
component's bone cut or bone cut facet features (e.g., thickness,
section volume, cut angle, surface area, and/or other features) can
be patient-adapted. For example, as described more fully below,
patient-specific data, such as imaging data of a patient's joint,
can be used to select and/or design an implant component (and,
optionally, a corresponding surgical procedure and/or surgical
tool) that matches a patient's anatomy and/or optimizes a parameter
of that patient's anatomy. Alternatively or in addition, one or
more aspects of an implant component, for example, one or more bone
cuts, can be selected and/or designed to match predetermined
resection cuts. Predetermined as used herein includes, for example,
preoperatively determined (e.g., preoperatively selected and/or
designed). For example, predetermined resection cuts can include
resection cuts determined preoperatively, optionally in conjunction
with a selection and/or design of one or more implant component
features and/or one or more guide tool features. Similarly, a
surgical guide tool can be selected and/or designed to guide the
predetermined resection cuts.
Joint-Facing Surface of an Implant Component
[0094] In various embodiments described herein, the outer,
joint-facing surface of an implant component includes one or more
patient-adapted (e.g., patient-specific and/or patient-engineered
features). For example, in certain embodiments, the joint-facing
surface of an implant component can be designed to match the shape
of the patient's biological structure. The joint-facing surface can
include, for example, the bearing surface portion of the implant
component that engages an opposing biological structure or implant
component in the joint to facilitate typical movement of the joint.
The patient's biological structure can include, for example,
cartilage, bone, and/or one or more other biological
structures.
[0095] For example, in certain embodiments, the joint-facing
surface of an implant component is designed to match the shape of
the patient's articular cartilage. For example, the joint-facing
surface can substantially positively-match one or more features of
the patient's existing cartilage surface and/or healthy cartilage
surface and/or a calculated cartilage surface, on the articular
surface that the component replaces. Alternatively, it can
substantially negatively-match one or more features of the
patient's existing cartilage surface and/or healthy cartilage
surface and/or a calculated cartilage surface, on the opposing
articular surface in the joint. As described below, corrections can
be performed to the shape of diseased cartilage by designing
surgical steps (and, optionally, patient-adapted surgical tools) to
re-establish a normal or near normal cartilage shape that can then
be incorporated into the shape of the joint-facing surface of the
component. These corrections can be implemented and, optionally,
tested in virtual two-dimensional and three-dimensional models. The
corrections and testing can include kinematic analysis and/or
surgical steps.
[0096] In certain embodiments, the joint-facing surface of an
implant component can be designed to positively-match the shape of
subchondral bone. For example, the joint-facing surface of an
implant component can substantially positively-match one or more
features of the patient's existing subchondral bone surface and/or
healthy subchondral bone surface and/or a calculated subchondral
bone surface, on the articular surface that the component attaches
to on its bone-facing surface. Alternatively, it can substantially
negatively-match one or more features of the patient's existing
subchondral bone surface and/or healthy subchondral bone surface
and/or a calculated subchondral bone surface, on the opposing
articular surface in the joint. Corrections can be performed to the
shape of subchondral bone to re-establish a normal or near normal
articular shape that can be incorporated into the shape of the
component's joint-facing surface. A standard thickness can be added
to the joint-facing surface, for example, to reflect an average
cartilage thickness. Alternatively, a variable thickness can be
applied to the component. The variable thickness can be selected to
reflect a patient's actual or healthy cartilage thickness, for
example, as measured in the individual patient or selected from a
standard reference database.
[0097] In certain embodiments, the joint-facing surface of an
implant component can include one or more standard features. The
standard shape of the joint-facing surface of the component can
reflect, at least in part, the shape of typical healthy subchondral
bone or cartilage. For example, the joint-facing surface of an
implant component can include a curvature having standard radii or
curvature of in one or more directions. Alternatively or in
addition, an implant component can have a standard thickness or a
standard minimum thickness in select areas. Standard thickness(es)
can be added to one or more sections of the joint-facing surface of
the component or, alternatively, a variable thickness can be
applied to the implant component.
[0098] Certain embodiments can include, in addition to a first
implant component, a second implant component having an opposing
joint-facing surface. The second implant component's bone-facing
surface and/or joint-facing surface can be designed as described
above. Moreover, in certain embodiments, the joint-facing surface
of the second component can be designed, at least in part, to match
(e.g., substantially negatively-match) the joint-facing surface of
the first component. Designing the joint-facing surface of the
second component to complement the joint-facing surface of the
first component can help reduce implant wear and optimize
kinematics. Thus, in certain embodiments, the joint-facing surfaces
of the first and second implant components can include features
that do not match the patient's existing anatomy, but instead
negatively-match or nearly negatively-match the joint-facing
surface of the opposing implant component.
[0099] However, when a first implant component's joint-facing
surface includes a feature adapted to a patient's biological
feature, a second implant component having a feature designed to
match that feature of the first implant component also is adapted
to the patient's same biological feature. By way of illustration,
when a joint-facing surface of a first component is adapted to a
portion of the patient's cartilage shape, the opposing joint-facing
surface of the second component designed to match that feature of
the first implant component also is adapted to the patient's
cartilage shape. When the joint-facing surface of the first
component is adapted to a portion of a patient's subchondral bone
shape, the opposing joint-facing surface of the second component
designed to match that feature of the first implant component also
is adapted to the patient's subchondral bone shape. When the
joint-facing surface of the first component is adapted to a portion
of a patient's cortical bone, the joint-facing surface of the
second component designed to match that feature of the first
implant component also is adapted to the patient's cortical bone
shape. When the joint-facing surface of the first component is
adapted to a portion of a patient's endosteal bone shape, the
opposing joint-facing surface of the second component designed to
match that feature of the first implant component also is adapted
to the patient's endosteal bone shape. When the joint-facing
surface of the first component is adapted to a portion of a
patient's bone marrow shape, the opposing joint-facing surface of
the second component designed to match that feature of the first
implant component also is adapted to the patient's bone marrow
shape.
[0100] The opposing joint-facing surface of a second component can
substantially negatively-match the joint-facing surface of the
first component in one plane or dimension, in two planes or
dimensions, in three planes or dimensions, or in several planes or
dimensions. For example, the opposing joint-facing surface of the
second component can substantially negatively-match the
joint-facing surface of the first component in the coronal plane
only, in the sagittal plane only, or in both the coronal and
sagittal planes.
[0101] In creating a substantially negatively-matching contour on
an opposing joint-facing surface of a second component, geometric
considerations can improve wear between the first and second
components. For example, the radii of a concave curvature on the
opposing joint-facing surface of the second component (e.g., a
tibial implant component) can be selected to match or to be
slightly larger in one or more dimensions than the radii of a
convex curvature on the joint-facing surface of the first component
(e.g., a femoral implant component). Similarly, the radii of a
convex curvature on the opposing joint-facing surface of the second
component can be selected to match or to be slightly smaller in one
or more dimensions than the radii of a concave curvature on the
joint-facing surface of the first component. In this way, contact
surface area can be maximized between articulating convex and
concave curvatures on the respective surfaces of first and second
implant components.
[0102] The bone-facing surface of the second component can be
designed to negatively-match, at least in part, the shape of
articular cartilage, subchondral bone, cortical bone, endosteal
bone or bone marrow (e.g., surface contour, angle, or perimeter
shape of a resected or native biological structure). It can have
any of the features described above for the bone-facing surface of
the first component, such as having one or more patient-adapted
bone cuts to match one or more predetermined resection cuts.
[0103] Many combinations of first component and second component
bone-facing surfaces and joint-facing surfaces are possible. Table
2 provides illustrative combinations that may be employed.
TABLE-US-00002 TABLE 2 Illustrative Combinations of Implant
Components 1.sup.st 1.sup.st 2.sup.nd component component 1.sup.st
2.sup.nd component 2.sup.nd bone-facing joint-facing component
component joint bone facing component surface surface bone cut(s)
facing surface surface bone cuts Example: Example: Example:
Example: Tibia Example: Example: Femur Femur Femur Tibia Tibia At
least one Cartilage Yes Negative-match of 1.sup.st At least one Yes
bone cut component joint-facing bone cut (opposing cartilage) At
least one Cartilage Yes Negative-match of 1.sup.st Subchondral
Optional bone cut component joint-facing bone (opposing cartilage)
At least one Cartilage Yes Negative-match of 1.sup.st Cartilage
Optional bone cut component joint-facing (same side, (opposing
cartilage) e.g. tibia) At least one Subchondral Yes Negative-match
of 1.sup.st At least one Yes bone cut bone component joint-facing
bone cut (opposing subchondral bone) At least one Subchondral Yes
Negative-match of 1.sup.st Subchondral Optional bone cut bone
component joint-facing bone (opposing subchondral bone) At least
one Subchondral Yes Negative-match of 1.sup.st Cartilage Optional
bone cut bone component joint-facing (same side, (opposing
subchondral e.g. tibia) bone) Subchondral Cartilage Optional
Negative-match of 1.sup.st At least one Yes bone component
joint-facing bone cut (opposing cartilage) Subchondral Cartilage
Optional Negative-match of 1.sup.st Subchondral Optional bone
component joint-facing bone (opposing cartilage) Subchondral
Cartilage Optional Negative-match of 1.sup.st Cartilage Optional
bone component joint-facing (same side, (opposing cartilage) e.g.
tibia) Subchondral Subchondral Optional Negative-match of 1.sup.st
At least one Yes bone bone component joint-facing bone cut
(opposing subchondral bone) Subchondral Subchondral Optional
Negative-match of 1.sup.st Subchondral Optional bone bone component
joint-facing bone (opposing subchondral bone) Subchondral
Subchondral Optional Negative-match of 1.sup.st Cartilage Optional
bone bone component joint-facing (same side, (opposing subchondral
e.g. tibia) bone) Subchondral Standard/ Optional Negative-match of
1.sup.st At least one Yes bone Model component joint-facing bone
cut standard Subchondral Standard/ Optional Negative-match of
1.sup.st Subchondral Optional bone Model component joint-facing
bone standard Subchondral Standard/ Optional Negative-match of
1.sup.st Cartilage Optional bone Model component joint-facing (same
side, standard e.g. tibia) Subchondral Subchondral Optional
Non-matching standard At least one Yes bone bone surface bone cut
Subchondral Cartilage Optional Non-matching standard At least one
Yes bone surface bone cut
[0104] The implants and implant systems described herein include
any number of patient-adapted implant components and any number of
non-patient-adapted implant components. An illustrative implant or
implant system is depicted in FIGS. 2A-2C. Specifically, FIG. 2A
shows a photograph of a patient-adapted knee replacement implant
system that includes a patient-specific bicompartmental implant
component 700 and patient-specific unicompartmental implant
component 710. Both components are patient-specific on both their
bone-facing surfaces and on their joint-facing surfaces. FIGS. 2B
and 2C show x-ray images showing the implant of FIG. 2A in the
coronal plane (FIG. 2B) and the sagittal plane (FIG. 2C).
[0105] Embodiments described herein can be applied to partial or
total joint replacement systems. Bone cuts or changes to an implant
component dimension described herein can be applied to a portion of
the dimension, or to the entire dimension.
Collecting and Modeling Patient-Specific Data
[0106] As mentioned above, certain embodiments include implant
components designed and made using patient-specific data that is
collected preoperatively. The patient-specific data can include
points, surfaces, and/or landmarks, collectively referred to herein
as "reference points." In certain embodiments, the reference points
can be selected and used to derive a varied or altered surface,
such as, without limitation, an ideal surface or structure. For
example, the reference points can be used to create a model of the
patient's relevant biological feature(s) and/or one or more
patient-adapted surgical steps, tools, and implant components. For
example the reference points can be used to design a
patient-adapted implant component having at least one
patient-specific or patient-engineered feature, such as a surface,
dimension, or other feature.
[0107] Sets of reference points can be grouped to form reference
structures used to create a model of a joint and/or an implant
design. Designed implant surfaces can be derived from single
reference points, triangles, polygons, or more complex surfaces,
such as parametric or subdivision surfaces, or models of joint
material, such as, for example, articular cartilage, subchondral
bone, cortical bone, endosteal bone or bone marrow. Various
reference points and reference structures can be selected and
manipulated to derive a varied or altered surface, such as, without
limitation, an ideal surface or structure.
[0108] The reference points can be located on or in the joint that
receive the patient-specific implant. For example, the reference
points can include weight-bearing surfaces or locations in or on
the joint, a cortex in the joint, and/or an endosteal surface of
the joint. The reference points also can include surfaces or
locations outside of but related to the joint. Specifically,
reference points can include surfaces or locations functionally
related to the joint. For example, in embodiments directed to the
knee joint, reference points can include one or more locations
ranging from the hip down to the ankle or foot. The reference
points also can include surfaces or locations homologous to the
joint receiving the implant. For example, in embodiments directed
to a knee, a hip, or a shoulder joint, reference points can include
one or more surfaces or locations from the contralateral knee, hip,
or shoulder joint.
[0109] In certain embodiments, an imaging data collected from the
patient, for example, imaging data from one or more of x-ray
imaging, digital tomosynthesis, cone beam CT, non-spiral or spiral
CT, non-isotropic or isotropic MRI, SPECT, PET, ultrasound, laser
imaging, photo-acoustic imaging, is used to qualitatively and/or
quantitatively measure one or more of a patient's biological
features, one or more of normal cartilage, diseased cartilage, a
cartilage defect, an area of denuded cartilage, subchondral bone,
cortical bone, endosteal bone, bone marrow, a ligament, a ligament
attachment or origin, menisci, labrum, a joint capsule, articular
structures, and/or voids or spaces between or within any of these
structures. The qualitatively and/or quantitatively measured
biological features can include, but are not limited to, one or
more of length, width, height, depth and/or thickness; curvature,
for example, curvature in two dimensions (e.g., curvature in or
projected onto a plane), curvature in three dimensions, and/or a
radius or radii of curvature; shape, for example, two-dimensional
shape or three-dimensional shape; area, for example, surface area
and/or surface contour; perimeter shape; and/or volume of, for
example, the patient's cartilage, bone (subchondral bone, cortical
bone, endosteal bone, and/or other bone), ligament, and/or voids or
spaces between them.
[0110] In certain embodiments, measurements of biological features
can include any one or more of the illustrative measurements
identified in Table 3.
TABLE-US-00003 TABLE 3 Exemplary patient-specific measurements of
biological features that can be used to create a model and/or to
select and/or design a tibial implant component Anatomical feature
Exemplary measurement Medullary cavity Shape in one or more
dimensions Shape in one or more locations Diameter of cavity Volume
of cavity Subchondral bone Shape in one or more dimensions Shape in
one or more locations Thickness in one or more dimensions Thickness
in one or more locations Angle, e.g., resection cut angle Cortical
bone Shape in one or more dimensions Shape in one or more locations
Thickness in one or more dimensions Thickness in one or more
locations Angle, e.g., resection cut angle Endosteal bone Shape in
one or more dimensions Shape in one or more locations Thickness in
one or more dimensions Thickness in one or more locations Angle,
e.g., resection cut angle Cartilage Shape in one or more dimensions
Shape in one or more locations Thickness in one or more dimensions
Thickness in one or more locations Angle, e.g., resection cut angle
Intercondylar notch Shape in one or more dimensions Location Height
in one or more locations Width in one or more locations Depth in
one or more locations Angle, e.g., resection cut angle Entire tibia
2D and/or 3D shape of a portion or all Height in one or more
locations Length in one or more locations Width in one or more
locations Depth in one or more locations Thickness in one or more
locations Curvature in one or more locations Slope in one or more
locations and/or directions Angle, e.g., resection cut angle Axes,
e.g., A-P and/or M-L axes Osteophytes Plateau slope(s), e.g.,
relative slopes medial and lateral Plateau heights(s), e.g.,
relative heights medial and lateral Bearing surface radii, e.g.,
e.g., relative radii medial and lateral Perimeter profile Medial
tibia 2D and/or 3D shape of a portion or all Height in one or more
locations Length in one or more locations Width in one or more
locations Depth in one or more locations Thickness or height in one
or more locations Curvature in one or more locations Slope in one
or more locations and/or directions Angle, e.g., resection cut
angle Perimeter profile Lateral tibia 2D and/or 3D shape of a
portion or all Height in one or more locations Length in one or
more locations Width in one or more locations Depth in one or more
locations Thickness/height in one or more locations Curvature in
one or more locations Slope in one or more locations and/or
directions Angle, e.g., resection cut angle Perimeter profile
[0111] In certain embodiments, the model that includes at least a
portion of the patient's joint also can include or display, as part
of the model, one or more resection cuts, one or more drill holes,
(e.g., on a model of the patient's femur), one or more guide tools,
and/or one or more implant components that have been designed for
the particular patient using the model. Moreover, one or more
resection cuts, one or more drill holes, one or more guide tools,
and/or one or more implant components can be modeled and selected
and/or designed separate from a model of a particular patient's
biological feature.
Modeling and Addressing Joint Defects
[0112] In certain embodiments, the reference points and/or
measurements described above can be processed using mathematical
functions to derive virtual, corrected features, which may
represent a restored, ideal or desired feature from which a
patient-adapted implant component can be designed. For example, one
or more features, such as surfaces or dimensions of a biological
structure can be modeled, altered, added to, changed, deformed,
eliminated, corrected and/or otherwise manipulated (collectively
referred to herein as "variation" of an existing surface or
structure within the joint).
[0113] Variation of the joint or portions of the joint can include,
without limitation, variation of one or more external surfaces,
internal surfaces, joint-facing surfaces, uncut surfaces, cut
surfaces, altered surfaces, and/or partial surfaces as well as
osteophytes, subchondral cysts, geodes or areas of eburnation,
joint flattening, contour irregularity, and loss of normal shape.
The surface or structure can be or reflect any surface or structure
in the joint, including, without limitation, bone surfaces, ridges,
plateaus, cartilage surfaces, ligament surfaces, or other surfaces
or structures. The surface or structure derived can be an
approximation of a healthy joint surface or structure or can be
another variation. The surface or structure can be made to include
pathological alterations of the joint. The surface or structure
also can be made whereby the pathological joint changes are
virtually removed in whole or in part.
[0114] Once one or more reference points, measurements, structures,
surfaces, models, or combinations thereof have been selected or
derived, the resultant shape can be varied, deformed or corrected.
In certain embodiments, the variation can be used to select and/or
design an implant component having an ideal or optimized feature or
shape, e.g., corresponding to the deformed or corrected joint
features or shape. For example, in one application of this
embodiment, the ideal or optimized implant shape reflects the shape
of the patient's joint before he or she developed arthritis.
[0115] Alternatively or in addition, the variation can be used to
select and/or design a patient-adapted surgical procedure to
address the deformity or abnormality. For example, the variation
can include surgical alterations to the joint, such as virtual
resection cuts, virtual drill holes, virtual removal of
osteophytes, and/or virtual building of structural support in the
joint that may be desired for a final outcome for the patient.
Corrections can be used to address osteophytes, subchondral voids,
and other patient-specific defects or abnormalities. In the case of
osteophytes, a design for the bone-facing surface of an implant
component or guide tool can be selected and/or designed after the
osteophyte has been virtually removed. Alternatively, the
osteophyte can be integrated into the shape of the bone-facing
surface of the implant component or guide tool.
[0116] In addition to osteophytes and subchondral voids, the
methods, surgical strategies, guide tools, and implant components
described herein can be used to address various other
patient-specific joint defects or phenomena. In certain
embodiments, correction can include the virtual removal of tissue,
for example, to address an articular defect, to remove subchondral
cysts, and/or to remove diseased or damaged tissue (e.g.,
cartilage, bone, or other types of tissue), such as osteochondritic
tissue, necrotic tissue, and/or torn tissue. In such embodiments,
the correction can include the virtual removal of the tissue (e.g.,
the tissue corresponding to the defect, cyst, disease, or damage)
and the bone-facing surface of the implant component can be derived
after the tissue has been virtually removed. In certain
embodiments, the implant component can be selected and/or designed
to include a thickness or other features that substantially matches
the removed tissue and/or optimizes one or more parameters of the
joint. Optionally, a surgical strategy and/or one or more guide
tools can be selected and/or designed to reflect the correction and
correspond to the implant component.
[0117] Certain embodiments described herein include collecting and
using data from imaging tests to virtually determine in one or more
planes one or more of an anatomic axis and a mechanical axis and
the related misalignment of a patient's limb. The imaging tests
that can be used to virtually determine a patient's axis and
misalignment can include one or more of such as x-ray imaging,
digital tomosynthesis, cone beam CT, non-spiral or spiral CT,
non-isotropic or isotropic MRI, SPECT, PET, ultrasound, laser
imaging, and photoacoustic imaging, including studies utilizing
contrast agents. Data from these tests can be used to determine
anatomic reference points or limb alignment, including alignment
angles within the same and between different joints or to simulate
normal limb alignment. Using the image data, one or more mechanical
or anatomical axes, angles, planes or combinations thereof can be
determined. In certain embodiments, such axes, angles, and/or
planes can include, or be derived from, one or more of a
Whiteside's line, Blumensaat's line, transepicondylar line, femoral
shaft axis, femoral neck axis, acetabular angle, lines tangent to
the superior and inferior acetabular margin, lines tangent to the
anterior or posterior acetabular margin, femoral shaft axis, tibial
shaft axis, transmalleolar axis, posterior condylar line,
tangent(s) to the trochlea of the knee joint, tangents to the
medial or lateral patellar facet, lines tangent or perpendicular to
the medial and lateral posterior condyles, lines tangent or
perpendicular to a central weight-bearing zone of the medial and
lateral femoral condyles, lines transecting the medial and lateral
posterior condyles, for example through their respective
centerpoints, lines tangent or perpendicular to the tibial
tuberosity, lines vertical or at an angle to any of the
aforementioned lines, and/or lines tangent to or intersecting the
cortical bone of any bone adjacent to or enclosed in a joint.
Moreover, estimating a mechanical axis, an angle, or plane also can
be performed using image data obtained through two or more joints,
such as the knee and ankle joint, for example, by using the femoral
shaft axis and a centerpoint or other point in the ankle, such as a
point between the malleoli.
[0118] As one example, if surgery of the knee or hip is
contemplated, the imaging test can include acquiring data through
at least one of, or several of, a hip joint, knee joint or ankle
joint. As another example, if surgery of the knee joint is
contemplated, a mechanical axis can be determined. For example, the
centerpoint of the hip knee and ankle can be determined. By
connecting the centerpoint of the hip with that of the ankle, a
mechanical axis can be determined in the coronal plane. The
position of the knee relative to said mechanical axis can be a
reflection of the degree of varus or valgus deformity. The same
determinations can be made in the sagittal plane, for example to
determine the degree of genu antecurvatum or recurvatum. Similarly,
any of these determinations can be made in any other desired
planes, in two or three dimensions.
[0119] Cartilage loss in one compartment can lead to progressive
joint deformity. For example, cartilage loss in a medial
compartment of the knee can lead to varus deformity. In certain
embodiments, cartilage loss can be estimated in the affected
compartments. The estimation of cartilage loss can be performed
using an ultrasound MRI or CT scan or other imaging modality,
optionally with intravenous or intra-articular contrast. The
estimation of cartilage loss can be as simple as measuring or
estimating the amount of joint space loss seen on x-rays. For the
latter, typically standing x-rays are preferred. If cartilage loss
is measured from x-rays using joint space loss, cartilage loss on
one or two opposing articular surfaces can be estimated by, for
example, dividing the measured or estimated joint space loss by two
to reflect the cartilage loss on one articular surface. Other
ratios or calculations are applicable depending on the joint or the
location within the joint. Subsequently, a normal cartilage
thickness can be virtually established on one or more articular
surfaces by simulating normal cartilage thickness. In this manner,
a normal or near normal cartilage surface can be derived. Normal
cartilage thickness can be virtually simulated using a computer,
for example, based on computer models, for example using the
thickness of adjacent normal cartilage, cartilage in a
contralateral joint, or other anatomic information including
subchondral bone shape or other articular geometries. Cartilage
models and estimates of cartilage thickness can also be derived
from anatomic reference databases that can be matched, for example,
to a patient's weight, sex, height, race, gender, or articular
geometry(ies).
[0120] In certain embodiments, a patient's limb alignment can be
virtually corrected by realigning the knee after establishing a
normal cartilage thickness or shape in the affected compartment by
moving the joint bodies, for example, femur and tibia, so that the
opposing cartilage surfaces including any augmented or derived or
virtual cartilage surface touch each other, typically in the
preferred contact areas. These contact areas can be simulated for
various degrees of flexion or extension.
Deformity Correction and Optimizing Limb Alignment
[0121] Information regarding the misalignment and the proper
mechanical alignment of a patient's limb, can be used to
preoperatively design and/or select one or more features of a joint
implant and/or implant procedure. For example, based on the
difference between the patient's misalignment and the proper
mechanical axis, a knee implant and implant procedure can be
designed and/or selected preoperatively to include implant and/or
resection dimensions that substantially realign the patient's limb
to correct or improve a patient's alignment deformity. In addition,
the process can include selecting and/or designing one or more
surgical tools (e.g., guide tools or cutting jigs) to direct the
clinician in resectioning the patient's bone in accordance with the
preoperatively designed and/or selected resection dimensions.
[0122] In certain embodiments, the degree of deformity correction
to establish a desired limb alignment is calculated based on
information from the alignment of a virtual model of a patient's
limb. The virtual model can be generated from patient-specific
data, such 2D and/or 3D imaging data of the patient's limb. The
deformity correction can correct varus or valgus alignment or
antecurvatum or recurvatum alignment. In a preferred embodiment,
the desired deformity correction returns the leg to normal
alignment, for example, a zero degree biomechanical axis in the
coronal plane and absence of genu antecurvatum and recurvatum in
the sagittal plane.
[0123] FIG. 3 illustrates a coronal plane of the knee with
exemplary resection cuts that can be used to correct lower limb
alignment in a knee replacement. As shown in the figure, the
selected and/or designed resection cuts can include different cuts
on different portions of a patient's biological structure. For
example, resection cut facets on medial and lateral femoral
condyles can be non-coplanar and parallel 1602, 1602', angled 1604,
1604', or non-coplanar and non-parallel, for example, cuts 1602 and
1604' or cuts 1602' and 1604. Similar, resection cut facets on
medial and lateral portions of the tibia can be non-coplanar and
parallel 1606, 1606', angled and parallel 1608, 1608', or
non-coplanar and non-parallel, for example, cuts 1606 and 1608' or
cuts 1606' and 1608. Non-coplanar facets of resection cuts can
include a step-cut 1610 to connect the non-coplanar resection facet
surfaces. Selected and/or designed resection dimensions can be
achieved using or more selected and/or designed guide tools (e.g.,
cutting jigs) that guide resectioning (e.g., guide cutting tools)
of the patient's biological structure to yield the predetermined
resection surface dimensions (e.g., resection surface(s), angles,
and/or orientation(s). In certain embodiments, the bone-facing
surfaces of the implant components can be designed to include one
or more features (e.g., bone cut surface areas, perimeters, angles,
and/or orientations) that substantially match one or more of the
resection cut or cut facets that were predetermined to enhance the
patient's alignment. As shown in FIG. 3, certain combinations of
resection cuts can aid in bringing the femoral mechanical axis 1612
and tibial mechanical axis 1614 into alignment 1616.
[0124] Alternatively, or in addition, certain implant features,
such as different implant thicknesses and/or surface curvatures
across two different sides of the plane in which the mechanical
axes are misaligned also can aid correcting limb alignment. As
described more fully below, independent tibial implant components
and/or independent tibial inserts on medial and lateral sides of
the tibial implant component can be used to enhance alignment at a
patient's knee joint. An implant component can include constant yet
different thicknesses in two or more portions of the implant (e.g.,
a constant medial tibial plateau thickness different from a
constant lateral tibial plateau thickness), a gradually increasing
thickness across the implant or a portion of the implant, or a
combination of constant and gradually increasing thicknesses.
[0125] The selection and/or design of one or more femoral resection
dimensions, femoral implant component thicknesses, femoral implant
component surface curvatures, tibial resection dimensions, tibial
implant component thicknesses, tibial implant component insert
thicknesses, and/or tibial implant component surface curvatures can
be used to adjust the femoral mechanical axis and tibial mechanical
axis into alignment in the sagittal plane (e.g., by altering
corresponding features across the sagittal plane, for example, by
altering anterior features relative to corresponding posterior
features). Alignment deformities in both the coronal and sagittal
planes, or in multiple planes about the mechanical axes, can be
addressed by designing and/or selecting one or more resection
dimensions, one or more implant component thicknesses, and/or one
or more implant component surface curvatures.
[0126] In certain embodiments, an implant component that is
preoperatively designed and/or selected to correct a patient's
alignment also can be designed or selected to include additional
patient-specific or patient-engineered features. For example, the
bone-facing surface of an implant or implant component can be
designed and/or selected to substantially negatively-match the
resected bone surface. As depicted in FIG. 4, the perimeters and
areas 1910 of two bone surface areas of a patient's proximal tibia
is different for two different bone resection cut depths 1920.
Similarly, FIG. 5 depicts a distal view of the femur in which two
different resection cuts are applied. As shown, the resected
perimeters and surface areas for two distal facet resection depths
are different for each of the medial condyle distal cut facet 1930
and the lateral condyle distal cut facet 1940.
[0127] If resection dimensions are angled, for example, in the
coronal plane and/or in the sagittal plane, various features of the
implant component, for example, the component bone-facing surface,
can be designed and/or selected based on an angled orientation into
the joint rather than on a perpendicular orientation For example,
the perimeter of tibial implant or implant component that
substantially positively-matches the perimeter of the patient's cut
tibial bone has a different shape depending on the angle of the
cut. Similarly, with a femoral implant component, the depth or
angle of the distal condyle resection on the medial and/or lateral
condyle can be designed and/or selected to correct a patient
alignment deformity. However, in so doing, one or more of the
implant or implant component condyle width, length, curvature, and
angle of impact against the tibia can be altered. Accordingly in
certain embodiments, one or more implant or implant component
features, such as implant perimeter, condyle length, condyle width,
curvature, and angle is designed and/or selected relative to the a
sloping and/or non-coplanar resection cut.
Preserving Bone, Cartilage or Ligament
[0128] Traditional orthopedic implants incorporate bone cuts. These
bone cuts achieve two objectives: they establish a shape of the
bone that is adapted to the implant and they help achieve a normal
or near normal axis alignment. For example, bone cuts can be used
with a knee implant to correct an underlying varus of valgus
deformity and to shape the articular surface of the bone to fit a
standard, bone-facing surface of a traditional implant component.
With a traditional implant, multiple bone cuts are placed. However,
since traditional implants are manufactured off-the-shelf without
use of patient-specific information, these bone cuts are pre-set
for a given implant without taking into consideration the unique
shape of the patient. Thus, by cutting the patient's bone to fit
the traditional implant, more bone is discarded than is necessary
with an implant that is specifically designed and/or selected to
address the particularly patient's structures and deficiencies.
[0129] In certain embodiments, resection cuts are optimized to
preserve the maximum amount of bone for each individual patient,
based on a series of two-dimensional images or a three-dimensional
representation of the patient's articular anatomy and geometry and
the desired limb alignment and/or desired deformity correction.
Resection cuts on two opposing articular surfaces can be optimized
to achieve the minimum amount of bone resected from one or both
articular surfaces.
[0130] By adapting resection cuts in the series of two-dimensional
images or the three-dimensional representation on two opposing
articular surfaces such as, for example, a femoral head and an
acetabulum, one or both femoral condyle(s) and a tibial plateau, a
trochlea and a patella, a glenoid and a humeral head, a talar dome
and a tibial plafond, a distal humerus and a radial head and/or an
ulna, or a radius and a scaphoid, certain embodiments allow for
patient individualized, bone-preserving implant designs that can
assist with proper ligament balancing and that can help avoid
"overstuffing" of the joint, while achieving optimal bone
preservation on one or more articular surfaces in each patient.
[0131] Implant design and modeling also can be used to achieve
ligament sparing, for example, with regard to the PCL and/or the
ACL. An imaging test can be utilized to identify, for example, the
origin and/or the insertion of the PCL and the ACL on the femur and
tibia. The origin and the insertion can be identified by
visualizing, for example, the ligaments directly, as is possible
with MRI or spiral CT arthrography, or by visualizing bony
landmarks known to be the origin or insertion of the ligament such
as the medial and lateral tibial spines.
[0132] An implant system can then be selected or designed based on
the image data so that, for example, the femoral component
preserves the ACL and/or PCL origin, and the tibial component
preserves the ACL and/or PCL attachment. The implant can be
selected or designed so that bone cuts adjacent to the ACL or PCL
attachment or origin do not weaken the bone to induce a potential
fracture.
[0133] For ACL preservation, the implant can have two
unicompartmental tibial components that can be selected or designed
and placed using the image data. Alternatively, the implant can
have an anterior bridge component. The width of the anterior bridge
in AP dimension, its thickness in the superoinferior dimension or
its length in mediolateral dimension can be selected or designed
using the imaging data and, specifically, the known insertion of
the ACL and/or PCL.
[0134] As can be seen in FIGS. 6A and 6B, the posterior margin of
an implant component, e.g. a polyethylene- or metal-backed tray
with polyethylene inserts, can be selected and/or designed using
the imaging data or shapes derived from the imaging data so that
the implant component does not interfere with and stay clear of the
PCL. This can be achieved, for example, by including concavities in
the outline of the implant that are specifically designed or
selected or adapted to avoid the ligament insertion.
[0135] Any implant component can be selected and/or adapted in
shape so that it stays clear of ligament structures. Imaging data
can help identify or derive shape or location information on such
ligamentous structures. For example, the lateral femoral condyle of
a unicompartmental, bicompartmental or total knee system can
include a concavity or divet to avoid the popliteus tendon. In a
shoulder, the glenoid component can include a shape or concavity or
divet to avoid a subscapularis tendon or a biceps tendon. In a hip,
the femoral component can be selected or designed to avoid an
iliopsoas or adductor tendons.
Establishing Normal or Near-Normal Joint Kinematics
[0136] In certain embodiments, bone cuts and implant shape
including at least one of a bone-facing or a joint-facing surface
of the implant can be designed or selected to achieve normal joint
kinematics.
[0137] In certain embodiments, a computer program simulating
biomotion of one or more joints, such as, for example, a knee
joint, or a knee and ankle joint, or a hip, knee and/or ankle joint
can be utilized. In certain embodiments, patient-specific imaging
data can be fed into this computer program. For example, a series
of two-dimensional images of a patient's knee joint or a
three-dimensional representation of a patient's knee joint can be
entered into the program. Additionally, two-dimensional images or a
three-dimensional representation of the patient's ankle joint
and/or hip joint may be added.
[0138] Optionally, other data including anthropometric data may be
added for each patient. These data can include but are not limited
to the patient's age, gender, weight, height, size, body mass
index, and race. Desired limb alignment and/or deformity correction
can be added into the model. The position of bone cuts on one or
more articular surfaces as well as the intended location of implant
bearing surfaces on one or more articular surfaces can be entered
into the model.
[0139] A patient-specific biomotion model can be derived that
includes combinations of parameters listed above. The biomotion
model can simulate various activities of daily life including
normal gait, stair climbing, descending stairs, running, kneeling,
squatting, sitting and any other physical activity. The biomotion
model can start out with standardized activities, typically derived
from reference databases. These reference databases can be, for
example, generated using biomotion measurements using force plates
and motion trackers using radiofrequency or optical markers and
video equipment.
[0140] The biomotion model can then be individualized with use of
patient-specific information including at least one of, but not
limited to the patient's age, gender, weight, height, body mass
index, and race, the desired limb alignment or deformity
correction, and the patient's imaging data, for example, a series
of two-dimensional images or a three-dimensional representation of
the joint for which surgery is contemplated.
[0141] An implant shape including associated bone cuts generated in
the preceding optimizations, for example, limb alignment, deformity
correction, bone preservation on one or more articular surfaces,
can be introduced into the model. The resultant biomotion data can
be used to further optimize the implant design with the objective
to establish normal or near normal kinematics. The implant
optimizations can include one or multiple implant components.
Implant optimizations based on patient-specific data including
image based biomotion data include, but are not limited to: [0142]
Changes to external, joint-facing implant shape in coronal plane
[0143] Changes to external, joint-facing implant shape in sagittal
plane [0144] Changes to external, joint-facing implant shape in
axial plane [0145] Changes to external, joint-facing implant shape
in multiple planes or three dimensions [0146] Changes to internal,
bone-facing implant shape in coronal plane [0147] Changes to
internal, bone-facing implant shape in sagittal plane [0148]
Changes to internal, bone-facing implant shape in axial plane
[0149] Changes to internal, bone-facing implant shape in multiple
planes or three dimensions [0150] Changes to one or more bone cuts,
for example with regard to depth of cut, orientation of cut
[0151] Any single one or combinations of the above or all of the
above on at least one articular surface or implant component or
multiple articular surfaces or implant components.
[0152] When changes are made on multiple articular surfaces or
implant components, these can be made in reference to or linked to
each other. For example, in the knee, a change made to a femoral
bone cut based on patient-specific biomotion data can be referenced
to or linked with a concomitant change to a bone cut on an opposing
tibial surface, for example, if less femoral bone is resected, the
computer program may elect to resect more tibial bone.
[0153] Similarly, if a femoral implant shape is changed, for
example on an external surface, this can be accompanied by a change
in the tibial component shape. This is, for example, particularly
applicable when at least portions of the tibial bearing surface
negatively-match the femoral joint-facing surface.
[0154] Similarly, if the footprint of a femoral implant is
broadened, this can be accompanied by a widening of the bearing
surface of a tibial component. Similarly, if a tibial implant shape
is changed, for example on an external surface, this can be
accompanied by a change in the femoral component shape. This is,
for example, particularly applicable when at least portions of the
femoral bearing surface negatively-match the tibial joint-facing
surface.
[0155] If a patellar component radius is widened, this can be
accompanied by a widening of an opposing trochlear bearing surface
radius or vice versa.
[0156] Similarly, in a hip, if a femoral implant shape is changed,
for example on an external surface, this can be accompanied by a
change in an acetabular component shape. This is, for example,
particularly applicable when at least portions of the acetabular
bearing surface substantially negatively-match the femoral joint
facing surface. For example, the acetabular rim can be altered, for
example via reaming or cutting. These surgical changes and
resultant change on cortical bone profile can be virtually
simulated and a new resultant peripheral margin(s) can be derived.
The derived peripheral bone margin or shape can then be used to
design or select an implant that substantially matches, in at least
a portion, the altered rim or joint margin or edge.
[0157] Similarly, in a shoulder, if a glenoid implant shape is
changed, for example on an external surface, this can be
accompanied by a change in a humeral component shape. This is, for
example, particularly applicable when at least portions of the
humeral bearing surface substantially negatively-match the glenoid
joint facing surface, or vice versa.
[0158] By optimizing implant shape in this manner, it is possible
to establish normal or near normal kinematics. Moreover, it is
possible to avoid implant related complications, including but not
limited to anterior notching, notch impingement, posterior femoral
component impingement in high flexion, and other complications
associated with existing implant designs.
[0159] Biomotion models for a particular patient can be
supplemented with patient-specific data and/or finite element
modeling or other biomechanical models known in the art. Resultant
forces in the knee joint can be calculated for each component for
each specific patient. The implant can be engineered to the
patient's load and force demands. For instance, a 125 lb. patient
may not need a tibial plateau as thick as a 280 lb patient.
Similarly, the polyethylene can be adjusted in shape, thickness and
material properties for each patient. For example, a 3 mm
polyethylene insert can be used in a light patient with low force
and a heavier or more active patient may need an 8 mm polymer
insert or similar device.
Complex Modeling
[0160] As described herein, certain embodiments can apply modeling,
for example, virtual modeling and/or mathematical modeling, to
identify optimum implant component features and measurements, and
optionally resection features and measurements, to achieve or
advance one or more parameter targets or thresholds. For example, a
model of patient's joint or limb can be used to identify, select,
and/or design one or more optimum features and/or feature
measurements relative to selected parameters for an implant
component and, optionally, for corresponding resection cuts and/or
guide tools. In certain embodiments, a physician, clinician, or
other user can select one or more parameters, parameter thresholds
or targets, and/or relative weightings for the parameters included
in the model. Alternatively or in addition, clinical data, for
example obtained from clinical trials, or intraoperative data, can
be included in selecting parameter targets or thresholds, and/or in
determining optimum features and/or feature measurements for an
implant component, resection cut, and/or guide tool.
[0161] Any combination of one or more of the above-identified
parameters and/or one or more additional parameters can be used in
the design and/or selection of a patient-adapted (e.g.,
patient-specific and/or patient-engineered) implant component and,
in certain embodiments, in the design and/or selection of
corresponding patient-adapted resection cuts and/or patient-adapted
guide tools. In particular assessments, a patient's biological
features and feature measurements are used to select and/or design
one or more implant component features and feature measurements,
resection cut features and feature measurements, and/or guide tool
features and feature measurements.
[0162] The optimization of joint kinematics can include, as another
parameter, the goal of not moving the joint line postoperatively or
minimizing any movements of the joint line, or any threshold values
or cut off values for moving the joint line superiorly or
inferiorly. The optimization of joint kinematics can also include
ligament loading or function during motion.
[0163] As described herein, implants of various sizes, shapes,
curvatures and thicknesses with various types and locations and
orientations and number of bone cuts can be selected and/or
designed and manufactured. The implant designs and/or implant
components can be selected from, catalogued in, and/or stored in a
library. The library can be a virtual library of implants, or
components, or component features that can be combined and/or
altered to create a final implant. The library can include a
catalogue of physical implant components. In certain embodiments,
physical implant components can be identified and selected using
the library. The library can include previously-generated implant
components having one or more patient-adapted features, and/or
components with standard or blank features that can be altered to
be patient-adapted. Accordingly, implants and/or implant features
can be selected from the library.
[0164] Accordingly, in certain embodiments an implant can include
one or more features designed patient-specifically and one or more
features selected from one or more library sources. For example, in
designing an implant for a total knee replacement comprising a
femoral component and a tibial component, one component can include
one or more patient-specific features and the other component can
be selected from a library. Table 4 includes an exemplary list of
possible combinations.
TABLE-US-00004 TABLE 4 Illustrative Combinations of
Patient-Specific and Library- Derived Components Implant
component(s) Implant component(s) having a patient- having a
library Implant component(s) specific feature derived feature
Femoral, Tibial Femoral and Tibial Femoral and Tibial Femoral,
Tibial Femoral Femoral and Tibial Femoral, Tibial Tibial Femoral
and Tibial Femoral, Tibial Femoral and Tibial Femoral Femoral,
Tibial Femoral and Tibial Tibial Femoral, Tibial Femoral and Tibial
none
[0165] In certain embodiments, a library can be generated to
include images from a particular patient at one or more ages prior
to the time that the patient needs a joint implant. For example, a
method can include identifying patients eliciting one or more risk
factors for a joint problem, such as low bone mineral density
score, and collecting one or more images of the patient's joints
into a library. In certain embodiments, all patients below a
certain age, for example, all patients below 40 years of age can be
scanned to collect one or more images of the patient's joint. The
images and data collected from the patient can be banked or stored
in a patient-specific database. For example, the articular shape of
the patient's joint or joints can be stored in an electronic
database until the time when the patient needs an implant. Then,
the images and data in the patient-specific database can be
accessed and a patient-specific and/or patient-engineered partial
or total joint replacement implant using the patient's originally
anatomy, not affected by arthritic deformity yet, can be generated.
This process results is a more functional and more anatomic
implant.
Tibial Implant Component Features
[0166] In various embodiments described herein, one or more
features of a tibial implant component are designed and/or
selected, optionally in conjunction with an implant procedure, so
that the tibial implant component fits the patient. For example, in
certain embodiments, one or more features of a tibial implant
component and/or implant procedure are designed and/or selected,
based on patient-specific data, so that the tibial implant
component substantially matches (e.g., substantially
negatively-matches and/or substantially positively-matches) one or
more of the patient's biological structures. Alternatively or in
addition, one or more features of a tibial implant component and/or
implant procedure can be preoperatively engineered based on
patient-specific data to provide to the patient an optimized fit
with respect to one or more parameters, for example, one or more of
the parameters described above. For example, in certain
embodiments, an engineered bone preserving tibial implant component
can be designed and/or selected based on one or more of the
patient's joint dimensions as seen, for example, on a series of
two-dimensional images or a three-dimensional representation
generated, for example, from a CT scan or MRI scan. Alternatively
or in addition, an engineered tibial implant component can be
designed and/or selected, at least in part, to provide to the
patient an optimized fit with respect to the engaging, joint-facing
surface of a corresponding femoral implant component.
[0167] Certain embodiments include a tibial implant component
having one or more patient-adapted (e.g., patient-specific or
patient-engineered) features and, optionally, one or more standard
features. Optionally, the one or more patient-adapted features can
be designed and/or selected to fit the patient's resected tibial
surface. For example, depending on the patient's anatomy and
desired postoperative geometry or alignment, a patient's lateral
and/or medial tibial plateaus may be resected independently and/or
at different depths, for example, so that the resected surface of
the lateral plateau is higher (e.g., 1 mm, greater than 1 mm, 2 mm,
and/or greater than 2 mm higher) or lower (e.g., 1 mm, greater than
1 mm, 2 mm, and/or greater than 2 mm lower) than the resected
surface of the medial tibial plateau.
[0168] Accordingly, in certain embodiments, tibial implant
components can be independently designed and/or selected for each
of the lateral and/or medial tibial plateaus. For example, the
perimeter of a lateral tibial implant component and the perimeter
of a medial tibial implant component can be independently designed
and/or selected to substantially match the perimeter of the
resection surfaces for each of the lateral and medial tibial
plateaus. FIGS. 7A and B show exemplary unicompartmental medial and
lateral tibial implant components without (FIG. 7A) and with (FIG.
7B) a polyethylene layer or insert. As shown, the lateral tibial
implant component and the medial tibial implant component have
different perimeters shapes, each of which substantially matches
the perimeter of the corresponding resection surface (see arrows).
In addition, the polyethylene layers or inserts 6010 for the
lateral tibial implant component and the medial tibial implant
component have perimeter shapes that correspond to the respective
implant component perimeter shapes. In certain embodiments, one or
both of the implant components can be made entirely of a plastic or
polyethylene (rather than having a having a polyethylene layer or
insert) and each entire implant component can include a perimeter
shape that substantially matches the perimeter of the corresponding
resection surface.
[0169] Moreover, the height of a lateral tibial implant component
and the height of a medial tibial implant component can be
independently designed and/or selected to maintain or alter the
relative heights generated by different resection surfaces for each
of the lateral and medial tibial plateaus. For example, the lateral
tibial implant component can be thicker (e.g., 1 mm, greater than 1
mm, 2 mm, and/or greater than 2 mm thicker) or thinner (e.g., 1 mm,
greater than 1 mm, 2 mm, and/or greater than 2 mm thinner) than the
medial tibial implant component to maintain or alter, as desired,
the relative height of the joint-facing surface of each of the
lateral and medial tibial implant components. As shown in FIGS. 7A
and B, the relative heights of the lateral and medial resection
surfaces 6020 is maintained using lateral and medial implant
components (and lateral and medial polyethylene layers or inserts)
that have the same thickness. Alternatively, the lateral implant
component (and/or the lateral polyethylene layer or insert) can
have a different thickness than the medial implant component
(and/or the medial polyethylene layer or insert). For embodiments
having one or both of the lateral and medial implant components
made entirely of a plastic or polyethylene (rather than having a
having a polyethylene layer or insert) the thickness of one implant
component can be different from the thickness of the other implant
component.
[0170] Different medial and lateral tibial cut heights also can be
applied with a one piece implant component, e.g., a monolithically
formed, tibial implant component. In this case, the tibial implant
component and the corresponding resected surface of the patient's
femur can have an angled surface or a step cut connecting the
medial and the lateral surface facets. For example, FIGS. 8A-C
depict three different types of step cuts 6110 separating medial
and lateral resection cut facets on a patient's proximal tibia. In
certain embodiments, the bone-facing surface of the tibial implant
component is selected and/or designed to match these surface depths
and the step cut angle, as well as other optional features such as
perimeter shape.
[0171] Tibial components also can include the same medial and
lateral cut height.
[0172] In certain embodiments, the medial tibial plateau facet can
be oriented at an angle different than the lateral tibial plateau
facet or it can be oriented at the same angle. One or both of the
medial and the lateral tibial plateau facets can be at an angle
that is patient-specific, for example, similar to the original
slope or slopes of the medial and/or lateral tibial plateaus, for
example, in the sagittal plane. Moreover, the medial slope can be
patient-specific, while the lateral slope is fixed or preset or
vice versa, as exemplified in Table 5.
TABLE-US-00005 TABLE 5 Exemplary designs for tibial slopes LATERAL
MEDIAL SIDE IMPLANT SLOPE SIDE IMPLANT SLOPE Patient-matched to
medial plateau Patient-matched to lateral plateau Patient-matched
to medial plateau Patient-matched to medial plateau Patient-matched
to lateral plateau Patient-matched to lateral plateau
Patient-matched to medial plateau Not patient-matched, e.g.,
preset, fixed or intraoperatively adjusted Patient-matched to
lateral plateau Not patient-matched, e.g., preset, fixed or
intraoperatively adjusted Not patient matched, e.g. preset,
Patient-matched to lateral plateau fixed or intraoperatively
adjusted Not patient matched, e.g., preset, Patient-matched to
medial plateau fixed or intraoperatively adjusted Not patient
matched, e.g. preset, Not patient-matched, e.g. preset, fixed or
intraoperatively adjusted fixed or intraoperatively adjusted
[0173] The exemplary combinations described in Table 5 are
applicable to implants that use two unicompartmental tibial implant
components with or without metal backing, one medial and one
lateral. They also can be applicable to implant systems that use a
single tibial implant component including all plastic designs or
metal backed designs with inserts (optionally a single insert for
the medial and lateral plateau, or two inserts, e.g., one medial
and one lateral), for example PCL retaining, posterior stabilized,
or ACL and PCL retaining implant components. The slope preferably
is between 0 and 7 degrees, but other embodiments with other slope
angles outside that range can be used. The slope can vary across
one or both tibial facets from anterior to posterior. For example,
a lesser slope, e.g., 0-1 degrees, can be used anteriorly, and a
greater slope can be used posteriorly, e.g., 4-5 degrees. Variable
slopes across at least one of a medial or a lateral tibial facet
can be accomplished, for example, with use of burrs (for example
guided by a robot) or with use of two or more bone cuts on at least
one of the tibial facets. In certain embodiments, two separate
slopes can be used medially and laterally. Independent tibial slope
designs can be useful for achieving bone preservation. In addition,
independent slope designs can be advantageous in achieving implant
kinematics that are more natural and closer to the performance of a
normal knee or the patient's knee.
[0174] In certain embodiments, the slope can be fixed, e.g. at 3, 5
or 7 degrees in the sagittal plane. In certain embodiments, the
slope, either medial or lateral or both, can be patient-specific.
The patient's medial slope can be used to derive the medial tibial
component slope and, optionally, the lateral component slope, in
either a single or a two-piece tibial implant component. The
patient's lateral slope can be used to derive the lateral tibial
component slope and, optionally, the medial component slope, in
either a single or a two-piece tibial implant component. A
patient's slope typically is between 0 and 7 degrees. In select
instances, a patient may show a medial or a lateral slope that is
greater than 7 degrees. In this case, if the patient's medial slope
has a higher value than 7 degrees or some other pre-selected
threshold, the patient's lateral slope can be applied to the medial
tibial implant component or to the medial side of a single tibial
implant component. If the patient's lateral slope has a higher
value than 7 degrees or some other pre-selected threshold, the
patient's medial slope can be applied to the lateral tibial implant
component or to the lateral side of a single tibial implant
component. Alternatively, if the patient's slope on one or both
medial and lateral sides exceeds a pre-selected threshold value,
e.g., 7 degrees or 8 degrees or 10 degrees, a fixed slope can be
applied to the medial component or side, to the lateral component
or side, or both. The fixed slope can be equal to the threshold
value, e.g., 7 degrees or it can be a different value. FIGS. 9A and
B show exemplary flow charts for deriving a medial tibial component
slope (FIG. 9A) and/or a lateral tibial component slope (FIG. 9B)
for a tibial implant component.
[0175] A fixed tibial slope can be used in any of the embodiments
described herein.
[0176] In another embodiment, a mathematical function can be
applied to derive a medial implant slope and/or a lateral implant
slope, or both (wherein both can be the same). In certain
embodiments, the mathematical function can include a measurement
derived from one or more of the patient's joint dimensions as seen,
for example, on a series of two-dimensional images or a
three-dimensional representation generated, for example, from a CT
scan or MRI scan. For example, the mathematical function can
include a ratio between a geometric measurement of the patient's
femur and the patient's tibial slope. Alternatively or in addition,
the mathematical function can be or include the patient's tibial
slope divided by a fixed value. In certain embodiments, the
mathematical function can include a measurement derived from a
corresponding implant component for the patient, for example, a
femoral implant component, which itself can include
patient-specific, patient-engineered, and/or standard features.
Many different possibilities to derive the patient's slope using
mathematical functions can be applied by someone skilled in the
art.
[0177] In certain embodiments, the medial and lateral tibial
plateau can be resected at the same angle. For example, a single
resected cut or the same multiple resected cuts can be used across
both plateaus. In other embodiments, the medial and lateral tibial
plateau can be resected at different angles. Multiple resection
cuts can be used when the medial and lateral tibial plateaus are
resected at different angles. Optionally, the medial and the
lateral tibia also can be resected at a different distance relative
to the tibial plateau. In this setting, the two horizontal plane
tibial cuts medially and laterally can have different slopes and/or
can be accompanied by one or two vertical or oblique resection
cuts, typically placed medial to the tibial plateau components.
FIG. 3 and FIGS. 8A-C show several exemplary tibial resection cuts,
which can be used in any combination for the medial and lateral
plateaus.
[0178] The medial tibial implant component plateau can have a flat,
convex, concave, or dished surface and/or it can have a thickness
different than the lateral tibial implant component plateau. The
lateral tibial implant component plateau can have a flat, convex,
concave, or dished surface and/or it can have a thickness different
than the medial tibial implant component plateau. The different
thickness can be achieved using a different material thickness, for
example, metal thickness or polyethylene or insert thickness on
either side. In certain embodiments, the lateral and medial
surfaces are selected and/or designed to closely resemble the
patient's anatomy prior to developing the arthritic state.
[0179] The height of the medial and/or lateral tibial implant
component plateau, e.g., metal only, ceramic only, metal backed
with polyethylene or other insert, with single or dual inserts and
single or dual tray configurations can be determined based on the
patient's tibial shape, for example using an imaging test.
[0180] Alternatively, the height of the medial and/or lateral
tibial component plateau, e.g. metal only, ceramic only, metal
backed with polyethylene or other insert, with single or dual
inserts and single or dual tray configurations can be determined
based on the patient's femoral shape. For example, if the patient's
lateral condyle has a smaller radius than the medial condyle and/or
is located more superior than the medial condyle with regard to its
bearing surface, the height of the tibial component plateau can be
adapted and/or selected to ensure an optimal articulation with the
femoral bearing surface. In this example, the height of the lateral
tibial component plateau can be adapted and/or selected so that it
is higher than the height of the medial tibial component plateau.
Since polyethylene is typically not directly visible on standard
x-rays, metallic or other markers can optionally be included in the
inserts in order to indicate the insert location or height, in
particular when asymmetrical medial and lateral inserts or inserts
of different medial and lateral thickness are used.
[0181] Alternatively, the height of the medial and/or lateral
tibial component plateau, e.g. metal only, ceramic only, metal
backed with polyethylene or other insert, with single or dual
inserts and single or dual tray configurations can be determined
based on the shape of a corresponding implant component, for
example, based on the shape of certain features of the patient's
femoral implant component. For example, if the femoral implant
component includes a lateral condyle having a smaller radius than
the medial condyle and/or is located more superior than the medial
condyle with regard to its bearing surface, the height of the
tibial implant component plateaus can be adapted and/or selected to
ensure an optimal articulation with the bearing surface(s) of the
femoral implant component. In this example, the height of the
lateral tibial implant component plateau can be adapted and/or
selected to be higher than the height of the medial tibial implant
component plateau.
[0182] Moreover, the surface shape, e.g. mediolateral or
anteroposterior curvature or both, of the tibial insert(s) can
reflect the shape of the femoral component. For example, the medial
insert shape can be matched to one or more radii on the medial
femoral condyle of the femoral component. The lateral insert shape
can be matched to one or more radii on the lateral femoral condyle
of the femoral component. The lateral insert may optionally also be
matched to the medial condyle. The matching can occur, for example,
in the coronal plane. This has benefits for wear optimization. A
pre-manufactured insert can be selected for a medial tibia that
matches the medial femoral condyle radii in the coronal plane with
a pre-selected ratio, e.g. 1:5 or 1:7 or 1:10. Any combination is
possible. A pre-manufactured insert can be selected for a lateral
tibia that matches the lateral femoral condyle radii in the coronal
plane with a pre-selected ratio, e.g. 1:5 or 1:7 or 1:10. Any
combination is possible. Alternatively, a lateral insert can also
be matched to a medial condyle or a medial insert shape can also be
matched to a lateral condyle. These combinations are possible with
single and dual insert systems with metal backing. Someone skilled
in the art can recognize that these matchings also can be applied
to implants that use all polyethylene tibial components, for
example, the radii on all polyethylene tibial components can be
matched to the femoral radii in a similar manner.
[0183] The matching of radii can also occur in the sagittal plane.
For example, a cutter can be used to cut a fixed coronal curvature
into a tibial insert or all polyethylene tibia that is matched to
or derived from a femoral implant or patient geometry. The path
and/or depth that the cutter is taking can be driven based on the
femoral implant geometry or based on the patient's femoral geometry
prior to the surgery. Medial and lateral sagittal geometry can be
the same on the tibial inserts or all poly tibia. Alternatively,
each can be cut separately. By adapting or matching the tibial poly
geometry to the sagittal geometry of the femoral component or
femoral condyle, a better functional result may be achieved. For
example, more physiologic tibiofemoral motion and kinematics can be
enabled.
[0184] The medial and/or the lateral component can include a
trough. The medial component can be dish shaped, while the lateral
component includes a trough. The lateral component can be dish
shaped, while the medial component includes a trough. The lateral
component can be convex, while the medial component includes a
trough. The shape of the medial or lateral component can be patient
derived or patient matched in one, two or three dimensions, for
example as it pertains to its perimeter as well as its surface
shape. The convex shape of the lateral component can be patient
derived or patient matched in one, two or three dimensions. The
trough can be straight. The trough can also be curved. The
curvature of the trough can have a constant radius of curvature or
it can include several radii of curvature. The radii can be patient
matched or patient derived, for example based on the femoral
geometry or on the patient's kinematics. These designs can be
applied with a single-piece tibial polyethylene or other plastic
insert or with two-piece tibial polyethylene or other plastic
inserts. FIGS. 10A-AD show exemplary combinations of tibial tray
designs having dual inserts (FIGS. 10A-O) and single inserts (FIGS.
10P-AD) with different medial and lateral surface shapes.
One- and Two-Piece Tibial Inserts
[0185] In a preferred embodiment, the tray component is able to
accept either a one piece insert or a two piece insert. The two
piece insert can be one piece insert cut in half at the approximate
medial-lateral midpoint of the insert. This can create a medial
insert and a lateral insert that each exhibit all of the features
described in the one piece insert described herein. Alternatively,
each piece can be formed separately, with different surface shapes
and also different locking mechanisms. One of the benefits to using
a two piece insert over a one piece insert is the ability to use
different thicknesses for each of the medial insert and the lateral
insert, to accommodate specific geometries of the patient's
specific joint. Thus, the surgeon may intraoperatively optimize
ligament balancing or soft-tissue balancing by, for example,
selecting a thicker piece on one side when compared to the other
side. Moreover, the surgeon can intraoperatively select pieces with
different profiles, which may help with joint kinematics and which
can also assist with ligament or soft-tissue balancing. For
example, the medial insert can have a substantially concave shape.
The lateral insert can have a convex shape. Alternatively, the
lateral insert can have a concave shape in mediolateral direction
that is, however, substantially straight in anteroposterior
direction. Alternatively, the lateral insert can have a concave
shape in mediolateral direction that follows the contour of the
normal gliding path of the lateral condyle on the lateral tibial
plateau in AP direction. Similarly, the medial insert can have a
substantially concave shape in mediolateral direction that follows
the contour of the normal gliding path of the medial condyle on the
medial tibial plateau in AP direction. Optionally, one or both
inserts can be flat.
[0186] The following are examples of possible combinations of
medial and lateral inserts with dual inserts (Table 6):
TABLE-US-00006 TABLE 6 Examples of possible medial and lateral
two-piece insert combinations (additionally illustrated in FIGS.
10A-O): Insert Thickness Medial Lateral Medial thickness = lateral
thickness Concave Convex Medial thickness = lateral thickness
Concave Flat Medial thickness = lateral thickness Concave Concave
Medial thickness = lateral thickness Flat Convex Medial thickness =
lateral thickness Flat Flat Medial thickness = lateral thickness
Flat Concave Medial thickness = lateral thickness Convex Convex
Medial thickness = lateral thickness Convex Flat Medial thickness =
lateral thickness Convex Concave Medial thickness less than lateral
thickness Concave Convex Medial thickness less than lateral
thickness Concave Flat Medial thickness less than lateral thickness
Concave Concave Medial thickness less than lateral thickness Flat
Convex Medial thickness less than lateral thickness Flat Flat
Medial thickness less than lateral thickness Flat Concave Medial
thickness less than lateral thickness Convex Convex Medial
thickness less than lateral thickness Convex Flat Medial thickness
less than lateral thickness Convex Concave Medial thickness greater
than lateral thickness Concave Convex Medial thickness greater than
lateral thickness Concave Flat Medial thickness greater than
lateral thickness Concave Concave Medial thickness greater than
lateral thickness Flat Convex Medial thickness greater than lateral
thickness Flat Flat Medial thickness greater than lateral thickness
Flat Concave Medial thickness greater than lateral thickness Convex
Convex Medial thickness greater than lateral thickness Convex Flat
Medial thickness greater than lateral thickness Convex Concave
[0187] The same surface profiles or similar surface profiles can be
used with a single piece insert. The following are examples of
possible combinations of medial and lateral implant surface
profiles with a single piece tibial insert (Table 7):
TABLE-US-00007 TABLE 7 Examples of possible medial and lateral
implant surface profiles with a single piece tibial insert
(additionally illustrated in FIGS. 10P-AD): Insert Thickness Medial
Lateral Medial thickness = lateral thickness Concave Convex Medial
thickness = lateral thickness Concave Flat Medial thickness =
lateral thickness Concave Concave Medial thickness = lateral
thickness Flat Convex Medial thickness = lateral thickness Flat
Flat Medial thickness = lateral thickness Flat Concave Medial
thickness = lateral thickness Convex Convex Medial thickness =
lateral thickness Convex Flat Medial thickness = lateral thickness
Convex Concave Medial thickness less than lateral thickness Concave
Convex Medial thickness less than lateral thickness Concave Flat
Medial thickness less than lateral thickness Concave Concave Medial
thickness less than lateral thickness Flat Convex Medial thickness
less than lateral thickness Flat Flat Medial thickness less than
lateral thickness Flat Concave Medial thickness less than lateral
thickness Convex Convex Medial thickness less than lateral
thickness Convex Flat Medial thickness less than lateral thickness
Convex Concave Medial thickness greater than lateral thickness
Concave Convex Medial thickness greater than lateral thickness
Concave Flat Medial thickness greater than lateral thickness
Concave Concave Medial thickness greater than lateral thickness
Flat Convex Medial thickness greater than lateral thickness Flat
Flat Medial thickness greater than lateral thickness Flat Concave
Medial thickness greater than lateral thickness Convex Convex
Medial thickness greater than lateral thickness Convex Flat Medial
thickness greater than lateral thickness Convex Concave
[0188] Referring to FIGS. 11A-C, medial and lateral gliding paths
can be estimated based on population data that can include
information on age, gender, race, body weight, BMI and other
demographic data. Alternatively, medial and lateral gliding paths
can be estimated based on kinematic modeling. Kinematic modeling
can also be database based. Kinematic modeling can include the
inclusion of patient specific data, e.g. age, gender, race, body
weight, BMI and other demographic data as well as patient specific
anatomy or geometry, for example derived from an imaging test. In
certain embodiments, at least one of a medial or lateral tibial
implant profile or both can be adapted so that the coronal
curvature, e.g. convex or concave, follows this glide path at least
in part.
[0189] Of note, several of the above embodiments describe an
implant system that uses a metal backing with a single or two piece
plastic inserts. The same surface profile and thickness
combinations shown in Tables 6 and 7 are applicable to tibial
implants that have no metal backing, and that have attachment
mechanisms incorporated into their base. Such tibial implant
systems can be composed of plastics including polyethylene and
ceramics or composites or combinations thereof; they can include
components that replace the entire tibial plateau or combinations
of a medial and a lateral unicompartmental tibial component.
[0190] Surface profiles can be patient-derived or patient-adapted.
For example, the sagittal radius of a femoral component can be
patient specific, e.g., derived based on the patient's subchondral
bone or cartilage shape in at least a portion of the femoral
component. The coronal radius of the femoral component can be
engineered. The mating tibial component can include, at least in
part, a sagittal radius derived from said patient specific femoral
component radius, e.g. slightly widened, as well as an engineered
coronal radius derived from said engineered femoral coronal radius
and, preferably, slightly widened relative to said engineered
femoral coronal radius. Any combination of patient specific and
engineered femoral and tibial radii is possible. Similarly, any
combination of patient specific and engineered radii is possible in
other joints.
[0191] An additional benefit of a two piece insert over a one piece
insert is ease of use. A one piece insert is often difficult to
place into a knee joint during surgery due to the size of the
insert and the spatial constraints of the joint. Each piece of the
two piece insert is not only smaller in size than a full one piece
insert, but it also enables insertion of the lateral side or the
medial side of the insert into the joint first, depending on the
size constraints of the joint.
[0192] An important goal of arthroplasty is the balancing of
soft-tissue and ligaments for different pose angles of the joint.
In the knee, this balancing can be achieved for different degrees
of knee flexion and extension. The surgeon has several options
available for soft-tissue and ligament balancing. These include,
for example, (1) selecting placement of bone cuts including height,
depth and orientation of bone cuts (e.g. tibial slope) for
optimizing soft-tissue and ligament balancing; (2) selecting
removal of osteophytes; and/or (3) soft-tissue and partial or
complete ligament releases, e.g., release of the medial collateral
ligament or lateral collateral ligament. However, once these steps
have been performed, the surgeon typically has no further means of
optimizing ligament or soft-tissue balance at his disposal. Thus,
if it turns out that a knee is too loose on one side or both sides
in flexion or extension, the surgeon has no means of correcting
this with traditional knee implants. Thus, in certain embodiments,
the surgeon will be provided with several different single piece
insert systems. Each piece has a different thickness and/or medial
or lateral surface profile. The insert systems can be accompanied
by matching trials that can be inserted into the locking system and
easily be removed. The surgeon can trial different insert systems
for different degrees of knee flexion and extension to correct for
any remaining ligament imbalance.
[0193] In some embodiments, the surgeon can use a two insert piece
system. Each insert, medial and lateral, can be provided with
different thicknesses and/or different implant profiles. Trial
medial and lateral insert systems can be provided that can be
inserted into the metal backing and lock and that can be readily
removed from the lock after testing. The surgeon can trial
different combinations of medial and lateral insert systems and can
optimize ligament and soft-tissue balancing by selecting a
combination of medial and lateral inserts that yields the best
balancing result for different flexion and extension angles.
[0194] All of the embodiments described herein can be compatible
with tibial components that (1) preserve the anterior and posterior
cruciate ligament; (2) preserve the posterior cruciate ligament
only; or (3) are posterior stabilized (i.e., sacrifice both
cruciate ligaments).
Ligament-Retaining
[0195] Referring to FIGS. 6A-B, 12, and 13A-B, examples of
ligament-retaining tibial implants are shown. For example, the
implant can provide space ligaments of the knee, for example the
posterior cruciate ligament (PCL), and allows the components to be
shaped so as to avoid interference with the ligament. Optionally,
the PCL origin and insertion can be identified in the imaging
study, e.g., an ultrasound, CT scan, MRI scan, optical scan, laser
scan, photoacoustic imaging and others. The PCL origin and
insertion as well as the ligament proper can be identified directly
on the imaging study, for example when an MRI is used.
Alternatively, the origin and/or insertion can be identified by
determining bony landmarks such as a groove on the posterior aspect
of the tibia that are representative of the bone attachment site.
In this manner, the tibial tray can be shaped so that the ligament
is avoided and can remain intact after the surgery. For example,
the tibial tray, e.g., the metal backing or insert or both or an
all poly component can be shaped to include a groove that is
recessed relative to the PCL insertion and that is slightly wider
than the PCL and its insertion.
[0196] Additionally, the tibial tray can be configured or selected
to account for the anterior cruciate ligament (ACL), and allows the
components to be shaped so as to avoid interference with the
ligament. Optionally, the ACL origin and insertion can be
identified in the imaging study, e.g. an ultrasound, CT scan, MRI
scan, optical scan, laser scan, photoacoustic imaging and others.
The ACL origin and insertion as well as the ligament proper can be
identified directly on the imaging study, for example when an MRI
is used. Alternatively, the origin and or insertion can be
identified by determining bony landmarks such as a groove or bony
irregularity on the femur or tibia that are representative of the
bone attachment site. In this manner, the tibial tray can be shaped
so that the ligament is avoided and can remain intact after the
surgery. Thus, embodiments described herein allow for
shaping/designing and/or selecting tibial implant components that
are adapted to the patient's anatomy in order to avoid any
interference with ligaments and to preserve these ligaments. This
is applicable to single and dual component systems, with metal
backing or without metal backing.
[0197] Moreover, the tibial and femoral components can be shaped so
that any soft-tissue interference is avoided using, for example,
imaging data. Other soft-tissue structures or bony landmarks
related to these soft-tissue structures can be identified, for
example on imaging data of the patient. For example, referring to
FIGS. 14A-B, in the knee, the popliteus tendon, medial capsule,
lateral capsule, posterior capsule, Hoffa's fat pad, plicae and
other soft-tissue structures can be identified. The femoral and/or
tibial implant components can be designed, shaped or selected so
that they avoid interference with or impingement on one or more of
these or other soft-tissue structures.
[0198] The joint can be moved virtually into different pose angles,
including kinematic simulation, in order to detect any potential
ligament or soft-tissue interference or impingement. The implant
components can be designed or adapted to avoid ligament or
soft-tissue interference or impingement for different degrees of
flexion and extension, abduction and adduction, elevation,
rotation, and/or other positions.
[0199] Similarly, in a hip the femoral and acetabular components
can be shaped so that any soft-tissue interference is avoided
using, for example, imaging data. Other soft-tissue structures or
bony landmarks related to these soft-tissue structures can be
identified, for example on imaging data of the patient. For
example, medial capsule, lateral capsule, posterior capsule,
anterior capsule, iliopsoas tendon and other soft-tissue structures
can be identified. The femoral and/or acetabular implant components
can be designed, shaped or selected so that they avoid interference
with or impingement on one or more of these or other soft-tissue
structures.
[0200] Similarly, in a shoulder the humeral and glenoid components
can be shaped so that any soft-tissue interference is avoided
using, for example, imaging data. Other soft-tissue structures or
bony landmarks related to these soft-tissue structures can be
identified, for example on imaging data of the patient. For
example, medial capsule, lateral capsule, posterior capsule,
anterior capsule, rotator cuff including the supraspinatus tendon,
infraspinatus tendon, teres minor and subscapularis and other
soft-tissue structures can be identified. The humeral and/or
glenoid implant components can be designed, shaped or selected so
that they avoid interference with or impingement on one or more of
these or other soft-tissue structures.
[0201] Various methods can be employed for designing a
cruciate-retaining implant. For example, FIGS. 15A-C depict one
exemplary method for designing a PCL retaining ligament. In FIG.
15A, a tibial implant perimeter is designed based on the perimeter
shape of the planned resected tibial surface. In FIG. 15B, the
implant perimeter design is altered so that the PCL is maintained.
FIG. 15C depicts the resulting shape of the PCL-retaining tibial
implant component, with the PCL shown as a circle.
Cruciate Substitution
[0202] In addition to the implant component features described
above, certain embodiments can include features and designs for
cruciate substitution. These features and designs can include, for
example, a keel, post, or projection that projects from the
bone-facing surface of the tibial implant component and engage a
corresponding intercondylar housing, receptacle, or bars on the
corresponding femoral implant component. FIGS. 16A-C depict a
tibial implant component that includes a stabilizing fin to help
stabilize a cruciate-sacrificing knee replacement.
[0203] FIGS. 17A and 17B depict exemplary cross-sections of tibial
implant components having a post (or keel or projection) projecting
from the surface of the implant component. In particular, FIG. 17A
shows (a) a tibial implant component with a straight post or
projection and (b)-(d) tibial implant components having posts or
projections oriented laterally, with varying thicknesses, lengths,
and curvatures. FIG. 17B shows (a)-(e) tibial implant components
having posts or projections oriented medially, with varying
thicknesses, lengths, and curvatures.
[0204] As shown in the figures, the upper surface of the tray
component has a "keel type" structure in between the concave
surfaces that are configured to mate with the femoral condyle
surfaces of a femoral implant. This "keel type" structure can be
configured to slide within a groove in the femoral implant. The
groove can comprise stopping mechanisms at each end of the groove
to keep the "keel type" structure within the track of the groove.
This "keel type" structure and groove arrangement may be used in
situations where a patient's posterior cruciate ligament is removed
as part of the surgical process and there is a need to posteriorly
stabilize the implant within the joint.
[0205] In certain embodiments, the tibial implant component can be
designed and manufactured to include the post or projection as a
permanently integrated feature of the implant component. However,
in certain embodiments, the post or projection can be modular. For
example, the post or projection can be designed and/or manufactured
separate from the tibial implant component and optionally joined
with the component, either prior to (e.g., preoperatively) or
during the implant procedure. For example, a modular post or
projection and a tibial implant component can be mated using an
integrating mechanism such as respective male and female screw
threads, other male-type and female-type locking mechanisms, or
other mechanism capable of integrating the post or projection into
or onto the tibial implant component and providing stability to the
post or projection during normal wear. A modular post or projection
can be joined to a tibial implant component at the option of the
surgeon or practitioner, for example, by removing a plug or other
device that covers the integrating mechanism and attaching the
modular post or projection at the uncovered integrating
mechanism.
[0206] The post or projection can include features that are
patient-adapted (e.g., patient-specific or patient-engineered). In
certain embodiments, the post or projection includes one or more
features that are designed and/or selected preoperatively, based on
patient-specific data including imaging data, to substantially
match one or more of the patient's biological features. For
example, the length, width, height, and/or curvature of one or more
portions of the post or projection can be designed and/or selected
to be patient-specific, for example, with respect to the patient's
intercondylar distance or depth, femoral shape, and/or condyle
shape. Alternatively or in addition, one or more features of the
post or projection can be engineered based on patient-specific data
to provide to the patient an optimized fit. For example, the
length, width, height, and/or curvature of one or more portions of
the post or projection can be designed and/or selected to be
patient-engineered. One or more thicknesses of the housing,
receptacle, or bar can be matched to patient-specific measurements.
One or more dimensions of the post or projection can be adapted
based on one or more implant dimensions (e.g., one or more
dimensions of the housing, receptacle or bar on the corresponding
femoral implant component), which can be patient-specific,
patient-engineered or standard. One or more dimensions of the post
or projection can be adapted based on one or more of patient
weight, height, sex, and body mass index. In addition, one or more
features of the post or projection can be standard.
[0207] Optionally, referring to FIGS. 17A and 17B, an exemplary
"keel type" structure or post can be adapted to the patient's
anatomy. For example, the post can be shaped to enable a more
normal, physiologic glide path of the femur relative to the tibia.
Thus, the post can deviate medially or lateral as it extends from
its base to its tip. This medial or lateral deviation can be
designed to achieve a near physiologic rolling and rotating action
of the knee joint. The medial and lateral bending of the post can
be adapted based on patient specific imaging data. For example, the
mediolateral curve or bend of the post or keel can be
patient-derived or patient-matched (e.g., to match the physical or
force direction of PCL or ACL). Alternatively or in addition, the
post or keel can deviate at a particular AP angle or bend, for
example, the sagittal curve of the post or keel can be reflection
of PCL location and orientation or combinations of ACL and PCL
location and orientation. The post can optionally taper or can have
different diameters and cross-sectional profiles, e.g. round,
elliptical, ovoid, square, rectangular at different heights from
its base.
[0208] Different dimensions of the post or projection can be
shaped, adapted, or selected based on different patient dimensions
and implant dimensions. Examples of different technical
implementations are provided in Table 8. These examples are in no
way meant to be limiting. Someone skilled in the art can recognize
other means of shaping, adapting or selecting a tibial implant post
or projection based on the patient's geometry including imaging
data.
TABLE-US-00008 TABLE 8 Examples of different technical
implementations of a cruciate-sacrificing tibial implant component
Corresponding patient anatomy, e.g., derived from imaging Post or
projection feature studies or intraoperative measurements
Mediolateral width Maximum mediolateral width of patient
intercondylar notch or fraction thereof Mediolateral width Average
mediolateral width of intercondylar notch Mediolateral width Median
mediolateral width of intercondylar notch Mediolateral width
Mediolateral width of intercondylar notch in select regions, e.g.
most inferior zone, most posterior zone, superior one third zone,
mid zone, and/or other zones Superoinferior height Maximum
superoinferior height of patient intercondylar notch or fraction
thereof Superoinferior height Average superoinferior height of
intercondylar notch Superoinferior height Median superoinferior
height of intercondylar notch Superoinferior height Superoinferior
height of intercondylar notch in select regions, e.g. most medial
zone, most lateral zone, central zone, and/or other zones
Anteroposterior length Maximum anteroposterior length of patient
intercondylar notch or fraction thereof Anteroposterior length
Average anteroposterior length of intercondylar notch
Anteroposterior length Median anteroposterior length of
intercondylar notch Anteroposterior length Anteroposterior length
of intercondylar notch in select regions, e.g. most anterior zone,
most posterior zone, central zone, anterior one third zone,
posterior one third zone, and/or other zones
[0209] The height or M-L width or A-P length of the intercondylar
notch can not only influence the length but also the position or
orientation of a post or projection from the tibial implant
component.
[0210] The dimensions of the post or projection can be shaped,
adapted, or selected not only based on different patient dimensions
and implant dimensions, but also based on the intended implantation
technique, for example, the intended tibial component slope or
rotation and/or the intended femoral component flexion or rotation.
For example, at least one of an anteroposterior length or
superoinferior height can be adjusted if a tibial implant is
intended to be implanted at a 7 degrees slope as compared to a 0
degrees slope, reflecting the relative change in patient or
trochlear or intercondylar notch or femoral geometry when the
tibial component is implanted. Moreover, at least one of an
anteroposterior length or superoinferior height can be adjusted if
the femoral implant is intended to be implanted in flexion, for
example, in 7 degrees flexion as compared to 0 degrees flexion. The
corresponding change in post or projection dimension can be
designed or selected to reflect the relative change in patient or
trochlear or intercondylar notch or femoral geometry when the
femoral component is implanted in flexion.
[0211] In another example, the mediolateral width can be adjusted
if one or both of the tibial and/or femoral implant components are
intended to be implanted in internal or external rotation,
reflecting, for example, an effective elongation of the
intercondylar dimensions when a rotated implantation approach is
chosen. Features of the post or projection can be oblique or curved
to match corresponding features of the femoral component housing,
receptacle or bar. For example, the superior portion of the post
projection can be curved, reflecting a curvature in the roof of the
femoral component housing, receptacle, or bar, which itself may
reflect a curvature of the intercondylar roof. In another example,
a side of a post or projection may be oblique to reflect an
obliquity of a side wall of the housing or receptacle of the
femoral component, which itself may reflect an obliquity of one or
more condylar walls. Accordingly, an obliquity or curvature of a
post or projection can be adapted based on at least one of a
patient dimension or a femoral implant dimension. Alternatively,
the post or projection of the tibial implant component can be
designed and/or selected based on generic or patient-derived or
patient-desired or implant-desired kinematics in one, two, three or
more dimensions. Then, the corresponding surface(s) of the femoral
implant housing or receptacle can be designed and/or selected to
mate with the tibial post or projection, e.g., in the ML plane.
Alternatively, the post or projection of the femoral receptacle or
box or bar or housing can be designed and/or selected based on
generic or patient-derived or patient-desired or implant-desired
kinematics in one, two, three or more dimensions. Then, the
corresponding surface(s) of the post or projection of the tibial
implant can be designed and/or selected to mate with the tibial
post or projection, e.g., in the ML plane.
[0212] The tibial post or projection can be straight.
Alternatively, the tibial post or projection can have a curvature
or obliquity in one, two or three dimensions, which can optionally
be, at least in part, reflected in the internal shape of the box.
One or more tibial projection or post dimensions can be matched to,
designed to, adapted to, or selected based on one or more patient
dimensions or measurements. Any combination of planar and curved
surfaces is possible.
[0213] In certain embodiments, the position and/or dimensions of
the tibial implant component post or projection can be adapted
based on patient-specific dimensions. For example, the post or
projection can be matched with the position of the posterior
cruciate ligament or the PCL insertion. It can be placed at a
predefined distance from anterior or posterior cruciate ligament or
ligament insertion, from the medial or lateral tibial spines or
other bony or cartilaginous landmarks or sites. By matching the
position of the post with the patient's anatomy, it is possible to
achieve a better functional result, better replicating the
patient's original anatomy.
Matching Features of a Tibial Implant Component
[0214] The perimeter of the tibial component, metal backed,
optionally poly inserts, or all plastic or other material, can be
matched to and/or derived from the patient's tibial shape, and can
be optimized for different cut heights and/or tibial slopes. In a
preferred embodiment, the shape is matched to the cortical bone of
the cut surface. The surface topography of the tibial bearing
surface can be designed or selected to match or reflect at least a
portion of the tibial geometry, in one or more planes, e.g., a
sagittal plane or a coronal plane, or both. The medial tibial
implant surface topography can be selected or designed to match or
reflect all or portions of the medial tibial geometry in one or
more planes, e.g., sagittal and coronal. The lateral tibial implant
surface topography can be selected or designed to match or reflect
all or portions of the lateral tibial geometry in one or more
planes, e.g., sagittal and coronal. The medial tibial implant
surface topography can be selected or designed to match or reflect
all or portions of the lateral tibial geometry in one or more
planes, e.g., sagittal and coronal. The lateral tibial implant
surface topography can be selected or designed to match or reflect
all or portions of the medial tibial geometry in one or more
planes, e.g., sagittal and coronal.
[0215] The surface topography of the tibial bearing surface(s) can
be designed or selected to match or reflect at least portions of
the femoral geometry or femoral implant geometry, in one or more
planes, e.g., a sagittal plane or a coronal plane, or both. The
medial implant surface topography can be selected or designed to
match or reflect all or portions of the medial femoral geometry or
medial femoral implant geometry in one or more planes. The lateral
implant surface topography can be selected or designed to match or
reflect all or portions of the lateral femoral geometry or lateral
femoral implant geometry in one or more planes. The medial implant
surface topography can be selected or designed to match or reflect
all or portions of the lateral femoral geometry or lateral femoral
implant geometry in one or more planes. The lateral implant surface
topography can be selected or designed to match or reflect all or
portions of the medial femoral geometry or medial femoral implant
geometry in one or more planes. The medial and/or the lateral
surface topography can be fixed in one, two or all dimensions. The
latter can typically be used when at least one femoral geometry,
e.g., the coronal curvature, is also fixed.
[0216] The implant surface topography can include one or more of
the following: [0217] Curvature of convexity in sagittal plane,
optionally patient derived or matched, e.g., based on tibial or
femoral geometry [0218] Curvature of convexity in coronal plane,
optionally patient derived or matched, e.g., based on tibial or
femoral geometry [0219] Curvature of concavity in sagittal plane,
optionally patient derived or matched, e.g., based on tibial or
femoral geometry [0220] Curvature of concavity in coronal plane,
optionally patient derived or matched, e.g., based on tibial or
femoral geometry [0221] Single sagittal radius of curvature,
optionally patient derived or matched, e.g., based on tibial or
femoral geometry [0222] Multiple sagittal radii of curvature,
optionally patient derived or matched, e.g., based on tibial or
femoral geometry [0223] Single coronal radius of curvature,
optionally patient derived or matched, e.g., based on tibial or
femoral geometry [0224] Multiple coronal radii of curvature,
optionally patient derived or matched, e.g., based on tibial or
femoral geometry [0225] Depth of dish, optionally patient derived
or matched, e.g., based on tibial or femoral geometry [0226] AP
length of dish, optionally patient derived or matched, e.g., based
on tibial or femoral geometry [0227] ML width of dish, optionally
patient derived or matched, e.g., based on tibial or femoral
geometry [0228] Depth of trough, optionally patient derived or
matched, e.g., based on tibial or femoral geometry [0229] AP length
of trough, optionally patient derived or matched, e.g., based on
tibial or femoral geometry [0230] ML width of trough, optionally
patient derived or matched, e.g., based on tibial or femoral
geometry [0231] Curvature of trough, optionally patient derived or
matched, e.g., based on tibial or femoral geometry
[0232] All of the tibial designs discussed can be applied with a:
[0233] single piece tibial polyethylene insert, for example with a
single metal backed component [0234] single piece tibial insert of
other materials, for example with a single metal backed component
[0235] two piece tibial polyethylene inserts, for example with a
single metal backed component [0236] two piece tibial inserts of
other materials, for example with a single metal backed component
[0237] single piece all polyethylene tibial implant [0238] two
piece all polyethylene tibial implant, e.g. medial and lateral
[0239] single piece metal tibial implant (e.g., metal on metal or
metal on ceramic) [0240] two piece metal tibial implant, e.g.,
medial and lateral (e.g., metal on metal or metal on ceramic)
[0241] single piece ceramic tibial implant [0242] two piece ceramic
tibial implant, e.g., medial and lateral
[0243] Any material or material combination currently known in the
art and developed in the future can be used.
[0244] Certain embodiments of tibial trays can have the following
features, although other embodiments are possible: modular insert
system (polymer); cast cobalt chrome; standard blanks (cobalt
portion and/or modular insert) can be made in advance, then shaped
patient-specific to order; thickness based on size (saves bone,
optimizes strength); allowance for 1-piece or 2-piece insert
systems; and/or different medial and lateral fins.
[0245] In certain embodiments, the tibial tray is designed or cut
from a blank so that the tray periphery matches the edge of the cut
tibial bone, for example, the patient-matched peripheral geometry
achieves >70%, >80%, >90%, or >95% cortical coverage.
In certain embodiments, the tray periphery is designed to have
substantially the same shape, but be slightly smaller, than the
cortical area.
[0246] If a shape, such as perimeter shape, of a tibial tray or
insert is derived based on the shape of cortical bone, portions or
the entire implant contour can be directly matched to the derived
cortical bone surface. If the tibial shape is derived based on
deriving the shape of endosteal or trabecular bone or bone marrow,
the implant contour can be matched to the edge of the tibial
plateau by adding, for example, an offset to the periphery of the
endosteal bone or trabecular bone or bone marrow. This offset can
be selected to be similar to the thickness of the cortical bone in
the area, e.g. 1 mm, 1.5 mm, 2 mm, 2.5 mm etc. The offset can
optionally be derived using a mathematical function.
[0247] The patient-adapted tibial implants of certain embodiments
allow for design flexibility. For example, inserts can be designed
to compliment an associated condyle of a corresponding femoral
implant component, and can vary in dimensions to optimize design,
for example, one or more of height, shape, curvature (preferably
flat to concave), and location of curvature to accommodate natural
or engineered wear pattern.
[0248] In the knee, a tibial cut can be selected so that it is, for
example, 90 degrees perpendicular to the tibial mechanical axis or
to the tibial anatomical axis. The cut can be referenced, for
example, by finding the intersect with the lowest medial or lateral
point on the plateau.
[0249] The slope for tibial cuts typically is between 0 and 7 or 0
and 8 degrees in the sagittal plane. Rarely, a surgeon may elect to
cut the tibia at a steeper slope. The slope can be selected or
designed into a patient-specific cutting jig using a preoperative
imaging test. The slope can be similar to the patient's
preoperative slope on at least one of a medial or one of a lateral
side. The medial and lateral tibia can be cut with different
slopes. The slope also can be different from the patient's
preoperative slope on at least one of a medial or one of a lateral
side.
[0250] The tibial cut height can differ medially and laterally, as
shown in FIG. 3 and FIGS. 8A-C. In some patients, the uncut lateral
tibia can be at a different height, for example, higher or lower,
than the uncut medial tibia. In this instance, the medial and
lateral tibial cuts can be placed at a constant distance from the
uncut medial and the uncut lateral tibial plateau, resulting in
different cut heights medially or laterally. Alternatively, they
can be cut at different distances relative to the uncut medial and
lateral tibial plateau, resulting in the same cut height on the
remaining tibia. Alternatively, in this setting, the resultant cut
height on the remaining tibia can be elected to be different
medially and laterally. In certain embodiments, independent design
of the medial and lateral tibial resection heights, resection
slopes, and/or implant component (e.g., tibial tray and/or tibial
tray insert), can enhance bone perseveration on the medial and/or
lateral sides of the proximal tibia as well as on the opposing
femoral condyles.
[0251] In certain embodiments, a patient-specific proximal tibia
cut (and the corresponding bone-facing surface of the tibial
component) is designed by: (1) finding the tibial axis
perpendicular plane ("TAPP"); (2) lowering the TAPP, for example, 2
mm below the lowest point of the medial tibial plateau; (3) sloping
the lowered TAPP 5 degrees posteriorly (with no additional slope on
the proximal surface of the insert); (4) fixing the component
posterior slope, for example, at 5 degrees; and (5) using the
tibial anatomic axis derived from Cobb or other measurement
technique for tibial implant rotational alignment. As shown in FIG.
18, resection cut depths deeper than 2 mm below the lowest point of
the patient's uncut medial or lateral plateau (e.g., medial
plateau) may be selected and/or designed, for example, if the
patient's anatomy includes an abnormality or diseased tissue below
this point, or if the surgeon prefers a lower cut. For example,
resection cut depths of 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, or 5 mm
can be selected and/or designed and, optionally, one or more
corresponding tibial and/or femoral implant thicknesses can be
selected and/or designed based on this patient-specific
information.
[0252] In certain embodiments, a patient-specific proximal tibial
cut (and the corresponding bone-facing surface of the tibial
component) uses the preceding design except for determining the A-P
slope of the cut. In certain embodiments, a patient-specific A-P
slope can be used, for example, if the patient's anatomic slope is
between 0 degrees and 7 degrees, or between 0 degrees and 8
degrees, or between 0 degrees and 9 degrees; a slope of 7 degrees
can be used if the patient's anatomic slope is between 7 degrees
and 10 degrees, and a slope of 10.degree. can be used if the
patient's anatomic slope is greater than 10 degrees.
[0253] In certain embodiments, a patient-specific A-P slope is used
if the patient's anatomic slope is between 0 and 7 degrees and a
slope of 7 degrees is used if the patient's anatomic slope is
anything over 7 degrees. Someone skilled in the art can recognize
other methods for determining the tibial slope and for adapting it
during implant and jig design to achieve a desired implant
slope.
[0254] A different tibial slope can be applied on the medial and
the lateral side. A fixed slope can be applied on one side, while
the slope on the other side can be adapted based on the patient's
anatomy. For example, a medial slope can be fixed at 5 degrees,
while a lateral slope matches that of the patient's tibia. In this
setting, two unicondylar tibial inserts or trays can be used.
Alternatively, a single tibial component, optionally with metal
backing, can be used wherein said component does not have a flat,
bone-facing surface, but includes, for example, an oblique portion
to connect the medial to the lateral side substantially
negatively-match resected lateral and medial tibial surfaces as
shown, for example, in FIG. 3 and FIGS. 8A-C.
[0255] In certain embodiments, the axial profile (e.g., perimeter
shape) of the tibial implant can be designed to match the axial
profile of the patient's cut tibia, for example as described in
U.S. Patent Application Publication No. 2009/0228113. Alternatively
or in addition, in certain embodiments, the axial profile of the
tibial implant can be designed to maintain a certain percentage or
distance in its perimeter shape relative to the axial profile of
the patient's cut tibia. Alternatively or in addition, in certain
embodiments, the axial profile of the tibial implant can be
designed to maintain a certain percentage or overhang in its
perimeter shape relative to the axial profile of the patient's cut
tibia.
[0256] Tibial tray designs can include patient-specific,
patient-engineered, and/or standard features. For example, in
certain embodiments the tibial tray can have a front-loading design
that can be seated using minimal impaction force. The trays can
come in various standard or standard blank designs, for example,
small, medium and large standard or standard blank tibial trays can
be provided. FIG. 19 shows exemplary small, medium and large blank
tibial trays. As shown, the tibial tray perimeters include a blank
perimeter shape that can be designed based on the design of the
patient's resected proximal tibia surface. In certain embodiments,
small and medium trays can include a base thickness of 2 mm (e.g.,
such that a patient's natural joint line may be raised 3-4 mm if
the patient has 2-3 mm of cartilage on the proximal tibia prior to
the disease state). Large trays can have a base thickness of 3 mm
(such that in certain embodiments it may be beneficial to resect an
additional 1 mm of bone so that the joint line is raised no more
than 2-3 mm (assuming 2-3 mm of cartilage on the patient's proximal
tibia prior to the disease state).
[0257] Any of the tibial implant components described herein can be
derived from a blank that is cut to include one or more
patient-specific features. For example, certain embodiments include
a pre-existing repair system wherein a stock of "standard" tray
components with the upper surface of the tray component machined
with the walls, grooves, and receptacles outlined above, are kept.
Similarly, a stock of standard tray inserts with the locking
mechanism already machined in with the walls, grooves, receptacles
can be kept. A patient's imaging data and anatomy information may
then be used to shape a "standard" tray component so that at least
one of the perimeter, shape, stem location, stem size, peg
location, peg size, lock location, cement pocket location and
cement pocket size of the tray component can be adapted for that
specific patient. A "standard" insert component is then similarly
shaped, according to the patient's individual imaging data and
anatomy, to mate with the tray component that is specific to that
patient. The insert component may also be initially configured to
be larger than the tray component and then shaped to match the
exact perimeter of the tray component to ensure there is no metal
on metal scorching between the femoral component and the tibial
component. FIGS. 20A-C depict three exemplary combinations of a
tibial tray 4800 and tibial tray insert 4810 manufactured and/or
machined to include matching perimeters. In FIG. 20A, the tray and
tray insert are manufactured to have the same perimeter, e.g., same
patient-specific, same patient-derived, or same standard perimeter.
In FIG. 20B, an oversized, e.g., standard or blank, tray is
machined to include a perimeter that matches the tibial tray insert
perimeter, e.g., matching patient-specific, matching
patient-derived, or matching standard perimeter. In FIG. 20C, an
oversized, e.g., standard or blank, tray insert is machined to
include a perimeter that matches the tibial tray perimeter, e.g.,
matching patient-specific, matching patient-derived, or matching
standard perimeter.
[0258] A patient-specific peg alignment (e.g., either aligned to
the patient's mechanical axis or aligned to another axis) can be
combined with a patient-specific A-P cut plane. For example, in
certain embodiments the peg alignment can tilt anteriorly at the
same angle that the A-P slope is designed. In certain embodiments,
the peg can be aligned in relation to the patient's sagittal
mechanical axis, for example, at a predetermined angle relative to
the patient's mechanical axis. FIG. 21A-21C show exemplary A-P and
peg angles for tibial trays. In particular, in FIG. 21A, the A-P
slope is 0 degrees and the tray tilts posteriorly 3 degrees; in
FIG. 21B, the A-P slope is 7 degrees and the tray tilts posteriorly
4 degrees; and in FIG. 21C, the A-P slope is 10 degrees and the
tray tilts posteriorly 7 degrees. The stem can be designed with a
standard or patient-adapted tilt, e.g., a posterior tilt. For
example, the stem can be designed to have a standard three degree
tilt relative to the tray tilt, as shown in FIG. 21A-C.
[0259] The joint-facing surface of a tibial implant component
includes a medial bearing surface and a lateral bearing surface.
Like the femoral implant bearing surface(s) described above, a
bearing surface on a tibial implant (e.g., a groove or depression
or a convex portion (on the lateral side) in the tibial surface
that receives contact from a femoral component condyle) can be of
standard design, for example, available in 6 or 7 different shapes,
with a single radius of curvature or multiple radii of curvature in
one dimension or more than one dimension. Alternatively, a bearing
surface can be standardized in one or more dimensions and
patient-adapted in one or more dimensions. A single radius of
curvature and/or multiple radii of curvature can be selected in one
dimension or multiple dimensions. Some of the radii can be
patient-adapted.
[0260] Each of the two contact areas of the polyethylene insert of
the tibial implant component that engage the femoral medial and
lateral condyle surfaces can be any shape, for example, convex,
flat, or concave, and can have any radii of curvature. In certain
embodiments, any one or more of the curvatures of the medial or
lateral contact areas can include patient-specific radii of
curvature. Specifically, one or more of the coronal curvature of
the medial contact area, the sagittal curvature of the medial
contact area, the coronal curvature of the lateral contact area,
and/or the sagittal curvature of the lateral contact area can
include, at least in part, one or more patient-specific radii of
curvature. In certain embodiments, the tibial implant component is
designed to include one or both medial and lateral bearing surfaces
having a sagittal curvature with, at least in part, one or more
patient-specific radii of curvature and a standard coronal
curvature. In certain embodiments, the bearing surfaces on one or
both of the medial and lateral tibial surfaces can include radii of
curvature derived from (e.g., the same length or slightly larger,
such as 0-10% larger than) the radii of curvature on the
corresponding femoral condyle. Having patient-adapted sagittal
radii of curvature, at least in part, can help achieve normal
kinematics with full range of motion.
[0261] Alternatively, the coronal curvature can be selected, for
example, by choosing from a family of standard curvatures the one
standard curvature having the radius of curvature or the radii of
curvature that is most similar to the coronal curvature of the
patient's uncut femoral condyle or that is most similar to the
coronal curvature of the femoral implant component.
[0262] In preferred embodiments, one or both tibial medial and
lateral contact areas have a standard concave coronal radius that
is larger, for example slightly larger, for example, between 0 and
1 mm, between 0 and 2 mm, between 0 and 4 mm, between 1 and 2 mm,
and/or between 2 and 4 mm larger, than the convex coronal radius on
the corresponding femoral component. By using a standard or
constant coronal radius on a femoral condyle with a matching
standard or constant coronal radius or slightly larger on a tibial
insert, for example, with a tibial radius of curvature of from
about 1.05.times. to about 2.times., or from about 1.05.times. to
about 1.5.times., or from about 1.05.times. to about 1.25.times.,
or from about 1.05.times. to about 1.10.times., or from about
1.05.times. to about 1.06.times., or about 1.06.times. of the
corresponding femoral implant coronal curvature. The relative
convex femoral coronal curvature and slightly larger concave tibial
coronal curvature can be selected and/or designed to be centered to
each about the femoral condylar centers.
[0263] In the sagittal plane, one or both tibial medial and lateral
concave curvatures can have a standard curvature slightly larger
than the corresponding convex femoral condyle curvature, for
example, between 0 and 1 mm, between 0 and 2 mm, between 0 and 4
mm, between 1 and 2 mm, and/or between 2 and 4 mm larger, than the
convex sagittal radius on the corresponding femoral component. For
example, the tibial radius of curvature for one or both of the
medial and lateral sides can be from about 1.1.times. to about
2.times., or from about 1.2.times. to about 1.5.times., or from
about 1.25.times. to about 1.4.times., or from about 1.30.times. to
about 1.35.times., or about 1.32.times. of the corresponding
femoral implant sagittal curvature. In certain embodiments, the
depth of the curvature into the tibial surface material can depend
on the height of the surface into the joint gap. As mentioned, the
height of the medial and lateral tibial component joint-facing
surfaces can be selected and/or designed independently. In certain
embodiments, the medial and lateral tibial heights are selected
and/or designed independently based on the patient's medial and
lateral condyle height difference. In addition or alternatively, in
certain embodiments, a threshold minimum or maximum tibial height
and/or tibial insert thickness can be used. For example, in certain
embodiments, a threshold minimum insert thickness of 6 mm is
employed so that no less than a 6 mm medial tibial insert is
used.
[0264] By using a tibial contact surface sagittal and/or coronal
curvature selected and/or designed based on the curvature(s) of the
corresponding femoral condyles or a portion thereof (e.g., the
bearing portion), the kinematics and wear of the implant can be
optimized. For example, this approach can enhance the wear
characteristics a polyethylene tibial insert. This approach also
has some manufacturing benefits.
[0265] For example, a set of different-sized tools can be produced
wherein each tool corresponds to one of the pre-selected standard
coronal curvatures. The corresponding tool then can be used in the
manufacture of a polyethylene insert of the tibial implant
component, for example, to create a curvature in the polyethylene
insert. FIG. 22A shows six exemplary tool tips 6810 and a
polyethylene insert 6820 in cross-section in the coronal view. The
size of the selected tool can be used to generate a polyethylene
insert having the desired coronal curvature. In addition, FIG. 22A
shows an exemplary polyethylene insert 6820 having two different
coronal curvatures created by two different tool tips. The action
of the selected tool on the polyethylene insert, for example, a
sweeping arc motion by the tool at a fixed point above the insert,
can be used to manufacture a standard or patient-specific sagittal
curvature. FIG. 22B shows a sagittal view of two exemplary tools
6830, 6840 sweeping from different distances into the polyethylene
insert 6820 of a tibial implant component to create different
sagittal curvatures in the polyethylene insert 6820.
[0266] In certain embodiments, one or both of the tibial contact
areas includes a concave groove having an increasing or decreasing
radius along its sagittal axis, for example, a groove with a
decreasing radius from anterior to posterior.
[0267] As shown in FIG. 23A, in certain embodiments the shape of
the concave groove 6910 on the lateral and/or on the medial sides
of the joint-facing surface of the tibial insert 6920 can be
matched by a convex shape 6930 on the opposing side surface of the
insert and, optionally, by a concavity 6940 on the engaging surface
of the tibial tray 6950. This can allow the thickness of the
component to remain constant 6960, even though the surfaces are not
flat, and thereby can help maintain a minimum thickness of the
material, for example, plastic material such as polyethylene. For
example, an implant insert can maintain a constant material
thickness (e.g., less than 5.5 mm, 5.5 mm, 5.6 mm, 5.7 mm, 5.8 mm,
5.9 mm, 6.0 mm, 6.1 mm, or greater than 6.1 mm) even though the
insert includes a groove on the joint-facing surface. The constant
material thickness can help to minimize overall minimum implant
thickness while achieving or maintaining a certain mechanical
strength (as compared to a thicker implant). The matched shape on
the metal backing can serve the purpose of maintaining a minimum
polyethylene thickness. It can, however, also include design
features to provide a locking mechanism between the polyethylene or
other insert and the metal backing. Such locking features can
include ridges, edges, or interference fit. In the case of an
interference fit, the polyethylene can have slightly larger
dimensions at the undersurface convexity than the matching
concavity on the metal tray. This can be stabilized against rails
or dove tail locking mechanisms in the center or the sides of the
metal backing. Other design options are possible. For example, the
polyethylene extension can have a saucer shape that can snap into a
matching recess on the metal backing. In addition, as shown in FIG.
23A, any corresponding pieces of the component, such as a metal
tray, also can include a matching groove to engage the curved
surface of the plastic material. Two exemplary concavity dimensions
are shown in FIG. 23B. As shown in the figure, the concavities or
scallops have depths of 1.0 and 0.7 mm, based on a coronal geometry
of R42.4 mm. At a 1.0 mm depth, the footprint width is 18.3 mm. At
a 0.70 mm depth, the footprint width is 15.3 mm. These dimensions
are only of exemplary nature. Other configurations are
possible.
[0268] In certain embodiments, the sagittal curvature of the
femoral component can be designed to be tilted, as suggested by
FIGS. 24A and B. The corresponding curvature of the tibial surface
can be tilted by that same slope, which can allow for thicker
material on the corresponding tibial implant, for example, thicker
poly at the anterior or posterior aspect of the tibial implant. The
femoral component J-curve, and optionally the corresponding
curvature for the tibial component, can be tilted by the same slope
in both the medial and lateral condyles, just in the medial condyle
or just in the lateral condyle or both independently or coupled. In
certain embodiments, some additional material can be removed or the
material thickness can be adapted from the posterior aspect of the
femoral and/or tibial curvatures to allow for rotation.
Locking Mechanisms
[0269] Various embodiments of tibial trays include a scaffold or
stage with one or more polymer inserts that can be inserted and
locked into the scaffold. One embodiment is a tibial implant for a
knee joint that is configured to be implanted onto a patient's
proximal tibia. The tibial implant comprises at least two
components: a first component that rests on the tibia; and a second
component that is configured to articulate with the femoral condyle
components of a femoral implant.
[0270] The tibial resting component is shaped as a tray (tray
component) that sits on the patient's proximal tibia that is
preferably surgically cut to become substantially flat. There may
be situations in which the tibia needs to be cut at an angle, in a
multi-tiered fashion or even contoured. This disclosure is not
intended to be limited to any one of these and is able to
accommodate each of them. In some embodiments, the tray component
has a peripheral geometry that matches the patient's existing bone
and in a further preferred embodiment the tray achieves significant
coverage of the tibial plateau, e.g., 80, 85, 90 or 95 percent
cortical coverage in AP or ML dimension or perimeter coverage or
area of resected bone coverage. The tray component has an upper
surface and a lower surface, a medial side, a lateral side, an
anterior or front side and a posterior or rear side. The tray
component can be attached to the patient's proximal tibia by way of
a central stem or post integrated into the lower surface of the
tray component. Other attachment mechanisms known in the art can be
used. As will be appreciated by those of skill in the art, the stem
or post may be attached to the tray component to provide the shape
of the bone surface. For example, if the tibial surface is
substantially flat, the stem or post may be attached substantially
perpendicular to the tray component so that the tray component is
positioned horizontal to the tibial axis. If, for example, the
tibial surface is at an angle, the stem or post may be attached to
the tray component at an angle so that the resulting position of
the tray component is horizontal to the tibial axis. The angle can
be selected based on the patient's unique anatomy, e.g. using an
imaging test. The stem or post may have fins attached to it for
further stabilization of the tray component. In one embodiment, the
fins are aligned asymmetrically, i.e., they are placed at different
angles from the horizontal middle of the tray component. The fins
can also have different lengths, e.g., the fins can be longer on
the medial side than on the lateral side or vice versa. By varying
the fin angle and length, access to the bone, in particular
posterior to the fins, can be facilitated when the surgeon performs
a revision surgery and, for example, cuts the bone with a bone saw.
In one embodiment, the stem is 13 mm in diameter and 40 mm long.
The fins can be 2 or 3 or 4 mm wide, with the lateral side, for
example, biased 15 degrees from horizontal and the medial side
biased 5 degrees from horizontal. To aid fixation, a pocket or
cut-out can be included in the lower surface of the tray component
to incorporate additional adhesive means such as bone cement. The
dimensions of the pocket or cut out can be adapted to the patient's
anatomy, for example by deriving a bone shape using an imaging
test.
[0271] The interior of the upper surface of the tray component can
be substantially flat or can have at least one or more curved
portions. There can be a wall that spans the posterior perimeter of
the upper surface, from approximately halfway up the medial side to
approximately halfway down the lateral side of the upper surface.
This wall can optionally contain grooves along the inner surface
for accepting an insert component of the implant. The wall can
extend into the middle of the upper surface of the tray component
from the posterior side towards the anterior side, approximately
halfway between the medial and lateral sides, creating a peninsular
wall on the upper surface. The outward facing sides of this
peninsular wall can optionally be sloped inward from the top of the
wall to the bottom of the wall, for mating with the insert
component of the implant. Towards the end of the peninsular wall,
receptacles can optionally be cut into either side of the wall for
receiving an optional locking member formed into the surface of the
insert of the implant. Perpendicular to the peninsular wall there
can be one or more grooves cut into the upper surface of the tray
component for accepting a notched portion extending from the lower
surface of the insert of the implant. The anterior side of the
upper surface of the tray component can contain at least one
slanted surface that acts as a ramp to assist with proper alignment
and insertion of the implant component into the tray component.
[0272] The articulating component, or insert component, has an
upper surface, a lower surface, a medial side, a lateral side and
anterior or front side and a posterior or rear side. The upper
surface of the insert component can be flat or can be shaped to
align with the geometry of the joint or the bearing surface of the
opposite implant component by having one or more concave surfaces
that are articulate with the convex surfaces of the femoral
component of an implant, but other configurations are possible,
such as a flat surface, a curved surface on a medial side and flat
surface on a lateral side, a curved surface on a lateral side and a
flat surface on a tibial side, or other configurations and
combinations.
[0273] The lower surface of the insert component can be flat and is
configured to mate with the tray component of the implant. The
posterior side of the implant can be cut out from approximately
half way up the medial side of the implant to approximately halfway
down the lateral side of the implant to align with the
geometrically matched wall of the upper surface of the tray
component. The remaining structure on the lower surface of the
implant can have a ledge extending along the medial and posterior
sides of the surface for lockably mating with the grooves of the
interior walls of the upper surface of the tray component.
Approximately halfway between the medial side and the lateral side
of the implant, a canal can be formed from the posterior side of
the implant towards the anterior side of the implant, for mating
with the peninsular wall of the upper surface of the tray
component. This canal can run approximately 3/4 the length of the
implant from the posterior to anterior of the lower surface of the
implant. The exterior walls of this canal can be sloped inward from
the bottom of the canal to the top of the canal creating a surface
that dovetails with the sloped peninsular walls of the upper
surface of the tray component. This dovetail joint can assist with
proper alignment of the insert into the tray component and then
locks the insert into the tray component once fully inserted. At
the anterior end of the canal, there can be a locking mechanism
consisting of bendable fingers that snap optionally into the
receptacles cut into the interior of the peninsular walls upon
insertion of the insert into the tray component of the implant,
thereby locking the implant component into the tray component.
Perpendicular to the canal running 3/4 the length of the lower
surface of the insert can be at least one notch for mating with the
at least one groove cut out of the upper surface of the tray
component.
[0274] Thus, multiple locking mechanisms can be designed into the
opposing surfaces of the walls and canal of the insert and the tray
component, as well as the notch and groove and they can help to
lock the insert into place on the tray component and resist against
anterior-posterior motion within the knee as well as against
medial-lateral motion. The bendable fingers can assist in
preventing any lifting motion between the insert and tray component
as pressure is applied to various parts of the joint.
Manufacturing and Machining
[0275] The tray component can be machined, molded, casted,
manufactured through additive techniques such as laser sintering or
electron beam melting or otherwise constructed out of a metal or
metal alloy such as cobalt chromium. Similarly, the insert
component may be machined, molded, manufactured through rapid
prototyping or additive techniques or otherwise constructed out of
a plastic polymer such as ultra high molecular weight polyethylene.
Other known materials, such as ceramics including ceramic coating,
may be used as well, for one or both components, or in combination
with the metal, metal alloy and polymer described above. It can be
appreciated by those of skill in the art that an implant may be
constructed as one piece out of any of the above, or other,
materials, or in multiple pieces out of a combination of materials.
For example, a tray component constructed of a polymer with a
two-piece insert component constructed one piece out of a metal
alloy and the other piece constructed out of ceramic.
[0276] Each of the components may be constructed as a "standard" or
"blank" in various sizes or may be specifically formed for each
patient based on their imaging data and anatomy. Computer modeling
may be used and a library of virtual standards may be created for
each of the components. A library of physical standards may also be
amassed for each of the components.
[0277] Imaging data including shape, geometry, e.g., M-L, A-P, and
S-I dimensions, then can be used to select the standard component,
e.g., a femoral component or a tibial component or a humeral
component and a glenoid component that most closely approximates
the select features of the patient's anatomy. Typically, these
components are selected so that they are slightly larger than the
patient's articular structure that are be replaced in at least one
or more dimensions. The standard component is then adapted to the
patient's unique anatomy, for example by removing overhanging
material, e.g. using machining
[0278] Thus, referring to the flow chart shown in FIG. 25, in a
first step, the imaging data is analyzed, either manually or with
computer assistance, to determine the patient specific parameters
relevant for placing the implant component. These parameters can
include patient specific articular dimensions and geometry and also
information about ligament location, size, and orientation, as well
as potential soft-tissue impingement, and, optionally, kinematic
information.
[0279] In a second step, one or more standard components, e.g., a
femoral component or a tibial component or tibial insert, are
selected. These are selected so that they are at least slightly
greater than one or more of the derived patient specific articular
dimensions and so that they can be shaped to the patient specific
articular dimensions. Alternatively, these are selected so that
they do not interfere with any adjacent soft-tissue structures.
Combinations of both are possible.
[0280] If an implant component is used that includes an insert,
e.g., a polyethylene insert and a locking mechanism in a metal or
ceramic base, the locking mechanism can be adapted to the patient's
specific anatomy in at least one or more dimensions. The locking
mechanism can also be patient adapted in all dimensions. The
location of locking features can be patient adapted while the
locking feature dimensions, for example between a femoral component
and a tibial component, can be fixed. Alternatively, the locking
mechanism can be pre-fabricated; in this embodiment, the location
and dimensions of the locking mechanism also is considered in the
selection of the pre-fabricated components, so that any adaptations
to the metal or ceramic backing relative to the patient's articular
anatomy do not compromise the locking mechanism. Thus, the
components can be selected so that after adaptation to the
patient's unique anatomy a minimum material thickness of the metal
or ceramic backing is maintained adjacent to the locking
mechanism.
[0281] In some embodiments, a pre-manufactured metal backing blank
can be selected so that it's exterior dimensions are slightly
greater than the derived patient specific dimensions or geometry in
at least one or more directions, while, optionally, at the same
time not interfering with ligaments, e.g. the PCL. The
pre-manufactured metal backing blank can include a pre-manufactured
locking mechanism for an insert, e.g. a polyethylene insert. The
locking mechanism can be completely pre-manufactured, i.e. not
requiring any patient adaptation. Alternatively, the locking
mechanism can have pre-manufactured components, e.g. an anterior
locking tab or feature, with other locking features that will be
machined later based on patient specific dimensions, e.g. a
posterior locking tab or feature at a distance from the anterior
locking feature that is derived from patient specific imaging data.
In this setting, the pre-manufactured metal blank will be selected
so that at least the anterior locking feature will fall inside the
derived patient specific articular dimensions. In a preferred
embodiment, all pre-manufactured locking features on the metal
backing and an insert will fall inside the derived patient specific
articular dimensions. Thus, when the blank is adapted to the
patient's specific geometry, the integrity of the lock is not
compromised and will remain preserved. An exemplary, by no means
limiting, process flow is provided below: [0282] Access imaging
data, e.g. CT, MRI scan, digital tomosynthesis, cone beam CT,
ultrasound, optical imaging, laser imaging, photoacoustic imaging
etc. [0283] Derive patient specific articular dimensions/geometry,
e.g. at least one of an AP, ML, SI dimension, e.g. an AP and/or ML
dimension of a tibial plateau and/or an AP and/or ML dimension of a
distal femur [0284] Determine preferred resection location and
orientation (e.g. tibial slope) on at least one or two articular
surface(s) [0285] In one dimension/direction, e.g. ML [0286] In two
dimensions/directions, e.g. ML and AP [0287] In three
dimensions/directions, e.g. ML, AP and sagittal tibial slope [0288]
Optionally, optimize resection location and orientation across two
opposing articular surface, e.g. one or more femoral condyles and a
tibial plateau or a femoral head/femoral neck and acetabulum [0289]
Derive/identify cortical edges or edges or margins of resected
articular bones, e.g. femoral condyle(s) and tibial plateau [0290]
Derive dimensions of resected bones, e.g. AP and ML dimension(s) of
femoral condyles post resection and tibial plateau post resection
[0291] Identify implant component blanks with exterior dimensions
greater than the derived dimension(s) of the resected bone, e.g.
femoral blank with ML and/or AP dimension greater than derived ML
and/or AP dimension of femoral condyles at simulated resection
level or tibial blank with ML and/or AP dimension greater than
derived ML and/or AP dimension at simulated resection level [0292]
Identify subset of implant component blanks found in step (g) with
pre-manufactured lock feature(s) and sufficient material thickness
adjacent to lock feature(s) located inside the derived dimension(s)
of the resected bone, e.g. tibial blank with ML and/or AP dimension
greater than derived ML and/or AP dimension at simulated resection
level and pre-manufactured lock feature(s) plus sufficient material
thickness adjacent to lock feature located inside the derived
dimension(s) of the resected bone, e.g. ML and/or AP dimension of
the resected bone. [0293] Adapt implant component blank to derived
patient specific dimensions of resected bone(s), e.g. remove
overhanging material from femoral component blank relative to
medial and lateral cortical edge or anterior and posterior cortical
edge or remove overhanging material from tibial blank relative to
medial, lateral, anterior or posterior cortical margin and,
optionally, relative to adjacent soft-tissue structures, e.g. PCL.
[0294] Optionally adapt lock features(s) to patient specific
geometry, e.g. on a tibial tray or polyethylene insert, adapt
distance between a posterior lock feature to be machined and a
pre-manufactured anterior lock feature based on patient specific
geometry. Or on a tibial tray or polyethylene insert, adapt
distance between a lateral lock feature to be machined and a
pre-manufactured medial lock feature based on patient specific
geometry.
[0295] Those of skill in the art will appreciate that not all of
these process steps will be required to design, select or adapt an
implant to the patient's geometry. Moreover, additional steps may
be added, for example kinematic adaptations or finite element
modeling of implant components including locks. Finite element
modeling can be performed based on patient specific input data
including patient specific articular geometry and virtually derived
implant component shapes.
[0296] Clearly, all combinations of pre-manufactured and patient
adapted lock features are possible, including pre-manufactured lock
features on a medial insert and patient specific lock features on a
lateral insert or the reverse. Other locations of lock features are
possible.
[0297] A locking mechanism for a tibial tray, for example, can:
[0298] Be completely standard with only the exterior dimensions of
the metal blank and/or insert adapted to the patient's articular
geometry. [0299] Have standard lock features at standard locations
and patient individualized lock features, e.g. standard anterior
lock feature and distance between anterior and posterior lock
feature on a metal tray and/or insert patient adapted. [0300] Have
completely individualized features on a metal tray and insert, e.g.
the location of each lock feature on a metal tray or insert is
individualized based on the patient's geometry. However, even in
this embodiment, certain lock components will have standard
features, e.g. a standard distance or location between interlocking
pieces on the metal tray and the tibial insert or standard distance
or location between the lock and an adjacent implant wall on the
metal tray or the insert.
[0301] Adapting implant component blank(s) to derived patient
specific dimensions of resected bone(s) can involve (1) a metal
tray only, (2) an insert only, or (3) a metal tray and an insert.
When no metal tray is used, the adaptation can involve a single
material component, e.g. a tibial implant manufactured of
polyethylene, wherein one or more dimensions are adapted to a
patient specific geometry.
[0302] Since the tibia has the shape of a champagne glass, e.g., it
tapers distally from the knee joint space down, moving the tibial
cut distally can result in a smaller resultant cross-section of the
cut tibial plateau, e.g., the ML and/or AP dimension of the cut
tibia is smaller. For example, referring to FIG. 26, increasing the
slope of the cut can result in an elongation of the AP dimension of
the cut surface--requiring a resultant elongation of a patient
matched tibial component. Thus, in one embodiment it is possible to
select an optimal standard, pre-made tibial blank for a given
resection height and/or slope. This selection can involve (1)
patient-adapted metal with a standard poly insert; or (2) metal and
poly insert, wherein both are adapted to patient anatomy. The metal
can be selected so that based on cut tibial dimensions there is a
certain minimum metal perimeter (in one, two or three dimensions)
guaranteed after patient adaptation so that a lock mechanism does
not fail. Optionally, one can determine minimal metal perimeter
based on finite element modeling (FEA) (once during initial design
of standard lock features, or patient specific every time e.g. via
patient specific FEA modeling).
[0303] The tibial tray can be selected (or a metal base for other
joints) to optimize percent cortical bone coverage at resection
level. This selection can be (1) based on one dimension, e.g., ML;
(2) based on two dimensions, e.g. ML and AP; and/or (3) based on
three dimensions, e.g., ML, AP, SI or slope.
[0304] The selection can be performed to achieve a target
percentage coverage of the resected bone (e.g. area) or cortical
edge or margin at the resection level (e.g. AP, ML, perimeter),
e.g. 85%, 90%, 95%, 98% or 100%. Optionally, a smoothing function
can be applied to the derived contour of the patient's resected
bone or the resultant selected, designed or adapted implant contour
so that the implant does not extend into all irregularities or
crevaces of the virtually and then later surgically cut bone
perimeter. FIG. 27 depicts a resected proximal tibial surface
perimeter 5300 and a smoothed perimeter line 5310 for a tibial
implant perimeter, the smoothed perimeter line 5310 and subsequent
implant perimeter being derived from the patient's resected tibial
perimeter.
[0305] Optionally, a function can be included for deriving the
desired implant shape that allows changing the tibial implant
perimeter if the implant overhangs the cortical edge in a convex
outer contour portion or in a concave outer contour portion (e.g.
"crevace"). These changes can subsequently be included in the
implant shape, e.g. by machining select features into the outer
perimeter.
[0306] Those of skill in the art can appreciate that a combination
of standard and customized components may be used in conjunction
with each other. For example, a standard tray component may be used
with an insert component that has been individually constructed for
a specific patient based on the patient's anatomy and joint
information.
[0307] Another embodiment incorporates a tray component with one
half of a two-piece insert component integrally formed with the
tray component, leaving only one half of the two-piece insert to be
inserted during surgery. For example, the tray component and medial
side of the insert component may be integrally formed, with the
lateral side of the insert component remaining to be inserted into
the tray component during surgery. Of course, the reverse can also
be used, wherein the lateral side of the insert component is
integrally formed with the tray component leaving the medial side
of the insert component for insertion during surgery.
[0308] Each of these alternatives results in a tray component and
an insert component shaped so that once combined, they create a
uniformly shaped implant matching the geometries of the patient's
specific joint.
[0309] The above embodiments are applicable to all joints of a
body, e.g., ankle, foot, elbow, hand, wrist, shoulder, hip, spine,
or other joint. For example, in a hip, an acetabular component can
be designed or selected or adapted so that its peripheral margin
can be closely matched to the patient-specific acetabular rim or
perimeter. Optionally, reaming can be simulated for placement of an
acetabular cup and the implant then can be designed and/or selected
or adapted so that it closely matches the resultant acetabular rim
after reaming. Thus, the exterior dimensions of the implant can be
matched to the patient's geometry in this fashion. Optionally,
standard, round dimensions of a polyethylene insert can be used
with this embodiment. Similarly, a glenoid component can be matched
to the glenoid rim, optionally after surgically preparing or
resectioning all or portions of the glenoid rim. Thus, edge
matching, designing, selecting or adapting implants including,
optionally lock features, can be performed for implants used in any
joint of the body.
[0310] An implant component can include a fixed bearing design or a
mobile bearing design. With a fixed bearing design, a platform of
the implant component is fixed and does not rotate. However, with a
mobile bearing design, the platform of the implant component is
designed to rotate e.g., in response to the dynamic forces and
stresses on the joint during motion.
[0311] A rotating platform mobile bearing on the tibial implant
component allows the implant to adjust and accommodate in an
additional dimension during joint motion. However, the additional
degree of motion can contribute to soft tissue impingement and
dislocation. Mobile bearings are described elsewhere, for example,
in U.S. Patent Application Publication No. 2007/0100462.
[0312] In certain embodiments, an implant can include a
mobile-bearing implant that includes one or more patient-specific
features, one or more patient-engineered features, and/or one or
more standard features. For example, for a knee implant, the knee
implant can include a femoral implant component having a
patient-specific femoral intercondylar distance; a tibial component
having standard mobile bearing and a patient-engineered perimeter
based on the dimensions of the perimeter of the patient's cut tibia
and allowing for rotation without significant extension beyond the
perimeter of the patient's cut tibia; and a tibial insert or top
surface that is patient-specific for at least the patient's
intercondylar distance between the tibial insert dishes to
accommodate the patient-specific femoral intercondylar distance of
the femoral implant.
[0313] As another example, in certain embodiments a knee implant
can include a femoral implant component that is patient-specific
with respect to a particular patient's M-L dimension and standard
with respect to the patient's femoral intercondylar distance; a
tibial component having a standard mobile bearing and a
patient-engineered perimeter based on the dimensions of the
perimeter of the patient's cut tibia and allowing for rotation
without significant extension beyond the perimeter of the patient's
cut tibia; and a tibial insert or top surface that includes a
standard intercondylar distance between the tibial insert dishes to
accommodate the standard femoral intercondylar distance of the
femoral implant.
[0314] The step of designing an implant component and/or guide tool
as described herein can include both configuring one or more
features, measurements, and/or dimensions of the implant and/or
guide tool (e.g., derived from patient-specific data from a
particular patient and adapted for the particular patient) and
manufacturing the implant. In certain embodiments, manufacturing
can include making the implant component and/or guide tool from
starting materials, for example, metals and/or polymers or other
materials in solid (e.g., powders or blocks) or liquid form. In
addition or alternatively, in certain embodiments, manufacturing
can include altering (e.g., machining) an existing implant
component and/or guide tool, for example, a standard blank implant
component and/or guide tool or an existing implant component and/or
guide tool (e.g., selected from a library). The manufacturing
techniques to making or altering an implant component and/or guide
tool can include any techniques known in the art today and in the
future. Such techniques include, but are not limited to additive as
well as subtractive methods, i.e., methods that add material, for
example to a standard blank, and methods that remove material, for
example from a standard blank.
[0315] Various technologies appropriate for this purpose are known
in the art, for example, as described in Wohlers Report 2009, State
of the Industry Annual Worldwide Progress Report on Additive
Manufacturing, Wohlers Associates, 2009 (ISBN 0-9754429-5-3),
available from the web www.wohlersassociates.com; Pham and Dimov,
Rapid manufacturing, Springer-Verlag, 2001 (ISBN 1-85233-360-X);
Grenda, Printing the Future, The 3D Printing and Rapid Prototyping
Source Book, Castle Island Co., 2009; Virtual Prototyping & Bio
Manufacturing in Medical Applications, Bidanda and Bartolo (Eds.),
Springer, Dec. 17, 2007 (ISBN: 10: 0387334297; 13: 978-0387334295);
Bio-Materials and Prototyping Applications in Medicine, Bartolo and
Bidanda (Eds.), Springer, Dec. 10, 2007 (ISBN: 10: 0387476822; 13:
978-0387476827); Liou, Rapid Prototyping and Engineering
Applications: A Toolbox for Prototype Development, CRC, Sep. 26,
2007 (ISBN: 10: 0849334098; 13: 978-0849334092); Advanced
Manufacturing Technology for Medical Applications Reverse
Engineering, Software Conversion and Rapid Prototyping, Gibson
(Ed.), Wiley, January 2006 (ISBN: 10: 0470016884; 13:
978-0470016886); and Branner et al., "Coupled Field Simulation in
Additive Layer Manufacturing," 3rd International Conference PMI,
2008 (10 pages).
EXAMPLES
[0316] Example 1 illustrates a patient-adapted implant design for
an implant having a femoral component and a patella component.
Example 2 describes and exemplary tibial implant design and related
resection techniques. Example 3 describes exemplary tibial tray and
insert designs and related jigs and cutting designs. Example 4
describes an exemplary design for a tibial implant component.
Example 5 illustrates a set of jigs for guiding patient-specific
bone cuts in a femur-first technique. Example 6 illustrates a set
of jigs for guiding patient-specific bone cuts in a tibia-first
technique.
Example 1
A Patient-Specific Engineered Trochlea Design
[0317] This example describes a patient-specific trochlea design
that is optimized for proper kinematics of the patella-femoral
("PF") joint.
1.1 Method
[0318] FIGS. 28 to 33 show an exemplary design of a knee implant,
including a femoral component and a patella component, with a
material cutaway region highlighted (darker) in certain figures.
The placement of the patella and material removal was as follows:
As shown in FIG. 28, the flat bone-bearing surface of the patella
12700, was made parallel to the epicondylar axis 12710 in the
coronal view. As shown in FIG. 29, the center plane of the patella
implant was made collinear with the epicondylar axis 12720. This
allows for general positioning at the peak area of the trochlea. As
shown in FIG. 30, in this position the medial-lateral center or
sulcus of the trochlea is identified 12730, and the patella implant
component is brought down so the lowest points are coincident
12740. As shown in FIGS. 31 through 33, the patella profile is
swept along the sagittal curve of the trochlear region 12750.
1.2 Results and Discussion
[0319] This exemplary implant design uses a patient-specific
sagittal curvature and an engineered coronal curvature to allow the
patella component to track properly in the trochlear groove. This
exemplary implant design for the femoral component and a patella
component can allow various advantages including a reduction of
lateral overstuffing of the P-F joint and a post-operative patella
tracking that is normal or close to the patient's pre-operative
and/or pre-disease state. In certain embodiments, the lateral peak
can be retained, which may minimize dislocation events. In certain
embodiments, the patella implant bone-bearing surface can be or
appear to be approximately parallel to the osteochondral junction
of the native patella.
Example 2
Tibial Implant Design and Bone Cuts
[0320] This example illustrates tibial implant components and
related designs. This example also describes methods and devices
for performing a series of tibial bone cuts to prepare a patient's
tibia for receiving a tibial implant component. Patient data, such
scans of the patient's joint, can be used to locate the point and
features used to identify planes, axes and slopes associated with
the patient's joint. As shown in FIG. 34A, the tibial proximal cut
can be selected and/or designed to be a certain distance below a
particular location on the patient's tibial plateau. For example,
the tibial proximal cut height can be selected and/or designed to
be 1 mm, 1.5 mm, 2 mm, 2.5 mm, 3 mm, 3.5 mm, or 4 mm or more below
the lowest point on the patient's tibial plateau or below the
lowest point on the patient's medial tibial plateau or below the
lowest point on the patient's lateral tibial plateau. In this
example, the tibial proximal cut height was selected and designed
to be 2 mm below the lowest point on the patient's medial tibial
plateau. For example, as shown in FIG. 34B, anatomic sketches
(e.g., using a CAD program to manipulate a model of the patient's
biological structure) can be overlaid with the patient's tibial
plateau. As shown in FIG. 34C, these sketched overlays can be used
to identify the centers of tubercles and the centers of one or both
of the lateral and medial plateaus. In addition, as shown in FIGS.
35A-C, one or more axes such as the patient's anatomic tibial axis
14420, posterior condylar axis 14430, and/or sagittal axis 14440
can be derived from anatomic sketches, e.g., based on a defined a
midpoint line 14450 between the patient's lateral condyle center
and medial condyle center.
[0321] As shown in FIG. 36A, the proximal tibial resection was made
a 2 mm below the lowest point of the patient's medial tibial
plateau with a an A-P slope cut that matched the A-P slope on the
patient's medial tibial plateau. As shown in FIGS. 36B and 36C, an
implant profile 14500 was selected and/or designed to have 90%
coverage of the patient's cut tibial surface. In certain
embodiments, the tibial implant profile can be selected and/or
designed such that tibial implant is supported entirely or
substantially by cortical bone and/or such that implant coverage of
the cut tibial surface exceeds 100% and/or has no support on
cortical bone.
[0322] FIGS. 37A to 47C describe exemplary steps for performing
resection cuts to the tibia using the anatomical references
identified above. For example, as shown in FIGS. 37A and B, one
step can include aligning the top of the tibial jig stylus to the
top of the patient's medial and lateral spines (see arrow). As
shown in FIGS. 38A and B, a second step can include drilling and
pinning the tibial axis (see arrow). As shown in FIG. 39, a third
step can include drilling and pinning the medial pin (see arrow).
As shown in FIG. 40, a fourth step can include removing the stylus.
As shown in FIG. 41, a fifth step can include sawing 2 mm of tibial
bone from the patient's tibial plateau with the patient's medial AP
slope. As shown in FIG. 42, a sixth step can include removing the
resected portion of the patient's tibial plateau. As shown in FIG.
43, a seventh step can include assembling stem and keel guide(s)
onto the tibial cut guide. As shown in FIG. 44, an eighth step can
include drilling, e.g., using a 14 mm drill bit (13 mm.times.40 mm
stem) to drill a central hole into the proximal tibial surface. As
shown in FIG. 45, a ninth step can include using a saw or osteotome
to create a keel slot, for example, a 3.5 mm wide keel slot. FIG.
46 shows the finished tibial plateau with guide tools still in
place. FIGS. 47A-C show each of a guide tool (FIG. 47A), a tibial
implant component (FIG. 47B), and tibial and femoral implant
components (FIG. 47C) in the aligned position in the knee.
[0323] This example shows that using a patient's joint axes (e.g.,
as identified from patient-specific data and optionally from a
model of the patient's joint) to select and/or design resection
cuts, e.g., the tibia, and corresponding guide tools can create
resection cuts perpendicular to the patient's tibial axis and based
on the patient's medial AP slope. In addition, one or more features
of the corresponding implant components (e.g., tibial tray implant
thickness) can be selected and/or designed to align the tibial axis
with the femoral axis and thereby correct the patient's
alignment.
Example 3
Tibial Tray and Insert Designs
[0324] This example illustrates exemplary designs and implant
components for tibial trays and inserts for certain embodiments
described herein. In particular, this example describes a standard
blank tibial tray and insert and a method for altering the standard
blanks based on patient-specific data to include a patient-adapted
feature (e.g., a patient-adapted tray and insert perimeter that
substantially match the perimeter of the patient's resected
tibia).
[0325] FIGS. 48A-E illustrate various aspects of an embodiment of a
standard blank tibial implant component, including a bottom view
(FIG. 48A) of a standard blank tibial tray, a top view (FIG. 48B)
of the standard blank tibial tray, a bottom view (FIG. 48C) of a
standard blank tibial insert, a top-front (i.e., proximal-anterior)
perspective view (FIG. 48D) of the standard blank tibial tray, and
a bottom front (i.e., distal anterior) perspective view (FIG. 48E)
of a patient-adapted tibial insert. In this example and in certain
embodiments, the top surface of the tibial tray can receive a
one-piece tibial insert or two-piece tibial inserts. The tibial
inserts can include one or more patient-adapted features (e.g.,
patient-matched or patient-engineered perimeter profile, thickness,
and/or joint-facing surface) and/or one or more standard features,
in addition to a standard locking mechanism to engage the tibial
tray. With reference to FIGS. 48D and E, in certain embodiments the
locking mechanism on the tray and insert can include, for example,
one or more of: (1) a posterior interlock, (2) a central dovetail
interlock, (3) an anterior snap, (4) an anterior interlock, and (5)
an anterior wedge.
[0326] Standard blank tibial trays and/or inserts can be prepared
in multiple sizes, e.g., having various AP dimensions, ML
dimensions, and/or stem and keel dimensions and configurations. For
example, in certain-sized embodiments, the stem can be 13 mm in
diameter and 40 mm long and the keel can be 3.5 mm wide, 15 degrees
biased on the lateral side and 5 degrees biased on the medial side.
However, in other-sized embodiments (e.g., having larger or small
tray ML and/or AP dimensions, the step and keel can be larger,
smaller, or have a different configuration.
[0327] As mentioned above, in this example and in certain
embodiments, the tibial tray can receive a one-piece tibial insert
or two-piece tibial inserts. FIGS. 49A-C show aspects of an
embodiment of a tibial implant component that includes a tibial
tray and a one-piece insert. FIGS. 50A-C show aspects of an
embodiment of a tibial implant component that includes a tibial
tray and a one-piece insert. Alternatively, a two-piece tibial
insert can be used with a two-piece tibial tray. Alternatively, a
one-piece tibial insert can be used with a two-piece tibial
tray.
[0328] FIGS. 51A-C show exemplary steps for altering a blank tibial
tray and a blank tibial insert to each include a patient-adapted
profile, for example, to substantially match the profile of the
patient's resected tibial surface. In particular, as shown in FIG.
51A, standard cast tibial tray blanks and standard machined insert
blanks (e.g., having standard locking mechanisms) can be finished,
e.g., using CAM machining technology, to alter the blanks to
include one or more patient-adapted features. For example, as shown
in FIG. 51B, the blank tray and insert can be finish machined to
match or optimize one or more patient-specific features based on
patient-specific data. The patient-adapted features machined into
the blanks can include for example, a patient-specific perimeter
profile and/or one or more medial coronal, medial sagittal, lateral
coronal, lateral sagittal bone-facing insert curvatures. FIG. 51C
illustrates a finished tibial implant component that includes a
patient-specific perimeter profile and/or one or more
patient-adapted bone-facing insert curvatures.
Example 4
Tibial Implant Component Design
[0329] This example illustrates tibial implant component selection
and/or design to address tibial rotation. FIGS. 52A and B describe
exemplary techniques for determining tibial rotation for a patient
and FIG. 52C shows resulting alignment data for the second
technique.
[0330] Various tibial implant component features can optimized to
ensure proper tibial rotation. For example, FIG. 53 illustrates
exemplary stem design options for a tibial tray including using
stem and keel dimensions that increase or decrease depending on the
size of the tibial implant component (e.g., in the ML and/or AP
dimension). Moreover, cement pockets can be employed to enhance
stabilization upon implantation, In addition, patient-specific stem
and keel guide tools can be selected and/or designed so that the
prepared stem and keel holes in a patient's proximal tibia are
properly sized, which can minimize rotation (e.g., of a keel in a
keel hole that is too large).
[0331] Another tibial implant component that can be used to address
tibial rotation is selecting and/or designing a tibial tray
perimeter profile and/or a tibial insert perimeter profile that
minimizes overhang from the patient's bone (which may catch and
cause rotation) and, optionally, that maximizes seating of the
implant component on cortical bone. Accordingly, in certain
embodiments, the tibial tray perimeter profile and/or a tibial
insert perimeter profile is preoperatively selected and/or designed
to substantially match the perimeter profile of the patient's
resected tibial surface. FIGS. 54A and B show an approach for
identifying the patient's tibial implant perimeter profile based on
the depth and angle of the proximal tibial resection, which can
applied in the selection and/or design of the tibial tray perimeter
profile and/or the tibial insert perimeter profile. As shown in the
bottom image, the lines inside the perimeter of the cut surface
represent the perimeters of the various cuts in the top image taken
at various depths from the patient's tibial surface. FIGS. 55A and
B show the same approach as described for FIGS. 54A and B, but
applied to a different patient having a smaller tibia (e.g.,
smaller diameter and perimeter length).
[0332] Similarly, FIGS. 56A-D show four different exemplary tibial
implant profiles, for example, having different medial and lateral
condyle perimeter shapes that generally match various different
relative medial and lateral condyle perimeter dimensions. In
certain embodiments, a tibial tray and/or insert can be selected
(e.g., preoperatively or intraoperatively) from a collection or
library of implants for a particular patient (e.g., to best-match
the perimeter of the patient's cut tibial surface) and implanted
without further alteration to the perimeter profile. However, in
certain embodiments, these different tibial tray and/or insert
perimeter profiles can serve as blanks. For example, one of these
tibial tray and/or insert profiles can be selected preoperatively
from a library (e.g., an actual or virtual library) for a
particular patient to best-match the perimeter of the patient's cut
tibial surface. Then, the selected implant perimeter can be
designed or further altered based on patient-specific data, for
example, to substantially match the perimeter of the patient's cut
tibial surface.
[0333] As described in this example, various features of a tibial
implant component can be designed or altered based on
patient-specific data. For example, the tibial implant component
design or alterations can be made to maximize coverage and extend
to cortical margins; maximize medial compartment coverage; minimize
overhang from the medial compartment; avoid internal rotation of
tibial components to avoid patellar dislocation; and avoid
excessive external rotation to avoid overhang laterally and
impingement on the popliteus tendon.
Example 5
Bone Cuts Using a Femur-First Jig Set
[0334] This example describes methods and devices for performing a
series of bone cuts to receive a patient-specific implant.
Specifically, a set of jigs is designed in connection with the
design of a patient-specific implant component. The designed jigs
guide the surgeon in performing one or more patient-specific cuts
to the bone so that those cut bone surface(s) negatively-match the
patient-specific bone cuts of the implant component. The set of
jigs described in this example are designed for a femur-first cut
technique.
[0335] In a first step, shown in FIGS. 57A and B, a first femur jig
is used to establish peg holes and pin placements for a subsequent
jig used for a distal cut. In this example, the first jig is
designed to circumvent 3 mm of cartilage thickness. In a second
step, shown in FIGS. 58A and B, the distal cut is performed with a
second femur jig. In this example, the second jig is
patient-specific. However, in certain embodiments that apply a
traditional distal cut, a standard jig can be used. In a third
step, as shown in FIG. 59A, the anterior cut, the posterior cut,
and the chamfer cuts are performed with a third femur jig. In this
example, the jig includes slots that are 1.5 mm wide to allow for a
saw blade thickness. As shown in FIG. 59B, in certain embodiments,
for implant component designs having six or more inner, bone-facing
surfaces, for example, having one or two additional chamfer cuts,
the additional cuts can be performed using one or more additional
jigs. In this example, the additional jig is designed to
accommodate two steep additional chamfer cuts.
[0336] Next, the tibia is cut using one or more jigs designed to
make patient-specific cuts to the tibia. An exemplary tibial jig is
depicted in FIGS. 60A and B. A tibial alignment pin 16900 is used
to help properly orient the jig. The portion 16910 of the jig
inserted between the femur and tibia can have a variable thickness.
In certain embodiments, the tibial jig can be designed to
accommodate for composite thickness from the distal cut femur
16920. Alternatively or additionally, a balancing chip can be used
to address differences in the distance between the tibia and femur
surfaces. For example, in certain embodiments a tibia jig may be
designed to rest on 2 mm of cartilage, while a balancing chip is
designed to rest on the distal cut femur.
[0337] A balancing chip is shown in FIG. 61. If a varus deformity
of the knee is observed, virtual realignment can be addressed by
including added thickness to the balancing chip in the area that
would produce a leg in neutral alignment 17010. For a grossly
mal-aligned contra-lateral leg, correction can be per a surgeon's
order. The balancing chip can include a feature 17020 to attach it
to the tibia jig, and thereby allow for accurate distal placement
of the tibial cut while at the same time accommodating for
composite thickness. An exemplary balancing chip attached to a
tibia jig is shown in FIGS. 62A and B. To facilitate attachment,
the balancing chip handle 18000 matches the tibial slope designed
into the tibial cut and tibial implant. Preferably, the balancing
chip is designed to enter into the joint easily.
Example 6
Bone Cuts Using a Tibial-First Jig Set
[0338] This example describes methods and devices for performing a
series of bone cuts to receive a patient-specific implant.
Specifically, a set of jigs is designed in connection with the
design of a patient-specific implant component. The designed jigs
guide the surgeon in performing one or more patient-specific cuts
to the bone so that those cut bone surface(s) negatively-match the
patient-specific bone cuts of the implant component. The set of
jigs described in this example are designed for cuts to a femoral
implant component in a tibia-first cut technique.
[0339] In a first step, shown in FIG. 63, a first jig is used to
establish placement and alignment of femoral implant peg holes. In
the example, the placement is flexed 5 degrees with respect to the
sagittal femoral axis. In a second step, shown in FIG. 64, a second
jig is used to establish placement pins for the distal cut jig. The
second jig can have different thicknesses 17300 to accommodate
composite thickness from the cut tibial surface. In a third step,
as shown in FIG. 65, a distal cut jig is positioned based on the
placement established by the previous jig. The distal cut jig can
be patient-specific or standard. Lastly, as shown in FIG. 66,
remaining cuts are performed with a chamfer cut jig. In the
example, the anterior cut is not oblique.
INCORPORATION BY REFERENCE
[0340] The entire disclosure of each of the publications, patent
documents, and other references referred to herein is incorporated
herein by reference in its entirety for all purposes to the same
extent as if each individual source were individually denoted as
being incorporated by reference.
EQUIVALENTS
[0341] The invention may be embodied in other specific forms
without departing from the spirit or essential characteristics
thereof. The foregoing embodiments are therefore to be considered
in all respects illustrative rather than limiting on the invention
described herein. Scope of the invention is thus indicated by the
appended claims rather than by the foregoing description, and all
changes that come within the meaning and range of equivalency of
the claims are intended to be embraced therein.
* * * * *
References