US20220362026A1 - Orthopedic implants and methods - Google Patents
Orthopedic implants and methods Download PDFInfo
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- US20220362026A1 US20220362026A1 US17/878,112 US202217878112A US2022362026A1 US 20220362026 A1 US20220362026 A1 US 20220362026A1 US 202217878112 A US202217878112 A US 202217878112A US 2022362026 A1 US2022362026 A1 US 2022362026A1
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/30767—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/38—Joints for elbows or knees
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/3094—Designing or manufacturing processes
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/38—Joints for elbows or knees
- A61F2/3872—Meniscus for implantation between the natural bone surfaces
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/30721—Accessories
- A61F2/30734—Modular inserts, sleeves or augments, e.g. placed on proximal part of stem for fixation purposes or wedges for bridging a bone defect
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/38—Joints for elbows or knees
- A61F2/3859—Femoral components
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/38—Joints for elbows or knees
- A61F2/389—Tibial components
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/46—Special tools or methods for implanting or extracting artificial joints, accessories, bone grafts or substitutes, or particular adaptations therefor
- A61F2/4644—Preparation of bone graft, bone plugs or bone dowels, e.g. grinding or milling bone material
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2002/30001—Additional features of subject-matter classified in A61F2/28, A61F2/30 and subgroups thereof
- A61F2002/30003—Material related properties of the prosthesis or of a coating on the prosthesis
- A61F2002/30004—Material related properties of the prosthesis or of a coating on the prosthesis the prosthesis being made from materials having different values of a given property at different locations within the same prosthesis
- A61F2002/30011—Material related properties of the prosthesis or of a coating on the prosthesis the prosthesis being made from materials having different values of a given property at different locations within the same prosthesis differing in porosity
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2002/30001—Additional features of subject-matter classified in A61F2/28, A61F2/30 and subgroups thereof
- A61F2002/30316—The prosthesis having different structural features at different locations within the same prosthesis; Connections between prosthetic parts; Special structural features of bone or joint prostheses not otherwise provided for
- A61F2002/30535—Special structural features of bone or joint prostheses not otherwise provided for
- A61F2002/30604—Special structural features of bone or joint prostheses not otherwise provided for modular
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/30767—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
- A61F2002/3092—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth having an open-celled or open-pored structure
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/3094—Designing or manufacturing processes
- A61F2002/30968—Sintering
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2310/00—Prostheses classified in A61F2/28 or A61F2/30 - A61F2/44 being constructed from or coated with a particular material
- A61F2310/00005—The prosthesis being constructed from a particular material
- A61F2310/00011—Metals or alloys
- A61F2310/00023—Titanium or titanium-based alloys, e.g. Ti-Ni alloys
Abstract
A prosthesis for replacing a natural articular surface on a bone may have a joint facing side with an articular surface, a bone anchoring side with a bone engagement surface, and a bone engagement pad secured to at least part of the bone engagement surface. The bone engagement pad may have a transverse portion extending transverse to a length of the bone, and one or more protruding portions extending generally perpendicular to the transverse portion. The transverse portion may have a pad bone-facing surface with a first porosity level, and a pad joint-facing surface on an opposite side of the transverse portion from the pad bone-facing surface, with a second, lower porosity level. The bone engagement surface may be formed via a first manufacturing process selected from the group consisting of forging, milling, and casting. The bone engagement pad may be formed via an additive manufacturing process.
Description
- The present application is a continuation application of U.S. patent application Ser. No. 16/505,595 filed on Jul. 8, 2019, entitled ORTHOPEDIC IMPLANTS AND METHODS, which claims the benefit of U.S. Provisional Application No. 62/694,834, filed on Jul. 6, 2018 and entitled ORTHOPEDIC IMPLANTS AND METHODS. U.S. patent application Ser. No. 16/505,595 is also a continuation-in-part of U.S. patent application Ser. No. 15/622,688, filed on Jun. 14, 2017, entitled KNEE ARTHROPLASTY SYSTEMS AND METHODS, which issued on Feb. 2, 2021 as U.S. Pat. No. 10,905,436, which claims the benefit of U.S. Provisional Application No. 62/466,249, filed Mar. 2, 2017 and entitled COMPOSITE JOINT ARTHROPLASTY SYSTEMS AND METHODS. All of the foregoing are incorporated by reference as though set forth herein in their entirety.
- The present disclosure relates to surgical systems and methods. More specifically, the present disclosure relates to implants and related methods for joint arthroplasty.
- Joint arthroplasty procedures are surgical procedures in which one or more articulating surfaces of a joint are replaced with prosthetic articulating surfaces. Such procedures are becoming increasingly commonplace.
- For a successful joint arthroplasty, it is important that the joint implants remain in place and maintain the necessary wear characteristics. Further, it is desirable for the arthroplasty procedure to be carried out quickly and smoothly. Many existing arthroplasty implants and methods are time-consuming to implant, do not form a sufficient attachment to the underlying bone, or leave excessive wear debris.
- The various systems and methods of the present disclosure have been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available arthroplasty systems and methods. The systems and methods of the present disclosure may provide prostheses that enhance bone fixation, manufacturability, and overall outcomes for arthroplasty procedures.
- According to one embodiment, a knee implant may be provided, for replacing a natural articular surface on bone. The knee implant may have a joint facing side with an articular surface shaped to replace the natural articular surface, a bone anchoring side comprising a bone engagement surface, and a bone engagement pad secured to at least part of the bone engagement surface. The articular surface may be one of a natural tibial articular surface and a natural femoral articular surface. The bone engagement pad may have a transverse portion extending transverse to a length of the bone. The transverse portion may have a pad bone-facing surface with a first porosity level, and a pad joint-facing surface on an opposite side of the transverse portion from the pad bone-facing surface. The pad joint-facing surface may have a second porosity level lower than the first porosity level. The bone engagement pad may further have one or more protruding portions extending generally perpendicular to the transverse portion. The bone engagement surface may be formed via a first manufacturing process selected from the group consisting of forging, milling, and casting. The bone engagement pad may be formed via a second manufacturing process different from the first manufacturing process. The second manufacturing process may be an additive manufacturing process.
- The bone engagement pad may extend generally transverse to a length of the bone, and may have a thickness, parallel to the length, that is substantially uniform. The thickness may be within the range of 0.5 mm to 1.5 mm.
- The bone engagement surface may have a bone engagement feature extending through an aperture formed in the transverse portion. The one or more protruding portions may extend from one or more edges of the aperture, alongside one or more surfaces of the bone engagement feature.
- According to one embodiment, a prosthesis for replacing a natural articular surface on bone may have a joint facing side with an articular surface, a bone anchoring side with a bone engagement surface, and a bone engagement pad secured to at least part of the bone engagement surface. The bone engagement pad may have a pad bone-facing surface with a first porosity level, and a pad joint-facing surface with a second porosity level lower than the first porosity level.
- The bone engagement surface may be formed via a first manufacturing process. The bone engagement pad may be formed via a second manufacturing process different from the first manufacturing process.
- The first manufacturing process may be selected from the group consisting of forging, milling, and casting. The second manufacturing process may be an additive manufacturing process.
- The bone engagement pad may have a thickness within the range of 0.5 mm to 1.5 mm.
- The bone engagement pad may have a transverse portion that extends generally transverse to a length of the bone. The pad bone-facing surface and the pad joint-facing surface may be on opposite sides of the bone engagement pad. The transverse portion may have a thickness, parallel to the length, that is substantially uniform.
- The bone engagement pad may have a transverse portion extending transverse to a length of the bone. The pad bone-facing surface and the pad joint-facing surface may be on opposite sides of the transverse portion. The bone engagement pad may further have one or more protruding portions extending generally perpendicular to the transverse portion.
- The bone engagement surface may have a bone engagement feature extending through an aperture formed in the transverse portion. The one or more protruding portions may extend from one or more edges of the aperture, alongside one or more surfaces of the bone engagement feature.
- The bone engagement pad may have a transverse portion that extends generally transverse to a length of the bone. The pad bone-facing surface and the pad joint-facing surface may be on opposite sides of the bone engagement pad. The transverse portion may have a porosity gradient by which porosity of the transverse portion gradually increases toward the pad bone-facing surface.
- The bone engagement pad may have a transverse portion that extends generally transverse to a length of the bone. The pad bone-facing surface and the pad joint-facing surface may be on opposite sides of the bone engagement pad. The transverse portion may have a low-porosity layer proximate the pad joint-facing surface, by which a porosity of the transverse portion abruptly increases toward the pad bone-facing surface.
- The prosthesis may be a knee implant. The articular surface may be shaped to replace the natural articular surface. The natural articular surface may be one of a natural tibial surface and a natural femoral articular surface.
- According to one embodiment, a prosthesis for replacing a natural articular surface on bone may have a joint facing side with the articular surface, a bone anchoring side with a bone engagement surface, and a bone engagement pad secured to at least part of the bone engagement surface. The bone engagement pad may have a transverse portion extending transverse to a length of the bone, and one or more protruding portions extending generally perpendicular to the transverse portion.
- The bone engagement surface may be formed via a first manufacturing process, and the bone engagement pad may be formed via a second manufacturing process different from the first manufacturing process.
- The first manufacturing process may be selected from the group consisting of forging, milling, and casting. The second manufacturing process may be an additive manufacturing process.
- The bone engagement pad may have a thickness within the range of 0.5 mm to 1.5 mm.
- The transverse portion may extend generally transverse to a length of the bone, and may have a thickness, parallel to the length, that is substantially uniform.
- The bone engagement surface may have a bone engagement feature extending through an aperture formed in the transverse portion. The one or more protruding portions may extend from one or more edges of the aperture, alongside one or more surfaces of the bone engagement feature.
- The prosthesis may be a knee implant. The articular surface may be shaped to replace the natural articular surface. The natural articular surface may be one of a natural tibial surface and a natural femoral articular surface.
- Exemplary embodiments of the disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only exemplary embodiments and are, therefore, not to be considered limiting of the scope of the appended claims, the exemplary embodiments of the present disclosure will be described with additional specificity and detail through use of the accompanying drawings in which:
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FIG. 1 is a perspective view of a knee arthroplasty system according to one embodiment. -
FIGS. 2A through 2F are left, posterior, right, anterior, cephalad, and caudal views, respectively, of the femoral prosthesis of the knee arthroplasty system ofFIG. 1 . -
FIG. 3 is an exploded, perspective view of the femoral prosthesis of the knee arthroplasty system ofFIG. 1 . -
FIG. 4 is an exploded, perspective view, from a different viewpoint, of the femoral prosthesis of the knee arthroplasty system ofFIG. 1 . -
FIGS. 5A through 5F are left, posterior, right, anterior, cephalad, and caudal views, respectively, of the tibial prosthesis of the knee arthroplasty system ofFIG. 1 . -
FIG. 6 is an exploded, perspective view of the tibial prosthesis of the knee arthroplasty system ofFIG. 1 . -
FIG. 7 is an exploded, perspective view, from a different viewpoint, of the tibial prosthesis of the knee arthroplasty system ofFIG. 1 . -
FIGS. 8A and 8B are exploded and fully-assembled perspective views, respectively, of the tibial prosthesis ofFIG. 1 , with an optional keel. -
FIG. 9 is a perspective view of a tibial bone anchoring component of a tibial prosthesis of a system according to one alternative embodiment. -
FIG. 10 is a perspective view, from a different viewpoint, of the tibial bone anchoring component ofFIG. 9 . - Exemplary embodiments of the disclosure will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the disclosure, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the apparatus, system, and method, as represented in
FIGS. 1 through 10 , is not intended to limit the scope of the claims, as claimed, but is merely representative exemplary of exemplary embodiments. - The phrases “connected to,” “coupled to” and “in communication with” refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interaction. Two components may be functionally coupled to each other even though they are not in direct contact with each other. The term “abutting” refers to items that are in direct physical contact with each other, although the items may not necessarily be attached together. The phrase “fluid communication” refers to two features that are connected such that a fluid within one feature is able to pass into the other feature.
- The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.
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FIG. 1 is a perspective view of a knee arthroplasty system, orsystem 100, according to one embodiment. Thesystem 100 may be designed to replace the natural articulating surfaces of a knee joint, and may thus have afemoral prosthesis 102 and atibial prosthesis 104. In some embodiments, thesystem 100 may be designed to replace only the femoral or tibial articulating surfaces, and may thus include only thefemoral prosthesis 102 or thetibial prosthesis 104. - The
femoral prosthesis 102 and thetibial prosthesis 104 may each have an articulating component with replacement articulating surfaces, and a bone anchoring component secured to the articulating component to secure the articulating component to the underlying bone. Specifically, thefemoral prosthesis 102 may have a femoral articulatingcomponent 110 and a femoralbone anchoring component 112. Similarly, thetibial prosthesis 104 may have a tibial articulatingcomponent 114 and a tibialbone anchoring component 116. Thetibial prosthesis 104 may also have atibial fastener 118. - Each of the aforementioned articulating components and bone anchoring components may have a joint-facing side and a bone-facing side. Thus, the
femoral articulating component 110 may have a joint-facingside 120 and a bone-facingside 122, and the femoralbone anchoring component 112 may have a joint-facingside 124 and a bone-facingside 126. Similarly, thetibial articulating component 114 may have a joint-facingside 130 and a bone-facingside 132, and the tibialbone anchoring component 116 may have a joint-facingside 134 and a bone-facingside 136. - The bone-facing
side 122 of the femoral articulatingcomponent 110 may have a shape that matches the shape of the joint-facingside 124 of the femoralbone anchoring component 112, and may be secured to the joint-facingside 124 of the femoralbone anchoring component 112 in a manner that will be set forth in greater detail subsequently. Similarly, the bone-facingside 132 of thetibial articulating component 114 may have a shape that matches the shape of the joint-facingside 134 of the tibialbone anchoring component 116, and may be secured to the joint-facingside 134 of the tibialbone anchoring component 116 in a manner that will be set forth in greater detail subsequently. - The joint-facing
side 120 of the femoral articulatingcomponent 110 may have a first articulatingsurface 140 and a second articulatingsurface 142, which are shaped to mimic the shapes of the natural articulating surfaces on the end of the femur. The shapes depicted inFIG. 1 are merely exemplary; according to alternative embodiments, any articulating surface shape known in the art may be used. - The bone-facing
side 126 of the femoralbone anchoring component 112 may have a plurality of features that enhance engagement of the femoralbone anchoring component 112 with the underlying bone. For example, the bone-facingside 126 of the femoralbone anchoring component 112 may have a pair ofposts 150, a firstfemoral anchoring member 152, a secondfemoral anchoring member 154, and a thirdfemoral anchoring member 156, which protrude from various surfaces of the bone-facingside 126 of the femoralbone anchoring component 112, as will be set forth in greater detail subsequently. - The first
femoral anchoring member 152, the secondfemoral anchoring member 154, and the thirdfemoral anchoring member 156 may be connected to each other and to the remainder of the bone-facingside 126 by aprimary femoral web 160, a firstfemoral web 162, and a secondfemoral web 164. Specifically, the secondfemoral anchoring member 154 may be connected to the firstfemoral anchoring member 152 with the firstfemoral web 162, and the thirdfemoral anchoring member 156 may be connected to the firstfemoral anchoring member 152 with the secondfemoral web 164. The firstfemoral anchoring member 152 may have atip 170 with a tapered shape. The firstfemoral anchoring member 152, the firstfemoral web 162, and the secondfemoral anchoring member 154 may cooperate to define afirst bevel 172. Similarly, the firstfemoral anchoring member 152, the secondfemoral web 164, and the thirdfemoral anchoring member 156 may cooperate to define asecond bevel 174. - The joint-facing
side 130 of thetibial articulating component 114 may also have a first articulatingsurface 180 and a second articulatingsurface 182. After implantation of thefemoral prosthesis 102 and thetibial prosthesis 104, the first articulatingsurface 140 may articulate with the first articulatingsurface 180, and the second articulatingsurface 142 may articulate with the second articulatingsurface 182. The articulation of the femoral articulatingcomponent 110 with thetibial articulating component 114 may be designed to mimic that of the natural knee joint. - The bone-facing
side 136 of the tibialbone anchoring component 116 may have a plurality ofposts 190 that protrude into the bone from the remainder of the bone-facingside 136. Further, the bone-facingside 136 of the tibialbone anchoring component 116 may have acentral post 192 that also protrudes from the remainder of the bone-facingside 136. Thecentral post 192 may further be connected to the remainder of the bone-facingside 136 by afirst tibial web 194 and asecond tibial web 196. -
FIGS. 2A through 2F are left, posterior, right, anterior, cephalad, and caudal views, respectively, of thefemoral prosthesis 102 of thesystem 100 ofFIG. 1 . These views further depict the various features described in connection withFIG. 1 . -
FIG. 3 is an exploded, perspective view of thefemoral prosthesis 102 of thesystem 100 ofFIG. 1 . The femoral articulatingcomponent 110 and the femoralbone anchoring component 112 may optionally be manufactured separately from each other. Accordingly, different manufacturing processes may be used to form thefemoral articulating component 110 and the femoralbone anchoring component 112. This may advantageously enable the use of materials and/or processes for each of the femoral articulatingcomponent 110 and the femoralbone anchoring component 112 that are best suited for the role to be performed. - For example, the
femoral articulating component 110 may be designed to endure cyclical loading in friction and compression. Accordingly, high-strength and/or low-wear materials and surface properties may be desired. Accordingly, thefemoral articulating component 110 may be made of a relatively hard material such as an alloy of Cobalt Chromium (“Cobalt Chrome,”). Specifically, thefemoral articulating component 110 may be made of an alloy of Cobalt Chromium Molybdenum (CoCrMo). A manufacturing process such as casting may be used. In some embodiments, the first articulatingsurface 140 and the second articulatingsurface 142 may be specially processed in a manner that increases their hardness and/or wear resistance. - Conversely, the femoral
bone anchoring component 112 may be designed to provide high-strength fixation of the femoral articulatingcomponent 110 to the underlying bone. It may be desirable for the femoralbone anchoring component 112 to have a porous structure that encourages bone in-growth. Accordingly, the femoralbone anchoring component 112 may be formed of a metal such as Titanium, or specifically, direct metal laser sintered (“DMLS”) Titanium. The femoralbone anchoring component 112 may be formed via an additive manufacturing method such as 3D printing. Such manufacturing methods may facilitate the creation of a porous structure, particularly on the bone-facingside 126 of the femoralbone anchoring component 112. - In some embodiments, the femoral
bone anchoring component 112 may be made such that the porosity varies in a gradient through the thickness of the femoralbone anchoring component 112. Thus, the bone-facingside 126 of the femoralbone anchoring component 112 may be made more porous to facilitate bone in-growth, while the joint-facingside 124 of the femoralbone anchoring component 112 may be made less porous to enhance attachment of the joint-facingside 124 to the bone-facingside 122 of the femoral articulatingcomponent 110. In some embodiments, the joint-facingside 124 may be made substantially solid (i.e., nonporous) to enhance adhesion to the bone-facingside 122 of the femoral articulatingcomponent 110, while the bone-facingside 126 may be highly porous. - As shown, the bone-facing
side 122 of the femoral articulatingcomponent 110 may have ananterior portion 300, aposterior portion 302, and adistal portion 304. Upon implantation of the femoral articulatingcomponent 110, theanterior portion 300 may be located on the anterior side of the knee, theposterior portion 302 may be located on the posterior side of the knee, and thedistal portion 304 may be located at the distal end of the femur. Thedistal portion 304 may be divided into three faces: an anterior-distal face 306, a posterior-distal face 308, and adistal face 310. The anterior-distal face 306 may reside between theanterior portion 300 and thedistal face 310, and the posterior-distal face 308 may be reside between theposterior portion 302 and thedistal face 310. - As shown, the
posts 150 may protrude from thedistal face 310. The firstfemoral anchoring member 152, the secondfemoral anchoring member 154, and the thirdfemoral anchoring member 156 may protrude from the posterior-distal face 308. Theprimary femoral web 160 may connect the firstfemoral anchoring member 152 to theanterior portion 300. The firstfemoral web 162 may connect the firstfemoral anchoring member 152 to the secondfemoral anchoring member 154 and to the anterior-distal face 306. Similarly, the secondfemoral web 164 may connect the firstfemoral anchoring member 152 to the thirdfemoral anchoring member 156 and the anterior-distal face 306. - The first
femoral anchoring member 152, the secondfemoral anchoring member 154, the thirdfemoral anchoring member 156, theprimary femoral web 160, the firstfemoral web 162, and the secondfemoral web 164 may cooperate to enhance engagement of the bone-facingside 126 of the femoralbone anchoring component 112 with the underlying bone. Specifically, these features may add to the surface area of the bone-facingside 126 in contact with the bone, providing a stronger bond with the bone via bone in-growth and/or application of bone cement. The position of these features on the anterior-distal face 306, proximate theanterior portion 300 may enable them to penetrate a relatively dense, sturdy bone mass proximate the distal end of the femur. Specifically, the bone that underlies the natural femoral articular surfaces to be replaced may, due to mechanical loading, have a denser structure and/or a thicker layer of cortical bone. Accordingly, the firstfemoral anchoring member 152, the secondfemoral anchoring member 154, the thirdfemoral anchoring member 156, theprimary femoral web 160, the firstfemoral web 162, and the secondfemoral web 164 may be optimally positioned for anchorage in strong, relatively dense bone that is likely to provide solid anchorage for the femoralbone anchoring component 112. - The
posts 150, the firstfemoral anchoring member 152, the secondfemoral anchoring member 154, the thirdfemoral anchoring member 156, theprimary femoral web 160, the firstfemoral web 162, and the secondfemoral web 164 may all protrude in a cephalad direction so that these features can penetrate the bone, helping to anchor the femoral articulatingcomponent 110 on the distal end of the femur (not shown). These features may also be shaped to facilitate entry into and/or compaction of the bone. - Specifically, the
tip 170, thefirst bevel 172, and thesecond bevel 174 may help to spread bone out of the path of the firstfemoral anchoring member 152, the secondfemoral anchoring member 154, the thirdfemoral anchoring member 156, the firstfemoral web 162, and the secondfemoral web 164 as these features are pressed into the bone, thereby easing placement of thefemoral prosthesis 102 on the distal end of the femur. Further, due to the presence of thetip 170, thefirst bevel 172, and/or thesecond bevel 174, the bone surrounding these features in their implanted state may be compacted and/or strengthened. - As also shown in
FIG. 3 , the bone-facingside 122 of the femoral articulatingcomponent 110 may have aperipheral ridge 320 that defines aninterior recess 322. The shape of theinterior recess 322 may closely match that of the joint-facingside 124 of the femoralbone anchoring component 112 so that the joint-facingside 124 of the femoralbone anchoring component 112 can be secured to theinterior recess 322. When the femoralbone anchoring component 112 and the femoral articulatingcomponent 110 are assembled together, the bone-facingside 126 of the femoralbone anchoring component 112 may lie substantially flush with theperipheral ridge 320 of the bone-facingside 122 of the femoral articulatingcomponent 110. - In some embodiments, the bone-facing
side 126 of the femoralbone anchoring component 112 may be treated to enhance porosity and/or bone in-growth. In some examples, the bone-facingside 126 of the femoralbone anchoring component 112 may be processed via a process such as anodizing to form Titanium Dioxide nanotubes on the bone-facingside 126. Specifically, the bone-facingside 126 may be anodized in a Fluoride electrolyte, as set forth in U.S. application Ser. No. 11/913,062, filed Jun. 10, 2008 and entitled “Compositions Comprising Nanostructures for Cell, Tissue and Artificial Organ Growth, and Methods for Making and Using Same, now U.S. Pat. No. 8,414,908, which is incorporated by reference as though set forth herein in its entirety. The result may be the formation of asurface layer 330 of Titanium Dioxide nanotubes on the bone-facingside 126. - The femoral articulating
component 110 and the femoralbone anchoring component 112 may be secured together in a variety of ways. Such ways may include, but are not limited to, welding, brazing, press fitting, and the like. According to some embodiments, asubstance 340 may be applied to one or both of the surfaces to be secured together via chemical and/or adhesive bonding. Any of the methods mentioned above may be used to secure thetibial articulating component 114 to the tibialbone anchoring component 116. - In addition to or in the alternative to the foregoing attachment methods, the methods disclosed in U.S. application Ser. No. 10/455,846, filed Jun. 6, 2003 and entitled “METHOD FOR ATTACHING A POROUS METAL LAYER TO A METAL SUBSTRATE,” now U.S. Pat. No. 6,945,448, may be used. This application is incorporated as though set forth herein in its entirety.
- Optionally, the surfaces to be bonded together may have features that facilitate and/or enhance the results of the bonding process. For example, the bone-facing
side 122 of the femoral articulatingcomponent 110 may have features that cooperate with corresponding features (shown inFIG. 4 ) on the joint-facingside 124 of the femoralbone anchoring component 112 to help align the femoral articulatingcomponent 110 with the femoralbone anchoring component 112 and/or add mechanical fastening to the bonding described above. These features of the bone-facingside 122 may include a pair ofpost bosses 350, a first femoral anchoringmember boss 352, a second femoral anchoringmember boss 354, and a third femoral anchoringmember boss 356. -
FIG. 4 is an exploded, perspective view, from a different viewpoint, of thefemoral prosthesis 102 of thesystem 100 ofFIG. 1 . The joint-facingside 124 of the femoralbone anchoring component 112 and the joint-facingside 120 of the femoral articulatingcomponent 110 are more clearly visible. - As shown, the joint-facing
side 124 of the femoralbone anchoring component 112 may have features that cooperate with thepost bosses 350, the first femoral anchoringmember boss 352, the second femoral anchoringmember boss 354, and the third femoral anchoringmember boss 356 of the bone-facingside 122 of the femoral articulatingcomponent 110 depicted inFIG. 3 . These features may include post bores 450, a first femoral anchoring member bore 452, a second femoral anchoring member bore 454, and a third femoral anchoring member bore 456. Each of the post bores 450 may reside in the interior of one of theposts 150. Similarly, the first femoral anchoring member bore 452, the second femoral anchoring member bore 454, and the third femoral anchoring member bore 456 may reside in the interiors of the firstfemoral anchoring member 152, the secondfemoral anchoring member 154, and the thirdfemoral anchoring member 156, respectively. - The post bores 450 may be shaped to receive the
post bosses 350. Similarly, the first femoral anchoring member bore 452, the second femoral anchoring member bore 454, and the third femoral anchoring member bore 456 may be shaped to receive the first femoral anchoringmember boss 352, the second femoral anchoringmember boss 354, and the third femoral anchoringmember boss 356, respectively. If desired, thepost bosses 350, the first femoral anchoringmember boss 352, the second femoral anchoringmember boss 354, and/or the third femoral anchoringmember boss 356 may each be tapered to facilitate insertion into the post bores 450, the first femoral anchoring member bore 452, the second femoral anchoring member bore 454, and/or the third femoral anchoring member bore 456, respectively. - The features of the bone-facing
side 122 may be received by these features of the joint-facingside 124 with some interference, which may cooperate with the bond described above to enhance attachment of the bone-facingside 122 to the joint-facingside 124. When the femoral articulatingcomponent 110 and the femoralbone anchoring component 112 are compressed together, as set forth above, the compression may be sufficient to urge thepost bosses 350, the first femoral anchoringmember boss 352, the second femoral anchoringmember boss 354, and the third femoral anchoringmember boss 356 into the post bores 450, the first femoral anchoring member bore 452, the second femoral anchoring member bore 454, and the third femoral anchoring member bore 456, respectively. - Additionally or alternatively, heat applied to the femoral articulating
component 110 and/or the femoralbone anchoring component 112 may cause thermal expansion that eases insertion of thepost bosses 350, the first femoral anchoringmember boss 352, the second femoral anchoringmember boss 354, and the third femoral anchoringmember boss 356 into the post bores 450, the first femoral anchoring member bore 452, the second femoral anchoring member bore 454, and the third femoral anchoring member bore 456, respectively. The femoral articulatingcomponent 110 may be made such that the femoral articulatingcomponent 110 has higher thermal expansion than the femoralbone anchoring component 112. Thus, after insertion of the bosses into the bores, thefemoral articulating component 110 and the femoralbone anchoring component 112 may be cooled, allowing the bores to tighten around the bosses. - In alternative embodiments, other positive and/or negative features may be used. Further, if desired, the positive features may be on the joint-facing
side 124 of the femoralbone anchoring component 112, and the negative features may be on the bone-facingside 122 of the femoral articulatingcomponent 110. -
FIGS. 5A through 5F are left, posterior, right, anterior, cephalad, and caudal views, respectively, of thetibial prosthesis 104 of thesystem 100 ofFIG. 1 . These views further depict the various features described in connection withFIG. 1 . -
FIG. 6 is an exploded, perspective view of thetibial prosthesis 104 of thesystem 100 ofFIG. 1 . As with thefemoral prosthesis 102, thetibial articulating component 114 and the tibialbone anchoring component 116 may optionally be manufactured separately from each other. Accordingly, different manufacturing processes may be used to form thetibial articulating component 114 and the tibialbone anchoring component 116. For example, thetibial articulating component 114 may be formed via casting, and the tibialbone anchoring component 116 may be formed via additive manufacturing such as 3D printing. - Like the femoral articulating
component 110, thetibial articulating component 114 may be made of Cobalt Chromium, or Cobalt Chromium Molybdenum. Similarly, like the femoralbone anchoring component 112, the tibialbone anchoring component 116 may be made of DMLS Titanium. A gradient of porosities may be present in the tibialbone anchoring component 116, with greater porosity on the bone-facingside 136, and lesser porosity on the joint-facingside 134. If desired, the joint-facingside 134 may be made substantially nonporous to enhance adhesion to thetibial articulating component 114, and the bone-facingside 136 may have a high level of porosity to promote bone in-growth. - As shown, the bone-facing
side 132 of thetibial articulating component 114 may have acentral plateau 600 that extends toward the tibialbone anchoring component 116, and aperipheral recess 602 that encircles thecentral plateau 600 and is recessed from the tibialbone anchoring component 116. The joint-facingside 134 of the tibialbone anchoring component 116 may have a shape that is complementary to that of the bone-facingside 132 of thetibial articulating component 114. Specifically, the joint-facingside 134 may have aperipheral ridge 610 that encircles aninterior recess 612. Analcove 614 may extend into theperipheral ridge 610, from the space above theinterior recess 612. When the tibial articulatingcomponent 114 and the tibialbone anchoring component 116 are assembled together, thecentral plateau 600 may be received within theinterior recess 612, and theperipheral ridge 610 may engage thecentral plateau 600. - In some embodiments, the
tibial articulating component 114 and the tibialbone anchoring component 116 may be secured together by the same bonding process described above in connection with the femoral articulatingcomponent 110 and the femoralbone anchoring component 112 of thefemoral prosthesis 102, or with a modified version of such a bonding process. Thus,FIG. 6 depicts the exemplary application of thesubstance 340, which may be a paste or the like, to theinterior recess 612 of the joint-facingside 134 of the tibialbone anchoring component 116. -
FIG. 6 also depicts thetibial fastener 118 in greater detail. Thetibial fastener 118 may have anenlarged head 620 and ashank 622 withthreads 624 thereon that enable thetibial fastener 118 to threadably engage the tibialbone anchoring component 116, as will be discussed in greater detail subsequently. -
FIG. 7 is an exploded, perspective view, from a different viewpoint, of thetibial prosthesis 104 of thesystem 100 ofFIG. 1 . As shown, thecentral plateau 600 of the bone-facingside 132 of thetibial articulating component 114 may have alip 700 that protrudes anteriorly. When the tibial articulatingcomponent 114 and the tibialbone anchoring component 116 are assembled, thelip 700 may protrude into thealcove 614 depicted inFIG. 6 . Engagement of thelip 700 and thealcove 614 may further help to hold the anterior portions of thetibial articulating component 114 and the tibialbone anchoring component 116 together. -
FIG. 7 also depicts the bone-facingside 136 of the tibialbone anchoring component 116 in greater detail. Four of theposts 190 may be present on the bone-facingside 136, and may help enhance the level of engagement of the bone-facingside 136 with the underlying bone, and in particular, with the cortical bone at the proximal end of the tibia. Thecentral post 192, thefirst tibial web 194, and thesecond tibial web 196 may each extend distally from the remainder of the bone-facingside 136, and may cooperate to provide a greater surface area in engagement with the underlying bone. Thus, thecentral post 192, thefirst tibial web 194, and thesecond tibial web 196 may - As shown, the
central post 192, thefirst tibial web 194, and thesecond tibial web 196 may each have a crenellated shape, withcrenellations 710 shown inFIG. 7 . Thecrenellations 710 may further increase the surface area of the bone-facingside 136 in contact with the bone of the tibia, thereby further enhancing the potential for bone cement bonding and/or bone in-growth between the tibia and the bone-facingside 136. Further, if desired, the tibialbone anchoring component 116 may be processed as described above in the description of the femoralbone anchoring component 112, such that the tibialbone anchoring component 116 has asurface layer 330 formed of Titanium Dioxide nanotubes. Such asurface layer 330 may further enhance bone in-growth to further secure the bone-facingside 136 to the bone of the tibia. - As mentioned previously, the
tibial articulating component 114 and the tibialbone anchoring component 116 may be secured together through the use of any of a variety of methods. Some of these are mentioned above in the description of assembly of the femoral articulatingcomponent 110 and the femoralbone anchoring component 112. Again, asubstance 340 may optionally be applied to the bone-facingside 132 of thetibial articulating component 114 and/or to the joint-facingside 134 of the tibialbone anchoring component 116 to facilitate attachment via chemical and/or adhesive bonding. - As further shown in
FIG. 7 , thecentral post 192 may have abore 712 that receives thetibial fastener 118. Thebore 712 may have interior threads (not shown) that receive thethreads 624 of theshank 622 of thetibial fastener 118. Thetibial fastener 118 may serve to seal thebore 712 and reduce the chance of having toxins or microbes enter thebore 712 during implantation. Theenlarged head 620 of thetibial fastener 118 may have asocket 720 with a hexagonal or other shape that can receive the shaped distal end of a removal tool (not shown), such as a hex key, to facilitate rotation of thetibial fastener 118 to remove thetibial fastener 118 from thebore 712. -
FIGS. 8A and 8B are exploded and fully-assembled perspective views, respectively, of thetibial prosthesis 104 ofFIG. 1 , with an optional anchoring member in the form of akeel 800. Thekeel 800 may have aproximal end 802 and adistal end 804, with ashank 806 extending between theproximal end 802 and thedistal end 804. Theproximal end 802 may be shaped to be inserted into thebore 712 of thecentral post 192 of the tibialbone anchoring component 116 of thetibial prosthesis 104, as shown inFIG. 8B . - Specifically, the
proximal end 802 may have a generally frustoconical shape. The walls of thebore 712 may define a similar, complementary shape. If desired, theproximal end 802 may be press-fitted into thebore 712. Additionally or alternatively, theproximal end 802 may havethreads 810, which may engage corresponding threads (not shown) within thebore 712. In the alternative, thethreads 810 may be used to receive another fastener (not shown), which may, in turn, be secured within thebore 712. - The
tibial prosthesis 104 may be provided to the surgeon with thetibial fastener 118 in place within thebore 712. The surgeon may remove thetibial fastener 118 from thebore 712, and may insert and secure theproximal end 802 of thekeel 800 within thebore 712. The intramedullary space of the tibia may be reamed and/or otherwise prepared to receive thekeel 800 prior to attachment of thetibial prosthesis 104, with thekeel 800, to the tibia. - The
keel 800 may help provide additional bone engagement and/or rotational stability for thetibial prosthesis 104. Thus, theshank 806 may optionally have a plurality ofsplines 812 that protrude outward from the axis of theshank 806 to engage the surrounding bone. Thesplines 812 may increase the surface area of thekeel 800 in contact with the bone to increase bone engagement, and may further resist rotation of thekeel 800 within the bone. If desired, some or all of thekeel 800 may have a porous structure that facilitates bone in-growth and/or bone cement engagement. Additionally or alternatively, thekeel 800 may be anodized to form asurface layer 330, as set forth in connection with the femoralbone anchoring component 112 and the tibialbone anchoring component 116. -
FIG. 9 is a perspective view of a tibialbone anchoring component 916 of a tibial prosthesis of a system according to one alternative embodiment. The tibialbone anchoring component 916 may have a joint-facingside 134 and a bone-facingside 936. The joint-facingside 934 may be identical or similar to the joint-facingside 134 of the tibialbone anchoring component 116 ofFIGS. 1 through 5 . Like the tibialbone anchoring component 116 ofFIGS. 1 through 5 , the tibialbone anchoring component 916 ofFIG. 9 may be designed to be secured to an articulating component like thetibial articulating component 114 ofFIGS. 1 through 5 . In the alternative, the tibialbone anchoring component 916 may be designed as a standalone tibial implant, with bone apposition surfaces and articulating surfaces, such as the first articulatingsurface 180 and the second articulatingsurface 182 of thetibial articulating component 114, which may be formed directly on the superior surface (not shown) of the tibialbone anchoring component 916, if desired. - Like the bone-facing
side 136 of the tibialbone anchoring component 116, the bone-facingside 936 of the tibialbone anchoring component 916 may have a plurality ofposts 990 that protrude into the bone from atransverse surface 992 oriented generally transverse to the tibia. Optionally, other bone anchoring features, as known in the art, may be used in addition to or in the alternative to theposts 990. - For example, in addition to the
posts 990, the bone-facingside 936 of the tibialbone anchoring component 916 may also havestem receiver 994 positioned proximate the center of the bone-facingside 936. Thestem receiver 994 may have anaperture 996 that can receive an anchoring element such as an intramedullary stem (not shown). Such an intramedullary stem may have a proximal end that can be inserted into and secured within theaperture 996, and a distal end that can be inserted into the intramedullary canal of the tibia to provide supplemental fixation of the tibialbone anchoring component 916 relative to the tibia. Thestem receiver 994 may have a generally tubular shape oriented generally parallel to the tibia, and perpendicular to thetransverse surface 992. - The tibial
bone anchoring component 916 may further haveflanges 998 that connect the side walls of thestem receiver 994 to thetransverse surface 992. Theflanges 998 may have crenellated shapes as shown, that present greater surface area to the interior of the tibia, thereby enhancing fixation of the tibial bone anchoring component to the tibia. - In some embodiments, the tibial
bone anchoring component 916 may not, in its entirety, be made via additive manufacturing. Rather, the majority of the tibialbone anchoring component 916 may be generally made via more traditional methods such as casting, milling, and forging. The tibialbone anchoring component 916 may have abone engagement pad 970 that is made separately from the remainder of the tibialbone anchoring component 916, and has a highly textured and/or porous shape that facilitate bone in-growth. In some embodiments, thebone engagement pad 970 may have nano-textured surfaces with features such as titanium nanotubes that provide enhanced bone engagement. - As shown, the
bone engagement pad 970 may be secured to certain bone-facing surfaces of the main body of the tibialbone anchoring component 916. For example, thebone engagement pad 970 may include atransverse portion 982 that covers substantially the entirety of thetransverse surface 992, postportions 980 that cover the proximal portions of theposts 990, andflange portions 988 that cover the proximal portions of theflanges 998. Theposts 990, stemreceiver 994, andflanges 998 may extend throughapertures 999 formed in thetransverse portion 982. Thepost portions 980 and theflange portions 988 may protrude from thetransverse portion 982 and may connect to thetransverse portion 982 at the peripheries of theapertures 999 through which theposts 990 andflanges 998 pass, respectively. - The
post portions 980 and theflange portions 988 may be called “protruding portions,” because they protrude from thetransverse portion 982, and thence, from the underlyingtransverse surface 992. The protruding portions may also extend generally perpendicular to thetransverse portion 982. “Generally perpendicular” means that the protruding portions extend along the adjacent surfaces (i.e., surfaces that are adjacent to the transverse surface) of typical bone engagement features (such as spikes, posts, keels, teeth, and/or the like) that protrude away from the transverse surface of the implant. Many such bone engagement features will have adjacent surfaces that extend perpendicular to the transverse surface, just as theposts 990, thestem receiver 994, and theflanges 998 extend perpendicular to thetransverse surface 992. However, some such bone engagement features may have adjacent surfaces that are not precisely perpendicular to the transverse surface. For example, a bone anchoring feature may have a tapered (for example, conical or pyramidal) shape that causes its adjacent surface(s) extend from the transverse surface at an angle of less than 90°. A bone engagement pad may have a “protruding portion” that extends along such a surface, even though it is not precisely perpendicular to thetransverse portion 982. - The
bone engagement pad 970 may be made via additive manufacturing through the use of any of the methods mentioned previously. In the alternative, different methods may be used to manufacture thebone engagement pad 970 with the desired porous and/or textured shape. - In some embodiments, the
bone engagement pad 970 may be relatively thin compared to the main body of the tibialbone anchoring component 916. For example, thebone engagement pad 970 may have a thickness within the range of 0.1 mm to 5 mm. More precisely, thebone engagement pad 970 may have a thickness within the range of 0.2 mm to 2 mm. Yet more precisely, thebone engagement pad 970 may have a thickness within the range of 0.5 mm to 1.5 mm. Still more precisely, thebone engagement pad 970 may have a thickness within the range of 0.8 mm to 1.2 mm. Yet more precisely, thebone engagement pad 970 may have a thickness of about 1 mm. - The
bone engagement pad 970 may be formed as a single piece, such that thepost portions 980, thetransverse portion 982, and theflange portions 988 are all formed as a single piece with each other. In the alternative, thepost portions 980, thetransverse portion 982, and theflange portions 988 may be formed separately and secured together and/or simply secured to the main body of the tibialbone anchoring component 916. - The
bone engagement pad 970 may be formed separately from the main body of the tibialbone anchoring component 916. Alternatively, thebone engagement pad 970 may be formed directly on the corresponding surfaces (i.e., thetransverse surface 992, theposts 990, and the flanges 998) of the tibialbone anchoring component 916. In either case, thebone engagement pad 970 may be secured to the corresponding bone engagement surfaces of the tibialbone anchoring component 916 via various methods, such as diffusion bonding and/or through the use of a substance, such as thesubstance 340 referenced previously, which may be applied to one or both of the surfaces to be secured together to facilitate chemical and/or adhesive bonding. In some embodiments, a paste including a metallic powder, such as Titanium nanoparticles, may be used to facilitate diffusion bonding, melting together of the surfaces to be attached, and/or other attachment mechanisms. Alternatively or additionally, various welding techniques such as laser welding, friction welding, and/or the like may be used. - In some embodiments, the
bone engagement pad 970 may have a non-uniform structure that presents different surface properties to the bone and the corresponding bone engagement surfaces of the tibialbone anchoring component 916 to which it is attached. For example, thebone engagement pad 970 may have a bone-facing surface with a high level of porosity and/or surface texturing to provide secure bone engagement and/or in-growth. Thebone engagement pad 970 may further have a joint-facing surface secured to the corresponding bone engagement surfaces of the tibialbone anchoring component 916, with a lower level of porosity and/or surface texturing to facilitate secure attachment of thebone engagement pad 970 to the corresponding bone engagement surfaces of the tibialbone anchoring component 916. - In some embodiments, the porosity of the
bone engagement pad 970 may have a gradient through the thickness of thebone engagement pad 970, from a highly-porous state at the bone-facing surface of thebone engagement pad 970, to a much less porous state at the joint-facing surface. In alternative embodiments, the change in porosity may be less gradual (i.e., “stepped.”). For example, additional material may be added to the joint-facing surface of thebone engagement pad 970 and melted, fused, and/or otherwise used to fill the pores in the joint-facing surface so that a layer exists on the joint-facing side in which the porosity is much lower than in the remainder of thebone engagement pad 970. In either case, the result may be that the joint-facing surface of thebone engagement pad 970 is much smoother than the bone engagement surface of thebone engagement pad 970, allowing the joint-facing surface to more readily and securely attach to the corresponding bone engagement surfaces of the tibialbone anchoring component 916, while retaining the enhanced bone in-growth of a porous structure in the bone engagement surface of thebone engagement pad 970. -
FIG. 10 is a perspective view, from a different viewpoint, of the tibialbone anchoring component 916 ofFIG. 9 .FIG. 10 depicts the positioning offlange portions 988 on both sides of theflanges 998 of the tibialbone anchoring component 916. Of course, this is merely exemplary. Those of skill in the art will recognize that thebone engagement pad 970 may be reconfigured in a wide variety of alternative configurations. - For example, in some configurations, the
post portions 980 may extend to cover more or less of theposts 990, or may be omitted altogether. Similarly, theflange portions 988 may extend to cover more or less of theflanges 998, or may be omitted altogether. One or more stem receiver portions (not shown) may be added to cover some portion(s) of the exterior-facing surfaces of thestem receiver 994, adjacent to thetransverse portion 982. Yet further, in other alternative embodiments, thebone engagement pad 970 may include a stem portion (not shown) that covers some or all of the stem (not shown). Such protruding portions may have thicknesses that are greater than, less than, and/or equal to the thickness of thetransverse portion 982. Further, thetransverse portion 982 may extend to cover more or less of thetransverse surface 992, or may be omitted altogether. - Further, those of skill in the art will recognize that the same principles may be applied to a femoral component. Specifically, a femoral component (not shown) according to an alternative embodiment may include a bone engagement pad that covers one or more bone-facing surfaces, including planar surfaces, post surfaces, and/or other bone-engaging surfaces.
- Yet further, those of skill in the art will recognize that the same principles may be applied to any implant for which secure bone engagement is desired. A bone engagement pad, consisting of one or more portions that may be separately formed or formed as a single piece with each other, may be secured to one or more bone-facing surfaces of an implant for arthroplasty, fusion, or modification of any joint, or for replacement of hard tissue such as a tooth or jaw.
- Any methods disclosed herein comprise one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified.
- Reference throughout this specification to “an embodiment” or “the embodiment” means that a particular feature, structure or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment.
- Similarly, it should be appreciated that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, Figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim require more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. Thus, the claims following this Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims.
- Recitation in the claims of the term “first” with respect to a feature or element does not necessarily imply the existence of a second or additional such feature or element. Elements recited in means-plus-function format are intended to be construed in accordance with 35 U.S.C. §112 Para. 6. Elements not so recited are not intended to be so construed. It will be apparent to those having skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles set forth herein.
- While specific embodiments and applications of the present disclosure have been illustrated and described, it is to be understood that the scope of the appended claims is not limited to the precise configuration and components disclosed herein. Various modifications, changes, and variations which will be apparent to those skilled in the art may be made in the arrangement, operation, and details of the methods and systems disclosed herein.
Claims (20)
1. A knee implant for replacing a natural articular surface on bone, the knee implant comprising:
a joint facing side comprising an articular surface shaped to replace the natural articular surface, wherein the natural articular surface is one of a natural tibial articular surface and a natural femoral articular surface;
a bone anchoring side comprising a bone engagement surface; and
a bone engagement pad secured to at least part of the bone engagement surface, the bone engagement pad comprising:
a transverse portion extending transverse to a length of the bone, the transverse portion comprising:
a pad bone-facing surface comprising a first porosity level; and
a pad joint-facing surface on an opposite side of the transverse portion from the pad bone-facing surface, the pad joint-facing surface comprising a second porosity level lower than the first porosity level; and
one or more protruding portions extending generally perpendicular to the transverse portion;
wherein:
the bone engagement surface is formed via a first manufacturing process selected from the group consisting of forging, milling, and casting;
the bone engagement pad is formed via a second manufacturing process different from the first manufacturing process; and
the second manufacturing process is an additive manufacturing process.
2. The knee implant of claim 1 , wherein:
the bone engagement pad extends generally transverse to a length of the bone, and has a thickness, parallel to the length, that is substantially uniform; and
the thickness is within the range of 0.5 mm to 1.5 mm.
3. The knee implant of claim 1 , wherein:
the bone engagement surface comprises a bone engagement feature extending through an aperture formed in the transverse portion; and
the one or more protruding portions extend from one or more edges of the aperture, alongside one or more surfaces of the bone engagement feature.
4. A prosthesis for replacing a natural articular surface on bone, the prosthesis comprising:
a joint facing side comprising an articular surface;
a bone anchoring side comprising a bone engagement surface; and
a bone engagement pad secured to at least part of the bone engagement surface, the bone engagement pad comprising:
a pad bone-facing surface comprising a first porosity level; and
a pad joint-facing surface comprising a second porosity level lower than the first porosity level.
5. The prosthesis of claim 4 , wherein:
the bone engagement surface is formed via a first manufacturing process; and
the bone engagement pad is formed via a second manufacturing process different from the first manufacturing process.
6. The prosthesis of claim 5 , wherein:
the first manufacturing process is selected from the group consisting of forging, milling, and casting; and
the second manufacturing process is an additive manufacturing process.
7. The prosthesis of claim 4 , wherein the bone engagement pad has a thickness within the range of 0.5 mm to 1.5 mm.
8. The prosthesis of claim 4 , wherein:
the bone engagement pad comprises a transverse portion that extends generally transverse to a length of the bone;
the pad bone-facing surface and the pad joint-facing surface are on opposite sides of the bone engagement pad; and
the transverse portion has a thickness, parallel to the length, that is substantially uniform.
9. The prosthesis of claim 4 , wherein the bone engagement pad comprises:
a transverse portion extending transverse to a length of the bone, wherein the pad bone-facing surface and the pad joint-facing surface are on opposite sides of the transverse portion; and
one or more protruding portions extending generally perpendicular to the transverse portion.
10. The prosthesis of claim 9 , wherein:
the bone engagement surface comprises a bone engagement feature extending through an aperture formed in the transverse portion; and
the one or more protruding portions extend from one or more edges of the aperture, alongside one or more surfaces of the bone engagement feature.
11. The prosthesis of claim 4 , wherein:
the bone engagement pad comprises a transverse portion that extends generally transverse to a length of the bone;
the pad bone-facing surface and the pad joint-facing surface are on opposite sides of the bone engagement pad; and
the transverse portion comprises a porosity gradient by which porosity of the transverse portion gradually increases toward the pad bone-facing surface.
12. The prosthesis of claim 4 , wherein:
the bone engagement pad comprises a transverse portion that extends generally transverse to a length of the bone;
the pad bone-facing surface and the pad joint-facing surface are on opposite sides of the bone engagement pad; and
the transverse portion comprises a low-porosity layer proximate the pad joint-facing surface, by which a porosity of the transverse portion abruptly increases toward the pad bone-facing surface.
13. The prosthesis of claim 4 , wherein:
the prosthesis comprises a knee implant;
the articular surface is shaped to replace the natural articular surface; and
the natural articular surface is one of a natural tibial surface and a natural femoral articular surface.
14. A prosthesis for replacing a natural articular surface on bone, the prosthesis comprising:
a joint facing side comprising the articular surface;
a bone anchoring side comprising a bone engagement surface; and
a bone engagement pad secured to at least part of the bone engagement surface, the bone engagement pad comprising:
a transverse portion extending transverse to a length of the bone; and
one or more protruding portions extending generally perpendicular to the transverse portion.
15. The prosthesis of claim 14 , wherein:
the bone engagement surface is formed via a first manufacturing process; and
the bone engagement pad is formed via a second manufacturing process different from the first manufacturing process.
16. The prosthesis of claim 15 , wherein:
the first manufacturing process is selected from the group consisting of forging, milling, and casting; and
the second manufacturing process is an additive manufacturing process.
17. The prosthesis of claim 14 , wherein the bone engagement pad has a thickness within the range of 0.5 mm to 1.5 mm.
18. The prosthesis of claim 14 , wherein the transverse portion extends generally transverse to a length of the bone, and has a thickness, parallel to the length, that is substantially uniform.
19. The prosthesis of claim 14 , wherein:
the bone engagement surface comprises a bone engagement feature extending through an aperture formed in the transverse portion; and
the one or more protruding portions extend from one or more edges of the aperture, alongside one or more surfaces of the bone engagement feature.
20. The prosthesis of claim 14 , wherein:
the prosthesis comprises a knee implant;
the articular surface is shaped to replace the natural articular surface; and
the natural articular surface is one of a natural tibial surface and a natural femoral articular surface.
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