WO2008112875A2 - Internal fixation devices - Google Patents

Internal fixation devices Download PDF

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Publication number
WO2008112875A2
WO2008112875A2 PCT/US2008/056828 US2008056828W WO2008112875A2 WO 2008112875 A2 WO2008112875 A2 WO 2008112875A2 US 2008056828 W US2008056828 W US 2008056828W WO 2008112875 A2 WO2008112875 A2 WO 2008112875A2
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WO
WIPO (PCT)
Prior art keywords
polymer material
internal fixation
fixation device
bone
material
Prior art date
Application number
PCT/US2008/056828
Other languages
French (fr)
Other versions
WO2008112875A3 (en
Inventor
James Rains
Mason Bettenga
John Rose
Malcolm Brown
Horacio Montes De Oca Balderas
Original Assignee
Smith & Nephew, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to US89450507P priority Critical
Priority to US60/894,505 priority
Priority to US60/912,738 priority
Priority to US91284507P priority
Priority to US91273807P priority
Priority to US60/912,845 priority
Application filed by Smith & Nephew, Inc. filed Critical Smith & Nephew, Inc.
Publication of WO2008112875A2 publication Critical patent/WO2008112875A2/en
Publication of WO2008112875A3 publication Critical patent/WO2008112875A3/en

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    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61BDIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/56Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor
    • A61B17/58Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor for osteosynthesis, e.g. bone plates, screws, setting implements or the like
    • A61B17/68Internal fixation devices, including fasteners and spinal fixators, even if a part thereof projects from the skin
    • A61B17/84Fasteners therefor or fasteners being internal fixation devices
    • A61B17/86Threaded wires, pins or screws; Nuts therefor
    • A61B17/866Material or manufacture
    • AHUMAN NECESSITIES
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    • A61BDIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/064Surgical staples, i.e. penetrating the tissue
    • A61B17/0642Surgical staples, i.e. penetrating the tissue for bones, e.g. for osteosynthesis or connecting tendon to bone
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
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    • A61B17/58Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor for osteosynthesis, e.g. bone plates, screws, setting implements or the like
    • A61B17/68Internal fixation devices, including fasteners and spinal fixators, even if a part thereof projects from the skin
    • A61B17/72Intramedullary pins, nails or other devices
    • A61B17/7216Intramedullary pins, nails or other devices for bone lengthening or compression
    • A61B17/7225Intramedullary pins, nails or other devices for bone lengthening or compression for bone compression
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    • A61B17/58Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor for osteosynthesis, e.g. bone plates, screws, setting implements or the like
    • A61B17/68Internal fixation devices, including fasteners and spinal fixators, even if a part thereof projects from the skin
    • A61B17/72Intramedullary pins, nails or other devices
    • A61B17/7233Intramedullary pins, nails or other devices with special means of locking the nail to the bone
    • A61B17/7258Intramedullary pins, nails or other devices with special means of locking the nail to the bone with laterally expanding parts, e.g. for gripping the bone
    • A61B17/7275Intramedullary pins, nails or other devices with special means of locking the nail to the bone with laterally expanding parts, e.g. for gripping the bone with expanding cylindrical parts
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    • A61B17/68Internal fixation devices, including fasteners and spinal fixators, even if a part thereof projects from the skin
    • A61B17/74Devices for the head or neck or trochanter of the femur
    • A61B17/742Devices for the head or neck or trochanter of the femur having one or more longitudinal elements oriented along or parallel to the axis of the neck
    • A61B17/744Devices for the head or neck or trochanter of the femur having one or more longitudinal elements oriented along or parallel to the axis of the neck the longitudinal elements coupled to an intramedullary nail
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    • A61B17/68Internal fixation devices, including fasteners and spinal fixators, even if a part thereof projects from the skin
    • A61B17/80Cortical plates, i.e. bone plates; Instruments for holding or positioning cortical plates, or for compressing bones attached to cortical plates
    • A61B17/8004Cortical plates, i.e. bone plates; Instruments for holding or positioning cortical plates, or for compressing bones attached to cortical plates with means for extending or compressing the bone or bones
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    • A61B17/68Internal fixation devices, including fasteners and spinal fixators, even if a part thereof projects from the skin
    • A61B17/80Cortical plates, i.e. bone plates; Instruments for holding or positioning cortical plates, or for compressing bones attached to cortical plates
    • A61B17/8033Cortical plates, i.e. bone plates; Instruments for holding or positioning cortical plates, or for compressing bones attached to cortical plates having indirect contact with screw heads, or having contact with screw heads maintained with the aid of additional components, e.g. nuts, wedges or head covers
    • A61B17/8047Cortical plates, i.e. bone plates; Instruments for holding or positioning cortical plates, or for compressing bones attached to cortical plates having indirect contact with screw heads, or having contact with screw heads maintained with the aid of additional components, e.g. nuts, wedges or head covers wherein the additional element surrounds the screw head in the plate hole
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    • A61L31/00Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/12Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
    • A61L31/125Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
    • A61L31/127Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix containing fillers of phosphorus-containing inorganic materials
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    • A61L31/00Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/14Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61BDIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/56Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor
    • A61B17/58Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor for osteosynthesis, e.g. bone plates, screws, setting implements or the like
    • A61B17/68Internal fixation devices, including fasteners and spinal fixators, even if a part thereof projects from the skin
    • A61B17/80Cortical plates, i.e. bone plates; Instruments for holding or positioning cortical plates, or for compressing bones attached to cortical plates
    • A61B17/8052Cortical plates, i.e. bone plates; Instruments for holding or positioning cortical plates, or for compressing bones attached to cortical plates immobilised relative to screws by interlocking form of the heads and plate holes, e.g. conical or threaded
    • AHUMAN NECESSITIES
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    • A61B17/00234Surgical instruments, devices or methods, e.g. tourniquets for minimally invasive surgery
    • A61B2017/00287Bags for minimally invasive surgery
    • AHUMAN NECESSITIES
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    • A61B2017/00831Material properties
    • A61B2017/00867Material properties shape memory effect
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    • A61B2017/00871Material properties shape memory effect polymeric
    • AHUMAN NECESSITIES
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    • A61B17/0401Suture anchors, buttons or pledgets, i.e. means for attaching sutures to bone, cartilage or soft tissue; Instruments for applying or removing suture anchors
    • A61B2017/0412Suture anchors, buttons or pledgets, i.e. means for attaching sutures to bone, cartilage or soft tissue; Instruments for applying or removing suture anchors having anchoring barbs or pins extending outwardly from suture anchor body
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    • A61L2400/00Materials characterised by their function or physical properties
    • A61L2400/16Materials with shape-memory or superelastic properties

Abstract

The present disclosure relates to an internal fixation device including an interface portion and a polymer material coupled to the interface portion, wherein the polymer material includes at least one feature on a surface of the polymer material. A method of fixating the internal fixation device to a bone and other internal fixation devices and methods for fixating are also disclosed.

Description

INTERNAL FIXATION DEVICES

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a PCT International Application claiming priority to United States Patent Application No. 60/894,505 . filed on March 13, 2007, United States Patent Application No. 60/912,845 filed on April 19, 2007, and United States Patent Application No. 60/912,738 filed on April 19, 2007, the disclosures of which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION FIELD OF THE INVENTION

[0002] The present disclosure relates to internal fixation devices for use in bone fracture repair and more specifically, an internal fixation devices that include a polymer material for improved device stabilization and fracture fixation. RELATED ART

[0003] Problems can arise when a bone fracture or fusion site is not sufficiently stabilized during the healing lifetime. Depending on the nature of the fracture, internal fixation devices, such as intramedullary nails and screws, may be used alone, or in combination. One objective of these devices is the anatomic reduction of the fracture. Another objective is to minimize or eliminate interfragmentary motion. Still another objective involves increasing or maximizing blood supply to the fracture site by reducing or minimizing additional vascular damage. Sustained compressive therapy can also be osteoinductive, due to its piezoelectric effects on osteoblasts themselves. Excessive interfragmentary motion results in the formation of fibrous, unmineralized scar tissue (resulting in non-union or pseudo-arthrosis) versus regeneration of bone. The unmineralized scar tissue is not load supporting and skeletal function is lost. A sufficient blood supply must be maintained to support skeletal metabolism, bone regeneration, and remodeling of the fracture site.

[0004] These internal fixation devices are made of metal, such as stainless steel or titanium. Overtime, however, these stainless steel and titanium fixation devices do not maintain adequate fixation to bone or compression across the fracture fragments. As the necrotic surfaces of the fracture are resorbed, a non-load bearing gap develops between the fragments, thereby decreasing compression and increasing the risk of interfragmentary motion and scar tissue formation. Loss of compression is contrary to the objectives of fracture fixation in general and these devices in particular. Improvements are therefore desired to help improve fixation to bone and maintain compressive load across the fracture site over a longer period of healing.

SUMMARY OF THE INVENTION

[0005] In one aspect, the present disclosure relates to an internal fixation device including an interface portion and a polymer material coupled to the interface portion, wherein the polymer material includes at least one feature on a surface of the polymer material. In an embodiment, the polymer material includes multiple features. In another embodiment, the feature includes a particulate material. In another embodiment, the particulate material includes a ceramic material. In yet another embodiment, the feature includes a protrusion, hi a further embodiment, the protrusion is selected from a group including a metal material, a non-metal material, a polymer material, and combinations thereof. In yet a further embodiment, the polymer material of the internal fixation device and the protrusion includes a resorbable material or a non-resorbable material. In still yet a further embodiment, the polymer material of the fixation device and the protrusion includes shape memory qualities. [0006] In another aspect, the present disclosure relates to a method of fixating an internal fixation device to a bone. The method includes providing an internal fixation device having an interface portion and a polymer material coupled to the interface portion, wherein the polymer material includes at least one feature on a surface of the polymer material; inserting the internal fixation device into a bone; and providing the polymer material with energy to deform the material and fixate the internal fixation device to the bone.

[00071 In a further aspect, the present disclosure relates to an internal fixation device including a channel and a shape memory polymer material located within the channel. In an embodiment, the channel partially extends a length of the device. In another embodiment, the shape memory polymer material includes a body having a stem portion, wherein the stem portion is located within the channel. In yet another embodiment, the internal fixation device includes a proximal portion and a distal portion, the shape memory polymer material located at the distal portion. In a further embodiment, the distal portion includes a hinge. In a further embodiment, the distal portion includes at least one feature on a surface of the distal portion. In yet a further embodiment, the feature includes a protrusion.

[0008] In yet a further aspect, the present disclosure relates to a method of fixating an internal fixation device to a bone including providing an internal fixation device including a channel and a shape memory polymer material located within the channel; inserting the internal fixation device into a bone; and providing the polymer material with energy to deform the material and fixate the internal fixation device to the bone. In an embodiment, the internal fixation device includes a proximal portion and a hinged distal portion, the shape memory polymer material located at the distal portion. In another embodiment, the distal portion extends outward and engages in the bone when the polymer material is provided with energy. [0009] In yet a further aspect, the present disclosure relates to an internal fixation device including a cannulated inner portion, an outer portion, at least two C-shaped channels located on the outer portion, the channels located on opposite sides of the device from each other, wherein each channel includes a tab, and a polymer material, the polymer material located within the cannulated inner portion and between the C-shaped channels.

[0010] In an even further aspect, the present disclosure relates to a method of fixating an internal fixation device to a bone including providing an internal fixation device including a cannulated inner portion, an outer portion, at least two C-shaped channels located on the outer portion, the channels located on opposite sides of the device from each other, wherein each channel includes a tab, and a polymer material, the polymer material located within the cannulated inner portion and between the C-shaped channels; inserting the internal fixation device into a bone; and providing the polymer material with energy to deform the material, wherein deforming the material causes the tabs to open and engage in the bone to fixate the device.

[0011] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present disclosure and together with the written description serve to explain the principles, characteristics, and features of the disclosure. In the drawings;

[0013] Fig. 1 shows a perspective view of an internal fixation device of the present disclosure.

[0014] Fig. 2A shows a cross-sectional view of an interface portion having a circular shape.

[0015] Fig. 2B shows a cross-sectional view of an interface portion having a triangular shape.

[0016] Fig. 2C shows a cross-sectional view of an interface portion having a rectangular shape.

[0017] Fig. 2D shows a cross-sectional view of an interface portion having a star shape.

[0018] Fig. 2E shows a cross-sectional view of an interface portion having an oval shape.

[0019] Fig. 2F shows a cross-sectional view of an interface portion having a hexagonal shape.

[0020] Fig. 2G shows a cross-sectional view of an interface portion having a Chinese star shape.

[0021] Fig. 2H shows a perspective view of an interface portion having a tapered surface.

[0022] Fig. 21 shows a perspective view of an interface portion having a beveled surface.

[0023] Fig. 2 J shows a perspective view of an interface portion having a surface with axial and radial grooves.

[0024] Fig. 2K shows a perspective view of an interface portion having a surface with helical grooves. [0025] Fig. 2L shows a perspective view of a sleeve of polymer material for use on a shaped interface portion of an internal fixation device of the present disclosure.

[0026] Fig. 2M shows a perspective view of a shaped interface portion of the present disclosure including strips of polymer material.

[0027] Fig. 3 shows a perspective view of an internal fixation device of the present disclosure having multiple interface portions.

[0028] Fig. 4 shows a perspective view of a second internal fixation device of the present disclosure.

[0029] Fig. 5 shows a first method of fixating an internal fixation device to a bone.

[0030] Figs. 6A and 6B illustrate an embodiment of internal fixation of the first method.

[0031] Fig. 7 shows a second method of fixating an internal fixation device to a bone.

[0032] Fig. 8 illustrates a first embodiment of internal fixation of the second method.

[0033] Fig. 9 illustrates a second embodiment of internal fixation of the second method.

[0034] Fig. 10 illustrates a third embodiment of internal fixation of the second method.

[0035] Fig, 1 1 shows a third method of fixating an internal fixation device to a bone.

[0036] Fig. 12 shows a first embodiment of internal fixation of the third method.

[0037] Fig. 13 shows a second embodiment of internal fixation of the third method.

[0038] Fig. 14 shows a method of stabilizing a fractured bone.

[0039] Figs. 15A and 15B illustrate a first embodiment of the fracture stabilization method.

[0040] Figs. 16A and 16B illustrate a second embodiment of the fracture stabilization method. [0041 J Fig. 17 shows a perspective view of an internal fixation device of the present disclosure having an interface portion that includes one hole.

[0042] Fig. 18 shows a perspective view of an internal fixation device of the present disclosure having an interface portion that includes multiple holes.

[0043] Fig. 19 shows a perspective view of an internal fixation device of the present disclosure having an interface portion that includes screw threads.

[0044] Fig. 20 shows a perspective view of an internal fixation device of the present disclosure having an interface portion that includes circumferential ribs.

[0045] Figs 21 A and 21B show a perspective view of an internal fixation device of the present disclosure having interface portions that include engravings.

[0046] Fig. 22 shows a perspective view of an internal fixation device of the present disclosure having multiple interface portions.

[0047] Fig. 23 shows a perspective view of a sleeve of polymer material for use on a shaped interface portion of an internal fixation device of the present disclosure.

[0048] Fig. 24 shows a perspective view of an interface portion of the present disclosure having engravings that include strips of polymer material,

[0049] Fig. 25A shows a perspective view of an internal fixation device of the present disclosure.

[0050] Fig. 25B shows a perspective view of an internal fixation device of the present disclosure.

[0051] Fig. 26 shows a method of fixating an internal fixation device to a bone.

[0052] Figs. 27A and 27B illustrate an embodiment of an internal fixation of the method of Fig. 26. [0053] Fig. 28 shows a method of fixating an internal fixation device to a bone.

[0054J Fig. 29 illustrates a first embodiment of an internal fixation of the method of Fig. 28.

[0055] Fig. 30 illustrates a second embodiment of an internal fixation of the method of Fig. 28.

[0056] Fig. 31 illustrates a third embodiment of an internal fixation of the method of Fig. 28.

[0057] Fig. 32 shows a method of fixating an internal fixation device to a bone.

[0058] Fig. 33 shows a first embodiment of an internal fixation of the method of Fig. 32.

[0059] Fig. 34 shows a second embodiment of an internal fixation of the method Fig. 32.

[0060] Fig. 35 shows a first method of stabilizing a fractured bone.

[0061] Figs. 36A and 36B illustrate a first embodiment of the fracture stabilization method of Fig. 35.

[0062] Figs. 37A and 37B illustrate a second embodiment of the fracture stabilization method of Fig. 35.

[0063] Fig. 38 shows a method of stabilizing a fractured bone.

[0064] Figs. 39A and 39B illustrate an embodiment of fracture stabilization of the method of Fig. 38.

[0065] Figs. 4OA and 4OB show a perspective view of an internal fixation device of the present disclosure before and after deformation of the polymer material.

[0066] Fig. 41 A shows a cross-sectional view of a fastener after insertion of the fastener into a hole having a polymer material and prior to deformation of the material. [0067] Fig. 41B shows a cross-sectional view of a fastener after insertion of the fastener into a hole having a polymer material and after deformation of the polymer material.

[0068] Figs. 42A and 42B illustrate use of the internal fixation device of Figs. 4OA and 4OB for fracture stabilization.

[0069] Figs. 43 A and 43B show a perspective view of the internal fixation device of the present disclosure before and after deformation of the polymer material.

[0070] Figs. 44 A and 44B illustrate use of the internal fixation device of Figs. 43a and 43B for fracture stabilization.

[0071] Figs 45 A and 45B show a side view of an internal fixation device of the present disclosure before and after deformation of the polymer material.

[0072] Fig. 45C shows a top view of the internal fixation device of Figs. 45A-45B.

[0073] Figs. 46A-46B illustrate use of the internal fixation device of Figs. 45 A-45B for fracture stabilization.

[0074] Figs. 47A and 47B illustrate use of an internal fixation device and a washer to stabilize a fracture.

[0075] Fig. 48 shows a perspective view of an internal fixation device of the present disclosure.

[0076] Figs. 49A and 49B illustrate a first embodiment of us of an internal fixation device of Fig. 48.

[0077] Figs. 5OA and 50B illustrate a second embodiment of use of an internal fixation device of Fig. 48.

[0078] Figs. 51 A and 5 IB show a perspective view of an internal fixation device of the present disclosure before and' after deformation of the polymer material. [0079] Figs. 52A and 52B show a cross-sectional view of an internal fixation device of the present disclosure before and after deformation of the polymer material,

[0080] Figs. 53A and 53B show a cross-sectional view of an internal fixation device of the present disclosure before and after deformation of the polymer material.

[0081] Figs. 54A and 54B show a perspective view of an internal fixation device of the present disclosure before and after deformation of the polymer material.

[0082] Fig. 55A shows a perspective view of a fastener, having a head that includes a shape memory polymer material, after insertion of the fastener into a hole and prior to deformation of the material.

[0083] Fig. 55B shows a perspective view of a fastener, having a head that includes a shape memory polymer material, after insertion of the fastener into a hole and after deformation of the polymer material.

[0084] Figs. 56A and 56B illustrate an embodiment of fracture stabilization.

[0085] Figs. 57A and 57B show a cross-sectional view of an internal fixation device of the present disclosure before and after deformation of the polymer material.

[0086] Fig. 58 A shows a perspective view of an internal fixation device of the present disclosure.

[0087] Figs. 58B and 58C show top cross-sectional views of the C-shaped channel region of the internal fixation device of Fig. 58A before and after deformation of the polymer material.

[0088] Fig. 59 shows a method of fixating a plate to a fractured bone.

[0089] Fig. 6OA shows a perspective view of an internal fixation device of the present disclosure. [0090] Fig. 6OB illustrates use of the internal fixation device of Fig. 60A in fracture fixation.

[0091] Figs. 61A-61B show cross-sectional views of an internal fixation device of the present disclosure before and after deformation of a shape memory polymer material.

[0092] Figs. 62A-62B show cross-sectional end views of internal fixation devices of the present disclosure located in bone.

[0093] Fig. 63 shows pullout test results for two embodiments of the internal fixation device of the present disclosure.

[0094] Fig. 64 shows torque test results for two embodiments of the internal fixation device of the present disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0095] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses.

[0096] Fig. 1 shows an internal fixation device 10 including a shaped interface portion 11 and a polymer material 12 coupled to the shaped interface portion 11. The internal fixation device 10 is an intramedullary nail, but could be any other internal fixation device that is used in the repair of bone fractures, such as a bone screw, a locking screw, or a rod. The shaped interface portion 11 has a square shape, but can be of any other shape that allows formation of bonds between the polymer material 12 and the shaped interface portion 11 once the polymer material is provided with energy, as described below. As shown in Figs. 2A-2G, the shaped interface portion 21 may include a shape that is circular, triangular, rectangular, star-shaped, oval, hexagonal, or Chinese star shaped, respectively. In addition, as also shown in Figs. 2H-2K, the surface of the shaped interface portion 21 may be tapered or beveled or include axial and/or radial grooves or helical grooves, respectively. These shapes and surfaces help the polymer material engage the device to provide support for axial and torsional loading and to substantially reduce motion in those directions after the device has been placed in a bone, as will be further described below. The shapes and surfaces can be machined, molded, cast, laser cut, or chemically etched into the internal fixation device or formed via another method known to one of ordinary skill in the art. Machining of the shapes and surfaces could take many forms, including wire and ram electrical discharge machining (EDM). In addition, the shaped interface portion may be located anywhere along the device.

[0097] As shown in Fig. 3, multiple shaped interface portions 31, including a polymer material 32, may be present on the internal fixation device 30 and the portions 31 may include a surface and a shape having a cross-section as described above. In addition, the shaped interface portions 31 may be present anywhere along the internal fixation device 30.

[0098] The polymer material that is coupled to the shaped interface portion includes an orientated resorbable or non-resorbable material and is selected from a group that includes an amorphous polymer, a semi-crystalline polymer, or a composition having a combination thereof. The polymer material may also include a shape memory polymer. Factors used to determine the type of polymer used on the shaped interface portion, include, but are not limited to, the desired amount of polymer deformation, the desired rate at which that deformation occurs, the rate at which the polymer is absorbed, and the strength of the polymer.

[0099] The orientated polymer material could include a sleeve of material having a uniform structure with an outside surface and a channel running through the middle of the structure with both the structure and the channel having the same or different shapes. For the purposes of Figs. 1 & 3 and as shown in Fig. 2L, the polymer material is in the form of a sleeve 22 having a cylindrical structure with an outside surface 23 that is circular and a channel 24 having a square shape to match the square shape of the shaped interface portion. However, the structure of the sleeve 22 and the channel 24 may have another shape. The sleeve 22 may be formed by die-drawing or molding (i.e. compression flow molding or thermoforming process) the above-mentioned polymers or polymer compositions. The channel 24 may be formed in the sleeve 22 during the die drawing or molding process. Alternatively, the channel 22 may be formed in the sleeve 22 post processing by drilling or by any other method of forming the channel 22.

[0010O] In addition, the polymer material may not be in the form of sleeve, but rather there may be several strips of polymer material each of which have a structure and each of which are coupled to the shaped interface portion. For example, a shaped interface portion 21 having a Chinese star shape, such as in Fig. 2M, would have strips of polymer material 22 coupled to the slotted areas 25 of the shaped interface portion 21. However, the polymer material may be in other forms. The strips 22 may be formed by the processes listed above or by another process, such as an extrusion process (i.e. single screw, twin screw, disk, ram, or pultrusion process).

[00101] Furthermore, for the purposes of this disclosure, the outer surface of the polymer material is shown, in Figs. 1, 3, 4, 15A, and 16A, as being flush, or forming the same plane with, the outer surface of the fixation device. However, the outer surface of the polymer material may be of a smaller or larger diameter than the outer surface of the fixation device.

[00102] The internal fixation device may be manufactured from a metal, such as titanium, titanium alloys, steel, stainless steel, cobalt-chromium alloys, tantalum, magnesium, niobium, nickel, nitinol, platinum, silver, and combinations thereof. Other metals known to one of ordinary skill in the art could also be used. The device may also be manufactured from a resorbable or non-resorbable polymer material and may be the same polymer material used on the shaped interface portion, as described above, or another type of polymer material.

[00103] Specific polymers that may be used for the shaped interface portion and/or the device include polyetheretherketone (PEEK), polymethyl methacrylate (PMMA), polyethyl methacrylate (PEMA), polyacrylate, poly-alpha-hydroxy acids, polycapropactones, polydioxanones, polyesters, polyglycolic acid, polyglycols, polylactides, polyorthoesters, polyphosphates, polyoxaesters, polyphosphoesters, polyphosphonates, polysaccharides, polytyrosine carbonates, polyurethanes, and copolymers or polymer blends thereof. In addition, bioactive agents may be incorporated into the polymer material to be released during the deformation or the degradation of the polymer material. These agents are included to help promote bone regrowth. Examples include bone morphogenic proteins, antibiotics, anti- inflamatoies, angiogenic factors, osteogenic factors, monobutyrin, omental extracts, thrombin, modified proteins, platelet rich plasma/solution, platelet poor plasma/solution, bone marrow aspirate, and any cells sourced from flora or fawna, such as living cells, preserved cells, dormant cells, and dead cells. Other bioactive agents known to one of ordinary skill in the art may also be used. Furthermore, the polymeric materials can be formed as a composite or matrix and include reinforcing material or phases such as fibers, rods, platelets, and fillers. For example, the polymeric material can include glass fibers, carbon fibers, polymeric fibers, ceramic fibers, or ceramic particulates. Other reinforcing material or phases known to one of ordinary skill in the art could also be used.

[00104] Fig. 4 shows another example of an internal fixation device 40 that includes a shaped interface portion 41 and a polymer material 42 coupled to the interface portion 41. The internal fixation device 40 of Fig. 4 includes a bone screw or locking screw. The physical and compositional properties of the intramedullary nail, shaped interface portion, and polymer material, as described above, also apply to the screw in Fig. 4.

[00105] Fig. 5 shows a first method of fixating an internal fixation device to a bone 50. An internal fixation device is provided that includes a shaped interface portion and a polymer material coupled to the interface portion 51. The internal fixation device is then inserted into a bone 52 and the polymer material is caused to deform 53, thereby fixating the internal fixation device to the bone.

[00106] For the purposes of this disclosure, the device may be inserted into the bone by creating an entry point at one end of the bone (Figs. 6A-6B, 7) and then forcing the device through the intramedullary canal of the bone. Other methods known to one of ordinary skill in the art may also be used. Also for the purposes of this disclosure, the polymer material is processed to have shape memory qualities and therefore changes shape or deforms by shrinking axially, or along the length of the material, and expanding radially, or along the width of the material. Although, in certain instances, it is possible for the material to shrink radially and expand axially. This expansion and shrinkage causes an interference fit between the polymer material and the bone, thereby fixating the internal fixation device to the bone.

[00107] Generally, polymers that display shape memory qualities show a large change in modulus of elasticity at the glass transition temperature (Tg). The shape-memory function can be achieved by taking advantage of this characteristic. Namely, a molded article (primary molded article) to which a definite shape (the original shape) has been imparted by a common method for molding plastics, is softened by providing the article with energy and heating to a temperature (Tf) higher than the Tg of the polymer, but lower than the melting temperature (Tm) thereof so as to deform it into a different shape. Next, the molded article is cooled to a temperature lower than the Tg, while maintaining the thus deformed shape (secondary molded article). When it is heated again to a temperature higher than the secondary molding temperature Tf, but lower than the Tm, the shape of the secondary molded article disappears and thus the article is recovered to the original shape of the primary molded article.

[00108] For the purposes of this disclosure, a molded article (i.e. the above-mentioned sleeve or strips), having a definite shape (original shape) is formed from polymer material and is provided with energy to heat the article to a temperature above the glass transition temperature of the polymer, but lower than the melting temperature (Tm) thereof so as to deform it into a different shape and effectively wedge the article between the fixation device and the bone. In this manner, the fixation device becomes fixed to the bone. However, rather than cooling the article and heating it again until it recovers its original shape, the article is kept in this deformed shape so as to maintain fixation of the device to the bone. The glass transition temperature of the polymer material will vary based on a variety of factors, such as molecular weight, composition, structure of the polymer, and other factors known to one of ordinary skill in the art. Examples of adding energy to heat the polymer material are described below.

[00109] Examples of the method in Fig. 5 are shown in Figs. 6A and 6B. The polymer material 61 is provided with thermal energy, or heat, upon deliverance of a liquid 62, such as saline, either through the internal fixation device 63, as shown in Fig. 6A, or around the internal fixation device 63, as shown in Fig. 6B. The liquid 62 is delivered via a syringe 64 or other method of delivery known to one of ordinary skill in the art. The liquid 62, which may be something other than saline, has a high enough temperature so that the heat transferred from the liquid 62 to the polymer material 61 will take the temperature of the polymer material 61 above its glass transition temperature. As mentioned above, once the material 61 reaches a temperature that is above its glass transition temperature, the material 61 expands radially 68, or along the width of the material 61, and shrinks axially 69, or along the length of the material 61. The volume of the liquid 62 delivered is such that it has the capacity to include the thermal energy necessary to take the temperature of the material 61 above its glass transition temperature. The volume of the liquid 62 may also be dependent on the volume of the material 61 that is used.

[0011O] It is also within the scope of this disclosure that once the device 63 is placed in the bone, body heat would be transferred from blood and tissue, via thermal conduction, to provide the energy necessary to deform the polymer material 61. In this instance, body temperature would be used as the thermal energy source.

[00111] As mentioned above, radial expansion and axial shrinkage of the polymer material 61 causes an interference fit between the polymer material 61 and the inner walls 66 of the canal portion of the bone 65 and consequently allows fixation of the internal fixation device 63 to the bone 65. In some applications, the expansion of the material 61 extends beyond the inner wall 66 and into the cancellous bone. In still other applications, the polymer material 61 replaces the need for other fixators, such as a screw, to provide fixation. This would eliminate the difficulty and time involved with the use of guides and/or x-ray machines to detect the location of the screw holes on the fixation device after the device is placed in the bone. In addition, this would also eliminate bone and tissue necrosis that can occur during the placement of the screws after the screw holes have been located on the device. Furthermore, the possibility of the screws serving as an irritant to surrounding tissue and the need, as a result of the irritation, to perform a second operation to remove these screws, would also be eliminated, When the material 61 is used on the distal end of the device 63, such as shown in Fig. 6A, it can be used to dynamize the device, as will be further described below. Dynamization is currently achieved by the distal screws of the device being removed several weeks or months after surgery to help encourage bone regeneration. However, with the devices of the present disclosure, the material does not need to be removed since it can slowly degrade away, thereby losing fixation distally with the bone and providing the dynamization that is desired. Also as mentioned above, the internal fixation device 63 may include multiple shaped interface portions. This would create more contact between the device 63 and the bone 65 and allow the two to share the amount of load that is placed on the bone 63.

[00112] Another method 70 of fixating an internal fixation device to a bone is shown in Fig. 7. The method includes providing an internal fixation device that includes at least one opening extending transversely through the internal fixation device 71. The internal fixation device is then inserted into a bone 72. A fastener, which includes a shaped interface portion and a polymer material coupled to the interface portion, is provided 73 and inserted through the opening and the bone 74. The polymer material is then deformed to fixate the internal fixation device to the bone 75.

[00113] The method may further include providing an internal fixation device having a shaped interface portion and a polymer material coupled to the interface portion 76. The polymer material may then be deformed to fixate the internal fixation device to the bone. In addition, the method may also include the opening having a polymer material 77. The polymer material may then be heated to expand the polymer material radially inward and fixate the fastener in the opening.

[00114] Examples of this method are shown in Figs. 8-10. In Fig. 8, the fastener 81 is located in the opening 82 of the internal fixation device 83, which is an intramedullary nail. The fastener 81 extends through the opening 82 and the bone 84. The opening 82 can be located anywhere along the intramedullary nail 83 and more than one opening may be present on the nail 83. The polymer material 85 on the screw 81 is deformed via any of the methods as described above. In Fig. 9, both the intramedullary nail 83 and the fastener 81 make use of a polymer material 85 to fixate the intramedullary nail 83. In Fig. 10, the polymer material 85 is located in both the opening 82 of the intramedullary nail 83 and on the fastener 81 and is deformed after insertion of the fastener 81 into the opening 82. Deforming the polymer material 85 aids in fixating the intramedullary nail 83 by fixating the fastener 81 in the opening 82. In other embodiments, the polymer material 85 may only be located in the opening 82, rather than in the opening 82 and on the fastener 81. When the material 85 is located in the opening 82, it is coupled to the inner walls of the opening and radial expansion of the material 85 occurs inwardly towards the fastener 81 when the material 85 is provided with energy. An example of a fastener includes a screw, pin, rod, or any other device used to fixate the intramedullary nail in the bone.

[00115] A further method 90 of fixating an internal fixation device to a bone is shown in Fig. 11. The method includes providing an internal fixation device that includes a shaped interface portion and a polymer material coupled to the interface portion, wherein the internal fixation device includes a conductive material 91. The internal fixation device is then inserted into a bone 92 and energy is applied to the conductive material 93. The energy is transferred from the conductive material to the polymer material and the polymer material expands radially and shrinks axially to fixate the internal fixation device to the bone. The internal fixation device may have an insulated conductor that includes a connector 94. The connector is able to receive an electrical source that provides heat to the insulated conductor via an electrical current. The heat is transferred from the insulated conductor to the polymer material and the polymer material expands to create an interference fit between the bone and the internal fixation device and allow the device to better engage the bone.

[00116] Examples of this method are shown in Figs. 12 and 13. In Fig. 12, thermal energy, or heat, is applied to the conductive material 101 of the intramedullary nail 102 via a heat generating device 103, namely a cauterizing device. The heat is transferred from the conductive material, via thermal conduction, to the polymer material 110, causing the polymer material 110 to deform. The conductive material 101 may be in the form of a sheath or sleeve that is placed over the device 102 or portions thereof, strips that are coupled to the device 102, or another form. In Fig. 13, the end of the insulated conductor 104 contains a connector 105 to allow electrical sources to connect to it and provide it with electrical energy, or an electrical current. Alternatively, the connector 105 may be coupled to another connector located at the end of the nail 102. The electrical energy extends the length of the insulated conductor 104 to the shaped interface portion 111. At the shaped interface portion 111, the conductor 104 is non- insulated, or exposed, and comes into contact with heating elements 109. The heat from these elements 109 causes the polymer material 110 to deform. The heating elements 109 shown in Fig. 13 are coils, but may be any other type of heating element known to one of ordinary skill in the art. The device that provides the current is a hand held battery powered device 106 which connects to the connector 105 via wires 107. The button 108 on the device 106 need only be activated once and the appropriate current is delivered. Other devices known to those of ordinary skill in the art for providing current may be used, such as, but not limited to, an electrosurgical generator. In addition, other heat generating devices known to those of ordinary skill in the art may be used, such as, but not limited to, a hot air gun, a small welding or soldering gun, ultrasonic welders, a bovie tip, infrared light, or lasers. [00117] Fig. 14 shows a method of compressing a fractured bone 200. The method includes providing an internal fixation device that includes a shaped interface portion and a polymer material coupled to the interface portion 201. The internal fixation device is then inserted into a bone having a fracture 202 and the polymer material is provided with energy to deform the material. Deforming the polymer material fixates the internal fixation device to the bone and cause compression of the fracture 203.

[00118] Examples of this method are shown in Figs. 15A-B and 16A-B. Fig. 15A shows a fractured bone 301 having an intramedullary nail 302 inserted through the bone 301. Fig. 15B shows the fractured bone 301 after the polymer material 303 has been provided with heat. It can be seen that by providing the polymer material 303 with heat, deformation of the material 303 occurs creating not only an interference fit between the intramedullary nail 302 and bone 301, but also compression of the fracture 304. As shown in Fig. 15 A, there are a pair of heating elements or coils 308,309 located at both of the shaped interface portions 305,306 with two conductors 311,312 connected to coils 308 and two conductors 310,313 connected to coils 309. Electrical energy is fed through the insulated conductors 310,312 to the heating elements 308,309 that are furthest away from the fracture 304 and heat is applied to the polymer material 303,307. Once the polymer material 303,307 in the area of these elements 308,309 begins to deform, electrical energy is fed through the insulated conductors 311,313 to the heating elements 308,309 that are closest to the fracture 304, heat is applied to the polymer material 303,307 in the area of these elements 308,309, and the polymer material 303,307 deforms. Upon deforming, the material 303,307 expands radially to fixate the device 302 to the bone 301 and shrinks axially to compress the fracture 304. [00119] Compression is achieved by applying heat to the polymer material 303,307 in a non-uniform manner, so as to control the direction that the axial shrinking is occurring. A fifth conductor (not shown) would be used as the ground for the coil circuits. Figs. 16A-B show similar examples of fracture compression with a bone screw. Compression by the bone screw could occur in a manner similar to the nail 302 in Figs. 15A and 15B. Any heating element known to one of ordinary skill in the art could be used. Also, any number of heating elements and conductors may be used together to deform the material. In addition, the conductors may be located on the inner wall of the internal fixation device, on the outer wall of the internal fixation device, or in the body of the internal fixation device. Furthermore, compression of the fracture could occur by another method known to one of ordinary skill in the art.

[00120] Figs. 17 and 18 show internal fixation devices 400 that include an interface portion 401 and a polymer material 402 coupled to the interface portion 401. The internal fixation devices 400 are intramedullary nails, but could be any other internal fixation device that is used in the repair of bone fractures, such as a bone screw, a locking screw, a rod, or a pin. The internal fixation devices 400 include at least one hole 403 and, as shown in Fig. 18, may include multiple holes 403 at the interface portion, Fig. 19 shows another internal fixation device 400 having an interface portion 401 that includes threads 403. Fig. 20 shows yet another internal fixation device 400 having an interface portion 401 that includes circumferential ribs 403. Figs. 21 A and 21B show internal fixation devices 400 having interface portions 401 that include engravings 403. All of the devices 400 disclosed in Figs. 17-21 include a polymer material 402 coupled to the interface portion 401. In addition to allowing formation of bonds between the polymer material 402 and the interface portion 401 once the polymer material 402 is provided with energy, these holes, threads, circumferential ribs, and engravings 403 help the polymer material 402 engage the device 400 to provide support for axial and torsional loading and to substantially reduce motion in those directions after the device 400 has been placed in the bone, as will be further described below. The holes, threads, circumferential ribs, and engravings 403 can be drilled, machined, molded, cast, laser cut, or chemically etched into the internal fixation device or formed via another method known to one of ordinary skill in the art. Machining could take many forms, including wire and ram electrical discharge machining (EDM). The interface portion 401 may be located anywhere along the device 400.

[0012I]In addition, as shown in Fig. 22, multiple interface portions 501, including a polymer material 502, may be present on the internal fixation device 500. The portions 501 include holes 503, but may include the above-shown threads, circumferential ribs, engravings, or combinations thereof. In addition, the interface portions 501 may be present anywhere along the internal fixation device 500.

[00122] The polymer material could include a sleeve of material having a uniform structure with an outside surface and a channel running through the middle of the structure with both the structure and the channel having the same or different shapes. For the purposes of Figs. 17-22, and as shown in Fig. 23, the polymer material is in the form of a sleeve 600 having a cylindrical structure with an outside surface 601 that is circular and a channel 602 having a circular shape to match the circular shape of the interface portion. However, the structure of the sleeve 600 and the channel 602 may have another shape. The sleeve 600 may be formed by die- drawing or molding (i.e. compression flow molding or thermoforming process) the above- mentioned polymers or polymer compositions. The channel 602 may be formed in the sleeve 600 during the die drawing or molding process. Alternatively, the channel 602 may be formed in the sleeve 600 post processing by drilling or by any other method of forming the channel 602. [00123] In addition, the polymer material may not be in the form of sleeve, but rather there may be several strips of polymer material each of which have a structure and each of which are coupled to the interface portion. For example, Fig. 24 shows an interface portion 401 having strips of polymer material 402 coupled to the engraved areas 403 of the interface portion 401. The strips of polymer material 402 may be formed to fit the design of the engraving 403 or may be in other forms. The strips 402 may be formed by the processes listed above or by another process, such as an extrusion process (i.e. single screw, twin screw, disk, ram, or pulltrusion process).

[00124] Furthermore, for the purposes of this disclosure, the outer surface of the polymer material is shown, in Figs. 17-22, as being flush, or forming the same plane with, the outer surface of the fixation device. However, the outer surface of the polymer material may be of a larger diameter than the outer surface of the fixation device.

[00125] Figs. 25 A and 25B show further examples of an internal fixation device 700 that includes an interface portion 701 and a polymer material 702 coupled to the interface portion 701. The internal fixation devices 700 of Fig. 25 A and 35B include a screw, which could be a bone screw or locking screw, and a rod, respectively. The physical and compositional properties of the intramedullary nail, interface portion, and polymer material, as described above, also apply to the internal fixation devices shown in Figs. 25A and 25B.

[00126] Fig. 26 shows a first method of fixating an internal fixation device to a bone 800. An internal fixation device is provided that includes an interface portion and a polymer material coupled to the interface portion 801. The internal fixation device is then inserted into a bone 802 and the polymer material is caused to deform 803, thereby fixating the internal fixation device to the bone. [00127] For the purposes of this disclosure, the device may be inserted into the bone by creating an entry point at one end of the bone (Figs. 27A-27B, 907) and then forcing the device through the intramedullary canal of the bone. Depending on the type of device that is inserted, other methods known to one of ordinary skill in the art may also be used. For example, the device may be entered at another point on the bone.

[00128] Examples of the method in Fig. 26 are shown in Figs. 27A and 27B. The polymer material 901 is provided with thermal energy, or heat, upon deliverance of a liquid 902, such as saline, either through the internal fixation device 903, as shown in Fig. 27 A, or around the internal fixation device 903, as shown in Fig. 27B. The liquid 902 is delivered via a syringe 904 or other method of delivery known to one of ordinary skill in the art. The liquid 902, which may be something other than saline, has a high enough temperature so that the heat transferred from the liquid 902 to the polymer material 901 will take the temperature of the polymer material 901 above its glass transition temperature. As mentioned above, once the material 901 reaches a temperature that is above its glass transition temperature, the material 901 expands radially, or along the width of the material 901, and shrinks axially, or along the length of the material 901. The volume of liquid 902 delivered is such that it has the capacity to include the thermal energy necessary to take the temperature of the material 901 above its glass transition temperature. The volume of the liquid 902 may also be dependent on the volume of the material 901 that is used.

[00129] It is also within the scope of this disclosure that once the device 903 is placed in the bone, body heat would be transferred from blood and tissue, via thermal conduction, to provide the energy necessary to deform the polymer material 901. In this instance, body temperature would be used as the thermal energy source. [00130] As mentioned above, radial expansion and axial shrinkage of the polymer material 901 causes an interference fit between the polymer material 901 and the inner walls 906 of the canal portion of the bone 905 and consequently allows fixation of the internal fixation device 903 to the bone 905. In some applications, the expansion of the material 901 extends beyond the inner wall 906 and into the cancellous bone. In some applications, the polymer material 901 replaces the need for other fixators, such as a screw, to provide fixation. This would eliminate the difficulty and time involved with the use of guides and/or x-ray machines to detect the location of the screw holes on the fixation device after the device is placed in the bone. In addition, this would also eliminate bone and tissue necrosis that can occur during the placement of the screws after the screw holes have been located on the device. Furthermore, the possibility of the screws serving as an irritant to surrounding tissue and the need, as a result of the irritation, to perform a second operation to remove these screws, would also be eliminated. When the material 901 is used on the distal end of the device 903, such as shown in Fig. 27A, it can be used to dynamize the device, as will be further described below. Dynamization is currently achieved by the distal screws of the device being removed several weeks or months after surgery to help encourage bone regeneration. However, with the devices of the present disclosure, the material does not need to be removed since it can slowly degrade away, thereby losing fixation distally with the bone and providing the dynamization that is desired. Also as mentioned above, the internal fixation device 903 may include multiple shaped interface portions. This would create more contact between the device 903 and the bone 905 and allow the two to share the amount of load that is placed on the bone 903.

[00131] Another method 1000 of fixating an internal fixation device to a bone is shown in Fig. 28. The method includes providing an internal fixation device that includes at least one opening extending transversely through a proximal portion of the internal fixation device 1001. The internal fixation device is then inserted into a bone 1002. A fastener, which includes an interface portion and a polymer material coupled to the interface portion, is provided 1003 and inserted through the opening and the bone 1004. The polymer material is then deformed to fixate the internal fixation device to the bone 1005.

[00132] The method may further include providing an internal fixation device having an interface portion and a polymer material coupled to the interface portion 1006. The polymer material may then be deformed to fixate the internal fixation device to the bone, hi addition, the method may also include the opening having a polymer material 1007. The polymer material may then be heated to expand the polymer material radially inward and fixate the fastener in the opening.

[00133] Examples of this method are shown in Figs. 29-31. In Fig. 29, the fastener 1101 is located in the opening 1102 of the internal fixation device 1103, which is an intramedullary nail. The fastener 1101 extends through the opening 1102 and the bone 1104. The opening 1102 can be located anywhere along the intramedullary nail 1103 and more than one opening may be present on the nail 1103. The polymer material 1105 on the screw 1101 is deformed via any of the methods as described above. In Fig. 30, both the intramedullary nail 1103 and the fastener 1101 make use of a polymer material 1105 to fixate the intramedullary nail 1103. In Fig, 31, the polymer material 1105 is located in both the opening 1102 of the intramedullary nail 1103 and on the fastener 1101 and is deformed after insertion of the fastener 1101 into the opening 1102. Deforming the polymer material 1105 aids in fixating the intramedullary nail 1103 by fixating the fastener 1101 in the opening 1102. In other embodiments, the polymer material 1105 may only be located in the opening 1102, rather than in the opening 1102 and on the fastener 1101. When the material 1105 is located in the opening 1102, it is coupled to the inner walls of the opening and radial expansion of the material 1105 occurs inwardly towards the fastener 1101 when the material 1105 is provided with energy. An example of a fastener includes a screw, pin, rod, or any other device used to fixate the intramedullary nail in the bone.

[00134] A further method 1200 of fixating an internal fixation device to a bone is shown in Fig. 32. The method includes providing an internal fixation device that includes an interface portion and a polymer material coupled to the interface portion, wherein the internal fixation device includes a conductive material 1201. The internal fixation device is then inserted into a bone 1202 and energy is applied to the conductive material 1203. The energy is transferred from the conductive material to the polymer material and the polymer material expands radially and shrinks axially to fixate the internal fixation device to the bone. The internal fixation device may have an insulated conductor that includes a connector 1204. The connector is able to receive an electrical source that provides heat to the insulated conductor via an electrical current. The heat is transferred from the insulated conductor to the polymer material and the polymer material expands to create an interference fit between the bone and the internal fixation device and allow the device to better engage the bone.

[00135] Examples of this method are shown in Figs. 33 and 34. In Fig. 33, thermal energy, or heat, is applied to the conductive material 1301 of the intramedullary nail 1302 via a heat generating device 1303, namely a cauterizing device. The heat is transferred from the conductive material, via thermal conduction, to the polymer material 1310, causing the polymer material 1310 to deform. The conductive material 1301 may be in the form of a sheath or sleeve that is placed over the device 1302 or portions thereof, strips that are coupled to the device 1302, or another form. In Fig. 34, the end of the insulated conductor 1304 contains a connector 1305 to allow electrical sources to connect to it and provide it with electrical energy, or an electrical current. The electrical energy extends the length of the insulated conductor 1304 to the shaped interface portion 1311. At the interface portion 1311, the conductor 1304 is non-insulated, or exposed, and comes into contact with heating elements 1309. The heat from these elements 1309 causes the polymer material 1310 to deform. The heating elements 1309 shown in Fig. 34 are coils, but may be any other type of heating element known to one of ordinary skill in the art. The device that provides the current is a hand held battery powered device 1306 which connects to the connector 1305 via wires 1307. The button 1308 on the device 1306 need only be activated once and the appropriate current is delivered. Other devices known to those of ordinary skill in the art for providing current may be used, such as, but not limited to, an electrosurgical generator. In addition, other heat generating devices known to those of ordinary skill in the art may be used, such as, but not limited to, a hot air gun, a small welding or soldering gun, ultrasonic welders, a bovie tip, infrared light, or lasers.

[00136] Fig. 35 shows a method of compressing a fractured bone 1400. The method includes providing an internal fixation device that includes an interface portion and a polymer material coupled to the interface portion 1401, The internal fixation device is then inserted into a bone having a fracture 1402 and the polymer material is provided with energy to deform the material. Deforming the polymer material fixates the internal fixation device to the bone and cause compression of the fracture 1403,

[00137] Examples of this method are shown in Figs. 36A-B and 37A-B. Fig. 36A shows a fractured bone 1501 having an intramedullary nail 1502 inserted through the bone 1501. Fig. 36B shows the fractured bone 1501 after the polymer material 1503 has been provided with heat. It can be seen that by providing the polymer material 1503 with heat, deformation of the material 1503 occurs creating not only an interference fit between the intramedullary nail 1502 and bone 1501, but also compression of the fracture 1504. As shown in Fig. 36A, there is a pair of heating elements or coils 1508,1509 located at both of the interface portions 1505,1506 with two conductors 1511,1512 connected to coils 1508 and two conductors 1510,1513 connected to coils 1509. Electrical energy is fed through the insulated conductors 1510,1512 to the heating elements 1508,1509 that are furthest away from the fracture 1504 and heat is applied to the polymer material 1503,1507. Once the polymer material 1503,1507 in the area of these elements 1508,1509 begins to deform, electrical energy is fed through the insulated conductors 1511,1513 to the heating elements 1508,1509 that are closest to the fracture 1504, heat is applied to the polymer material 1503,1507 in the area of these elements 1508,1509, and the polymer material 1503,1507 deforms. Upon deforming, the material 1503,1507 expands radially to fixate the device 1502 to the bone 1501 and shrinks axially to compress the fracture 1504.

[00138] Compression is achieved by applying heat to the polymer material 1503,1507 in a non-uniform manner, so as to control the direction that the axial shrinking is occurring. A fifth conductor (not shown) would be used as the ground for the coil circuits. Figs. 37A-B show similar examples of fracture compression with a bone screw. Compression by the bone screw could occur in a manner similar to the nail 1502 in Figs. 36A and 36B, Any heating element known to one of ordinary skill in the art could be used. Also, any number of heating elements and conductors may be used together to deform the material. In addition, the conductors may be located on the inner wall of the internal fixation device, on the outer wall of the internal fixation device, or in the body of the internal fixation device. Furthermore, compression of the fracture could occur by another method known to one of ordinary skill in the art. [00139] Fig. 38 shows another method of compressing a bone fracture 1600. The method 1600 includes providing internal fixation devices that have interface portions and a polymer material coupled to the interface portions 1601. The internal fixation devices are then inserted into a bone having a fracture 1602 and the polymer material is provided with energy, by one of the methods mentioned above, or another method known to one of ordinary skill in the art, to deform the material. Deforming the polymer material fixates the internal fixation devices to the bone and causes compression of the fracture 1603.

[00140] An example of this method is shown in Figs. 39A and 39B. The internal fixation devices 1701, shown as rods, are inserted into the intramedullary canal, through the entry point 1705 at the one end of the bone 1702, and are placed across the fracture site 1703 until the canal is full. The polymer material 1704 is then deformed, by one of the methods mentioned above, or another method known to one of ordinary skill in the art. During deformation, the material 1704 expands vertically such that contact is made with the endosteal surface 1706 of the cortical wall 1707 and with the polymer material 1704 that is located on the other devices 1701 within the canal. In addition to expanding vertically, during deformation the material 1704 also shrinks horizontally. This simultaneous expansion and shrinkage of the material 1704 respectively fixates the device 1701 to the bone 1702 and compresses the fracture 1703, as shown in Fig. 39B. In some applications, the material 1704 expands vertically beyond the endosteal surface and into the cancellous bone. The interface portion and polymer material may be located anywhere along the devices. In addition, instead of having an interface portion to which the polymer material is coupled, the devices may include both metal material and polymer material located in alternating sections along the body of the device. It is also possible for the devices to be made completely out of polymer material that is resorbable and includes shape memory qualities, doesn't include shape memory qualities, or have a combination of both. Furthermore, other alternative embodiments are also within the scope of this disclosure. For example, a mixture of devices that include polymer material having shape memory qualities and devices that include polymer material that does not have shape memory qualities could be used. Also, the fracture may be stabilized by inserting resorbable polymeric rods into the intramedullary canal and filling the remaining space with an injectable, in-situ cured biodegradable thermoset matrix. Providing the canal with the thermoset matrix adds strength to the rod/thermoset matrix construct in bending, torsion, and shear. Any thermoset matrix known to one of ordinary skill in the art may be used. Alternatively, in order to contain the matrix and prevent the injected liquid from running out of bone at the fracture site, a bag can be pushed down the canal and filled with the rods, fibers, or particles. The bag may be made of a solid film, shape memory tubes, or of woven fibers. When the cement or thermoset matrix is injected, the liquid will flow through the canal and will wet the entire construct without spilling into soft tissue through the fracture.

[00141] Figs. 4OA and 40B show another embodiment of an internal fixation device 1800 of the present disclosure. The plate 1800 in Figs. 4OA and 4OB includes two end sections 1801, both of which are constructed of a first material, and a middle section 1802 that includes a second material. For the purposes of this figure, the first material is a metal material and the second material is a polymer material having shape memory qualities. However, it is within the scope of this figure that the two end sections 1801 could include a non-metal material, a combination of metal and non-metal materials, or the sections 1801 could include different types of material with one end section 1801 including a metal material and the other end section 1801 including a non-metal material. The end sections 1801 are coupled to the middle section 1802 via an engagement whereby grooves 1809 on the end sections 1801 are shaped to interlock with tabs 1808 that are located on the middle section 1802. However, other means known to those of ordinary skill in the art, of coupling the middle section 1802 to the end sections 1801, may be used. The end sections 1801 include holes 1803 that extend through the device 1800. As described further below, the device 1800 is coupled to a bone by inserting fasteners through the holes 1803 and into the bone. As shown in Fig. 4OB, the polymer material 1802 deforms upon the application of energy, via one of the methods described above, or another method known to one of ordinary skill in the art, It is also within the scope of this disclosure for the plate 1800 to include multiple sections of polymer material 1802.

[00142] Figs. 41 A and 41B show that the inner walls 1804 of the holes 1803 may also include polymer material 1802. Once a fastener 1805 is inserted into the hole 1803, the polymer material 1802 may provided with energy, via one of the methods described above, or another method known to one of ordinary skill in the art, to deform the material 1802 and fixate the fastener 1805 within the hole 1803, as shown in Fig. 4 IB. For the purposes of this disclosure, the polymer material may be used on the inner walls of holes that are located on devices other than plates.

[00143] Figs. 42A and 42B show a fractured bone 1806 both before and after compression of the fracture 1807 by the plate 1800. The plate 1800 is placed on the bone 1806 such that the middle section 1802 is located over the fracture 1807. The plate 1800 is then coupled to the bone 1806 by inserting fasteners 1805 through the holes 1801 and into the bone 1806. Energy is then applied to the polymer material 1802, via one of the methods described above, or another method known to one of ordinary skill in the art, to deform the material 1802 and compress the fracture 1807, as shown in Fig. 42B. [00144] Figs. 43 A and 43B show an alternative plate 1900, in the shape of a bracelet, which includes alternating sections of material 1901,1902. For the purposes of this figure, sections 1901 include metal material and sections 1902 include polymer material having shape memory qualities, However, it is within the scope of this figure that section 1901 could include a non-metal material or a combination of metal and non-metal materials. Similar to the plate 1800 in Figs. 4OA and 4OB, sections 1901 and 1902 are coupled via grooves 1905 and tabs 1906 located on sections 1901 and 1902, respectively. Also similar to Figs. 40A and 4OB, the polymer material 1902 deforms upon the application of energy via a method described above, or another method known to one of ordinary skill in the art. Figs. 44A and 44B show a fractured bone 1903 both before and after fixation of the plate 1900 to the bone 1903. The plate 1900 is placed on the bone 1903 and energy is then applied to the polymer material 1902, via one of the methods described above, or another method known to one of ordinary skill in the art, to deform the material 1902 and fixate the plate 1900 to the bone 1903, specifically, to ends 1904a,1904b of the fracture 1904, as shown in Fig. 44B.

[00145] The section or sections of polymer material included in the plates, of the above figures, may be located anywhere along the body of the plates. In addition, it is also possible for the devices to be made completely out of polymer material. Furthermore, the devices may include an interface portion to which the polymer material is coupled, similar to the intramedullary nails, screws, and rods shown in the above figures.

[00146] Figs. 45A-45C show another alternative fixation device in the form of a staple

2000. The staple 2000 includes a plate 2002, having two recesses 2006 and 2007, and two anus

2001, wherein each arm 2001 includes a head 2005 that is located at a proximal portion of each arm 2001. The arms 2001 extend through the recesses 2006,2007 such that the head 2005 of each arm 2001 rests within each recess 2006,2007. Each arm 2001 includes barbs 2008 located on an inside surface of the arm 2001 for substantially reducing the possibly of axial movement of the staple 2000 out of the bone. The number of barbs 2008 and the location of the barbs 2008 may vary, In addition, the arms may be without barbs. After the arms 2001 are inserted into each recess 2006,2007, the top portion of each recess 2006,2007 is closed off with a piece of material that is shaped to fit the recess 2006,2007. The arms 2001 and head 2005 include a metal material, but may include a non-metal, a combination of metal and non-metal, or the arm 2001 and the head 2005 may include different types of material. The plate 2002 includes a polymer material that includes shape-memory qualities. As shown in Fig. 45B, once energy is applied to the polymer material 2002, the material 2002 deforms. It is also within the scope of this disclosure for polymer material to be located on one or both arms 2001 of the staple 2000, either coupled to an interface portion of one or both of the arms or as an alternating section of material.

[00147] Figs. 46A and 46B show a fractured bone 2003 both before and after compression of the fracture 2004 by the staple 2000. The staple 2000 is placed in the bone 2003 such that the legs 2001 are located on both sides of the fracture 2004. Energy is then applied to the polymer material 2002, via one of the methods described above, or another method known to one of ordinary skill in the art, to deform the material 2002 and compress the fracture 2004, as shown in Fig. 46B. As stated above, polymer material may be located one or both of the arms 2001 of the staple 2000. If polymer material is located one or both of the arms 2000, then the polymer material may also be deformed to increase the compression on the fracture 2004 and fixation of the device 2000 to the bone 2003.

[00148] Figs. 47A and 47B show compression of a fracture 2104 via the use of a compression screw 2100 and a washer 2102 that includes polymer material having shape memory qualities. The screw 2100 is placed through the washer 2102 and across a fracture 2104. The washer 2102 can be provided with energy immediately, via one of the methods described above, or done slowly through heat transfer from surrounding tissue and blood. This results in deformation of the washer 2102, which pushes the head of the screw 2100 away from the surface 2105 of the bone 2103, and causes the application of a compressive force across the fracture 2104. The compression screw 2100 may include a polymer material

[00149] In an alternative embodiment, and as shown in Fig. 48, use of the washer may be eliminated with a screw 2200 having a head 2201 with an upper portion 2202 made from metal material and a lower portion 2203 made from polymer material. Similar to the washer in Figs. 47A and 47B, the lower portion 2203 of the head 2201 would deform upon the application of energy, via one of the methods described above, or another method known to one of ordinary skill in the art, and causes the application of a compressive force across a fracture. In some applications, the upper portion 2202 may be made from metal material.

[00150] In addition to the washer 2102 and the head 2201 of the screw 2100,2200 including a polymer material, is also within the scope of this disclosure that the screw 2100,2200 may include an additional polymer material anywhere along the length of the screw 2100,2200 either coupled to an interface portion or as an alternating section of material. This additional polymer material may also be deformed, once the screw 2100,2200 is placed in the bone, to provide further fixation of the screw 2100,2200 and further compression of the fracture.

[00151] Figs. 49A and 49B show an alternative method of compressing a fracture, hi Figs. 49A and 49B, an internal fixation device 2300, which includes a polymer material 2301 coupled to a shaft 2302 of the device 2300, is located in a hole 2303 that has been drilled through a fracture 2304 of a bone 2305. The polymer material 2301 is then provided with energy, via any of the methods described above or any other method known to one of ordinary skill in the art, to deform the material 2301, thereby fixating the device 2300 to the bone 2305 and compressing the fracture 2304, as shown in Fig. 49B. Figs. 50A and 50B provide a similar method of compressing the fracture, but rather than being located in a drilled hole, the internal fixation device 2400 is located in a tapped hole 2403. The sides 2406 of the tapped hole 2403 have serrated edges 2407, rather than the substantially smooth sides 2306 that are present in the drilled hole 2303. Upon deformation of the polymer material 2401, the material 2401 may deform to fit within these serrations 2407. With the material 2401 being coupled to the shaft 2402 and deformed to fit within the serrations 2407, the shape of the device/material combination resembles that of a threaded fastener and therefore, removal of the device 2400 from the hole 2403 may be done in a manner similar to the removal of a threaded fastener.

[00152] The polymer material 2401 may be located anywhere on the internal fixation device 2300,2400. In addition, the holes 2303,2403 may be formed by a drill and a tap, but may be formed by any other device known to one of ordinary skill in the art for making drilled and tapped holes. Furthermore, rather than being drilled or tapped, the holes may be broached or formed in any other manner known to one of ordinary skill in the art.

[00153] Figs. 51 A and 5 IB show an internal fixation device 2500 having an interface pprtion 2501, a polymer material 2502 coupled to the interface portion 2501, and at least one feature, such as protrusions 2503, that are coupled to a surface 2504 of the polymer material 2502. The protrusions 2503 may be coupled to the polymer surface 2504 via a variety of methods, such as an interference fit between the polymer 2502 and the protrusions 2503, adhesion of the protrusion 2503 to the polymer 2502, or any other method known to one of ordinary skill in the art. In addition, the number of protrusions 2503 present on the polymer material 2502 may vary. As shown in figures 51 A and 5 IB, the protrusions 2503 include serrations 1505 located on an outside surface of the protrusions 2503. The serrations 2505 provide multiple contact points to increase the friction between the polymer material 2502 and the bone 2506, thereby providing increased fixation between the device 2500 and the bone 2506 and substantially reducing the possibility of axial and torsional rotation of the device 2500. The protrusions 2503 are selected from a group that includes a metal material, a non-metal material, a polymer material, and combinations thereof and may be of any shape or size. If a polymer material is used for the protrusions 2503, the polymer material may include a resorbable or non- resorbable polymer material. In addition, surface features other than serrations may be used to provide multiple contact points and increase the friction between polymer material 2502 and the bone 2506.

[00154] Use of the protrusions 2503 in Figs, 5 IA and 5 IB maybe eliminated by including a particulate material 2607 within or on an outer surface of a polymer material 2602, as shown in Figs. 52A and 52B. The particulate material 2607 may include a ceramic material, a crystalline polymer, or any other type of material that would provide the polymer material 2602 with multiple contact points to increase the friction between the polymer material 2602 and the bone 2606.

[00155] Fig. 53 A shows an internal fixation device 2700, such as an intramedullary nail, having a channel 2701 partially extending the length of the device 2700. The channel 2701, which includes a threaded inner surface 2702, may be of a variety of lengths and widths. In addition, the inner surface 2702 of the channel 2701 may include a feature other than threads or may be smooth. A polymer material 2703, including a body 2703a having a stem portion 2703b, is coupled to the device 2700, such that the stem portion 2703b is located within the channel 2701. As shown in Fig. 53B, once the device 2700 is inserted into a bone, the polymer material 2703 is deformed, via one of the methods described above or another method known to one of ordinary skill in the art, to expand the material 2703 radially and fixate the device 2700 to bone. The stem portion 2703b of the material 2703 also expands radially to engage the threaded inner surface 2702 and fixate the material 2703 to the device 2700.

[00156] In some applications, the stem portion 2703b may include threads configured for engagement with the threads on the inner surface 2702 when the stem portion 2703b is disposed within the channel 2701. In some further applications, the outer surface of the device 2700 may include surface features, such as the holes, slots, threads, ribs, and engravings shown in Figs. 17- 21 above or other surface features known to one of skill in the art, which may extend between the outer surface and the channel 2701. In addition to allowing formation of bonds between the polymer material 2703 and the inner 2702 and outer surfaces, once the polymer material 2703 is provided with energy, these surface features help the polymer material 2703 engage the device 2700 to provide support for axial and torsional loading and to substantially reduce motion in those directions after the device 2700 has been placed in bone. It is within the scope of this disclosure that the channel 2701 may extend the full length of the device 2700. It is also within the scope of this disclosure that the body 2703a may extend over and around the outer surface of the device 2700 and, in some applications, may extend around the surface features described above.

[00157] Fig. 54A shows a bone plate 2800 that includes two end portions 2801 and a middle portion 2802. The middle portion 2802 includes a center opening 2803 and a polymer material that has shape memory qualities or a shape memory alloy material. Both end portions 2801 include at least one hole 2804 and a metal, a non-metal, or a polymer material that does not have shape memory qualities. The plate 2800 is placed on a fractured bone 2805, such that the middle portion 2802 is located adjacent to the fracture 2806, and fixated to the bone 2805 by inserting fasteners 2807 through the holes 2804 of the end portions 2801 and into the bone 2805. The fasteners 2807 include locking screws, non-locking screws, rods, pins, or any other fastener that may be used to fixate the plate 2800 to the bone 2805. Once the plate 2800 is fixated to the bone 2805, the middle portion 2802 of the plate 2800 is provided with energy to deform the middle portion 2802 and compress the fracture 2806, as shown in Fig. 54B. The number and location of holes 2804 on the end portions 2801 may vary.

[00158] Fig. 55 A shows a fastener 2900 located in an opening 2901 of a fixation device 2902. The fastener 2900 includes a head 2900a and a shaft 2900b. The head 2900a, which includes a shape memory polymer material, rests within an inner wall 2903 of the opening 2901. Once the fastener 2900 is inserted through the opening 2901 and into a bone, the head 290Oa is provided with energy, via one of the methods described above or another method known to one of ordinary skill in the art, to engage the head 2900a with the inner wall 2903 and further fixate the fixation device 2902 to the bone. The fastener 2900 includes a locking screw, a non-locking screw, a rod, a pin, or any other fastener that may be used to fixate the fixation device 2902 to the bone. In addition, the head 2900a of the fastener 2900 may be of a variety of shapes and sizes. Furthermore, the inner wall 2903 of the opening 2901 includes a v-shaped cross section, but may include a variety of other surface features, such as ridges, threads, protrusions, or other features that would provide engagement with the head 2900a, upon deformation, and further fixate the device 2902 to the bone.

[00159] Figs. 56A and 56B show first internal fixation devices 3000, shown as rods, which have been inserted into the intramedullary canal, through the entry point 3001 at the one end of the bone 3002, and placed across the fracture site 3003. However, mixed with these devices 3000 is a second internal fixation device 3004 that is made entirely out of a high strength resorbable polymer material and does not have shape memory qualities. The second internal fixation devices 3004 provide reinforcement to the first internal fixation devices 3000. The number of first 3000 and second 3004 internal fixation devices varies and includes as many as is necessary to fill the canal. Alternatively, instead of having first internal fixation devices that include a shape memory polymer material coupled to the ends of the devices, the first internal fixation devices may be entirely composed of a shape memory polymer material. In addition, the second internal fixation devices 3004 may include a metal or non-metal material, rather than a high strength resorbable polymer material.

[00160]Fig. 57A shows an internal fixation device 3100 that includes protrusions 3101 on an outer surface 3102 of the device 3100. The protrusions 3101 extend the length of the device 3100 and may include a polymer material that does not include shape memory qualities, a metal material, or a non-metal material. The internal fixation device 3100 is composed completely of a shape memory polymer material. The number and location of the protrusions 3101 on the outer surface 3102 of the device 3100 varies. In use, the device 3100 is inserted into a bone 3103 and then provided with energy to deform the device 3100 and allow engagement of the protrusions with the bone 3103, thereby fixating the device 3100 to the bone 3103, as shown in Fig. 57B. The protrusions 3101 may extend less than the length of the device 3100 and may include serrations or other surface features that would allow the protrusions 3101 to further engage the bone 1903.

[00161]Fig. 58A shows an internal fixation device 3200, such as an intramedullary nail, that includes a cannulated inner portion 3201 and at least two C-shaped channels 3202 located opposite each other on an outer portion 3203 of the internal fixation device 3200, wherein the channels 3202 include tabs 3204. The tabs 3204 include a material, such as elastic, that would allow the tabs 3204 to open outward, away from the outer portion 3203 of the device 3200, upon deformation of a polymer material and close, after resorption of the material, as described below. As shown in Figs. 58B and 58C, a resorbable shape memory polymer material 3205 is located within the inner portion 3201 of the device 3200 and between the C-shaped channels 3202. The material 3205 may be held within the inner portion 3201 via an interference fit between the material 3205 and the inner portion 3201 or by another method known to one of ordinary skill in the art. In use, the device 3200 is inserted into a bone and the polymer material 3205 is provided with energy, via one of the methods described above or another method known to one of ordinary skill in the art, to expand the material 3205 radially and open the tabs 3204 outwardly away from the outer portion 3203 of the device, as shown in Fig. 58C, and toward the bone. In this manner, the tabs 3204 engage the bone and provide fixation of the device 3200 to the bone. Upon resorption of the polymer material 3205, the tabs 3204 would move back towards the device 3200, thereby allowing the device 3200 to lose fixation with the bone and provide the dynamization that is required, as described above. The number and location of channels 3202 may vary. In addition, the canmilated inner portion 3201 may be of a variety of lengths and widths and the polymer material 3205 may be in a variety of shapes and sizes.

[00162] Fig. 59 shows a method 3300 of fixating a bone plate to a fractured bone. The method includes placing a bone plate on a surface of a fractured bone 3301, causing holes to be made through the plate and into the bone 3302, inserting a fastener into the holes 3303, and deforming the fastener to fixate the plate to the bone 3304, The bone plate would not include holes prior to placing the plate on the bone, but may include suggested areas in which holes could be made. For example, the plate may include indentations, notches, or circled areas on an outer surface of the plate that represent recommended areas in which to create holes. The holes may be caused by drilling, tapping, broaching, or any other method known to one of ordinary skill in the art for creating holes in a bone plate and bone. The fastener includes shape memory polymer material and may be composed entirely of this material or be composed of alternating sections of polymer material having shape memory qualities and polymer material that does not have shape memory polymer material. For example, the fastener may be in the form of a cylindrical rod and the portion of the rod that is housed in the holes of the plate and the bone may be composed of non-shape memory polymer material, but the portion that is located outside of the holes may be composed of shape memory polymer material. In this example, the portion located outside of the holes would be provided with energy to deform the portion and fixate the plate to the bone.

[00163] Fig. 6OA shows an internal fixation device 3400, such as an intramedullary nail, that includes a cannulated inner portion 3401 and an opening 3402 on an outer portion 3403 of the device 3400. The cannulated inner portion 3401 includes a first section 3404 and a second section 3405, wherein the second section 3405 includes a larger diameter than the first section 3404. Located within the second section 3405 is a shape memory polymer material 3406. The opening 3402 is located adjacent to the second section 3405 and the polymer material 3406. In use, the device 3400 is inserted through an intramedullary canal of a fractured bone 3407, such that the second section 3405 and the opening 3402 are placed across the fracture 3408. A fastener 3409, having a head 3410 and a shaft 3411, is inserted through the outer surface 3409 of the bone 3407, through the opening 3402, and into the inner surface 3412. In this manner, the fastener 3409 stabilizes and reduces the fracture 3408. Once the fastener 3409 has been located in the bone 3407, the polymer material 3406 is then provided with energy to deform the material 3406 and further fixate the fastener 3409 to the device 3400. The first and second sections 3404, 3405 of the cannulated inner portion 3401 may be of a variety of lengths and widths and the polymer material 3406 may be in a variety of shapes and sizes. In addition, the opening 3402 is of any diameter that is larger than the diameter of the shaft 3411 of the fastener 3409.

[00164] Fig. 61 A shows a cross-sectional view of an internal fixation device 3500, such as an intramedullary nail, having a proximal portion 3501, a distal portion 3502, and a central channel 3503 extending an entire length of the device 3500. A polymer material 3504 is located within the channel 3503 at the distal portion 3502 of the device 3500. The distal portion 3502 is hinged or tabbed to allow expansion of the distal portion 3502 upon expansion of the polymer material 3504, as will be further described below. In addition, the distal portion 3502 includes at least one feature, such as protrusions 3505, on a surface 3502a of the distal portion 3502. As shown in Fig. 61B, once the device 3500 is inserted into a bone, the polymer material 3504 is deformed, via one of the methods described above or another method known to one of ordinary skill in the art, to expand the material 3504 radially, thereby expanding the hinged distal portion 3502 outward to engage the bone and fixate the device 3500 to bone. The distal portion 3502 of the device 3500 may be coupled to the proximal portion 3501 via a hinge, tab, or any other coupling device that is made from biocompatible material. Alternatively, the distal portion 3502 may have an area that is thinner than the rest of the device 3500 and allows the distal portion 3502 to expand outward and engage bone.

[00165] Fig. 62A shows a cross-sectional end view of a construct 3600 including an internal fixation device 3601 having channels 3602, rods 3603 disposed within the channels 3602, and a sleeve 3604 of shape memory polymer material, similar to the sleeves described above, disposed over the device 3601 and the rods 3603. The construct 3600 is disposed within bone 3700 with the material 3604 having been supplied with energy, via a process described above or another process known to one of skill in the art, to deform the material 3604 and fixate both the device 3601 to the bone 3700 and the material 3604 to the rods 3603.

[00166] The device 3601 includes a metal material, but may include a non-metal material. The channels 3602 may be formed in the device 3601 via a machining process or other process known to one of skill in the art. The rods 3603 may include a metal material or another material that would make the rods 3603 solid enough in construction to substantially reduce deformation of the rods 3603 when the construct 3600 is inserted into the bone 3700 and the material 3604 is activated. The channels 3602 and rods 3603 may be continuous and extend a partial or full length of the device 3601 or they may be non-continuous and separated along a full or partial length of the device 3601. In addition, it is not necessary for the channels 3602 and the rods 3603 to extend the entire diameter of the device 3601 and the number of channels 3602 and rods

3603 will vary. In some applications, the rods 3603 may be textured to improve the integration of the material 3604 into the rods 3603, therefore allowing for increased fixation of the material

3604 to the rods 3603.

[00167] Fig. 62B shows a cross-sectional end view of a construct 3800 similar to the construct 3600 shown in Fig. 62 A. The construct 3800 includes an internal fixation device 3801, a sleeve 3802 of shape memory polymer material, similar to the sleeves described above, and components 3803 located between the device 3801 and the sleeve 3802. The components 3803 include barbs 3803a on the outer surface 3803b of the components 3803 for purposes that will be described below. The construct 3800 is disposed within bone 3900 with the material 3802 having been supplied with energy, via a process described above or another process known to one of skill in the art, to deform the material 3802 and fixate both the device 3801 to the bone 3900 and the material 3802 to the components 3803.

[00168] The device 3801 includes a non-metal material, such as a polymer material, but may include other non-metal or metal materials that allow the barbs 3803a to be embedded within the device 3801. The components 3803 may include a metal material or another material that would make the components 3803 solid enough in construction to allow the components 3803 to be embedded within the device 3801 and the sleeve 3802 when the construct 3800 is inserted into the bone 3900 and the material 3802 is activated. The components 3803 may be continuous and extend a partial or full length of the device 3801 or they may be non-continuous and separated along a full or partial length of the device 3801. In addition, it is not necessary for the components 3803 to extend the entire diameter of the device 3801 and the number of components 3803 will vary. In some applications, the components 3803 may be textured to improve the integration of the material 3802 into the components 3803, therefore allowing for increased fixation of the mat material 3802 to the components 3803.

[00169] As stated throughout this disclosure, internal fixation devices are used for fracture reduction, fixation or stabilization, and compression. For devices such as intramedullary nails, rods, and pins, fracture reduction and stabilization may occur via a method according to the following steps: creation of an entry portal at a location along the bone, provisional reduction of a fracture via the use of a reducer or other tool known to one of ordinary skill in the art for reducing fractures, insertion of the internal fixation device through the entry portal and placement of the device across the fracture, fixation of one side of the fracture by insertion of at least one fastener through the device or, as described above, expansion of a shape memory polymer material, reduction of the fracture via the application of pressure on the device or on the other side of the fracture that has not been fixated, and fixation of the other side of the fracture by insertion of at least one fastener through the device or, as described above, expansion of a shape memory polymer material. It is within the scope of this disclosure that the fixation and reduction steps may occur in a different order. For example, both sides of the fracture may be fixated before the fracture is reduced. This is especially true through, as described above, the use of a device that can compress the fracture via the use of an expandable polymer material.

[00170] For a device, such as a bone plate, fracture reduction and stabilization may occur via a method according to the following steps: reduction of the fracture, placement of a plate across the fracture via the use of an instrument or provisional fixation device, such as a forceps or pins/wires, to hold the plate to the bone while the plate is being fixated to the bone, placement of at least one non-locking or locking fastener through a hole in the plate and a hole on one side of the fracture, placement of at least one nonlocking or locking fastener through a hole in the plate and a hole on another side of the fracture and compression of the fracture either manually, via the use of compression screws, or with a device that uses expandable polymer material, as described above. It is within the scope of this disclosure that the holes may be made in the plate and the bone after the plate is placed across the fracture. The holes may be created through the use of a drill, a tap, a broach, or another instrument known to one of ordinary skill in the art for creating holes in the plate and bone. It is also within the scope of this disclosure that the fasteners may be fasteners that lock to the plate via the use of expandable material on either the head of the fastener or on the inner wall of the plate or bone holes, as described above. Also, multiple fasteners, used on one or both sides of the fracture, may be used to fixate the plate to the bone. It is within the scope of this disclosure that the fixation and reduction steps may occur in a different order. For example, both sides of the fracture may be fixated before the fracture is reduced. This is especially true through, as described above, the use of a device that can compress the fracture via the use of an expandable polymer material.

[00171] When the polymer material includes alternating segments of a shape memory polymer material and a non-shape memory polymer material, each shape memory segment can be individually provided with energy at separate time intervals in order to gradually cause straightening, bending, shortening, or lengthening of the material. For example, a first segment of shape memory polymer material can be activated to expand and shorten. This causes a first length of the material attached to the device to shorten. After a period of time, a second segment of shape memory polymer is activated to cause further shortening of material. This is beneficial for treatments requiring long-term remodeling, such as scoliosis or other deformities.

[00172] The present disclosure is directed to the use of electrical and thermal energy sources to heat the polymer material and deform it. However, the polymer material could be deformed via other methods known to those of ordinary skill in the art, including, but not limited to the use of force, or mechanical energy, a solvent, and /or a magnetic field. Any suitable force that can be applied either preoperatively or intra-operatively can be used. One example includes the use of ultrasonic devices, which can deform the polymer material with minimal heat generation. Solvents that could be used include organic-based solvents and aqueous-based solvents, including body fluids. Care should be taken that the selected solvent is not contra indicated for the patient, particularly when the solvent is used intra-operatively. The choice of solvents will also be selected based upon the material to be deformed. Examples of solvents that can be used to deform the polymer material include alcohols, glycols, glycol ethers, oils, fatty acids, acetates, acetylenes, ketones, aromatic hydrocarbon solvents, and chlorinated solvents. Finally, the polymer material could include magnetic particles and deformation could be initiated by inductive heating of the magnetic particles through the use of a magnetic field.

[00173] It is also within the scope of this disclosure to include a pressure sensor within the sleeve of shape memory polymer material that is coupled to the internal fixation device. This pressure sensor may communicate with the hand-held battery powered device described above or another power control unit to provide the user with a measurement of the amount of force that exists between the bone and the internal fixation device when the sleeve is provided with energy and expands against the inner wall of the bone. The force may be monitored and regulated based on the measurement. In addition, a thermocouple may be placed on the inner wall of the sleeve to measure the temperature of the polymer material as it is provided with energy. The thermocouple may communicate with the hand-held battery-powered device to allow the user to know when the temperature of the material has gone above the glass transition temperature of the material and the material has therefore begun to deform. The thermocouple would also be advantageous in monitoring the temperature of the material during the application of energy such that the user would be able to substantially reduce the possibility of the temperature reaching the melting temperature of the material.

[00174] Within the scope of this disclosure is also the possibility of the sleeve of shape memory polymer being fixated to the interface portion of the internal fixation device via the use of biocompatible glue, rather than relying on the above-described properties or textures on the surface of the interface portion to provide fixation of the sleeve to the device. EXAMPLE ONE

[00175] The present example provides a fabrication process for the internal fixation device of the present disclosure, a method of fixating the device to bone, and test results on the fixation strength of the device.

[00176] Sleeves of a polymer composite were manufactured using a copolymer and a filler material. Specifically, 600 g of a copolymer of poly L-lactic acid (PLLA) and poly D-lactic acid (PDLA) having a glycolide component was vacuum dried at a temperature of about 500C and a pressure of about 10 millibars for 48 hours. The ratio between the lactide unit and the glycolide unit was 85:15. 300 g of a filler material, namely calcium carbonate, were placed in a 1000 ml glass jar and vacuum dried at about 15O0C and a pressure of about 10 millibars for 48 hours. A dry blend was then produced by mixing the copolymer and calcium carbonate. This blend was then compounded in a prism twin screw extruder to form pellets of a copolymer/calcium carbonate composite. These pellets were placed into a cylindrical mould that was sealed at one end with a plug. A pressure of about 20 MPa was applied to the pellets via a plunger and the temperature of the mould was raised to a level that was sufficient to melt the pellets, or about 2000C. The temperature was maintained at this level for 20 minutes. The mould was then cooled to room temperature and the pressure was released by removal of the plunger. The plug was removed from the mould and a billet of the polymer composite material was pressed out of the mold. The billet was die drawn to produce a final rod of material having a diameter of about 8 mm.

[00177] Interface portions corresponding to Figs. 21 and 2K were machined onto 2 steel rods, each rod having an outside diameter of 0.375 inches. The length of the interface portion was about 0.75 inches. The above-mentioned sleeves of polymer composite, also having an outer diameter of 0.375 inches, were machined and placed over the interface portion of each rod. The interface portion/polymer composite area of the rods were placed into a 7/16 inch hole that had been drilled into a block of 20 Ib synthetic bone. The rod and synthetic bone combinations were then immersed in a water batch at 5O0C for 1 hour and then removed and allowed to dry at room temperature. Immersion of the rod and synthetic bone combinations into water caused the polymer material to deform and fixate the rod to the bone. The fixation of the rods was tested by clamping the synthetic bone and testing the pullout and torque strengths of the rods by using a loading rate of 0.1 inches/min and 10°/min, respectively. Results for the pullout test and the torsion test are given in Figs. 63 and 64, respectively. The test results for the interface portion corresponding to Fig. 21 are represented as "I" in the figures and the test results for interface portion corresponding to Fig. 2K are represented as "K" in the figures.

[00178] This example shows that an internal fixation device, having a shaped interface portion and a polymer material coupled to the interface portion, can be fixated to bone by providing energy to the polymer material and thereby causing the material to deform and engage the bone. In addition, tests performed on the fixation strength of the device show that the device is able to withstand a variety of loading rates without becoming dislodged from the bone. As mentioned above, fixation of these devices to bone via use of the polymer material, rather than mechanical fasteners, such as screws and pins, provide significant advantages to both the surgeon and the patient. In addition, adequate fixation of the device to bone will be beneficial in maintaining a compressive load across a fracture site over a longer period of healing.

EXAMPLE TWO

[00179] Two Delrin rods were used to simulate a fractured bone. Ends of the rods were placed adjacent to each other with the point at which the ends of the two rods met being defined as the simulated fracture point. Each rod had a diameter of about .75 inches, a length of about 4.3 inches, and a 7 mm diameter through hole that extended the entire length of each rod.

[00180] Fiber reinforced composite rods were then manufactured. PLLA fiber was first made by taking PLLA granules with a nominal intrinsic viscosity of 3.8 and extruding the granules into a fiber. A single screw extruder fitted with a gear pump and a 2 mm spinneret die was used. The extruder also had a provision for air cooling. The extruded fiber was batched on spools for the next processing step. Subsequently, the fiber was progressively stretched at elevated temperatures to produce a final diameter of ca. 100 microns and a draw ratio between about 8 and about 15. The final molecular weight of the drawn fiber was between about 290,000 g/mol"1 to about 516,000 gmoi'1. The resultant fiber had an average tensile strength of greater than about 800 MPa.

[00181] Composites were then made using an 85:15 co-polymer of PDLLA and PGA with a 35 % weight addition of calcium carbonate (CaCO3) as the matrix material. The drawn poly (L-lactide) fibers were then wound around a support frame of parallel bars that were held a constant distance apart. For each sample the fiber was wrapped 75 times around the support frame, resulting in 150 fibers in each composite. The matrix was dissolved in a solvent, methyl acetate, at 10% wt/vol of solvent. The solvent/polymer mixture was then coated onto the fibers. The composite was then placed in a vacuum oven at 400C for 12 hours to remove the solvent.

[00182] The composite was then placed in a cylindrical mold with an internal diameter of about 2 mm and heated to 1650C. This temperature is used to melt the matrix material to allow it to flow and consolidate the composite. Once thermal equilibrium was reached, slight tension was applied to the fibers to align them in the mold. The mold was then closed completely to consolidate the fibers and the matrix. The closed mold was then maintained at 1650C for up to 5 minutes and then removed from the heated press and placed between cool metal blocks to cool the composite down to room temperature to allow tension to be released from the fibers. This resulted in lengths of composite rod with an approximate diameter of 2 mm.

[00183] A construct was then made by placing the rods within the simulated bone to extend across the fracture point and gluing the rods into place using a thermoset matrix material, such as a degradable 2 part polyurethane material obtainable from PolyNovo Biomaterials Ltd. located in Victoria, Australia. The polyurethane was inserted into the simulated bone via the use of a syringe and allowed to cure overnight. The polyurethane material stabilizes the rods and fixates the rods to the bone, thereby stabilizing the fracture.

[00184JThe bending strength and shear strength of the construct were then tested. The bending strength was tested using a cantilever test, in which one half of the construct was held rigid while a load was applied to the other half of the construct at a point that was located about 50 mm away from the fracture location. The construct was loaded at a rate of 5 mm/min to deflect the one half of the construct at a 10° angle relative to the other half. The force required to deflect the construct 10° was 19 lbs. The shear strength was tested by clamping both halves of the construct to displace the two halves 2 mm relative to each other at a rate of 10 mm/min. The force required to shear the construct 2 mm was 362 lbs,

EXAMPLE THREE

[00185] A die-drawn PLDLA(70/30) rod containing 35% wt/wt of calcium carbonate was machined into a plug having a diameter of 13 mm and a length of 25mm. The plug included a stem having a length of 20 mm and a diameter of 8 mm. The plug was similar in construction to the polymer material shown in Figs. 53A-53B. A hole of 3/16 inch diameter was drilled through the centre the plug. Once machined into these dimensions, a 40mm length of steel tubing, referred to as a metal sleeve, was inserted into the hole.

[00186] A stainless steel tubing (8mm ED/12 mm OD) was generated such that one end of the tubing was profiled to have slots, 3 (6mm semicircle slots) and 3 (4X8mm elliptical slots), and the other end was machined to have 3 flat surfaces suitable for an instron to grip. The stem of the plug with metal sleeve was inserted into the end (containing the slots) of the stainless steel tubing, to form a construct, and this construct was placed into the canal of a section of femur, approximately 50mm in length and 17mmX16mm in diameter. The bone was left to equilibrate to room temperature.

[00187] A heating probe (4mm diameter), which was connected to and controlled by a DC power supply, was inserted into the metal sleeve and the power supply was switched on (18 Volts and a little over 1 Amp). Once the probe reached the desired temperature, a timer was started. At a set time point, about 15 minutes, the heating probe was removed from inside the sleeve and the bone containing the polymer plug was immersed in cold water.

[00188] Once removed from the cold water, a pushout test was carried out using an Instron 5566 with 1OkN load cell and Bluehill software program. The stainless steel tubing was clamped in the stationary grip at the top of the test frame and the bone with plug was placed on a plate on top of the crosshead. During testing, the plate on the crosshead was raised upwards at a rate of 1 mm/minute. The push out forces for the bone/tube construct was measured and found to 1353N. EXAMPLE FOUR

[00189] The experiment of example three was repeated with a section of femur having a canal of approximately 50mm in length and lSJmmX 17.6mm in diameter. A pushout force of 96 IN was recorded.

[0019O]As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the disclosure, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present disclosure should not be limited by any of the above- described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.

Claims

CLAIMSWhat is claimed is:
1. An internal fixation device comprising: an interface portion and a polymer material coupled to the interface portion, wherein the polymer material includes at least one feature on a surface of the polymer material.
2. A method of fixating an internal fixation device to a bone comprising: providing an internal fixation device having an interface portion and a polymer material coupled to the interface portion, wherein the polymer material includes at least one feature on a surface of the polymer material; inserting the internal fixation device into a bone; and providing the polymer material with energy to deform the material and fixate the internal fixation device to the bone.
3. The internal fixation device of claim 1 wherein the polymer material includes multiple features.
4. The internal fixation device of claim 1 wherein the feature includes particulate material.
5. The internal fixation device of claim 4 wherein the particulate material includes a ceramic material.
6. The internal fixation device of claim 1 wherein the feature includes a protrusion.
7. The internal fixation device of claim 6 wherein the protrusion is selected from a group consisting essentially of a metal material, a non-metal material, a polymer material, and combinations thereof.
8. The internal fixation device of any of claims 1 or 7 wherein the polymer material includes shape memory qualities.
9. The internal fixation device of any of claims 1 or 7 wherein the polymer material includes a resorbable or a non-resorbable polymer material.
10. An internal fixation device comprising: a channel; and a shape memory polymer material located within the channel.
11. A method of fixating an internal fixation device to a bone comprising: providing an internal fixation device including a channel and a shape memory polymer material located within the channel; inserting the internal fixation device into a bone; and providing the polymer material with energy to deform the material and fixate the internal fixation device to the bone.
12. The internal fixation device of claim 10 wherein the channel partially extends a length of the device.
13. The internal fixation device of claim 12 wherein the shape memory polymer material includes a body having a stem portion, the stem portion located within the channel.
14. The internal fixation device of claim 10 wherein the internal fixation device includes a proximal portion and a distal portion, the shape memory polymer material located at the distal portion.
15. The internal fixation device of claim 14 wherein the distal portion includes a hinge.
16. The internal fixation device of claim 14 wherein the distal portion includes at least one feature on a surface of the distal portion.
17. The internal fixation device of claim 16 wherein the feature includes a protrusion.
18. The method of claim 11 wherein the internal fixation device includes a proximal portion and a hinged distal portion, the shape memory polymer material located at the distal portion.
19. The method of claim 18 wherein the distal portion extends outward and engages in the bone when the polymer material is provided with energy.
20. A method of fixating at least one internal fixation device to a bone comprising: providing at least one internal fixation device; inserting the internal fixation device into the bone; and inserting a thermoset matrix into the bone.
21. The method of claim 20 further comprising providing a plurality of internal fixation devices and inserting the plurality of internal fixation devices into the bone.
22. The method of claim 20 wherein the at least one internal fixation device includes a polymer material.
23. The method of claim 21 wherein the plurality of internal fixation devices include a polymer material.
PCT/US2008/056828 2007-03-13 2008-03-13 Internal fixation devices WO2008112875A2 (en)

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