Intramedullary Nail

Abstract

An intramedullary device includes an intramedullary nail extending along a longitudinal axis from a proximal end to a distal end, a proximal portion of the intramedullary nail including a cavity extending from an opening at the proximal end along the longitudinal axis and a locking hole extending transversely therethrough along with a first insert sized and shaped for insertion into the cavity along the longitudinal axis thereof and including a transverse bore aligning with the locking hole.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No. 13/098,935 entitled “Intramedullary Nail” filed May 2, 2011, now pending, which claims priority to and the benefit of U.S. Provisional Application Ser. No. 61/362,937 filed on Jul. 9, 2010, entitled “Intramedullary Nail.” The disclosure of each application identified above is incorporated herein by reference in its entirety for all purposes.

TECHNICAL FIELD

The present disclosure generally relates to an intramedullary nail for fixation of fractured bones and more particularly to an intramedullary nail comprising an attachment structure for an insertion instrument and an insert for firmly securing locking screws to the intramedullary nail.

BACKGROUND

Intramedullary nails are commonly used as bone fixation devices for osteosynthesis purposes. Often these intramedullary nails feature locking screws inserted transversely through the intramedullary nail for either stabilizing the intramedullary nail in the bone or for fixation of individual bone fragments. These intramedullary nails may permit multiple locking screws to be inserted therethrough at different angles relative to one another. The locking screws are often secured in the intramedullary nail via a plastic bushing or ring preventing the screw from migrating out of the intramedullary nail due to micro-motion or other loads. To secure these screws in the intramedullary nail, an interference fit and a forced tapping of the screw into the bushing is generally applied. Other fixation features include metal interfaces that may be mechanically deformed and/or permit forced tapping in metal. These bushings should be formed of a material that is biocompatible. However, there is limited availability of such a material. One such available plastic material is Ultra High Molecular Weight Poly-Ethylene (UHMWPE), which is a material that has been approved worldwide for implantation. Although the biocompatibility of this material is ideal, the material is difficult to process with required accuracy using conventional processing and molding techniques.

An example of a locking intramedullary nail including transverse locking holes and an insert for securing the locking screws in these locking holes is known from EP Patent No. B 0 306 709 DAUERER. This known intramedullary nail comprises a proximal and a distal insert with transverse bores having a diameter smaller than the outer diameter of the locking screws so as to secure the locking screws in the locking holes of the intramedullary nail. The insert is slidably inserted into the central cavity of the intramedullary nail. This known intramedullary nail, however, does not comprise an attachment structure at the proximal end to fix an insertion instrument to the nail.

One problem associated with the above described intramedullary nails involves the attachment mechanism for an insertion handle or aiming device which is usually arranged at the proximal end of commonly used intramedullary nails is that the insert must have a small outer diameter in order to be introduced through a central opening of the attachment mechanism.

Thus, there remains a need for an improved intramedullary nail for a rigid fixation between the nail and the bone including an attachment mechanism for a surgical instrument and an insert, which permits the locking screws to be firmly secured in the locking holes of the intramedullary nail

SUMMARY

The present disclosure relates to an intramedullary nail having an attachment mechanism for an insertion instrument and an insert with transverse holes that are adapted and configured to firmly secure locking screws in the intramedullary nail.

According to the present disclosure, an intramedullary nail is extending along a longitudinal axis from a proximal end to a distal end, the nail comprising a cavity extending from an opening at the proximal end along the longitudinal axis and a first locking hole extending transversely through the nail sized and shaped to receive a locking screw therethrough along with a first insert sized and shaped for insertion into the cavity including a first transverse bore arranged so that, when the insert is in the desired position within the cavity, the first bore is aligned with the first locking hole so that a locking screw inserted through the first locking hole passes through the insert via the first bore and a second insert sized and shaped to be lockingly received within the cavity proximal of the insert to lock the insert at the desired position in the cavity.

Some advantages of the intramedullary nail according to an embodiment of invention are that the insert does not have to be assembled through an attachment mechanism, e.g. an internal thread at the proximal end of the intramedullary nail, and can therefore have an increased diameter. In addition, due to the increased diameter, the insert can be manufactured from ultra-high molecular weight polyethylene (UHMWPE) by using conventional processing and molding techniques. Further, due to the increased diameter of the insert, the locking screws can be firmly secured in the transverse bores of the insert and consequently in the locking holes of the intramedullary nail.

In one exemplary embodiment of the intramedullary nail, the first insert has an outer diameter D and the central bore has an inner diameter d and wherein the outer diameter D is greater than the inner diameter d of the central bore of the second insert.

In a further exemplary embodiment of the intramedullary nail, the first insert is made of ultra-high molecular weight polyethylene (UHMWPE). Preferably, the second insert and the intramedullary nail are made of TAN.

In another exemplary embodiment of the intramedullary nail, the first insert has an anti-rotation mechanism for preventing rotation of the first insert in the cavity in the intramedullary nail. Due to the anti-rotation mechanism the first insert is kept in a rotatively fixed position relative to the intramedullary nail so that the transverse bores in the first insert are aligned with the locking holes in the proximal part of the intramedullary nail.

In again another exemplary embodiment of the intramedullary nail, the first insert has more than one transverse bore.

In yet a further exemplary embodiment of the intramedullary nail, at least two transverse bores in the first insert extend in different directions.

In still a further exemplary embodiment of the intramedullary nail the second insert is fixed in the cavity of the intramedullary nail by one or more laser-welds. Preferably, the laser weld is a circumferential weld. Alternatively, the laser-welds are two small longitudinal laser-welds. Additionally, the second insert can be fixed in the cavity in the intramedullary nail via an external thread or a press-fit.

In another exemplary embodiment, the first insert has a cylindrical shape.

According to a further aspect of the present disclosure, an assembly is provided comprising an intramedullary nail and one or more locking screws, wherein the locking screws have a greater diameter than the transverse bores in the first insert.

In accordance with another aspect of the present disclosure, a method for assembling the intramedullary nail according to the invention is provided which comprises the steps of inserting a first insert into a cavity of a intramedullary nail, the intramedullary extending along a longitudinal axis from a proximal end to a distal end and including a first locking hole extending transversely through the nail sized and shaped to receive a locking screw therethrough, the cavity extending from an opening at the proximal end along the longitudinal axis, the insert including a first transverse bore arranged so that, when the insert is in the desired position within the cavity, the first bore is aligned with the first locking and inserting a second insert into the cavity of the intramedullary nail, the second insert sized and shaped to be lockingly received within the cavity proximal of the insert to lock the insert at the desired position in the cavity.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the present disclosure will be described in the following by way of example and with reference to the accompanying drawings in which:

FIG. 1 illustrates a perspective exploded view of an exemplary embodiment of the intramedullary nail according to the present disclosure;

FIG. 2 illustrates an exploded view in a longitudinal section of the embodiment of the intramedullary nail of FIG. 1;

FIG. 3 illustrates a longitudinal section of the embodiment of the intramedullary nail of FIG. 1 in the assembled state;

FIG. 4 illustrates a perspective view of the embodiment of the intramedullary nail of FIG. 1 in the assembled state; and

FIG. 5 illustrates a lateral exploded view of the embodiment of the intramedullary nail of FIG. 1.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The present disclosure may be further understood with reference to the following description and the appended drawings, wherein like elements are referred to with the same reference numerals. The present disclosure generally relates to an intramedullary nail for fixation of fractured bones and more particularly to an intramedullary nail comprising an attachment structure for an insertion instrument and an insert for firmly securing locking screws to the intramedullary nail. It should be noted that the terms “proximal” and “distal” as used herein are intended to refer to a direction toward (proximal) and away from (distal) a user of the intramedullary nail.

As shown in FIGS. 1 to 5, an intramedullary nail 1 extends along a longitudinal axis 11 from a proximal end 13 to a distal end and includes a cavity 14 extending through a proximal portion 12 thereof. The intramedullary nail 1 further comprises a first insert 2 and a second insert 3 insertable through the cavity 14. The intramedullary nail 1 includes the proximal portion 12 and a distal portion 9, the proximal portion 12 including the cavity 14 extending longitudinally therethrough and a plurality of locking holes 15 for receiving locking screws extending transversely therethrough. The first insert 2 is inserted into the cavity 14 and the second insert 3 is inserted into the cavity 14 proximally of the first insert 2. The cavity 14 extends coaxially with the longitudinal axis 11 and is open at the proximal end 13. The cavity 14 may include an enlarged diameter portion at the proximal end 13 including an internal thread 19 extending thereabout for engaging the second insert 3. Further, the cavity 14 may also include a contraction which forms an axial stop 16 to prevent the first insert 2 from moving distally therepast toward the distal part 9 of the intramedullary nail 1. The plurality of locking holes 15 extend through the proximal portion 12 of the intramedullary nail 1 transversely to the longitudinal axis 11. Each of the locking holes 15 have a hole axis 17 and are arranged in such a manner that the hole axis 17 of each of the locking holes 15 orthogonally cuts the longitudinal axis 11 of the intramedullary nail 1. Further, the locking holes 15 are spaced apart from each other along the longitudinal axis 11 of the intramedullary nail 1. The locking holes 15 are staggeredly arranged so that the hole axes 17 of the four locking holes 15 extend at an angle relative to one other when viewed in a cross-section orthogonal to the longitudinal axis 11 of the intramedullary nail 1. In a preferred embodiment, the intramedullary nail 1 includes four locking holes 15. It will be understood by those of skill in the art, however, that the intramedullary nail 1 may include any number of locking holes 15.

The first insert 2 may have a cylindrical body 27 extending along a central axis 24 from a proximal end 21 to a distal end 22. The first insert 2 includes an eccentric nose 25 at the distal end 22. The first insert 2 is coaxially positioned in the cavity 14 and includes a plurality of transverse bores 20 extending transversely therethrough, each of the transverse bores 20 having a bore axis 26. The transverse bores 20 are arranged in such a manner that the bore axes 26 extend orthogonally of the central axis 24 and are equally spaced apart and extend at equal angles relative to each other, corresponding to a position of the locking holes 15 in the proximal part 12 of the intramedullary nail 1. Thus, when inserted into the cavity 14, the transverse bores 20 in the first insert 2 may be exactly aligned with the locking holes 15 in the proximal part 12 of the intramedullary nail 1.

As illustrated in FIG. 3, the eccentric nose 25 engages a complementarily shaped eccentric portion 10 in the cavity 14 when the first insert 2 is inserted in the cavity 14. Thus, the eccentric nose 25 and the eccentric portion 10 form an anti-rotation mechanism 6, which prevents the first insert 2 from rotating relative to the cavity 14 in the intramedullary nail 1. The cylindrical body 27 of the first insert 2 may also include a stop face 23 proximally of the eccentric nose 25 for contacting the axial stop 16 in the cavity 14 of the intramedullary nail 1 when the first insert 2 is completely inserted in the cavity 14. The second insert 3 may also be cylindrical, including a central bore 30. The second insert 3 is fixedly positioned in the cavity 14 coaxially and proximally of the first insert 2. The second insert 3 may have an internal thread 31 along an inner surface of the central bore 30 and an external thread 32 along an outer surface thereof, which corresponds to the internal thread 19 of the enlarged diameter portion of the cavity 14 such that the second insert 3 may threadedly engage the cavity 14. The cavity 14 also includes a shoulder 18 therein, which is distal of the enlarged portion so that the second insert 3 contacts the shoulder 18 and is prevented from moving distally therepast, further into the cavity 14.

The first insert 2 has been described as having an eccentric nose 25. It will be understood by those of skill in the art, however, that other nose configurations are also possible. For example, the nose could be concentric but have a flattened edge to provide the anti-rotation mechanism with a complementarily shaped eccentric portion in a cavity. In another example, the nose could feature two or more complementary edges that have rotational symmetry of, for example, order 2.

As illustrated in FIG. 2, a portion of the cavity 14 which receives the first insert 2 and which is axially limited by the axial stop 16 and by the shoulder 18 has a length L which is slightly greater than a length l₂ of the cylindrical body 27 of the first insert 2. The central bore 30 of the second insert 3 may act as a fixation structure for coupling an insertion instrument such as, for example, an insertion handle and/or an aiming device, to the intramedullary nail 1. The first insert 2 has an outer diameter D and the central bore 30 has an inner diameter d, wherein the outer diameter D of the insert 2 is greater than the inner diameter d of the central bore 30 of the second insert 3. Thus, once the first insert 2 is fully inserted in the cavity 14 it cannot be axially displaced upon insertion of the second insert 3 but is retained by the second insert 3 in the cavity 14.

As illustrated in FIGS. 4 and 5, the second insert 3 is fixed in the cavity 14 of the intramedullary nail 1 via a longitudinal laser-weld 5, which may be positioned in an oblong opening 28, which extends through a wall of the proximal portion 12 of the intramedullary nail 1. In one exemplary embodiment, the intramedullary nail 1 includes two longitudinal laser-welds 5 and two oblong openings 28 that are axially located between the shoulder 18 in the cavity 14 and the proximal end 13 of the intramedullary nail 1. Further, the two oblong openings 28 have a long axis each which extends parallel to the longitudinal axis 11 of the intramedullary nail 1 and when viewed in a cross-section orthogonal to the longitudinal axis 11 the two oblong openings 28 are arranged at an angle relative to one another. In another embodiment, the second insert 3 may be welded, for example circumferentially, to the cavity 14 at the proximal end 13 of the intramedullary nail 1, between an exterior surface of the second insert 3 and an interior of the enlarged diameter portion at the proximal end 13 which receives the second insert 3.

Furthermore, the transverse bores 20 in the first insert 2 have a smaller diameter than the locking screws (not shown) used to lock the intramedullary nail 1 in a bone. Therefore, the thread of the locking screw cuts into the wall which limits the respective transverse bore 20 so that the locking screws are secured against loosening within the transverse bores 20 and consequently within the locking holes 15 of the intramedullary nail 1 so that a rigid fixation of the locking screws in the intramedullary nail 1 can be achieved.

Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present disclosure, processes, machines, manufacture, composition of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure.

It will be appreciated by those skilled in the art that various modifications and alterations of the invention can be made without departing from the broad scope of the appended claims. Some of these have been discussed above and others will be apparent to those skilled in the art.

Claims

1. A intramedullary bone fixation system comprising:

an intramedullary nail having a proximal end, a distal end spaced from the proximal end along a longitudinal axis, a cavity extending from the proximal end of the nail toward the distal end, and at least one locking hole that extends through the nail along a locking hole axis that is substantially transverse to the longitudinal axis, the at least one locking hole having a first cross-sectional dimension; and

an insert in the nail cavity, the insert having a first end, a second end spaced from the first end along a longitudinal axis toward the distal end of the nail, and at least one bore that extends through the insert, wherein the at least one bore is aligned with the at least one locking hole along the locking hole axis, wherein the at least one bore defines a second cross-sectional dimension that is less than the first cross-sectional dimension.

2. The intramedullary bone fixation system of claim 1, further comprising at least one locking screw configured for insertion into the at least one locking hole and the least one bore, wherein the at least one locking screw has a threaded portion having a third cross-sectional dimension that is greater than the second cross-sectional dimension.

3. The intramedullary bone fixation system of claim 2, wherein the threaded portion of the at least one locking screw is configured to cut into the at least one bore when the threaded portion of the at least one locking screw is inserted into the at least one bore.

4. The intramedullary bone fixation system of claim 3, wherein the insert is ultra-high molecular weight polyethylene.

5. The intramedullary bone fixation system of claim 4, wherein the intramedullary nail is metallic.

6. The intramedullary bone fixation system of claim 1, wherein the intramedullary nail defines a stop in the cavity, and wherein the cavity includes a proximal cavity portion that extends from the proximal end of the intramedullary nail to the stop, wherein the insert is disposed in at least a portion of the proximal cavity portion.

7. The intramedullary bone fixation system of claim 6, wherein the second end of the insert defines a stop face that is adjacent to the stop in the cavity.

8. The intramedullary bone fixation system of claim 7, wherein the insert has a projection that extends from the stop face toward the distal end of the intramedullary nail.

9. The intramedullary bone fixation system of claim 6, wherein the insert is a first insert, wherein the bone fixation further comprises a second insert configured for insertion in the cavity adjacent to the first insert.

10. The intramedullary bone fixation system of claim 9, wherein the second insert includes an external thread on an outer surface thereof, wherein the cavity defines an internal thread adjacent to the proximal end of the nail, wherein the external thread of the second insert is configured to engage the internal thread of the intramedullary nail.

11. The intramedullary bone fixation system of claim 9, wherein the cavity includes a shoulder disposed between the proximal end of the intramedullary nail and the stop, and the second insert is configured to contact the first end of the first insert and the shoulder.

12. The intramedullary bone fixation system of claim 1, wherein the at least one locking hole is a first locking hole and a second locking hole, and wherein the at least one bore is a first bore and a second bore, wherein the first bore is aligned with the first locking hole and the second bore is aligned with the second locking hole along respective locking hole axes.

13. The intramedullary bone fixation system of claim 12, wherein the first and second locking holes extend through the intramedullary nail at an angle relative to one another.

14. The intramedullary bone fixation system of claim 12, wherein the at least one locking screw is a first locking screw and a second locking screw, wherein the first locking screw is configured for insertion into the first locking hole and the first bore, and the second locking screw is configured for insertion into the second locking and the second bore.

15. A method for securing an intramedullary nail to a bone, the nail having a proximal end, a distal end spaced from the proximal end along a longitudinal axis, and a cavity extending from the proximal end toward the distal end, the method comprising:

inserting a locking screw through at least one locking hole in the intramedullary nail, the at least one locking hole extending along a locking hole axis that is substantially transverse to the longitudinal axis, wherein the locking screw has a threaded portion defining a first diameter; and

causing the threaded portion of the locking screw to cut into the at least one bore defined by an insert, the at least one bore extending transversely through the insert, and wherein the insert is disposed in the cavity such the at least one bore is aligned with the at least one locking hole, wherein the at least one bore has a second diameter that is less than first diameter.

16. The method of claim 15, wherein the at least one locking hole is a first locking hole and second locking hole, and the at least one bore is a first bore and a second bore, and the locking screw is a first locking screw, wherein the method further comprises the steps of:

inserting a second locking screw into the second locking hole; and

causing a threaded portion of the second locking screw to cut into the second bore.

17. The method of claim 15, wherein the step of inserting the locking screw includes the step of inserting the locking screw in at least one locking hole that is disposed at a proximal portion of the intramedullary nail, the proximal portion being adjacent to the proximal end of the intramedullary nail.

18. The method of claim 15, further comprising advancing the threaded portion of the locking screw through the at least one locking hole and the at least one bore so as to engage the bone.

19. The method of claim 15, wherein the insert is a first insert, wherein the method further comprises the step of inserting a second insert through an opening at the proximal end of the nail into the cavity proximal to the first insert.

20. The method of claim 19, wherein the step of inserting the second insert further comprises advancing the second insert into the cavity along the longitudinal axis into contact with a shoulder defined by the cavity and a proximal end of the first insert.