IMPLANT COMPONENTS AND METHODS

Abstract

Systems, devices, and methods are provided for orthopedic implants. The implants may include a base member, such as an acetabular shell or an augment, that is configured to couple with an augment, flange cup, mounting member, or any other suitable orthopedic attachment. A mounting member may be used to attach to an implant and anchor the implant to a patient's bone or soft tissue. The mounting member may be integral with the implant or may be provided as a separate component. A mounting member may be adjustably positionable around the implant to provide flexibility and allow the mounting member to meet needs of a particular patient and implant.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 61/352,705, filed Jun. 8, 2010, U.S. Provisional Application No. 61/352,722, filed Jun. 8, 2010, U.S. Provisional Application No. 61/422,903, filed Dec. 14, 2010, and U.S. Provisional Application No. 61/466,817, filed Mar. 23, 2011, which are hereby incorporated by reference herein in their entireties.

BACKGROUND

Joints often undergo degenerative changes due to a variety of reasons. When joint degeneration becomes advanced or irreversible, it may become necessary to replace the natural joint with a prosthetic joint. Artificial implants, including hip joints, shoulder joints, and knee joints are widely used in orthopedic surgery. Specifically, hip joint prostheses are common. The human hip joint acts mechanically as a ball and socket joint, wherein the ball-shaped head of the femur is positioned within the socket-shaped acetabulum of the pelvis. Various degenerative diseases and injuries may require replacement of all or a portion of a hip using synthetic materials, typically metals, ceramics, or plastics.

More particularly, natural hips often undergo degenerative changes, requiring replacement of the hip joint with a prosthetic joint. Often, the hip is replaced with two bearing surfaces between the femoral head and the acetabulum. The first bearing surface is typically a prosthesis shell or acetabular cup, which may be formed of metal, ceramic material, or as otherwise desired. A liner (conventionally formed of polyethylene material such as ultra high molecular weight polyethylene, a ceramic material, or in some cases, even a metal liner) is then fit tightly within the shell to provide an inner bearing surface that receives and cooperates with an artificial femoral head in an articulating relationship to track and accommodate the relative movement between the femur and the acetabulum.

The cup (or a cup and liner assembly) is typically fixed either by placing screws through apertures in the cup or by securing the cup with cement. In some cases, only a liner is cemented in a patient due to poor bone stock. In other cases, a cup having a porous surface may be press fit into the reamed acetabular surface.

It may become necessary to conduct a second or subsequent surgery in order to replace a prosthetic joint with a (often larger) replacement joint. Such surgeries often become necessary due to further degeneration of bone or advancement of a degenerative disease, requiring removal of further bone and replacement of the removed, diseased bone with a larger or enhanced prosthetic joint, often referred to as a revision prosthesis. For example, bone is often lost around the rim of the acetabulum, and this may provide less rim coverage to securely place a press-fit cup. Such surgeries may thus be referred to as revision surgeries.

In acetabular revision surgery, an acetabular prosthesis generally includes additional mounting elements, such as augments, flanges, hooks, plates, or any other attachment or mounting points or members that provide additional support and/or stability for the replacement prosthesis once positioned. These additional mounting or attachment members are often required due to bone degeneration, bone loss, or bone defects in the affected area (in this instance, the hip joint).

Various types of these mounting members (which term is intended to include but not be limited to flanges, blades, plates and/or hooks) may be provided in conjunction with a prosthesis system in order to help the surgeon achieve optimal fixation, non-limiting examples of which include iliac flanges (providing securement and fixation in and against the ilium region of the pelvis), ischial blades (providing securement and fixation in and against the ischium), and obturator hooks (providing securement and inferior fixation by engaging the obturator foramen). Although there have been attempts to provide such mounting attachments with modularity, the solutions to date have generally fallen short of providing true modularity. Instead, they typically provide a few discrete positions at which the mounting members may be positioned, without providing the surgeon a fuller range of decision options.

Additionally, in some primary surgeries and more often in revision surgeries, the acetabulum may have a bone defect or void that the surgeon must fill with bone grafts before inserting a new shell. This can be time consuming and expensive, and may subject the patient to additional health risks. Some techniques use an augment in connection with the acetabular shell, which can be coupled to or otherwise attached to the outer surface of the shell.

With current augments, the surgeon can attach the augment to the bone and then implant the cup. However, many acetabular shells rely on bone screws to achieve proper fixation and the augment often gets in the way of a screw. In short, surgeons need the freedom to place screws in the best location, but this compromises their ability to use augments. With current systems, it also takes an increased amount of time surgical time to trial the component orientation and then try to find good bone fixation for the cup. The surgeon will often have to free-hand the amount of bone removed while estimating the size of augment needed. In the cases where bone is often deficient, surgeons are hesitant to take away any more bone than necessary.

Various additional features and improved features intended for use and application with various types of joint implants are also described herein, such as improved bone screws, improved coatings, and various augment removal and insertion options.

SUMMARY

Disclosed herein are systems, devices, and methods for providing modular orthopedic implants. The implants may include a base member, such as an acetabular shell or an augment, that is configured to couple with an augment, flange cup, mounting member, any other suitable orthopedic attachment, or any combinations thereof. Mounting members include, for example, flanges, blades, hooks, and plates. In some embodiments, the orthopedic attachments may be adjustably positionable about the base member or other attachments thereby providing modularity for assembling and implanting the device. Various securing and/or locking mechanisms may be used between the components of the implant. In certain embodiments, the orthopedic attachments are removably coupled to the base member or other components. In certain embodiments, the orthopedic attachments are integrally provided on the base member or other components, yet may still be adjustably positionable thereabout. In some embodiments, expandable augments, base members, or other bone filling devices are provided. In some embodiments, surface features are provided that create friction and allow for surrounding bone ingrowth at the interface of the implants and a patient's bone.

Systems, devices, and methods described herein provide implants having attachment mechanisms that provide a plurality of positioning options for the orthopedic attachments. In certain embodiments, an orthopedic device includes an implant structured to fit with and stabilize a patient's orthopedic joint, the implant having a plurality of attachment sites, and a mounting member having a first end that anchors to the patient's bone or soft tissue and a second end that mates with the implant at each of the plurality of attachment sites. The plurality of attachment sites can include portions of a crossbar extending about an acetabular shell. Alternatively or additionally, the attachment sites can include a groove extending along a rim of the implant. In some embodiments, attached mounting members may include conventional holes, locking holes, or slots. The sites may be threaded, unthreaded, or partially threaded, and may be fixed or polyaxial. In some embodiments, attachment sites may include variable low-profile holes that allow for locking at a variety of angles. In some embodiments, a porous surface is disposed on a portion of the mounting member. In some embodiments, the mounting member is a flange that is adjustably positionable about the circumference of an acetabular implant. For example, the flange (or any other suitable mounting member) can pivot in a plane that is perpendicular to the circumference of an acetabular shell. The flange can include a split eye-let and/or a hook that joins a rail or groove on the implant. The flange can also include a key that removably inserts within a complementary rim on an acetabular shell. In certain embodiments, the flange is a flexible strap, or the flange may include a frangible portion that allows the flange to bend or break. In certain embodiments, the implant includes an annular recessed slot with an overhanging lip, where the mounting member includes a distal portion that fits within the annular recessed slot. The implant can be an augment that mounts to a surgical shell or cage, and the implant can fit within one of a shoulder, hip, or ankle joint. In certain embodiments, the mounting member includes a plurality of flanges, at least one flange being adjustably positionable with respect to more than one of the attachment sites.

In certain embodiments, a method of installing an orthopedic implant within a patient includes the steps of inserting the implant into the patient, selecting a site along the inserted implant to receive a first mounting member, attaching the first mounting member to the selected site, and anchoring the first mounting member to the patient. The selected site may be chosen from a plurality of attachment sites that are angularly spaced about the implant. The method may further include the step of applying a porous surface to a portion of the first mounting member. In some embodiments, the inserting step may include the step of mounting an acetabular shell or cage within the patient's acetabulum. In some embodiments, the implant may be an acetabular augment, and the inserting step may include the step of mounting the acetabular augment to an acetabular shell. The method may further include the step of detaching a detachable portion of the first mounting member after attaching the first mounting member to the selected site. In some embodiments, the anchoring step includes the step of anchoring the first mounting member to a first entry point within the selected site. The method may further include the step of cementing the implant into the patient's acetabulum prior to attaching the first mounting member to the selected site. The method may further include the step of adjustably positioning the mounting member about the circumference of the implant and along the selected site. In some embodiments, the mounting member may include a flange, hook, or plate.

In certain embodiments, mounting members or augments shown and described in the figures contained herein may comprise tacks, spikes, coatings, or textured surfaces so as to improve initial fixation. The geographic locations of tacks, spikes, coatings, or textured surface structures may be strategically placed on select portions of a mounting member or implant so as to evenly load the mounting member or implant assembly and obtain the best biologic response initially, and over an extended period of time.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects and advantages will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:

FIGS. 1-4 show various perspectives of an illustrative rim augment or mounting member;

FIGS. 5 and 6 schematically show the use of an illustrative pivot joint to add a mounting member to an acetabular shell;

FIG. 7 shows an illustrative mounting member having a hook that receives a crossbar;

FIG. 8 shows an illustrative mounting member having a split opening that receives a crossbar;

FIG. 9 shows an illustrative T-slot into which a correspondingly-shaped receiving portion may be disposed;

FIG. 10 shows a plurality of illustrative entry portions that may be provided around an acetabular shell;

FIGS. 11-13 show an illustrative augment having one or more mounting members;

FIGS. 14-19 show one or more illustrative porous pieces or surfaces provided on bendable mounting members such as bendable flanges or plates;

FIG. 20 shows an illustrative mounting member having peripheral notches or inlets;

FIG. 21 shows an illustrative mounting member having cross-hatches or removed material from the surface;

FIGS. 22 and 23 show illustrative mounting members having various reduced surface area portions;

FIG. 24 shows an illustrative mounting member having one or more porous areas that are spaced out on the member;

FIG. 25 shows a mounting member having an illustrative orthopedic mesh;

FIG. 26 shows an illustrative mesh portion placed on an outer portion of a shell;

FIG. 27 shows an illustrative mesh that includes a plurality of trim lines that may be cut to separate the mounting members attached thereto;

FIG. 28 shows illustrative separated mounting members from the mesh of FIG. 27 placed into a patient's hip region;

FIGS. 29 and 30 show an illustrative honeycomb design that may be provided on a mounting member or augment;

FIG. 31-34 show illustrative cleats provided proximate to a rim of an acetabular shell or cage, mounting member, or augment;

FIG. 35 shows illustrative cleat portions configured for securing soft tissues;

FIGS. 36 and 37 show an illustrative augment attached peripherally to an acetabular shell or cage via a recess;

FIGS. 38 and 39 show an illustrative mounting member attached peripherally to an acetabular shell or cage via a recess; and

FIG. 40 shows an acetabular shell or cage having an illustrative annular protrusion.

DETAILED DESCRIPTION

To provide an overall understanding of the systems, devices, and methods described herein, certain illustrative embodiments will be described. Although the embodiments and features described herein are specifically described for use in connection with acetabular systems, it will be understood that all the components, connection mechanisms, adjustable systems, fixation methods, manufacturing methods, coatings, and other features outlined below may be combined with one another in any suitable manner and may be adapted and applied to medical devices and implants to be used in other surgical procedures, including, but not limited to: spine arthroplasty, cranio-maxillofacial surgical procedures, knee arthroplasty, shoulder arthroplasty, as well as foot, ankle, hand, and other extremity procedures.

Various implants and other devices described herein in their various embodiments may be used in conjunction with any appropriate reinforcement material, non-limiting examples of which include bone cement, appropriate polymers, resorbable polyurethane, and/or any materials provided by PolyNovo Biomaterials Limited, or any suitable combinations thereof. Further non-limiting examples of potential materials that may be used are described in the following references: U.S. Patent Application Publication No. 2006/0051394, entitled “Biodegradable Polyurethane and Polyurethane Ureas,” U.S. Patent Application Publication No. 2005/0197422, entitled “Biocompatible Polymer Compositions for Dual or Multi Staged Curing,” U.S. Patent Application Publication No. 2005/0238683, entitled “Biodegradable Polyurethane/Urea Compositions,” U.S. Patent Application Publication No. 2007/0225387, entitled “Polymer Compositions for Dual or Multi Staged Curing,” U.S. Patent Application Publication No. 2009/0324675, entitled “Biocompatible Polymer Compositions,” U.S. Patent Application Publication No. 2009/0175921, entitled “Chain Extenders,” and U.S. Patent Application Publication No. 2009/0099600, entitled “High Modulus Polyurethane and Polyurethane/Urea Compositions.” Each of the prior references is incorporated by reference herein in its entirety.

FIGS. 1-4 show some embodiments where a rim augment or a mounting member may be configured for a left hip. Rim mounting member 202 may be press-fit onto an outer diameter 203 of an acetabular cup 204 (e.g., acetabular shell, cup, cage, or augment). The rim mounting member 202 has at least one curved or spherical inner surface 205 that matches a contour profile 207 of an outer surface of the acetabular cup 204 to which the mounting member 202 is attached. In some embodiments, more than one opposing curved or spherical surfaces may be provided on the inner surface 205 of the rim mounting member 202, each curved or spherical surface comprising a similar radius of curvature. The size, shape, and profile of these one or more curved or spherical surfaces correspond to the outer diameter and outer surface profile of the acetabular cup 204.

By providing two curved or spherical surfaces, for example, the rim mounting member 202 may be configured for universal use and, therefore, may be flipped or inverted in order to allow its use with a left to a right acetabular cup. In other words, the rim mounting member 202 may be inverted when used in conjunction with a contralateral hip. It may further be provided in any suitable number of available sizes in order to fit multiple cup sizes (e.g., acetabular cups having outer diameter sizes ranging between approximately 30 mm and 90 mm).

One or more flanges or other mounting members, or any combinations thereof, may be provided on mounting member 202. In the particular embodiment shown, three mounting members 208 are shown, which extend radially from the rim of the acetabular cup 204. The mounting members 208 are configured to be bent, cut, or otherwise shaped as needed in order to conform to the pelvis of a particular patient's anatomy. Alternatively or additionally, one or more of the mounting members 208 may be oriented at predetermined radial locations circumferentially around the rim of the acetabular cup to correspond with, engage, or otherwise accommodate the ilium, ischium, superior ramus, or any other suitable patient anatomy. It should further be understood that any of the alternate and adjustable mounting and securement mechanisms described herein may also be used with these embodiments. The described rim mounting members are of particular use in acetabulums having defects and damage along the acetabular rim. The holes of the mounting members 208 may be threaded, unthreaded, or partially threaded, and may be fixed or polyaxial. In some embodiments, attachment sites may include variable low-profile holes that allow for locking at a variety of angles.

FIGS. 5-8 schematically illustrate the use of a pivot joint 210 to add a mounting member (such as a flange, plate, or any other attachment or mounting member) to an acetabular shell, cup member, or augment according to some embodiments. For example, as shown in FIG. 5, a crossbar 212 may be provided in one or more recesses 214 on an upper shell surface of proximal rim portion 216 of the acetabular shell 218 and aligned generally parallel to a tangent of the shell 218 adjacent its rim. The one or more recesses 214 may comprise, for instance, a V-shaped slot, although any other suitably-shaped slot may be used. A plurality of attachment sites may be provided, with each being spaced angularly about the rim or other portion of the implant. This allows a plurality of positioning options for mounting members and gives the surgeon more flexibility to position the attachments along the implant for ease of anchoring. The acetabular shell 218 includes a ridge 230 on inner surface 228 that mates with a correspondingly-shaped ridge of a liner, for example, although any other suitable mounting member or augment may have a similarly-shaped ridge for mating with ridge 230. In some embodiments, the ridge 230 may be provided alternatively, or additionally, on outer surface 226.

A mounting member 220 has a first end 221 that anchors to the patient's bone or soft tissue and a second end or receiving portion 223 that mates with the implant, such as acetabular shell 218, at each of the plurality of attachment sites provided along, for example, the crossbar 212. The second end or receiving portion 223 of mounting member 220 may have a hook or a split opening that receives the crossbar 212. For example, mounting member 220′ of FIG. 7 includes a hook 222, and mounting member 220″ of FIG. 8 includes a split opening 224, which may also be referred to as a split eyelet. The mounting members shown in FIGS. 6-8 may be moved independently of the shell positioning. One of the advantages provided by this design is that the flanges and other mounting members are completely modular and do not have to be positioned in the same discrete place or in only one of a few pre-determined locations, but can instead be positioned anywhere around the rim of the shell and can pivot in a plane that is perpendicular to the plane defined by the circumference of the shell.

FIGS. 9 and 10 illustrate some embodiments where one or more mounting members and/or augments translate or ride, or otherwise move, in a circumferentially-extending T-slot, dovetail slot, tongued groove, or undercut groove provided in an outer shell surface 244 proximate to the rim. The mounting members or augments may be configured with a receiving portion that may enter a portion of the shell 246 and slide within the circumferentially-extending T-slot, dovetail slot, tongued groove, or undercut groove. For example, FIG. 9 shows a T-slot 240 on an outer surface 244 of shell 246 into which a correspondingly-shaped receiving portion may be disposed. The mounting members or augments can revolve around the shell to the proper angular position around the rim and then be locked, retained, or otherwise secured in position. For example, the receiving portions may include a locking member or an expanding member that locks or expands, respectively, when the mounting member or augment is place in a particular location along the shell to thereby secure the mounting member or augment into position. A plurality of attachment sites may be provided, with each being spaced angularly about the rim or other portion of the implant. This allows a plurality of positioning options, as opposed to the discrete few options typically provided, for example, where the mounting member or augment must be positioned at the discrete location where attached. Similar to the acetabular shell 218 of FIG. 5, shell 246 may also include a ridge 248 on inner surface 242 that mates with a correspondingly-shaped ridge of a liner, for example, although any other suitable mounting member or augment may have a similarly-shaped ridge for mating with ridge 248. In some embodiments, the ridge 248 may be provided alternatively, or additionally, on outer surface 244.

One or more entry points may be provided within the T-slot, dovetail slot, tongued groove, undercut groove, or other attachment site to allow quick insertion, placement, access, or removal of the flanges, plates, or augments with respect to the shell. Particularly, multiple entry portions may be configured to allow one or more mounting members or augments to be engaged with the shell and positioned angularly around the shell even after the shell has been impacted into a prepared acetabulum and portions of the shell proximate to the rim are obstructed by bone, grafts, or cement. For example, as shown in FIG. 10, a plurality of entry portions 254 may be provided around shell 258. A mounting member 250 that includes a receiving portion 252 shaped as a key may be engaged with a reciprocally-shaped groove 256 at one of entry portions 254. The mounting member 250 may engage with the shell by placing mounting member 250 into one of the grooves 256 at an entry point 254 and then positioned angularly around the shell therefrom to one of a plurality of attachment sites. Furthermore, mounting member 250 may be inserted into a first entry point 254, rotated about the shell 258 to a second entry point 254, and then removed.

In the embodiments shown in FIGS. 11-13, one or more mounting members 262 (shown as flanges, but not limited thereto) are added to an acetabular augment 260. The mounting members 262 may be permanently fixed or detachable, and may be adjustably positionable about augment 260 as described above. Mounting members 262 may have frangible portions 264 between screw holes 266 or other structures for receiving fasteners. The frangible portions 264 may be provided, for example, as reduced cross-sections that allow bending or breaking or cutting of the mounting members 262 without disturbing the internal geometries of the screw holes 266. In certain embodiments, the frangible portions 264 may be prestressed or otherwise pretreated to make the frangible portions 264 weaker than other areas of the mounting members 262. Screw holes 266 may be smooth or provided with threads or other protrusions to be used with locking head screws or polyaxial screws. The screw holes 266 may be conventional holes, locking holes, or slots. The holes may be threaded, unthreaded, or partially threaded, and may be fixed or polyaxial. In some embodiments, screw holes 266 may include variable low-profile holes that allow for locking at a variety of angles. The augment 260 and mounting members 262 may be implanted proximate a patient's acetabulum. For example, as shown in FIGS. 12 and 13, augment 260 having mounting members 262 is implanted into an area having a posterior column defect region 268.

As shown in the embodiments depicted in FIGS. 14-19, one or more porous pieces or surfaces may be provided on bendable mounting members such as bendable flanges or plates, or any of the other mounting members. In some instances, solid or rigid augments may replace bendable mounting members. The mounting members may be modular, attachable, or integrally-provided on an acetabular implant structure such as an acetabular shell. As shown in FIG. 14, a mounting member 280 includes a porous coating 282 about a periphery while top portion 284 is substantially smooth and flat. Mounting member 280 also includes a plurality of fastening through-holes 286 for receiving screws or other fastening members. Through-holes 286 may include conventional holes, locking holes, or slots. The holes may be threaded, unthreaded, or partially threaded, and may be fixed or polyaxial. In some embodiments, through-holes 286 may include variable low-profile holes that allow for locking at a variety of angles. Exemplary bending motion of flanges is shown with respect to FIGS. 15 and 16. A mounting member such as flange 290 has a first portion 291 and a second portion 292 and is flat. Flange 294 may be bent in a first direction about bending axis 295 such that a second portion 298 is bent relative to a first portion 296. Because in some instances there may be a chance that porous structures integrally provided on mounting members (such as porous coating 282 of FIG. 14) may fracture, delaminate, or separate from the mounting members during or after bending, porous pieces may be provided separate from and/or spaced between securement devices such as screw holes, as shown in FIG. 17 and FIG. 19. In FIG. 17, a separate porous in-growth pad 306 is provided, which can be secured to a bendable mounting member 300 via screw 304, so that the bendable mounting member 300 may still be bent, while also featuring the desired in-growth advantages of the porous in-growth pads 306, without being subject to delamination or decoupling upon bending. This allows bending of the mounting members without stressing the struts of each porous piece. The porous piece may be positioned before or after bending. Screws 302 may be provided for securing the mounting member 300 to a patient's bone or soft tissue, an acetabular shell, augment, or other mounting member.

In lieu of screw holes, or in addition to screw holes, in some embodiments spikes, tacks, or other appropriate fasteners may be utilized. J-slots may be provided in the porous pieces or the mounting members to allow adjustability of the position of the porous piece relative to the augment or mounting member in both rotation and translation. For example, FIG. 18 shows a mounting member 270 having a plurality of screw holes 272 and J-slots 274. Screws or any appropriate fixation members may be used to rigidly fix the porous pieces to the augment or mounting member, or other members such as shape memory or deformable pegs (e.g., rivet structure) may be used to rigidly fix the porous pieces to the augment or mounting member. In some instances, members fixing the porous pieces to the augment or mounting member may be configured to allow the porous pieces to move during bending of the mounting members.

As shown in FIG. 19, a mounting member 310 includes a first portion 312 that is bent in a first direction about bending axis 320 relative to a second portion 314. The first portion 312 and second portion 314 of mounting member 310 each include J-slots 316 to allow adjustability of the position of the porous pieces 318 attached thereto relative to mounting member 310.

FIGS. 20-24 show various embodiments of adjustable and/or flexible mounting members. Stiff mounting members, such as stiff plates or flanges, or any other suitable stiff members that may be used to extend from a surgical implant for securing it into place, may be difficult to bend or position. It may thus be desirable in some instances to provide mounting members that are configured to bend or otherwise adjust.

FIG. 20 shows a mounting member 340 having peripheral notches or inlets 342 cut into the profile of the mounting member 340. In some embodiments, these features allow mounting member 340 to be flexed, bent, shaped, or otherwise contoured to bone or around other devices. In the embodiment shown, the notches 342 are Z-shaped, but it will be understood that any appropriate shape, such a J-slots, C-slots, V-slots, any other appropriate shapes, or any combinations thereof, may be used. FIG. 21 shows a mounting member 350 having cross-hatches or removed material 352 from the surface, thereby reducing the cross-sectional surface area of the member. These features may make it easier for mounting member 350 to flex, bend, shape, or contour. FIGS. 22 and 23 show further embodiments of mounting members that may have various reduced surface area portions, such as notches, indents, removed material, cut outs, or other portions of reduced surface area, or any combinations thereof. For example, mounting member 360 includes notches 362 and cross-hatches or removed material 364. These reduced surface area portions may have any appropriate profile or cross-sectional shape, examples of which may be circular, curved, triangular, irregularly-shaped or any other appropriate option. The reduced surface area portions may help enhance the flexibility or bendability of the member.

FIG. 24 shows a mounting member 370 having one or more porous areas 372 that are spaced out on the member 370. In certain embodiments, the mounting member 370 may be bent or otherwise configured as desired, without being limited by the porous areas, as discussed above in connection with FIGS. 14-19. For example, mounting member 370 may be bent about region 374 or 376 without introducing bending stresses to the porous areas 372 or substantially limiting the bending stresses on porous areas 372. Mounting member 370 may have any of the above-discussed reduced surface area portions, or mounting member 370 may be provided as a typical, traditional mounting member.

In the embodiments shown in FIGS. 25-28, one or more mounting members and/or augments may be integrally provided with orthopedic mesh to define one or more mesh mounts or void fillers. FIG. 25 shows a mounting member 380 having an orthopedic mesh 382. In FIG. 26, the orthopedic mesh portion 382 may be placed on an outer portion 384 of the shell 386 between bone, and a cement mantle can fill between the mesh 382. The cement mantle rigidly connects the mounting member 380 (or, in some embodiments, an augment) to the shell 386 via the surgical mesh 382. Rapid manufacturing techniques may be used to simultaneously create the mounting members or augments integrally with the orthopedic mesh portion. The mesh 382 may be honeycomb, diamond, or other weave pattern, or any combination thereof, and may come in multiple thicknesses. Mesh portion 382 may be oversized, customized for an individual patient, and/or standardized and trimmed by the surgeon to fit a particular patient's needs. Fasteners of all types may be inserted through one or more cells of the mesh 382, as well as through the one or more mounting members or augments to further secure the implant to bony anatomy. For example, as shown in FIG. 25, a first screw 388 may be inserted through cell 390, and a second screw 394 may be inserted through one of the plurality of screw holes 392 of mounting member 380. Screw holes 392 may include conventional holes, locking holes, or slots. The holes may be threaded, unthreaded, or partially threaded, and may be fixed or polyaxial. In some embodiments, screw holes 392 may include variable low-profile holes that allow for locking at a variety of angles. Soft tissues may be reattached using the porosities of the mesh 382 as suture anchors, or simply as a bioscaffold. If desired, preformed trim lines may be provided by forming predetermined frangible portions in various areas of the mesh, in order to help configuration of the device for a particular patient. For example, as shown in FIG. 27, mesh 400 includes a plurality of trim lines 402 that may be cut to separate the mounting members attached thereto, such as mounting members 404. The separated mounting members 404 and the mesh 400 may then be placed into a patient's hip region 406 as shown in FIG. 28.

FIGS. 29 and 30 illustrate some embodiments of a honeycomb design that may be provided on a mounting member or augment in order to control cement mantle thickness and spacing between said mounting member or augment and an adjacent acetabular shell, augment, bone, or other implant. For example, mounting member 410 of FIG. 29 includes honeycomb portion 412 provided on an attachment surface portion 414 of the mounting member 410. The honeycomb feature 412 may be provided as any desired geometric shape. The mounting member 410 (or, in some embodiments, the augment) may comprise one or more securing holes 416 for receiving a surgical fastener 418 such as a polyaxial screw, cancellous screw, peg, or other securing device. The securing holes 416 may include conventional holes, locking holes, or slots. The holes may be threaded, unthreaded, or partially threaded, and may be fixed or polyaxial. In some embodiments, securing holes 416 may include variable low-profile holes that allow for locking at a variety of angles. The attachment portion 414 of the mounting member 410 may extend generally perpendicularly from another portion 415 of the mounting member 410, and may comprise one or more concave curved surfaces 417 configured to abut an outer portion 422 of an acetabular shell 420, or one or more convex surfaces (not shown) configured to abut an inner portion of a prepared acetabulum.

In the embodiments shown in FIGS. 31-34, cleats may be provided proximate to a rim of an acetabular shell, cage, mounting member, or augment. For example, in some embodiments, one or more cleats 780 and 781 may extend or project from a superior aspect of a rim portion 782 of an acetabular shell 784 as shown. Cleats 780 and 781 may be used to secure soft tissues to the acetabular shell 784 or may serve as a means to attach secondary augments or any type of mounting member 786 to the acetabular shell 784. In the particular instance shown in FIGS. 33 and 34, a “quarter-turn” fastener connector arrangement is utilized. The quarter-turn fastener arrangement may comprise, for instance, a generally T-shaped male member 790 located on one or more regions of an acetabular shell, cage, or augment, and one or more complementary female members 792 located on more secondary augments or mounting members. The one or more secondary augments or mounting members engage the one or more male members 790 on the acetabular shell, cage, or augment in one degree of rotation, and then are rotated by a specified or variable number of degrees (e.g., 90 degrees) to lock the one or more secondary augments or mounting members to the one or more male members 790. Of course, one of ordinary skill in the art would appreciate that the male and female members could be reversed to provide the same function. It should also be understood that other locking mechanisms may be used.

FIG. 35 further depicts one or more cleat portions 794 located at various portions of an acetabular shell or cage 796 (or, in some embodiments, an augment) configured for securing soft tissues. The one or more cleat portions 794 can be arranged in any particular fashion around the acetabular shell 796; however, it is preferred that the cleats 794 extend proximally from a rim portion or otherwise away from the acetabular shell 796 in order to provide clearance from liner-mating surfaces, cement mantle surfaces, bone contacting surfaces, and bony anatomy, for example. Cleat portions 794 may comprise suturing holes, roughened surfaces, clamps, hooks, or biologic coatings, or any other appropriate protrusions, or combinations thereof, to encourage fixation of the soft tissues to the implant (e.g., acetabular shell 796). For example, as shown in the inset of FIG. 55, sutures may be wrapped around cleat portion 794 and then secured to surrounding soft tissues.

FIGS. 36-40 illustrate embodiments wherein a mounting member 802 or an augment 804 may be attached peripherally to an acetabular shell or cage 806 via a recess 800 provided proximate a rim portion 808 of the acetabular shell or cage 806. The recess 800 is sized to accept a protruding insertion portion 810 of the mounting member 802 or a protruding insertion portion 812 of the augment 804, and the recess 800 may extend annularly circumferentially around the rim portion 808 to allow orbital placement of the mounting member 802 or augment 804 around a periphery of the shell or cage 806. The mounting member 802 or augment 804 may be inserted into the acetabular shell or cage 806 before or after shell/cage impaction or cementing into a prepared acetabulum. One or more screw holes in the mounting member (e.g., screw holes 814) or augment (e.g., screw holes 816) rigidly secure the mounting member 802 or augment 804 to the bone and prevent orbital movement of the mounting member 802 or augment 804 around the shell or cage 806. Screw holes 814 and 816 may include conventional holes, locking holes, or slots. The holes may be threaded, unthreaded, or partially threaded, and may be fixed or polyaxial. In some embodiments, screw holes 814 and 816 may include variable low-profile holes that allow for locking at a variety of angles. Once the mounting member 802 or augment 804 is positioned, the cantilever force pushes the rim 808 of the shell or cage 806 toward bone. The protruding insertion portion of the mounting member (e.g., portion 810) or augment (e.g., portion 812) provides a hold-down force to the shell or cage 806 after a screw is inserted through the mounting member 802 or augment 804 and into surrounding pelvic bone.

FIGS. 36 and 37 show an augment 804 being positioned with respect to an acetabular shell or cage 806. FIGS. 38 and 39 illustrate a mounting member 802 being positioned with respect to an acetabular shell or cage 806. The mounting member 802 is shown as having multiple securing holes 814 for use with fasteners. Securing holes 814 may be smooth, tapered, or threaded and may be used with any appropriate fastener, including but not limited to polyaxial screws. The securing holes 814 through the mounting member 802 (or securing holes 816 through the augment 804) may be positioned at any appropriate angle, as shown, such as parallel to the member, oblique through the member, or otherwise as desired. While not shown, a honeycomb feature may be placed on outer portions of the mounting member 802 or augment 804 to provide spacing for a cement mantle between the mounting member 802 or augment 804 and surrounding bone. Moreover, porous structures, textured surfaces, biologic coatings, or orthopedic meshes may be integrally provided on, or incorporated between outer surfaces of the mounting members 802 or augments 804 and surrounding bone.

In the embodiments of FIGS. 38 and 39, a recess 800 in the shell or cage 806 is defined by a proximally-extending lip 818 such that the mounting member 802 will sit on bone surrounding the acetabulum. In this way, the mounting members 802 will not interfere with the press-fit area between the shell 806 and prepared acetabulum adjacent the acetabular rim 808. Moreover, because the connection is configured to allow mounting members 802 to sit on surrounding bone, the surrounding bone does not need to be countersunk or otherwise prepared to receive mounting members 802.

FIG. 40 depicts an acetabular shell or cage 820 comprising an annular protrusion 822 along a rim portion 824 of the acetabular shell 820. The annular protrusion 822 may extend partially around (as shown) or entirely around the circumference of the acetabular shell 820, or one or more protrusions may be provided in any fashion around the acetabular shell 820. The annular protrusion 822 may comprise an annular lip 826 defining an annular undercut groove 828 running circumferentially around the acetabular shell 820 proximate the rim portion 824. The annular protrusion 822 may comprise one or more openings 830 for receiving sutures (e.g., for soft tissue or capsule re-attachment) or fasteners 832 such as set screws for contacting and frictionally engaging surfaces (e.g., divots) provided on protruding insertion portions 834 and 836 of mounting members 840 or augments 838 alike.

Fasteners 832 may be inserted into openings 830 located circumferentially laterally of the insertion portions 834 and 836 to serve as stops for preventing or limiting rotational movement of the attached mounting members 840 or augments 838. The mounting members 840 or augments 838 may be secured down to surrounding bone after being inserted into the annular undercut groove 828 via long bone screws, thereby providing a hold-down force to the acetabular shell or cage 820. The hold-down forces provided may complement the press fit, threaded fit, or cemented fixation between the acetabular shell or cage and surrounding prepared acetabular bone. In the instance shown, shell 820 is provided as a “hooded” shell similar to a cage, and may act as a buttress for a cemented or pressed-in liner to support various liner inclinations in varying degrees of acetabular or pelvic degradation, although it will be understood that these features may be provided on any other type of shell or cage.

The foregoing is merely illustrative of the principles of the disclosure, and the systems, devices, and methods can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation. It is to be understood that the systems, devices, and methods disclosed herein, while shown for use in acetabular systems, may be applied to medical devices to be used in other surgical procedures including, but not limited to, spine arthroplasty, cranio-maxillofacial surgical procedures, knee arthroplasty, shoulder arthroplasty, as well as foot, ankle, hand, and extremities procedures.

Variations and modifications will occur to those of skill in the art after reviewing this disclosure. The disclosed features may be implemented, in any combination and subcombinations (including multiple dependent combinations and subcombinations), with one or more other features described herein. The various features described or illustrated above, including any components thereof, may be combined or integrated in other systems. Moreover, certain features may be omitted or not implemented.

Examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the scope of the information disclosed herein. All references cited herein are incorporated by reference in their entirety and made part of this application.

Claims

1. An orthopedic device comprising:

an implant structured to fit with and stabilize a patient's orthopedic joint, the implant having a plurality of attachment sites; and

a mounting member having a first end that anchors to the patient's bone or soft tissue and a second end that mates with the implant at each of the plurality of attachment sites.

2. The device of claim 1, wherein the plurality of attachment sites include portions of a crossbar extending about an acetabular shell.

3. The device of claim 1, wherein the plurality of attachment sites include portions of a groove extending along a rim of the implant.

4. The device of claim 1, wherein the mounting member is a flange.

5. The device of claim 4, wherein the flange is adjustably positionable about the circumference of an acetabular implant.

6. The device of claim 5, wherein the flange includes a split eyelet that joins a rail or groove on the implant.

7. The device of claim 5, wherein the flange includes a hook that joins a rail or groove on the implant.

8. The device of claim 5, wherein the flange includes a key that removably inserts within a complementary rim on an acetabular shell.

9. The device of claim 4, wherein the flange pivots in a plane that is perpendicular to the circumference of an acetabular shell.

10. The device of claim 4, wherein the flange is a flexible strap.

11. The device of claim 4, wherein the flange includes a frangible portion that allows the flange to bend or break.

12. The device of claim 1, wherein the implant includes an annular recessed slot with an overhanging lip, and wherein the mounting member includes a distal portion that fits within the annular recessed slot.

13. The device of claim 1, wherein the implant is an augment that mounts to a surgical shell or cage.

14. The device of claim 1, wherein the implant fits within one of a shoulder, hip, or ankle joint.

15. The device of claim 1, wherein the mounting member includes a plurality of flanges, at least one flange being adjustably positionable with respect to more than one of the attachment sites.

16. The device of claim 1, comprising a porous surface disposed on a portion of the mounting member.

17. A method of installing an orthopedic implant within a patient, comprising the steps of:

inserting the implant into the patient;

selecting a site along the inserted implant to receive a first mounting member;

attaching the first mounting member to the selected site; and

anchoring the first mounting member to the patient.

18. The method of claim 17, further comprising the step of applying a porous surface to a portion of the first mounting member.

19. The method of claim 17, the inserting step comprising the step of mounting an acetabular shell or cage within the patient's acetabulum.

20. The method of claim 17, wherein the implant is an acetabular augment.

21. The method of claim 20, wherein the inserting step comprises the step of mounting the acetabular augment to an acetabular shell.

22. The method of claim 21, further comprising the step of detaching a detachable portion of the first mounting member after attaching the first mounting member to the selected site.

23. The method of claim 17, wherein the selected site is chosen from a plurality of attachment sites that are angularly spaced about the implant.

24. The method of claim 17, wherein the anchoring step includes the step of anchoring the first mounting member to a first entry point within the selected site.

25. The method of claim 17, further comprising the step of cementing the implant into the patient's acetabulum prior to attaching the first mounting member to the selected site.

26. The method of claim 17, further comprising the step of adjustably positioning the mounting member about the circumference of the implant and along the selected site.

27. The method of claim 26, wherein the mounting member comprises a flange, hook, or plate.