Abstract:
An implant is provided for use in an ankle joint between reconditioned end surfaces established on a distal end of an upper tibia bone and an opposing lower talus bone. The implant comprises a substantially porous rigid component adapted to be anchored against the upper tibia reconditioned end surface and the lower talus reconditioned end surface. The component defining an opening therethrough. An intramedullary nail is configured to pass through the opening in the component when the nail is driven through the talus and into the tibia.

Description:
CROSS-REFERENCES 
       [0001]    This application is a continuation application of U.S. patent application Ser. No. 15/162,525, filed May 23, 2016, which is related to U.S. provisional application No. 62/165,376, filed May 22, 2015, entitled “JOINT OR SEGMENTAL BONE IMPLANT FOR DEFORMITY CORRECTION”, naming Samuel Adams as the inventor, the contents of both of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    A medical implant is described and, more particularly, a medical implant for use in joint or segmental bone defects for deformity correction with or without obtaining arthrodesis. 
         [0003]    Implants may be used in humans or animals to support or secure one or more bones. Once implanted, the implant may provide support between the bones and bone growth may take place around and through the implant to at least partially fuse the bones for long-term support. 
         [0004]    There is a need for an improved medical implant for use in body areas, such as bones of the foot and ankle. 
       SUMMARY 
       [0005]    An implant is provided for use in an ankle joint between reconditioned end surfaces established on a distal end of an upper tibia bone and an opposing lower talus bone. The implant comprises a substantially porous rigid component adapted to be anchored against the upper tibia reconditioned end surface and the lower talus reconditioned end surface. The component defining an opening therethrough. An intramedullary nail is configured to pass through the opening in the component when the nail is driven through the talus and into the tibia. 
         [0006]    A method of securing an ankle joint is also provided. The method comprises the steps of reconditioning end surfaces on a distal end of an upper tibia bone and an opposing lower talus bone of the ankle joint. A substantially porous rigid component is positioned against the upper tibia reconditioned end surface and the lower talus reconditioned end surface. The component defining an opening therethrough. An intramedullary nail configured to be driven through the through the talus and the opening in the component and into the tibia. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    For a more complete understanding of the bone implant, reference should now be had to the embodiments shown in the accompanying drawings and described below. In the drawings: 
           [0008]      FIG. 1  is a top plan view of an embodiment of a joint or segmental bone implant. 
           [0009]      FIG. 2  is a top perspective view of the bone implant as shown in  FIG. 1 . 
           [0010]      FIG. 3  is a perspective view of the bone implant as shown in  FIG. 1  receiving a portion of an intramedullary nail. 
           [0011]      FIG. 4  is a perspective view of the bone implant as shown in  FIG. 1  positioned in a foot and ankle joint. 
           [0012]      FIG. 5  is an exploded perspective view of the bone implant and the foot and ankle joint as shown in  FIG. 4 . 
           [0013]      FIG. 6A  is a side elevation view of the bone implant as shown in  FIG. 1  positioned in a foot and ankle joint. 
           [0014]      FIG. 6B  is an opposite side elevation view of the bone implant positioned in a foot and ankle joint as shown in  FIG. 6A . 
           [0015]      FIG. 6C  is a rear perspective view of the bone implant positioned in a foot and ankle joint as shown in  FIG. 6A . 
           [0016]      FIG. 6D  is a front perspective view of the bone implant shown in phantom positioned in a foot and ankle joint as shown in  FIG. 6A . 
           [0017]      FIG. 6E  is a top perspective view of the bone implant positioned in a foot and ankle joint as shown in  FIG. 6A . 
           [0018]      FIG. 7A  is a side elevation view of the bone implant as shown in  FIG. 1  positioned in a foot and ankle joint and a portion of an intramedullary nail shown in phantom. 
           [0019]      FIG. 7B  is a rear perspective view of the bone implant positioned in a foot and ankle joint as shown in  FIG. 7A . 
           [0020]      FIG. 7C  is an opposite side elevation view of the bone implant positioned in a foot and ankle joint as shown in  FIG. 7A . 
           [0021]      FIG. 7D  is a top plan view of the bone implant positioned in a foot and ankle joint as shown in  FIG. 7A . 
           [0022]      FIG. 7E  is an up-close view of the bone implant positioned in a foot and ankle joint as shown in  FIG. 7A . 
           [0023]      FIG. 8  is a perspective view of another embodiment of a bone implant positioned in a foot and ankle joint and including a fixation device. 
           [0024]      FIG. 9  is an elevation view of a third embodiment of a bone implant having a planar surface to accommodate a plate or other device. 
           [0025]      FIG. 10  is an elevation view of a fourth embodiment of a bone implant positioned in a foot and ankle joint. 
           [0026]      FIG. 11  is a perspective view of fifth embodiment of a bone implant for use in a foot and ankle joint. 
           [0027]      FIG. 12  is a perspective view of a sixth embodiment of a bone implant for use in a foot and ankle joint. 
           [0028]      FIG. 13  is schematic elevation view of the third embodiment of the bone implant as shown in  FIG. 9  between two portions of bone. 
           [0029]      FIG. 14  is schematic elevation view of a seventh embodiment of a bone implant shown between two portions of bone. 
       
    
    
     DESCRIPTION 
       [0030]    Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configuration shown in the FIGs. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. 
         [0031]    Referring now to  FIGS. 1 and 2 , there is shown an embodiment of a medical joint or segmental bone implant for deformity correction and generally designated at  20 . The implant  20  comprises a porous web structure  22  configured to interface with human bone tissue. The web structure  22  extends throughout the implant  20  to provide support. The web structure  22  disperses the stress of compressive forces throughout implant  20 , wherein the implant  20  is supported against tensile, compressive, and shear forces. The web structure  22  can be further employed to receive and distribute throughout the implant  20  loading forces of the surrounding tissue. The web structure  22  may also reinforce the implant  20  along multiple planes. 
         [0032]    In one embodiment, the web structure  22  is formed with interconnected triangular-shaped building blocks. The result is a web structure  22  formed from a pattern of triangularly-shaped geometrical building blocks. The triangularly-shaped building blocks may form tetrahedrons that may also be used as building blocks. Other patterns from the triangles are also contemplated. Each tetrahedron may include four triangular faces in which three of the four triangles meet at each vertex. At least two of the plurality of tetrahedrons are coupled together via one or more common components connecting two respective vertices on each of the two tetrahedrons such that two tetrahedrons share a common unit to form a hexahedron. 
         [0033]    In one embodiment, the porous web structure  22  is configured to form a substantially spherical structure as shown in  FIGS. 1 and 2 . The implant  20  can have a diameter of at least about 38 mm to about 40 mm. However, it is understood that the design of the implant  20  may be sized appropriately to meet specified dimensions of the implantation site. In some embodiments, multiple implants of different sizes may be constructed and delivered in a kit. A medical health professional may choose an implant (e.g., according to a needed size) during surgery. It is understood that while the embodiment of the implant  20  has been described with respect to a particular spherically-shaped web structure, various shapes of web structures are contemplated. For example, a portion of the spherical implant may be removed to form an implant  44  having a planar side ( FIG. 9 ). In another embodiment shown in  FIG. 14 , the implant  54  may be egg-shaped ( FIG. 14 ). 
         [0034]    The implant  20  may be formed from a biocompatible material such as a titanium alloy (e.g., y-titanium aluminides), cobalt, chromium, stainless steel, polyetheretherketone (PEEK), ceramics, or other suitable material. The implant  20  may be made through a rapid prototyping process (e.g., electron beam melting (EBM) process). Other processes are also possible, such as injection molding, casting, sintering, selective laser sintering (SLS), direct metal laser sintering (DMLS), etc). SLS may include laser-sintering of high-performance polymers such as that provided by EOS of North America, Inc., headquartered in Novi, Mich., U.S.A. High-performance polymers may include various forms of PEEK (e.g., HP3 having a tensile strength of up to about 95 mega Pascal (MPa) and a Young&#39;s modulus of up to about 4400 MPa and continuous operating temperature between about 180° C. (356° F.) and 260° C. (500° F.)). Other materials may include PA 12 and PA 1 1 provided by EOS of North America, Inc. Multiple parts may be cast or injection molded and joined together (e.g., through welding, melting, etc.). For example, individual components  24  forming the implant  20  may be generated separately (e.g., by casting, injection molding, etc.) and welded together to form the implant  20 . The porous web structure  22  may be made according to the disclosure of International Application No. PCT/US2012/045717, filed Jul. 6, 2012, and published Jan. 10, 2013, as International Publication No. WO 2013/006778, the contents of which are hereby incorporated by reference in their entirety. 
         [0035]    In another embodiment shown in  FIG. 12  and generally designated at  50 , the web structure  22  of the implant  50  may be formed from a generally porous material having random openings  45 . 
         [0036]    The implant  20 ,  50  may include a top face  26  and an opposed bottom face  28  wherein at least a portion of the top face  26  and the bottom face  28  are generally parallel to one another. In use, the top and bottom faces  26 ,  28  are configured to be disposed in contact, or near contact, of an adjacent bony structure for contacting the bony structure during use to adhere or couple with the adjacent structure when implanted. As depicted, for example, the implant  20 ,  50  is intended to sandwich between two adjacent bony structures interfacing with bone structure of a foot and ankle joint  34 . The top contact face  26  may couple to a portion of the first bony structure disposed above implant  20  and the bottom contact face  28  may couple to the second bony structure disposed below implant  20 . 
         [0037]    The web structure  22  defines openings configured to define open volume to enable bone growth through the openings of the web structure  22 , thereby enhancing coupling of the implant  20  to the adjacent bony structure. At least a portion of the web structure  22  is in contact, or near contact, with the adjacent bony structure, thereby enabling bone growth to extend into or through at least a portion of open volume of the web structure  22  such that the bone growth interlocks with the web structure  22  of the implant  20 . The interlocking of the bone growth and the web structure  22  may rigidly fix the implant  20  in a fixed location relative to the bony structure. For example, a web structure  22  may define an open space for bone growth therethrough, thereby enabling bone through growth to interlock the bone structure and the web structure  22  with one another to couple the implant  20  to the bony structure at or near the contact surface. Such interlocking bone through growth may inhibit movement between the implant  20  and the bony structure, which could otherwise lead to loosening, migration, subsidence, or dislodging of the implant  20  from the intended position. 
         [0038]    The web structure  22  of the implant  20  may also provide surface area for bone graft fusion. For example, the voids in the web structure  22  of the implant  20  may be filled with, or surfaces of the web structure  22  may be coated with, bone grafting material, a biologic, growth factor or the like. The web structure  22  extending throughout the implant  20  may add additional surface area on the surface of the components  24  to fuse to the bone graft material and prevent the bone graft material from loosening or migrating from the implant  20 . In some embodiments, the web structure  22  may also support and facilitate bone in-growth. For example, adjacent bone in an ankle joint may grow over at least a portion of the components  24  of the implant  22 . The bone growth and engagement between the bone growth and the implant  20  may further stabilize the implant. In some embodiments, the surfaces of the implant  20  may be formed with a rough surface to assist in bone in-growth adhesion. 
         [0039]    At least a portion of the open volume of the web structure  22  of the implant  20  may be filled with bone growth material. For example, cancellous bone may be packed into the openings internally of the implant  20 . In some embodiments, at least a portion of the surfaces of implant  20  may be coated or treated with a material intend to promote bone growth or bone adhesion or an antimicrobial agent to prevent infections. For example, in some embodiments, the surface of the web structure  22  may be coated with a biologic or a bone growth factor. For example, the biologic or growth factor may be physically secured to the web structure  22  in a central portion of the implant  20  provided there is the physical attachment of the biologic or growth factor. The biologic may include a coating, such as hydroxyapatite, bone morphaginic protein (BMP), insulin-like growth factors I and II, transforming growth factor-beta, acidic and basic fibroblast growth factor, platelet-derived growth factor, or similar bone growth stimulant that facilitates good biological fixation between the bone growth and a surface of the implant  20 . The bone growth factor may include a naturally occurring substance capable of stimulating cellular growth, proliferation and cellular differentiation (e.g., a protein or steroid hormone). 
         [0040]    As shown in the  FIGS. 1 and 2 , the center portion of the spherical web structure  22  defines a cylindrical passage  30 . The central passage  30  is configured to receive an intramedullary nail extending therethrough ( FIG. 3 ). 
         [0041]    In the embodiment of the implant  44  shown in  FIG. 9 , the planar or aspherical portion of the implant  44  accommodates a plate  42  or the like to facilitate attaching the combined porous web structure  45  and the plate  42  to bone using screws  48 . For example, where an implant is implanted adjacent to a bony structure, one or more structures may be disposed on or extend from a surface (e.g., an interface plate) of the implant that is intended to contact, and at least partially adhere to, the bony structure during use. 
         [0042]    A method is provided that includes the steps of providing an opening in a foot or ankle  34  of a human, and installing into the opening the implant  20 ,  44 ,  50 ,  54 . The implant location is first prepared, including surgical dissection for forming an opening proximate the foot or ankle  34  to the level of proposed implantation. Next, a bone bed can be prepared from the adjacent bony structure either by using a spherical reaming device or using a saw and osteotomes. The bone bed may be formed in either a joint or within a single bone. Bone graft material may be packed in the bone bed or within the porous web structure  22  of the implant  20 . The implant  20  is then inserted into the bone bed. The implant  20  may be incorporated into the end surfaces established between an upper tibia bone  36  and an opposite and lower talus bone  38 . The shape of at least a portion of the implant  20  allows the bone or the joint surface on either side of the implant  20  to be placed in a preferred position, for example, to correct a deformity.  FIGS. 6A-6E  show the implant  20  disposed in respective openings of the foot and ankle bones. 
         [0043]    In some embodiments, inserting the implant  20  includes positioning the implant  20  adjacent the boney structure, aligning the web structure  22  with a complementary portion of the boney structure, or advancing a contact surface toward the boney structure such that at least the web structure  22  is in contact or near contact with the boney structure. In some embodiments, the implant  20  may be advanced until the contact surface is in contact or near contact with the boney structure, such that at least portion or substantially all of the web structure  22  is disposed in the boney structure. 
         [0044]    The implant  20  then may, or may not be, fixed in place. In one embodiment, an intramedullary nail  32  is inserted into the heel and through the passage  30  in the web structure  22  of the implant  20 . The nail  32  is driven into the end of the tibia  36  for fusing the foot and ankle joint  34  ( FIGS. 7A-7E ). In an embodiment shown in  FIG. 8 , a tab  40  integral with the web structure  22  may be included on the implant  20 . The tab  40  may be secured to adjacent bone with staples, screws, plates, or other means of fixation.  FIG. 11  shows openings in the intramedullary nail  32  for receiving at least one screw passing through another part of the foot and ankle joint. 
         [0045]      FIGS. 13 and 14  schematically show the implants  44 ,  54  having an aspherical side and an egg-shape implant contacting adjacent bony structure  56 . As depicted, the implants  44 ,  54  are intended to be disposed between the adjacent bony structures interfacing with bone structure of a foot and ankle joint. The top of the implants  44 ,  54  may couple to a portion of the first bony structure  56  disposed above the implants and the bottom contact faces  28  may couple to the second bony structure disposed below implants  44 ,  54 . 
         [0046]    Once the implant is positioned in the foot and ankle joint  34 , the access point to the implant site may be closed using sutures or other closure devices. 
         [0047]    Although the bone implant has been shown and described in considerable detail with respect to only a few exemplary embodiments thereof, it should be understood by those skilled in the art that I do not intend to limit the invention to the embodiments since various modifications, omissions and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages, particularly in light of the foregoing teachings. Accordingly, I intend to cover all such modifications, omission, additions and equivalents as may be included within the spirit and scope of the bone implant as defined by the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures.