HOLE CAPS FOR PROSTHETIC IMPLANTS

Abstract: The disclosed hole cap (110) supports a prosthesis and provides a physical barrier between the prosthesis and underlying bone matter. In a preferred embodiment, the hole cap includes at least one compression spring (120) formed along the cap perimeter to maintain the hole cap within a counter-bored hole (112). The compression spring deflects slightly towards the center of the hole cap and provides sufficient compression force against the sidewalls of the counter-bored hole to thereby hold the hole cap in place within the hole. With the use of bone screws (104) or otherwise, the hole caps cover holes in implants to prevent the flow of unwanted debris into the counter-bored hole and into the underlying bone matter.

Description: HOLE CAPS FOR PROSTHETIC IMPLANTS BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates generally to prosthetic implants, and more particularly to such implants which use caps or covers to support the prosthesis and to maintain a physical barrier between the prosthesis and the bone to which the prosthesis is secured. 2. Description of Related Art Prosthetic implant devices for replacement of damaged or deteriorating portions of bone are well known in the art. There are currently two prevailing means used to secure prosthetic implants to the patient's bone: bone cement or a plurality of bone fixation screws. Both bone cement and fixation screws can be used separately or together to ensure that the implant is secured to the patient's bone. Many commercially available prosthetic implants accommodate both affixation methods. For example, as shown in FIGURE 1, a tibial tray 100 includes a plurality of holes 102 which are designed to receive a plurality of bone screws 104. In practice, a surgeon prepares a patient's bone by first cleaning and then placing bone cement into a properly prepared proximal end of the tibia. The bone cement is preferably applied using a syringe or with digital pressure to obtain intrusion of bone cement into the trabeculae of the patient's tibia. The surgeon typically inserts the stem 103 of the tibial tray 100 into the prepared tibia by hand or by using an impactor or similar tool. After inserting the tibial tray 100 into the prepared tibia, the tibial cement is allowed to harden. The surgeon maintains pressure across the tibial tray 100 while the cement hardens. Supplemental fixation of the tibial tray can also be achieved by screwing the plurality of bone screws 104 into the patient's tibial bone through the plurality of holes 102 in the tibial tray 100 with or without cement. Not all holes 102 are necessarily used to receive a bone screw 104. Disadvantageously, the plurality of bone screw holes 102 in the tibial tray 100 provide passageways for debris to pass from a top surface 106 of the tibial tray through the tibial tray 100. If a hole 102 is not occupied by a bone screw 104, and if bone cement is not used, such debris has a higher likelihood of coming into contact with the patient's underlying bone than it does if the hole 102 is occupied by a bone screw 104. As is known, unwanted debris or particles of polyethylene or metal may be generated by the articulation of the mating femoral component during use. In addition, this unwanted debris can comprise polyethylene particles, or "shavings", or metal debris which result when a polyethylene tibial insert 108 bears, over a period of time, upon the top surface 106 of the tibial tray 100. Additionally, experience has shown that the polyethylene tibial insert 108 deforms slightly when bearing the weight of a patient over a period of time, causing the polyethylene material on the bottom surface of the insert 108 to "cold flow" or protrude slightly into the holes 102 and may also lead to particle wear with time. The unwanted debris has been shown to elicit an osteolytic response in the patient's bone tissue. Disadvantageously, this response can lead to bone resorption and eventual loss of foundation strength within the patient's bone which supports the fixation of the implant 100. Eventually, d e implant 100 can become loose causing further complica- tions. In addition, even when bone screws 104 are inserted in the holes 102, cold flow of die polyethylene tibial insert 108 into the space above the screws can cause problems. As the polyethylene material flows into the holes 102, die thickness of the polyethylene tibial insert 108 is reduced or its shape distorted, increasing the likelihood of premature wear of die prosthetic implant, and thereby reducing the bearing capability of the insert 108. Therefore, mere is a need for a mechanism which will eliminate the problems associated with the presence of bone screw holes 102 used in existing prosthetic devices. The present invention provides such a mechanism. SUMMARY OF THE INVENTION An inventive hole cap and associated counter-bored hole for use in protecting and supporting a prosthetic implant are disclosed. The hole cap is preferably sufficiently thick to adequately withstand loading forces produced by a prosthetic insert during use. During surgery, after inserting bone screws into a patient's body, a surgeon quickly and easily inserts the hole cap into an associated counter-bored hole to prevent die flow of unwanted debris into d e counter- bored hole and diereafter into die patient's bone underlying the implant. Alternatively, die present hole cap can be used to cover bone screw holes in applications where bone screws are not used and where only bone cement is used to affix die implant to die patient's bone. In accordance with one preferred embodiment, die present hole cap includes at least one compression spring. When deflected inwardly toward die center of d e hole cap, the compression spring is designed to provide a bias force in an outward direction away from die center of d e hole cap. When inserted within the counter-bored hole, the compression spring is deflected by die sidewalls of die counter-bored hole and thereby is compressed outwardly against the surface walls of die hole. During use, the outward compression force of d e spring is sufficient to hold d e cap in place within die counter-bored hole. The cap diereby provides a block or seal against unwanted flow of metal or plastic debris through die hole and into die patient's bone matter. The cap is easily removed by forcing an instrument through d e underside of die hole in an upward direction against die cap. In the preferred embodiment, d e cap includes a flat-topped disk having a plurality of compression springs formed along the circumference of the disk. The compression springs are formed around d e circumference of d e cap by forming a plurality of compression spring slots along an inner diameter of d e cap. Each compression spring preferably includes a protrusion formed along d e tips of die springs. The protrusions are designed to ease die insertion of d e caps into d e counter-bored hole. The edges or comers of die disk are preferably rounded during manufacture to also ease the insertion and removal of d e caps into and out of the counter-bored holes. Once inserted within d e hole, die top-facing surface of the cap is substantially flush with the top surface of d e implant. The configuration of the present hole cap and counter-bored hole facilitates the intrusion of bone cement into the counter-bored hole which advantageously increases die strength of die mechanical interlock between the implant and die cement mantle. The cap is preferably manufactured using an Electro-Discharge Machining (EDM) manufacturing process. Alternative configurations for d e inventive hole cap are disclosed. These alternative embodiments contemplate die use of various cap retaining means and associated implant holes which are shaped to receive the alternative cap embodiments. The details of die preferred embodiment and d e alternative embodiments of die present invention are set forth in die accompanying drawings and die description below. Once die details of die invention are known, numerous additional innovations and changes will become obvious to one skilled in the art. BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a front perspective exploded view of a tibial tray insert including a plurality of screw holes designed to receive a plurality of bone screws. FIGURE 2 is a front perspective exploded view of a tibial tray showing d e hole caps and associated counter-bored holes of die present invention. FIGURE 3a shows a top plan view of the preferred embodiment of die hole cap of die present invention. FIGURE 3b shows a top plan view of a first alternative embodiment of die inventive hole cap. FIGURE 3c shows a side cross-sectional view of the hole cap shown in FIGURE 3b. FIGURE 3d shows a top plan view of a second alternative embodiment of die inventive hole cap. FIGURE 3e shows a side cross-sectional view of die hole cap shown in FIGURE 3d. FIGURE 3f shows a top plan view of a diird alternative embodiment of die inventive hole cap. FIGURE 3g shows a top plan view of a fourth alternative embodiment of die inventive hole cap. FIGURE 4 shows a detailed top view of one compression spring of the hole cap of FIGURE 3a. FIGURE 5 shows a cross-sectional view of die screw hole and die hole cap of FIGURES 2-4. FIGURE 6 shows a side cross-sectional view of die hole cap of FIGURES 2-5 showing d e top-facing surface of the hole cap substantially flush wiui die top surface of the implant 100 after insertion of the hole cap wid in die counter-bored hole. FIGURE 7 shows d e hole cap of FIGURE 6 showing the spacing between die hole cap and the counter-bored hole which allows die bone screw head to rotate wid respect to die hole cap. FIGURE 8 shows details of die hole cap and die top surface of die implant shown in FIGURES 2-6. FIGURE 9 shows die hole cap and counter-bored hole of FIGURE 8 in dieir least material condition. FIGURE 10 shows a side cross-sectional view of the implant, hole cap, and counter-bored hole of FIGURE 5, shown with die implant secured to a patient's bone using bone cement in addition to, or alternatively, in the place of the plurality of bone screws shown in FIGURE 2. FIGURE 11 shows a side cross-sectional view of an alternative embodiment of die present hole cap and counter-bored hole. Like reference numbers and designations in die various drawings refer to like elements. DETAILED DESCRIPTION OF THE INVENTION Throughout this description, d e preferred embodiment and examples shown should be considered as exemplars, rather than as limitations on the present invention. Overview FIGURE 2 shows hole caps or covers 110 and associated counter-bored holes 112 of die present invention. The invention is illustrated diroughout die specification as being used in a tibial tray 100 and tibial insert prostiietic device. However, the tibial tray 100 and tibial insert 108 is exemplary only, and should not be taken as a limitation of die present invention. For example, die inventive cap 110 and counter-bored holes 112 can be used witii any prosthetic device having holes for die supplemental fixation of the prosthetic device using bone screws. In particular, die present invention may be used with many odier prosdietic devices including an acetabular cup, a glenoid component, an ulnar component, a vertebral body, and a bone plate. Referring again to FIGURE 2, once die tibial tray 100 is inserted within die patient's bone, die bone screws 104 can be used to affix the tray 100 to die patient's bone. The bone screws 104 may be used witii or widiout bone cement. Once d e screws are fully inserted within die holes 102, the head of die screws 114 are received by spherical screw head counter-bores 116 formed into die holes 102. When fully inserted within die holes 102, a top surface 118 in die bone screw head 114 is positioned below die top surface 106 of d e tibial tray 100. With d e tibial tray 100 securely attached to the bone, and die bone screws 104 fully inserted within die patient's bone, die surgeon prepares die tibial tray for die tibial insert 108 by placing die caps 110 within the counter-bored holes 112 formed in the holes 102. As shown in FIGURE 2 and described in more detail hereinbelow with respect to FIGURES 5, 8 and 9, die diameter of die cap 110 and its associated counter-bored hole 112 slightly exceeds die diameter of die screw head spherical counter-bore 116. In addition, die cap 110 is manufactured sufficiently thin to provide adequate clearance between die bottom-facing surface of die cap 110 and die top surface 118 of die screw head 114. However, die cap 110 is manufactured sufficiently diick to adequately witiistand loading forces produced by die insert 108 on the cap 110. As described in more detail hereinbelow witii reference to FIGURES 5 and 6, a surgeon simply inserts die cap 110 into its associated counter-bored hole 112 after die screws 104 are fully inserted widiin the patient's bone. The caps 110 include at least one compression spring 120, each of which compress outwardly against die surface walls of d e counter-bored holes 112. During insertion, die downward force created by die surgeon's placement of a cap 110 into a counter-bored hole 112 causes each spring 120 to deflect in an inward direction toward the center of the cap 110. Once the caps 110 are fully inserted within die holes 112, the compression springs 120 compress outwardly against the surface walls of the counter-bored holes 112. The compression force of each spring 120 holds die caps 110 in place during use. While inserted widiin die counter-bored holes 112, die upwardly facing surface of the caps 1 10 are preferably flush witii die top surface 106 of die tibial tray 100. Thus, die caps 110, in combination witii die top surface 106 of die tibial tray, provide a substantially continuous surface against which the tibial insert 108 bears during use. The caps 1 10 provide a block or a seal which prevents metal and plastic debris from flowing through the holes 102 and becoming lodged widiin die patient's bone. The caps 1 10 also provide a bearing support to die polyetiiylene liner or insert which prevents cold flow of polyed ylene material which consequently can compromise die strength of the implant 108. The caps 110 are easily pressed into place by die surgeon by simply placing the cap 110 over die hole 102 and pressing die cap within die counter-bored hole 112. The caps 110 are easily removed from a tibial tray 100 (prior to insertion in a patient) by forcing an instrument having a smaller diameter than die diameter of die hole 102 dirough the underside of die hole 102 in an upward direction against the cap 110. The instrument is pressed against die underside of the caps 110 with a force that exceeds die compression force produced by d e compression springs 120. The compression force exerted by die compression springs 120 is preferably approximately between 0.5 and 1.0 pound-force. Thus, in die preferred embodiment, the compression force is easily overcome by the surgeon and die caps 1 10 are diereby easily removed. Details of Cap Configuration FIGURE 3a shows a top view of the cap 110 of die present invention. As shown in FIGURE 3a, and described above, each cap 110 preferably comprises a flat-topped disk having at least one compression spring 120 formed along die perimeter of the cap 110. The diameter "D" 122 of d e cap 110 is manufactured to be slightly smaller than the diameter of die counter- bored hole 112 (FIGURE 2) into which the cap 110 is inserted during use. The difference in diameters between die diameter D 122 and die diameter of die hole 112 preferably ranges between -0.0005 to 0.0025 inches. The caps 110 are manufactured so tiiat the diameter d 124 is always greater than d e diameter D 122. This ensures that die sidewalls of die counter- bored holes 112 first contact die compression springs 120 when the cap 110 is first inserted within the holes 102. The maximum ratio of D/d is preferably approximately 0.995. The ratio of the diameter d 124 over die diameter of die counter-bore hole 112 ranges between approximately 1.009 (max) to 1.001 (min). As shown in FIGURE 3 a, the preferred cap 110 includes a plurality of compression springs 120 formed along its circumference. Although FIGURE 3a shows d e cap 110 having four compression springs 120, one or more compression springs may be used. The compression springs 120 are formed around the circumference of the cap 110 by forming a plurality of compression spring slots 126 as shown in FIGURE 3a. The slots 126 provide an area into which the compression springs 120 are deflected when d e cap 110 is fully inserted widiin die counter-bored hole 112 of the tibial tray 100 (FIGURE 2). Although the preferred embodiment of d e hole cap is shown in FIGURE 3a, a number of alternative embodiments are contemplated. For example, alternative embodiments of die inventive hole caps 110 having alternative configurations are shown in FIGURES 3b-3g. FIGURE 3b shows a top plan view of a first alternative embodiment of die hole cap 110 of the present invention. FIGURE 3c shows a side cross-sectional view of d e hole cap 110 shown in FIGURE 3b. Now referring simultaneously to both FIGURES 3b and 3c, die hole cap 110 includes sidewalls 200 which are formed to fit widiin die counter-bored hole 112 shown in FIGURE 2. As shown in FIGURE 3c, the sidewalls 200 are preferably inclined slightly toward a center 202 of die cap 110 starting from a top-facing surface 204 down toward a bottom-facing surface 206. By forming die sidewalls 200 in die manner shown in FIGURE 3c, the hole caps 110 have a slightly greater diameter at its top-facing surface 204 than it does at its bottom-facing surface 206. The diameter of die cap 110 at its bottom-facing surface 206 is preferably slightly less tiian die diameter of die counter-bored hole 112 (FIGURE 2) into which the cap 110 is to inserted during use. When a surgeon inserts the cap 110 shown in FIGURES 3b and 3c into a counter- bored hole, a top plate 208 of die cap 110 bows slightly in an upward direction so that die top- facing surface 204 of the cap 110 is slightly convex. The dimensions of die hole cap 110 and the hole 112 are designed so tiiat the top plate is not permanently deformed by the bowing action beyond die elastic range of either die cap 110 or die hole 112. That is, die top plate is not deformed beyond its yield strength. When the cap 110 is fully inserted widiin an associated counter-bored hole 112, die bowing action of die top plate 208 causes the sidewalls 200 to exert a compression force against die sidewalls of die hole 112 in a direction away from die center 202 of the cap 110. This force is preferably widiin die elastic range of both die counter-bored hole material and die cap 110. Thus, the force exerted by the cap 110 shown in FIGURES 3b and 3c does not permanendy deform die sidewalls of the counter-bored hole 112. FIGURES 3d and 3e show a second alternative embodiment of die hole cap 110 of d e present invention. FIGURE 3d shows a top plan view and FIGURE 3e shows a side cross-sectional view of die second alternative embodiment of die hole cap 110. Referring simultaneously to both FIGURES 3d and 3e, die hole cap 110 includes a plurality of inwardly facing flexible "teeth" 210 formed along d e perimeter of the cap. Unlike die first alternative embodiment of FIGURES 3b and 3c, the sidewalls 200 of die cap 110 are not inclined. Ratiier, die sidewalls 200 are shaped so that die cap 110 has a slightly greater diameter than die diameter of die counter-bored hole 112 into which die cap is inserted during use. When die cap 110 is inserted widiin its associated counter-bored hole, compression forces are exerted upon the sidewalls 200 in a direction toward die center 202 of die cap 110. Due to their flexible construction, the teeth 210 flex in an inward direction. The maximum compression forces exerted upon the teeth 210 are preferably below die yield strength of die teeth 210. Consequently, the teeth 210 do not permanendy deform after multiple insertions Because die teeth 210 are attached to an inner portion of die cap 110, when die cap is inserted within the hole 112, the teetii 210 are biased to exert a force in an outward direction away from die center 202 of the cap 1 10. This outward force is sufficient to maintain die cap 110 within the hole 1 12 during use. FIGURE 3f shows a top plan view of a tiiird alternative embodiment of the inventive cap 110. Similar to the embodiment shown in FIGURE 3 a, the embodiment shown in FIGURE 3f includes compression springs 120 formed along die outer circumference of die cap 110. The compression springs 120 are formed into the cap 110 by forming a plurality of compression spring slots 126 into the cap as shown in FIGURE 3f. The slots 126 and springs 120 shown in FIGURE 3f are elongated relative to tiiose shown in FIGURE 3a. As described above witii reference to die preferred embodiment shown in FIGURE 3a, the compression springs 120 flex in an inward direction when inserted within an associated counter-bored hole. The springs 120 exert a sufficient force away from the center 202 of die cap 110 and against die sidewalls of die hole 112 to prevent the cap from inadvertently disengaging from die hole 112 during use. FIGURE 3g shows a top plan view of a fourth alternative embodiment of die hole cap 110 of the present invention. The alternative embodiment shown in FIGURE 3g differs from those shown in FIGURES 3a-3f in that it includes at least two substantially parallel mating tines 220 which extend away from the center 202 of die cap 110. The mating tines 220 may be manufactured as an integral part of the cap 110 or may optionally be attached to die rounded cap after die cap is manufactured. The tines 220 are preferably positioned proximate each otiier as shown in FIGURE 3g. Although not shown, die fourth alternative embodiment shown in FIGURE 3g is intended to be used with a prostiietic device which includes an insertion slot shaped to receive the cap 110 and the mating tines 220. Thus, when the cap 110 shown in FIGURE 3g is inserted over a hole in die prostiietic device, the tines 220 align with an insertion slot on the prostiietic device. The distance "d" 222 between die outer edges of die mating tines 220 is preferably slightly greater than the widtii of the insertion slot on die prosthetic device. Therefore, when the mating tines 220 are inserted widiin the insertion slot, d e tines 220 flex inwardly toward one another. Consequently, the tines 220 exert a compression force in a direction away from one another when fully inserted widiin die insertion slot on the prosthetic device. This compression force is sufficient to maintain the cap 110 in place during use. FIGURE 4 shows a detailed top view of one compression spring 120 shown in FIGURE 3a. The compression springs 120 preferably include a protrusion 128 formed along tips of die springs 120. As shown in FIGURE 4, die diameter of die cap 110, when measured from die outer periphery of the protrusion 128, is slightly larger than die diameter of die cap 110 when measured from die outer periphery of die remainder of die spring 120. That is, the protrusion 128 extends a distance slightly beyond the rest of the perimeter of die hole cap 110. The distance that die protrusion 128 extends beyond die perimeter of die hole cap is preferably approximately between 0.001 to 0.010 in. FIGURE 5 shows a cross-sectional view of die hole 102 and die inventive cap 110 of FIGURES 2-4. The bone screw hole 102 preferably includes a counter-bored hole 112 configured to receive die cap 110 when die cap 110 is inserted widiin die counter-bored hole 112. As shown in FIGURE 5, the diameter of die cap 110 and die counter-bored hole 112 slightly exceeds d e diameter of d e spherical counter-bore 116. The cap protrusions 128 (FIGURE 4) extend slightly beyond die diameter of die counter-bored hole 112. In one preferred embodiment, an insertion ramp or an inclined surface 130 is milled around die top- facing surface of die counter-bored hole 112 and inclined in a direction toward d e center of the counter-bored hole 112 as shown in FIGURE 5. The inclined surface 130 of die counter- bored hole 112 has a diameter which is slightly larger than die diameter of die counter-bored hole 1 12. The inclined surface 130 allows the cap 110 to be easily centered widiin die counter-bored hole 112 and allows die surgeon to insert the cap widiin die hole 112. During manufacture, the inventive cap 110 preferably is removed of all burrs during manufacture and is tumble-polished so that all of die edges of die cap 110 have a slightly curved corner radius. For example, die corners 132 of the cap 110 shown in FIGURE 5 are slightly curved so that they have no sharp edges. The curved corners 132 of die cap 110 serve to aid assembly of die cap 110 into the counter-bored hole 112. The cap 110 is preferably inserted by a surgeon into die counter-bored hole 112 by placing die cap 110 over die hole 102 and pressing die cap against the inclined surface 130 in a downward direction toward die screw hole 102. The cap 110 may be assembled having either side facing upward, and is also rotationally independent. That is, die rotation of die cap 110 widiin die counter-bored hole 112 is unimportant to d e operation of die implant. During insertion, the downward force applied by die surgeon upon a top-facing surface 134 of the cap 110 causes d e compression springs 120 to compress and deflect in an inward direction into an area 123 defined by die slots 126 (FIGURE 3a). Some slight resistance is initially exerted by die compression springs 120 because the protrusions 128 and die compression springs 120 have a slightly greater diameter tiian the diameter of die counter- bored hole 112. The resistance exerted by die compression springs 120 is easily overcome due to die inclined surfaces 130 and die curved corners 132 of die cap 1 10. Once die surgeon overcomes die resistance exerted by die compression springs 120, the cap is pushed downward into die counter-bored hole 112. Thus, die caps 110 are self-centering widiin die counter-bored hole 112 once the surgeon places the cap over the hole 102 as shown in FIGURE 5. Once inserted widiin die counter-bored hole 112, die top-facing surface 134 of the cap 110 is substantially flush with die top surface 106 of the implant 100 as shown in FIGURE 6. A bottom-facing surface 136 of the cap 110 is kept a short distance away from die top surface 118 of the screw head 114 when die screw 104 is completely inserted widiin die patient's bone. When fully inserted within die counter-bored hole 112, the bottom surface 136 of the cap 110 and die top surface 118 of the screw head 114 define a volume 138 within which the top surface 118 of the screw head 114 can be angled or rotated. For example, as shown in FIGURE 7, die spacing between the present hole cap 110 and die counter-bored hole 112 provides adequate room in die area 138 into which the bone screw head 114 can be angled or rotated. This feature is particularly advantageous because a surgeon often needs to tilt the screw 104 to reach good bone purchase. The compression springs 120 exert a sufficient force away from die center of die cap 110 and against the sidewalls of die counter-bored hole 112 to prevent die cap 110 from inadvertently disengaging from die counter-bored hole 112 during use. The springs 120 preferably exert a compression force which falls within the elastic range of the counter-bored hole material (i.e., below die yield strength). The compression springs also preferably remain in their elastic range during insertion. That is, the force exerted by die springs 120 also falls below the yield strength of die compression springs 120. Thus, neither die springs 120, nor the sidewalls of die counter-bored hole 112, are permanendy deformed during insertion and removal of the cap 110. The spring slots 126 (FIGURE 3a) are designed to provide adequate room for the plurality of springs 120 to deflect into when die cap 110 is fully inserted widiin the counter-bored hole 112. However, the deflection area 123 formed by die slots 126 is dimensioned to be less tiian die width 133 of die base of die counter-bored hole 112. This ensures that unwanted debris does not pass through die slot 126 into d e hole 102. FIGURE 8 shows details of die cap 110 and die top surface 106 of die implant 100 shown in FIGURES 2-6. As shown in FIGURE 8, when die cap 110 is fully inserted widiin die counter-bored hole 112, die forces exerted by die compression springs 120 (FIGURE 3 a) keep the cap 110 widiin die counter-bored hole 112. The cap provides a seal to die bone screw hole 102. When fully inserted within the counter-bored hole 112, die cap 110 prevents flow of polyethylene and metal from die top surface 106 of die insert 100 through die hole 102. The cap 110 also provides a surface upon which the insert 108 (FIGURE 1) can bear during use. The cap 110 is manufactured to be relatively tiiin to provide adequate room for die screw head 1 14 and the screw head surface 118 as described above witii reference to FIGURE 7. However, the cap 110 must be sufficiently thick to withstand die bending loads diat are applied to it via compression forces exerted by die insert 108 (FIGURE 1 ). The thickness of die cap 110 and the deptii of the counter-bored hole 112 are machined to very close tolerances. At their maximum material condition, die top-facing surface 134 of die cap 1 10 is exactly flush with die top surface 106 of die tray 100 as shown in FIGURE 8. However, when both the cap 110 and die counter-bored hole 112 are at their least material condition, the top surface 134 of the cap 110 is not flush witii die top surface 106 of the tray 100 as shown in FIGURE 9. Ratiier, a slight step-down of preferably approximately no greater tiian .002 inches exists between die top surface 106 of die tray 100 and die top surface 134 of the cap 110. By manufacturing die cap 110 and die counter-bored hole 112 to diese tolerances, the top surface 134 of the cap 110 does not interfere with die bottom-facing surface of die polyetiiylene insert 108 (FIGURE 1). These tolerances also ensure that the cap 1 10 will not cause premature wear to die insert 108 nor will it interfere witii the insertion of die insert 108 in die prostiietic device. The cap 110 is preferably manufactured using an Electro-Discharge Machining (EDM) manufacturing process. The caps 110 are easily and inexpensively manufactured widiin desired tolerances using tiiis well-known manufacturing technique. Several caps can be concurrently machined by stacking sufficiently thin sheets of metal on top of each other. The material from which die caps are manufactured is preferably of the same type as the prosthetic implant material. For example, if die implant 100 comprises titanium alloy, the caps 100 are produced from substantially the same titanium alloy. Similarly, if cobalt chromium implants are used, die caps 110 are preferably produced from cobalt chromium. The specific materials used for the caps 110 and implants 100 are not crucial, as long as the corrosive effects of in vivo prostiietics are avoided. FIGURE 10 shows the inventive cap 110 and die counter-bored hole 112 used witii an implant 100 when the implant 100 is secured to die patient's bone using bone cement 140 in addition to, or alternatively, in die place of d e plurality of bone screws 104 (FIGURE 2). The present invention allows bone cement to intrude into die spherical counter-bored hole 116 as shown in FIGURE 10. The intrusion of bone cement 140 into the counter-bored hole 116 and the screw hole 102 creates a strong mechanical interlock between die implant and die cement mantle. Prior art prosthetic devices require a surgeon to manually prevent the intrusion of the bone cement 140 into the liner cavity. Preventing intrusion of the bone cement is a time- consuming process and thus increases operating-room time and tiiereby increases the costs and morbidity associated witii prosthetic surgery. In addition, bone cement particles often become loose within the patient's joint, leading to foreign body abrasive wear which in turn leads to premature insert wear. As shown in FIGURE 10, the present invention takes advantage of die intrusion of the bone cement 140 into die spherical counter-bored hole 116. The cap serves as a barrier to the bone cement intruding into the liner cavity. A number of embodiments of die present invention have been described. Nevertheless, it will be understood that various modifications may be made witiiout departing from die spirit and scope of the invention. For example, FIGURE 11 shows an alternative embodiment of die inventive cap 110 and the counter-bored hole 112 used witii an implant 100 when die implant 100 is secured to die patient's bone. As shown in FIGURE 11, the present invention contemplates an inventive cap 110 which includes a plurality of protrusions 150 formed into the sidewalls 152 of die cap 110. As shown in FIGURE 11, die protrusions 150 are designed to mate witii detents or undercuts 154 formed widiin die sidewalls of die counter-bored hole 112. Thus, when the cap 110 is inserted within the counter-bored hole 112, die protrusions 150 interlock with the detents 154 formed within die hole 112. The cap 110 is tiiereby secured in place widiin die hole 112. Accordingly, it is to be understood tiiat die invention is not to be limited by the specific illustrated embodiment, but only by die scope of die appended claims.

Claims: CLAIMS 1. A hole cap for a prostiietic implant, comprising: a. a substantially flat disk; and b. at least one compression spring formed by a slot cut into die perimeter of the disk, wherein die compression spring extends slightly beyond die outer diameter of die disk, but is deflected into an area defined by die slot, and wherein each cap is shaped to be received by a substantially round counter- bored hole formed into a prostiietic implant. 2. The hole cap of claim 1, wherein the hole cap is substantially round. 3. The hole cap of claim 1 , wherein die hole cap is substantially flat. 4. The hole cap of claim 1, wherein the at least one compression spring is formed by a slot which is cut into the perimeter of the disk. 5. The hole cap of claim 1, wherein the spring is deflected when the cap is inserted into the counter-bored hole. 6. The hole cap of claim 1, wherein the at least one compression spring includes a protrusion which extends die spring slightly beyond die diameter of d e disk. 7. The hole cap of claim 1 , wherein die disk comprises titanium alloy. 8. The hole cap of claim 1 , wherein die disk comprises cobalt chromium alloy. 9. The hole cap of claim 1, wherein the counter-bored hole includes a cap insertion ramp, and wherein the insertion ramp has an inclined surface which assists insertion of die cap into die hole. 10. The hole cap of claim 1, wherein die implant has a top surface, and wherein die disk and die top surface of the implant are substantially flush when the hole cap is inserted within the counter-bored hole. 11. The hole cap of claim 1, wherein die implant has a screw hole including a spherical counter-bored hole for receiving a bone screw, and wherein the counter-bored hole is formed in die implant in a position just above die spherical counter-bored hole. 12. The hole cap of claim 11, wherein the hole cap seals die screw hole against flow of debris through the screw hole. 13. The hole cap of claim 12, wherein the hole cap bears load forces produced by a prosthetic insert shaped to be received by die implant, and wherein die hole cap thereby prevents a bearing surface of the insert from cold flowing into the screw hole. 14. A device for sealing a screw hole in a prostiietic implant, comprising: a. a hole cap having a plurality of compression springs formed along die perimeter of die cap; b. a cap retaining hole, formed into a side wall of die screw hole, wherein the cap retaining hole is shaped to receive die hole cap, and wherein the compression springs exert forces against sidewalls of die cap retaining hole which are sufficient to prevent inadvertent removal of die cap from the cap retaining hole. 15. The device of claim 14, wherein the screw hole includes a top portion which is shaped to receive a screw head of a bone screw, and wherein die hole cap does not interfere with a tilting of die screw head when die cap is fully inserted widiin die cap retaining hole. 16. The device of claim 14, wherein the plurality of compression springs include protrusions which extend slightly beyond the outer diameter of die hole cap, and wherein d e protrusions contact the sidewalls of die cap retaining hole when the cap is inserted widiin die retaining hole. 17. The device of claim 14, wherein die hole cap includes a plurality of rounded edges. 18. The device of claim 14, wherein die cap retaining hole includes a cap insertion ramp, and wherein die insertion ramp has an inclined surface which assists insertion of die cap into d e hole. 19. The device of claim 14, wherein die hole cap includes at least one protrusion formed along the perimeter of die cap, and wherein the cap retaining hole includes at least one detent formed into die side wall of die screw hole, and wherein die at least one protrusion interlocks witii the at least one detent when die hole cap is inserted into die hole. 20. A method for affixing a prosthetic implant to a patient's bone, wherein d e implant has at least one hole, and wherein each hole includes a cap retaining hole shaped to receive a hole cap, comprising the steps of: a. inserting a hole cap into each cap retaining hole; b. positioning the implant at a proper location within the patient's bone; c. distributing bone cement at die proper location; d. allowing die bone cement to intrude into each implant hole and into each cap retaining hole; and e. waiting a period of time sufficient to allow the bone cement to cure thereby mechanically locking the implant with die patient's bone. 21. A hole cap for a prosthetic implant, comprising: a. a substantially flat disk; and b. a means for retaining die cap widiin a cap retaining hole formed into a prostiietic device, wherein die retaining means comprises mating tines extending from an outer perimeter of die disk, and wherein die mating tines are shaped to be received by an insertion slot formed into die cap retaining hole. 22. The hole cap of claim 21, wherein die retaining means comprises a plurality of inwardly facing flexible teeth formed along d e circumference of the hole cap. 23. The hole cap of claim 21, wherein the retaining means comprises hole cap sidewalls shaped to be received by die cap retaining hole, and wherein d e hole cap sidewalls exert a compression force against the cap retaining hole when the hole cap is inserted witiiin die hole.

Inventors: CLOUTIER RAYMOND J, MAULDIN CARY M, CLOUTIER, RAYMOND, J., MAULDIN, CARY, M.
Applicants: EXACTECH INC, EXACTECH, INC.
Application year: 1995
Main classification: A61F2
IPC codes: A61B17, A61F2