Impaction handle for implanting a tibial tray of an orthopaedic knee prosthesis and associated method of making the same

Patent metadata

Field	Value
Publication number	US-2024024128-A1
Application number	US-202217872350-A
Country	US
Kind code	A1
Filing date	Jul 25, 2022
Priority date	Jul 25, 2022
Publication date	Jan 25, 2024
Grant date	—

Abstract

An impaction handle for use during a surgical procedure to implant a tibial tray into a surgically-prepared proximal end of a tibia includes an impact plate defining a proximal end of the impaction handle and an impact head defining a distal end of the impaction handle. The impaction handle also has an elongated shaft extending between the impact plate and the impact head, along with a locking mechanism to lock the handle to the tibial tray. The impact plate, the impact head, the elongated shaft, and the locking mechanism of the impaction handle collectively define a single monolithic metallic component.

First claim

1 . An orthopaedic surgical instrument for use during a surgical procedure to implant a tibial tray into a surgically-prepared proximal end of a tibia, comprising:
an impaction handle, comprising:
an impact plate defining a proximal end of the impaction handle,
an impact head defining a distal end of the impaction handle, the impact head having an impact surface that is sized and shaped to be positioned on a superior surface of the tibial tray when the impaction handle is used to impact the tibial tray,
an elongated shaft extending between the impact plate and the impact head, the elongated shaft being hollow along its entire length, and
a locking mechanism positioned in the impact head, the locking mechanism comprising a locking tab that is movable between (i) a locked positioned in which the locking tab is extended outwardly from the impact head so as to be received into a locking slot defined in the tibial tray, and (ii) an unlocked position in which the locking tab is retracted inwardly toward the impact head so as to remove the locking tab from the locking slot of the tibial tray,
wherein the impact plate, the impact head, the elongated shaft, and the locking mechanism of the impaction handle collectively define a single monolithic metallic component.

2 . The orthopaedic surgical instrument of claim 1 , wherein the single monolithic metallic component defined by the impact plate, the impact head, the elongated shaft, and the locking mechanism of the impaction handle comprises a plurality of laminations.

3 . The orthopaedic surgical instrument of claim 1 , wherein:
the locking tab is defined in an end of a flange, the flange is slidable relative to the impact head so as to move the locking tab between its locked position and its unlocked position, the locking mechanism further comprises an eccentric cylinder having a tip, the tip of the eccentric cylinder is positioned in a slot defined in the flange, and rotation of the of the eccentric cylinder causes the flange to slide relative to the impact head.

4 . The orthopaedic surgical instrument of claim 3 , wherein:
the single monolithic metallic component defined by the impact plate, the impact head, the elongated shaft, and the locking mechanism of the impaction handle comprises a plurality of laminations, and at least one of the plurality of laminations defines a portion of each of the impact head, the flange of the locking mechanism, and the eccentric cylinder of the locking mechanism.

5 . The orthopaedic surgical instrument of claim 4 , wherein at least one of the plurality of laminations defines a portion of each of the impact head, the flange of the locking mechanism, and the tip of the eccentric cylinder of the locking mechanism.

6 . The orthopaedic surgical instrument of claim 3 , wherein:
the eccentric cylinder rotates about an axis of rotation, and the tip of the eccentric cylinder has a longitudinal axis that is offset from the axis of rotation of the eccentric cylinder.

7 . The orthopaedic surgical instrument of claim 3 , wherein:
the eccentric cylinder has a lever extending outwardly therefrom, and movement of the lever causes rotation of the eccentric cylinder.

8 . An orthopaedic surgical instrument for use during a surgical procedure to implant a tibial tray into a surgically-prepared proximal end of a tibia, comprising:
a single monolithic metallic impaction handle including a plurality of laminations of metallic material, comprising:
an impact plate defining a proximal end of the impaction handle,
an impact head defining a distal end of the impaction handle, the impact head having an impact surface that is sized and shaped to be positioned on a superior surface of the tibial tray when the impaction handle is used to impact the tibial tray,
an elongated shaft extending between the impact plate and the impact head, the elongated shaft being hollow along its entire length, and
a locking mechanism positioned in the impact head, the locking mechanism comprising a locking tab that is movable between (i) a locked positioned in which the locking tab is extended outwardly from the impact head so as to be received into a locking slot defined in the tibial tray, and (ii) an unlocked position in which the locking tab is retracted inwardly toward the impact head so as to remove the locking tab from the locking slot of the tibial tray.

9 . The orthopaedic surgical instrument of claim 8 , wherein:
the locking tab is defined in an end of a flange, the flange is slidable relative to the impact head so as to move the locking tab between its locked position and its unlocked position, the locking mechanism further comprises an eccentric cylinder having a tip, the tip of the eccentric cylinder is positioned in a slot defined in the flange, and rotation of the of the eccentric cylinder causes the flange to slide relative to the impact head.

10 . The orthopaedic surgical instrument of claim 9 , wherein at least one of the plurality of laminations defines a portion of each of the impact head, the flange of the locking mechanism, and the eccentric cylinder of the locking mechanism.

11 . The orthopaedic surgical instrument of claim 9 , wherein at least one of the plurality of laminations defines a portion of each of the impact head, the flange of the locking mechanism, and the tip of the eccentric cylinder of the locking mechanism.

12 . The orthopaedic surgical instrument of claim 9 , wherein:
the eccentric cylinder rotates about an axis of rotation, and the tip of the eccentric cylinder has a longitudinal axis that is offset from the axis of rotation of the eccentric cylinder.

13 . The orthopaedic surgical instrument of claim 9 , wherein:
the eccentric cylinder has a lever extending outwardly therefrom, and movement of the lever causes rotation of the eccentric cylinder.

14 . A method of making an impaction handle for use during a surgical procedure to implant a tibial tray into a surgically-prepared proximal end of a tibia, the method comprising:
layering metallic material in a fabrication machine so as to simultaneously form an impact head and a locking mechanism positioned in the impact head, the locking mechanism comprising a locking tab that is movable between (i) a locked positioned in which the locking tab is extended outwardly from the impact head, and (ii) an unlocked position in which the locking tab is retracted inwardly into the impact head.

15 . The method of claim 14 , further comprising:
layering metallic material in the fabrication machine so as to form an elongated body onto the impact head, and layering metallic material in the fabrication machine so as to form an impact flange onto the elongated body.

16 . The method of claim 14 , wherein layering metallic material in the fabrication machine so as to simultaneously form the impact head and the locking mechanism positioned in the impact head comprises forming the impact head and the locking mechanism as a single monolithic component.

17 . The method of claim 14 , wherein layering metallic material in the fabrication machine so as to simultaneously form the impact head and the locking mechanism positioned in the impact head comprises forming the impact head and the locking mechanism as a single monolithic component comprising a plurality of laminations of metallic material.

18 . The method of claim 14 , wherein layering metallic material in the fabrication machine so as to simultaneously form the impact head and the locking mechanism positioned in the impact head comprises oper

Assignees

• Depuy Synthes Products Inc

Inventors

• Nemiraj Rakshak
• Miltner Nicholas A
• Steiner Colton D
• Gatrell Bernice A

Classifications

• A61F2/461 Primary

  of knees · CPC title

• B33Y80/00 Primary

  Products made by additive manufacturing · CPC title

• A61F2002/4627

  with linear motion along or rotating motion about the instrument axis or the implantation direction, e.g. telescopic, along a guiding rod, screwing inside the instrument · CPC title

• A61F2002/4681

  by applying mechanical shocks, e.g. by hammering · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title