GRAFT TRUSSING AND SUSPENSION CONSTRUCT

Abstract

A quadricep graft suspension construct, having a button loop, including a generally rectangular button, defining four apertures, including an innermost pair of apertures; and a suture loop looping through the innermost pair of apertures. The construct also has a graft holding assembly, including a reinforcement of first fibers braided with two second fibers, and wherein the first fibers have a first and second lengthwise end and the second fibers continue separately, extending from the first lengthwise end to form a pair of first tails and from the second lengthwise end to form a pair of second tails and wherein the first tails are jointly swaged to a needle. And wherein the graft holding assembly is affixed to the suture loop at a position opposed to the button at least in part by the second tails being joined together about the suture loop and further includes a packaging holding the needle.

Description

TECHNICAL FIELD

The disclosure relates to methods, devices, and systems for a surgical device used to attach tissue to bone. More particularly, the disclosure relates to a suture construct that can be used to attach tissue to bone for various orthopedic repair applications.

BACKGROUND OF THE INVENTION

To perform an anterior cruciform ligament (ACL) reconstruction surgery in the knee, it is necessary to supply a graft, and attach the graft to constructs for suspending the graft in a tunnel created in the femur and the tibia. The place where the graft attaches to each suspension construct will be subjected to substantial tensile force, possibly causing the suture of the suspension construct to rip through the tissue of the graft, causing a catastrophic failure of the ACL reconstruction.

Within the last few years, a graft harvested from the quadricep tendon (quad), directly above the knee has become increasingly popular, due to good graft performance, and less morbidity at the harvest site. This type of graft requires particular care, to be certain that the suture that suspends the graft at a beneficial position in the tunnel will not pull through the graft tissue. Unlike a hamstring tendon graft, a quad graft is not folded over a loop, to be doubled up (as the hamstring tendon is thinner). And unlike a patella harvested tendon, there is not bone on either side, to provide a particularly strong piece of tissue to which the suture is engaged.

Various entities have originated constructs and methods for attaching a suspension construct to a quad graft. A reinforcement element is sometimes used, to better ensure that the suture does not pull through the graft. One of the constructs requires a few extra needle pass steps to strongly affix one portion of the construct to another, during graft/construct preparation. Eliminating these steps would save medical personnel some valuable medical time during surgery preparation.

SUMMARY OF INVENTION

The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools, and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.

In a first separate aspect the present invention may take the form of a method of attaching a graft to a construct that utilizes a construct having a reinforcement comprising a flat braid of fibers, which has a first end and an opposed second end and wherein two of the fibers extend out of both the first end to form a pair of first tails and the second end of the reinforcement to form a pair of second tails, and wherein a needle is swaged onto the ends of the first tails, joining them together. The construct further has a button loop assembly, including a suture loop, the suture loop further being engaged to a generally rectangular button defining four apertures, by looping through two of the apertures and wherein the flat braid of fibers is attached to the suture loop at least in part by the second tails being joined together about the suture loop at a location generally opposed to the button. In the method, the reinforcement of woven fibers is placed on the graft. Then, the needle and first tails are used to whipstitch the reinforcement to the graft by starting at a first location of the reinforcement.

In a second separate aspect, the present invention may take the form of a quadricep graft suspension construct, having a button loop, including a generally rectangular button, defining four apertures, including an innermost pair of apertures; and a suture loop looping through the innermost pair of apertures. The construct also has a graft holding assembly, including a reinforcement of first fibers braided with two second fibers, and wherein the first fibers have a first and second lengthwise end and the second fibers continue separately, extending from the first lengthwise end to form a pair of first tails and from the second lengthwise end to form a pair of second tails and wherein the first tails are jointly swaged to a needle. And wherein the graft holding assembly is affixed to the suture loop at a position opposed to the button at least in part by the second tails being joined together about the suture loop and further including packaging holding the needle.

In a third separate aspect the present invention may take the form of a method of making a fiber reinforcement and needle construct that begins by braiding a group of fibers into a braid construct, the fibers including a group of first fibers and two second fibers. Then a sacrificial portion of the first fibers are removed to leave a flat braided portion with two first tails extending therefrom. Finally, a needle is swaged onto the ends of the two fibers.

BRIEF DESCRIPTION OF DRAWINGS

Various embodiments of the invention are disclosed in the following detailed description and accompanying drawings.

FIG. 1 is a plan view of a needle and reinforcement component of a graft suspension construct.

FIG. 2 is a plan view of an adjustable button loop component of a graft suspension device.

FIG. 3 is an illustration of a step in a method of attaching the needle and reinforcement component to the adjustable button loop component of the graft suspension device.

FIG. 4 is an illustration of a further step in a method of attaching the needle and reinforcement component to the adjustable button loop component of the graft suspension device.

FIG. 5 is an illustration of the needle and reinforcement construct attached to the adjustable button loop component.

FIG. 6 is an illustration of the configuration of FIG. 5, but with some of the needle and reinforcement component cut off.

FIG. 7 is a plan or top view of the graft suspension construct, with the reinforcement laid upon a graft.

FIG. 8 is a plan view of a completed graft suspension construct, whipstitched to a quadricep graft.

FIG. 9 is an illustration of a braid that is created and used in the construction of the needle and reinforcement component.

FIG. 10 is an illustration of the braid of FIG. 9, at a further stage of construction.

FIG. 11 is a plan view of a different portion of the stage of FIG. 10.

FIG. 12 is a plan view of an alternative embodiment of a needle and reinforcement component of a graft suspension construct.

FIG. 13 is a detailed view of the reinforcement portion of the component of FIG. 12.

FIG. 14 shows an initial step of combining the alternative needle and reinforcement component to an adjustable button loop component of a graft suspension device.

FIG. 15 shows a subsequent step of combining the alternative needle and reinforcement component to an adjustable button loop component of a graft suspension device.

FIG. 16 shows an additional subsequent step of combining the alternative needle and reinforcement component to an adjustable button loop component of a graft suspension device.

FIG. 17 shows a penultimate step of combining the alternative needle and reinforcement component to an adjustable button loop component of a graft suspension device.

FIG. 18 shows a completed graft suspension device affixed to a packaging element.

FIG. 19 shows a completed graft suspension device whipstitched onto a graft.

DETAILED DESCRIPTION AND EMBODIMENTS

The following is a detailed description of exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. The scope of the invention encompasses numerous alternatives, modifications and equivalent; it is limited only by the claims.

Numerous specific details are set forth in the following description in order to provide a thorough understanding of the invention. However, the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured.

To assist the description of the scope and its components the coordinate term “under” and “over” are used to describe the disclosed embodiments. The terms are used only as relative terms, for ease of description. Accordingly, in a sequence of operations, if the first step states that a first item is placed under a second item, and the next step states that the first item, or a portion thereof, is brought over the second item, the terms “under” and “over” could be reversed, with the first step stating that first item is placed over the second item, and the second step stating the first item or a portion thereof is brought under the second item.

Stated differently, “under” simply means “on a first side of” and “over” means “on a second side of, opposed to said first side.” Because the terms “under” and “over” are more familiar to most readers and are less wordy and easier to understand, applicant is choosing those terms, over the more verbose terms.

Referring to FIG. 1, a needle and reinforcement component 10 includes a reinforcement 12 that consists of a flat braid of fibers, two warp strands 14 that extend out of reinforcement 12, to form a pair of tails 15 and a needle 16 swaged onto the ends of the two tails 15. FIG. 2 shows the button loop component 20 to which component 10 will be attached. This includes a trap section 22, in which the inner length of suture 24 accepts portions of middle suture length 26 and outer suture length 28 in its lumen. Outer suture lengths 28 extend out of holes in button 30 and may be pulled on to shorten the length of triple loop 32. Skilled persons will recognize that this type of adjustable loop is used to suspend a graft into a tunnel created in the femur and tibia.

Referring, now, to FIGS. 3-6, component 10 is attached to trap section 22 of component 20, by first placing reinforcement 12 underneath trap 22 and piercing reinforcement 12 with a lacing tool 40, as shown in FIG. 3, thereby creating a broach 42 in reinforcement 12, at a position inside the triple loop 32. Next the reinforcement 12 is grabbed by lacing tool 40, as shown in FIG. 4, at a position outside of triple loop 32 and pulled over trap 22 and through broach 42. The pulling continues until the remainder of reinforcement 12, tails 15 and needle 16 are pulled through the broach 42, resulting in the configuration shown in FIG. 5. Finally, the remainder of reinforcement 12 is cut with a hot knife, with the resultant construct 60 shown in FIG. 6 and FIG. 7 (shown with graft).

As noted, FIG. 7 shows construct 60 positioned relative to a graft 70, so that reinforcement 12 is directly on top of graft 70 and with needle 16 being used to whipstitch reinforcement 12 onto graft 70, with a stitch 72, already completed. FIG. 8 shows construct 60 attached to graft 70, by means of whipstitching 72. The advantages of this configuration will now be apparent to skilled persons, as a strong construct 60 is affirmatively connected to tendon 70, with reinforcement 12 adding strength to the connection, thereby preventing tails 15 from pulling through graft 70.

FIGS. 9-11 show stages in the production of component 10, with FIG. 9 showing the configuration 80 after braiding by a round-to-flat braiding machine, such as those available from Herzog Maschinenfabrik Gmbh & Co. of Oldenburg, Germany. Portion 82 is braided while the machine is in its flat braiding configuration, with seventeen 100 denier fibers 84 visible in the center, and two larger warp strands 14 shown at the sides, integrally braided with fibers 84. In alternative embodiments another size of fibers 84 are used. Portion 86 is braided after the braiding machine has been switched to round mode at transition point 87, so that fibers 84 are configured in a round braid 88, with warp strands 14 excluded. Then the round braid 88 is cut off at the transition point 87, as shown in FIGS. 10 and 11, thereby forming a separate reinforcement 12, with two tails 15 extending out from it. A needle 16 is swaged to the ends of the two tails 15 to result in the component 10 shown in FIG. 1.

In a preferred embodiment warp strands 14 have an irregular, somewhat helical appearance, as they are formed by co-braiding together fifteen carriers of 100 denier fiber with 1 carrier of 650 denier fiber, depending on the specific embodiment, resulting in the irregular, unbalanced and somewhat bumpy or helical appearance shown. In alternative embodiments, other sizes of fibers are used.

Referring to FIGS. 12-18, in an additional embodiment, a separate reinforcement and needle component 10′ is made in a manner similar to component 10, except for that the warp strands 19 are smooth, in contrast to the bumpy warp strands 14. In an alternative embodiment bumpy warp strands 14 are used in embodiment 10′ instead of smooth warp strands 19. Also, braiding begins with the braiding machine set to “round,” thereby producing second tails 17′ (after cutting off the round center braid at a transition point 87 [FIG. 13]), then flat, producing reinforcement 12, and then round again, producing tails 17 (similar to tails 15, but made of smooth warp strand 19). As shown, both pairs of tails 17 and 17′ are swaged to a needle 16 and 16′, respectively. Referring to FIGS. 14 and 15, the initial steps of attaching component 10′ to component 20 is the same as for connecting component 10 to component 20, as shown in FIGS. 3 and 4. FIGS. 16-18 show an additional step of buttressing the connection between components 10′ and 20 by looping tails 14′ about trap 22, engaging them to reinforcement 12′, by piercing 45 reinforcement 12′ with swaged needle 16′ and pulling both tails 14′ through reinforcement 12, until looped tautly about trap 22. Referring to FIG. 18 the ends of second tails 14′ are then tied together in a knot 46, to produce a finished construct 60′, which as shown may be engaged to packaging 62, in which needle 16′ is safely retained by tabs 64. FIG. 19 shows whipstitching 72, joining construct 60′ onto quadricep graft 70.

In embodiments, the warp strands 14 and 84 are made of a combination of absorbable material, such as polycaprolactone, polyester amides, modified polyethylene terephthalate, polylactic acid and its copolymers, terpolymers based on polylactic acid, polyglycolic acid, polyalkyline carbonates (e.g., polyethylene carbonate, poly(glycolideco-trimethylene carbonate, etc.), polyhydroxyalkanoates, poly-3-hydroxybutyrate, poly-20 3-hydroxyvalerate, poly-3-hydroxybutyrate-co-4-hydroybutyrate, poly-3-hydroxybutyrate-co-3-hydroxyvalerate copolymers, poly-3-hydroxybutyrate-co-3-hydroxyhexanoate, poly-3-hydroxybutyrate-co-3-hydroxyoctanoate, poly-3-hydroxybutyrate-co-3-hydroxydecanoate, poly-3-hydroxybutyrate-co-3-hydroxyoctadecanoate, and succinate based aliphatic polymers (e.g., polybutylene succinate, as noted below, polybutylene succinate adipate, polyethylene succinate, etc. Anyone of the above materials could be mixed with hydroxyapatite, a bone growth stimulant, to encourage the tunnel drilled in the femur and tibia to have ingrowth into the fiber, thereby promoting healing. Notably, hydroxyapatite has good biocompatibility, bioactivity and osteoconductivity. In further embodiments these qualities are used, with hydroxyapatite utilized as a scaffold for drug and/or bone growth agent delivery. That is to say that a drug or further bone growth agent or agents is mixed with the hydroxyapatite in the fiber. In further embodiments, a high strength material, such as ultra-high molecular weight polyethylene is included, particularly where high strength is needed, for example in fibers 17 or 19.

The system and method described above provides unsurpassed ease of use and certainty of proper healing.

The disclosed embodiments are illustrative, not restrictive. While specific configurations of the graft suspension construct have been described, it is understood that the present invention can be applied to a wide variety of tissue holding constructs. There are many alternative ways of implementing the invention.

Claims

1. A method of attaching a suture construct to a graft, comprising: providing a suture construct having: a button loop assembly; a needle;a first strand with a first strand diameter and a second strand with a second strand diameter; anda reinforcement section comprising a textile construction, a section length, a section width, a first end and a second end, the reinforcement section extending between the first strand and the second strand,the first strand diameter and the second strand diameter being different than the section width, at least a portion of the first strand and the second strand extending from the first end to form a pair of tails, the needle is connected to the ends of the pair of tails,connecting a portion of the reinforcement section to a portion of the button loop assembly; andsecuring at least a portion of the reinforcement section of the suture construct to the graft.

2. The method of claim 1, wherein the step of connecting a portion of the reinforcement section of the suture construct to a portion of the button loop assembly comprises a portion of the reinforcement section being extending though itself at a broach point to cinch around a portion of the button loop assembly.

3. The method of claim 2, wherein the textile construction comprises a woven textile or a braided textile.

4. The method of claim 3, wherein at least a portion of the braided textile comprises a flat, braided textile.

5. The method of claim 3, wherein at least a portion of the reinforcement section comprises hydroxyapatite.

6. The method of claim 5, wherein the hydroxyapatite comprises a bone growth agent.

7. The method of claim 1, wherein the first strand and second strand are co-braided with the reinforcement section.

8. The method of claim 1, wherein the first strand and second strand comprise an irregular shape.

9. The method of claim 8, wherein the irregular shape comprises a helical, bumpy or twisted shape.

10. The method of claim 1, wherein the first strand and the second strand comprise a round suture or a flat suture.

11. The method of claim 1, wherein the first strand and the second strand comprise ultra-high molecular weight polyethylene.

12. The method of claim 1, wherein the first strand and the second strand comprise an absorbable material.

13. The suture construct comprises: a needle;a reinforcement section comprising a textile construction, a section length, a section width, a first end and a second end; anda first strand and a second strand, the first strand having a first strand width, the second strand having a second strand width, the reinforcement section extending between a portion of the first strand and the second strand, the first strand width and the second strand width being different than the section width, at least a portion of the first strand and the second strand extending from the first end of the reinforcement section to form a pair of tails,the needle is connected to a first and second ends of the pair of tails.

14. The suture construct of claim 13, wherein the textile construction comprises a woven textile or a braided textile.

15. The suture construct of claim 14, wherein at least a portion of the braided textile comprises a flat, braided textile.

16. The suture construct of claim 13, wherein a portion of the first strand and second strand are co-braided with the reinforcement section.

17. The suture construct of claim 13, wherein the first strand and the second strand comprise an absorbable or non-absorbable material.

18. The suture construct of claim 13, wherein the first strand and second strand comprise an irregular shape.

19. The suture construct of claim 18, wherein the irregular shape comprises a helical, bumpy or twisted shape.

20. A method of making a suture construct, comprising: Creating textile construct, the textile construct comprises a reinforcement section, a first strand and a second strand, the reinforcement section extending between a portion of the first strand and the second strand, the reinforcement section including a first end and a second end;Removing a portion of the reinforcement section to expose a portion of the first strand and the second strand, the at least a portion of the first strand and the second strand extend from the first end of the reinforcement section; andConnecting a needle onto a first and second end of the first and second strands.