This disclosure relates to the field of surgical procedures and implants for fusing plural bones, in particular for fusing plural separate bones across one or more joints in the human midfoot, to improve anatomical alignment.
Charcot midfoot deformity is a condition associated with diabetic neuropathy and lack of sensation in the extremities. A person with limited sensation can suffer a sprain, fracture, dislocation or similar damage to a foot during regular activities and be unaware of the injury, or unaware of the extent of the injury. Continued activities on the injured foot cause additional damage. The damage is progressive. A characteristic condition includes partial dislocation, fracture and misalignment of the metatarsal, cuneiform and navicular bones that form the midfoot. The normal arched shape of the midfoot along the successions of bones from the calcaneus to the distal phalanges, known as the midfoot “columns,” can collapse and in some cases assume a rocker bottom or rounded plantar side of the foot.
One way to ameliorate Charcot deformity is arthrodesis or fusion of the bones of the midfoot columns. The distinct bones can be re-aligned in a surgical procedure that may include resecting as well as fixing the successive bones to one another so that the bones fuse or ossify across abutting faces of the bones that formerly met at joints. A main load bearing column that is advantageously fused is the medial column (to the great toe). Two or more midfoot columns can be caused to fuse, such as the first and third metatarsal columns.
The procedure may include attaching one or more bracing plates along the exteriors of adjacent bones along the midfoot columns in need of support. The bracing plates are attached to the respective bones using screws. An alternative technique includes installing a longitudinal intramedullary nail or bolt as a supporting structure within the midfoot column. A compression screw from the metatarsal to the talus advantageously applies compression to urge the midfoot bones into engagement. Immobilizing the bones in that position permits them to fuse.
The shape as well as the alignment of abutting bones of a midfoot column can be modified. Spaces can be incised to receive wedges or spacers, or spaces can be excised and the adjacent bones brought together, e.g., to reverse the rounding of the foot and thereby achieve a more plantigrade contour. Patient harvested bone or allografts or synthetic materials capable of bone ingrowth can be inserted to supplement the degraded bones and joints and fill in structural stress points. The bones are held stationary, and after healing become fused or ossified. The object is at least to align the structures of the foot in a more nearly anatomical state, although there is a consequent loss of natural flexibility or relative freedom of motion.
Intramedullary supports also are known for fusing bone segments across a break, typically in a relatively large bone, such as a tibia, femur, humerus or the like. An elongated intramedullary support is placed in a longitudinally drilled bore forming a lumen in the bone. The support bridges between the segments of the bone across the break. The support is comprises an elongated shaft of stainless steel, titanium alloy or the like, variously termed a shaft, bolt, nail, screw or bar, etc. The shaft is smooth to permit the bone segments freedom to slide along the shaft and to abut one another endwise. Transverse screws can be inserted into the shaft through the bone to fix the relative positions of the bone segments and the intramedullary support. The intramedullary support may be an alternative to a bracing plate affixed externally to the broken bone segments by transverse screws. Or a bracing plate and an intramedullary support can be used concurrently.
The bones of the midfoot are smaller than the long bones of the arm or leg, although the metatarsals as elongated to an extent. The more proximal bones of the midfoot columns are block shaped. However, compression screws and other intramedullary supports are known for supporting bones in the midfoot in arthrodesis procedures. International publication WO 2004/014243-William discloses use of an elongated intramedullary nail for fixing the alignment of the first metatarsal, medial cuneiform, navicular and talus bones.
In such surgical procedures, for example considering arthrodesis of the medial column, the medial phalange is dislocated downwardly at the distal first metatarsal. The bones along the medial column are aligned while being drilled through with a pilot hole, from the distal first metatarsal into the talus. Alignment of the column may include excising a wedge extending laterally on the plantar side and opening downwardly, whereby closing the wedge reverses some of the downward arch in the medial column.
A K-wire or guide is inserted into the drilled hole and the alignment of the bones can be checked fluoroscopically. The hole is enlarged in diameter along the medial column, back to the talus, using a cannulated reamer guided on the K-wire. The talus is a primary base of structural support for the foot, carrying the tibia and fibula. The reamed bore has an inside diameter that accommodates the intramedullary nail with minimal clearance (e.g., 0.5 mm diametric clearance). The intramedullary nail is inserted through the entire medial column and into the talus at the proximal end, i.e., through the lengths of the first metatarsal, medial cuneiform and navicular bones, and proceeding about half the span of the talus.
In some cases, the intramedullary support can comprise a compression screw having a thread along the distal or pointed end threaded into the talus, and also a “headless” but externally threaded proximal end. The shaft is smooth over a distance between the threaded ends. The thread at the proximal end has a shorter thread pitch (less longitudinal advance per unit of rotation) than the thread on the distal part of the shaft extending into the talus, and the fastener length is selected such that the bones of the medial column are compressed against one another like pulling beads together along a string.
In alternative arrangements, such as the William example mentioned above, the entire length of the shaft is unthreaded and smooth. After the shaft is inserted into the midfoot column, lateral fasteners (screws or pins) are inserted through the respective bones and through transverse holes provided at spaced locations along the inserted shaft. In the example described in William, three transverse fasteners are used to affix the first metatarsal to the intramedullary shaft or “nail,” two fasteners to affix the talus, and one to affix each of the medial cuneiform and navicular bones. For the cuneiform and navicular bones, the transverse holes are slots with additional longitudinal clearance, permitting some longitudinal and/or rotational displacement of the bones held along the smooth shaft.
An object of this disclosure is to provide an improved intramedullary supporting beam or shaft for correction of Charcot midfoot deformities and the like. In particular, an elongated intramedullary support is provided with external surface areas carrying a hard porous material adapted for bone ingrowth. These surface areas can be strategically placed and spaced longitudinally, for example residing at the ends of the beam or shaft and/or being spaced along or around the beam or shaft. Porous areas spaced along the beam or shaft between smooth areas can be selectively placed to reside in the dense cortical tissue of the bones that are supported along the beam or shaft as opposed to less dense cancellous tissue. The porous surface areas also can be arranged to have a mechanical effect or to cooperate with the cross sectional shape of the beam or shaft. For example, the porous material can form splines or runners that provide mechanical engagement as well as surfaces apt for bone ingrowth. The beam or shaft can have a polygonal cross section with the porous material carried in areas that are at the junctions or between the junctions of the polygonal faces. The porous material can comprise particles or shaped trabecular pieces that are sintered onto the outside of the beam or shaft structure.
In some embodiments, spaced porous areas, splines or runners advantageously comprise Wright Medical Co. BIOFOAM® material or a similar material that is particularly apt for bone ingrowth. The BIOFOAM material includes irregularly shaped titanium elements that are fused at their surfaces by sintering, to provide a structurally robust thickness of porous reticulated material that secures the beam or shaft in cancellous or cortical bone and immobilizes the beam or shaft and the bones that are to be fused. As the bone heals, the bone tissue grows into the porous material to form a composite that supports the midfoot column.
BIOFOAM material is known for use in wedges and spacers, for example in Cotton osteotomies of the midfoot and Evans osteotomies in the rear foot, in each case structured as spacers or wedges inserted between bones, or into incised or resected bones, and affixed using supporting plates that are external to the bone and are held in place by screws driven through the plates and into the bones adjacent to the location of the wedge or spacer. For arthrodesis to ameliorate Charcot deformity, the BIOFOAM material facilitates bone ingrowth and incorporation of the supporting structure into the structure of the bone. The configurations described herein enhance engagement between the support and the bone, reducing the need for additional structures such as external support plates, lateral screws, compression threads and the like.
The intramedullary beam or shaft according to this disclosure is elongated and may have a cross section that is smoothly cylindrical or otherwise shaped. Certain embodiments are splined and certain embodiments have polygonal cross sections with the longitudinal apices or cusps between facets of the beam or shaft providing elongated edges that limit rotational migration. The porous metal material can comprise sintered particles, and in different embodiments is sintered to fuse with the body of the beam or shaft at the outer surface, or is wholly or partly embedded in a groove on the surface for mechanical fixation. The porous material can reside on the surface as a surface covering or can be arranged to be flush with the surface, or can protrude from the surface at elongated embedded splines. Areas of the porous material can be continuous or discontinuous, regularly or irregularly spaced, and optionally placed to engage with particular bone tissue types. For example, the porous areas can be located at either end of the shaft and/or at intervals along the shaft. The splines can extend longitudinally, obliquely or with a helical twist, along or between facets of a polygonal beam/shaft cross section.
The splines engage the bone along the inside surfaces of the elongated bore provided through the adjacent bones of the medial column, and reduce or prevent migration (longitudinal or rotational relative displacement of the bones and the beam or shaft). The BIOFOAM material is apt for ingrowth and with healing engages with and supports the bones of the medial column, whether used with or without supplementary transverse screws or pins or external supporting plates.
These and other objects and aspects will be appreciated by the following discussion of preferred embodiments and examples, with reference to the accompanying drawings, and wherein:
As seen in
Charcot deformity can result from the accumulation of minor injuries that are not painful or perhaps are not noticed or fail to be regarded as serious, due to diabetic neuropathy and loss of sensation. An arthrodesis surgical procedure is indicated, for regaining reasonably anatomically correct alignment, which in
It is an aspect of the invention that the external surface of the beam or shaft 22 is provided with at least one porous metal formation 24 that admits bone ingrowth for structurally affixing the beam to the respective bones. The beam fits closely against the internal surfaces of the bone. The porous metal formation advantageously comprises porous surgical metal material such as Wright Medical BIOFOAM. The porous material can have irregularly shaped titanium bodies affixed to one another and to the beam or shaft 22 as a substrate, to emulate the structure of cancellous bone for accepting bone ingrowth. The porous material is securely affixed to the substrate beam or shaft, for example by sintering of the particles to one another and to a one-piece integral substrate, or by integrally forming the substrate to include the porous areas at the surface, or by other affixation techniques. After ingrowth along the bones, the beam or shaft becomes structurally joined with the bone.
In a certain embodiments, the porous metal formation comprises BIOFOAM cancellous titanium, for example about 1.5 mm thick. This material is made from commercially pure Titanium and is readily fused to a Titanium or Titanium alloy shaft structure. BIOFOAM has a modulus similar to that of Tantalum (around 3 GPa) and a pore diameter of about 500 microns in a trabecular matrix architecture. BIOFOAM has a trabecular structure. Alternative embodiments can employ other forms of porous metal such as sintered beads or particles powders and other non-trabecular structures. Likewise, surfaces can be etched or otherwise treated to provide irregularities that support bone ingrowth.
The main shaft portion of the intramedullary beam 22 can comprise a known surgical implant metal such as commercially pure titanium (CPTi) or cobalt chrome or a titanium alloy such as Ti6AI4V (titanium, aluminum and vanadium) or austenitic 316 stainless steel, etc. In the embodiments shown in
Although the shaft of the beam comprises an elongated solid and the porous metal formation is provided on the external surface, there are several ways in which this can be accomplished. In
The grooves 33 are provided on every other face or facet of the octagonal cross section, thus providing four porous metal formation 24. Similar grooves 33 could be placed on all the eight facets or alternatively, fewer grooves could be used, for example at two diametrically opposite facets.
As described, an intramedullary support for arthrodesis of a human midfoot at the medial column having metatarsal, cuneiform, navicular and talus bones, comprises an elongated beam 22 having a length substantially spanning a plurality of the bones of the midfoot, preferably from the distal metatarsal up to one third to two thirds and preferably half the span of the talus. The beam comprises a shaft with an external surface, and at least one porous metal formation 24 if provided on all or part of the external surface. The porous metal formation 24 admits bone ingrowth for structurally affixing the beam to the plurality of bones of the midfoot. Structurally similar midfoot beams can be placed in the other midfoot columns, such as in the medial and next lateral column or the first and third midfoot column.
The porous metal formation 24 advantageously comprises porous titanium configured to emulate cancellous bone, such as Wright Medical's BIOFOAM material. The porous metal can comprise one or more particular formations such a splines or longitudinal, oblique or helical areas on the surface of the shaft such as on the faces and/or cusps of a polygonal shape or annular collar areas, especially at the ends of the beam.
Exemplary steps in an associated method for surgical repair of a collapsed medial column of a human midfoot are shown in
Although not shown in
Drilling through the medial column (as aligned) proceeds into the talus, for example one third to two thirds of the thickness of the talus, to form a straight elongated bore generally coextensive with the longitudinal axis of the medial column and anchored in the talus. Advantageously, the K-wire guide rod 44 resides in place for guiding the cannulated surgical drill 42. The reamed bore is sized match the minor diameter of the intramedullary beam 22. The beam 22 is inserted as seen in
Referring back to
In embodiments where the central length 53 is smooth and cylindrical, as in
The porous metal arrangements as described can be employed on forms of beams or nails other than the simple lengths of metal shown in the drawings. For example, one or more porous formations as described can be provided on a compression screw, in particular over a part of a smooth shaft part of the compression screw between ends, either or both of which may be threaded.
The invention has been disclosed in connection with a number of alternatives intended to exemplify the subject matter. However the invention is not limited to the embodiments disclosed as examples. Reference should be made to the appended claims rather than the foregoing examples, in order to assess the scope of the invention in which exclusive rights are claimed.
Filing Document | Filing Date | Country | Kind |
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PCT/US2014/052716 | 8/26/2014 | WO | 00 |