Patent Application
20210267650
The present invention generally relates to surgical equipment and, more particularly, to surgical instruments used to fix or locate segments of bone.
Bone plates and surgical fasteners, such as screws, are used for the fixation of bone during surgery. A standard bone plate is a piece of material, usually metal, having circular and/or slotted holes through which bone screws are fixated. Typically, the bone plate is used to span a discontinuity between two adjacent bones or bone segments, and the screws are placed through holes in the bone plate that are positioned on both sides of the fracture to secure the plate to the bone segments to promote fusion between the adjacent bone or bone segments.
The length, shape, contour, and segments of a bone plate can vary, depending upon where the bone plate is inserted. For example, some bone plates could have multiple segments, while others could have a single segment. Moreover, multiple segment bone plates can include spaced apart segments.
Typically once the bone plate and fasteners (anchors) are sterilized, the surgeon will locate the bone plate on the bone and then insert each individual fastener, one at a time. This requires another person to provide the screws to the surgeon and/or the surgeon to retrieve a screw from a screw rack. This is a time-consuming process. Moreover, the surgeon will need to locate each individual screw over each individual hole in the bone plate. Again, this takes additional time and can also result in screws becoming cross-threaded and/or being advanced too far or not far enough into the bone.
Accordingly, the need exists for a surgical device that pre-locates the screws over the holes in the bone plate and permits the screws to be easily advanced by use of a driving tool, while maintaining the screws in the proper alignment and preventing over-tightening of the screws.
One aspect of the present invention is a surgical plate and cavity assembly. The assembly includes a bone plate having a top surface, a bottom surface, and a plurality of fastener apertures. The surgical plate and caddy assembly also includes a caddy that is coupled to the bone plate. The caddy has a top surface, a bottom surface, and at least two side surfaces. The caddy also has an inserter aperture and a plurality of fastener apertures that are aligned with the plurality of fastener apertures in the bone plate when the caddy is coupled to the bone plate. At least two of the caddy side surfaces include a clip portion that has a tab that extends below and contacts the bottom surface of the bone plate. At least one of the clip portions will deflect to remove the tab from contact with the bottom surface of the bone plate when the insertion tool is inserted into the inserter aperture. The surgical plate and caddy assembly also includes a plurality of fasteners that are inserted into the plurality of fastener apertures in the caddy.
Another aspect of the present invention is a method of installing fasteners into the bone plate. The method includes forming a caddy that has a top surface, a bottom surface, and at least two clip portions. The caddy also has at least one insertion aperture and a plurality of fastener apertures. The method includes inserting fasteners into the fastener apertures in the caddy. The caddy is then coupled to a bone plate such that the fastener and the fastener apertures of the caddy are aligned with the fastener apertures in the bone plate. When the caddy is coupled to the bone plate, the clip portions are engaged to a lower surface of the bone plate. The method includes advancing the fasteners to secure the bone plate to the bone. The method includes removing the caddy from the bone plate by inserting an insertion tool into the inserter aperture in the caddy to deflect at least one of the clip portions.
Yet another aspect of the present invention is a surgical fastener caddy guide. The caddy guide includes a caddy body that has a top surface, a bottom surface, and at least two side surfaces. The caddy body also has at least one fastener aperture extending through the caddy body from the top surface of the caddy body to the bottom surface of the caddy body. The caddy body includes an inserter aperture. One side surface of the caddy body includes a first clip member with a tab on the lower surface of the first clip member. The fastener aperture(s) includes at least one vertically extending finger that is located between two vertically extending slots in a side wall of the fastener aperture.
Examples of the preferred embodiments are shown in the drawings. It should be appreciated, however, that the invention is not limited to the precise arrangements and instrumentally shown. In the drawings:
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
The fastener caddy 4 has a top surface 13 and a bottom surface 12. Fastener caddy 4 also has sides 3 and 5 that have the same general contour as the segment of the bone plate 40 to which it is coupled. The fastener caddy 4 also has a number of fastener apertures 6. The fastener apertures 6 can be unthreaded, partially threaded, or entirely threaded. In the illustrated embodiments, the fastener caddy 4 has four fastener apertures 6, although any number of fastener apertures can be used depending upon the size and purpose of the associated bone plate 40. The top surface of the fastener aperture 6 includes a tapered portion 7. The tapered portion 7 will generally engage a surface of the head 72 of a fastener 70 when the fasteners are preloaded into the fastener caddy 4. The fastener caddy 4 also has an insertion tool aperture 8 with a similarly tapered surface 9.
The fastener caddy 4 couples to the bone plate 40 by the engagement of tabs 16 and 20. Specifically, the fastener caddy 4 has a first clip 10 on side 3 with a lower surface 14 and a tab 16 extending therefrom. The opposite side 5 of the fastener caddy 4 has a second clip 24 with a bottom surface 22 and a tab 20. As illustrated in
As illustrated in
The embodiment of the fastener caddy 4 illustrated in
As illustrated in
While
The insertion tool 200 is illustrated in
The insertion tool 200 is also used to remove the fastener caddy 4 from the bone plate 40, as illustrated in
In use, the fastener caddy 4 has preloaded fasteners 70 in the fastener aperture 6 of the fastener caddy 4. The fastener caddy 4 is coupled to the bone plate 40 by the use of the tabs 16, 20 that engage the lower surface 50 of the bone plate 40. When the fastener caddy 4 is coupled to the bone plate 40, the fastener apertures in the fastener caddy 4 are aligned with the fastener apertures 42 of the bone plate 40. The contours of the sides 3, 5 of the fastener caddy 4 match the contours of the sides 44, 46 of the segment of the bone plate 40 to permit the alignment of the fastener aperture 6, 42. Once the bone plate 40 is aligned on the segment of bone during surgery, the surgeon advances the fasteners 70 through the fastener apertures 6 in fastener caddy 4 until the fasteners 70 are fully installed in the fastener apertures 42 of the bone plate 40. Once the preloaded fasteners 70 in the fastener caddy 4 are advanced into the bone plate 40, the fastener caddy 4 is removed by use of an insertion tool 200 that is inserted into the insertion tool aperture 8. The insertion tool 200 presses against one or both of the clips 10, 24 of the fastener caddy 4 to disengage one or both of tabs 16, 20 from the bottom surface 50 of the bone plate 40 permitting the fastener caddy 4 to be removed laterally and/or upwards.
In the illustrated examples, the lower surface 14 of clip 10 and the bottom surface 22 of clip 24 do not extend beyond the bottom surface 50 of bone plate 40. That is because bone plate 40 has an indented surface 53 in the area of tabs 16, 20. This permits the portions of the bone plate 40 to rest directly against the bone and to permit removal of the fastener caddy 4 from bone plate 40 once all fasteners 70 have been installed.
The fastener caddy 4 can be made of any suitable material that permits one or more of the clips 10, 24 to be deflected by the insertion tool. The fastener caddy 4 can be made from a polymeric material, metal, or a combination thereof. For example, the fastener caddy 4 can be made by injection molding a polymeric material, such as plastic and/or resin. The fastener caddy 4 can also be machined or stamped from a polymeric or metal material. The fastener caddy 4 can also be made from additive manufacturing or 3D printing. The flexibility of the material used in the fastener caddy 4 permits the installation of the fasteners 70 into the bone plate 40 by permitting the tapered portion of the head 72 to deflect the sides of the fastener opening 6 as the fastener 70 is advanced toward the bone plate 40.
The bone plate 40 can also be made of a biocompatible polymeric and/or metal material that is suitable for installation to the bone. Similarly, the fasteners 70 can also be made of a biocompatible polymeric and/or metal material.
The shape of the fastener caddy 4 can vary depending upon the shape of the bone plate 40. The shape of the fastener caddy 4 will require the alignment of the fastener aperture 6 in the fastener caddy 4 with the fastener aperture 42 in the bone plate 40. The shape of the fastener caddy 4 will also require at least one clip with a tab that can engage a lower surface of the bone plate 40.
While the illustrated embodiments show the fastener caddy 4 being coupled to bone plate 40 by the use of a clipping mechanism, the fastener caddy 4 could be coupled to the bone plate 40 by other mechanisms. For example, the fastener caddy 4 could be coupled to the bone plate 40 by use of one or more removable fasteners, such as screws, adhesive tape, etc. The fastener caddy 4 could also be coupled to the bone plate 40 by use of a releasable liner, such as tape, adhesive, and hook-and-loop fasteners.
The fastener caddy 4, fasteners 70, and bone plate 40 can be packaged together. Thus, a single, sterilized package could contain the fastener caddy 4 coupled to the bone plate 40 with the fasteners 70 already installed in the fastener apertures 6 of the fastener caddy 4. Alternatively, the fastener caddy 4 could be packaged with the fasteners 70 installed or uninstalled. The fastener caddy 4 can be disposable such that once the fasteners 70 are installed into the bone plate 40 and the fastener caddy 4 is decoupled from the bone plate 40, the fastener caddy 4 is disposed. Alternatively, the fastener caddy 4 can be reused if it is sterilized again.
In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.
It will be understood by one having ordinary skill in the art that construction of the present disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.
For purposes of this disclosure, the term “coupled” or “operably coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated. In addition, while certain embodiments have shown threaded connections, the threaded connections could include tape or other sealing material in the threaded connection. In addition, the threaded connection could be replaced by other suitable connections or couplings, such as compression couplings or other couplings.
For purposes of this disclosure, the term “connected” or “operably connected” (in all of its forms, connect, connecting, connected, etc.) generally means that one component functions with respect to another component, even if there are other components located between the first and second component, and the term “operable” defines a functional relationship between components.
It is also important to note that the construction and arrangement of the elements of the present disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that, unless otherwise described, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating positions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
