APPARATUS AND METHOD FOR IMPLANTING BONE ANCHOR UNDER CONTROLLED TENSION

Abstract

A graft tensioning tool includes an elongate frame having a proximal end, a distal end, and an axial passage extending therethrough. The distal end is configured to detachably engage a tunnel ring at an entrance to a tunnel in bone, and the frame includes a first suture puller and a second suture puller. Each suture puller detachably engages a length of suture emerging through the attached to suture and/or a soft tissue implant in the bone tunnel. A tensioner on the elongate frame displaces the suture pullers in a proximal direction to apply a controlled tension to the suture lengths and/or implant. A tension gauge measures tension applied to the suture pullers, and a locking tool is configured to engage the suture lock through the axial passage of the frame, allowing a user to fix the suture ends to bone when a target tension is attained.

Claims

1. A graft tensioning tool for use with a tunnel ring and a suture lock, said tool comprising: an elongate frame having a proximal end, a distal end, and an axial passage extending therethrough, wherein the distal end is configured to detachably engage the tunnel ring; a first suture puller and a second suture puller on the tensioner frame, each suture puller configured to detachably engage a length of suture; a tensioner on the elongate frame configured to displace the first and second suture pullers in a proximal direction relative to the elongate frame; a tension gauge coupled to the tensioner to measure tension applied by the tensioner to the first and second suture pullers the frame; and a locking tool configured to engage the suture lock through the axial passage of the frame to when the distal end of the frame engages the opening in the tunnel ring.

2. The graft tensioning tool of claim 1, wherein the first suture puller is disposed on a first side of the elongate frame and the second suture puller is disposed on a second side of the tensioner frame.

3. The graft tensioning tool of claim 1, wherein the tensioner is configured to displace the first and suture pullers simultaneously.

4. The graft tensioning tool of claim 1, wherein the locking tool is configured to carry the suture lock through the axial passage of the frame and position the suture lock in the opening in the tunnel ring.

5. The graft tensioning tool of claim 1, wherein the distal end of the elongate frame comprises an opening configured to circumscribe the tunnel ring.

6. The graft tensioning tool of claim 5, wherein the tunnel ring has a lower surface configured to engage bone and un upper surface and wherein the opening of the elongate frame is configured to circumscribe the upper surface of tunnel ring.

7. The graft tensioning tool of claim 5, wherein the opening is configured to interlock with the upper surface the tunnel ring.

8. The graft tensioning tool of claim 5, further comprising an interlock including a protrusion on the opening of distal end of the elongate frame and a recess on an exterior surface of the tunnel ring, wherein the protrusion is configured to engage the recess when the opening circumscribes the tunnel ring.

9. The graft tensioning tool claim 1, wherein the first and second suture pullers each comprise a cleat.

10. The graft tensioning tool of claim 1, wherein the first and second suture pullers are mounted on a carriage that is slidably disposed in a distal portion of the passage in the frame, wherein the suture pullers are exposed through slots in the frame.

11. The graft tensioning tool of claim 10, wherein the tensioner comprises a shuttle assembly coupled to the carriage, wherein the shuttle assembly is configured to be retracted to proximally displace the carriage.

12. The graft tensioning tool of claim 11, wherein the shuttle assembly is configured to be manually retracted.

13. The graft tensioning tool of claim 11, wherein shuttle assembly comprises an externally threaded cylinder and an internally threaded knob, where in knob is rotatably mounted on the frame at a fixed axial position and the threaded cylinder is slidably mounted in the passageway of the frame but prevented from rotating, wherein a proximal portion of the threaded cylinder is received in a distal portion of the knob so that manual rotation of the knob will proximally retract the threaded cylinder.

14. The graft tensioning tool of claim 13, further comprising a spring coupling the threaded cylinder to the puller carriage.

15. The graft tensioning tool of claim 14, wherein the tension gauge is coupled to the spring to provide a tension readout based upon elongation of the spring.

16. The graft tensioning tool of claim 1, further comprising a tilt sensor configured to measure joint flexion and a display, wherein the tilt sensor has a digital output, wherein the tension gauge comprises a load cell transducer having a digital output, and the digital display is configured to display a plot of flexion angle versus tension.

17. The graft tensioning tool of claim 16, further comprising a wireless transmitter connected to the load cell and tilt sensor for transmission to a remote digital display.

18. The graft tensioning tool of claim 16, wherein the load cell is wired to a digital display on the elongate frame.

19. The graft tensioning tool of claim 1, wherein the locking tool comprises a shaft with a proximal handle and a distal end configured to detachably engage the suture lock.

20. A graft tensioning system comprising: the graft tensioning tool of claim 1; a tunnel ring; and a suture lock.

21. The graft tensioning system of claim 20, wherein the tunnel ring comprises a shoulder washer.

22. The graft tensioning system of claim 21, wherein the shoulder washer has a pair of interior channels on an interior surface for receiving and guiding the suture lengths.

23. The graft tensioning system of claim 22, wherein the interior surface is threaded.

24. The graft tensioning system of claim 20, wherein the suture lock comprises a threaded shaft that can be rotatably advanced into the tunnel ring to compress and lock the suture and/or a graft implant.

25. A cortical implant comprising a tunnel ring and a suture lock, wherein the suture lock is configured to be advanced into an interior of the tunnel ring to compress and lock suture and/or a graft implant.

26. The cortical implant as in claim 25, wherein the suture ring lock comprises locking element configured to compressively engage the suture lock as the suture lock is advanced into the interior of the tunnel ring.

27. The cortical implant of claim 25, wherein the interior of the tunnel ring comprises a threaded passage having a pair of axial suture channels formed therein and the suture lock comprised a threaded shaft configured to be rotatably advanced into the threaded passage to compress and lock the suture.

28. A method of tensioning a pair of suture ends extending through an opening of a tissue tunnel in bone, said method comprising: fixing at least one suture strand to a tissue structure or implant to be tensioned, wherein the pair of suture ends extends through the opening of the tissue tunnel; providing a tensioning tool comprising an elongated frame, first and second suture pullers, and a locking tool; engaging a distal end of the elongated frame against a tunnel ring disposed at the opening of the tissue tunnel; detachably securing each of the suture ends to one of the suture pullers; drawing the suture pullers in a proximal direction relative to the frame to tension the at least one suture strand; advancing of a locking tool distally through a central passage of the frame to engage a suture lock proximate the tunnel ring; and tightening the suture lock in the opening of the tunnel ring with the locking tool to lock the suture in place.

29. The method of claim 28, wherein the suture lock is advanced to the tunnel ring through the central passage of the frame by the locking tool.

30. The method of claim 28, wherein the suture lock is placed in the opening of the tunnel ring prior to engaging the distal end of the elongated frame against the tunnel ring.

31. The method of claim 30, further comprising determining an amount of tension exerted on the suture while the drawing the suture pullers, wherein the suture lock is positioned and coupled to the tunnel ring when the amount of tension is at target value or within a target range.

32. The method of claim 28, further comprising displaying the amount of tension to allow monitoring by a user while the user is manually drawing the suture pullers.

33. The method of claim 28, wherein fixing the at least one suture strand comprises attaching the suture strand directly or indirectly to a prosthetic joint graft.

34. The method of claim 28, wherein engaging the distal end of the elongated frame against the tunnel ring comprises circumscribing an upper opening of the tunnel ring to align the central passage of the elongated frame with said upper opening.

35. The method of claim 28, wherein detachably securing each of the suture ends to one of the suture pullers comprises securing the suture ends to a pair of cleats on opposite side of the frame.

36. The method of claim 35, wherein the cleats are coupled to a carriage slidably mounted in the central passage of the frame and drawing the suture pullers in a proximal direction comprises drawing the carriage proximally through the central passage.

37. The method of claim 36, wherein drawing the carriage proximally through the central passage comprises rotating a knob that is threadably coupled to the carriage.

38. The method of claim 28, wherein the tunnel ring has a threaded interior surface with channels for receiving the suture ends and the suture lock comprises a threaded shaft, wherein coupling the suture lock to the tunnel ring comprises rotatably inserting the threaded shaft into the tunnel ring to compress and lock the suture in place.

39. The method of claim 28, further comprising determining and an angle of flexion of a joint.

40. The method of claim 39, further comprising observing an amount of tension exerted on the suture at different angles of flexion and locking the suture in place when a target amount of attention is observed.

41. The cortical implant of claim 1, wherein the tensioner is configured to apply a continuously variable tension.

42. The cortical implant of claim 1, wherein the tensioner is configured to displace the first and second suture pullers simultaneously.

43. The cortical implant of claim 1, wherein the tensioner is configured to displace the first and second suture pullers both a proximal direction and a distal direction relative to the elongate frame.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0046] FIG. 1 is a top view of a graft tensioning tool constructed in accordance with the principle of the present invention.

[0047] FIG. 2 is a top view of the graft tensioning tool of FIG. 1 shown with portions broken away.

[0048] FIG. 3 is an exploded view of the graft tensioning tool of FIGS. 1 and 2 shown with portions broken away.

[0049] FIGS. 4A and 4B are top and side views, respectively, of an exemplary embodiment of a tunnel ring constructed in accordance with the principles of the present invention.

[0050] FIGS. 5A and 5B are end and side views, respectively, of an exemplary embodiment of suture lock intended for use with the tunnel ring of FIGS. 4A and 4B.

[0051] FIGS. 6A and 6B illustrate the attachment of the suture lock of FIGS. 5A and 5B to a driver tip of an attachment tool in accordance with principles of the present invention.

[0052] FIG. 7 illustrates the placement of the tunnel ring and suture lock of the previous figures in a bone tunnel to lock suture in place.

[0053] FIG. 8 illustrates an alternative embodiment of a combination tunnel ring and suture lock constructed in accordance with the principles of the present invention.

[0054] FIG. 9 illustrates a second alternative embodiment of a combination tunnel ring and suture lock constructed in accordance with the principles of the present invention

[0055] FIGS. 10A to 10D illustrate use of the tensioning and locking tools of the present invention for tensioning and fixating a pair of suture ends emerging from a bone tunnel in cortical bone.

[0056] FIG. 11 illustrates flexion of a knee during ligament reconstructive surgery of the knee.

[0057] FIGS. 12A and 12B illustrate plots of flexion versus graft tension which may be generated using the graft tensioning tool of the present invention during knee ligament surgery.

DETAILED DESCRIPTION OF THE INVENTION

[0058] Referring to FIGS. 1 to 3, a graft tensioning tool 10 constructed in accordance with the principles of the present invention comprises an elongate frame 12 having a distal end 14 and proximal end 16. An axial passage 18 (best seen in FIG. 3) extends from the distal end 14 to the proximal end 16, and a pair of suture pullers 20 and 22 are slidably mounted on the sides of the elongated frame 12.

[0059] A tensioner assembly 30 is coupled to the pair of suture pullers 20 and 22 to allow a user to apply a controlled on during ligament reconstruction or other surgery, as described in more detail below. The tensioner assembly 30 typically includes a partially threaded cylinder 32 having a threaded portion 34 and a distal extension 36. A ring 38 is disposed in the middle of the partially threaded cylinder 32 between the threaded portion 34 and the distal extension 36. The ring has a pair of sliders 40, generally located on diametrically opposed sides, which are received in slots 42 in sides of the frame 12. The sliders 40 allow the partially threaded cylinder 32 to axially translate in the axial passage 18 of the elongated frame 12 while preventing rotation. In this way, a knob 50, which is rotatably mounted in the proximal end 16 of the elongated frame 12, can be used to advance and retract the partially threaded cylinder 32 within the axial passage 18. As best seen in FIG. 3, the knob 50 has an internally threaded receptacle 52 which receives the threaded portion 34 of the partially threaded cylinder 32. As the knob 50 is mounted to rotate without axial movement, rotation of the knob causes the partially threaded cylinder 32 to axially translate in either a proximal or distal direction, depending on the clockwise or counterclockwise rotation of the knob. The threads of both the receptacle 52 in threaded portion 34 and of the partially threaded cylinder 32 will be chosen to provide a relatively low ratio of translational distance to knob rotation. For example, one full rotation of the knob 50 will typically translate the partially threaded cylinder 32 by a distance in a range from 0.1 mm to 3 mm, usually from 0.5 mm to 2 mm. Such fine control of the translational distance allows control of the tension in small increments.

[0060] Axial translation of the partially threaded cylinder 32 is coupled to a puller body 70 of the tensioner assembly 30 by a spring 60. The spring 60 is typically a coil spring which is fully axially collapsed in a non-tensioned state. A proximal end of the spring 60 is attached to the partially threaded cylinder 32 on the distal side of the ring 38. A distal end of the spring 60 is attached to a proximal end of the puller body 70 so that proximal translation of the partially threaded cylinder 32 will axially tension the spring 60 causing a spring force to draw the puller body 70 in a proximal direction which in turn will draw suture pullers 20 and 22 in the proximal direction. The amount of tension applied to the puller 70 will depend on both the distance that the partially threaded cylinder 32 travels as well as the spring constant of the spring 60.

[0061] While use of a spring, such as spring 60, to transmit a proximal force to the puller body 70 is generally preferred, in other instances, the tensioner assembly 30 could be directly attached to the puller body 70 or other equivalent structure so that the suture pullers are translated directly by the tensioner assembly with a 1:1 travel ration.

[0062] The puller body 70 has a viewing slot 72 with a tension scale 74 aligned along an edge thereof. A distal end 44 of the distal extension 36 of the partially threaded cylinder 32 is visible through the viewing slot 72 and provides a marker which indicates the amount of tension being applied by the spring 60 on the tensioner assembly 30. The combination of the spring 60 and puller body 70 provides a simple spring scale which allows a user to monitor the tension applied by the tensioning tool 10 to the suture at all times during a procedure.

[0063] The suture pullers 20 and 22 typically comprise cleat bodies 76 and cleat arms 78 and are typically fixedly attached to the puller body 70 by attachment screws 82. The cleat arms 78 are attached to the cleat bodies at pivots 80, and can be moved between an open configuration, as shown in broken line in FIG. 2, and a closed configuration as shown in full line. Suture S can be passed over the cleat arm 78 the between the cleat arm and the cleat body 76, and the cleat arm can then be closed to lock the suture to the puller body 70, as shown in FIG. 2 in full line.

[0064] Referring now to FIGS. 4A and 4B, an exemplary tunnel ring 100 comprises a cylindrical body 112 having an opening 104 therethrough. The opening 104 is typically threaded and will have a pair of suture channels 106 running axially therethrough, typically being diametrically opposed. An upper end of the cylindrical body 112 is surrounded by a flange 108 having a pair of notches or grooves 110 formed therein. The notches 110 are configured to engage corresponding features (not shown) on the distal end 14 of the elongate frame 12 to aid in aligning and stabilizing the distal end against the tunnel ring 100 during a suture tensioning procedure, as described in greater detail below.

[0065] Referring now to FIGS. 5A and 5B, an exemplary suture lock 102 comprises a threaded shaft 114 and a drive head 116. The drive head 116 includes a mating feature 118 configured to receive and rotatably couple to the distal driver tip 94 of the locking tool 90. As further shown in FIGS. 6A, a hexagonal driver tip 94 may be detachably introduced into the mating feature, a hexagonal receptacle 118, on the driver head 16 so that the locking tool 90 can be used to both advance the suture lock 102 and to rotate (screw) the suture lock through the tunnel ring 100 and into a bone tunnel, as described in more detail below. It will be appreciated that many other coupling features could be employed.

[0066] Referring now to FIG. 7, placement of the suture lock 102 through the tunnel ring 100 and into a bone tunnel BT is shown to capture a pair of suture ends S which emerge upwardly through the bone tunnel and are attached at a lower end (not shown) to a graft or other soft tissue prosthesis. A portion of each suture end S is captured between an outer peripheral surface of the drive head 116 and an inner surface of the opening 104 in the tunnel ring 100. The clearance between the drive head and the opening is limited, assuring that the suture is tightly held. The threaded shaft 114 extends downwardly into the bone tunnel BT and further immobilizes the suture ends as well as threadably engaging the tunnel walls to anchor both the tunnel ring 100 the suture lock 102 in place.

[0067] Other embodiments of suture ring-suture lock combinations are shown in FIGS. 8 and 9. A threaded shaft 204 in FIG. 8 is similar to previously described threaded shaft 114, while tunnel ring 200 differs from tunnel ring 100 as it includes a pair of windows 200 on the side of a cylindrical body 206. The windows 200 allow the graft to directly contact the bone tunnel and increase the surface area for graft incorporation.

[0068] FIG. 9 illustrates a shorter suture ring-suture lock combination where threaded shaft 304 has a length approximately equal to the length of the tunnel ring 300. As the threaded shaft 304 does not extend into the bone tunnel, spring locks 302 are provided to engage cortical bone at the opening into the bone tunnel to both stabilize and immobilize the tunnel ring 300 after implantation. Typically, the spring locks 302 will expand in an outwardly radial direction, as shown by the arrow, when the threaded shaft 304 is advanced in the suture ring. When in the expanded configuration, the spring locks provide further axial and rotational stability of the tunnel ring 300 during tensioning and further construct stability after locking.

[0069] Referring now to FIGS. 10A to 10D, use of the graph insertion tool 10 of the present invention for tensioning and fixating a pair of suture ends S will be described. The tensioning tool 10 initially has the cleat arms 78 open, as shown in FIG. 10A, and is brought to the site of a bone tunnel BT. Tunnel ring 100 may then be placed in an opening the bone tunnel BT, and suture ends pulled through the bone tunnel and tissue ring, as shown in FIG. 10B. The sutures are then threaded through the suture pullers 22, and the cleat arms 78 are closed to secure the suture ends S, as shown in FIG. 10C. Before closing the cleat arms 78, the suture ends S will be lightly tensioned to remove slack before tensioning. The suture pullers 20 and 22 on the tensioning tool 10 may then be translated proximally to apply a target tension to the suture, usually simultaneously but in some embodiments the pullers may be modified to allow separate tensioning.

[0070] At this point in the procedure, the distal end 44 the distal extension 36 of the partially threaded cylinder 32 will be at the 0 marker on the scale 74. The knob 50 may then be rotated to draw the pullers 20 and 22 proximally, applying tension to the sutures as indicated on the scale 74. When the distal end 44 is observed to reach a desired tension level as indicated on the tension scale 74. When a target tension is achieved, rotation of the knob 50 may be stopped and tensioning of suture left at the target level, as shown in FIG. 10D. At this point, the tension on the suture ends S will remain fixed, allowing the user to advance a suture lock through the axial passage 18 (FIG. 2) of the elongate frame of the tensioning tool using the locking tool 90, as shown FIG. 6B. The locking tool 90 may then be manually rotated to drive the threaded shaft 114 of the suture lock 102 through the tunnel ring 100 and into the bone tunnel BT, as shown in FIG. 7.

[0071] Alternatively, the suture lock 102 may be loosely placed into the suture ring 100 prior to tensioning of the suture, and the locking tool 90 used only to heighten a suture lock after the desired suture tension has been achieved. In either case, use of the separate locking tool to advance and/or lock suture lock in place allows the target tension to be maintaining with minimal or no variation.

[0072] The graft tensioning tools 10 of the present invention may be used to check graft tension in the knee or other joint while the joint is moved through different degrees of flexion. As shown in FIG. 11, the knee they be moved through different flexion angles α while the suture remains tensioned by the graft tensioning tool 10, as shown for example in FIG. 10C. The degree of flexion may be measured using a conventional instrument, such as a goniometer, but is preferably measured using an embedded tilt sensor, such as an electrolytic tilt sensor. The flexion angle and tension may thus be recorded for a range of knee flexions, for example from 0° to 90°. By plotting the measured graph against knee flexion, as shown in FIGS. 12A and 12B, the quality of the graft implantation and degree of tensioning may be determined. In some instances, when the graft tensioning tool 10 has a digital tension measurement output as well as a digital flexion angle output, such plots may be automatically generated and presented on a display and/or printed by a printer plotter.

[0073] Such plots can be useful for determining the outcome of an implementation. As shown in FIG. 12A, for example, if graph tension remains substantially constant over the number of flexion cycles, the graft is stable and the tension appropriate. In contrast, as shown in FIG. 12B, if the tension lessens over repeated cycles, the graft is likely unstable and/or the graph tension is inappropriate.

[0074] While preferred embodiments of the present invention have and the opening shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention methods and structures within the scope of these claims and their equivalents be covered thereby.