CONNECTIVE TISSUE GRAFTING

Abstract

A system and method for an improved connective tissue repair option that reduces disadvantages of conventional fixation options. Biologic press fit fixation of a connective tissue unit may include in situ expansion of a pre-compressed connective tissue unit within a prepared bone tunnel of a portion of bone. An external opening accessing a cavity of the prepared bone tunnel may be smaller than that of the cavity such that expansion of the installed/compressed connective tissue unit increases lateral fixation forces exerted by the expanding/decompressing compressed connective tissue unit within the bone tunnel.

Claims

1. A method for preparing a bone tunnel in a portion of bone, the bone tunnel configured to receive an installation of a ligament, comprising: operating a bone-shaping implement configured to produce a non-cylindrical bone tunnel having a bone tunnel profile; and shaping the portion of bone using said bone-shaping implement to create a non-cylindrical bone tunnel including said bone tunnel profile.

2. The method of claim 1 wherein the bone tunnel includes an opening in the portion of bone with said opening including an opening cross-section having an opening cross-section area, wherein the bone tunnel includes a cavity defined in the portion of bone with said cavity accessed through said opening, said cavity including a cavity cross-section parallel to said opening cross-section having a cavity cross-section area, and wherein said cavity cross-section area is greater than said opening cross-section area.

3. The method of claim 1 wherein the ligament includes a compressible portion configured to include an expanded diameter greater than an opening diameter, wherein said compressible portion is further configured to include a compressed portion having a compressed diameter less than said opening diameter, and wherein said compressed portion is configured to de-compress or expand, in situ, within the bone tunnel to substantially fill an external opening of the bone tunnel.

4. The method of claim 2 wherein the ligament includes a compressible portion configured to include an expanded diameter greater than an opening diameter, wherein said compressible portion is further configured to include a compressed portion having a compressed diameter less than said opening diameter, and wherein said compressed portion is configured to de-compress or expand, in situ, within the bone tunnel, including said cavity, to substantially fill said opening.

5. The method of claim 3 further comprising coupling a set of sensors to said compressed portion wherein said set of sensors are configured to assess one or more of (A) intra-tunnel interface forces (pressures), in order to determine if/when interface forces are adequate (high) enough for direct type and/or indirect type healing and (B) intra-articular ligament tensile, shear, and/or torsional forces (within the bone tunnel) to determine failure mechanisms and maximal load to failure in the case of re injury or re rupture.

6. The method of claim 4 further comprising coupling a set of sensors to said compressed portion wherein said set of sensors are configured to assess one or more of (A) intra-tunnel interface forces (pressures), in order to determine if/when interface forces are adequate (high) enough for direct type and/or indirect type healing and (B) intra-articular ligament tensile, shear, and/or torsional forces (within the bone tunnel) to determine failure mechanisms and maximal load to failure in the case of re injury or re rupture.

7. The method of claim 3 further comprising securing said compressed portion with said compressed diameter less than, or about equal to, said opening diameter prior to an installation of said compressed portion within the bone tunnel.

8. The method of claim 7 wherein said securing said compressed portion includes an encapsulation of said compressed portion within a compression-retaining sheath and wherein said compression-retaining sheath is removed prior to said installation.

9. The method of claim 4 further comprising securing said compressed portion with said compressed diameter less than, or about equal to, said opening diameter prior to an installation of said compressed portion within the bone tunnel.

10. The method of claim 9 wherein said securing said compressed portion includes an encapsulation of said compressed portion within a compression-retaining sheath.

11. The method of claim 3 wherein said compressible portion includes a decompressor modality configured to decompress or expand said compressible portion after installation within the bone tunnel.

12. The method of claim 11 wherein said decompressor modality includes a fluid absorption structure defined in said compressible portion.

13. The method of claim 12 wherein said fluid absorption structure is configured to absorb fluid from within the bone tunnel after installation of the compressible portion into the bone tunnel.

14. The method of claim 11 wherein said decompressor modality includes an expandable fluid storage structure defined in said compressible portion, said expandable fluid storage structure is configured to respond to an introduction of a fluid, after said compressible portion is installed within the bone tunnel, to decompress or expand said compressible portion in situ.

15. A connective tissue installation system, comprising: a bone tunnel prepared in a portion of bone, said bone tunnel including an external opening and a cavity in the portion of bone with said cavity accessed through said external opening; and a connective tissue unit secured within said bone tunnel using a biologic press fit fixation responsive to an in situ expansion of at least a portion of said connective tissue unit within said bone tunnel.

16. The connective tissue installation system of claim 15 wherein said biologic press fit fixation excludes a mechanical fixator, for example an interference screw, or a cortical suspensor disposed within said bone tunnel.

17. The connective tissue installation system of claim 15 wherein said biologic press fit fixation excludes a mechanical fixator, for example an interference screw, or a cortical suspensor disposed within said bone tunnel.

18. The connective tissue installation system of claim 15 wherein the connective tissue unit includes a compressible portion configured to include an expanded diameter greater than an opening diameter, wherein said compressible portion is further configured to include a compressed portion having a compressed diameter less than said opening diameter, and wherein said compressed portion is configured to de-compress or expand, in situ, within the bone tunnel to substantially fill an external opening of the bone tunnel.

19. The connective tissue installation system of claim 15 further comprising a set of sensors coupled to a portion of the connective tissue unit installed within said bone tunnel wherein said set of sensors are configured to assess one or more of (A) intra-tunnel interface forces (pressures), in order to determine if/when interface forces are adequate (high) enough for direct type and/or indirect type healing and (B) intra-articular ligament tensile, shear, and/or torsional forces (within the notch and the bone tunnels) to determine failure mechanisms and maximal load to failure in the case of re injury or re rupture.

20. A connective tissue graft for an installation within a bone tunnel having an external opening into a cavity prepared in a portion of a bone, comprising: a connective tissue unit having a compressed portion with a diameter smaller than a diameter of the external opening; wherein said compressed portion is configured for an in situ decompression or an in situ expansion within the bone tunnel after installation wherein said decompression or said expansion is configured for a biologic press fit fixation of said connective tissue unit within the bone tunnel.

21. (canceled)

22. A method for preparing a bone tunnel in a portion of bone, the bone tunnel configured to receive an installation of a ligament, comprising: operating a bone-shaping implement configured to produce a bone tunnel having a bone tunnel profile; and shaping the portion of bone using said bone-shaping implement to create said bone tunnel including said bone tunnel profile without use of a pre-determined guide wire or over drilling technique.

23-24. (canceled)

25. A method for delivery of a growth factor into a prepared bone tunnel, comprising: (a) treating a precompressed tissue graft with the biological growth factor; and (b) installing the precompressed tissue graft into a prepared bone tunnel producing an installed tissue graft; wherein said installed tissue graft delivers said growth factor into said prepared bone tunnel.

26-27. (canceled)

28. A method for embedding a set of one or more prosthetic elements inside a connective tissue graft, comprising: (a) disposing a set of one or more natural, synthetic, and/or hybrid materials within a natural ligament graft producing an enhanced natural ligament graft; and thereafter (b) fixing said enhanced natural ligament graft within a prepared bone tunnel.

29. A method for expanding a natural connective tissue graft, comprising: (a) disposing a set of one or more expansion structures within a natural ligament graft producing an expandable natural ligament graft; and (b) fixing said natural ligament graft within a prepared bone tunnel producing a fixed expandable natural ligament graft.

30. The method of claim 29 further comprising: (c) expanding said fixed expandable natural ligament graft after fixation into said prepared bone tunnel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention.

[0052] FIG. 1 illustrates an example of suspensory cortical fixation;

[0053] FIG. 2 illustrates an example of aperture interference screw fixation;

[0054] FIG. 3 illustrates an example of a native connective tissue graft;

[0055] FIG. 4 illustrates an example of a compressed connective tissue graft that may result from a pre-operative compressive treatment of the native connective tissue graft of FIG. 3;

[0056] FIG. 5 illustrates a perspective view of a graft platform;

[0057] FIG. 6 illustrates a side view of the graft platform of FIG. 5 with repositioned stages;

[0058] FIG. 7 illustrates a sectional view of a pair of collets gripping the native connective tissue graft of FIG. 3;

[0059] FIG. 8 illustrates an end view of FIG. 7;

[0060] FIG. 9 illustrates an end view similar to FIG. 8 but after lateral compression to produce the compressed connective tissue graft of FIG. 4;

[0061] FIG. 10 illustrates a perspective view of a collet of the graft platform;

[0062] FIG. 11 illustrates an end view of the collet of FIG. 10;

[0063] FIG. 12 illustrates a side sectional view of the collet of FIG. 10;

[0064] FIG. 13-FIG. 14 illustrates a reconstruction of an ACL in a pair of cylindrical bone tunnels;

[0065] FIG. 13 illustrates pre-expansion of a compressed ACL graft;

[0066] FIG. 14 illustrates a post-expansion of the compressed ACL graft;

[0067] FIG. 15-FIG. 16 illustrates a reconstruction of an ACL into a pair of profiled bone tunnels;

[0068] FIG. 15 illustrates pre-expansion of a compressed ACL graft;

[0069] FIG. 16 illustrates a post-expansion of the compressed ACL graft;

[0070] FIG. 17 illustrates different conforming expansions of a compressed ACL graft, dependent upon a preparation of a bone tunnel;

[0071] FIG. 18 illustrates a preparation of a profiled bone tunnel by an automated surgical apparatus;

[0072] FIG. 19 illustrates an allograft system including a pre-compressed allograft with a sheathing subsystem having an outer sheath and an inner sheath;

[0073] FIG. 20 illustrates an allograft system including a pre-compressed allograft with a prosthesis subsystem having at least one connective tissue prosthetic element; and

[0074] FIG. 21 illustrates an allograft system including a pre-compressed allograft with an expansion subsystem having at least one expansion element.

DETAILED DESCRIPTION OF THE INVENTION

[0075] Embodiments of the present invention provide a system and method for an improved connective tissue repair option that reduces disadvantages of conventional fixation options. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements.

[0076] Various modifications to the preferred embodiment and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiment shown but is to be accorded the widest scope consistent with the principles and features described herein.

Definitions

[0077] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this general inventive concept belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0078] The following definitions apply to some of the aspects described with respect to some embodiments of the invention. These definitions may likewise be expanded upon herein.

[0079] As used herein, the term or includes and/or and the term and/or includes any and all combinations of one or more of the associated listed items. Expressions such as at least one of, when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list.

[0080] As used herein, the singular terms a, an, and the include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an object can include multiple objects unless the context clearly dictates otherwise.

[0081] Also, as used in the description herein and throughout the claims that follow, the meaning of in includes in and on unless the context clearly dictates otherwise. It will be understood that when an element is referred to as being on another element, it can be directly on the other element or intervening elements may be present therebetween. In contrast, when an element is referred to as being directly on another element, there are no intervening elements present.

[0082] As used herein, the term set refers to a collection of one or more objects. Thus, for example, a set of objects can include a single object or multiple objects. Objects of a set also can be referred to as members of the set. Objects of a set can be the same or different. In some instances, objects of a set can share one or more common properties.

[0083] As used herein, the term adjacent refers to being near or adjoining. Adjacent objects can be spaced apart from one another or can be in actual or direct contact with one another. In some instances, adjacent objects can be coupled to one another or can be formed integrally with one another.

[0084] As used herein, the terms connect, connected, and connecting refer to a direct attachment or link. Connected objects have no or no substantial intermediary object or set of objects, as the context indicates.

[0085] As used herein, the terms couple, coupled, and coupling refer to an operational connection or linking. Coupled objects can be directly connected to one another or can be indirectly connected to one another, such as via an intermediary set of objects.

[0086] The use of the term about applies to all numeric values, whether or not explicitly indicated. This term generally refers to a range of numbers that one of ordinary skill in the art would consider as a reasonable amount of deviation to the recited numeric values (i.e., having the equivalent function or result). For example, this term can be construed as including a deviation of 10 percent of the given numeric value provided such a deviation does not alter the end function or result of the value. Therefore, a value of about 1% can be construed to be a range from 0.9% to 1.1%.

[0087] As used herein, the terms substantially and substantial refer to a considerable degree or extent. When used in conjunction with an event or circumstance, the terms can refer to instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation, such as accounting for typical tolerance levels or variability of the embodiments described herein.

[0088] As used herein, the terms optional and optionally mean that the subsequently described event or circumstance may or may not occur and that the description includes instances where the event or circumstance occurs and instances in which it does not.

[0089] As used herein, the term size refers to a characteristic dimension of an object. Thus, for example, a size of an object that is spherical can refer to a diameter of the object. In the case of an object that is non-spherical, a size of the non-spherical object can refer to a diameter of a corresponding spherical object, where the corresponding spherical object exhibits or has a particular set of derivable or measurable properties that are substantially the same as those of the non-spherical object. Thus, for example, a size of a non-spherical object can refer to a diameter of a corresponding spherical object that exhibits light scattering or other properties that are substantially the same as those of the non-spherical object. Alternatively, or in conjunction, a size of a non-spherical object can refer to an average of various orthogonal dimensions of the object. Thus, for example, a size of an object that is a spheroidal can refer to an average of a major axis and a minor axis of the object. When referring to a set of objects as having a particular size, it is contemplated that the objects can have a distribution of sizes around the particular size. Thus, as used herein, a size of a set of objects can refer to a typical size of a distribution of sizes, such as an average size, a median size, or a peak size.

[0090] As used herein, the term compress or compression with respect to a compressible connective tissue unit means a decrease in a diameter of the compressible connective tissue unit whether the decrease occurs actually through a compression or otherwise such as a tensioning and/or a torsioning or other manipulation or operation on the tissue unit.

[0091] The present invention may be useful for a wide-range of connective tissue grafts used in a wide-range of repair techniques. With this understanding, to simplify the discussion a particular type of graft used in a particular type of repair technique: an ACL graft used for repair of a ruptured ACL.

[0092] The knee is a simple hinge joint at the connection point between the femur and tibia bones. It is held together by several important ligaments. The most important of these to the knee's stability is the Anterior Cruciate Ligament (ACL). The ACL attaches from the front part of the tibia to the back part of the femur. The purpose of this ligament is to keep the tibia from sliding forward on the femur. For this reason, the ACL is most susceptible to injury when rotational or twisting forces are placed on the knee. Although this can happen during a contact injury many ACL tears happen when athletes slow down and pivot or when landing from a jump.

[0093] After the ACL is torn the knee is less stable and it becomes difficult to maintain a high level of activity without the knee buckling or giving way. It is particularly difficult to perform the repetitive cutting and pivoting that is required in many sports.

[0094] Regardless of how the ACL is torn a physician will work with their patient to determine what the best course of treatment will be. In the case of an isolated ACL tear (no other ligaments are involved) the associated pain and dysfunction may often be successfully treated with rest, anti-inflammatory measures, activity modification and Physical Therapy. After the swelling resolves and range of motion and strength is returned to the knee a decision can be made as to how to proceed. Many people elect to use a sports brace and restrict their activity rather than undergo surgery to reconstruct the ACL. When a non-surgical approach is taken the patient must understand that it is imperative that she or he maintain good strength in her or his leg and avoid sports or activities that require pivoting or cutting. When conservative measures are unsuccessful in restoring function the patient and their physician may elect to have the torn ligament reconstructed.

[0095] ACL reconstruction surgery is not a primary repair procedure. This means that the ligament ends cannot simply be sewn back together. The new ACL must come from another source and grafted into place in the knee. There are a few different options as to what tissue is used for the ACL graft (three most common sources include patella tendon, hamstring tendon, and cadaver tendon) and each patient should consult with his or her surgeon to determine the best choice. During the procedure a set of tunnels are drilled within the tibia and femur and the new ACL graft is passed into these tunnels and anchored into place. Some or all of this anchoring, in embodiments of the present invention, occur by use of an in situ decompression of a compressed end portion of the ACL graft within a prepared tunnel.

[0096] The ACL graft includes a highly hydrated and compressible tissue. As observed by applicant, a diameter of a typical ACL graft may be compressed, for example by up to 2 to 4 millimeters, with special techniques that can be employed just prior to installation. The native ACL graft can be manipulated (e.g., compressed and/or stretched) to produce a manipulated ACL graft that has a smaller diameter than the native ACL graft. For this discussion, the native ACL graft may include a 10-millimeter diameter while the manipulated ACL graft may include a 7-millimeter diameter.

[0097] The manipulated ACL may subsequently be implanted at a significantly compressed diameter than its original form (i.e. 7 mm instead of 10 mm) and allowed to expand, in a delayed fashion, within bone tunnels formed and used during the repair procedure, producing high contact forces at an interface between the manipulated ACL graft and the bone of the tunnel (e.g., a tendon/bone interface).

[0098] This repair may be accomplished with all the positive attributes of suspensory cortical and aperture fixation and without any of the negative attributes of the two fixation methods.

[0099] This method of biological press fit fixation does not have the negative attributes of interference screw fixation including: without the use of an interference screw and its attendant negative attributes including: (i) damage to the graft and bone; (ii) loss of circumferential contact; and (iii) foreign material within the tunnels causing late inflammatory and destructive reactions in bone. Similarly, the biological press fit fixation dos not have the negative attributes of suspensory cortical fixation including: (i) micro motion at the aperture causing bungee (lengthwise micro motion) and windshield wiper (side-to-side micro motion) effects, (ii) increasing risk of tunnel widening; and (iii) low tendon-bone interface compression forces leading to indirect type healing (Sharpey Fibers, with no transitional zone of mineralized and non-mineralized fibrocartilage, for specialized transfer of force).

[0100] An embodiment of the present invention may allow all the positives attributes of both suspensory cortical and aperture fixation. Biologic press fit fixation may embody all the positive attributes of suspensory cortical fixation including: (i) circumferential 360-degree contact between tendon and bone (maximized surface area contact for tendon to bone healing); (ii) easier operation to perform; (iii) less damage to bone and tendon at the time of surgery (less invasivebone and tendon sparing); (iv) strong fixation. Biological press fit fixation similarly may embody all the positive attributes of aperture fixation including: (i) significantly higher compression forces between tendon/bone interface; (ii) rigid fixation with minimal or no micro motion in the bone tunnel; (iii) ideal healingby direct type insertion with specialization of the tendon bone interface, allowing for progressive force transfer from tendon to bone (formation of the four zones: tendon, fibrocartilage, mineralized fibrocartilage, bone); and (iv) faster healing.

[0101] The combination of factors noted above are believed to allow high interference forces that may be obtained soon after implantation (including decompression of manipulated ACL graft within a portion of a one tunnel), these interference forces due to the in situ decompression of the manipulated ACL graft, without interference of foreign material within the tunnels.

[0102] Some embodiments may include application of one or more remotely readable biological sensors to the manipulated ACL graft. The sensors may, for example, include a capacity to measure contact forces at the tendon/bone interface of the expanding manipulated ACL graft within a tunnel. These sensors may be applied to the ACL graft as part of the preparation or provided to the surgeon prior to compression. There may be various uses of this/these sensor(s), in order to assess compressive forces produced at the tendon/bone junction at time zero and over defined periods of time.

[0103] FIG. 3 illustrates an example of a native connective tissue graft 300. Graft 300 is provided with predetermined general dimensions, including a length L1 and a diameter D1. For example, for an ACL reconstruction, graft may have L1 about 90-180 millimeters (determined by patient anatomy) and D1 about 10 millimeters.

[0104] FIG. 4 illustrates an example of a compressed connective tissue graft 400 that may result from a pre-operative compressive treatment of native connective tissue graft 300. Graft 400 includes a length L2 that may be about greater than or equal to L1 and further includes a diameter D2 that is less than D1. One or more remotely readable biologic sensors 405 may be included with graft 400.

[0105] Sensor(s) 405 may be included as part of graft 300 (pre-manipulation) or may be applied to a surface of graft 400 or bulk-integrated into a body of graft 400 as part of, or attendant to, pre-reconstruction preparation of graft 400.

[0106] Sensor(s) 405 may be used for different purposes to assess a quality of various aspects of the reconstruction procedure. For example, a compression reading at one or more interfaces between one or more end portions of graft 400 within the bone tunnel into which graft 400 was installed may be used to measure healing and fixation. A sensor 405 disposed outside of a tunnel between the femur and the tibia may include a stress-strain gauge to understand the potentially rupturing forces that the patient applies to the reconstructed ACL graft (after surgery) in the course of their activities. Readings may be taken immediately after installation and then at various subsequent times to assess a magnitude of the graft/bone interface at that/those portion(s). The readings may indicate that healing is progressing (and some metric of how well the healing has progressed), healing has largely completed past a predetermined threshold, or that there may be some complication in the healing process.

[0107] FIG. 5 illustrates a perspective view of a graft platform 500. Platform 500 may include a table 505 supporting a pair of moveable sleeve housings 510. Housings 510 move relative to each other (one or both housings 510 may move). Movement may be controlled by a drive rod 515 having a knob 520. Knob 520 may be turned using a torque wrench 525 to understand how much force is being used to separate housings 510. One may want to be sure that not too small or too large force is used in separating housings 510 as this influences an amount of tension/deformation to any graft being manipulated by platform 500.

[0108] Each housing 510 supports a graft sleeve that defines a conical internal sleeve structure into which a collet chuck is introduced and upon which a collet nut is threaded over the collet chuck within the internal sleeve structure using complementary threaded portions of an end of the graft sleeve. A wrench 530 may be used to tighten the collet nut onto the graft sleeve. One or more suture holders may be used to support graft 300 when initially installed into graft platform 500. For purposes of this illustration FIG. 5, sleeve housings 510 are shown facing away from each, while in actual operation housings 510 are reversed as illustrated in FIG. 6.

[0109] FIG. 6 illustrates a side view of graft platform 500 with repositioned housings 510 to face each other. Platform 500 includes a graft sleeve 605 coupled to housing 510. Each graft sleeve 605 defines a conical internal sleeve structure 610 into which a collet chuck 615 is positioned. A threaded collet nut 620 is positioned over collet chuck 615 and is installed onto sleeve 605 by use of a threaded end 625 of graft sleeve 605. Each graft sleeve 605 includes one or more suture holders 630.

[0110] In operation, graft 300 is installed into graft platform 500 with each sleeve 605 gripping one end. There are different possible operational modes for graft platform 500 to compress graft 300 and produce graft 400, depending upon the procedure agreed upon by the patient and surgeon.

[0111] Graft platform 500 may compress some or all of graft 300 by applying equal lateral compressive forces along its length (by appropriate positioning and tightening of collet chucks 625 into structures 610 using nut 620 and/or separating housings 510 from each other using knob 520 to rotate rod 515.

[0112] FIG. 7 illustrates a sectional view 700 of a pair of collet chucks 615 of platform 500 gripping native connective tissue graft 300 by being forced into structure 610. Each collet chuck 615 includes a longitudinal tunnel having a variable diameter. That diameter is greatest when it is initially installed into structure 610. As nut 620 is tightened, such as with wrench 530, the corresponding chuck 615 is forced deeper into conical structure 610 which decrease the diameter of the longitudinal tunnel. Decreasing the longitudinal tunnel while a portion of graft 300 is installed is one manner by which lateral compressive forces may be applied to that portion of graft 300 (which decreases the diameter of that portion of graft 300). Chuck 615 may be designed to have a physically determined minimum diameter to help ensure that graft 300 is not excessively compressed.

[0113] FIG. 8 illustrates an end view of FIG. 7 in the context of platform 500. In this view, chuck 615 is in the initial or open state. Each collet chuck includes a number of tabs arrayed around the longitudinal tunnel, and in the open state, these tabs are separated. Forcing chuck 615 into structure 610 by turning nut 620 moves these tabs closer together to narrow the longitudinal tunnel and to thereby compress graft 300.

[0114] FIG. 9 illustrates an end view 900 similar to FIG. 8 but after lateral compression (e.g., longitudinal tunnel of chuck 615 closed) to produce compressed connective tissue graft 400. In FIG. 9 the tabs of chuck 615 are closed/touching which produces the smallest diameter longitudinal tunnel. This is in contrast to FIG. 8 where the tabs are separated and define a larger diameter longitudinal tunnel.

[0115] FIG. 10-FIG. 12 illustrate details of collet chuck 615. FIG. 10 illustrates a perspective view of collet chuck 615 of graft platform 500; FIG. 11 illustrates an end view of collet chuck 615 of FIG. 10; and FIG. 12 illustrates a side sectional view of collet chuck 615 of FIG. 10. Collet chuck 615 includes an N number, N2, of moveable tabs 1005 that collectively define a longitudinal tunnel 1010. N may be any integer two or greater and may often be an even number, for example N is an element of the set {2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, . . . } depending upon various design considerations in compressing and shaping an outer perimeter of graft 300 to produce graft 400. In FIG. 10-FIG. 12, N=4. In FIG. 8 and FIG. 9, N=7.

[0116] In operation, platform 500 may include one or more different modalities for decreasing D1 of graft 300 and providing D2 of graft 400 that may be significantly smaller. One modality includes inserting all or portion of graft 300 into one or both collet chucks 615 (chucks 615 may have a length to accommodate the intended use. A single chuck 615 that is long enough may compress an entire length of graft 300. The tightening of the collet nut while some of all of graft 300 is disposed inside the longitudinal tunnel of the corresponding collet chuck will compress D1 of graft 300 to D2 of graft 400.

[0117] In other embodiments, a portion of each end, up to one-half, of graft 300 is installed into each of two opposing collet chucks on platform 500. That end portion in each collet chuck may then be compressed by tightening the corresponding collet nut. In this example, one-half of graft 300 is compressed by each stage. Variations are possible, such as where of graft 300 is installed into one chuck and the remainder of graft 300 installed into the other chuck. This allows for each end or portion of each end to be compressed to different diameters (the compressed diameter of one end may be different than the compressed diameter of the opposite end). Some procedures or protocols may be advantaged by producing differently sized tunnels in the different bonesone tunnel size in a femur and a different one in the tibia for example. Some embodiments of the present invention allow for this as necessary or desired.

[0118] Another possible modality for decreasing D1 of graft 300 is to use platform 500 to grip ends of graft 300 in each housing and then to use the drive rod to separate the housings. By using the torque wrench, an operator understands how much tension is applied to graft 300 intermediate the gripped ends which tensions, stretches, and thins the intermediate portion. The degree of thinning of this intermediate portion is dependent upon the force applied and the tensile and compressive moduli (mechanical properties) of graft 300. As long as the thinning occurs in the elastic deformation range, there will be a tendency for the intermediate portion thinned this way to return towards a thicker instance. The graft may also exhibit elastic and/or inelastic behavior frequently described in solids, where a subset of viscoelastic materials have a unique equilibrium configuration and ultimately recover fully after removal of a transient load, such that after being squeezed, they return to their original shape, given enough time. The transient strain is recoverable after the load or deformation is removed. Time scale for recovery may be short, or it may be so long as to exceed the observer's patience.

[0119] In some embodiments, it is thus possible to produce a diameter profile over a length L2 of graft 400. Typically graft 400 includes a single diameter D1 over the entire length L1. However, embodiments of the present invention may tailor each end or portion thereof with a desired diameter (the same or different from the other end) and with a desired diameter for the intermediate portion that is the same or different from either or both ends. Some amount of each end, and the intermediate portion, may have its diameter be relatively independently controlled. Any end or intermediate portion may have a greater or lesser diameter than another part of graft 400. The intermediate portion may have the same, larger, or smaller diameter than one or both end portions. The same is true of each end relative to the other end and the intermediate portion.

[0120] In the above discussion, the grafts and tunnels, and structures complementary thereto have been described as generally elongate circular cross-sectional structures (e.g., cylindrical tunnels). This is because the current procedures provide for drilling tunnels in the implicated bones and the drilling produces generally circular cross-sectional tunnels. In general all ACL reconstructive techniques, whether performed arthroscopically or open, utilize the particular technique of initially proposing the tibial and femoral tunnels with a guide wire, which is drilled in the desired position, and after confirmation, over-drilled with a cannulated drill bit to produce a perfect cylindrical tunnel.

[0121] In some instances, it may be possible to produce tunnels in the bones, possibly utilizing different techniques and completely different technologies, with the tunnels having other than circular (e.g., cylindrical) cross-sections. Perhaps healing and recovery may be better achieved with a generally elliptical cross-section tunnel such as a frustrum (e.g., of a pyramid or cone or other closed three-dimensional cavity volume), a rectilinear cross-section tunnel, or a tunnel that has a varying diameter over its length. In some cases, a bone preparation tool may include a LASER, a 3 dimensional (3D) bone sculpting tools, or robotic instruments to define a desired regular/irregular/symmetric/asymmetric tunnel that varies from a same-sized cylindrical bore (iv) typically produced in the femur and the tibia for current ACL reconstructive techniques.

[0122] An advantage of some embodiments of the present invention when installing a compressed graft 400 into any of these alternative types of tunnels (as well as the cylindrical bores from a drill) is that the graft 400 may selectively expand to fill any variable profile of the tunnel in the femur and tibia.

[0123] FIG. 13-FIG. 14 illustrates a reconstruction 1300 of an ACL in a pair of cylindrical bone tunnels. FIG. 13 illustrates pre-expansion of a compressed ACL graft 1305, such as an appropriately sized embodiment of graft 400 in FIG. 4 and FIG. 14 illustrates a post-installation-expansion of compressed ACL graft 1305. A bone tunnel 1310 is prepared in a portion of a femur 1315 and a bone tunnel 1320 is prepared in a portion of an adjacent tibia 1325. There may be several ways to prepare these bone tunnels, such as by installing a guide wire along a desired path and then using a cannulated drill bit to follow the guide wire to the desired depth. For example, these tunnels may have a diameter of about 9 millimeters and ACL graft may have an uncompressed diameter of about 10 millimeters and a compressed diameter of about 6-8 millimeters. With these dimensions, the compressed ACL graft may easily be installed into a prepared bone tunnel and an uncompressed ACL graft may produce significant lateral frictional forces holding it in place as the healing occurs and natural fixation completes itself to bond the uncompressed ACL graft into the prepared bone tunnels (with or without external fixation devices or structures).

[0124] After decompression of compressed ACL graft 1305 (in FIG. 14) the expanded ACL graft 1305 tightly fills each bone tunnel as it conforms to the cross-section profile (e.g. circle for a cylindrical bone tunnel). A diameter/profile of bone tunnel 1310 need not, but may be, the same as a diameter/profile of bone tunnel 1320. As long as portions of the diameters of the bone tunnels where the ACL graft is to be bonded (e.g., openings of the bone tunnels) are smaller than an original unexpanded diameter of the compressed ACL graft, temporary press-fit fixation from the decompression of the installed graft will secure the decompressing ACL graft into the bone tunnels and provide the advantages noted herein.

[0125] Once the bone tunnels are prepared, a first end 1330 of compressed ACL graft 1305 is installed into bone tunnel 1310 and a second end 1335 of compressed ACL graft 1305 is installed into bone tunnel 1320. As compressed graft decompresses it expands towards its original pre-compressed shape unless constrained (by a bone tunnel side wall for example).

[0126] FIG. 15-FIG. 16 illustrates an alternative reconstruction 1500 of an ACL into a pair of profiled bone tunnels. FIG. 15 illustrates pre-expansion of a compressed ACL graft 1505 (which may be similar to ACL graft 1305 in FIG. 13), such as an appropriately sized embodiment of graft 400 in FIG. 4 and FIG. 14 illustrates a post-installation-expansion of compressed ACL graft 1505.

[0127] Alternative reconstruction 1500 is similar to reconstruction 1300 with the exception of the shape of the bone tunnels (and consequently the manner of the formation of the profiled bone tunnels in FIG. 15 and FIG. 16. The noted characteristic of the conforming decompression of a compressed ACL graft 1505 is used in this alternative to expand into specially profiled bone tunnels that may have a number of shapes where an opening profile is purposefully and significantly smaller than a cavity profile deeper into the bone.

[0128] A profiled bone tunnel 1510 is prepared in a portion of a femur 1315 and a profiled bone tunnel 1520 is prepared in a portion of an adjacent tibia 1325. There may be several ways to prepare these profiled bone tunnels, such as by use of a surgical robot or three-dimensional bone sculpting as described herein, for example in the discussion of FIG. 18 below. For example, these profiled tunnels may be generally shaped as a frustum have a narrower opening diameter of about 8 millimeters, a wider base diameter of about 9-10 millimeters, and the ACL graft may have an uncompressed diameter of about 10 millimeters and a compressed diameter of about 6-7 millimeters. With these dimensions, the compressed ACL graft may easily be installed into a prepared bone tunnel and a decompressing ACL graft, when decompressed, may produce significant frictional and mechanical forces (e.g., normal forces) holding it in place as the healing occurs and natural fixation completes itself to bond the uncompressed ACL graft into the prepared bone tunnels (with or without external fixation devices or structures).

[0129] After decompression of compressed ACL graft 1505 (in FIG. 15) the expanded ACL graft 1505 tightly fills each profiled bone tunnel as it conforms to the cross-section profile (e.g. circle for a cylindrical frustum bone tunnel). A shape of profiled bone tunnel 1510 need not, but may be, the same shape as the shape of profiled bone tunnel 1520. As long as portions of the diameters of the profiled bone tunnels where the ACL graft is to be bonded (e.g., openings of the bone tunnels) are smaller than an original unexpanded diameter of the compressed ACL graft, temporary biologic press-fit and mechanical fixation from the decompressing ACL graft will secure the ACL graft into the profiled bone tunnels and provide the advantages noted herein along with improved resistance to pull-out.

[0130] Once the bone tunnels are profiled, a first end 1530 of compressed ACL graft 1505 is installed into bone tunnel 1510 and a second end 1535 of compressed ACL graft 1505 is installed into bone tunnel 1520. As compressed graft decompresses it expands towards its original pre-compressed shape unless constrained (by a bone tunnel profiled side wall for example).

[0131] FIG. 17 illustrates different conforming expansions 1700 of a compressed ACL graft 1705, dependent upon a preparation of a bone tunnel and represent the examples from FIG. 13-FIG. 16. For example, when compressed ACL graft 1705 is installed into cylindrical bone tunnels (a simple example of a profiled bone tunnel), its decompression results in an uncompressed graft similar to graft 1710. When compressed ACL graft 1705 is installed into inverted frustum profiled bone tunnels (e.g., as illustrated in FIG. 15 and FIG. 16), its decompression results in an uncompressed graft similar to graft 1715. In general, the bone tunnel includes an opening in the prepared bone and a cavity defined in the prepared bone access through this opening. The opening defines a cross-section having an opening area. The cavity defines a cavity cross-section, parallel to the opening cross-section, that includes a cavity cross-section area. For cylindrical bone tunnels, the opening cross-section and the opening cross-section area matches the cavity cross-section and the cavity cross-section area. For asymmetrical bone tunnels, the opening cross-section and the cavity cross-section do not match, and the cavity cross-section area is greater than the opening cross-section area. The magnitude of this difference in area may vary on design considerations and procedure and may range from 5%-50% greater, to even more (e.g., greater than 100%). The area difference includes configurations to permit biological press fit fixation of the in-tunnel-expanded connective tissue, particularly without interference screws or cortical suspenders or other non-connective tissue structures installed or disposed within the bone tunnel.

[0132] FIG. 18 illustrates a bone profiling apparatus 1800 for a preparation of a profiled bone tunnel 1805 by an automated surgical apparatus 1810. In FIG. 18, apparatus 1810 has produced a first profiled bone tunnel 1805 in tibia 1325 and is preparing to produce a second profiled bone tunnel in femur 1315. Apparatus 1810 includes a bone preparation implement 1815 having a mechanical coupling 1820 (direct or indirect) between a controller 1825 (e.g., a stored program computing system including processor executing instructions from a memory including a user interface to set user options and parameters).

[0133] There are automated assistive surgical devices which may fill the role of apparatus 1810, such as robotic assisted surgical platforms (e.g., MAKO, da Vinci, Verb, Medtronic, TransEnterix, Titan Medical systems, NAVIO blue belt, and the like). These platforms provide positional control/limitation of surgical implements operated by a surgeon, such that the robotic tools (some of which utilize custom software and CT data) resist the movements by the surgeon that may attempt to deviate from a planned procedure, bone preparation, or other processing. These platforms are often installed into a known reference frame shared by the patient so precise position control/limitation may be imposed. Installing bone preparation tool 1815 (e.g., a high-speed rotating burr or the like) the surgeon may operate the platform to form a precisely profiled bone tunnel as described herein (e.g., first profiled tunnel 1805). A profiled tunnel may be initiated from a bit-prepared cylindrical tunnel and then profiled from there or apparatus 1810 may prepare the entirety of the profiled bone tunnel.

[0134] Further, current ACL techniques require that the surgeon estimate the length of the graft to fit the combined length of the tibial and femoral tunnels plus the intra-articular length of the ACL graft, housed in the notch. Despite best efforts mismatches between the length of the graft and the tunnels is not infrequent, which adversely affects the outcome. The use of automated surgical devices noted above has the advantage of providing the exact lengths of the tibial and femoral tunnels as well as the intra-articular length of the ACL graft within the notch. These techniques allow bone resection of any profile with varying trajectories and depths based on planned procedure, for example to within a millimeter. The tunnel lengths can be determined pre-operatively or intra-operatively and correlated with the length and diameter of the prepared allograft. Growth factors can be applied to pre-prepared allograft with external of and/or internal sheaths, or to auto-grafts prepared at the time of surgery.

[0135] Apparatus 1810 may be used to produce internal ridges, dimples, or other irregularities in the lateral wall of a bone tunnel (profiled or conventional cylindrical tunnel). The uncompressing ACL graft will fill these irregularities which may further promote fixation and healing.

[0136] Described above are embodiments (apparatus and methods) for production of a compressed connective tissue graft. Such a graft may be prepared from the patient or may be provided separately (e.g., a frozen pre-prepared allograft) that may be sized and compressed.

[0137] An embodiment of the present invention includes off-site advance preparation of compressed connective tissue graft that are shipped and stored in the compressed state. They may be frozen in the compressed state sufficiently partially thawed at the time of installation to allow appropriate decompression in situ. It may be that the pre-compressed allograft is delivered in a peel pack while freeze dried in the compressed state. The allograft is removed from the packaging and the surgeon will have some time for installation before it decompresses. In some cases, the allograft's decompression is accelerated by saline solution. Exposure of the compressed allograft to body fluids in the bone tunnels may also accelerate the decompression for fixation into the bone tunnel.

[0138] In other embodiments, a protective sheath may be provided that is installed after compression to maintain the connective tissue graft in the compressed state. Removal of the sheath allows for decompression. The sheath may be dissolvable in body fluids and installation into a bone tunnel begins the dissolution and decompression.

[0139] The sheath may be provided as a two-part element: an outer protective film prevents decompression and an inner layer that may temporarily inhibit decompression during the installation process. When ready to install, the outer layer is removed and the connective tissue graft (with inner layer) is inserted into the bone tunnel. Alternatively, the outer and inner sheaths of compressed ACL prepared grafts can be embedded with a combination of biological growth factors including the TGF family, bone morphogenic proteins (BMP), insulin like growth factors, matrix metalloproteinases, fibroblast growth factors, vascular endothelial growth factors, platelet derived growth factors, and or other stem cell derived growth factors (including epithelial and mesenchymal stromal cells), which alone or in combination can significantly improve healing of tendon to bone, promoting angiogenesis and osteogenesis at the tendon-bone interface after ACL reconstruction. The sheaths may also include other allogenic sources of growth factors such as amniotic membrane products and the like.

[0140] FIG. 19 illustrates an allograft system 1900 including a pre-compressed allograft 1905 with a sheathing subsystem having one or more sheaths (e.g., an inner sheath 1910 and an outer sheath 1915). The sheathing subsystem may accomplish one or more functions depending upon implementation, to achieve desired goals as described herein. Those goals may include a number of functions, such as maintaining a pre-compressed allograft 1905 in its compressed mode until installed into a prepared bone tunnel for decompression as described herein. Other functions include enhancing preservation of sterility and delivery of growth factors into the bone tunnel at the graft/tunnel interface.

[0141] FIG. 20 illustrates an allograft system 2000 including a pre-compressed allograft 2005 with an embedded prosthesis subsystem having at least one connective tissue prosthetic element 2010 that runs a length. There is a history of development and investigation of synthetic ACL grafts but have generally not proven to be successful. There are a number of problems of a pure synthetic connective tissue graft, including a) breakdown of the synthetic material with exposure in the joint that too often leads to synovitis and arthritis due to existence of the foreign material in joints; and b) not finding a synthetic graft that has equivalent material properties of connective tissue. There is not complete agreement on the mechanical properties needed or desired for such a synthetic graft: some materials discuss a stiffness of the synthetic material. However, it may be the case that a graft that has the similar toughness properties of native ACL may be preferable: i.e., more ductile than brittle (i.e. a larger plastic range).

[0142] Allograft system 2000 is believed to address some of these drawbacks as it is a hybrid system: native connective tissue on the outside with an embedded prosthetic element(s) inside. Illustrated is embedding the prosthetic elements inside a pre-compressed allograft as described herein. Some embodiments may embed these synthetic elements within a conventional allograft and use an alternative fixation method.

[0143] The one or more prosthetic elements may each include single strands of suitable material (e.g., natural and/or synthetic material) or may include a weave of such materials (including composite weaves of multiple different materials). The one or more embedded prosthetic elements do not provide for intra-articular bone exposure.

[0144] When embedded into a pre-compressed, the expansion fixation of the decompressing allograft into a bone tunnel secures the prosthetic elements along with the outer native decompressed graft.

[0145] FIG. 21 illustrates an allograft system 2100 including a pre-compressed allograft 2105 with an expansion subsystem having at least one expansion element 2110 disposed in one or more portions that are to be expanded. These portions may be one or both end portions and/or middle portion. In some cases, the at least one expansion element may run a length of the compressed allograft. In many embodiments, the enlargement of a pre-compressed allograft has been described as a generally passive process in which a compressed allograft is allowed to decompress. It is the case that under some circumstances that natural connective tissue may expand somewhat when subjected to bodily fluids or pre-operative fluid baths (e.g., saline solution) for thawing an often-frozen allograft.

[0146] Allograft system 2100 includes an active expansion system which expands compressed native connective tissue. Expansion may be accomplished by use of the at least one embedded expansion element 2110. This at least one expansion element 2110 may be embedded into a pre-compressed allograft as described herein or embedded into a conventional allograft. In some implementations, the at least one expansion element 2110 may be part of, included within, integrated with, or provided as part of at least synthetic prosthetic element as illustrated in FIG. 21. For example, a structure may have a dual use of providing the synthetic prosthetic element and the expansion element.

[0147] System 2100 introduces the concept of internal expandable structures (e.g., tubes) for configuring/implementing biological press fit interference fixation of pre-compressed ACL grafts (it being noted that herein that these expandable structures may be used with conventional allografts and/or with conventional fixation methods).

[0148] One method to increase tendon/bone interface pressures (in lieu of interference screws or cortical suspending hardware) is a new concept of introducing expandable tubes, cages or stents within the ends of the allografts, and allowing the tube, cage or stent to expand passively or actively, to subsequently increase graft bone interface pressures to assure direct type fixation.

[0149] The material for the intra graft tubes can be synthetic non-absorbable material such as plastic and or polyester or similar material; or absorbable material. Current methods of in tunnel fixation compromise tendon/bone surface contact area. An embodiment of the present invention may include a method, apparatus, and system where the graft, or synthetic material disposed within the graft, may be expanded which is juxtaposed and pressed, in some instances uniformly pressed, to interior surface walls of the prepared bone tunnel. In this manner tendon/bone interface is not required to be compromised by the addition of hardware fixation solutions. A surgeon may desire to supplement this pure non-hardware biologic press fit fixation with hardware, such as interference screws and/or cortical suspensors. The hardware may be more limited and less intrusive as it is not required to be the primary fixation.

[0150] Absorbable material could be polymer based as in polylactide (PLLA), polyglycolic acid (PGA), copolymers (PGA/PLA) poly paradiaxanone, and various stereoisomers of lactic acid, along with various bio-composite materials including a mix of polymers noted above plus calcium phosphate etc. Alternatively, absorbable material could be magnesium alloy based with similar functionality where the material absorbs over time (i.e. over three months).

[0151] The expansion of the tubes may occur passively over defined period of time or actively. Active expansion can be done by balloon expansion after implantation of the graft, similar to what is done with balloon expandable stents in vascular procedures, where inflation of a balloon within the tube expands the tube inside the graft to increase intra graft pressure on the graft/bone interface, without any contact of the tube (whether bio absorbable or synthetic) with the tendon/bone interface. This concept theoretically eliminates the current problem of screw breakdown and release of inflammatory cytokines associated with tunnel widening and poor graft healing. Active expansion can also occur by unsheathing the tube or pulling a rip cord immediately after implantation of the graft, which is also done in vascular procedures.

[0152] The system and methods above have been described in general terms as an aid to understanding details of preferred embodiments of the present invention. In the description herein, numerous specific details are provided, such as examples of components and/or methods, to provide a thorough understanding of embodiments of the present invention. Some features and benefits of the present invention are realized in such modes and are not required in every case. One skilled in the relevant art will recognize, however, that an embodiment of the invention can be practiced without one or more of the specific details, or with other apparatus, systems, assemblies, methods, components, materials, parts, and/or the like. In other instances, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention.

[0153] Reference throughout this specification to one embodiment, an embodiment, or a specific embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention and not necessarily in all embodiments. Thus, respective appearances of the phrases in one embodiment, in an embodiment, or in a specific embodiment in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any specific embodiment of the present invention may be combined in any suitable manner with one or more other embodiments. It is to be understood that other variations and modifications of the embodiments of the present invention described and illustrated herein are possible in light of the teachings herein and are to be considered as part of the spirit and scope of the present invention.

[0154] It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application.

[0155] Additionally, any signal arrows in the drawings/Figures should be considered only as exemplary, and not limiting, unless otherwise specifically noted. Combinations of components or steps will also be considered as being noted, where terminology is foreseen as rendering the ability to separate or combine is unclear.

[0156] The foregoing description of illustrated embodiments of the present invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed herein. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the present invention, as those skilled in the relevant art will recognize and appreciate. As indicated, these modifications may be made to the present invention in light of the foregoing description of illustrated embodiments of the present invention and are to be included within the spirit and scope of the present invention.

[0157] Thus, while the present invention has been described herein with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosures, and it will be appreciated that in some instances some features of embodiments of the invention will be employed without a corresponding use of other features without departing from the scope and spirit of the invention as set forth. Therefore, many modifications may be made to adapt a particular situation or material to the essential scope and spirit of the present invention. It is intended that the invention not be limited to the particular terms used in following claims and/or to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include any and all embodiments and equivalents falling within the scope of the appended claims. Thus, the scope of the invention is to be determined solely by the appended claims.