Conical end cap for intramedullary nail

Abstract

An end cap is provided comprising a head with a tool engagement portion and a shaft with a tip, wherein the shaft comprises a threaded conical portion starting from the tip and extending in a direction to the head. The thread may be provided with a constant pitch, i.e. with a constant distance between the turns of the thread.

Claims

1. An end cap for use with an intramedullary nail, comprising: a head portion with a tool engagement portion; a shaft with a longitudinal axis and a tip, wherein a thread with a constant pitch is provided on at least a portion of the shaft; wherein the threaded portion of the shaft comprises a first end adjacent the tip of the shaft, a first conical section, a second conical section and a second end, wherein the first conical section extends between the first end and the second conical section; and wherein the first conical section defines a first cone with a first angle between its cone surface and the longitudinal axis, the first conical section having a first thread turn and a second thread turn aligned with the first angle, and the second conical section defines a second cone with a second angle between its cone surface and the longitudinal axis, the second conical section having a third thread turn and a fourth thread turn aligned with the second angle, wherein the first angle differs from the second angle, wherein a first distance perpendicular to the longitudinal axis is defined between a major diameter of the first thread turn and a major diameter of the second thread turn of the first conical section and a second distance perpendicular to the longitudinal axis is defined between a major diameter of the third thread turn and a major diameter of the fourth thread turn of the second conical section, the first distance being less than the second distance.

2. The end cap of claim 1, wherein the first angle of the first conical section is smaller than the second angle of the second conical section.

3. The end cap of claim 1, wherein the threaded portion comprises a further section between the second conical section and the second end of the threaded portion, wherein the further section of the threaded portion is cylindrical.

4. The end cap of claim 1, wherein the threaded portion comprises a further section between the second conical section and the second end of the threaded portion, wherein the further section of the threaded portion defines a third cone with a third angle between its cone surface and the longitudinal axis, wherein the third angle differs from the first angle and differs from the second angle.

5. The end cap of claim 1, wherein the first angle is between 5 and 10 and the second angle is between 20 and 25.

6. The end cap of claim 1, wherein the thread has a maximal diameter adjacent to the head portion, which diameter corresponds to a nominal diameter of an inner thread of a bone nail.

7. The end cap of claim 1, wherein the shaft of the end cap further comprises a section without thread between the threaded portion and the head of the end cap, wherein the unthreaded section has a diameter being greater than a maximal diameter of the threaded portion.

8. The end cap of claim 1, wherein a diameter of the head portion is similar to a maximal diameter of the threaded portion.

9. The end cap of claim 1, wherein the tip has rounded edges.

10. The end cap of claim 1, wherein the tool engagement portion is an inner tool engagement portion.

11. The end cap of claim 1, further comprising a sub-portion having a circumferential section without thread formed in the threaded portion of the shaft, wherein the circumferential section has an outer diameter corresponding to a minor diameter of the thread and extends on at least a third of a circumference of the sub-portion.

12. A system comprising: an end cap of claim 1; and a bone nail with an inner thread for receiving the end cap.

13. The system of claim 12, further comprising a locking screw, wherein the bone nail further comprises a transverse bore for receiving the locking screw, wherein the end cap is configured to be in contact with the locking screw, when the locking screw is inserted in the transverse bore of the bone nail and when the end cap is inserted into the inner thread of the bone nail.

14. An end cap for use with an intramedullary nail comprising: a first end with a tool engagement structure and a second end; a first threaded conical section and a second threaded conical section extending between the first and second ends, the first conical threaded section adjacent the second end of the end cap and the second threaded conical section extending from the first threaded conical section towards the first end of the end cap, the first and second threaded conical sections having different cone angles with the cone angle of the first threaded conical section being less than the cone angle of the second threaded conical section, the first threaded conical section having at least two first thread turns aligned with the cone angle of the first threaded conical section, and the second threaded conical section having at least two second thread turns aligned with the cone angle of the second threaded conical section.

15. The end cap of claim 14 further comprising a third threaded section located between the second threaded conical section and the first end of the end cap, the third threaded section having a cylindrical thread.

16. The end cap of claim 14, wherein the threaded portion comprises a further section between the second conical section and the second end of the threaded portion, wherein the further section of the threaded portion defines a third cone with a third angle between its cone surface and the longitudinal axis, wherein the third angle differs from the first angle and differs from the second angle.

17. The end cap of claim 14, wherein the first angle is between 5 and 10 and the second angle is between 20 and 25.

18. The end cap of claim 14, further comprising a shaft having a section without thread between the threaded portion and the head of the end cap, wherein the unthreaded section has a diameter being greater than a maximal diameter of the threaded portion.

19. The end cap of claim 14, wherein a diameter of the head portion is similar to a maximal diameter of the threaded portion.

20. The end cap of claim 14, wherein the tool engagement portion is an inner tool engagement portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will now be detailed by way of exemplary embodiments with reference to the attached drawings.

(2) FIG. 1 shows an end cap according to the prior art;

(3) FIGS. 2a-2d show a sequence illustrating an introduction of the prior art end cap of FIG. 1 into a threaded trailing end of a bone nail;

(4) FIGS. 3a and 3b show an end cap according to a first embodiment;

(5) FIG. 4 is a section view of the end cap of FIGS. 3a, 3b including a detailed view of the thread;

(6) FIG. 4a is an enlarged view of detail A of FIG. 4;

(7) FIGS. 5a-5d show a sequence illustrating an introduction of an end cap of FIGS. 3a, 3b, 4 into a trailing end of a bone nail;

(8) FIGS. 6a and 6b show an end cap according to a second embodiment;

(9) FIG. 7 is a section view of the end cap of FIGS. 6a, 6b including a detailed view of the thread;

(10) FIG. 7a is an enlarged view of detail B of FIG. 7;

(11) FIGS. 8a-8d show a sequence illustrating an introduction of an end cap of FIGS. 6a, 6b, 7 into a trailing end of a bone nail;

(12) FIGS. 9a and 9b show an end cap according to a third embodiment;

(13) FIGS. 10a and 10b show an end cap according to a fourth embodiment; and

(14) FIG. 11 is an image of an end cap introduction during surgery.

(15) It is noted that the illustration in the drawings is only schematically and not to scale. Throughout the drawings, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components, or portions of the illustrated embodiments. Moreover, while the present invention as defined by the appended claims will now be described in detail with reference to the figures, it is done so in connection with the illustrative embodiments and is not limited by the particular embodiments illustrated in the figures.

DETAILED DESCRIPTION

(16) In FIGS. 3a and 3b, an end cap 200 according to a first embodiment is shown, with FIG. 3a being a view onto the tip 240 of the end cap 200, i.e. with a viewing direction from the bottom to the top of FIG. 3b.

(17) The end cap 200 comprises a head 210, a conical portion 220, a clearance groove 230 as well as a tip 240. In this embodiment, the conical portion 220 is completely formed with a thread at the outer surface thereof. As a transition between the clearance groove 230 and the head 210, a chamfer 232 is provided.

(18) As shown in FIG. 4, the head portion 210 of the end cap 200 comprises an inner tool engagement portion 212 as well as rounded edges 214. The conical portion may be described by an outer surface 222 which is inclined by an angle 224 relative to a longitudinally extending central axis 216 of the end cap 200. Threads 270 are cut into the outer surface 222.

(19) Detail A is an enlarged view of the threads 270. In this embodiment, the threads are cut into the outer surface 222 of the conical portion so as to form two flanks 272. Between the flanks 272, a bisecting line 274 can be defined which is orientated perpendicularly to the outer surface 222. The threads 270 comprise a pitch 276, i.e. a distance between two turns of the threads, which is constant over the length of the threads.

(20) An introduction of an end cap 200 into a trailing end of a bone nail 700 is illustrated by the sequence shown in FIGS. 5a-5d. Assuming that the end cap 200 will be initially inserted into the trailing end of the bone nail 700 in a tilted direction or orientation, as shown in FIG. 5a, the threads on the conical portion of the end cap 200 will engage an edge at the trailing end of the bone nail 700 and/or the first turns of the threads 710 within a bore 712 in the bone nail 700, as indicated by the circle denoted with Y. The conical thread 270 allows screwing in the end cap 200 into the inner threads 710, although the axis 216 of the end cap 200 is inclined relative to the central axis of the bore 712 of bone nail 700, as shown in FIG. 5c. The axis 216 of the end cap 200 will be aligned automatically with the axis of bore 712 of the bone nail 700 by the chamfer 232 provided beneath the head 210 of the end cap, as indicated by the circle denoted with Z in FIG. 5c. Finally, the axis 216 of the end cap will be aligned with the axis of the bore 712 and at least the turn of the outer thread with the maximum diameter will engage the inner threads 710 in the bone nail trailing end.

(21) As shown in FIG. 5d, the end cap 200 may have a length along axis 216 which corresponds to the distance between the trailing end and a first transverse through bore 720 in the bone nail 700. Therefore, the end cap 200 may be configured to be in contact with an outer surface of a locking screw (not shown), when the locking screw is inserted through the through bore 720 and the end cap is completely introduced into the trailing end of the bone nail 700, thus fixing the locking screw within the through bore.

(22) In FIGS. 6a and 6b, an end cap 300 according to a second embodiment is shown, with FIG. 6a being a view onto the tip 340 of the end cap 300.

(23) The end cap 300 comprises a head 310, a conical portion 320, a clearance groove 330 as well as a tip 340, with the conical portion 320 being completely formed with a thread at the outer surface thereof. The end cap 300 further comprises a sub-portion 350. The threads on the conical portion 320 continue over the sub-portion 350, wherein the sub-portion 350 is cylindrically formed, thus having threads with a constant diameter.

(24) Furthermore, the sub-portion includes a first circumferential section 360 without threads and a second circumferential section 362 with threads.

(25) As shown in FIG. 7 which is a section view along the section plane C-C as indicated in FIG. 6a, the head portion 310 of the end cap 300 comprises an inner tool engagement portion 312 as well as rounded edges 314. The conical portion may be described by an outer surface 322 which is inclined by an angle 324 relative to a longitudinally extending central axis 316 of the end cap 300.

(26) Threads 370 of the end cap 300 may be generated by firstly cutting threads continuously into the outer surface of the conical portion 320 and into the outer surface of the sub-portion 350, and then removing the threads in the first circumferential section 360 by reducing the outer diameter in this section.

(27) For example, the circumferential section 360 may form 50% of the circumference of the shaft portion and 80% to 100% of the threads may be removed in this section by machining, like for example by grinding or milling. When machining the threads, the shaft may be moved linearly from a side to a machining tool, may then be rotated for 180 about its axis, and may then be moved linearly again and sidewardly away from the machining tool. By way of such process, a circumferential section 360 with two opposite transition sections 364 may be formed, as shown in FIG. 6a, with the transition sections 364 forming a smooth transition from the first circumferential section 360 without threads to the second circumferential section 362 with threads.

(28) Detail B is an enlarged view of the threads 370. In this embodiment, the threads are cut into the outer surface 322 of the conical portion so as to form two flanks 372, between which a bisecting line 374 can be defined which is orientated perpendicularly to the axis 316 of the end cap 300. The threads 370 comprise a pitch 376 which is constant over the length of the threads.

(29) An introduction of an end cap 300 into a trailing end of a bone nail 700 is illustrated by the sequence shown in FIGS. 8a-8d. Also here, assuming that the end cap 300 will be initially inserted into the trailing end of the bone nail 700 in a tilted orientation, as shown in FIG. 8a, the threads 370 on the conical portion of the end cap 300 will engage at least an edge at the trailing end of the bone nail 700 and/or the first turns of the threads 710 within the bore 712 of bone nail 700. The conical thread 370 allows screwing in the end cap 300 into the inner threads 710, although the axis 316 of the end cap 300 is inclined relative to the axis of the bone nail 700, as shown in FIGS. 8b and 8c. The axis of the end cap 300 will be aligned automatically with the central axis of the bore 712 of the bone nail 700 when screwing in the end cap.

(30) As soon as the end cap 300 is completely introduced into the bone nail 700, the turns of the outer thread at the second circumferential section 362 of the sub-portion 350 will engage the inner threads 710 in the bone nail and the axis 316 of the end cap will finally be aligned with the central axis of bore 712 of the bone nail.

(31) As long as the end cap axis 316 is not aligned with the axis of the bone nail, while screwing in the end cap 300, the first circumferential section 360 without threads will prevent any clamping of the threads. With regard to end cap 200 or 300, the diameter of the threads 270, 370 at the conical portion of the end cap 200, 300 is smaller than the diameter of the inner threads 710 in the bone nail 700, and with regard to end cap 300, the thread 370 is provided in a cylindrical portion of the shaft only on one side, so as to avoid an asynchronic engagement of threads on opposite sides, i.e. to avoid for example an engagement of one turn of the outer thread into two different turns of the inner thread on opposite sides.

(32) In FIGS. 9a and 9b, an end cap 400 according to a third embodiment is shown, with FIG. 9a being a side view and FIG. 9b being a section view of the end cap 400.

(33) The end cap 400 comprises a length L, with four sections along the length of the end cap. The end cap comprises a threaded portion with a first conical section 420, a second conical section 460 and a cylindrical section 450. The end cap further comprises a section 410 without a thread. The thread of the threaded portion is formed as a continuous thread with a constant pitch over the first conical section, the second conical section and the cylindrical section at the outer surface of the end cap. As the threads continue over the cylindrical section, the threads have a constant diameter there.

(34) The first conical section 420 may be described by a cone which is inclined by an angle 424 relative to a longitudinally extending central axis 416 of the end cap 400. The second conical section 460 may be described by a cone which is inclined by an angle 464 relative to the longitudinal axis 416.

(35) As shown in FIG. 9b which is a section view along a centre plane of the end cap, the end cap 400 further comprises an inner tool engagement portion 412 as well as a through bore 414 in axial direction of the end cap. The diameter D of the unthreaded section 410 which may also be denoted as head portion is slightly greater than the maximal outer diameter of the thread in section 450 of the threaded portion.

(36) The length of the first conical section 420 may be between 0.35 L and 0.55 L, the length of the second conical section 460 may be between 0.05 L and 0.15 L, the length of the cylindrical section 450 may be between 0.1 L and 0.25 L, and the length of the head portion 410 may be the remainder of L.

(37) According to an example, the first conical section 420 may have a diameter of 5.5 mm at the tip of the end cap, a cone angle of 7.125, and a length of 6 mm, so that the diameter between the first and second conical sections may be 6.8 mm. The second conical section 460 may have a cone angle of 22.5 and a length of only 1.5 mm, with a maximal diameter at the transition to the cylindrical section of 8 mm. The length of the cylindrical section 450 may be 2.5 mm and the length of the unthreaded head portion 410 may be 3 mm. Consequently, the total length L of the end cap 400 according to this example may be 13 mm. Further, the thread may be a metric thread denoted as M8x1, wherein a skilled person will understand that the nominal diameter of the thread of 8 mm will be realized only on the cylindrical section 450, whereas the pitch is intended to be constant over the complete length of the threaded portion. The head portion 410 may have an outer diameter D of 8.2 mm.

(38) In FIGS. 10a and 10b, an end cap 500 according to a fourth embodiment is shown, with FIG. 10a being a side view and FIG. 10b being a section view of the end cap 500.

(39) The end cap 500 comprises a tip 540, a first conical section 520 with a first cone angle 524, a second conical section 560 with a second cone angle 564, a cylindrical section 550, an unthreaded section 530 as well as a head portion 510. The head portion includes a surface 518 which faces towards the threaded portion and which extends perpendicular to the longitudinal axis 516. The surface 518 will abut for example at an end face of a bone nail, when the end cap is inserted into the nail and engages an inner thread of the same.

(40) The end cap 500 according to the fourth embodiment can be seen as a combination of the previously described embodiments, with the threaded portion of the third embodiment and the head portion as well as the unthreaded portion of the second embodiment. The concrete form of the thread of end cap 500 may be as described above in connection with FIG. 4, detail A or FIG. 7, detail B. Furthermore, the end cap 500 may or may not have a clearance groove in the unthreaded section, but may preferably have a diameter in the unthreaded section 530 which is slightly larger than the outer diameter of the thread.

(41) In particular, the end cap 500 can be seen as an end cap 400 having additionally a head portion. Thus, the total length L of the end cap 500 may be 18 mm, i.e. a head portion with a length of 5 mm together with a 13 mm shaft like that described with respect to the end cap 400. The outer diameter H of the head portion 510 may be 13 mm.

(42) With respect to an introduction of an end cap according to both the third and fourth embodiment, it is referred to the description of FIGS. 5 and 8, respectively. The end cap may be inserted into a bore in an end of an intramedullary nail with a tilted orientation, and may nevertheless be easily screwed in. Upon engagement of the threaded and conical portion of the end cap with an inner thread in the bore in the nail, and upon rotation of the end cap, the end cap will automatically find its correct position and orientation within the end of the nail.

(43) FIG. 11 is an image showing circumstances under which a surgeon may insert an end cap 100, 200, 300, 400, 500 into a trailing end of a bone nail 600, 700. With the end cap at the end of the tool 800, the end cap 100, 200, 300, 400, 500 may be inserted into the trailing end of the bone nail, wherein only a small part of the bone as well as of the bone nail is visible so that the actual orientation of the axis of the bone nail cannot be seen. Furthermore, the insertion of the end cap 100, 200, 300, 400, 500 is difficult as the surrounding soft tissue provides less space to manipulate the tool 800. The invention proposes an end cap an insertion of which is facilitated.

(44) While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. The invention is not limited to the disclosed embodiments. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.

(45) In the claims, the word comprising does not exclude other elements, and the indefinite article a or an does not exclude a plurality.

(46) The mere fact that the certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.

(47) Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.

LIST OF REFERENCE SIGNS

(48) 100, 200, 300, 400, 500 end cap

(49) 110, 210, 310, 410, 510 head/head portion

(50) 212, 312, 412, 512 inner tool engagement portion

(51) 214, 314 rounded edges

(52) 414, 514 through bore

(53) 216, 316, 416, 516 centre axis

(54) 120, 220, 320, 420, 460, 520, 560 cone/conical portion/conical section

(55) 222, 322 outer surface

(56) 224, 324, 424, 464, 524, 564 cone angle

(57) 130 intermediate portion

(58) 131 clearance groove

(59) 132, 232, 332 shoulder, chamfer

(60) 240, 340, 440, 540 tip

(61) 150 threaded portion

(62) 350, 450, 550 cylindrical section, sub-portion

(63) 360 first circumferential section

(64) 362 second circumferential section

(65) 364 transition section

(66) 270, 370 threads

(67) 272, 372 flanks

(68) 274, 374 bisecting line

(69) 276, 376 pitch

(70) 600, 700 bone nail

(71) 610, 710 inner threads

(72) 712 longitudinal bore

(73) 720 through bore

(74) 800 tool