IMPLANT FOR RECONSTRUCTING AN ACETABULUM AND AT LEAST PART OF A PELVIC STRUCTURE

Abstract

The present invention provides an implant for reconstructing an acetabulum and at least part of a pelvic structure. To this end, the implant comprises a frame structure embodied by at least one first profile element for transferring joint forces, a joint section which forms at least part of an artificial acetabulum, at least two attachment sections for attaching the implant to bone tissue, wherein a first attachment section is provided for attachment to a sacral bone or iliac bone and a second attachment section is provided for attachment to a pubic bone, and at least one plate element for supporting internal organs, which is surrounded by the frame structure, at least in sections.

Claims

1. Implant for reconstructing an acetabulum and at least part of a pelvic structure, said implant comprising: a frame structure embodied by at least one first profile element for transferring joint forces, a joint section, which forms at least part of an artificial acetabulum, at least two attachment sections for attaching the implant to bone tissue, wherein a first attachment section is provided for attachment to a sacrum or ilium and a second attachment is provided for attachment to a pubis, and at least one plate element for supporting internal organs, which is surrounded by the frame structure at least in sections.

2. The implant according to claim 1, wherein the implant comprises a second frame structure embodied by at least one profile element to replace at least part of an ischium.

3. The implant according to claim 2, wherein the second frame structure further comprises a plate element and/or an attachment section.

4. The implant according to claim 1, in which at least one attachment section comprises, at least in sections, an osseointegrative bone contact surface, in particular a trabecular structure, and/or an osseoinductive bone contact surface.

5. The implant according to claim 1, in which the joint section comprises an approximately hemispherical recess, into which a universal socket with an articular surface can be inserted or which forms an articular surface.

6. The implant according to claim 1, in which at least one profile element, preferably all profile elements, is/are free from edges.

7. The implant according to claim 1, in which at least one profile element of the frame structure is configured as a hollow profile, at least in sections.

8. The implant according to claim 1, in which at least one attachment section is provided with at least one connecting element, in particular a through hole, for a fastening element.

9. The implant according to claim 1, in which at least one plate element abuts an attachment section and/or joint section, at least in sections.

10. The implant according to claim 1, in which substantially two curved profile elements are provided for transferring the joint forces from the joint section, wherein the profile elements are each connected at one end to an attachment element and, at the second end opposite this, to the joint section, the first and second end of each of the profile elements preferably pointing in opposite directions.

11. Method for manufacturing a patient-specific implant suitable for reconstructing a joint and at least part of an adjacent bone structure, said method comprising the steps: designing the implant with at least one attachment section for attaching the implant to bone tissue, at least one frame structure embodying at least one profile element, at least one plate element surrounded by the frame structure at least in sections, and at least one joint section forming at least a part of an artificial joint; preparing shape data of the implant designed in this manner; and manufacturing the implant based on the shape data.

12. The method according to claim 11, in which at least one profile element and/or plate element are bent three-dimensionally.

13. The method according to claim 11, in which the frame structure, the joint section and/or the at least one plate element are connected by means of a welded joint.

14. The method according to claim 11, in which at least one section of the implant is manufactured using an additive manufacturing process.

15. The method according to claim 11, in which a plate element, the joint section and/or the frame structure is/are surface treated at least in sections.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0054] In the accompanying drawings, which are referred to in the detailed description of currently preferred embodiments, elements that have the same function and/or design are designated by the same reference numerals. In the drawings:

[0055] FIG. 1 shows an oblique front view of an implant according to the invention integrated in a pelvic structure to replace part of a pelvic structure,

[0056] FIG. 2 shows a side view of a pelvic structure according to the invention from FIG. 1 seen from a patient's left side,

[0057] FIG. 3 shows a medial side view of a pelvic structure according to the invention; and

[0058] FIG. 4 shows a representative native pelvic structure from the front.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0059] FIG. 1 shows an implant according to the invention for a partial replacement of a pelvic structure including the acetabulum in the implanted state. More precisely, the exemplary embodiment of the implant shown in FIGS. 1 to 3 is replacing the ilium 2, the ischium 3, the pubis 4, the pubis symphysis 5 and, in particular, the acetabulum 6 (see FIG. 4). At one point the implant is connected to the patient's sacrum 1 by means of an attachment section 41 provided on the replacement ilium 2. However, depending upon the extent of the damaged or missing bone tissue, attachment of the attachment section 41 can also take place at a location on the ilium.

[0060] The implant in FIG. 1 is further connected at a second point by means of a further attachment section 42 to the pubis 4 of the opposite side of the pelvic structure to that being replaced. Equally, it is possible to attach the attachment section 42 for the pubis to the part of the pubis located on the side of the acetabulum being replaced. This retains the pubis symphysis and allows pliable and cushioned absorption of loads and vibrations in particular.

[0061] Depending upon the extent of tissue to be replaced, it can also be expedient to connect the attachment section 42 not to the pubis but instead to the ilium 2 or sacrum 1 on the opposite side of the pelvis to that being replaced. In such a case, both acetabula 6 are replaced accordingly.

[0062] As can be seen in FIG. 1, the acetabulum 6 or hip socket has been replaced by a joint section 10. This comprises an approximately hemispherical recess 12, which, as described above, is intended to receive a femoral head. In the illustrated case, the joint section 10 also comprises an approximately hemispherical shape on the opposite or outer side, so that the wall-thickness of the joint section 10 is more or less constant.

[0063] Connection of the joint section 10 to the attachment section 41 of the ilium replacement is achieved by means of the profile element 21 and connection of the joint section 10 to the attachment section 42, which, in the illustrated case, is connected to the patient's right pubic bone, is achieved by means of the profile element 22.

[0064] As illustrated in FIG. 1, the attachment section 42 comprises a connecting element 45, which, in the present exemplary embodiment, is configured as a through hole. The two through holes 45 provided in the illustrated attachment section 42 serve for fastening the implant by means of fastening elements, such as bone screws, pins, clamps or wires, for example. At least two connecting elements are generally preferredon the one hand to achieve a solid attachment and, on the other, to have an option during the operation for optimum fastening of the implant to bone tissue, should this be necessary. This ensures that a stable attachment of the implant to the patient's skeleton can be achieved at the time of the operation.

[0065] On the other side of the joint section, the attachment section 41 likewise comprises connecting elements 45 in the form of through holes (FIG. 2), with which a firm connection of the implant to the patient's sacrum is achieved during the surgical procedure (primary stability).

[0066] As can be seen in FIG. 3, the attachment section of the implant for the ilium 41 and/or the attachment section 42 for the pubis can comprise a surface 43 and/or 44 adapted to the respective bone geometry. The faces of the attachment sections 41 and 42 in contact with the bone tissue are preferably designed to be osseointegrative and/or osseoinductive. If this is the case, the implant is possibly also fastened to the connecting elements 45 by deposition or ingrowth of bone tissue, thereby achieving so-called secondary stability. This also applies to the case where the face of the attachment section 41 and/or 42 facing the bone tissue is not adapted to the surface of the adjacent bone tissue in a patient-specific manner but instead the surface of the patient's bone tissue is adapted to the relevant attachment section during a surgical procedure.

[0067] Diverging from the illustrated embodiment, at least one attachment section can also be provided to achieve an attachment to the bone tissue merely by bracing.

[0068] In addition to the profile elements 21 and 22, the implant shown in FIGS. 1 to 3 also comprises further profile elements 24a, 24b, 24c for ilium replacement, which, as described above, are preferably connected by means of welded joints.

[0069] It is also possible to replace some or all of these profile elements 24a, 24b, 24c by a single profile element, which is appropriately bent or deformed. As can be seen in FIGS. 1 and 2 in particular, the profile elements 24a, 24b, 24c are rounded at their connection points, so as to prevent any damage to surrounding tissue in their implanted state. Profile elements 24a, 24b, 24c substantially form the cranial external contour of the native ilium.

[0070] The ilium replacement further comprises a plate element 51, which is particularly intended to support the internal organs. In order to protect the patient's tissue from the circumferential edge of the plate element 51, said plate element is completely enclosed both by the frame structure 21, 24a, 24b, 24c and also by the joint section 10 and the attachment section 41.

[0071] Accordingly, the at least one profile element of the frame structure has a cross-section which is larger or thicker, at least in the dimension perpendicular to the plate element. Preferably, the thickness of a profile element along the at least one plate element is at least double, preferably at least five times and most preferably at least ten times the thickness of this plate element.

[0072] As can be seen from FIG. 2 in particular, the attachment section 41 is similarly configured as a plate element. However, with such a plate-like attachment section it is not necessary to surround it with profile elements as well, since the edges of the attachment section 41 are not free-standing edges. In other words, the edges of the attachment section 41 fit closely against the bone tissue, thereby preventing any danger to the internal organs. The edges of the attachment section 41 are preferably rounded.

[0073] In the implant illustrated in FIGS. 1 to 3, complete replacement 25 of the native ischium 3 is also envisaged. Here the ischium replacement 25 comprises the two profile elements 25a, 25b and a further plate element 52. By means of this extension, the exemplary embodiment of the implant comprehensively maintains the supporting function performed by the native pelvic structure (cf. FIG. 4), which is a considerable advantage.

[0074] Diverging from the illustrated embodiment of the implant, the plate element 52 can also be omitted or reconfigured for replacing the ischium 3, in particular in order to allow structures located in this region in the native pelvic structure to be led through or secured.

[0075] If the part of the native ischium 3 and pubis 4 replaced by the profile element 25b is to be retained (cf. FIG. 4), the part of the implant intended to replace the ischium can be provided with an additional attachment section (not illustrated).

[0076] If this type of bone replacement is necessary or in order to achieve an attachment to the bone tissue that is as stable as possible, it can be advantageous to replace the entire ischium and pubis of one side of the pelvic structure, as shown in FIG. 1.

[0077] It should also be noted that, as described above, the pelvic implant according to the invention is not only able to functionally replace the native pelvic structure or a part thereof but, in addition, is cheap to produce, especially by means of additive and/or adaptive manufacturing. After computer-assisted planning of a patient-specific implant according to the invention, subsequent manufacture can be almost completely automated. In this way it is possible to provide the implant quickly, cheaply and customized to the patient.

[0078] Depending upon the manufacturing technique used for the implant, the plate elements, profile elements and/or attachment sections can be at least partially preformed prior to assembly of the implant, thereby facilitating assembly of the individual components, particularly if welding is used.

[0079] However, it is particularly preferred to use an additive technique to manufacture the implant.

[0080] Electron Beam Melting (EBM) and Selective Laser Melting (SLM) are particularly suitable for this. In both methods, a metal powder for processing is applied to a base plate in a thin layer. The powdered material is then locally melted or irradiated by an electron beam or laser beam, forming a solid layer of material once it solidifies. The base plate is then lowered by one layer thickness and powder is reapplied. This cycle is repeated until all layers have been remelted.

[0081] It is also possible to use an additive process to produce a mould, which is then used to cast the implant. Similarly, the implant can be produced as a green body using an additive process and then sintered. The use of an additive process is especially advantageous in the context of the pelvic replacement, since the design freedom it offers in creating the structure means that stresses can be equally distributed and material load can be kept to a minimum. It is consequently possible to reduce the material strength. This is particularly true in the case of the EBM and SLM techniques, since neither method requires the removal of casting cores, there is no need to consider material creep behaviour in designing the replacements and, moreover, it is possible to create sealed cavities, for example. Moreover, these techniques produce the end product straightaway instead of an intermediate product, from which the end product then has to be made.

[0082] Furthermore, as already described above, the surface of the at least one plate element, the frame structure and/or the joint section can be specially treated, at least in sections, in order to facilitate connection of the surrounding soft tissue or connective tissue with the implant and thereby further improve the supporting function, particularly of the ilium replacement.

[0083] Where there is a plate element 52 in the region of the ischium replacement, it can be advantageous if this only fills in the border formed by the profile elements 25a, 25b, 22 and the joint section 10 in sections, in order to facilitate the attachment of musculature, tendons and/or ligaments.

REFERENCE NUMERALS

[0084] 1 Sacrum (os sacrum) [0085] 2 Ilium (os ilium) [0086] 3 Ischium (os ischii) [0087] 4 Pubis (os pubis) [0088] 5 Pubis symphysis (symphysis pubis) [0089] 6 Acetabulum [0090] 7 Foramen obturatum [0091] 8 Coccyx (os coccygis) [0092] 10 Joint section [0093] 12 Joint recess [0094] 20 First frame structure [0095] 21 Profile element between joint and sacrum/ilium attachment section [0096] 22 Profile element between joint and pubis attachment section [0097] 24a, 24b, 24c Profiles for the ilium [0098] 25 Second frame structure [0099] 25a, 25b Ischium profiles [0100] 41 Attachment section to the sacrum/ilium [0101] 42 Attachment section to the pubis [0102] 43, 44 Bone contact surface [0103] 45 Connecting element for fastening element [0104] 51 Plate element for replacing the ilium [0105] 52 Plate element for at least partially closing the ischium