Prosthetic penile implants with tethered rear tip extenders and related methods

Abstract

Rear tip extenders having a tether attached to a collar for penile implants that can be mounted onto a respective cylinder forward of a fluid line (that communicates with a scrotal pump) to prevent full separation or detachment from the cylinder during a revision procedure can be fabricated by molding. The fabrication methods include: providing a mold with a mold cavity configured to define three attached members of defined shapes, including a rear tip extender, a collar and a tether attaching the rear tip extender and collar; and flowably introducing moldable material into the mold cavity to form the collar, rear tip extender and attached tether as a molded assembly.

Claims

1. A method of fabricating a penile implant, comprising: providing a mold with a mold cavity configured to define three attached members of defined shapes, including a rear tip extender, a collar and a tether attaching the rear tip extender and collar; and flowably introducing moldable material into the mold cavity to form the collar, rear tip extender and attached tether as a molded assembly.

2. The method of claim 1, further comprising sterilizing the molded assembly for medical use.

3. The method of claim 1, wherein the rear tip extender is sized and configured to attach to an end portion of an elongate cylinder of a penile prosthesis implant, wherein the collar is sized and configured to reside against an outer surface of the cylinder, and wherein the collar is sized to be loosely held on the cylinder with an inner diameter that is between 10-50% greater than an outer diameter of the cylinder and/or is configured to expand when the cylinder expands due to inflation.

4. The method of claim 1, wherein the rear tip extender comprises a rear tip cap with a closed end.

5. The method of claim 1, wherein the moldable material comprises silicone rubber.

6. The method of claim 1, wherein the collar comprises at least one arcuate recess.

7. The method of claim 1, wherein the collar comprises a plurality of circumferentially spaced apart arcuate recesses.

8. The Method of claim 1, wherein the providing the mold is a first mold to form a first molded assembly with the collar, rear tip extender and attached tether, and wherein the method further comprises: providing a second mold with a mold cavity configured to define three attached members of defined shapes, including a rear tip extender, a collar and a tether attaching the rear tip extender and collar; and flowably introducing moldable material into the mold cavity of the second mold to form the collar, rear tip extender and attached tether as a seconded molded assembly, wherein the rear tip extender of the second molded assembly has a shorter or longer length than the rear tip extender of the first molded assembly.

9. The method of claim 8, wherein the collar, tether and/or rear tip extender of the second molded assembly has a different color than the collar, tether and/or rear tip extender of the first molded assembly.

10. The method of claim 1, wherein the tether is a single tether.

11. The method of claim 1, wherein the tether has a width that is between about 0.001 inches to about 0.1 inches.

12. The method of claim 1, wherein the collar is between about 0.1 inches to about 0.5 inches in axial length.

13. The method of claim 1, wherein the tether has a length between about 0.5 inches to about 10 inches.

14. The method of claim 1, wherein the tether has a length between about 0.5 inches to about 5 inches and a width between about 0.001 inches to about 0.1 inches.

15. The method of claim 1, further comprising providing at least one core rod to cooperate with the mold cavity, the at least one core rod shaped to form the collar to have at least one arcuate recess.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a top perspective view of an exemplary three-piece prior art prosthetic implant.

(2) FIG. 2 is a side perspective view of an exemplary two-piece prior art prosthetic implant.

(3) FIG. 3 is a side view of a cylinder with a RTE assembly for a penile implant according to embodiments of the invention.

(4) FIG. 4 is a top view of the device shown in FIG. 3.

(5) FIG. 5 is a side perspective view of the device shown in FIG. 3.

(6) FIG. 6 is an end view of the device shown in FIG. 3.

(7) FIG. 7A is an enlarged view of a cylinder illustrating an exemplary assembly procedure for a collar with tether attachment and RTE according to embodiments of the present invention.

(8) FIG. 7B is an enlarged front perspective view of the device shown in FIG. 3 according to embodiments of the present invention.

(9) FIG. 7C is a partial side perspective schematic illustration of an alternate embodiment of the collar and tether according to embodiments of the present invention.

(10) FIG. 7D illustrates the collar and tether embodiment shown in FIG. 7C separate from the implant cylinder.

(11) FIG. 8 is an enlarged rear side perspective view of the device shown in FIG. 1 illustrating a two-piece snap fit collar construction according to embodiments of the present invention.

(12) FIG. 9A is a schematic side perspective view of an alternate RTE assembly according to embodiments of the present invention.

(13) FIG. 9B is a schematic illustration to show that two RTE assemblies can be used together according to embodiments of the present invention.

(14) FIG. 10 is a side perspective view of another RTE/collar/tether embodiment according to embodiments of the present invention.

(15) FIG. 11 is a side schematic view of a kit of RTE assemblies according to embodiments of the present invention.

(16) FIG. 12 is a flow chart of exemplary operations or actions that can be carried out to assemble an RTE assembly according to embodiments of the present invention.

(17) FIG. 13 is a flow chart of an exemplary fabrication process for an RTE assembly according to embodiments of the present invention.

(18) FIG. 14A is a schematic perspective view of an exemplary mold for an integral RTE assembly according to embodiments of the present invention.

(19) FIG. 14B is a schematic perspective view of an exemplary set of core rods that may be used to form a tethered RTE according to embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(20) The present invention will now be described more fully hereinafter with reference to the accompanying figures, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like numbers refer to like elements throughout. In the figures, certain layers, components or features may be exaggerated for clarity, and broken lines illustrate optional features or operations unless specified otherwise. In addition, the sequence of operations (or steps) is not limited to the order presented in the figures and/or claims unless specifically indicated otherwise. In the drawings, the thickness of lines, layers, features, components and/or regions may be exaggerated for clarity and broken lines illustrate optional features or operations, unless specified otherwise.

(21) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms, “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including” when used in this specification, specify the presence of stated features, regions, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, steps, operations, elements, components, and/or groups thereof.

(22) It will be understood that when a feature, such as a layer, region or substrate, is referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when an element is referred to as being “directly on” another feature or element, there are no intervening elements present. It will also be understood that, when a feature or element is referred to as being “connected”, “attached” or “coupled” to another feature or element, it can be directly connected, attached or coupled to the other element or intervening elements may be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached” or “directly coupled” to another element, there are no intervening elements present. Although described or shown with respect to one embodiment, the features so described or shown can apply to other embodiments. The term “distal” refers to a direction or location that is closer to or toward a patient while the term “proximal” refers to the opposing direction or a location that is further away from the patient.

(23) 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 invention 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 present application and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

(24) The term “tether” refers to a flexible or semi-rigid member that extends between and attaches two separate components.

(25) The term “about” means that the recited number or value can vary by +/−20%.

(26) The term “sterile” means that the noted device or material meets or exceeds defined medical guidelines of cleanliness and is substantially (if not totally) without contaminants so as to be suitable for medical uses.

(27) The term “semi-rigid” means that the implant is flexible but has sufficient rigidity to substantially maintain its three-dimensional shape under normal loading in the body.

(28) The term “instructional media” refers to electronic and/or paper manuals, videos, user guides, or the like illustrating and/or describing pre-surgical assembly steps and/or a surgical procedure using the tethered penile implant.

(29) Referring now to the figures, FIGS. 3-6 illustrate a cylinder 20 of an inflatable penile implant 10 (FIG. 1, 2) according to embodiments of the present invention. The cylinder 20 has longitudinally opposing front (forward) and rear end portions 20f, 20r. As shown, a collar 60 resides on the cylinder 20 on the rear end portion 20r proximate a fluid junction 40j at which junction the flexible tube or conduit 40 extends to connect the scrotal pump 50 (FIGS. 1, 2). The collar 60 includes at least one attached tether 70 that is also attached to the rear extender tip 25. The tether 70 can be a single longitudinally extending tether or may be a plurality of longitudinally extending, circumferentially spaced apart tethers (not shown).

(30) The tether 70 is typically attached to or integrally formed onto a wall or the outer surfaces of both the collar 60 and the RTE 25. Although shown in most embodiments as a single tether, more than one tether may be used.

(31) The tether 70 can comprise a thread, strap, suture, wire or other elongate member. The tether 70 can be flexible. The tether 70 can be semi-rigid. The tether 70 can be an integrally molded component of the collar 60.

(32) The collar 60 can be a unitary monolithic component of suitable medical grade material. The collar 60 can comprise silicone rubber or other medical grade suitable elastomeric or polymeric material. The collar 60 can also comprise a biocompatible, non-cytotoxic metal or ceramic. The collar 60 can comprise a combination of materials.

(33) The collar 60 can include at least one arcuate recess 61 (FIGS. 7A, 8). The arcuate recess 61 can be aligned to abut the fluid junction 40j so that the conduit junction or conduit extension 40 resides therein (FIG. 9). The recess 61 can receive the extension 40j which may angle out of the cylinder 20 at about 45 degrees or other angles (FIG. 3).

(34) The collar 60 can be provided in different sizes for different sizes of cylinders 20. The collar 60 can optionally abut the outer surface of the cylinder 20 at the rear end portion 20r or may reside loosely against the outer surface of the cylinder 20 (e.g., so as to not contact at least a portion of the outer wall of the cylinder thereat). The collar 60 can have any suitable axial length and any suitable cross-sectional width and is not required to matably correspond to the cylinder outer diameter. The collar 60 can be between about 0.1 inches to about 0.5 inches in axial length but other lengths may also be suitable.

(35) In some embodiments, the collar 60 can have an axially extending centerline 60c that is concentric with an axially extending centerline 20c of the cylinder 20 as shown in FIGS. 1-6, for example.

(36) In some embodiments, as shown in FIG. 7C, the collar 60 can have a transversely extending centerline 60t that angles away from the outer wall of the cylinder so that the centerlines 20c, 60t are offset from each other, typically between about 10 degrees to about 75 degrees in either a forward or rearward tilt orientation (shown in FIGS. 7C and 7D as in a rearward tilt orientation).

(37) The collar 60 can be configured to be able to expand in response to inflation/expansion of the cylinders 20 so as not to provide undue compression on the cylinder when in an expanded configuration. The collar 60 can have an accordion, undulated or pleated segment or segments to facilitate expansion and/or may be formed of a resilient, flexible and/or otherwise expandable material.

(38) In some embodiments, the collar 60 can reside loosely against the outer wall of the cylinder and is not required to expand with the expansion of the cylinder 20. The collar 60 can have an inner wall with a cross-sectional width that is 10-50% larger than an outer diameter of the cylinder 20.

(39) The collar 60 can be in the shape of a disk (e.g., with a substantially circular opening). The collar 60 can be in other shapes not requiring a circular opening or circular external outer Wall shape. The collar 60 can have any closed geometric shape, e.g., oval, polygonal, triangular and the like.

(40) The tether 70 can have the same material as the collar 60 or the RTE 25 or may comprise a different material. The tether 70 has a length sufficient to extend from at least a front end portion of the RTE 25 to the collar 60; typically, the tether 70 has a length between about 0.5 inches to about 10 inches, typically between about 0.5 inches to about 5 inches. The tether 70 can be longer as it can reside in local tissue and when pulled, it pulls the RTE along with the collar upon a revision or other surgery to provide a positive retention of the two components.

(41) As shown in FIG. 3, for example, the tether 70 can be thin. The tether 70 can have a small width, such as a width that is between about 0.001 inches to about 0.1 inches. In other embodiments, the tether 70 can have a greater width, but if so, the width is typically less than about 40% of the circumference, e.g., between about 1% to about 40% of the circumference. The tether 70 can be configured to reside closely spaced to the body of the cylinder 20 when the RTE 25 and collar 60 are in position on the cylinder 60.

(42) The RTE 25 can be a rear tip end cap (with a closed end tip) as shown in FIGS. 3-6.

(43) In some embodiments, the collar 60, tether 70 and RTE 25 can be provided pre-assembled as an assembly 25a and provided in a kit 100 of different sizes of RTEs 25 (FIG. 11). The surgeon or other clinician can select an appropriate assembly 25a for use when sizing the patient's anatomical requirements. An assembly 25a can be attached to each respective cylinder 20 prior to placement in a patient.

(44) In some embodiments, the tether 70 is moldably attached to the collar 60 and RTE 25. In some embodiments, the tether 70 is adhesively attached to the respective collar 60 and/or RTE 70. In some embodiments, the collar 60 is mechanically fastened to the tether 70 and/or RTE 70 using, for example, hooks, VELCRO (e.g., loop and hook), or mechanical slide and channel, tongue and groove, rivets, pins or clamp attachment configurations.

(45) In some embodiments, the assembly 25a includes a single RTE 25 and tether 70 attached to a respective collar 60 as shown, for example, in FIG. 11. In other embodiments, as shown in FIG. 9A, the subassembly 25a′ can include the collar 60 attached to two or more RTEs, including a medial and end cap RTE 25m, 25c, using two or more tethers 70.sub.1, 70.sub.2. In some embodiments, as shown in FIG. 9B, two RTE assemblies 25a with respective at least one tether and collar can be used on a single cylinder 20. The collars 60.sub.1, 60.sub.2 can reside in abutting contact and the respective tethers 70.sub.1, 70.sub.1 can attach to different RTEs 75 (shown as 25m and 25c, for example).

(46) FIG. 7A illustrates a sequence of steps that can be used to position the assembly 25a onto the cylinder 20. As shown, first (1) the assembly 25a is aligned with the cylinder so that the collar 60 slides onto the tapered forward end of the cylinder. Next (2), the collar 60 (with the RTE 25 attached and able to be move side to side relative to the cylinder while attached to the tether 70) is slid back to reside adjacent the fluid line junction 40j. Then (3) the RTE 25 can be attached to the rear end of the cylinder 20. The RTE 25 is then tethered to the collar 60 and the fluid junction provides a hard “stop” so that the RTE 25 remains attached to the collar 60 even if it becomes detached from the cylinder end.

(47) FIG. 7B illustrates position (3), the use/implant configuration. FIG. 7B also illustrates the arcuate recesses 61 and the integral (moldably attached) configuration of the tether 70 to the collar 60 and/or the RTE 25.

(48) FIGS. 7C and 7D illustrate a hoop-like collar 60 that can reside at an oblique angle with respect to the cylinder 20. As shown, a line drawn through a centerline 60t of the collar 60 can intersect the axial centerline 20c of the cylinder 20 typically at an angle α that is between about 10-75 degrees. The centerline 60t can be described as a transversely extending centerline as it is in a width dimension of the collar. This configuration may allow expansion of the cylinder 20 without exertion of compression onto the cylinder when in an expanded configuration.

(49) FIG. 8 illustrates an alternate embodiment where the collar 60 is a two-piece collar 60a, 60b with two (substantially) circumferentially extending segments that can be attached about the cylinder 20 after it is in position proximate the fluid junction 40j to avoid the step of sliding the collar over the cylinder 20. The attachment can be a bayonet fit, snap-fit or other mechanical fastening configuration. Adhesive may be used but is not preferred.

(50) As the RTEs 25 can be provided in different lengths, the collars 60 or tethers 70 (or both) can be color-coded to represent a length of the RTE for facilitating physician size selection.

(51) FIG. 10 illustrates that the tether 70′ can be attached to the collar 60 and/or RTE 25 after the RTE size is selected, e.g., the devices can be provided as separate components that can be assembled by a clinician prior to implantation of the device. The tether 70′ can be attached to attachment members on the respective collar 60 and RTE 25. In some embodiments, the tether 70′, collar 60 and RTE 25 are all provided as separate components and the tether 70′ is attached in situ. In some embodiments, the collar and tether 60, 70 are provided as an assembly that is attached to the RTE 25 when the RTE size is selected for a patient. In some embodiments, the tether 70′ and RTE 25 are provided as an assembly that is then attached to the collar 60 proximate to or during a surgical preparation or the actual surgery, typically after the collar 60 is in position on the cylinder 20.

(52) FIG. 12 is a flow chart of exemplary operations that can be used to carry out embodiments of the present invention: The method can include: providing a penile implant with elongate cylinders (block 225); placing a collar onto a front end of respective cylinders (block 230); sliding the collars over the respective cylinder to place the collar proximate a fluid junction at a rear end portion of the respective cylinder (block 240); then, placing a rear tip extender onto the rear end portion of the cylinder thereby tethering the rear tip extender to the cylinder (block 245).

(53) The method may optionally include providing a plurality of collars, each attached to a different length rear tip extender (block 227). The collars can be color-coded to designate a particular length rear tip extender (block 228).

(54) The placing steps can be carried out at a surgical site prior to implanting the cylinder in a patient (block 247).

(55) FIG. 13 is a flow chart of exemplary steps of fabrication methods for fabricating an RTE assembly according to embodiments of the present invention. A mold is provided, the mold having a mold cavity defining a rear tip extender, collar and tether attaching the rear tip extender and collar (block 270). Moldable material is introduced into the mold cavity (block 275). A rear tip extender, collar and tether are formed as an integral (molded) assembly (block 280).

(56) The mold shape for the collar can include arcuate regions that form longitudinally extending arcuate recesses in the collar (block 272). The moldable material can include (or be made totally of) silicone rubber (block 277).

(57) The method can include sterilizing the assembly for medical use (block 282).

(58) FIG. 14A is a schematic illustration of a mold 300 that has a mold cavity 301 with a cavity shape and internal mold members 320, 321, 325 that form an integral RTE 25, collar 60 and tether 70 attached to both according to embodiments of the present invention. The mold 300 can be for injection molding or blow molding, for example. FIG. 14B illustrates cooperating core rods 325r, 326 with shapes that can form the collar with arcuate recess according to some embodiments of the present invention.

(59) The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. In the claims, means-plus-function clauses, if used, are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.