Bone removal device

Abstract

A bone removal device configured to increase efficiency of total ankle surgery by enabling removal of resected portion of tibia from a patient is disclosed. In particular, the bone removal device may enable a resected portion of a bone, such as, but not limited to, a tibia, to be pulled from the bone. The bone removal device may be configured to be used in total ankle surgery on a tibia, in carpectomies on hand or wrists, and other surgeries in which assistance removing a resected portion of bone would be beneficial. The bone removal device may include one or more filaments to remove the resected tibia from the tibia. The bone removal device may include a bone removal device body supporting one or more arms which, in an open position, enable the bone removal device to pull the resected portion of bone from the bone.

Description

INVENTORS Ryan C. Keefer Steven J. Idem Marls V. Prledhis GT Docket: 208356.013301 BONE REMOVAL DEVICE CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The patent application claims the benefit of United States Provisional Patent Application No. 63 / 623,161, filed January 19, 2024, which is incorporated by reference in its entirety. BACKGROUND

[0002] The disclosure relates to orthopedic devices, and more particularly, to medical devices usable to assist in removing bone material during total ankle surgery, carpectomies and the like.

[0003] In convention total ankle surgery, a portion of the tibia is resected using a saw to cut the tibia. The resected portion of the tibia is removed from the patient so that a tibial implant can be installed. The resected portion of the tibia is attached to soft tissue on the posterior side of the tibia and is very difficult to remove, in part, because the attached soft tissue is difficult to access. Removal of the resected portion of the bone, such as a portion of a tibia, is time consuming due to the soft tissue being difficult to access, which results in unnecessary time being spent trying to remove the resected portion from the tibia. SUMMARY

[0004] A bone removal device configured to increase efficiency of total ankle surgery by enabling mechanically assisted removal of a resected portion of a tibia from a patient is disclosed. In particular, the bone removal device may enable a resected portion of a bone, such as, but not limited to, a tibia, to be pulled from the bone. The bone removal device may be configured to be used in total ankle surgery on a tibia, in carpectomies on hand or wrists, and other surgeries in which assistance removing a resected portion of bone would be beneficial. In at least one embodiment, the bone removal device may include at least one filament, such as, but not limited to a suture, configured to be placed under tension to remove the resected portion of a bone from the bone. In another embodiment, the bone removal device may include a bone removal device body supporting one or more arms pivotably coupled to the body. The arms may be capable of being moved between a closed position against the body and an open position configured to bear against a surface of resected portion of a bone once the bone removal device has been inserted into position within a hole in the resected portion of the bone to enable the bone removal device to pull the resected portion of the bone from the bone.

[0005] In at least one embodiment, the bone removal device may include one or more filaments and one or more buttons coupled to the filament. The bone removal device may include a button insertion shaft configured to receive the button and to insert the button into a hole in a resection portion of a bone. The bone removal device may include one or more button removal devices configured to apply adjustable tension to the filament to enable a resected portion of the bone to be pulled from the bone. The button removal device configured to apply adjustable tension to the filament may be configured to apply adjustable tension to the filament while simultaneously applying pressure to the bone so that the filament, the button and the resected portion of the bone can be pulled from the bone.

[0006] In at least one embodiment, the button removal device may include one or more rotatable filament capture devices configured to secure the filament and retrieve the filament as the rotatable filament capture device is rotated. The rotatable filament capture device may include one or more removable filament capture supports configured to be threadably attached to one or more bone removal device support structures. The removable filament capture support may include a shaft with a threaded portion at one end and one or more rotatable filament tensioner receivers at another end configured to receive one or more rotatable filament tensioners. The rotatable filament tensioner may be a handle configured to be rotatable on the rotatable filament tensioner receiver thereby enabling the filament and attached button to be pulled from the bone.

[0007] In at least one embodiment, the rotatable filament capture device may include one or more rotatable filament tensioners positioned to be rotated about an axis nonparallel to a longitudinal axis of the hole in a resected portion of the bone. The rotatable filament tensioner may be positioned generally orthogonal to the longitudinal axis of the hole in a resected portion of the bone. In at least one embodiment, the rotatable filament tensioner may be a rotatable handle.

[0008] In at least one embodiment, the bone removal device may include one or more bone removal device bodies having an inner receiver and may include one or more arms rotatably mounted to the bone removal device body. The bone removal device may include one or more shafts positioned within the inner receiver and in mechanical communication with the arm whereby linear movement of the shaft in a first direction places the arm in a first position in which the arm is collapsed against the bone removal device body and linear movement of the shaft in a second direction, which is generally in a direction opposite to the first direction places the arm in a second position in which the arm extends at least partially radially outward from the bone removal device body. Pulling the shaft deploys the arm into an open position to grasp a resected portion of the bone to be pulled from the bone.

[0009] The bone removal device body may include an outer surface configured to fit inside the hole in the bone. The bone removal device body may include an outer surface having a cylindrical shape configured to fit inside the hole in the bone. The bone removal device body may include one or more arm receivers configured to receive the arm in a closed position. The arm and the arm receiver may be sized and configured such that when the arm is in the closed position, an outer surface of the arm is aligned with an outer surface of the bone removal device body or radially closer to a longitudinal axis of the bone removal device body than the outer surface of the arm so that the bone removal device body with arms can be inserted into a hole in a resected portion of a bone.

[0010] In at least one embodiment, the bone removal device may include a removable withdrawal system configured to enable the bone removal device body to be removably attached to a bone removal device support structure. The removable withdrawal system may include a threaded sleeve configured to receive the bone removal device body and permit the bone removal device body to move longitudinally relative to the sleeve. After the arms have been deployed into an open position, the sleeve can be rotated to bear against a guide plate and continued rotation of the sleeve causes the bone removal device body to be pulled away from the guide plate and bone.

[0011] In at least one embodiment, the arm of the bone removal device may be formed from two or more arms, such as one or more first arms and one or more second arms. One or more second arms may be pivotably coupled to the at least one bone removal device body. The first and second arms may be pivotably coupled to the bone removal device body. The first and second arms may be pivotably coupled to a distal end of the at least one bone removal device body. The first arm may be configured to be rotated into an open position extending radially from a longitudinal axis of the bone removal device body in a first direction and the second arm may be configured to be rotated into an open position extending radially from the longitudinal axis of the bone removal device body in a second direction. In at least one embodiment, the second direction may be opposite to the first direction.

[0012] An advantage of the bone removal device is that the device enables a resected portion of a bone to be removed quickly from a bone in a patient via a mechanical device configured to pull the resected portion of the bone from the bone, thereby eliminating wasted time found in conventional processes of removing the resected bone from soft tissue that is difficult to access during surgery.

[0013] Another advantage of the bone removal device is that the device enables a resected portion of a tibia to be removed quickly from a tibia in a patient via a mechanical device configured to pull the resected portion of the tibia from the tibia, thereby eliminating wasted time found in conventional processes of removing the resected tibia from soft tissue that is difficult to access during surgery.

[0014] Yet another advantage of the bone removal device is that the bone removal device only requires a single hole to be drilled into a resected portion of a tibia to then quickly remove the resected portion of the tibia from the tibia.

[0015] These and other embodiments are described in more detail below. BRIEF DESCRIPTION OF THE FIGURES

[0016] Figure 1 is a perspective view of the bone removal device attached to a tibia.

[0017] Figure 2 is another perspective view of the bone removal device attached to a tibia.

[0018] Figure 3 is yet another perspective view of the bone removal device attached to a tibia within a foot of a patient.

[0019] Figure 4 is an exploded view of a bone removal device support structure.

[0020] Figure 5 is a side view of a bone removal device support structure attached to a tibia.

[0021] Figure 6 is a side view of a bone removal device support structure attached to a tibia and a rotatable suture capture device attached to the bone removal device support structure.

[0022] Figure 7 is a perspective view of a tibia with a button and filament attached thereto.

[0023] Figure 8 is another perspective view of a tibia with a button and filament attached thereto.

[0024] Figure 9 is a side view of another embodiment of the bone removal device having a bone removal device body with arms in a closed position.

[0025] Figure 10 is a side view of the bone removal device body with arms between open and closed positions.

[0026] Figure 11 is a side view of the bone removal device body with arms in an open position.

[0027] Figure 12 is a perspective view of another embodiment of the bone removal device in a closed position.

[0028] Figure 13 is a perspective view of the embodiment of the bone removal device shown in Figure 12 in an open position.

[0029] Figure 14 is a perspective view of a resected portion of a tibia that has been removed from a tibia with a filament.

[0030] Figure 15 is a side view of a button insertion shaft. DETAILED DESCRIPTION OF THE FIGURES

[0031] As shown in Figures 1-15, a bone removal device 10 configured to increase efficiency of by enabling mechanically assisted removal of resected portion 12 of bone 14 from a patient is disclosed. In particular, the bone removal device 10 may enable a resected portion 12 of a bone 14, such as, but not limited to, a tibia, to be pulled from the bone 14. The bone removal device 10 may be configured to be used in total ankle surgery on a tibia, in carpectomies on hand or wrists, and other surgeries in which assistance removing a resected portion of bone would be beneficial. In at least one embodiment, the bone removal device 10 may include at least one filament 16, such as, but not limited to a suture 18, configured to be placed under tension to remove the resected portion 12 of a bone 14 from the bone 14. In another embodiment, the bone removal device 10 may include a bone removal device body 20 supporting one or more arms 22 pivotably coupled to the body 20. The arms 22 may be capable of being moved between a closed position 24 against the body 20 and an open position 26 configured to bear against a surface 28 of resected portion of a bone 14 to enable the bone removal device 10 to pull the resected portion 12 of the bone 14 of the bone 14 from the bone 14.

[0032] In at least one embodiment, as shown in Figures 1-6, the bone removal device 10 may include one or more filaments 16, such as, but not limited to a suture 18, configured to be placed under tension to remove the resected portion 12 of a bone 14 from the bone 14. In at least one embodiment, the filament 16 may have any appropriate length to function as described herein. The filament 26 may be formed from any material capable of withstanding the forces exerted thereon while removing resected portions 12 of a bone 14 from the bone 14.

[0033] The bone removal device 10 may include one or more buttons 30 coupled to the filament 16. The button 30 may have any appropriate shape and configuration. In at least one embodiment, the button 30 may have a generally oblong shape with a relatively thin flat profile. The button 30 should be sized to pass through a hole 36 drilled in a resected portion 12 of a bone 14 and sized so that when a filament 16 attached to the button 30 is pulled, the button 30 engages portions of the resected portion of a bone 14 and is not pulled back through the hole 36 in the resected portion of a bone 14. In such configuration, the button 30 may have dimensions along two axes orthogonal to each other that is less than a diameter of the hole 36 in the resected portion of a bone 14 and a dimension along a third axis orthogonal to both the first and second axes that is greater than the diameter of the hole 36 in the resected portion of a bone 14. As such, the button 30 can be placed in a first orientation and pushed through the hole 36. In a second orientation, the button 30 is prevented from being pulled through the hole 36. The button 30 may include one or more filament attachment systems 32 configured to removably attach the filament 16 to the button 30. In at least one embodiment, the filament attachment systems 32 may be one or more holes 34 positioned in the button 30 so that one or more filaments 16 can be attached to the button 30.

[0034] The bone removal device 10 may include a button insertion shaft 40, as shown in Figure 15, configured to receive the button 30 and insert the button 30 into a hole 36 in a bone 14. The button insertion shaft 40 may include any appropriate shape and configuration enabling the button insertion shaft 40 to be used to push the button 30 and portion of the filament 16 attached to the button through the hole 36 in the bone 14. The button insertion shaft 40 may have an outer diameter less than diameter of the hole 36 in the resected portion 12 of the bone 14. The button insertion shaft 40 may be formed from materials, such as, but not limited to, metal, such as, but not limited to, stainless steel.

[0035] The bone removal device 10 may include one or more button removal devices 42 configured to apply adjustable tension to the filament 16 to enable a resected portion 12 of the bone 14 to be pulled from the bone 14. The button removal device 42 may be configured to apply adjustable tension to the filament 16 while simultaneously applying pressure to the bone 14 so that the filament 16, the button 30 and the resected portion 12 of the bone 14 can be pulled from the bone 14. The button removal device 42 may include one or more rotatable filament capture devices 44 configured to secure the filament 16 and retrieve the filament 16 as the rotatable filament capture device 42 is rotated.

[0036] In at least one embodiment, as shown in Figure 6, the rotatable filament capture device 44 may include one or more removable filament capture supports 46 configured to be threadably attached to one or more bone removal device support structures 48. The removable filament capture support 46 may include a shaft 50 with a threaded portion 52 at one end 54 and one or more rotatable filament tensioner receivers 56 at another end 58 configured to receive at least one rotatable filament tensioner 60. In at least one embodiment, the least one rotatable filament tensioner 60 may be handle 62 configured to be rotatable on the rotatable filament tensioner receiver 56 thereby enabling the filament 16, attached button 30 and resected portion 12 of the bone 14 to be pulled from the bone 14.

[0037] In at least one embodiment, as shown in Figures 1 and 3, the rotatable filament capture device 44 may include one or more rotatable filament tensioners 60 positioned to be rotated about an axis 64 nonparallel to a longitudinal axis 66 of the hole 36 in the resected portion 12 of the bone 14. In at least one embodiment, the rotatable filament tensioner 60 may be positioned generally orthogonal to the longitudinal axis 66 of the hole 36 in the bone 14. In at least one embodiment, the rotatable filament tensioner 60 may be a rotatable handle 62.

[0038] The bone removal device support structure 48 may be configured to enable force to be applied to the bone 14, directly or indirectly, so that the filament 16 can be used to pull the resected portion 12 of the bone 14 from the bone 14. In at least one embodiment, the bone removal device support structure 48 may be a tube 70 with a guide plate 72. The tube 70 may have any appropriate shape, such as, but not limited to, square, rectangular, cylindrical and the like.

[0039] During use, the embodiment shown in Figures 1-8 may be used to pull a resected portion 12 of a bone 14 from the bone 14. Once the bone 14 has been cut to form the resected portion 12 of the bone 14, a hole 36 may be drilled into the resected portion 12 of the bone 14. In at least one embodiment, the hole 36 may extend completely through the resected portion 12 of the bone 14. The button insertion shaft 40 may be used to insert the button 30 and a portion of the filament 16 attached to the button 30 via the filament attachment system 32. The button insertion shaft 40 may be used to push the button 30 completely through the hole 36 in the resected portion 12 of the bone 14. The button insertion shaft 40 may be withdrawn, leaving the button 30 in position. The button insertion shaft 40 may be used to at least partially rotate the button 30 so that as the filament 16 is pulled toward the entrance opening 38 in the hole 36, the button 30 binds against the bone 14 so that the button 30 cannot be pulled back through the hole 36 and the entrance opening 38. A bone removal device support structure 48 may be positioned around the entrance opening 38. A removable filament capture support 46 may be threadably attached to the bone removal device support structure 48. A rotatable filament tensioner 60 may be attached to the removable filament capture support 46. The filament 16 may be attached to the rotatable filament tensioner 60. Depending on which embodiment is used, the rotatable filament tensioner 60 may be positioned in different positions. The rotatable filament tensioner 60 may be rotated to tighten the filament 16. The rotatable filament tensioner 60 may continue to be rotated to break the soft tissue attachment to the resected portion 12 of the bone 14 so that the resected portion 12 of the bone 14 is removed from the bone 14.

[0040] In another embodiment, as shown Figures 9-11, bone removal device 10 may include a bone removal device body 20 configured to be inserted into a hole 36 in a resected portion 12 of a bone 14 to retrieve the resected portion 12 from the bone 14. The bone removal device body 20 of the bone removal device 10 may support one or more arms 22 pivotably coupled to the body 20 and capable of being moved between a closed position 24, as shown in Figure 9, against the body 20 and an open position 26, as shown in Figure 11, configured to bear against a surface 28 of resected portion 12 of a bone 14 to enable the bone removal device 10 to pull the resected portion 12 of the bone 14 from the bone 14.

[0041] The bone removal device body 20 may have an inner receiver 80 configured to receive one or more shafts 82. The inner receiver 80 may have any shape configured to retain and guide the at least one shaft 82. The bone removal device body 20 may include one or more arms 22 rotatably mounted to the bone removal device body 20. The bone removal device 10 may include one or more shafts 82 positioned within the inner receiver 80 and in mechanical communication with one more arms 22 whereby linear movement in a first direction 84 places the arm 22 in a first position 86 in which the arm 22 is collapsed against the bone removal device body 20 and linear movement in a second direction 88 that is generally in a direction opposite to the first direction 84 places the arm 22 in a second position 89 in which the arm 22 extends at least partially radially outward from the bone removal device body 20. Pulling the shaft 82 deploys the arm 22 into an open position 26 to grasp a resected portion 12 of the bone 14 to be pulled from the bone 14.

[0042] The one or more arms 22 of the bone removal device 10 may be first arm 90 and second arm 92. The first and second arms 90, 92 may be pivotably coupled to the bone removal device body 20 such as to a distal end 94 of the bone removal device body 20 or other location. The first arm 90 may be configured to be rotated into an open position 26 extending radially from a longitudinal axis 96 of the bone removal device body 20 in a first direction 98, and the second arm 92 may be configured to be rotated into an open position 26, as shown in Figure 11, extending radially from the longitudinal axis 96 of the bone removal device body 20 in a second direction 100. In at least one embodiment, the second direction 100 may be opposite to the first direction 98. The second arm 92 may be pivotably coupled to the bone removal device body 20.

[0043] The bone removal device body 20 may include an outer surface 110 configured to fit inside the hole 12 in the resected portion 12 of the bone 14. The outer surface 110 may have a cylindrical shape configured to fit inside the hole 12 in the resected portion 12 of the bone 14. The bone removal device body 20 may include one or more arm receivers 112 configured to receive the arm 22 in a closed position 24, as shown in Figure 9. The arm 22 and the arm receiver 112 may be sized and configured such that when the arm 22 is in the closed position 24, an outer surface 114 of the arm 22 may be aligned with an outer surface 110 of the bone removal device body 20 or radially closer to a longitudinal axis 96 of the bone removal device body 20 than the outer surface 114 of the at least one arm 22.

[0044] As shown in Figures 12 and 13, the bone removal device 10 may also include a removable withdrawal system 116 configured to enable the bone removal device body 20 to be removably attached to a bone removal device support structure 48. The removable withdrawal system 116 may include a sleeve 120 configured to receive the bone removal device body 20 and permit the bone removal device body 20 to move longitudinally relative to the sleeve 120. In at least one embodiment, the sleeve 120 may be a cylindrical tube, a nut or the like. An inner surface 122 of the sleeve 120 may include threads 124 enabling the sleeve 120 to be threadably attached to the bone removal device body 20. The sleeve 120 may contact the guide plate 72 and be configured such that when the sleeve 120 is rotated and bears against the guide plate 72, the bone removal device body 20 is pulled away from the bone 14, thereby enabling the resected portion 12 of the bone 14 to be pulled from the bone 14 with the arms 22.

[0045] During use, the embodiments shown in Figures 9-13, may be used to pull a resected portion 12 of a bone 14 from the bone 14. The one or more arms 22 may be placed in a closed position 24 by moving the shaft 82 in the first direction 84, and the bone removal device body 20 inserted into the hole 36 in the resected portion 12 of a bone 14 until the arms 22 are completely through the hole 36 in the resection portion 12 of the bone 14. The one or more arms 22 may be moved into an open position 26, whereby a total width of the arms 22 from a distal end of a first arm 90 to a distal end of a second arm 92 is greater than a diameter of the hole 36 in the resected portion 36 of the bone 14. The shaft 82 may be pulled away from the bone 14 to break the soft tissue attachment to the resected portion 12 of the bone 14 so that the resected portion 12 of the bone 14 can be removed from the bone 14. The sleeve 120 may be attached to the bone removal device body 20. The sleeve 120 may be rotated such that the sleeve 120 contacts a guide plate 72 and pushes the bone removal device body 20 and the resected portion 12 of the bone 14 away from the bone 14 as the sleeve 120 is continued to be rotated.

[0046] The foregoing is provided for purposes of illustrating, explaining, and describing embodiments. Modifications and adaptations to these embodiments will be apparent to those skilled in the art.

Claims

1. A bone removal device, comprising:at least one filament;at least one button coupled to the at least one filament;at least one button insertion shaft configured to receive the at least one button and insert the at least one button into a hole in a bone; andat least one button removal device configured to apply adjustable tension to the at least one filament to enable a resected portion of the bone to be removed from the bone.

2. The bone removal device of claim 1, wherein the at least one button removal device configured to apply adjustable tension to the at least one filament is device configured to apply adjustable tension to the at least one filament while simultaneously applying pressure to the bone so that the at least one filament, the at least one button and the resected portion of the bone can be pulled from the bone.

3. The bone removal device of claim 1, wherein at least one button removal device comprises at least one rotatable filament capture device configured to secure the at least one filament and retrieve the at least one filament as the at least one rotatable filament capture device is rotated.

4. The bone removal device of claim 3, wherein the at least one rotatable filament capture device comprises at least one removable filament capture support configured to be threadably attached to at least one bone removal device support structure.

5. The bone removal device of claim 4, wherein the at least one removable filament capture support includes a shaft with a threaded portion at one end and at least one rotatable filament tensioner receiver at another end configured to receive at least one rotatable filament tensioner.

6. The bone removal device of claim 5, wherein the at least one rotatable filament tensioner is a handle configured to be rotatable on the at least one rotatable filament tensioner receiver thereby enabling the filament, attached at least one button, and resected bone portion to be pulled from the bone.

7. The bone removal device of claim 1, wherein the at least one rotatable filament capture device comprises at least one rotatable filament tensioner positioned to be rotated about an axis nonparallel to a longitudinal axis of the hole in the bone.

8. The bone removal device of claim 7, wherein the at least one rotatable filament tensioner is positioned generally orthogonal to the longitudinal axis of the hole in the bone.

9. The bone removal device of claim 7, wherein the at least one rotatable filament tensioner is a rotatable handle.

10. A bone removal device, comprising:at least one bone removal device body having an inner receiver;at least one arm rotatably mounted to the at least one bone removal device body;at least one shaft positioned within the inner receiver and in mechanical communication with the at least one arm whereby linear movement in a first direction places the at least one arm in a first position in which the at least one arm is collapsed against the at least one bone removal device body and linear movement15in a second direction that is generally in a direction opposite to the first direction places the at least one arm in a second position in which the arm extends at least partially radially outward from the at least one bone removal device body.

11. The bone removal device of claim 10, wherein the at least one bone removal device body comprises an outer surface configured to fit inside the hole in the bone.

12. The bone removal device of claim 11, wherein the at least one bone removal device body comprises an outer surface having a cylindrical shape configured to fit inside the hole in the bone.

13. The bone removal device of claim 10, wherein the at least one bone removal device body includes at least one arm receiver configured to receive the at least one arm in a closed position.

14. The bone removal device of claim 13, wherein the at least one arm and the at least one arm receiver are sized and configured such that when the at least one arm is in the closed position, an outer surface of the at least one arm is aligned with an outer surface of the at least one bone removal device body or radially closer to a longitudinal axis of the at least one bone removal device body than the outer surface of the at least one arm.

15. The bone removal device of claim 10, further comprising a removable withdrawal system configured to enable the at least one bone removal device body to be removably attached to a bone removal device support structure.

16. The bone removal device of claim 15, wherein the removable withdrawal system comprises a sleeve configured to receive the at least one boneremoval device body and permit the at least one bone removal device body to move longitudinally relative to the sleeve.

17. The bone removal device of claim 10, wherein the at least one arm comprises at least one first arm and at least one second arm.

18. The bone removal device of claim 17, wherein the at least one first and second arms are pivotably coupled to the at least one bone removal device body.

19. The bone removal device of claim 17, wherein the at least one first and second arms are pivotably coupled to a distal end of the at least one bone removal device body.

20. The bone removal device of claim 17, wherein the at least one first arm is configured to be rotated into an open position extending radially from a longitudinal axis of the at least one bone removal device body in a first direction and the at least one second arm is configured to be rotated into an open position extending radially from the longitudinal axis of the at least one bone removal device body in a second direction.

21. The bone removal device of claim 19, wherein the second direction is opposite to the first direction.

22. A tibial bone removal device, comprising:at least one filament;at least one button coupled to the at least one filament;at least one button insertion shaft configured to receive the button and insert the button into a hole in a tibia; andat least one button removal device configured to apply adjustable tension to the at least one filament to enable a resected portion of the tibia to be removed from the tibia.18

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