The present invention relates to an orthopedic surgical instrument, namely an improved orthopedic cutting block assembly.

In knee joint replacement surgery, a distal femoral component is placed upon the patient's distal femur. A cooperating tibial component is placed on the patient's proximal tibia. A common type

of femoral prosthesis is a generally "J" shaped prosthesis that

provides a curved articulating surface that can include one or two

condylar portions.

Many of these commercially available femoral components

have five flat surfaces on the rear or proximal side of the femoral

implant. In order to mount this type of implant on the patient's distal

femur, the surgeon must make five cuts on the distal femur that correspond to the five flat surfaces on the prosthesis. These five

cuts are known in the art as the distal femoral cut, the anterior and posterior cuts, and the anterior chamfer and posterior chamfer cuts.

Cutting blocks are presently commercially available that allow

the surgeon to make these five cuts. There are also cutting block systems that comprise two separate cutting blocks including the first

block for making the anterior and posterior cuts and a different block

that makes the diagonally extending anterior chamfer and posterior chamfer cuts.

Many cutting blocks for preparing a patient's bone tissue to

receive a knee prosthesis have been patented. The Whiteside Patent No. 4,474,177 provides a method and apparatus for preparing the distal surface of a femur to receive a distal femoral prosthesis employing an intramedullary reamer which is used to

internally locate the central long axis of the femur, an intramedullary alignment guide which is inserted into the space left in the intramedullary canal upon removal of the reamer and at least one femoral surface modifying instrument which cooperatively engages with a guide handle attached to the intramedullary alignment guide to accomplish the shaping of the distal femoral surface. The

intramedullary alignment guide has a rod portion extending into the femoral intramedullary canal whose central long axis corresponds with the central long axis of the femur. The guide handle is attached to that rod portion at a preselected angle such that the shaping

instruments fixed thereto assume the proper alignment with respect

to the central long axis of the femur such that the distal femoral surface is shaped relative to that axis in a simple and accurate manner.

A triplanar knee resection system for preparing a knee joint for a prosthesis is disclosed in U.S. Patent 4,487,203. The

apparatus includes a single guide member for use in resecting the distal femoral condyles, the proximal tibia, and the distal femur. The guide member cooperates with a simplified set of instruments, including femur and tibia guide rods, a tibia adaptor, a tibia bar, and

a femur bar, for establishing equal flexion and extension gaps and triplanar resections. The method of the triplanar knee system provides a simplified procedure for use by ann orthopedic surgeon in properly preparing a knee joint for implantation of a prosthesis.

A method and apparatus for resecting a distal femoral

surface is disclosed in U.S. Patent No. 4,703,751 in which an intramedullary rod is inserted through the distal surface of the femur and along the femoral shaft access, leaving a protruding end. A jig is attached to the protruding end, the jig having a shaft for receiving the rod end and a support plate attached to an end of the shaft and extending parallel to the rod, attaching a reference bar to the shaft. The bar provides a pair of opposing flanges and a central opening which receives the shaft therethrough. Adjusting the bar on the shaft is such that the flanges contact condylar apices of the femur

and fixing the jig relative to the femur. A cutting plate has blade guides thereon, pivoting the cutting plate relative to the jig such that the blade guides made a predetermined angle with the rod, securing

the cutting plate to the jig, and inserting a saw blade through the blade guides to make a resection of the distal femoral surface.

The Kaufman et al. Patent No. 4,721,104 relates to a surgical

apparatus for providing an accurately recess in a distal femoral

surface for the intercondylar stabilizing housing of a posterior-

stabilized knee implant prosthesis. The Russell et al. Patent No. 4,722,330 relates to distal femoral surface shaping guide for mounting on a intramedullary alignment guide which references the central long axis of the femur in shaping the distal femoral surface

and a method for shaping the distal femur using the shaping guide.

The Dunn et al. Patent No. 4,759,350 provides a system of instruments for shaping the distal femur and proximal tibia surfaces

to receive components of a knee prosthesis for knee replacement

surgery. The system references the femur intramedullary channel with a femoral alignment guide to prepare the distal femur that, in turn, is a reference for several cutting guides for sequential attachment to the femoral alignment guide and prepared bone

surfaces whereby the prepared distal femur is prepared to a flat

surface that is peφendicular to the patient's mechanical axis with

bone surfaces adjacent thereto sectioned to surfaces that are at right angles to that distal femur surface with chamfers therebetween to receive the femur component of a knee prosthesis.

U.S. Patent No. 4,773,407 issued to Petersen discloses a method and instruments for resection of the distal femur. The instruments include a distal femoral resector and a femoral alignment guide/rod. The distal femoral resector is designed to be

attached to the distal femur on a plane filed on the anterior femoral cortex. The distal femoral resector includes a feeler gauge laterally adjustable to adapt to the intercondylar notch of the particular patient and further includes a rotating rod having openings therethrough for fastening pins, which rotating rod is designed to facilitate the placement of the resector on the anterior femoral cortex in a flush manner. The femoral alignment guide/rod includes a plate insertable within a slot in the resector designed for the insertion of

the cutting tool and further includes a pivotable rod which may be utilized to align the resector with the mechanical axis of the leg. The rod may then be pivoted to a position facilitating the insertion of a fastening pin through the resector. The method of operation using these instruments is also disclosed.

U.S. Patent No. 4,892,093 issued to Zarnowski et al.

discloses a cutting guide for guiding a saw blade during the preparation of a femur for the implant of the femoral component of a knee prothesis includes guide surfaces for enabling the cutting of all four of the anterior femoral cut, the posterior femoral cut, the

anterior chamfer and the posterior chamfer, fully and completely, with certitude and accuracy, while the cutting guide remains located and secured to the femur in a single position on a transverse surface located along the distal femur.

The Whiteside et al. U.S. Patent No. 4,935,023 relates to a distal femoral surface shaping guide for mounting on an intramedullary alignment which references the central long axis of the femur in shaping the distal femoral surface and a method for shaping the distal femur using that shaping guide with particular applicability for shaping one condyle for attachment of a unicondylar prosthesis.

The present invention provides an improved orthopaedic cutting block apparatus which can be used for preparing a patients distal femur to receive a knee prosthesis.

According to the invention, a composite orthopaedic cutting block comprises a) a first block body having a triangular cross section defined by a flat surface that is adapted to engage the patient's bone and a pair of inclined surfaces that each form an angle with the flat surface, wherein the inclined surfaces define anterior and posterior chamfer cutting guide surfaces for making anterior chamfer and

posterior chamfer cuts on the patient's bone, and an apex portion at the intersection of said inclined surfaces; b) a second block body having a first surface and a second, opposed surface, opposed anterior and posterior surfaces and opposed medial and lateral surfaces, and an elongate slot extending between said medial and lateral surfaces and from said first surface towards said opposed second surface and communicating with said first surface, said slot being sized to allow at least a part of said first block body to fit into the slot such that said flat bone-engaging surface of said first blcok body is generally parallel with said first surface of said second block body; c) connection means for holding said first block body within said slot to define an assembled position. d) the assembly of the first block body and second block body having attachment means for anchoring the assembly of the first block body and the second block body to the patient's bone; e) the second block body having opposed, cutting guide surfaces that are each angled with respect to the first surface of the second block body; and f) the second block body forming a guard

over the first block body upon assembly.

A surgeon can track the inclined surfaces one at a time for making the anterior chamfer and the posterior chamfer cuts on the patient's distal femur. During a cutting of the femur with the first block, the flat distal surface of the first cutting block rests against the flat surface of the surgically prepared distal femur that has already

received a transverse distal cut.

A second blo Tbody provides an elongate slot that extends between the medial and lateral sides of the block. The second block

body can be of a rectangular prism shape, providing flat preferably

parallel first and second or proximal and distal planar surfaces, flat,

preferably parallel medial and lateral surfaces, and flat preferably parallel anterior and posterior surfaces.

The slot is an elongate slot that extends between the medial and

lateral surfaces and communicates with the flat first or lower surface. The slot preferably has a "T" shaped transverse cross sectional configuration providing a wider portion at said first surface and a narrower portion spaced from said first surface. Preferably the slot

includes at least one, preferably two, elongate edges facing into the

slot which define bearing points that bear against the inclined surfaces

of the first block body when the first block body is assembled into said slot.

A connector is provided for holding the first block body in the slot of the second block body to define an assembled position of the two blocks.

An anchor on the assembly of the first block body and the

second block body is provided for anchoring the assembly of the first and second block bodies to the patient's bone. In the preferred

embodiment, the anchor is in the form of a pair of spaced apart bone spikes that extend peφendicularly to the flat distal surfaces of the first

block body.

The anterior and posterior flat surfaces of the second block body preferably define opposed cutting guide surfaces that are each

generally peφendicular to the first surface of the second block body.

The surgeon may use these two opposed, anterior and posterior

surfaces for making anterior and posterior cuts on a patient's distal femur after the assembly of the first and second block bodies have been attached to the distal femur. During this cutting of the anterior

and posterior cuts, the second block is attached to and forms a guard

over the first block. This requires the surgeon to first make the anterior

and posterior cuts and only after the assembly of the first and second blocks is affixed to the patient's distal femur in a desired position.

Because the first and second blocks are attached to each other, orientation of the first block body is automatic when the two block bodies are attached to the patient's distal femur. Since the overall

assembly of the first and second block bodies properly orients the two

relative to one another, all cuts will be properly oriented. When the surgeon finishes making anterior and posterior cuts, the second block body can be removed exposing the first block body and its anterior and

posterior angled surfaces.

With the second block body removed, the surgeon has full view of the anterior and posterior chamfer cutting guide surfaces of the first block body and is assured that those surfaces are properly oriented

relative to the anterior and posterior cuts that were made using the second block body.

In the preferred embodiment, a knob with a threaded shaft

extends through an opening of the second block body and engages an

internally threaded opening of the first block body. The knife edges of

the elongated slot on the second block body in combination with the

threaded engagement of the shaft and internally threaded opening ensures a three point geometric contacting surface that always orients the first and second block bodies properly relative to one another.

For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed

description, of one embodiment of the invention, given by way of

example only, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein:

FIGURE 1 is a perspective exploded view of a preferred

embodiment of the apparatus of the present invention;

FIGURE 2 is an elevational view thereof; FIGURE 3 is a side view thereof;

FIGURE 4 is a top view of the first cutting block portion of the

preferred embodiment of the apparatus of the present invention;

FIGURE 5 is a bottom view of the second cutting block portion

of the preferred embodiment of the apparatus of the present invention; FIGURE 6 is perspective view of the preferred embodiment of the apparatus of the present invention;

FIGURE 7 is another perspective view of the preferred

embodiment of the apparatus of the present invention;

FIGURE 8 is a proximal view of the preferred embodiment of the apparatus of the present invention;

FIGURE 9 is a sectional view taken along lines 9-9 of Figure 8;

FIGURE 10 is a partial proximal view of the preferred

embodiment of the apparatus of the present invention illustrating the first cutting block portion thereof;

FIGURE 11 is a sectional view taken along lines 11-11 of Figure

10; and

FIGURE 12 is a sectional view taken along lines 12-12 of Figure 10.

Figures 1-3 and 7-9 show generally the preferred embodiment

of the apparatus of the present invention designated generally by the

numeral 10. Knee cutting instrument 10 includes a first cutting block 11 having a flat distal surface 12 that is to be positioned by the surgeon upon the flat surgically prepared distal femur after the surgeon has

formed a distal femoral cut. The knee cutting instrument 10 of the

present invention can be used to form anterior and posterior cuts and

the anterior and posterior chamfer cuts.

The assembly of knee cutting instrument 10 includes bone

spikes 13, 14 for attaching the knee cutting instrument 10 to the

patient's distal femur. In the preferred embodiment, the two bone spikes 13, 14 extend peφendicularly from the fiat distal surface of the first cutting block 11. The first cutting block 11 provides a pair of diagonally extending surfaces 15, 16 that each form an acute angle

with flat distal surface 12. The end portions of first cutting block 11 can

be angled as shown with end surfaces 17. The periphery of first cutting

block 11 includes edge portions 19, 20, 21, 22 as shown in Figures 1 and 4.

Diagonally extending surfaces 15, 16 intersect along apex 23. Slot 24 holds the first cutting block 11 when it attaches to second

cutting block 25 as shown in Figures 1 , 3 and 6-9. Slot 24 is sized and shaped to hold the first cutting block 11 so that the distal surface 12 of

first cutting block 11 is in the same plane 40 with the distal surface 27 of second cutting block 25. The slot 24 can be sized and shaped to place the first cutting block 11 in a position so that the distal surface 12 of the first cutting block 11 is nested within the slot 24 and slightly below the plane 40. The plane 40 is defined by distal surface 27 of

second cutting block 25. It is desired that the surface 12 rest upon on the prepared distal surface of the bone.

Second cutting block 25 has a flat proximal surface 26, a flat

distal surface 27, and flat anterior and posterior surfaces 28, 29. The

sides of second cutting block 25 define flat parallel medial and lateral surfaces 30, 31.

The first 11 and second 25 cutting blocks can be assembled using knob 32 and its attached threaded shaft 33. The user simply

rotates the knob 32 so that the shaft 33 rotates therewith. An internally threaded opening 18 on first cutting block 11 receives and engages shaft 33. The threaded opening 18 is a cylindrically shaped opening having a central axis that is peφendicular to the flat distal surface 12 of

first cutting 11. Slot 24 is defined by a plurality of flat surfaces 34,

35,36, 37 as shown in Figures 1 , 3 and 5.

In Figure 3, the slot 24 is generally 'T' shaped having a smaller

thickness slot portion defined by surfaces 34 and 35 and a larger thickness slot portion defined by surfaces 36 and 37. The intersection of surfaces 34 and 36 is defined by the opposed shaφ edge portions

38, 39. Upon assembly of first and second cutting blocks 11 , 25 the

diagonally extending surfaces 15, 16 engage the shaφ edges 38, 39 as shown in Figure 3.

Internally threaded opening 18 is centered in apex 23 as shown in Figure 4. Thus, a three point contact is defined between the block

11 and block 25 as shown in Figure 3. This three point attachment is

defined by the threaded engagement of shaft 33 and opening 18 as well as the engagement of the shaφ edges 38, 39 against the diagonally extending surfaces 15, 16. Upon assembly of first and second blocks 11 and 25, Figure 3 shows that a small gap is positioned

between the edges 19 and 20 of first cutting block 11 and the second

cutting block 25.

In Figures 10-12, block 11 can have a pair of diagonally

extending bores 41 that extend between surfaces 15 and 12. The

bores 41 can be angled relative to surface 16 (see Figure 12). The

15 bores 42 can be angled relative to surface 15 (see Figure 11). These

bores 41 , 42 enable the surgeon to attach a saw capture (not shown) to

the cutting block 11 at either surfaces 15 or 16. Angled openings 43

(see Figures 1 and 7) at end surfaces 17 can accept a bone spike.

The following table lists the parts numbers and parts

descriptions as used herein and in the drawings attached hereto.

Part Number Description

10 knee cutting instrument

11 first cutting block

12 flat distal surface

13 bone spike

14 bone spike

15 diagonally extending surface

16 diagonally extending surface

17 angled end surfaces

18 threaded opening

19 edge

20 edge

21 edge

22 edge

23 apex

24 slot

25 second cutting block

26 flat proximal surface

27 distal surface

28 anterior surface

29 posterior surface

30 medial surface

31 lateral surface

32 knob

33 threaded shaft

34 flat surface

35 flat surface

36 flat surface

37 flat surface

38 edge

39 edge

40 plane

41 bore

42 bore

43 opening