# US 11,992,941 B2 · High accuracy molded navigation arrays, systems, and methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,992,941 B2 - Document ID: US11992941B2 - Status: Granted - Kind: B2 - Application number: 17/542,936 - Filed: 2021-12-06 - Published: 2022-06-16 - Granted: 2024-05-28 - Earliest claimed: 2020-12-11 - Assignees: Depuy Ireland Unlimited Company - Applicants: DePuy Ireland Unlimited Company - Inventors: Hervé Collet - Web page: https://patentgrep.com/patent/US11992941B2 ## CPC - A61B 90/39: {Markers, e.g. radio-opaque or breast lesions markers} - B25J 19/023: {including video camera means} - B25J 5/007: {mounted on wheels} - B25J 11/008: {Manipulators for service tasks} - B25J 19/04: Viewing devices - A61B 34/30: Surgical robots - A61B 2017/00526: {Methods of manufacturing} - A61B 2034/2055: {Optical tracking systems} - A61B 2034/2059: {Mechanical position encoders} - A61B 2034/2068: {using pointers, e.g. pointers having reference marks for determining coordinates of body points} - A61B 2090/3983: {Reference marker arrangements for use with image guided surgery} - A61B: DIAGNOSIS; SURGERY; IDENTIFICATION (usefulness limited to only animals A61D) - B25J: MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES ({manipulators specially adapted for use in surgery A61B34/70; manipulators used in cleaning hollow articles B08B9/04}; manipulators associated with rolling mills B21B39/20; manipulators associated with forging machines B21J13/10; {manipulators associated with picking-up and placing mechanisms B23P19/007}; means for holding wheels or parts thereof B60B30/00; {vehicles with ground-engaging propulsion means, e.g. walking members B62D57/02, B62D57/032; devices for picking-up and depositing articles or materials between conveyors B65G47/90, B65G47/91; manipulators with gripping or holding means for transferring packages B65H67/065}; cranes B66C; {manipulators used in the protection or supervision of pipe-line installations F17D5/00; walking equipment adapted for nuclear steam-generators F22B37/006}; manipulators specially adapted for, or associated with, nuclear reactors G21C; {apparatus used for handling wafers during manufacture or treatment of semiconductor H10P72/50}) ## Abstract Systems, methods, and devices are described for high accuracy molded navigation arrays. In a first embodiment, a navigation array is formed by molding, as a single component, an array having a plurality of marker regions. The marker regions include a reflective layer disposed thereon. In other embodiments, a navigation array is formed by molding over a frame having a plurality of marker elements. In still other embodiments, a navigation array is formed by molding over individual marker elements. In certain embodiments, a navigation array is formed by molding a frame with a plurality of voids and subsequently molding marker elements into each void where the marker elements include a reflective layer disposed thereon. In some embodiments, a navigation array is formed by molding a plurality of marker elements on a frame and disposing a reflective layer on the marker elements. ## Claims ### Claim 1 A navigation array for use in a computer-assisted surgical system, the array comprising: a molded monolithic array body comprising: a nonreflective frame region; and a plurality of spaced apart marker regions; wherein each of the marker regions has an associated reflective element configured to be detected and tracked by an optical tracking sensor. ### Claim 2 (depends on 1) The navigation array of claim 1, wherein the frame region and the marker regions of the monolithic array body are comprised of the same material. ### Claim 3 (depends on 2) The navigation array of claim 2, wherein the material is a polysulfone polymer or a polyether ether ketone polymer. ### Claim 4 (depends on 1) The navigation array of claim 1, wherein the frame region of the monolithic array body is comprised of a first material, and the marker regions of the monolithic array body are comprised of a second material. ### Claim 5 (depends on 4) The navigation array of claim 4, wherein the first material has a higher molding temperature than the second material. ### Claim 6 (depends on 4) The navigation array of claim 4, wherein the first material is an acrylonitrile butadiene styrene polymer, an N,N-methylene-bis-acrylamide polymer, a polybutylene terephthalate polymer, a polymethyl methacrylate polymer, or an N,N-methylene-bis-acrylamide polymer. ### Claim 7 (depends on 4) The navigation array of claim 4, wherein the second material is transparent. ### Claim 8 (depends on 4) The navigation array of claim 4, wherein the second material is a polycarbonate polymer or a polyethyleneimine polymer. ### Claim 9 (depends on 1) The navigation array of claim 1, wherein the marker regions of the monolithic array body are each coated with the reflective element. ### Claim 10 (depends on 1) The navigation array of claim 1, wherein the reflective element is embedded in each of the marker regions of the monolithic array body. ### Claim 11 (depends on 10) The navigation array of claim 10, wherein the marker regions can be detected and tracked by the optical tracking sensor from either side of the navigation array. ### Claim 12 (depends on 1) The navigation array of claim 1, wherein the marker regions of the monolithic array body are all similarly shaped. ### Claim 13 (depends on 1) The navigation array of claim 1, wherein at least two of the marker regions of the monolithic array body have different shapes. ### Claim 14 (depends on 1) The navigation array of claim 1, wherein the marker regions of the monolithic array have unequal diameters between a first side of the array and a second side of the array. ### Claim 15 (depends on 1) The navigation array of claim 1, further comprising an insert over molded into the monolithic array body. ### Claim 16 (depends on 1) A computer assisted surgical system, the system comprising: a navigation array of claim 1; an optical tracking unit associated with at least one optical tracking sensor; and a control unit, wherein the control unit is adapted to utilize a predetermined fixed geometric relationship between the marker regions and detected positions of the marker regions to determine a three-dimensional position and orientation of the navigation array. ### Claim 17 (depends on 16) The system of claim 16, further comprising a robot arm and a surgical instrument mounted to the robot arm. ### Claim 18 (depends on 17) The system of claim 17, wherein the navigation array is adapted to be mounted to the robot arm or the surgical instrument. ### Claim 19 (depends on 1) A method manufacturing a navigation array of claim 1, comprising: injection molding, in a single operation, the monolithic array body. ### Claim 20 (depends on 1) A method manufacturing a navigation array of claim 1, comprising: over molding the monolithic array body over a navigation marker sub-assembly.