Orthopedic locking screw for an orthopedic fastening system and method of securing an orthopedic locking screw

1. An orthopedic fastening system, comprising:

an orthopedic implant comprising a bore; and

an orthopedic locking screw configured to be retained inside the bore, the orthopedic locking screw comprising:

a shaft extending along an axis between a first and a second end, the first end sized to be received in the bore;

a drive member disposed at the second end;

a casing secured to and rotationally fixed around an outer surface of the shaft in a non-secured state of the screw, wherein the casing is formed of a plastically deformable material, the casing having a first end proximate the first end of the shaft and a second end proximate the second end of the shaft; and

a forward external thread disposed on the shaft between the first end of the casing and the first end of the shaft,

wherein the casing has an outer cross-sectional width (W 1 ) that is larger than a smallest inside cross-sectional width of the bore and forms a press-fit pressure against the bore when operably disposed in the bore, and

wherein the casing comprises a deformable thread disposed along an outer surface of the casing, wherein the deformable thread is an external thread that is configured to engage an internal thread feature of the bore.

2. The orthopedic fastening system of claim 1 , wherein the outer cross-sectional width of the casing is larger than a largest outside diameter of the first end of the shaft and any threads disposed on the first end of the shaft.

3. The orthopedic fastening system of claim 1 , wherein the shaft comprises a polygonal or other non-circular profile that prevents the casing from rotationally slipping on the shaft.

4. The orthopedic fastening system of claim 1 , wherein the deformable thread has a minor diameter (Dmin) that is constant along the length of the deformable thread.

5. The orthopedic fastening system of claim 1 , wherein the deformable thread is a continuous thread extending from adjacent the first end of the casing to the second end of the casing.

6. The orthopedic fastening system of claim 1 , wherein the first end of the casing is tapered radially inwardly toward the outer surface of the shaft.

7. The orthopedic fastening system of claim 1 , wherein the shaft includes a groove, wherein the groove extends circumferentially around the shaft, and wherein the casing is disposed in the groove.

8. The orthopedic fastening system of claim 7 , wherein the groove extends axially along the shaft between a first shoulder proximate the first end of the shaft and a second shoulder proximate the second end of the shaft, wherein the first and second shoulders secure or assist securing the casing on the shaft.

9. The orthopedic fastening system of claim 8 , wherein the first end of the casing engages the first shoulder and the second end of the casing engages the second shoulder.

10. The orthopedic fastening system of claim 7 , wherein a radially inner surface of the casing is secured against a radially outer surface of the groove.

11. The orthopedic fastening system of claim 1 , wherein the orthopedic locking screw includes a rear external thread disposed on the shaft between the second end of the shaft and the second end of the casing.

12. The orthopedic fastening system of claim 11 , wherein the outer diameter of the casing is larger than the outer diameter of at least one of the forward and rear external threads.

13. The orthopedic fastening system of claim 11 , wherein at least one of the forward external thread and the rear external thread is axially spaced apart from the casing.

14. The orthopedic fastening system of claim 1 , wherein the orthopedic locking screw includes a tip disposed at the first end of the shaft, wherein the tip comprises a self-tapping feature.

15. The orthopedic fastening system of claim 1 , wherein the drive member comprises:

a head configured to engage with a rotational drive member, the head forming a shoulder extending radially outwardly from an outer surface of the shaft to an outer surface of the head.

16. The orthopedic fastening system of claim 1 , wherein each of the shaft and the casing is formed of a bio-compatible material, wherein the material of the casing is softer than the material of the shaft, the material of the casing comprising at least one of a plastic and a metal, and the material of the shaft comprising at least one of a plastic, a metal, and a ceramic.

17. The orthopedic fastening system of claim 1 , wherein the orthopedic implant is formed of a biocompatible material.

18. The orthopedic fastening system of claim 1 , wherein the deformable thread has an outside diameter that is larger than a corresponding inside diameter of the bore.

19. The orthopedic fastening system of claim 1 , wherein the deformable thread has a variable pitch that varies along the direction of the axis.

20. The orthopedic fastening system of claim 1 , wherein the orthopedic implant comprises an intramedullary nail.

21. A method of securing an orthopedic screw in a bore of an orthopedic implant, the method comprising the steps:

providing an orthopedic locking screw comprising a shaft extending along an axis between a first end and a second end, the first end sized to be received in the bore; a drive member disposed at the second end; a casing secured to and rotationally fixed around an outer surface of the shaft in a non-secured state of the screw, wherein the casing is formed of a plastically deformable material, the casing having a first end proximate the first end of the shaft and a second end proximate the second end of the shaft; and a forward external thread disposed on the shaft between the first end of the casing and the first end of the shaft, wherein the casing has an outer cross-sectional width (W 1 ) that is larger than a smallest inside cross-sectional width of the bore;

inserting the first end of the shaft into the bore;

engaging the casing with the bore;

rotating the drive member to rotate the shaft and the casing so as to operably engage the casing with the bore, thereby achieving a deformable press-fit of the casing against the bore, wherein the casing comprises a deformable thread disposed along an outer surface of the casing, wherein the deformable thread is an external thread that operably engages the bore so as to form a mechanical interfit with the bore.

22. The method of claim 21 , wherein a minor diameter (Dmin) of the deformable thread is larger than a smallest inner diameter of the bore, and wherein rotating the drive member causes the deformable press-fit to include a radially directed pressure between the casing and the smallest inner diameter.

23. The method of claim 21 , wherein the deformable thread has a variable pitch that varies along the direction of the axis, and wherein rotating the drive member causes the deformable press-fit to include an axially directed pressure between the casing and the deformable thread.