Implant Inserter Having a Laterally-Extending Dovetail Engagement Feature

Abstract

A method of inserting a fastener into a fusion cage can include attaching a fastener head of a bone fastener to a flexible bone fastener driver. The method can also include inserting the bone fastener into a threaded throughhole of a fusion cage comprising a front wall, a pair of opposing side walls, a back wall, and top and bottom surfaces adapted for gripping opposed vertebral endplates, wherein the front wall comprises the threaded throughhole.

Claims

1. A method of inserting a fastener into a fusion cage, comprising the step of: i) attaching a fastener head of a bone fastener to a flexible bone fastener driver; and ii) inserting the bone fastener into a threaded throughhole of a fusion cage comprising a front wall, a pair of opposing side walls, a back wall, and top and bottom surfaces adapted for gripping opposed vertebral endplates, wherein the front wall comprises the threaded throughhole.

2. The method of claim 1, wherein inserting the bone fastener into the threaded throughhole comprises: grasping a proximal handle of the bone screw driver; and guiding the bone fastener into the throughhole.

3. The method of claim 2, wherein the attaching step includes attaching the fastener head to a distal end portion of the bone screw driver, wherein the bone screw driver includes an intermediate shaft that extends from the proximal handle to the distal end portion, the method further comprising the step of bending the distal end.

4. The method of claim 3, wherein the bending step comprise manipulating a plurality of interlocking segments of the distal end portion.

5. The method of claim 4, wherein the bending step further comprises coupling a pre-bent sleeve to the distal end portion so as to transition the distal end portion from a straight configuration to a curved configuration.

6. The method of claim 5, wherein transitioning the distal end portion from the straight configuration to the curved configuration is performed prior to inserting the fusion cage at an implant site.

7. The method of claim 6, further comprising rotating the distal end portion while the distal end portion is in the curved configuration such that the bone fastener threadedly engages a bone.

8. The method of claim 6, further comprising, during the rotating step, the step of maintaining the handle portion substantially parallel to a position of an inserter as the inserter inserts the fusion cage into an intervertebral space.

9. The method of claim 7, further comprising after the rotating step, decoupling the pre-bent sleeve from the distal end portion.

10. The method of claim 5, wherein the coupling step includes positioning the pre-bent sleeve such that the pre-bent sleeve at least partially envelops the distal end portion.

11. The method of claim 10, wherein the pre-bent sleeve includes a fixed curvature such that the coupling step causes the distal end portion to adopt the curvature of the pre-bent sleeve.

12. The method of claim 5, wherein the coupling step includes enveloping at least half of an outer periphery of the distal end portion with the pre-bent sleeve.

13. The method of claim 5, wherein the pre-bent sleeve includes a central axis and the method further comprises rotating the pre-bent sleeve about its central axis when a distal tip of the distal end portion is coupled to the fastener head.

14. The method of claim 5, wherein the coupling step includes coupling the pre-bent sleeve to the distal end portion such that a distal end of the pre-bent sleeve is proximal to a distal tip of the distal end portion.

15. The method of claim 5, wherein the distal end portion includes a first end and a second end spaced from the first end along a central axis and the method further includes sliding the pre-bent sleeve relative to the distal end along the central axis.

16. The method of claim 5, wherein the distal end portion includes a first end and a second end spaced from the first end along a central axis and the coupling step includes fixing a position of the pre-bent sleeve relative the distal end portion along the central axis.

17. The method of claim 5, wherein the pre-bent sleeve includes a longitudinal slit and the coupling step includes moving the distal end portion through the longitudinal slit.

18. The method of claim 5, wherein the distal end portion includes a plurality of interlocking segments and the coupling step includes coupling the pre-bent sleeve to the plurality of interlocking segments.

19. The method of claim 2, wherein the distal end portion is flexible.

20. The method of claim 5, wherein the pre-bent sleeve is flexible.

Description

DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1A shows a cross-sectional view of an insertion instrument of the present invention.

[0028] FIG. 1B shows a plan view of the insertion instrument of FIG. 1A.

[0029] FIGS. 2A-2C show a perspective view of three embodiments of a forked inner shaft of the present invention.

[0030] FIG. 3 shows a perspective view of the implant being inserted into a prepared disc space using the insertion instrument of FIGS. 1A-2C.

[0031] FIGS. 4A and 4B show two views of an instrument of the present invention having dovetail gripping features approaching an implant having corresponding dovetail recess features.

[0032] FIG. 5 discloses an intervertebral fusion cage of the present invention.

[0033] FIG. 6 discloses a corner of an implant having a sidewall having recess therein, wherein the recess comprises two acute angles α and β.

[0034] FIG. 7 discloses a perspective view of an inserter tip of the present invention.

[0035] FIG. 8 discloses a perspective view of a lighted inserter tip of the present invention.

[0036] FIGS. 8A-8F disclose a flexible screw inserter and a prebent sleeve.

DETAILED DESCRIPTION OF THE INVENTION

[0037] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The same number appearing in different drawings represents the same item. The drawings are not necessarily to scale, with emphasis instead being placed upon illustrating the principles of the invention.

[0038] In general, the present invention is related to an apparatus and a method for safely inserting an implant into a spine. The implant can be an artificial disc or spinal fusion cage, or a spinal plate. Referring to FIGS. 1A and 1B, insertion instrument 100 is shown in a side cross-sectional view and a plan view, respectively. Insertion instrument 100 includes a frame or driver body assembly 110, an actuator assembly 126 and a forked inner shaft 160 (FIG. 2A-2C). Insertion instrument 100 is a normally closed device, that is, the proximal rod of the forked inner shaft 160 is normally substantially contained within actuator assembly 126.

[0039] Actuator assembly 126 includes an outer sleeve 130, a proximal inner shaft 140, and a retaining pin 148. Outer sleeve 130 includes a tapered end 175 which slidably engages tapers 163 on the forked inner shaft 160 (FIG. 2A-2C), allowing for compression and expansion of the forked inner shaft 160 when in use. Inner shaft 140 includes a female threaded end 142 and a male threaded end 144. Female threaded end 142 mates with a spring retaining screw 152 and male threaded end 144 mates with the forked inner shaft 160. Internal compression spring 150 is fastened to the actuator assembly 126 and is held in place by spring retaining screw 152. Once actuator assembly 126 is assembled, it is inserted into driver body assembly 110 and retained within assembly 110 with retaining pin 148. Optional knob 170 can be mechanically attached to outer sleeve 130 to allow outer sleeve 130 and proximal inner shaft 140 to rotate about the driver body assembly 110. Optional guides 171 can be attached to outer sleeve 130 to slidably mate with spinal disc distraction instrument 950 (FIG. 3). Depth control member 173 can also be fixedly or slidably attached on outer sleeve 130 for providing a predetermined insertion depth of the implant.

[0040] Driver body assembly 110 includes handle 112, handle transition 114, strike boss 116, trigger mechanism 120, and pivot pin 122. Trigger mechanism 120 can be any type of trigger mechanism known in the art. Trigger mechanism 120 pivots about pivot pin 122 in the driver body assembly 110. When trigger mechanism 120 is squeezed toward handle 112, the forked inner shaft 160 (FIG. 2A-2C) extends from actuator assembly 126 and expands to release an implant. When trigger mechanism 120 is released, forked inner shaft 160 recedes into actuator assembly 126 and compresses, thereby engaging the implant or returning to its normally closed position. Optional drag adjustment screw 124 is rotatably coupled to driver body assembly 110 for adjusting the drag force between trigger mechanism 120 and spring retaining screw 152 of actuator assembly 126.

[0041] FIGS. 2A-2C show various forked inner shafts 160 of the present invention. Each forked inner shaft 160 includes engagement features 162 for mechanically engaging the implant. engagement features 162 may be various shapes and sizes depending upon implant selection. As shown, engagement features 162 may be dovetail-shaped (162a, 162b, 162c, 162d). Engagement features 162 can engage implants having multiple heights. It should be understood engagement features 162 can be any shape which can engage any type of implant. In an alternative embodiment, proximal inner shaft 140 and forked inner shaft 160 can be integral.

[0042] Each forked inner shaft 160 includes female threaded hole 161 for mating to male threaded end 144 of proximal inner shaft 140 of actuator assembly 126. It should be understood that any means known in the art can be used to attach forked inner shaft 160 to proximal inner shaft 140.

[0043] Each forked inner shaft 160 includes tapers 163 and relatively long expansion/compression slot 164 to allow forked inner shaft 160 to expand and compress during use. FIGS. 2A-2C show forked inner shaft 160 in the expanded position. Each forked inner shaft 160 also includes sizing slot 166 to allow for a variation of tab and forked inner shaft slot dimensional differences. Expansion/compression slot 169 (FIG. 2B) is an alternative embodiment of sizing slot 166. In some embodiments, the forked member has a quick connect feature.

[0044] Cephalad markers 168 can be included on a surface of forked inner shaft 160 to allow the user to determine the position of the implant. Markers 168 can be pin 168a or machined slots 168b. In some embodiments, the inserter (squeeze handle) has a quick connect feature.

[0045] In one method of using the present invention, and now referring to FIGS. 4a and 4b, the user first squeezes the trigger mechanism 120 (FIG. 1) on the implantation instrument 100, thereby causing the engagement features 162c, 162d on the instrument to separate. The user then approaches the target implant (in this case, a cervical plate 201) with the implantation instrument so that the dovetail features of these two devices align, whereby the engagement features 162 straddle the opposed engagement indents 906 on the implant. Once engagement features 162 straddle the engagement indents 906, the user then releases the trigger mechanism 120, causing engagement features 162 to collapse inwards and engage engagement indents 906 on the implant.

[0046] In other embodiments, the reverse is provided, wherein the user squeezes the instrument to engage the implant.

[0047] Now referring to FIG. 5, there is provided an intervertebral fusion cage 301 of the present invention. This cage comprises a front wall 303, a back wall 304, a pair of opposing side walls 305 connecting the front and back walls, a top surface 306 adapted to engage an upper vertebra, a bottom surface (not shown) adapted to engage a lower vertebra, and a throughhole 307 extending between the top and bottom surfaces for promoting fusion therethrough, wherein the front wall comprises a pair of recesses 311, each recess opening onto a respective sidewall and forming a dovetail shape in the respective sidewall. The front wall of this particular cage also has screwholes 313 extending therethrough. The screwholes are typically threaded and are adapted to receive bone screws for securing the cage to opposing vertebral bodies without the need for posterior instrumentation, thereby providing “stand alone’ capabilities.

[0048] Now referring to FIG. 6, also in accordance with the present invention, there is provided a spinal implant having a front wall, a pair of opposing side walls, a back wall, and top and bottom surfaces, wherein the front wall comprises a pair of recesses, each recess opening onto a respective side wall and forming at least two acute angles α and β in the respective side wall. The acute nature of these two angles in the same recess creates the condition necessary to preclude toggle and rotation.

[0049] In some embodiments, the top and bottom surfaces of the implant are spaced at a distance suitable for contacting opposing vertebral endplates. This feature is advantageous for spinal implants inserted into a disc space.

[0050] In some embodiments, the implant of the present invention has a throughhole extending from its top surface to its bottom surface. This throughhole feature promotes bony fusion through the implant and so provides a performance advantage for fusion cage embodiments of the present invention.

[0051] In some embodiments thereof, a bone graft material is contained in the throughhole of the fusion cage. This graft material also promotes fusion through the implant and so provides a performance advantage for fusion cage embodiments of the present invention.

[0052] In some implant embodiments, the fusion cage has a front wall that is manufactured separately from the remainder of the implant. Preferably, the front wall is metallic and the remainder of the implant is polymeric. This preferred embodiment advantageously provides strength in the front wall so that screw holes can pass therethrough without fracturing the wall.

[0053] In some embodiments, first and second bone fasteners extend through the screwholes located in the front wall of the fusion cage. This feature allows the cage to be secured to the opposing vertebrae and so eliminates the need for posterior instrumentation. In some embodiments thereof, the first fastener further extends through the top surface of the implant, while the second fastener further extends through the bottom surface of the implant.

[0054] In some embodiments, the first and second bone fasteners extend only through the front wall, as in a plate embodiment.

[0055] In some embodiments, the implant has an articulation interface, as in an articulating motion disc.

[0056] FIG. 3 discloses an instrument of the present invention inserting an implant of the present invention into a disc space.

[0057] As shown in FIG. 3, distraction instrument 950 is inserted over pins (not shown) that are secured into vertebral bodies 962, 964. Cervical fusion cage 330 is passed between the forks of distraction instrument 950 using implantation instrument 100 (FIGS. 1A-1B). In an alternate embodiment, guides 170 on insertion instrument 100 slidably engage slots in the forks of distraction instrument 950 to help the user guide cervical fusion cage 330 into prepared disc space 970. Once the cervical fusion cage 330 is in a desired location within prepared disc space 970, the user actuates (e.g., squeezes, or releases or rotates a knob) trigger mechanism 120 (FIG. 1A), which releases cervical fusion cage 330 into the prepared disc space 970. The user can determine the desired position by observing cephalad markers 168 (FIG. 3) located on a surface of forked inner shaft 160. In an alternative embodiment, implantation instrument 100 can include a depth control member 173 (FIG. 1A) (which might be an adjustable and slidable), such that cervical fusion cage 330 can be inserted into prepared disc space 970 at a predetermined depth.

[0058] Lastly, the implantation instrument 100 and distraction instrument 950 are removed, causing superior vertebra 962 and inferior vertebra 964 to engage cervical fusion cage 330.

[0059] Now referring to FIG. 7, there is provided one embodiment of an inserter tip 701 of the present invention. This inserter tip includes barrel stop 703 that prevents the bone screw from stripping. There is a distal quick connect/release feature 705 that allows for ease of connection to the remainder of the inserter instrument. Barrels 707 prevent the implant from being placed too far posteriorly. Relief features 709 on the dovetail allow for the engagement feature to disengage with ease from the implant. Lastly, barrels 711 can be a fixed barrel or adjustable via sliding member such as a ratcheting feature.

[0060] Now referring to FIG. 8, there is provided one embodiment of a lighted inserter tip 801 of the present invention. The inserter cannula is fitted with at least one secondary lumen 803 adapted for delivering light or delivering a fiber optic. Light emanating from the secondary lumen is shown by the dashed lines in FIG. 8. Alternatively, light can be fed down the major lumen that holds the inserter tip (not shown). In one embodiment, at least the engagement features 805 of the tip are made of hard clear plastic that allows visibility of the other instruments passed through the barrels.

[0061] When performing a spinal procedure such as an anterior cervical discectomy and fusion (ACDF), the surgeon often has a number of implant options that may achieve the desired clinical outcomes of disc height maintenance and pain relief. Because of their clinical benefits, zero-profile fusion cages that accept bone anchors and are secured to the adjacent anatomy have experienced an increased usage and adoption in the ACDF procedure. These cages typically have angled bone anchors (such as screws) that pass through a portion of the cage's anterior wall and into the adjacent vertebral endplates.

[0062] However, if a surgeon were to choose a low profile, stand-alone fusion device (such as a fixation cage comprising one or more bone screws), there remains a surgical technique challenge associated with the insertion of the screws. Traditionally, an instrument having a straight shaft is used to insert the screws through the cage at the steep angle to ensure bone penetration. However, screw insertion with a straight-shaft instrument at locations up near a patient's chin or sternum produces some challenging approach angles. Recently, there have been improvements to the insertion instrument that help facilitate screw placement at these difficult approach angles. Some of these improvements include the adoption of universal joints and flexible inserter instruments that allow for torque transmission while still positioning their handles off-axis from the trajectory of the screw. For example, some flexible inserter instruments achieve flexibility by possessing a plurality of interlocking segments just proximal of their distal working tip. Once the tip of such a flexible driver is inserted into the drill guide, the handle of the driver can be repositioned to the desired location and torque can be transmitted to advance the screw.

[0063] However, one of the challenges associated with this flexible technology is that the flexible shaft is typically straight in its resting configuration. Accordingly, one of two procedures needs to be carried out. In a first procedure, the amount of soft tissue retraction has to temporarily be increased in order to engage the tip of the driver into the drill guide and once engaged, the soft tissue retraction can be minimized again and the handle can be held in a desirable position, such as near parallel to the implant inserter. In a second procedure, the tip can be inserted into the drill guide at a less steep angle than the screw trajectory (but not perfectly parallel to the inserter) and the spring force of the flex segment has to be overcome in order for the tip to find the drill guide trajectory. Upon this “turning the corner” step, as a downforce is provided, the self-retention of the screw may become disengaged.

[0064] Therefore, to overcome these issues, in one aspect of the present invention, and now referring to FIGS. 8A-8F, there is provided an improvement on the flexible shaft technology that has benefits for the patient and the surgeon. The improvement is a bone screw driver having a) a proximal handle (not shown), b) an intermediate shaft 851, c) a flexible distal end portion 853 comprising a plurality of interlocking segments 855 and distal tip 857 (wherein the flexible distal end portion is substantially straight in its unloaded configuration), and d) a pre-bent sleeve 861 that is placed over and around the flexible segments, thereby pre-determining the trajectory of the tip and facilitating the appropriate and desired insertion angle of the screw into the drill guide without increasing the amount of retraction. As shown in FIGS. 8a-8f, this pre-bent sleeve (which has a longitudinal slit 863) allows a screwdriver handle to be perfectly in-line with the cage inserter if desired, while still taking advantage of the tactile feel and torque transmission of the flex segment in its bent position. Accordingly, a surgeon can limit the amount of retraction and keep the driver handle close to the inserter without having to overcome the forces of the flexible segments' natural straight configuration. The sleeve can be fixed, slidable, or removable and can fully or partially encompass the flexible segments. The sleeve can have geometries that allow for flexing, attachment (snapping-on) to the driver, and removal for cleaning, if desired. The sleeve can be made of any biocompatible material that will maintain the desired shape (such as metal or plastic).

[0065] Therefore, in accordance with the present invention, there is provided a flexible bone screw driver comprising: [0066] a) a proximal handle, [0067] b) an intermediate shaft, [0068] c) a flexible distal end portion comprising a plurality of interlocking segments and a distal tip adapted to engage a screw head, and [0069] d) a pre-bent sleeve placed over and around the plurality of interlocking segments.

[0070] Also in accordance with the present invention, there is provided an assembly comprising: [0071] a) a fusion cage comprising a front wall, a pair of opposing side walls, a back wall, and top and bottom surfaces adapted for gripping opposed vertebral endplates, wherein the front wall comprises at least one threaded throughhole, [0072] b) a bone screw received in the threaded throughhole, the bone screw having a threaded shaft and a proximal head, [0073] c) the inserter of FIGS. 8A-8F, wherein the distal tip of the inserter is received in the proximal head of the bone screw.

[0074] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.