Corpectomy implant
10667924 ยท 2020-06-02
Assignee
Inventors
- Joseph M. Nyahay (Eagleville, PA, US)
- Edward J. McShane, III (Collegeville, PA, US)
- Sean S. Bishop (Malvern, PA, US)
- Christopher J. Ryan (Lincoln University, PA, US)
- Megan A. Stauffer (Wayne, PA, US)
Cpc classification
A61F2/4455
HUMAN NECESSITIES
A61F2002/3092
HUMAN NECESSITIES
A61F2002/4495
HUMAN NECESSITIES
A61F2002/4629
HUMAN NECESSITIES
A61F2/447
HUMAN NECESSITIES
International classification
Abstract
A corpectomy implant is comprised of multiple layers of structural elements having a generalized helical geometry. These elements are separated by structural elements having an undulating planar geometry. The corpectomy implant also includes centrally located structural elements that have a closed loop geometry.
Claims
1. An implant, comprising: a first layer of generalized helical elements; a second layer of generalized helical elements; a first undulating planar element; and wherein the first undulating planar element is disposed between the first layer of generalized helical elements and the second layer of generalized helical elements; the first layer of generalized helical elements including at least one continuous helical element that extends in a substantially U-shaped configuration around a perimeter of the implant; and wherein the at least one helical element is continuously formed with the first undulating planar element.
2. The implant according to claim 1, wherein the implant further comprises: a third layer of generalized helical elements; a fourth layer of generalized helical elements; a second undulating planar element; a third undulating planar element; wherein the second undulating planar element is disposed between the second layer of generalized helical elements and the third layer of generalized helical elements; and wherein the third undulating planar element is disposed between the third layer of generalized helical elements and the fourth layer of generalized helical elements.
3. The implant according to claim 2, wherein the implant further comprises: a fifth layer of generalized helical elements; a sixth layer of generalized helical elements; a fourth undulating planar element; a fifth undulating planar element; wherein the fourth undulating planar element is disposed between the fourth layer of generalized helical elements and the fifth layer of generalized helical elements; and wherein the fifth undulating planar element is disposed between the fifth layer of generalized helical elements and the sixth layer of generalized helical elements.
4. The implant according to claim 1, wherein: the implant further includes a first body member on an anterior side of the implant and a second body member on a posterior side of the implant; wherein a height of the second body member is equal to a height of the implant on the posterior side; and wherein a height of the first body member is less than a height of the implant on the anterior side.
5. The implant according to claim 1, wherein a portion of the first layer of generalized helical elements is exposed on an anterior side of the implant.
6. The implant according to claim 1, wherein the first layer of generalized helical elements and the second layer of generalized helical elements are arranged in a mirror symmetric manner about a plane defined by the first undulating planar element.
7. An implant, comprising: a first side and a second side disposed opposite the first side; a body member disposed on the first side; a first layer including a first structural element comprising a first end, a second end and an intermediate portion; wherein the first structural element has a generalized helical geometry; wherein the first structural element is continuous and extends around the perimeter of the implant with the first end being directly attached to the body member, the second end being directly attached to the body member, and the intermediate portion extending across the second side of the implant; the implant further including a second layer including a second structural element having a first end, a second end, and a generalized helical geometry; wherein the second structural element continuously extends around the perimeter of the implant; and wherein the first end and the second end of the second structural member are directly attached to the body member.
8. The implant according to claim 7, wherein the first side is a posterior side of the implant and wherein the second side is an anterior side of the implant.
9. The implant according to claim 7, wherein the first end of the first structural element is continuously formed with the body member.
10. The implant according to claim 9, wherein the second end of the first structural element is continuously formed with the body member.
11. The implant according to claim 7, wherein the first structural element has a first portion having a generalized helical geometry and a second portion having an undulating planar geometry.
12. The implant according to claim 7, wherein the implant includes an additional body member disposed on the second side.
13. The implant according to claim 12, wherein the intermediate portion is attached to the additional body member on the second side.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The embodiments can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
DETAILED DESCRIPTION
(24) The embodiments described herein are directed to an implant for use in a spine. In addition to the various provisions discussed below, any embodiments may make use of any of the body/support structures, frames, plates, coils or other structures disclosed in Morris et al., U.S. Publication Number 2016/0324656, published on Nov. 10, 2016, currently U.S. patent application Ser. No. 15/141,655, filed on Apr. 28, 2016 and titled Coiled Implants and Systems and Methods of Use Thereof, which is hereby incorporated by reference in its entirety. For purposes of convenience, the Morris application will be referred to throughout the present application as The Coiled Implant Application. Also, any embodiments may make use of any of the body/support structures, members, elements, frames, plates or other structures disclosed in McShane III et al., U.S. Publication Number 2017/0042697, published on Feb. 16, 2017, currently U.S. patent application Ser. No. 15/334,053, filed on Oct. 25, 2016 and titled Implant with Arched Bone Contacting Elements, which is hereby incorporated by reference in its entirety. Also, any embodiments may make use of any of the body/support structures, members, elements, frames, plates or other structures disclosed in McShane III et al., U.S. Publication Number 2018/0110626, published on Apr. 26, 2018, and titled Implant with Protected Fusion Zones, which is hereby incorporated by reference in its entirety and referred to as The Protected Fusion Zones application. Also, any embodiments may make use of any of the body/support structures, members, elements, frames, plates or other structures disclosed in Nyahay et al., U.S. Publication Number 2018/0256352, published on Sep. 13, 2018, and titled Implant with Bone Contacting Elements Having Helical and Undulating Planar Geometries, which is hereby incorporated by reference in its entirety and referred to as The Helical and Undulating Elements application.
(25) Implantation
(26)
(27) If second vertebral body 102 and/or portions of first vertebral body 101 and third vertebral body 103 are diseased or otherwise damaged, a corpectomy procedure may be performed by a surgeon to remove the damaged tissue. The removed tissue may be replaced with a bone graft and/or corpectomy cage to facilitate vertebral fusion between the remaining vertebral bodies.
(28)
(29) In some embodiments, portions of first vertebral body 101 and/or third vertebral body 103 may also be removed to enlarge space 120. This may also be done to remove any diseased bony tissue at the portions of first vertebral body 101 and/or third vertebral body 103 disposed closest to second vertebral body 102.
(30) In
(31) Overview of the Implant
(32) For purposes of clarity, reference is made to various directional adjectives throughout the detailed description and in the claims. As used herein, the term anterior refers to a side or portion of an implant that is intended to be oriented towards the front of the human body when the implant has been placed in the body. Likewise, the term posterior refers to a side or portion of an implant that is intended to be oriented towards the back of the human body following implantation. In addition, the term superior refers to a side or portion of an implant that is intended to be oriented towards a top (e.g., the head) of the body while inferior refers to a side or portion of an implant that is intended to be oriented towards a bottom of the body. Reference is also made herein to lateral sides or portions of an implant, which are sides or portions facing along lateral directions of the body following implantation.
(33)
(34) Implant 200 may also be associated with various edges that are located at the intersections between various sides. For example, superior side 230 and first lateral side 214 may meet at a superior-lateral edge. Likewise, inferior side 240 and first lateral side 214 may meet at an inferior-lateral edge. It may be appreciated that the term edge as used herein is not limited to a precise contour of implant 200 and is used instead to refer to a general region proximate the intersection of two sides or faces of implant 200.
(35) Reference is also made to directions or axes that are relative to the implant itself, rather than to its intended orientation with regards to the body. For example, the term distal refers to a part that is located further from a center of an implant, while the term proximal refers to a part that is located closer to the center of the implant. As used herein, the center of the implant could be the center of mass and/or a central plane and/or another centrally located reference surface.
(36) An implant may also be associated with various axes. Referring to
(37) An implant may also be associated with various reference planes or surfaces. As used herein, the term median plane refers to a vertical plane, which passes from the anterior side to the posterior side of the implant, dividing the implant into right and left halves, or lateral halves. As used herein, the term transverse plane refers to a horizontal plane located in the center of the implant that divides the implant into superior and inferior halves. As used herein, the term coronal plane refers to a vertical plane located in the center of the implant that divides the implant into anterior and posterior halves. In some embodiments, the implant is symmetric about two planes, such as the transverse plane.
(38) Implant 200 is comprised of one or more body members attached to one or more structural elements. In the embodiments shown in
(39) In some embodiments, each body member may have a relatively smooth outer surface with few or no holes or other openings. In the embodiment shown in
(40) Embodiments can include provisions to promote bone growth on an anterior side of the implant and restrict bone growth along the posterior side, to help reduce the tendency of bone growth adjacent and/or into the spinal column. In some embodiments, the size and geometry of first body member 220 and second body member 222 may be selected to maximize bone growth on the anterior side and limit or prevent bone growth on the posterior side.
(41)
(42) Alternatively, in embodiments that may be characterized by multiple levels of generalized helical elements alternating with undulating planar elements (see discussion below), height 250 could be chosen such that height 250 is less than the total height of two layers of generalized helical elements. Thus, in the exemplary embodiment of
(43) Because first body member 220 does not extend the full height of implant 200 on anterior side 210, some area of anterior side 210 comprises exposed bone contacting members.
(44) As seen in
(45) Some embodiments can include one or more fastener receiving provisions. In some embodiments, an implant can include one or more threaded cavities. In some embodiments, a threaded cavity can be configured to mate with a corresponding threaded tip on an implantation tool or device. In other embodiments, a threaded cavity can receive a fastener for purposes of fastening an implant to another device or component in an implantation system that uses multiple implants and/or multiple components.
(46) As best seen in
(47) In different embodiments, the shapes of one or more body members could vary. As seen in
(48) The variations in size and shape between first body member 220 and second body member 222 are best depicted in
(49) In some embodiments, first body member 220 and second body member 222 could be joined by one or more structural elements. In the embodiment shown in
(50) As used herein, each structural element comprises a distinctive member or element that spans a region or area of an implant. In some embodiments, these elements may overlap or intersect, similar to elements in a lattice or other 3D mesh structure. In other embodiments, the elements may not overlap or intersect. Some embodiments may use elongated elements, in which the length of the element is greater than its width and its thickness. For example, in embodiments where an element has an approximately circular cross-sectional shape, the element has a length greater than its diameter. In the embodiments seen in
(51) The present disclosure discusses peripheral structural elements and central structural elements. As used herein, a peripheral structural element, or simply peripheral element, is any element that is exposed on an anterior side or a lateral side of an implant. In some embodiments, each peripheral element may include at least one bone contacting region that is configured to directly contact bony tissue (e.g., vertebrae) and/or other kinds of tissue adjacent the cervical spine. Moreover, outer elements may include one or more portions exposed along the superior side, inferior side, anterior side and/or one or both lateral sides of an implant.
(52) In contrast, a central structural element, or simply central element, is any element that is disposed inwardly (or proximally) from the set of peripheral elements. In some cases, central elements may lack bone contacting regions since these elements may not contact with bony tissue (e.g., vertebrae) immediately following implantation. In some cases, however, central elements may include bone contacting regionsfor example where the central elements include portions exposed on the superior or inferior sides of an implant.
(53) Element Geometry
(54) Embodiments can include provisions for protecting bone growth along and adjacent to elements of an implant. In some embodiments, an element can be configured with a geometry that helps to protect new bone growth in selected regions that may be referred to as protected fusion zones. In a protected fusion zone new bone growth may be partially protected from forces transmitted directly between vertebrae and bone contacting surfaces of an implant, or between adjacent elements in an implant, thereby increasing the rate at which new bone growth may propagate through the implant.
(55) In some embodiments, an element can have a spiral, helical or twisted geometry that provide a series of such protected fusion zones for enhanced bone growth. In other embodiments, an element can have a planar undulating geometry (e.g., sinusoidal) that may also create protected fusion zones. In some embodiments, an implant may include elements with generalized helical geometries and other elements with planar undulating geometries.
(56) Some elements may have a generalized helical geometry. As used herein, a generalized helical geometry or spiraling geometry refers to a geometry where a part (portion, element, member, etc.) winds, turns, twists, rotates or is otherwise curved around a fixed path. In some cases, the fixed path could be straight. In other cases, the fixed path can be curved. In the present embodiments, for example, the fixed path is generally a combination of straight segments and curved segments.
(57) Curves having a generalized helical geometry (also referred to as generalized helical curves) may be characterized by coils, turns or windings about a fixed path. Exemplary parameters that may characterize the specific geometry of a generalized helical curve can include coil diameter (including both a major and minor diameter) and the pitch (i.e., spacing between adjacent coils). In some cases, the amplitude of a coil or loop may also be used to describe the diameter or widthwise dimension of the coil or loop. Each of these parameters could be constant or could vary over the length of a generalized helical curve.
(58) Generalized helical curves need not be circular or even round. In some embodiments, for example, a generalized helical curve could have a linearly segmented shape (or locally polygonal shape) such that each coil or turn is comprised of straight line segments rather than arcs or other curved segments. Generalized helical curves may also include combinations of curved and straight segments. Examples of generalized helical curves are shown and described in The Protected Fusion Zones Application.
(59) For purposes of characterizing the geometry of one or more structural elements, each element can be identified with one or more curves. Each element may be identified with a central curve. The central curve of each element may be defined as a curve that extends along the length (or longest dimension) of the element such that each point along the curve is centrally positioned within the element.
(60)
(61) In some embodiments, an element could have a cross-sectional diameter that is larger than its winding diameter. Such an embodiment is discussed in The Protected Fusion Zones Application. In the embodiment shown in
(62) Generally, an element may not have a generalized helical geometry through its entire length. In other embodiments, for example, its central curve may be configured with a winding segment where the central curve completes several full turns around a fixed path. Away from the winding segment, its central curve may not include any turns, twists, etc.
(63) Although the present embodiment includes at least one element with a winding segment that makes one or more full turns around a fixed path, other embodiments could be configured with central curves that only make partial turns around a fixed path.
(64) While the description here has focused on the geometry of a single element, it may be appreciated that other elements of implant 200, including peripheral and central structural elements, may exhibit similar generalized helical geometries, or segments with generalized helical geometries. It may be further appreciated that two different elements could have slightly different geometries, with distinct central curves that include variations in the number of windings, shape of the windings, etc.
(65) In some embodiments, elements may be characterized as having an undulating planar geometry. As used herein, the term undulating planar geometry refers to a geometry where the central curve of an element undulates (e.g., waves or oscillates) in a single plane. In other words, the central curve is an undulating planar curve. A specific example of an undulating planar curve is a sinusoidal curve, though the term undulating planar curve is not restricted to curves that undulate in a regular manner like sinusoidal curves. This undulating planar geometry is distinct from a generalized helical geometry, since generalized helical curves are not confined to a single plane.
(66)
(67) It may be appreciated that in some embodiments, an element could have a combination geometry. For example, in some cases an element may include at least one segment with a generalized helical geometry and at least one segment with an undulating planar geometry. An exemplary embodiment of an implant including at least one hybrid outer structural element is depicted in
(68) Superior/Inferior Arrangement of Structural Elements
(69) Along the superior and inferior sides of implant 200, peripheral structural elements may be arranged to provide multiple bone contacting regions and multiple protected fusion zones that help protect new bone growth.
(70)
(71) As seen in
(72) As also seen in
(73) Implant 200 may also include second central element 530. In some embodiments, second central element 530 may be configured identically to first central element 520 and arranged in a mirror symmetric manner about the median plane of implant 200.
(74) It may be appreciated that in some embodiments structural elements may be similarly arranged on inferior side 240 of implant 200. In some embodiments, structural elements on inferior side 240 could be arranged identically and in a mirror symmetric manner about the transverse plane of implant 200.
(75) Anterior and Lateral Side Arrangement
(76) In addition to elements arranged on superior side 230 and inferior side 240, implant 200 may include additional sets of structural elements arranged at distinct levels, or layers, of implant 200. As best seen in
(77) To increase the number of protected fusion zones along the anterior and/or lateral sides of a device while reinforcing the implant along directions parallel with the transverse plane, embodiments can use bone contacting elements that undulate in a single plane. In some embodiments, these undulating planar elements may facilitate attachment between generalized helical elements in adjacent levels of a device.
(78) As best seen in
(79) Implant 200 may include additional peripheral elements with an undulating planar geometry arranged at distinct levels, or layers. Thus, implant 200 may include second peripheral element 650, third peripheral element 652, fourth peripheral element 654 and fifth peripheral element 656, which may be collectively referred to as peripheral element set 670. Each of these undulating planar elements provides additional bone contacting regions and protected fusion zones along anterior side 210 as well as first lateral side 214 and second lateral side 216 of implant 200. Additionally, these undulating planar elements help improve strength and facilitate attachment between generalized helical elements in adjacent levels or layers of implant 200.
(80) Together, the generalized helical elements of peripheral element set 570 and the undulating planar elements of peripheral element set 670 are arranged into six levels of generalized helical members with each level being separated by an undulating planar element. Moreover, these elements may collectively be characterized as a peripheral bone contacting portion of implant 200. In this case, peripheral bone contacting portion includes peripheral elements arranged on first lateral side 214, anterior side 210 and second lateral side 216.
(81) In some embodiments, generalized helical peripheral elements can be stacked in an alternating configuration with the elements arranged in a symmetric manner about each undulating planar element. As an example, as best shown in the anterior view of
(82) Similarly, for example, second peripheral element 550 and third peripheral element 552 are arranged in an approximately symmetric manner about second peripheral element 650. Specifically, corresponding helical portions of second peripheral element 550 and third peripheral element 552 are attached to second peripheral element 650 at similar locations along lateral axis 211. Using these symmetric configurations may help distribute forces evenly throughout the implant as loads are applied in both the superior and inferior directions.
(83) Outer/Internal Arrangement
(84)
(85) In different embodiments, the geometry of one or more central elements could vary. In some embodiments, a central element could have a closed loop geometry. As seen in
(86) Optionally, in some embodiments, a central structural element could include a connecting portion that connects opposing segments in the closed loop. For example, as seen in
(87) As seen in
(88) Embodiments may vary according to the locations where a central structural element is attached to other elements disposed at the periphery of an implant. In some embodiments, adjacent layers of central structural elements may be separated and not directly attached to one another. In some embodiments, adjacent inner layers of central structural elements could be joined. As an example, in
(89) In some embodiments, portions of a central structural element could be attached to second body member 222 on posterior side 212. In the embodiment of
(90) In some embodiments, portions of a central structural element could be attached to first body member 220. For example, a vertical segment 761 of third central element 703 may be attached to first body member 220. In some embodiments, one or more central structural elements may not be attached to first body member 220 or to any other portions on anterior side 210 of implant 200. For example, first central element 520 and second central element 530 are both spaced apart from (and unattached to) adjacent elements disposed on anterior side 210 (including peripheral element 602 and generalized first peripheral element 502).
(91) In some embodiments, central structural elements could be attached to elements disposed on one or more lateral sides of an implant. In the embodiment of
(92) The arrangement of central structural elements described herein may collectively form a central support portion for implant 200. The central support portion extends from superior side 230 to inferior side 240 and core of support for implant 200. Such a configuration may provide enhanced strength under vertical loading compared to hollow cages.
(93) In addition to improving vertical strength for implant 200, using central structural elements with helical segments may create protected fusion zones within an interior of implant 200. For example, as seen in
(94) Bone Contacting Regions
(95) Embodiments may include one or more bone contacting regions. Bone contacting regions may be regions along a structural element and/or body member that are configured to directly contact a vertebral body or other adjacent bone or tissue following implantation. In some cases, these regions may comprise the distal most surfaces of an implant, including the distal most surfaces on the superior, inferior and lateral sides of the implant.
(96) In different embodiments, the geometry of one or more bone contacting regions could vary. In some embodiments, bone contacting regions could be relatively smooth regions. In some cases, bone contacting regions could be relatively flat regions. In other embodiments, a bone contacting region may be curved. In some cases, the bone contacting region could have a curvature that matches the curvature of the adjacent surface regions of the outer member. In other cases, the distal surface region could have a different curvature (e.g., more convex) than adjacent surface regions of the outer member.
(97) As seen in
(98) In some embodiments, generalized helical elements and undulating planar elements may also include bone contacting regions on one or more lateral sides of an implant. As seen in
(99) In different embodiments, the number of bone contacting regions could vary. In some embodiments, an implant could include between 10 and 100 bone contacting regions. In other embodiments, an implant could include less than 10 bone contacting regions. In still other embodiments, an implant could include more than 100 bone contacting regions. In the exemplary embodiment of
(100) Using bone contacting elements having generalized helical and/or undulating planar geometries may help facilitate new bone growth since elements with these geometries may naturally incorporate one or more protected fusion zones. These protected fusion zones may occur at locations along the structural elements that are convex and may be disposed between two bone contacting regions. These protected fusion zones are discussed in further detail below.
(101) Surface Texture
(102) Embodiments can include provisions for texturing one or more surfaces of an implant. Such texturing can increase or otherwise promote bone growth and/or fusion to surfaces of the implant. In some embodiments, bone contacting elements and/or sections of a body may be textured.
(103) In some embodiments, the surface structure of one or more regions of an implant may be roughened or provided with irregularities. Generally, this roughened structure may be accomplished through the use of acid etching, bead or grit blasting, sputter coating with titanium, sintering beads of titanium or cobalt chrome onto the implant surface, as well as other methods. This can result in a prosthesis with a surface roughness with about 3-5 microns of roughness peak to valley. However, in some embodiments, the surface roughness may be less than 3-5 microns peak to valley, and in other embodiments, the surface roughness may be greater than 3-5 microns peak to valley.
(104)
(105) Selective Bone Growth
(106)
(107) In
(108)
(109) Referring to
(110) As seen in
(111) Referring now to
(112) As previously discussed, new bone growth does not occur along posterior side 212. Specifically, while new bone growth may occur along interior surface 229 of second body member 222 (see
(113) Lordosis, Etc.
(114) In different embodiments, the geometry of a superior and/or inferior surface of an implant could vary. For example, the inferior and/or superior surfaces of an implant could be concave, flat, tapered/angulated to provide lordosis or kyphosis, etc. in shape.
(115) Embodiments can also be provided with various flat/parallel (0-degree), lordotic, and hyper-lordotic angles. In some embodiments, the implant can be configured with an approximately 8-degree angle between the superior and inferior surfaces. In other embodiments, the implant can be configured with an approximately 15-degree angle between the superior and inferior surfaces. In still other embodiments, the implant can be configured with an approximately 20-degree angle between the superior and inferior surfaces. Still other angles are possibly including any angles in the range between 0 and 30 degrees. Still other embodiments can provide a lordotic angle of less than 8 degrees. Still other embodiments can provide a hyper-lordotic angle of more than 20 degrees.
(116) As best shown in
(117) An alternative embodiment of an implant 900 is shown in
(118) Alternative Arrangement of Elements
(119)
(120) As seen in
(121) Referring to
(122) Adjacent to first element 1111 is a second element 1131. A first end 1132 of second element 1131 is attached at central region 1180 of first body member 1020. From first end 1132, second element 1131 extends both laterally and longitudinally until it contacts first element 1111. At this contact point, second element 1131 turns and extends to second body member 1022, with a second end 1138 attached to second body member 1022.
(123) Third element 1141 extends along the opposing side of implant 1000 from second element 1131. Specifically, in the embodiment shown in FIG. 23, third element 1141 is configured in a mirror symmetric manner from second element 1131 about the median plane.
(124) Adjacent to second element 1131 is fourth element 1151. A first end 1152 of fourth element 1151 extends from second element 1131 and continues longitudinally (while spiraling) to second body member 1022. A second end 1158 of fourth element 1151 attaches to central region 1182 of second body member 1022.
(125) Fifth element 1161 extends along the opposing side of implant 1000 from fourth element 1151. Specifically, in the embodiment shown in
(126) Although the discussion focuses on the arrangement of structural elements at superior side 1030 of implant 1000, it may be appreciated that in some embodiments each level of implant 1000 may comprise a similar configuration of generalized helical elements. In some cases, the arrangements may alternate in a mirror symmetric manner about a horizontal plane at different locations along implant 1000. Moreover, inferior side 1040 may comprise a similar arrangement of elements to those disposed on superior side 1030.
(127) The embodiment shown in
(128) Other embodiments could include elements arranged in any other configuration, and having any other geometries, including any of the configurations and/or geometries disclosed in The Helical and Undulating Elements Application.
(129) Variations in Layers and Sizes
(130) Different embodiments could vary in size. In some embodiments, the footprint of an implant could vary. As used herein, the footprint of the device comprises its approximate area in the transverse (or another horizontal) plane. In some embodiments, an implant could be manufactured in two or more distinct footprint sizes. In some embodiments, an implant could be manufactured in three or more distinct footprint sizes, including a small, medium and large footprint. Implants of different footprint sizes could be used to accommodate different sized vertebrae. In one embodiment, footprint sizes may be as follows: a small footprint having dimensions of 1214.5 mm; a medium footprint having dimensions of 12.516 mm; and a large footprint having dimensions of 1318 mm.
(131) Different embodiments could incorporate implants of varying heights. For example, an implant could be manufactured in two or more distinct heights. In other embodiments, an implant could be manufactured in three or more distinct heights. In some embodiments, an implant could be manufactured with a height approximately in the range between 15 mm and 33 mm.
(132) In different embodiments, implants can vary in the number of levels or layers of distinct helical elements. In the embodiments depicted in
(133) Bone Growth Promoting Material
(134) In some embodiments, bone growth can be facilitated by applying a bone growth promoting material in or around portions of an implant. As used herein, a bone growth promoting material (or BGPM) is any material that helps bone growth. Bone growth promoting materials may include provisions that are freeze dried onto a surface or adhered to the metal through the use of linker molecules or a binder. Examples of bone growth promoting materials are any materials including bone morphogenetic proteins (BMPs), such as BMP-1, BMP-2, BMP-4, BMP-6, and BMP-7. These are hormones that convert stem cells into bone forming cells. Further examples include recombinant human BMPs (rhBMPs), such as rhBMP-2, rhBMP-4, and rhBMP-7. Still further examples include platelet derived growth factor (PDGF), fibroblast growth factor (FGF), collagen, BMP mimetic peptides, as well as RGD peptides. Generally, combinations of these chemicals may also be used. These chemicals can be applied using a sponge, matrix or gel.
(135) Some bone growth promoting materials may also be applied to an implantable prosthesis through the use of a plasma spray or electrochemical techniques. Examples of these materials include, but are not limited to, hydroxyapatite, beta tri-calcium phosphate, calcium sulfate, calcium carbonate, as well as other chemicals.
(136) A bone growth promoting material can include, or may be used in combination with a bone graft or a bone graft substitute. A variety of materials may serve as bone grafts or bone graft substitutes, including autografts (harvested from the iliac crest of the patient's body), allografts, demineralized bone matrix, and various synthetic materials.
(137) Some embodiments may use autograft. Autograft provides the spinal fusion with calcium collagen scaffolding for the new bone to grow on (osteoconduction). Additionally, autograft contains bone-growing cells, mesenchymal stem cells and osteoblast that regenerate bone. Lastly, autograft contains bone-growing proteins, including bone morphogenic proteins (BMPs), to foster new bone growth in the patient.
(138) Bone graft substitutes may comprise synthetic materials including calcium phosphates or hydroxyapatites, stem cell containing products which combine stem cells with one of the other classes of bone graft substitutes, and growth factor containing matrices such as INFUSE (rhBMP-2-containing bone graft) from Medtronic, Inc.
(139) It should be understood that the provisions listed here are not meant to be an exhaustive list of possible bone growth promoting materials, bone grafts or bone graft substitutes.
(140) In some embodiments, BGPM may be applied to one or more outer surfaces of an implant. In other embodiments, BGPM may be applied to internal volumes within an implant. In still other embodiments, BGPM may be applied to both external surfaces and internally within an implant.
(141) Manufacturing and Materials
(142) The various components of an implant may be fabricated from biocompatible materials suitable for implantation in a human body, including but not limited to, metals (e.g. titanium or other metals), synthetic polymers, ceramics, and/or their combinations, depending on the particular application and/or preference of a medical practitioner.
(143) Generally, the implant can be formed from any suitable biocompatible, non-degradable material with sufficient strength. Typical materials include, but are not limited to, titanium, biocompatible titanium alloys (e.g. Titanium Aluminides, Ti.sub.6Al.sub.4V ELI (ASTM F 136), or Ti.sub.6Al.sub.4V (ASTM F 1108 and ASTM F 1472)) and inert, biocompatible polymers, such as polyether ether ketone (PEEK) (e.g. PEEK-OPTIMA, Invibio Inc). Optionally, the implant contains a radiopaque marker to facilitate visualization during imaging.
(144) In different embodiments, processes for making an implant can vary. In some embodiments, the entire implant may be manufactured and assembled via injection-molding, cast or injection molding, insert-molding, co-extrusion, pultrusion, transfer molding, overmolding, compression molding, 3-Dimensional (3-D) printing, dip-coating, spray-coating, powder-coating, porous-coating, milling from a solid stock material and their combinations. Moreover, the embodiments can make use of any of the features, parts, assemblies, processes and/or methods disclosed in The Coiled Implants Application.
(145) While various embodiments have been described, the description is intended to be exemplary, rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Although many possible combinations of features are shown in the accompanying figures and discussed in this detailed description, many other combinations of the disclosed features are possible. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Therefore, it will be understood that any of the features shown and/or discussed in the present disclosure may be implemented together in any suitable combination. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.