Graft material injector system and method

Abstract

A graft material injector device and method are disclosed. The injector device includes an elongated injector tube and a side loading aperture for receiving graft material. A graft material loader and a cover for the side loading aperture may optionally be included.

Claims

1. A graft material injector comprising: an elongated injector tube including an internal lumen, a distal injection aperture communicating with the internal lumen, and at least one loading aperture communicating with the internal lumen, wherein the at least one loading aperture is configured for loading graft material into the internal lumen; and an outer cannula, wherein the outer cannula is configured to move relative to the elongated injector tube from a first position that exposes the at least one loading aperture to a second position that extends over the at least one loading aperture.

2. The injector of claim 1 further comprising a guide adapted for cooperative engagement with the elongated injector tube for guiding graft material into the at least one loading aperture.

3. The injector of claim 1 wherein the at least one loading aperture comprises an elongated slot in the elongated injector tube proximal to the injection aperture.

4. The injector of claim 3 further comprising a funnel configured for temporary association with the elongated injector tube in registration with the elongated slot to guide graft material through the elongated slot and into the elongated injector tube.

5. The injector of claim 2 wherein the guide includes a funnel, wherein the guide is configured to position the at least one loading aperture in registration with an outlet of the funnel to receive graft material from the guide into the internal lumen.

6. The injector of claim 1 further comprising a handle secured to a proximal end of the injector tube, the handle including an actuator operable to move the outer cannula between the first position and the second position.

7. The injector of claim 1 wherein the injector includes a proximal end aperture for receiving a pusher into the internal lumen proximal to the at least one loading aperture.

8. The injector of claim 1 wherein the elongated injector tube comprises more than one loading aperture.

9. A graft material injector comprising: an injector tube, wherein the injector tube includes a proximal end portion and a distal end portion with a lumen extending therethrough, an injection aperture in the distal end portion of the injector tube, and at least one loading aperture in the injector tube proximal to the injection aperture; a cannula tube, wherein the cannula tube is sized to receive the injector tube therein, the cannula tube being movable between a first position in which the cannula tube substantially covers the at least one loading aperture and a second position in which the cannula tube does not substantially cover the at least one loading aperture, wherein the at least one loading aperture is configured to receive graft material into the lumen in the second position; and a handle with an actuator engaged with the cannula tube for sliding the cannula tube between the first position and the second position.

10. The injector of claim 9 further comprising a pusher rod sized for insertion into an aperture of the proximal end portion of the injector tube to apply force to graft material in the lumen to force it out of the injection aperture.

11. The injector of claim 10 in which the cannula tube is sized for close fitting sliding engagement over the injector tube and the pusher rod is sized for close fitting sliding engagement within the lumen.

12. The injector of claim 9 further comprising a funnel for engagement with the at least one loading aperture of the injector tube to introduce graft material into the lumen.

13. The injector of claim 9 wherein the injector tube comprises a push rod slidably received within the lumen.

14. The injector of claim 12 wherein the funnel is configured to prevent graft material exceeding a selected size from entering the lumen.

15. The injector of claim 9 wherein the injector tube comprises more than one loading aperture.

16. A method of injecting graft material comprising: employing a graft material injector of claim 1; inserting the graft material injector device into a graft material loader; introducing graft material into the graft material loader and into the internal lumen in alignment with a longitudinal axis of the injector tube; positioning the distal end of the injector tube to introduce graft material into an implant; and moving a push rod through the internal lumen, thereby applying force to the graft material to force it out of the distal injection aperture and into association with the implant.

17. The method of claim 16 further comprising placing the elongated injector tube in registration with a funnel and introducing the graft material into the at least one loading aperture through the funnel.

18. The method of claim 16 further comprising substantially covering the at least one loading aperture after introduction of the graft material.

19. The method of claim 17 in which the at least one loading aperture and the funnel each comprise an elongated opening to provide for introduction of the graft material along a length of the elongated opening of the at least one loading aperture.

20. The method of claim 16 in which the graft material comprises bone graft material.

Description

DETAILED DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a perspective view that shows one embodiment of a graft material injector device.

(2) FIG. 2 shows an exploded perspective view of graft injector device of FIG. 1.

(3) FIG. 3 shows one embodiment of a possible application for the bone graft injector of FIG. 1.

(4) FIG. 4 is a perspective view that shows one embodiment of a potential loading hopper or graft material guide.

(5) FIG. 5 shows one embodiment of a potential step one of the usage of the device.

(6) FIG. 6 shows one embodiment of a potential step two of the usage of the device.

(7) FIG. 7 shows one embodiment of a potential step two of the usage of the device.

(8) FIG. 8 shows one embodiment of a potential step three of the usage of the device.

(9) FIG. 9 shows one embodiment of a potential step four of the usage of the device.

(10) FIG. 10 shows one embodiment of a potential step five of the usage of the device.

(11) FIG. 11 is a perspective view of another embodiment of a graft material injector device/system.

(12) FIG. 12 is a perspective of the graft material injector device of FIG. 11 with components in different operative positions.

(13) FIG. 13 is a perspective view of the graft material injector device of FIG. 12, with components in different operative positions.

(14) FIG. 14 is a perspective view of the graft material injection device of FIG. 11 taken from a different angle.

(15) FIG. 15 is a perspective of the graft material injection device of FIG. 11 with components in different operative positions.

DETAILED DESCRIPTION

(16) FIGS. 1 and 2 depict one non-limiting example of a fusion graft material injection assembly or device generally at 20 embodying certain aspects of the present subject matter. The illustrated injection device 20 includes an elongated injector tube 22, that is axially relatively movable with respect to an outer cannula 24, and a pusher 26 that is advancable through the injector tube. The elongated injector tube has an internal lumen extending between a proximal end opening 28 and a distal end opening 30. A side loading aperture illustrated in the form of an elongated slot 32 in the wall of the injector tube, is located preferably but not exclusively in the distal end portion of the tube proximal of the distal end opening 26. The distal tip of the injector tube could be square cut or beveled to facilitate entry into tighter locations. A beveled tip could be oriented with respect to injector tube handle 34 to be indicative to the surgeon of bevel opening direction. The tip could also have longitudinally oriented slits that could allow the tube to collapse into tighter spaces and then expand when graft material and pusher 26 are advanced through the injector tube lumen. Alternatively, the tip of the injector tube could be made of soft, pliable, non-atraumatic material. The injector tube, cannula and/or pusher may be made of any suitable material, such as stainless steel or rigid plastic.

(17) Handle 34 is attached to the proximal end portion of the injector tube 22 and is ergonomically configured for gripping ease. The handle includes a proximal opening in axial alignment with the injector tube lumen to receive the pusher 26. The illustrated handle includes an axially extending slot 36 that slidably receives an actuator, such as a thumb tab 38, connected to the proximal end of cannula 24. Pusher 26 includes an elongated rod or pin 40 having a closed distal end 42. An ergonomically shaped handle 44 is secured to a proximal end of the rod.

(18) The cannula 24 and injector tube 22 are respectively sized for close fitting but still slidable engagement between the outer surface of the injector tube and the inner lumen surface of the cannula. With this arrangement, the cannula 24 defines, in effect, a cover that is movable relative to the injector tube between (1) a substantially open or uncovered position that exposes the side aperture or elongated slot 32 for loading graft material into the injector tube, and (2) a substantially closed or covered position, where the cannula extends over and covers the slot 32 after graft material has been introduced into the slot.

(19) Similarly, the injector tube lumen and the pusher rod 40 are respectively sized for close fitting but relatively movable engagement. As explained herein, the pusher is used to push against graft material that has been loaded into the injector tube so as to apply force against the graft material and push it out the distal end opening 30 of the injector tube. The relative close fit between the pusher rod 40 and injector tube lumen prevents substantial amounts of graft material from entering the spacing between the pusher rod distal end and the injector tube lumen when the pusher rod is advanced against graft material in the injector tube lumen. The illustrated pusher 26 is configured for slidable moving of the pusher rod 40 within the injector tube lumen. However, the injector device may also be configured with a threaded engagement between the pusher 26 and injector tube or injector tube handle such that rotation of the pusher handle 44, which could be in the form of a knob, advances the pusher rod within and along the injector tube lumen. Threaded engagement may provide greater control of injection rate and/or volume and provide mechanical advantage over a sliding arrangement. As a further alternative, the pusher rod 40 could be significantly smaller than the injector tube lumen, but terminate at a larger distal end such as a flexible, compliant polymeric or low-friction tip that is closely sized relative to the injector tube lumen or in a state of compression therein so as to fully fill the lumen. Still another alternative is for the plunger distal tip to be of metal to provide a stiff rigid member that can be used as a graft material tamp after the material is ejected from the distal end of the injector tube.

(20) While FIGS. 1 and 2 show a graft injection device or assembly 20 with an injector tube 22 having side loading aperture in the form of a single elongated slot 32, the injector tube may have more than one loading aperture, and the aperture(s) may be of any suitable size or shape. Because bone graft material can include bone chips or particles of relatively large size that clog or impede delivery through the injector tube, the side loading aperture may also include or be in the form of a filter mesh or sieve that allows only graft material below a certain size to pass into the injector tube lumen. Such a filter or sieve may take any suitable configuration and may be in the form of pores or slits laser cut through the side wall of the injector tube.

(21) In the illustrated embodiment, the graft material device assembly may optionally include a guide or hopper 46 to assist in introducing graft material into the injector tube. The guide may have any suitable shape. As illustrated in FIG. 4, the guide is in the form of a funnel having a funnel wall 48 inclined toward a funnel outlet 50. More particularly, in this non-exclusive embodiment the guide is elongated and has an elongated outlet substantially the same length at the elongated slot 32 in the injector tube 22. The width of the outlet slot 50 in the guide may be approximately the width of the elongated slot 32 or may have a wider or narrower width. A narrower width may be selected to prevent graft particles exceeding a certain size from entering the injector tube. In this form, the elongated funnel outlet acts as a filter or sieve. Alternatively, a separate filter or sieve structure may be located in the funnel outlet or otherwise mounted in the funnel to filter or sieve the graft material. The size and profile of the guide affords a stable, horizontal loading position for introducing graft material into the injector tube. Variations of these features allow the guide and injector device to be adapted to change the angle of orientation with respect to the user, such as a 30° or 45° angle.

(22) The illustrated guide 40 includes an injector tube guide in the form of an opening or aperture 52 into which the injector tube is inserted for graft material loading purposes. The opening 52 is located so as to cause alignment of the elongated slot 32 in the injector tube 22 with the elongated outlet 50 in the funnel-shaped guide 46 when the injector tube is inserted into the aperture 52. More specifically, when the injector tube is inserted into the aperture 52 of the funnel, the elongated slot 32 and elongated outlet 50 are in registration and contact so that graft material can be forced, typically by manually applied pressure, from the funnel into the injector tube. This provides a selected quantity or bolus of graft material in the injector tube having a length approximately that of the elongated slot 32 and a diameter or cross-sectional size of the injector tube lumen.

(23) Steps for introducing graft material into the injector tube are generally illustrated in FIGS. 5-9. FIG. 5 shows the graft injection assembly in a loading configuration with the pusher 26 withdrawn to a position where the distal end of pusher rod 40 is proximal of the elongated slot 32. Similarly, the thumb tab 38 of the cannula 24 is slid to the proximal end of handle slot 36. In this position, the cannula 24 is retracted to substantially and preferably completely uncover the elongated slot 32 of the injection tube 22.

(24) FIG. 6 depicts the injector assembly, in the loading configuration of FIG. 5, with the injector tube inserted into opening 52 of guide 46. This positions the elongated slot of the injector tube in registration with the elongated outlet 50 of the funnel shaped guide. (FIG. 7 is essentially similar to FIG. 6.)

(25) In the position of FIGS. 6 and 7, graft material may be forced, by manual pressure or tamp, from the funnel shaped guide, through the elongated outlet 50 and elongated injector tube slot 32, into the injector tube lumen, filling it with a selected amount (e.g., about 1 cc) of graft material axially positioned within the lumen.

(26) The cannula 24 is then moved to the distal position in the handle slot 36, as shown in FIG. 8. This covers and closes the slot, readying the assembly for the next steps. The injector assembly is then withdrawn from the guide 46, with the pusher 26 still in the retracted position, as seen in FIG. 9.

(27) The distal end portion injection assembly is then introduced into the surgical site where the graft material is required. One such surgical site may be the intradiscal space of the human spine. FIG. 3 shows such an exemplary site, with an implant 54 located within a central area of a disc 56, from which the nucleus has been removed in preparation for the procedure. An access tube 58 is shown extending through an access opening in the disc annulus 60 and into a window 62 in the disc implant. The distal end of the injector tube 22 and cannula 24 may be inserted through the access tube or directly into the implant window (without an access tube), requiring only a small access opening in the tissue, such as about 5 mm, that reduces risk of tissue trauma. When suitably located, the pusher 26 is advanced while the injector tube is held fixed. The distal end of the pusher rod 40 engages and pushes the length of graft material along the distal end portion of the injector tube and out the distal end opening 30 into the central space within the implant. The travel of the pusher rod may be configured to optimize or indicate to the user the volume of graft material dispensed or the maximum volume dispensed. Of course, the illustrated implant is but one example, and the fusion graft injection assembly or device as described herein may be used with other forms or types of implants or even without implants if only delivery of graft material to a surgical site is desired. After injection, the assembly 20 may be withdrawn, and the loading and injection procedure repeated until sufficient graft material has been delivered to the surgical site.

(28) An alternative embodiment of the fusion graft injection assembly or device is shown in FIGS. 11-15, and generally identified by reference numeral 80 in FIG. 11. As illustrated, the assembly or device 80 includes an injector tube and handle assembly 82 and pusher 84. The pusher 84 is constructed essentially the same as the pusher 26 described earlier, and includes a handle 86 and pusher rod 88, illustrated with a slightly enlarged blunt distal end 90.

(29) The injector tube and handle assembly 82 includes elongated injector tube 92 and a handle or frame 94. In this embodiment the injector tube 92 includes an internal lumen that extends between the handle 94 at the proximal end and a distal end opening 96. The handle 94 has a side loading aperture 98 that is sized to receive a magazine 100 having a plurality of graft material chambers 102.

(30) In the illustrated embodiment, the magazine 100 is illustrated in the form of a rotary cylinder with six graft material chambers disposed around the cylinder and extending through the length of the cylinder so as to be open at each end or through chambers. The cylinder is rotatable within the handle 94 to allow each of the graft material chambers to axially align with the axis of the injector tube lumen in an injection position. The proximal end of the handle 94, as in the prior embodiment, has a proximal opening 104 that is also axially aligned with the injector tube lumen, for receiving the pusher rod 88.

(31) In this arrangement the graft material chambers 102 may be pre-filled with graft material and loaded into the handle 94 side loading opening 98. Rotation of the magazine or cylinder brings one of the chambers into axial alignment with the injector tube lumen, allowing the pusher rod 88 to be advanced through the handle proximal end opening 104, through the aligned graft chamber 102 and through the injector tube 92. In this manner, graft material in the aligned chamber can be pushed by the force of the pusher rod out of the chamber and along the injector tube lumen, exiting from the distal end opening 96 of the injector tube into the desired location at the surgical site. The pusher rod may then be retracted proximal to the magazine 100, which can be rotated to align another graft material chamber with the injector tube lumen and the pusher rod again advanced to push another quantity or bolus of graft material along the injector tube for delivery to the surgical site. This can be repeated as needed to deliver the desired amount of graft material without the need to withdraw the injector tube from the surgical site to refill it.

(32) Although the graft material magazine is illustrated as a cylinder, it may be of any other suitable shape, such as a linear feed arrangement where the graft material chambers are disposed in a side by side relationship for sequential positioning into an aligned injection position or one behind another, if so desired. Also, the magazine may be removable from the handle to allow an emptied magazine to be refilled with graft material or replaced with a full magazine without the need to withdraw the injector tube from the surgical site.

(33) Referring back to the figures, FIG. 11, shows the injection assembly with the magazine 100 received within the handle side loading aperture 98 and the pusher rod 88 advanced fully through the handle, the aligned graft material chamber and the injector tube lumen. The distal end 90 of the pusher rod may be seen extending beyond the distal end of the injector tube, where it may be used to tamp the graft material at the surgical site.

(34) FIG. 12 shows the assembly 80 in a loading position with the pusher retracted to a position where the pusher rod 88 is proximal of the side loading aperture 98. This permits the magazine 100 to be inserted into the side loading aperture 98 without interference from the pusher rod 88.

(35) FIG. 13 shows a position where the magazine 100 has been inserted in the side loading aperture 98 and the pusher is positioned for insertion into proximal opening 104 in handle 94. FIG. 14 illustrates the pusher fully advanced through the handle, magazine and injector tube and extending beyond the distal end opening 96 of the injector tube. FIG. 15 illustrates a more fully exploded view of the injector assembly 80, with the magazine 100 completely removed from the side loading aperture 98.

(36) Although the present disclosure is described in light of the illustrated embodiments, it is understood that this for the purposes illustration and not limitation. Other applications, modifications or use of the support or distraction device may be made without departing for the scope of this invention, as set forth in the claims now or hereafter filed.