Zero profile spinal fusion cage
10624758 ยท 2020-04-21
Assignee
Inventors
- Michael A. Slivka (Berkley, MA, US)
- Alexander Grinberg (Auburndale, MA, US)
- John C. Voellmicke (Franklin, MA, US)
- John Riley Hawkins (Cumberland, RI, US)
Cpc classification
A61F2310/00023
HUMAN NECESSITIES
A61F2310/00017
HUMAN NECESSITIES
A61F2002/30062
HUMAN NECESSITIES
A61F2002/4628
HUMAN NECESSITIES
A61F2310/00293
HUMAN NECESSITIES
A61F2/446
HUMAN NECESSITIES
A61F2002/3079
HUMAN NECESSITIES
A61F2310/00029
HUMAN NECESSITIES
A61F2002/4627
HUMAN NECESSITIES
A61F2002/30594
HUMAN NECESSITIES
A61F2/447
HUMAN NECESSITIES
A61F2/4455
HUMAN NECESSITIES
A61F2002/443
HUMAN NECESSITIES
A61F2/4465
HUMAN NECESSITIES
A61F2310/00239
HUMAN NECESSITIES
A61F2/30965
HUMAN NECESSITIES
International classification
Abstract
An interbody fusion cage having upper and lower canals for receiving the heads of bone screws that have been pre-installed in opposing vertebral body endplates. The proximal wall of the cage preferably has a vertical slot that communicates with each canal and is adapted to allow access by a screwdriver and tightening of the screws.
Claims
1. An intervertebral implant configured to be inserted into an intervertebral space defined by a superior vertebra and an inferior vertebra, the intervertebral implant comprising: a proximal end and a distal end spaced from one another along a first direction, the proximal end defining a bone screw aperture that extends therethrough, the bone screw aperture configured to receive a bone screw and direct the bone screw into a first one of the superior vertebra and the inferior vertebra; first and second sidewalls spaced from one another along a second direction, perpendicular to the first direction, the first and second sidewalls extending from the proximal end to the distal end, each of the first and second sidewalls including an upper bearing surface configured to grip the superior vertebra and a lower bearing surface configured to grip the inferior vertebra, the upper bearing surfaces of the first and second side walls cooperating to define an upper opening configured to promote bony fusion, and the lower bearing surfaces of the first and second side walls cooperating to define a lower opening configured to promote bony fusion; a central strut that extends from the distal end toward the proximal end along a centerline of the intervertebral implant such that the central strut is elongate along the first direction, the central strut having at least one guiding surface that extends along the first direction; and at least one sliding component configured to ride along the at least one guiding surface of the central strut along the first direction, wherein the at least one sliding component comprises a threaded shank that is configured to be anchored in a second one of the superior vertebra and the inferior vertebra.
2. The intervertebral implant of claim 1, wherein the proximal end, the central strut and the distal end are unitary.
3. The intervertebral implant of claim 1, wherein the central strut is disposed between the first and second sidewalls with respect to the second direction.
4. The intervertebral implant of claim 1, wherein the implant defines first and second apertures that extends through the implant from the upper opening to the lower opening along a third direction, perpendicular to both the first and second directions, the first and second apertures configured to promote bony fusion.
5. The intervertebral implant of claim 4, wherein the first aperture extends from the upper bearing surface of the first sidewall to the lower bearing surface of the first sidewall, and the second aperture extends from the upper bearing surface of the second sidewall to the lower bearing surface of the second sidewall.
6. The intervertebral implant of claim 4, wherein the central strut is disposed between the first and second apertures.
7. The intervertebral implant of claim 6, wherein the first aperture extends from the central strut to the first sidewall along the second direction, and the second aperture extends from the central strut to the second sidewall along the second direction.
8. The intervertebral implant of claim 1, wherein the upper bearing surfaces and the lower bearing surfaces of the first and second sidewalls each include a plurality of teeth configured to engage bone.
9. The intervertebral implant of claim 1, wherein the at least one guiding surface includes a first guiding surface defined on an upper portion of the central strut and a second guiding surface defined on a lower portion of the central strut.
10. The intervertebral implant of claim 9, wherein the first guiding surface and the second guiding surface are spaced from on another along a third direction, perpendicular to both the first and second directions.
11. The intervertebral implant of claim 1, wherein each of the first and second sidewalls is configured to attach to the proximal end and the distal end.
12. The intervertebral implant of claim 1, wherein the at least one sliding component is configured to be anchored to the second one of the superior and inferior vertebra when the at least one sliding component is received by the central strut.
13. The intervertebral implant of claim 1, wherein the threaded shank is a first threaded shank, and the at least one sliding component comprises a second threaded shank configured to be anchored in one of the superior vertebra and the inferior vertebra.
14. An intervertebral system, comprising the intervertebral implant of claim 13 and a bone screw configured to extend through the bone screw aperture and into the one of the superior and inferior vertebra.
15. The intervertebral system of claim 14, wherein the bone screw is a first bone screw, the bone screw aperture is a first bone screw aperture, the proximal end defines a second bone screw aperture that extends therethrough the proximal end and defines a second bone screw aperture that extends therethrough, and the intervertebral system comprises a second bone screw configured to extend through the second bone screw aperture and into one of the superior and inferior vertebra.
16. An intervertebral system comprising the intervertebral implant of claim 1 and a bone screw configured to extend through the bone screw aperture and into the first one of the superior and inferior vertebra.
17. The intervertebral system of claim 16, wherein the bone screw is a first bone screw, the bone screw aperture is a first bone screw aperture, the proximal end defines a second bone screw aperture that extends therethrough, and the intervertebral system comprises a second bone screw configured to extend through the second bone screw aperture and into one of the superior and inferior vertebra.
18. The intervertebral implant of claim 1, wherein the at least one sliding component comprises at least one sliding surface that is configured to slide along the at least one guiding surface of the central strut along the first direction.
19. The intervertebral implant of claim 18, wherein the at least one sliding component is configured to slide along the at least one guiding surface without rotating.
20. The intervertebral implant of claim 1, wherein the at least one sliding component is configured to ride along at least a midpoint of the at least one guide surface of the central strut that is midway between the proximal and distal ends.
Description
DESCRIPTION OF THE FIGURES
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19) Now referring to
(20) Typically, the guide surface depression forms a longitudinal canal in each bearing surface. The distal portion 21 of the guide surface depression acts as a means for guiding the more proximal portion of the canal to the screw head. When the proximal portion 23 of the canal is slid over the screw head, it envelops the screw head, thereby locking the cage in place. Further tightening of the screw can be performed to further lock the cage in place.
(21) In some embodiments, the cross-sectional profile of the depression or canal is substantially equivalent to the cross-sectional profile of the screw head, so that the first depression is well adapted for distal-to-proximal translation of the first canal towards the screw head. In some preferred embodiments thereof, the screw head is substantially spherical, while the transverse cross-section of the first canal substantially forms a portion of a circle, thereby providing a substantially matching fit of the canal and screw head.
(22) In some embodiments, the first canal extends substantially along a centerline of the cage, thereby allowing the use of a single screw per bearing surface.
(23) In some preferred embodiments, the first canal comprises a distal recess 25 and a proximal process 27. The proximal process effectively acts to lock the cage in place when it slides over and envelops the screw head.
(24) In some embodiments, the first canal includes an outwardly extending (longitudinal) bump (not shown) adapted to limit translational movement of the interbody device with respect to the screw. This bump acts as an additional means for guiding the deeper portion of the canal to the screw head, at which the cage becomes locked.
(25) Now referring to
(26) In some embodiments, it is helpful to provide a final seating of the screw head once it becomes seated in the deeper proximal portion of the canal. In these embodiments, the proximal wall of the cage preferably has a vertical slot 35 that communicates with the horizontal guide surface canal and is adapted to allow access by a screwdriver. Thus, the surgeon has direct access to the screw head via a proximal route and can easily accomplish its final tightening.
(27) In some embodiments (as in
(28) It is believed that the device of the present invention can be advantageous used in implanting lateral cages. Therefore, now referring to
(29) It is believed that the device of the present invention can be advantageous used in implanting cervical cages. Therefore, now referring to
(30) In some embodiments, it is advantageous to add additional screws to the device in order to more completely secure the device to the vertebral endplates. Now referring to
(31)
(32) Various aspects of the present invention include an implant/instrument system, and a method of implantation. The present invention also includes a kit comprising: a) trial instruments comprising interbody spacing blocks having various sizes (height, angle, footprint), each with bone anchor placement guides. b) at least two bone fixation anchors to be placed into adjacent vertebral bodies while trialing with the aforementioned instrument, and c) an interbody implant configured for engaging with the heads of the implanted bone anchors after removing the trial instrument.
(33) Now referring to
(34) The kit of the present invention allows the surgeon to fix the opposing vertebral bodies to one another through the interbody device without having the implant protrude outside of the disc space. Preferably, the heads of the bone anchors snap into proximal processes formed in canals located in the upper and lower surfaces of the interbody implant, thereby helping the implant resist migration. Preferably, the anchors can be inserted at various angles to accommodate anatomical differences as well as avoid any pre-existing hardware.
(35) Preferably, the canals of the interbody implant sufficiently envelop the respective bone anchor heads so as to prevent back-out and pull-out of the anchor. In such situations, a secondary locking step/feature is not required. Preferably, the interbody implant allows passage therethrough of a driver to further seat and tighten the bone anchor into the bone after the implant has been placed. This is typically accomplished by a vertical slot 35 in the proximal wall that communicates with the canals. Preferably, the major diameter of the bone anchor is larger than the screw head diameter. In some embodiments, the major diameter is 5.5 mm). Larger major screw diameters can be used, as compared to conventional devices wherein the anchors are placed through the wall of the fixation device and limited by the height of the device. This is a major advantage.
(36) The embodiments described herein are preferably designed for the cervical region, but also could be utilized for lumbar spine interbody fusion as well.
(37) In a preferred embodiment of the invention shown in
(38) In some embodiments, the proximal wall of the cage has a small vertical slot 35 that provides access by a screwdriver shaft to the guide surface canals (and thereby the screw heads). After interbody device insertion into the disc space, the screws are preferably tightened through these slots to ensure construct stability. Screw backout is prevented by design of the cage and method of cage installation, as the screw heads are seated on the inner surfaces of the respective canals.
(39)
(40) Revision surgery can be performed by loosening the screws and removing the cage. In effect, the screws do not need to be removed during cage revision.
(41)
(42)
(43) Now referring to
(44) To implant the cage, the surgeon has to spread the blades and insert the cage in between the blades, aligning the cage's proximal opening with the pusher pin 112. The cage has to be positioned along the inserter so that the pedals are reasonably collapsed in order to be inserted into intervertebral space. The central slots 113 of the blades need to be aligned with the already-implanted screw heads, and the inserter needs to be as vertical as possible (i.e., perpendicular to the anterior plane of the vertebrae) and inserted as deep as the blades' stop surfaces 114 will allow. At this point, the inserter handle is turned clockwise, thereby pushing the pusher and the cage forward. During insertion, pedals 115 become distracted, thereby making space for the cage. The cage is pushed into the disc space until the pusher stops contacting the vertebrae. The cage stops advancing forward and the blades withdraw from the disc space by continuing advance of the pusher until the blades are completely withdrawn.
(45) The pusher blade 119 rides inside the pusher guiding slot 117, thereby preventing the pusher from spinning and aligning it properly to the blades. An impactor (not shown) is then used to advance the cage into the final position. At this point, the screw heads serve as stops for the impactor, and the cage cannot move any further distally. At this point, the anterior surface of the cage is flush with the screw heads' most protruding points. The final step is the tightening of the screws.
(46) In some embodiments of the present invention, trialing occurs before implantation of the fusion cage. In particular, in accordance with the present invention, there is provided a method of inserting a fusion cage into an intervertebral disc space formed by upper and lower vertebral endplates, comprising the sequential steps of: a) inserting a trial having a guide surface canal into the disc space, b) drilling or awling the hole through the trial drill guides, c) inserting first and second sliding components into the upper and lower vertebral endplates, the first sliding component having a threaded shank and a screw head, d) removing the trial, e) inserting a fusion cage having a guide surface canal into the disc space so that the screw head is received in a distal portion of the canal, and f) distally translating the cage into the disc space so that the screw head becomes received in a proximal portion of the cage canal.
(47) These cages of the present invention may be made from any non-resorbable material appropriate for human surgical implantation, including but not limited to, surgically appropriate metals, and non-metallic materials, such as carbon fiber composites, polymers and ceramics.
(48) The interbody device and bone anchors are preferably made out of PEEK or CFRP or any other suitable material providing adequate strength and radiolucency. However, implantable metals such as titanium or stainless steel components may be required to ensure adequate strength for either the interbody device or bone anchors. In some cases the interbody device can be made as a combination of PEEK and metal. The metal component is preferably used for screw head retaining feature. In some cases, resorbable materials such as polylactide, polyglycolide, and magnesium are preferred.
(49) In some embodiments, the cage material is selected from the group consisting of PEEK, ceramic and metallic. The cage material is preferably selected from the group consisting of metal and composite (such as PEEK/carbon fiber).
(50) If a metal is chosen as the material of construction for a component, then the metal is preferably selected from the group consisting of titanium, titanium alloys (such as Ti-6Al-4V), chrome alloys (such as CrCo or CrCoMo) and stainless steel.
(51) If a polymer is chosen as a material of construction for a component, then the polymer is preferably selected from the group consisting of polyesters, (particularly aromatic esters such as polyalkylene terephthalates, polyamides; polyalkenes; poly(vinyl fluoride); PTFE; polyarylethyl ketone PAEK; polyphenylene and mixtures thereof.
(52) If a ceramic is chosen as the material of construction for a component, then the ceramic is preferably selected from the group consisting of alumina, zirconia and mixtures thereof. It is preferred to select an alumina-zirconia ceramic, such as BIOLOX Delta, available from CeramTec of Plochingen, Germany. Depending on the material chosen, a smooth surface coating may be provided thereon to improve performance and reduce particulate wear debris.
(53) In some embodiments, the cage member comprises PEEK. In others, it is a ceramic.
(54) In some embodiments, the first component consists essentially of a metallic material, preferably a titanium alloy or a chrome-cobalt alloy. In some embodiments, the second component consists essentially of the same metallic material as the first plate.
(55) In some embodiments, the components are made of a stainless steel alloy, preferably BioDur CCM Plus Alloy available from Carpenter Specialty Alloys, Carpenter Technology Corporation of Wyomissing, Pa. In some embodiments, the outer surfaces of the components are coated with a sintered beadcoating, preferably Porocoat, available from DePuy Orthopaedics of Warsaw, Ind.
(56) In some embodiments, the components are made from a composite comprising carbon fiber. Composites comprising carbon fiber are advantageous in that they typically have a strength and stiffness that is superior to neat polymer materials such as a polyarylethyl ketone PAEK. In some embodiments, each component is made from a polymer composite such as a PEKK-carbon fiber composite.
(57) Preferably, the composite comprising carbon fiber further comprises a polymer. Preferably, the polymer is a polyarylethyl ketone (PAEK). More preferably, the PAEK is selected from the group consisting of polyetherether ketone (PEEK), polyether ketone ketone (PEKK) and polyether ketone (PEK). In preferred embodiments, the PAEK is PEEK.
(58) In some embodiments, the carbon fiber comprises between 1 vol % and 60 vol % (more preferably, between 10 vol % and 50 vol %) of the composite. In some embodiments, the polymer and carbon fibers are homogeneously mixed. In others, the material is a laminate. In some embodiments, the carbon fiber is present in a chopped state. Preferably, the chopped carbon fibers have a median length of between 1 mm and 12 mm, more preferably between 4.5 mm and 7.5 mm. In some embodiments, the carbon fiber is present as continuous strands.
(59) In especially preferred embodiments, the composite comprises: a) 40-99% (more preferably, 60-80 vol %) polyarylethyl ketone (PAEK), and b) 1-60% (more preferably, 20-40 vol %) carbon fiber, wherein the polyarylethyl ketone (PAEK) is selected from the group consisting of polyetherether ketone (PEEK), polyether ketone ketone (PEKK) and polyether ketone (PEK).
(60) In some embodiments, the composite consists essentially of PAEK and carbon fiber. More preferably, the composite comprises 60-80 wt % PAEK and 20-40 wt % carbon fiber. Still more preferably the composite comprises 65-75 wt % PAEK and 25-35 wt % carbon fiber.
(61) Although the present invention has been described with reference to its preferred embodiments, those skillful in the art will recognize changes that may be made in form and structure which do not depart from the spirit of the invention.
(62) Alternatively, combinations of cage materials could be beneficial (i.e., a ceramic bottom half with a PEEK top half).
(63) In other embodiments, the components are made from resorbable materials, such as Biocryl Rapide, a PLA, PLG, TCP composite marketed by DePuy Mitek, located in Raynham, Mass.
(64) When resorbable materials are selected, Preferred bioresorbable materials which can be used to make the sutures of the present invention include bioresorbable polymers or copolymers, preferably selected from the group consisting of hydroxy acids, (particularly lactic acids and glycolic acids; caprolactone; hydroxybutyrate; dioxanone; orthoesters; orthocarbonates; and aminocarbonates). Preferred bioresorbable materials also include natural materials such as chitosan, collagen, cellulose, fibrin, hyaluronic acid; fibronectin, and mixtures thereof. However, synthetic bioresorbable materials are preferred because they can be manufactured under process specifications which insure repeatable properties.
(65) A variety of bioabsorbable polymers can be used to make the suture of the present invention. Examples of suitable biocompatible, bioabsorbable polymers include but are not limited to polymers selected from the group consisting of aliphatic polyesters, poly(amino acids), copoly(ether-esters), polyalkylenes oxalates, polyamides, tyrosine derived polycarbonates, poly(iminocarbonates), polyorthoesters, polyoxaesters, polyamidoesters, polyoxaesters containing amine groups, poly(anhydrides), polyphosphazenes, biomolecules (i.e., biopolymers such as collagen, elastin, bioabsorbable starches, etc.) and blends thereof. For the purpose of this invention aliphatic polyesters include, but are not limited to, homopolymers and copolymers of lactide (which includes lactic acid, D-,L- and meso lactide), glycolide (including glycolic acid), -caprolactone, p-dioxanone(1,4-dioxan-2-one), trimethylene carbonate(1,3-dioxan-2-one), alkyl derivatives of trimethylene carbonate, -valerolactone, -butyrolactone, -butyrolactone, -decalactone, hydroxybutyrate, hydroxyvalerate, 1,4-dioxepan-2-one (including its dimer 1,5,8,12-tetraoxacyclotetradecane-7,14-dione), 1,5-dioxepan-2-one, 6,6-dimethyl-1,4-dioxan-2-one, 2,5-diketomorpholine, pivalolactone, ,-diethylpropiolactone, ethylene carbonate, ethylene oxalate, 3-methyl-1,4-dioxane-2,5-dione, 3,3-diethyl-1,4-dioxan-2,5-dione, 6,8-dioxabicycloctane-7-one and polymer blends thereof. Poly(iminocarbonates), for the purpose of this invention, are understood to include those polymers as described by Kemnitzer and Kohn, in the Handbook of Biodegradable Polymers, edited by Domb, et. al., Hardwood Academic Press, pp. 251-272 (1997). Copoly(ether-esters), for the purpose of this invention, are understood to include those copolyester-ethers as described in the Journal of Biomaterials Research, Vol. 22, pages 993-1009, 1988 by Cohn and Younes, and in Polymer Preprints (ACS Division of Polymer Chemistry), Vol. 30(1), page 498, 1989 by Cohn (e.g. PEO/PLA). Polyalkylene oxalates, for the purpose of this invention, include those described in U.S. Pat. Nos. 4,208,511; 4,141,087; 4,130,639; 4,140,678; 4,105,034; and 4,205,399. Polyphosphazenes, co-, ter- and higher order mixed monomer-based polymers made from L-lactide, D,L-lactide, lactic acid, glycolide, glycolic acid, para-dioxanone, trimethylene carbonate and -caprolactone such as are described by Allcock in The Encyclopedia of Polymer Science, Vol. 13, pages 31-41, Wiley Intersciences, John Wiley & Sons, 1988 and by Vandorpe, et al in the Handbook of Biodegradable Polymers, edited by Domb, et al, Hardwood Academic Press, pp. 161-182 (1997). Polyanhydrides include those derived from diacids of the form HOOCC.sub.6H.sub.4O(CH.sub.2).sub.mOC.sub.6H.sub.4COOH, where m is an integer in the range of from 2 to 8, and copolymers thereof with aliphatic alpha-omega diacids of up to 12 carbons. Polyoxaesters, polyoxaamides and polyoxaesters containing amines and/or amido groups are described in one or more of the following U.S. Pat. Nos. 5,464,929; 5,595,751; 5,597,579; 5,607,687; 5,618,552; 5,620,698; 5,645,850; 5,648,088; 5,698,213; 5,700,583; and 5,859,150. Polyorthoesters such as those described by Heller in Handbook of Biodegradable Polymers, edited by Domb, et al, Hardwood Academic Press, pp. 99-118 (1997).
(66) Advantages of the present invention include an ability to have a larger screw diameters. There is no need for a special screw locking mechanism. The screws are locked by the cage design, following a screw first concept. There is high reliability in the screw lock. The cage features screw dynamism, so that there is angle flexibility and no bending stress (tension only). The cage allows screw self-adjustment to the cage. The cage may have centrally aligned screws, so there is less risk to veins and arteries. The cage is strongly resistant to axial impact during insertion. The screws are closer to the anterior edge. Lastly, there is a possibility of reducing spondylothesis anteriorly.