MULTIPLE EXPANSION STAGE INTERBODY DEVICES

Abstract

An example expandable interbody device can include a structural body having an upper endplate and a lower endplate. The device can include at least one wedge block and at least one linkage block arranged between the upper and lower endplates. The linkage block can include a plurality of linkages and a shear pin disposed at a respective proximal end of each of the linkages. The device can include a drive screw extending through the wedge and linkage blocks. The drive screw can be configured to rotate and drive the wedge block to expand the upper and lower endplates of the structural body from the closed position to an intermediate position. Additionally, the drive screw can be further configured to rotate and drive the linkage block to expand the upper and lower endplates of the structural body from the intermediate position to an open position.

Claims

1-38. (canceled)

39. An expandable interbody device comprising: a structural body that has an upper endplate and a lower endplate; said upper and lower endplates are movable between an open and a closed position; a first wedge block that is at least partially positioned between said upper and lower endplates of said structural body; a first linkage arrangement that is at least partially positioned between said upper and lower endplates of said structural body; and a first drive screw that extends at least partially through said first wedge block and said first linkage arrangement; said first drive screw is configured to cause said upper and lower endplates of said structural body to move from said closed position to an intermediate position; said first drive screw is engaged with said first wedge block and is configured to cause said first wedge to move and cause said upper and lower endplates of said structural body to move from said closed position toward said intermediate position; said first screw is also configured to engage and to cause movement of said first linkage arrangement so as to cause further movement of said upper and lower endplates of said structural body; said first screw is configured to cause initial movement of said first linkage arrangement after said first screw has caused movement of said first wedge.

40. The expandable interbody device as defined in claim 39, further including: a second wedge block that is at least partially positioned between said upper and lower endplates of said structural body; a second linkage that is at least partially positioned between said upper and lower endplates of said structural body, and wherein said first drive screw extends at least partially through said second wedge block and said second linkage arrangement; said first drive screw is engaged with said second wedge block and is configured to cause said second wedge to move and cause said upper and lower endplates of said structural body to move from said closed position toward said intermediate position; said first screw is also configured to engage and to cause movement of said second linkage arrangement so as to cause further movement of said upper and lower endplates of said structural body; said first screw is configured to cause initial movement of said second linkage after said first screw has caused movement of said second wedge.

41. The expandable interbody device as defined in claim 40, wherein said first screw is configured to cause simultaneous movement of said first and second wedge blocks toward one another.

42. The expandable interbody device as defined in claim 40, wherein said first screw is configured to cause simultaneous movement of said first and second linkage arrangements toward one another.

43. The expandable interbody device as defined in claim 41, wherein said first screw is configured to cause simultaneous movement of said first and second linkage arrangements toward one another.

44. The expandable interbody device as defined in claim 39, wherein said upper and lower endplates include first endplate oblique surfaces; said first wedge block includes first wedge oblique surfaces; said first endplate oblique surfaces on said upper and lower endplates are configured to engage said first wedge oblique surfaces to facilitate in moving said upper and lower endplates of the structural body from said closed position toward said intermediate position.

45. The expandable interbody device as defined in claim 41, wherein said upper and lower endplates include first endplate oblique surfaces; said first wedge block includes first wedge oblique surfaces; said first endplate oblique surfaces on said upper and lower endplates are configured to engage said first wedge oblique surfaces to facilitate in moving said upper and lower endplates of the structural body from said closed position toward said intermediate position.

46. The expandable interbody device as defined in claim 43, wherein said upper and lower endplates include first endplate oblique surfaces; said first wedge block includes first wedge oblique surfaces; said first endplate oblique surfaces on said upper and lower endplates are configured to engage said first wedge oblique surfaces to facilitate in moving said upper and lower endplates of the structural body from said closed position toward said intermediate position.

47. The expandable interbody device as defined in claim 39, wherein said first linkage arrangement includes a first pin and a first linkage; said first linkage is connected to said first pin and one of said upper and lower endplates; said first pin is positioned in a first wedge slot of said first wedge block; said first pin is movable in said first wedge slot during movement of said upper and lower endplates of the structural body from said closed position toward said intermediate position.

48. The expandable interbody device as defined in claim 46, wherein said first linkage arrangement includes a first pin and a first linkage; said first linkage is connected to said first pin and one of said upper and lower endplates; said first pin is positioned in a first wedge slot of said first wedge block; said first pin is movable in said first wedge slot during movement of said upper and lower endplates of the structural body from said closed position toward said intermediate position.

49. The expandable interbody as defined in claim 39, wherein said first drive screw includes a first threaded portion and a second threaded portion; said second threaded portion is spaced apart from said first threaded portion; said first threaded portion is configured to threadedly engage said first wedge block and said second threaded portion is configured to threadedly engage said first linkage arrangement.

50. The expandable interbody as defined in claim 48, wherein said first drive screw includes a first threaded portion and a second threaded portion; said second threaded portion is spaced apart from said first threaded portion; said first threaded portion is configured to threadedly engage said first wedge block and said second threaded portion is configured to threadedly engage said first linkage arrangement.

51. The expandable interbody as defined in claim 50, wherein said first drive screw includes a third threaded portion and a fourth threaded portion; said third threaded portion is spaced apart from said fourth threaded portion; said third threaded portion is configured to threadedly engage said second wedge block and said fourth threaded portion is configured to threadedly engage said second linkage arrangement.

52. The expandable interbody as defined in claim 39, wherein at least a portion of said expandable interbody device is formed of one or more materials selected from the group consisting of molybdenum-rhenium (MoRe) alloy, titanium (Ti) alloy, titanium-molybdenum (TiMo) alloy, and cobalt-chromium (CoCr) alloy.

53. The expandable interbody as defined in claim 51, wherein at least a portion of said expandable interbody device is formed of one or more materials selected from the group consisting of molybdenum-rhenium (MoRe) alloy, titanium (Ti) alloy, titanium-molybdenum (TiMo) alloy, and cobalt-chromium (CoCr) alloy.

54. A method of expanding an interbody from a closed position to an intermediate position comprising: providing an expandable interbody device; said expandable interbody device including: a structural body that has an upper endplate and a lower endplate; said upper and lower endplates are movable between an open and a closed position; a first wedge block that is at least partially positioned between said upper and lower endplates of said structural body; a first linkage arrangement that is at least partially positioned between said upper and lower endplates of said structural body; and a first drive screw that extends at least partially through said first wedge block and said first linkage arrangement; said first drive screw is configured to cause said upper and lower endplates of said structural body to move from said closed position to an intermediate position; said first drive screw is engaged with said first wedge block and is configured to cause said first wedge to move and cause said upper and lower endplates of said structural body to move from said closed position toward said intermediate position; said first screw is also configured to engage and to cause movement of said first linkage arrangement so as to cause further movement of said upper and lower endplates of said structural body; said first screw is configured to cause initial movement of said first linkage arrangement after said first screw has caused movement of said first wedge; initially rotating said first drive screw to cause said first wedge block to move and to initially cause said upper and lower endplates of said structural body to move from said closed position toward said intermediate position; said first drive screw not causing movement of said first linkage arrangement during said initial movement of said first wedge block; and continuing rotation of said first drive screw to cause said first drive screw to move said first linkage arrangement after said initial movement of said first wedge block; said movement of said first linkage arrangement causing said upper and lower endplates of said structural body to move toward said intermediate position.

55. The method as defined in claim 54, wherein during said step of continuing rotation of said first drive screw, said upper and lower endplates of said structural body disengage from contact with said first wedge block.

56. The method as defined in claim 54, wherein said expandable interbody device further includes: a second wedge block that is at least partially positioned between said upper and lower endplates of said structural body; a second linkage that is at least partially positioned between said upper and lower endplates of said structural body, and wherein said first drive screw extends at least partially through said second wedge block and said second linkage arrangement; said first drive screw is engaged with said second wedge block and is configured to cause said second wedge to move and cause said upper and lower endplates of said structural body to move from said closed position toward said intermediate position; said first screw is also configured to engage and to cause movement of said second linkage arrangement so as to cause further movement of said upper and lower endplates of said structural body; said first screw is configured to cause initial movement of said second linkage after said first screw has caused movement of said second wedge.

57. The method as defined in claim 56, wherein said step of initial rotation of said first screw causes simultaneous movement of said first and second wedge blocks toward one another.

58. The method as defined in claim 56, wherein said step of continued rotation of said first screw causes simultaneous movement of said first and second linkage arrangements toward one another.

59. The method as defined in claim 54, wherein said upper and lower endplates include first endplate oblique surfaces and said first wedge block includes first wedge oblique surfaces; said first endplate oblique surfaces on said upper and lower endplates are configured to engage said first wedge oblique surfaces to facilitate in moving said upper and lower endplates of the structural body from said closed position toward said intermediate position.

60. The method as defined in claim 54, wherein said first linkage arrangement includes a first pin and a first linkage; said first linkage is connected to said first pin and one of said upper and lower endplates; said first pin is positioned in a first wedge slot of said first wedge block; said first pin is movable in said first wedge slot during movement of said upper and lower endplates of the structural body from said closed position toward said intermediate position.

61. The method as defined in claim 54, wherein said first drive screw includes a first threaded portion and a second threaded portion; said second threaded portion is spaced apart from the said first threaded portion; said first threaded portion is configured to threadedly engage said first wedge block and said second threaded portion is configured to threadedly engage said first linkage arrangement.

62. The method as defined in claim 54, wherein at least a portion of said expandable interbody device is formed of one or more materials selected from the group consisting of molybdenum-rhenium (MoRe) alloy, titanium (Ti) alloy, titanium-molybdenum (TiMo) alloy, and cobalt-chromium (CoCr) alloy.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The components in the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding parts throughout the several views.

[0018] FIG. 1 illustrates a side view of an expandable interbody device in the closed position according to an implementation described herein.

[0019] FIG. 2 illustrates a side view of the expandable interbody device of FIG. 1 in the open position.

[0020] FIG. 3 illustrates a transparent top view of the expandable interbody device of FIG. 1 in the closed position.

[0021] FIG. 4 illustrates a transparent top view of the expandable interbody device of FIG. 1 in the open position.

[0022] FIG. 5 illustrates a transparent side view of the expandable interbody device of FIG. 1 in the open position.

[0023] FIGS. 6A and 6B illustrate another example expandable interbody device according to an implementation described herein. FIG. 6A illustrates a cross-sectional view of the expandable interbody device in the closed position. FIG. 6B illustrates a cross-sectional view of the expandable interbody device in the open position.

[0024] FIGS. 7A-7D illustrate another example expandable interbody device according to an implementation described herein. FIG. 7A illustrates a side view of the expandable interbody device in the closed position. FIG. 7B illustrates a transparent side view of the expandable interbody device during a first (e.g., initial) stage of expansion. FIG. 7C illustrates a side view of the expandable interbody device during a second stage of expansion. FIG. 7D illustrates a side view of the expandable interbody device in the open position.

[0025] FIG. 8 illustrates an alignment block of an expandable interbody device according to an implementation described herein.

[0026] FIG. 9 illustrates a rail system of an expandable interbody device according to an implementation described herein.

[0027] FIG. 10 illustrates a drive hole (e.g., insertion mechanism) of an expandable interbody device according to an implementation described herein.

DETAILED DESCRIPTION

[0028] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure. As used in the specification, and in the appended claims, the singular forms a, an, the include plural referents unless the context clearly dictates otherwise. The term comprising and variations thereof as used herein is used synonymously with the term including and variations thereof and are open, non-limiting terms. The terms optional or optionally used herein mean that the subsequently described feature, event or circumstance may or may not occur, and that the description includes instances where said feature, event or circumstance occurs and instances where it does not. Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, an aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent about. it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0029] Multiple expansion stage interbody devices are described herein. An interbody device is a spine implant to position within an intervertebral space to facilitate bone fusion. More specifically, the interbody devices described herein are expandable to be used, for example, in a Transforaminal Lumbar Interbody Fusion (TLIF) approach. The interbody device can be inserted in the intervertebral space at an initial height profile, and through actuation of a control screw (e.g., turned clockwise), can cause the upper and lower bodies of the assembly to extend superiorly and inferiorly, respectively. The control screw can be turned in the counter-clockwise direction to cause the interbody to collapse to its initial height to reposition or remove the interbody device. The interbody device described herein has a two-stage expansion mechanism; where at lower heights, the expansion is controlled by the ramps on proximal and distal blocks, and at a certain height, the upper and lower bodies disengage from the ramps and the expansion is controlled by the linkages assembled within the interbody device. The use of linkages allows expansion to be controlled by the length of the linkages, which pivot around a point. Because of this, the linkages can fit within the insertion profile of the interbody device, but are also able to pivot, extending beyond the initial profile if the length of the profile is larger than the height of the profile.

[0030] The interbody devices described herein facilitate a less invasive surgical procedure because the devices allow the implant to be inserted at a lower insertion profile and expanded to fit within the patient's intervertebral space. Additionally, the use of multiple expansion stages (e.g., ramps and linkages) allows for a greater range of expansion than conventional ramped devices, allowing the upper and lower bodies to extend beyond its initial height profile. The ramped portion also provides greater mechanical stability to mitigate the linkages' inherent weakness at more acute angles.

[0031] Referring now to FIGS. 1-5, an expandable interbody device is described. The device can include a structural body having an upper endplate 1001 a and a lower endplate 1001 b (collectively endplates 1001), where the upper and lower endplates 1001 are shaped to nest tightly in a closed position. Optionally, porous and/or roughened surfaces can be used on the endplates 1001, which can improve osseointegration. Example interbody devices that promote on-growth of bone are described in WO 2018/053403, published Mar. 22, 2018, titled INTERBODY FUSION DEVICES AND RELATED METHODS OF MANUFACTURE, the disclosure of which is expressly incorporated herein by reference in its entirety. In the closed position, the device is at its minimum height. This disclosure contemplates that a range of initial, minimum heights can be implemented in the design of the devices, allowing a range of expansion possibilities. Expansion of the device is accomplished through multiple stages (e.g., two stages) as described below. For example, the device can be actuated using a control screw (e.g., drive screw 1004 in FIGS. 1-5). During a first stage of expansion, actuation of the drive screw causes proximal and distal blocks (e.g., wedge blocks 1002 in FIGS. 1-5) to translate simultaneously in opposing horizontal directions, which results in the distraction of the superior endplate (e.g., upper endplate 1001 a in FIGS. 1, 2, and 5) and the inferior endplate (e.g., lower endplate 1001 b in FIGS. 1, 2, and 5) in opposing vertical directions. In the first stage, the device is expanded from the closed position to an intermediate position. During a second stage of expansion, actuation of the drive screw causes linkages (e.g., linkages 1003 a-1003 d in FIGS. 2, 4, and 5) to deploy, which results in the further distraction of the superior endplate (e.g., upper endplate 1001 a in FIGS. 1, 2, and 5) and the inferior endplate (e.g., lower endplate 1001 b in FIGS. 1, 2, and 5) in opposing vertical directions. In the second stage, the device is expanded from the intermediate position to an open position.

[0032] The endplates 1001 are configured to make direct contact with the patient's bone. e.g., with vertebral bodies in the section of the spine undergoing fixation/fusion. The endplates 1001 are designed to nest tightly with protrusions beyond center line to allow angled bosses to extend farther and thus allow more expansion of the structural body. Each of the endplates 1001 has faces oblique to the surfaces configured to contact the patient's bone (e.g., first oblique surfaces 1005 in FIGS. 1 and 2). The device can also include at least one wedge block 1002 arranged between the upper and lower endplates 1001 of the structural body. As shown in FIGS. 1-5, the device includes a plurality of wedge blocks 1002 (e.g. proximal and distal wedge blocks). Each of the wedge blocks 1002 has faces oblique to the top and bottom surfaces of the wedge blocks 1002, creating ramped surfaces (e.g., second oblique surfaces 1006 in FIGS. 1 and 2). The wedge blocks 1002 are support structures with the second oblique surfaces 1006 designed to accommodate the first oblique surfaces 1005 of the endplates 1001. As described below, when the wedge blocks 1002 travel, the second oblique surfaces 1006 interact with the corresponding first oblique surfaces 1005 of the endplates 1001 to cause expansion of the device.

[0033] The device can also include at least one linkage block 1003 arranged between the upper and lower endplates 1001 of the structural body. As shown in FIGS. 2-5, the device includes a plurality of linkage blocks 1003 (e.g. proximal and distal linkage blocks). This disclosure contemplates that the wedge and linkage blocks can be integrated into a single block in some implementations, i.e., the linkage block can be a sub-portion of the wedge block. While in other implementations, this disclosure contemplates that the wedge and distal blocks can be separate and distinct blocks. The linkage blocks 1003 can include one or more linkages 1003 a-1003 d (e.g., levers). For example, the device shown in FIGS. 1-5 can include eight linkages (i.e., four linkages per linkage block 1003). Each of the linkages 1003 a-1003 d extends between a shear pin 1010, which is located at a proximal end of the linkage, and an endplate pin 1012, which is located at a distal end of the linkage. The linkages 1003a-1003d can be coupled to the wedge and/or linkage blocks and the endplates with the shear pins 1010 and the endplate pins 1012, respectively. The linkages 1003a-1003d rotate around a pivot point (e.g., the center of the shear pin) during actuation to expand the device. The device can optionally include four shear pins 1010a-1010d (i.e., two shear pins per linkage block, one on each opposing lateral side of the linkage block), which is shown in FIG. 4. Alternatively, the device can optionally include two shear pins 1010 (i.e., one shear pin per linkage block). Each of the shear pins 1010 can extend from a linkage block 1003 into a portion of a wedge block 1002, which is also shown in FIG. 4. For example, the shear pin 1010 can extend into a lateral side or portion of the wedge block 1002. Optionally, in some implementations, each of the shear pins 1010 is coupled with a portion of a wedge block 1002. Optionally, in some implementations, each of the shear pins 1010 can extend from a linkage block 1003 without extending into a portion of the wedge block 1002 (e.g., the shear pins are only part of the linkage block 1003). Accordingly, each of the shear pins 1010 can support load during second stage expansion. Additionally, each of the shear pins 1010 can prevent rotation of the endplates 1001 about the axis of the drive screw 1004. It should be understood that four shear pins (i.e., two per linkage block) is provided only as an example. This disclosure contemplates using one, two, or three shear pins with the device to prevent rotation of the endplates 1001.

[0034] Additionally, as described herein, the device can further include a drive screw 1004 extending through the wedge blocks 1002 and the linkage blocks 1003. The drive screw 1004 can include threads, and the wedge blocks 1002 and/or linkage blocks 1003 can include threads corresponding to the threads of the drive screw 1004. In this way, the threads of the drive screw 1004 can engage corresponding threads of the wedge blocks 1002 and/or linkage blocks 1003. In some implementations, only the wedge blocks 1002 include threads. In other implementations, both the wedge blocks 1002 and the linkage blocks 1003 include threads. Optionally, the pitches of the respective threads for controlling the wedge blocks 1002 and the linkage blocks 1003 are the same. Optionally, the pitches of the respective threads for controlling the wedge blocks 1002 and the linkage blocks 1003 are different. The drive screw 1004 can include a driver hole 1007 at one end of the drive screw 1004. The driver hole 1007 can be configured to accept the bit of a driver instrument or tool. Optionally, this disclosure contemplates that the drive screw 1004 can be operated from either end by providing a driver hole 1007 at both ends. FIG. 10 illustrates a close-up view of a driver hole 1007 (e.g., insertion mechanism) of an expandable interbody device. In FIG. 10, the drive screw 1004 extends through the wedge block 1002 of the device.

[0035] Referring again to FIGS. 1-5, the device can further include an alignment block 1008. The alignment block 1008 can guide expansion of the structural body. The alignment block 1008 can also prevent rotation of the endplates 1001 about the axis of the drive screw 1004. For example, the alignment block 1008 is located in the center of the device and prevents rotation of the endplates 1001, further constraining the expansion to one direction (i.e., the vertical direction). FIG. 8 illustrates a close-up view of an alignment block 1008 of an expandable interbody device. As shown in FIG. 8, the alignment block 1008 can include one or more notches that correspond to vertical grooves in the endplates 1001. This keeps the expansion of the structural body in the vertical direction and/or prevents rotation of the endplates about the axis of the drive screw.

[0036] Referring again to FIGS. 1-5, the first oblique surfaces 1005 of the endplates 1001 engage with the second oblique surfaces 1006 of the wedge blocks 1002 during the first stage of expansion. Optionally, in some implementations, the device can include a rail system. For example, the first oblique surfaces 1005 of the endplates 1001 can be coupled to the second oblique surfaces 1006 of the wedge blocks 1002 by the rail system. FIG. 9 illustrates a close-up view of a rail system of an expandable interbody device. As shown in FIG. 9, grooves 1113a located on oblique surfaces of the endplate 1001 can couple with bosses 1113b located on oblique surfaces of the wedge block 1002. The rail system (e.g., grooves 1113a, bosses 1113h) can more effectively constrain the expansion of the device to one direction (i.e., the vertical direction).

[0037] Referring again to FIGS. 1-5, the device includes a plurality of wedge blocks 1002 arranged between the upper and lower endplates 1001 and on opposite sides of the structural body (e.g., proximal and distal wedge blocks). Each of the wedge blocks 1002 can be threaded in an opposite-handed direction such that the drive screw 1004 is configured to rotate and drive the wedge blocks 1002 in opposite directions and towards the center of the device (when expanding the device). Additionally, as shown in FIGS. 2-5, the device can further include a plurality of linkage blocks 1003 arranged between the upper and lower endplates 1001 and on opposite sides of the structural body. In some implementations, the device can include eight linkages. For example, the device can include two linkages per articular point, e.g., four linkages on each side of the device for a total of eight. It should be understood that the number of linkages is provided only as an example. In some implementations, each of the linkage blocks 1003 can be threaded in an opposite-handed direction such that the drive screw 1004 is configured to rotate and drive the linkage blocks 1003 in opposite directions and towards the center of the device (when expanding the device).

[0038] As described herein, the device has a dual stage mechanism (e.g., wedge blocks 1002 and linkage blocks 1003) controlled by rotation of the drive screw 1004. In a first stage, the device expands between the closed and intermediate positions. Expansion in the first stage is controlled exclusively using the wedge blocks 1002. To accomplish this, the threads of the drive screw 1004 are timed such that the wedge blocks 1002 are engaged by the drive screw 1004 during the first stage. The threads can be timed such that the wedge blocks 1002 move together and in opposite directions. The drive screw 1004 is therefore configured to rotate and drive the wedge blocks 1002, which moves the upper and lower endplates 1001 of the structural body from a closed position to an intermediate position. FIGS. 1 and 3 illustrate the device in the closed position, while FIGS. 2, 4, and 5 illustrate the device in the open position. As shown in FIGS. 1 and 2, the first oblique surfaces 1005 are included on the upper and/or lower endplates 1001, and the second oblique surfaces 1006 are included on the wedge blocks 1002. The second oblique surfaces 1006 can be configured to interact with the first oblique surfaces 1005 to expand the upper and lower endplates 1001 of the structural body as the wedge blocks 1002 translate due to rotation of the drive screw 1004. In other words, the wedge blocks 1002 control expansion in the first stage by physically forcing the endplates 1001 apart. Optionally, the first oblique surfaces 1005/second oblique surfaces 1006 can function as a ratchet. e.g., such that the structural body expands (or contracts) in a step-wise manner as the drive screw 1004 is rotated. Optionally, the first oblique surfaces 1005/second oblique surfaces 1006 can include a rail system to further constrain expansion. Once the device reaches the intermediate position, the wedge blocks 1002 can optionally disengage with the structural body (e.g., no more contact with the structural body). At this point, expansion control is transferred to the linkage blocks 1003 as described below. Additionally, during the first stage, the linkages 1003a-1003d are neither load supporting nor impacting/controlling expansion.

[0039] In a second stage, the device expands between the intermediate and open positions. Expansion in the second stage is controlled exclusively using the linkage blocks 1003, for example, by deployment of the linkages 1003a-1003d. Horizontal translation of the proximal end of the linkages 1003a-1003d can be limited so that the endplates 1001 cannot re-engage with the wedge blocks 1002 during the second stage. This can be accomplished in different ways. For example, in some implementations, the linkage blocks 1003 are provided with threads corresponding to threads of the drive screw 1004 such that displacement of the linkage blocks 1003 is controlled directly by a pitch of the threads of the drive screw 1004. This is described in detail with regard to FIGS. 6A-6B. In other implementations, deployment of the linkages 1003a-1003d is controlled by interaction between slots in the wedge blocks 1002 and the shear pins 1010. This is described in detail with regard to FIGS. 7A-7D.

[0040] Referring again to FIGS. 1-5, expansion during the second stage is described. FIGS. 1 and 3 illustrate the device in the closed position, while FIGS. 2, 4, and 5 illustrate the device in the open position. As shown in FIGS. 2, 4, and 5, the linkage blocks 1003 include one or more linkages 1003a-1003d (e.g., levers) that are configured to displace the endplates 1001 when the linkage blocks 1003 are engaged by the drive screw 1004. A linkage (e.g., one of linkages 1003a-1003d) is attached between a linkage block (e.g., one of linkage blocks 1003) with the shear pin (e.g., one of shear pins 1010) and an endplate 1001 (e.g., one of endplates 1001) with the endplate pin (e.g., one of endplate pins 1012). The linkage blocks 1003 control expansion in the second stage by moving the endplates 1001 with the linkages 1003a-1003d. The dual stage expansion described above (e.g., using both wedge and linkage blocks) allows the device to expand farther than conventional devices. For example, by using the linkage blocks 1003, the device can expand double its initial height, which would be a limiting factor for devices that use only wedge blocks as a drive mechanism. Additionally, since the linkages 1003a-1003d experience higher stresses at the attachment to the device at more acute angles of the linkages, the wedge blocks 1002 are bearing the load during the first expansion stage (e.g., when the linkages 1003a-1003d are most acute). Once the expansion has reached its maximum height facilitated by the wedge blocks, the wedge blocks 1002 disengage and the linkage blocks 1003 provide for additional expansion of the device.

[0041] Referring now to FIGS. 6A-6B, another example expandable interbody device is described. FIG. 6A illustrates a cross-sectional view of the expandable interbody device in the closed position. FIG. 6B illustrates a cross-sectional view of the expandable interbody device in the open position. The device includes endplates 1001a and 1001b (collectively endplates 1001), wedge blocks 1002, and linkage blocks 1003 (and linkages 1003a-1003d). As shown in FIGS. 6A-6B, the wedge blocks 1002 and linkage blocks 1003 are concentric with the drive screw 1004. A drive screw 1004 extends through the wedge blocks 1002 and the linkage blocks 1003, and a driver hole 1007 is provided at one end of the drive screw 1004. An alignment block 1008 is also provided in the device. Except as provided below, the device shown in FIGS. 6A and 6B operates similarly as described above with regard to FIGS. 1-5. For example, during a first stage of expansion, the wedge blocks 1002 exclusively control expansion of the device. To accomplish this, the drive screw 1004 is actuated to drive the wedge blocks 1002, which move together and in opposite directions. For example, when the device is expanded, the wedge blocks 1002 move towards one another (e.g., one wedge block moves to the left and the other wedge block moves to the right). It should be understood that when the device is collapsed, the wedge blocks 1002 move away from one another (e.g., one wedge block moves to the left and the other wedge block moves to the right). The drive screw 1004 includes a first threaded portion 1004a and a second threaded portion 1004b. The first threaded portion 1004a is spaced apart from the second threaded portion 1004b. As described herein, the first threaded portion 1004a engages with the wedge block 1002, and the second threaded portion 1004b engages with the linkage block 1003. The second oblique surfaces 1006 of the wedge blocks 1002 interact with the first oblique surfaces 1005 of the endplates 1001 to expand the upper and lower endplates 1001 of the structural body as the wedge blocks 1002 translate due to rotation of the drive screw 1004. Thus, the wedge blocks 1002 control expansion in the first stage by physically forcing the endplates 1001 apart.

[0042] On the other hand, during a second stage of expansion, the linkage blocks 1003 exclusively control expansion of the device. The drive screw 1004 is actuated to drive the linkage blocks 1003, which move together and in opposite directions. For example, when the device is expanded, the linkage blocks 1003 move towards one another (e.g., one linkage block moves to the left and the other linkage block moves to the right). It should be understood that when the device is collapsed, the linkage blocks 1003 move away from one another (e.g., one linkage block moves to the left and the other linkage block moves to the right). To accomplish this, both the wedge blocks 1002 and the linkage blocks 1003 are provided with threads corresponding to those of the drive screw 1004. For example, the drive screw 1004 includes the first threaded portion 1004a and the second threaded portion 1004b, which is spaced apart from the first threaded portion 1004a. The portion of the drive screw 1004 between the first threaded portion 1004a and the second threaded portion 1004b (i.e., the unthreaded portion) does not have any threads. The first threaded portion 1004a engages with the wedge block 1002 during the first stage (see FIG. 6A), and the second threaded portion 1004b engages with the linkage block 1003 during the second stage (see FIG. 6B). The unthreaded portion of the drive screw 1004 is aligned with the linkage blocks 1003 and the wedge blocks during the first and second stages, respectively. In other words, the respective first and second threaded portions are used to drive the wedge and linkage blocks, respectively. The threads of the second threaded portion 1004b of the drive screw 1004 are timed such that the linkage blocks 1003 are engaged by the drive screw 1004 during the second stage. The threads can be timed such that the linkage blocks 1003 move together and only after initial expansion by the wedge blocks 1002. The drive screw 1004 can therefore be configured to engage the linkage blocks 1003 at the intermediate position, and at this point, the shear pins (not shown in FIGS. 6A and 6B) take on load as the linkages deploy. As described above, a shear pin (e.g., shear pins 1010 in FIGS. 4 and 5) can extend through the proximal end of each of the linkages 1003a-1003d to a portion of the wedge block 1002 (e.g., to a lateral side of the wedge block 1002). The device in FIGS. 6A-6B includes two shear pins, each of which extends through the proximal end of four linkages (e.g., two on each lateral side of a linkage block). The shear pin can be anchored or attached to the wedge block 1002. For example, the shear pin can be coupled with or within the lateral side of the wedge block 1002. Then, as the drive screw 1004 is further actuated, it rotates and drives the linkage blocks 1003, which further expands the upper and lower endplates 1001 of the structural body from the intermediate position to an open position. In this way, the linkage blocks 1003 are directly controlled by the pitch of the second threaded portion 1004b of the drive screw 1004. Additionally, the unthreaded portion of the drive screw 1004 allows the drive screw 1004 to travel without resistance, which prevents loading of the linkages 1003a-1003d during the first stage of expansion. In some implementations, the first threaded portion 1004a has the same pitch as the second threaded portion 1004b, while in other implementations, the first threaded portion 1004a has a different pitch than the second threaded portion 1004h.

[0043] Referring now to FIGS. 7A-7D, another example expandable interbody device is described. FIG. 7A illustrates a side view of the expandable interbody device in the closed position. FIG. 7B illustrates a transparent side view of the expandable interbody device during a first (e.g., initial) stage of expansion. FIG. 7C illustrates a side view of the expandable interbody device during a second stage of expansion. FIG. 7D illustrates a side view of the expandable interbody device in the open position. The device includes endplates 1001a and 1001b (collectively endplates 1001), wedge blocks 1002, and linkage blocks 1003 (and linkages 1003a-1003d). A drive screw 1004 extends through the wedge blocks 1002 and the linkage blocks 1003, and a driver hole 1007 is provided at one end of the drive screw 1004. As shown in FIGS. 7A-7D, the wedge blocks 1002 and linkage blocks 1003 are concentric with the drive screw 1004. An alignment block 1008 is also provided in the device. Except as provided below, the device shown in FIGS. 7A-7D operates similarly as described above with regard to FIGS. 1-5. For example, during a first stage of expansion, the wedge blocks 1002 exclusively control expansion of the device. To accomplish this, the drive screw 1004 is actuated to drive the wedge blocks 1002, which move together and in opposite directions. For example, when the device is expanded, the wedge blocks 1002 move towards one another (e.g., one wedge block moves to the left and the other wedge block moves to the right). It should be understood that when the device is collapsed, the wedge blocks 1002 move away from one another (e.g., one wedge block moves to the left and the other wedge block moves to the right). The second oblique surfaces 1006 of the wedge blocks 1002 interact with the first oblique surfaces 1005 of the endplates 1001 to expand the upper and lower endplates 1001 of the structural body as the wedge blocks 1002 translate due to rotation of the drive screw 1004. Thus, the wedge blocks 1002 control expansion in the first stage by physically forcing the endplates 1001 apart.

[0044] On the other hand, during a second stage of expansion, the linkage blocks 1003 exclusively control expansion of the device. The drive screw 1004 is actuated to deploy the linkages 1003a-1003d, which are attached to the endplates 1001 by endplate pins 1012 and to the linkage blocks 1003 by shear pins 1010 as described above. To accomplish this, a shear pin 1010 can extend through the proximal end of each of the linkages 1003a-1003d and through a portion of the wedge block 1002. One shear pin 1010 can extend through the proximal end of each of the linkages of each linkage block 1003. For example, the device in FIGS. 7A-7D includes two shear pins, each of which extends through the proximal end of four linkages (e.g., two linkages on each lateral side of a linkage block). Additionally, a slot 1011 is arranged in the lateral side of the wedge block 1002. The device in FIGS. 7A-7D includes four slots 1011 (e.g., two on each lateral side of a wedge block and/or one slot for each end of the shear pin). The size and/or shape of the slot 1011 (e.g., outer diameter of the slot 1011) is designed such that the shear pin 1010 can traverse within the slot 1011. For example, in the closed position shown in FIG. 7A, the shear pins 1010 are located within the slots 1011 and centrally with respect to the device. During the first stage of expansion shown in FIG. 7B, the shear pins 1010 traverse within the slots 1011 outwardly with respect to the device as the drive screw 1004 is actuated. Eventually as shown in FIGS. 7C and 7D, the shear pins 1010 reach the outermost edge of the slots 1011 near the intermediate position. As a result, further actuation of the drive screw 1004 drives the shear pins 1010 causing the linkages 1003a-1003d to deploy. As described herein, the shear pins 1010 take on load as they deploy and expand the device between the intermediate and open positions. Optionally, in some implementations, the drive screw 1004 can include a first threaded portion and a second threaded portion as described with regard to FIGS. 6A and 6B. As described herein, the first threaded portion can engage with the wedge block 1002, and the second threaded portion can engage with the linkage block 1003.

[0045] Although examples are provided for expanding the device, it should be understood that the drive screw can be rotated in the opposite direction to contract or collapse the device. For example, the linkage blocks can be used to collapse the device from the open position to the intermediate position, and the wedge blocks can be used to collapse the devices from the intermediate position to the closed position. Additionally, it should be understood that the device can be expanded to a desired height and stay at this desired height during and after implantation. The desired height is independent of the intermediate and/or fully open positions. For example, some patients may require the device to be expanded to a height less than the intermediate position, while some patients may require the device to be expanded to a height greater than the intermediate position. In other words, the device does not need to be expanded to the fully open position (or even the intermediate position) in every case. The dual stage expansion mechanism facilitates the ability of the device to expand to a larger range of heights.

[0046] This disclosure contemplates that the devices (e.g., components of the devices such as the structural body, wedge blocks, linkage blocks, linkages, drive screw, etc.) described herein can be made using alternative medical grade materials. This disclosure contemplates that some or all of the components can be made of the same material in some implementations, while in other implementations some or all of the components can be made of different materials. In some implementations, the device can be made of a molybdenum-rhenium (MoRe) alloy. Optionally, the MoRe alloy is Mo47.5Re. Alternatively, the alloy is optionally 99.99% pure with at least 40 weight percent (wt. %) rhenium. Optionally, the alloy is optionally 99.99% pure with between 40 wt. % and 99.9 wt. % rhenium (e.g., 40.0 wt. %, 40.01 wt. %, 40.02 wt. % . . . 99.88 wt. %, 99.89 wt. %, 99.9 wt. %) and any value or range therebetween. In other implementations, the device can be made of titanium (Ti). In other implementations, the device can be made of a titanium-molybdenum (TiMo) alloy including, but not limited to, Ti-15 Mo. In other implementations, the device can be made of a titanium (Ti) alloy. In other implementations, the device can be made of a cobalt-chromium (CoCr) alloy. Other example alloys that can be used are described, for example, in U.S. 2019/0008995, published Jan. 10, 2019, titled Molybdenum Alloys for Medical Devices, the disclosure of which is expressly incorporated herein by reference in its entirety.

[0047] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.