MOTION PRESERVING SYSTEM AND APPARATUS

Abstract

Systems, apparatuses and methods for preserving motion in an intervertebral disc. Modular disc implant segments can be constructed from a relatively rigid material with compressive spring lobes to act similar to an elastomer. The lobes may be configured to have a C-shaped outer wall and one or more spring arms, such as a leaf springs, to facilitate the modular disc implant segment's ability to compress, thereby enabling an entire intervertebral disc constructed from multiple modular disc implant segments to compress with the implant recipient's movement. The implant segments are sized to be inserted serially into a space defined by the annular fibrosus after removal of the nucleus pulposus with connections being made between adjacent segments in the space during the insertion process.

Claims

1. A disc nucleus replacement assemblage for insertion and for assembly in a row extending across a space defined by and within an annulus fibrosis of a human spine after removal of the nucleus pulposus, the assemblage comprising: a plurality of modular disc implant segments, wherein at least one of the plurality of implant segments comprises: a central base portion formed of a rigid polymer, a superior compressible spring lobe unitary with and extending upwardly from the central base portion, a inferior compressible spring lobe unitary with and extending downwardly from the central base portion, each of the superior compressible spring lobe and inferior compressible spring lobe having a respective C-shaped exterior wall portion defining an open interior, each the exterior wall portion having an exteriorly facing wall surface and an interiorly facing wall surface, each of the superior compressible spring lobe and inferior compressible spring lobe further having a plurality of spring arms within the open interior, each of the spring members connecting to at least one of the respective exterior wall portion and the central base portion by way of a living hinge.

2. The disc nucleus replacement assemblage of claim 1, wherein when viewed from the posterior or anterior, the open interior comprises a plurality of separated voids, each void at defined by one or more of the plurality of spring arms, the exterior wall portion, and/or an interiorly facing surface of the central base portion.

3. The disc nucleus replacement assemblage of claim 1, wherein each of the plurality of spring arms extend to and are unitary with the respective C-shaped exterior wall portion and are also connected to the central base portion.

4. The disc nucleus replacement assemblage of claim 1, wherein when under axial compression, the interiorly facing wall surface confronts and engages a stop portion extending in a vertical direction from the central base portion.

5. The disc nucleus replacement assemblage of claim 1, wherein the central base portion has a minimal circumference that is less than the circumference of superior compressible spring lobe and is less than the circumference of the inferior compressible spring lobe.

6. The disc nucleus replacement assemblage of claim 1, wherein each of the respective C-shaped exterior wall portions extend from the central base portion in a posterior direction and in an anterior direction.

7. The disc nucleus replacement assemblage of claim 1, wherein the base portion comprises a threaded opening for receiving an implant tool, the threaded opening extending in a posterior anterior direction.

8. The disc nucleus replacement assemblage of claim 1, wherein when assembled the assemblage provides a convex smooth upwardly facing surface and a convex downwardly facing surface, a pair of sideward facing surfaces with an elongate central recess extending from one end disk implant segment to an opposite end disk segment.

9. The disc nucleus replacement assemblage of claim 1, wherein the at least one of the plurality of implant segments in an intermediate implant segment that is placed intermediate two end implant segments when assembled, and wherein there are a plurality of intermediate implant segments, each of the plurality of intermediate implant segments comprising: a central base portion formed of a rigid polymer, a superior compressible spring lobe unitary with and extending upwardly from the central base portion, and a inferior compressible spring lobe unitary with and extending downwardly from the central base portion.

10. The disc nucleus replacement assemblage of claim 1, wherein each of the plurality of modular disk segments is formed of polyetheretherketone.

11. A disc nucleus replacement assemblage for insertion and for assembly in a row extending across and within an annulus fibrosis of a human spine after removal of the nucleus pulposus, the assemblage comprising: a plurality of modular disc implant segments, including a pair of end implant segments and a plurality of intermediate implant segments, wherein each of the plurality of intermediate implant segments comprises: a central base portion formed of a polymer with a Youngs Modulus of greater than 3.0 GPa, the central base portion having an interconnecting portion for connecting to an adjacent disc implant segment, and a threaded hole for receiving an implant tool; a superior compressible spring lobe unitary with and extending upwardly from the central base portion, the superior compressible spring lobe formed of the polymer with a Youngs Modulus of greater than 3.0 GPa, the superior compressible spring lobe unitary with the base portion; and an inferior compressible spring lobe unitary with and extending downwardly from the central base portion, the superior compressible spring lobe formed of the polymer with a Youngs Modulus of greater than 3.0 GPa, the inferior compressible spring lobe unitary with the base portion; wherein each of the superior compressible spring lobe and inferior compressible spring lobe having a respective C-shaped exterior wall portion defining an open interior, each the exterior wall portion having an exteriorly facing wall surface and an interiorly facing wall surface, each of the superior compressible spring lobe and inferior compressible spring lobe further having a plurality of spring members within the open interior resisting axial compression of the respective spring lobe.

12. The disc nucleus replacement assemblage of claim 11, wherein the polymer with a Youngs Modulus of greater than 3.0 GPa is polyetheretherketone.

13. The disc nucleus replacement assemblage of claim 11, wherein each spring member has a length of at least 6.0 mm.

14. The disc nucleus replacement assemblage of claim 11, wherein, when viewed from the side, the intermediate implant segments have an I-shape.

15. The disc nucleus replacement assemblage of claim 11, wherein when assembled the assemblage provides a convex smooth upwardly facing surface and a convex downwardly facing surface, a posteriorly facing surface and a anteriorly facing surface each with an elongate central recess extending from one end disk implant segment to an opposite end disk segment, and opposing surfaces with smooth convex surfaces.

16. The disc nucleus replacement assemblage of claim 11, wherein each of the intermediate implant segments have a pair of interconnecting portions, and each of the pair of end implant segments have a single interconnecting portion.

17. The disc nucleus replacement assemblage of claim 16, wherein each of the interconnecting portions is configured as a dovetail joint portion.

18. The disc nucleus replacement assemblage of claim 11, wherein each of the C-shaped exterior wall portions has a thickness of less than 2.0 mm.

19. A disc nucleus replacement assemblage for insertion and for assembly in a row extending across and within an annulus fibrosis of a human spine after removal of the nucleus pulposus, the assemblage comprising: a plurality of modular disc implant segments, wherein each of the plurality of intermediate implant segments comprises: a base portion formed of a polymer with a Youngs Modulus of greater than 3.0 GPa, the central base portion having an interconnecting portion for connecting to an adjacent disc implant segment, and a threaded hole for receiving an implant tool; a first compressible spring lobe unitary with and extending upwardly or downwardly from the central base portion, the first compressible spring lobe formed of the polymer with a Youngs Modulus of greater than 3.0 GPa, the spring lobe having a respective C-shaped exterior wall portion defining an open interior, the exterior wall portion having an exteriorly facing wall surface and an interiorly facing wall surface, and further having a plurality of spring members arranged within the open interior for resisting vertical compression of the spring lobe.

20. The disc nucleus replacement assemblage of claim 19, wherein each of the plurality of intermediate implant segments comprises a second compressible spring lobe extending in a direction from the base portion different than the direction of the first spring lobe, the second spring lobe unitary with the base portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0058] FIG. 1A depicts a top view of a nucleus polposus in an annulus fibrosus on a vertebral body.

[0059] FIG. 1B depicts the vertebral body of FIG. 1A with the nucleus polposus replaced by a disc replacement implant of assembled modular disc implant segments.

[0060] FIG. 1C depicts an assemblage of modular disc implant segments.

[0061] FIG. 1D depicts the assemblage of FIG. 1C assembled.

[0062] FIG. 2A depicts a representative embodiment of an intermediate modular disc implant segment that can form part of an intervertebral disc prosthesis that includes a plurality of modular disc implant segments.

[0063] FIG. 2B depicts the faces of the representative isometric modular disc implant segment.

[0064] FIG. 2C depicts a number of cross-sectional views of the isometric modular disc implant segment 200.

[0065] FIG. 2D depicts a number of cross-sectional views of the opposite side of the isometric modular disc implant segment 200.

[0066] FIG. 2E depicts a representative manner of connecting two (or more) of the modular disc implant segments together.

[0067] FIG. 2F is an example of a constructed intervertebral disc nucleus prosthesis formed by a plurality of connected modular disc implant segments.

[0068] FIG. 2G depicts some of the faces of the representative intervertebral disc nucleus prosthesis 210.

[0069] FIG. 2H depicts an exploded view of the termination and internal modular disc implant segments of a representative five-component intervertebral disc nucleus prosthesis.

[0070] FIG. 2I depicts another embodiment of a constructed intervertebral disc nucleus prosthesis formed by a plurality of connected modular disc implant segments.

[0071] FIG. 2J depicts a representative termination modular disc implant segment that may be used as an endcap of the intervertebral disc nucleus prosthesis.

[0072] FIGS. 3A-3E depict another embodiment of an intervertebral disc nucleus prosthesis utilizing a leaf spring design in accordance with the principles of the disclosure.

[0073] FIG. 4 depicts a representative manner in which the modular disc implant segments may be implanted into the annulus fibrosus.

[0074] FIG. 5 depicts a representative process in which a surgeon can implement the teachings herein to implant a unitary intervertebral disc nucleus prosthesis.

DETAILED DESCRIPTION

[0075] In the following description of various exemplary embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration representative embodiments in which the features described herein may be practiced. It is to be understood that other embodiments may be utilized, as structural and operational changes may be made without departing from the scope of the disclosure.

[0076] Referring to FIGS. 1A to 1D, systems, apparatuses and methods are disclosed for providing an implantable prosthesis 100 for repairing damaged intervertebral discs 110, such as a herniation 119, between vertebral bones 112, the discs comprising a nucleus pulposus 118 in an annulus fibrosus 120. The prosthesis, rather than be inserted as a unitary component, is configured as an assemblage 130 of modular disk implant segments 132 capable of being assembled in the cavity defined by the annulus fibrosus after the damaged nucleus pulposus 118 is removed. Embodiments include modular end disc implant segments 135, 136, and intermediate disc implant segments 138 that are constructed to include one or more portions 140 that are configured to have a greater compressibility than if the structure was solid of the same material, thereby facilitating compression/deflection of the encompassing structure into the one or more internal portions of greater compressibility.

[0077] Referring to FIGS. 1C and 2A, in embodiments, intermediate disk implant segment 138 has a central base portion 144 and a pair of compressible spring lobes 147, 148 unitary therewith and extending therefrom. Each spring lobe 147, 148 having an exterior wall portion 150 with an exteriorly facing surface 152 and an interiorly facing wall surface 153. The exterior wall portion connects to the central base portion 144 at junctures 157, defining an open interior 160. The exterior wall portion 150 extends outwardly from the central base portion 144 and loops around to the opposite side of the central base portion 144 having a C-shape or U-shape and defining the open interior 160. Internal spring members configured as spring arms 166, 168, extend through the open interior and are connected to the exterior wall portion 150 at junctures 169 that function as a living hinge 170; in that during compression, there may be some rotation of the arm portion 171 adjacent the living hinge 170 about the juncture. The spring arms 166, 168 may provide resistance to compression of the spring lobe by bending, extending, and/or contracting under resistance as the spring lobe is compressed and resiliently rebounds.

[0078] The assemblage 130 of modular disc implant segments can be sequentially inserted into a disc space 180 defined by the annulus fibrosus 120 and connected to one another, as further described below, to form a unitary structure, the prosthesis 100, capable of serving as a replacement nucleus pulposus in a damaged intervertebral disc. Referring to FIG. 1D, the prosthesis has a smooth convex upwardly facing surface 184, a smooth convex downwardly facing surface 186, smooth convex sideward facing surfaces 190, 192, and a forward facing surface 194 and a rearward facing surface 195, each with an elongate central recess 197 extending from one end disk implant segment 135 to an opposite end disk segment 136. The elongate recess at the central base portion 144 of the disk implant segments 132. In embodiments, the forward facing surface 194 and a rearward facing surface 195 may be convex with a plurality of openings associated with insertion tools and/or segment connection features.

[0079] Embodiments of the medical apparatus include a vertebral disc nucleus replacement apparatus comprising compressible disc implant segments formed of substantially non-elastomeric material, where an exterior wall portion and spring members facilitate compressibility of the component formed of substantially non-elastomeric material when arranged within the vertebral disc as a replacement to an original nucleus pulposus. For example, some embodiments involve a leaf spring-type structure, where the structure is compressible due to flexing of the leaf spring(s) relative to another part(s) of the disc implant segment.

[0080] In one embodiment, a connectable or interlockable modular disc nucleus implant system and apparatus is provided, where the connectable/interlockable modular implants are made from a rigid material (for example a Young's Modulus greater than 3.0 GPa) that is configured to have compressibility and can withstand rigorous manipulation in the body. One such material is polyether ether ketone, or PEEK. PEEK materials used in embodiments herein may exhibit high temperature and chemical resistances, mechanical strength, resistance to abrasion, and biocompatibility. Such materials may also exhibit a compression modulus similar to that of human bone.

[0081] In embodiments, the present invention utilizes polyetheretherketone (PEEK), specifically Victrex PEEK 450G, as the material for a spinal disc nucleus replacement implant. PEEK is a high-performance, semi-crystalline thermoplastic that exhibits exceptional stiffness, mechanical strength, and resistance to deformation under physiological loading conditions. The superior performance of PEEK is supported by experimental data comparing it to polymeric materials under increasing load conditions.

[0082] The superior performance of PEEK in resisting displacement under load can be attributed to its high mechanical strength and stiffness: Tensile Strength: 98 MPa at 23 C. (ISO 527); Flexural Strength: 165 MPa at yield, 23 C. (ISO 178); Tensile Modulus: 4.0 GPa at 23 C., demonstrating high resistance to deformation; Young's Modulus (Flexural Modulus): 3.8 GPa at 23 C., providing rigidity necessary for spinal load-bearing applications.

[0083] Additionally, PEEK exhibits excellent thermal stability with a melting point of 343 C. and low water absorption of 0.45% at 23 C., ensuring dimensional stability and consistent mechanical performance in a physiological environment.

[0084] In embodiments, other materials may be used that have performance properties above that are withing 30% plus or minus of the specific values above.

[0085] When a plurality of such adjacently positioned modular disc implant segments 132 are connected to form a unitary compressible structure 100, it serves as a motion-preserving device to replace an extracted, impaired nucleus pulposus. In some embodiments, one or more end modular disc implant segments 136 may have the same, or different, internal configuration as the intermediary modular disc implant segments 138. As represented by FIG. 1, there may be any total number of modular disc implant segments utilized (with or without end segments). In some embodiments, the plurality of modular disc implant segments 132 may be as low as two and up to as many as can be reasonably inserted and connected within the given disc space, although sizing preferences may involve more practical implementations from about three to five total implant segments.

[0086] Embodiments include implementation of any number of configurations providing spring members and open interiors. The spring members and open interior regions can be symmetrically or asymmetrically (e.g., offset to one side) positioned within the modular disc implant segment, or alternatively may be configured into a symmetric or asymmetric geometric lobe shape. Spring members may be of various lengths, for example from 4 mm to 20 mm. Spring members may be of various lengths, for example from 6 mm to 15 mm. The spring members may be greater than 4 mm in length embodiments. The spring members may be greater than 8 mm in length in embodiments. The spring members may be greater than 15 mm in length in embodiments. The spring members may have a first thickness of 2 to 2.0 mm displaced from the ends. In embodiments, the spring member may have a second thickness measured transverse to the first thickness of from 0.2 to 2.0 mm displaced from the ends. The spring members may have a first thickness of 4 to 3.0 mm displaced from the ends. In embodiments, the spring member may have a second thickness measured transverse to the first thickness of from 0.4 to 3.0 mm displaced from the ends.

[0087] Alternative embodiments to a structural void(s) (e.g., an open space(s)) include using a first material (e.g., PEEK) proximate one or more adjacent portions of greater compressibility, so that the first material can be compressed into, bend into, or otherwise be flexed into the receiving area(s) having a higher coefficient of compressibility. For example, in some embodiments the open regions may contain a material or substance(s) having a greater compressibility than the material from which the implant segments 100A-100n are otherwise constructed. That is, having a lesser Young's Modulus.

[0088] Thus, the overall compressibility is impacted by at least the material used in the portions having greater compressibility, which could be a pure void (e.g., air), fluid, gel, foam, and/or other material being more compressible than the first material (e.g., PEEK). The first material can be substantially incompressible (or at least inconsequentially compressible), or may itself have some level of compressibility. In some embodiments the first material and/or the second greater compressibility material may respectively be made from a homogeneous material, or alternatively one or both may be made from a heterogeneous material.

[0089] The modular disc implant segments may be constructed in known manners, including but not limited to extrusion, molding (e.g., injection molding, compression molding, blow molding, etc.) 3-dimensional (3D) printing, casting, machining, and the like.

[0090] The structure of exemplary modular disc implant segments therefore provides struts, arms, support tiers, trusses, leaf spring designs, and/or other design that incorporates structural support where necessary while facilitating compression in targeted areas of the modular disc implant segments.

[0091] While the embodiment of FIG. 2A can be constructed from polymers, metals, and/or other biocompatible material, the embodiment of FIG. 2A is described in terms of using PEEK. PEEK has a compression modulus analogous to human bone, so provides a somewhat natural structure for building a nucleus pulposus prosthetic. PEEK also exhibits characteristics that facilitate smooth or otherwise relatively unhindered movement or sliding between adjacent modular disc implant segments as they are successively implanted into the target disc space.

[0092] PEEK also exhibits a very robust longevity, thereby enabling long term benefit from the intervertebral disc prosthesis. The principles described herein are also equally applicable to other materials and compounds exhibiting some or all of these characteristics, such as metal, other polymers, etc. For example, one embodiment utilizes a titanium alloy for the body of the modular disc implant segments.

[0093] FIG. 2A depicts a representative embodiment of a modular disc implant segment 200 that can form part of a intervertebral disc prosthesis that includes a plurality of such modular disc implant segments 200. The representative embodiment of FIG. 2A includes a plurality of structural voids having some symmetry therein, including compression-absorbing spaces 202A, 202B, 202C, 202D, 202E, and 202F. These spaces or voids are strategically positioned, shaped, contoured, and otherwise arranged to properly equilibrate the absorption of, and resistance to, compression that will eventually be provided by a human recipient's spinal movement.

[0094] The representative modular disc implant segment 200 further includes an insertion-facilitating mechanism or portion 204 to assist in the insertion of the implant segment 200 into the target disc space. In the illustrated embodiment, the insertion-facilitating mechanism 204 comprises a female-threaded hole to receive a threaded instrument that can be used to guide, and in some embodiments lock, the modular disc implant segments into the target disc space. It should be recognized that the modular disc implant segments may be equipped with any connection mechanism to facilitate its surgical positioning in the intervertebral disc within the annulus fibrosus.

[0095] The representative modular disc implant segment 138 of FIG. 2A also includes a connection mechanism 206, which in the present example comprises slip fit components including male connector 206A and female connector 206B. In this manner, a tool coupled to the modular disc implant segment 138 via the female-threaded hole 204 can facilitate the coupling of the male connector 206A onto the female connector 206B of an adjacently positioned modular disc implant segment to connect two neighboring implant segments 200.

[0096] The male and female connectors 206A, 206B also facilitate proper alignment of the adjoining implant segments while connecting. In some embodiments, the connection is an interface or mating of physical elements, where in other embodiments the connection is made stronger in that it serves as an interlocked coupling. In some embodiments, the interface, mating, or interlocking mechanisms may be provided by intersecting physical components (e.g., tongue and groove, dovetail), interlocking physical components (e.g., a slip fit), etc. In one interlocking embodiment, the mating physical components are configured to create an interference fit to provide a retention force and thereby prevent unintended separation of the adjoining parts.

[0097] In still other embodiments, magnetics can be used to mate neighboring modular disc implant segments. For example, some or all of the top half of a modular disc implant segment 200 could include magnetic material that is magnetized with a first polarity (e.g., north), and some or all of the bottom half of the implant segment 200 could include magnetic material that is magnetized with a second polarity (e.g., south) to facilitate a magnetic snap fit (with or without additional physical mating or connecting items) between the two neighboring modular disc implant segments. In such an embodiment, magnetic material in the modular disc implant segment can also serve as a radiopaque marker for visualization during the surgical procedure.

[0098] FIG. 2B depicts the faces of the representative isometric modular disc implant segment 138 of FIG. 2A. The depicted faces include the left, front, right, back, top and bottom views, where reference numbers used in connection with FIG. 2A are reproduced in FIG. 2B.

[0099] FIG. 2C depicts a number of cross-sectional views of the isometric modular disc implant segment 200 of FIG. 2A. In the illustrated embodiment, the cross sections are depicted along the X-Y PLANE, the Y-Z PLANE, and the X-Z PLANEs.

[0100] FIG. 2D depicts a number of cross-sectional views of the opposite side of the isometric modular disc implant segment 200 of FIG. 2A. From this view, one embodiment of the mail connector 206A of the connection mechanism 206 is visible.

[0101] FIG. 2E depicts a representative manner of connecting two (or more) of the modular disc implant segments 200A, 200B together. In one embodiment, these segments 200A, 200B are connected after the segment 200A has been inserted into the disc space created by evacuating the existing nucleus pulposus, and during insertion of the adjacent segment 200B into the disc space. In the illustrated embodiment, an insertion part 206A of a first modular disc implant segment 200A is slid over and along a groove 206B of the adjacent modular disc implant segment 200B, such as in a slip fit configuration. In one embodiment, the shape of the male connector 206A within the female connector 206B holds the two modular disc implant segments 200A, 200B together. In other embodiments, a friction or interference fit may instead, or additionally, be implemented to maintain the two modular disc implant segments 200A, 200B in their desired relative positions.

[0102] FIG. 2F is an example of a constructed intervertebral disc nucleus prosthesis 210 formed by a plurality of connected modular disc implant segments 200. In this embodiment, there are five modular disc implant segments, including 3 internal modular disc implant segments 200, and first and second termination modular disc implant segments 201A, 201B. In one embodiment, the termination modular disc implant segments 201A, 201B differ in structural arrangement from the internal modular disc implant segments 200, as they have only one open side in the illustrated embodiment. The cross-sectional view 211 of the representative intervertebral disc nucleus prosthesis 210 reveals the internal portions of the aggregation of modular disc implant segments, including the insertion-facilitating mechanism male connector 206A and female connector 206B of the connection mechanism 206. As previously noted, the male connector 206A and female connector 206B of the connection mechanism 206 hold the modular disc implant segments together to form a unitary intervertebral disc nucleus prosthesis 210, thereby serving as a motion-preserving device.

[0103] In one embodiment, the intervertebral disc nucleus prosthesis 210 is sized, relative to the receiving target disc space of the extracted nucleus pulposus, to eliminate or limit migration. For example, in one embodiment, the intervertebral disc nucleus prosthesis 210 is sized to as large or larger (at least in some dimensions) than the target disc space. In other embodiments, the size of the intervertebral disc nucleus prosthesis 210 may be smaller than the target disc space, but preferably held substantially in place with minimal ability to internally migrate.

[0104] FIG. 2G depicts some of the faces of the representative intervertebral disc nucleus prosthesis 210 of FIG. 2F. FIG. 2G depicts an isometric view, a side view of each termination modular disc implant segments 201A, 201B, a top view, a front view, and a back view. The representative intervertebral disc nucleus prosthesis 210 of FIG. 2G. When external pressure is exerted on such an intervertebral disc nucleus prosthesis 210 (e.g., from lateral, anterior and/or posterior movement of the prosthesis-receiving patient), the pressure-experiencing portion(s) of the intervertebral disc nucleus prosthesis 210 will deflect inward to absorb and respond to the exerted pressure.

[0105] FIG. 2H depicts an exploded view of the modular disc implant segments 200, 201A, 201B of a five-component intervertebral disc nucleus prosthesis 210. Among other things, this depiction indicates a representative manner to connect the modular disc implant segments, such as by way of the male connector 206A of the connection mechanism 206 (receiving/female connector 206B not visible in FIG. 2H). In one embodiment, the mail connector 206A is slid over a receiving groove (not shown) on an adjacent modular disc implant segment. In one particular embodiment, the abutting modular disc implant segments can then be locked together using, for example, a set screw in the insertion-facilitating 204 may bolster the connection therebetween, where in other embodiments such set screw or other additional connection means is not used in addition to the physical mating of the connection elements.

[0106] FIG. 2I depicts another embodiment of a constructed intervertebral disc nucleus prosthesis 210B formed by a plurality of connected modular disc implant segments 200. In the illustrated embodiment, the intervertebral disc nucleus prosthesis 210B includes fewer modular disc implant segments than the example of FIGS. 2F and 2G. This illustrates that the intervertebral disc nucleus prostheses described herein may be of any number of sizes, with any number of disc implant segments (including or exclusive of termination modular disc implant segments), where in this illustrated embodiment the total number of modular disc implant segments is three. Particularly, this illustrative intervertebral disc nucleus prosthesis 210B includes one modular disc implant segments 200, and two termination modular disc implant segments 201A, 201B.

[0107] FIG. 2J depicts a representative termination modular disc implant segment 201A. In this embodiment, the insertion-facilitating mechanism 204 (e.g., female-threaded hole) can be accessed through an access space 212A in the termination modular disc implant segment 201A. In the illustration, the female connector 206B of the connection mechanism 206 is visible, and in a state where it can receive a mail connector 206A from an adjacently placed modular disc implant segment in order to interconnect the segments. Additionally, pivot hinges 212A and 212B may further facilitate deflection, in addition to the structure of the termination modular disc implant segment 201A into the structural void created thereby.

[0108] The examples of FIGS. 2A-2J depict a representative modular connectable segment that can be assembled in situ with one or more other such modular connectable segments to ultimately provide an implanted intervertebral disc prosthesis, where the modular connectable segment may be constructed from a generally non-elastic material that is compressible into one or more integrated spaces or voids. For example, in one embodiment, a modular disc implant segment is provided that includes one or more structural gaps, openings, slits, or other structural voids to facilitate compression of the implant segment in response to an external force, where the implant segment is configured to return towards its original geometric shape in response to diminution of the external force.

[0109] FIG. 3A depicts another embodiment of an intervertebral disc nucleus prosthesis 310 in accordance with the principles of the disclosure. This embodiment includes first and second termination modular disc implant segments 301A, 301B, and 3 intermediary modular disc implant segments 300. Set screw 303 depicts a representative manner in which the modular disc implant segments can be locked together. When interconnected, the modular disc implant segments 300, 301A, 301B collectively form the intervertebral disc nucleus prosthesis 310 depicted in FIG. 3B.

[0110] FIG. 3C depicts another representative configuration of structural voids in the modular disc implant segments. In this embodiment, the structural voids are represented by slits or open channels terminating at opposite ends of the modular disc implant segments 300. These structural voids enable bending/flexing of the arms 314A, 314B to facilitate the compression of the aggregate intervertebral disc nucleus prosthesis 310. As in other embodiments, this leaf spring arrangement properly equilibrates the absorption of, and resistance to, compression that will eventually be exerted due to a human recipient's spinal movement.

[0111] FIG. 3D depicts four faces of the representative modular disc implant segment 300 of FIGS. 3A-3C. FIG. 3D depicts locations of the gaps 302A, 302B (structural voids) between the arms 314A, 314B relative to the internal body of the modular disc implant segment 300 itself. FIG. 3D also displays a connection mechanism including a male connector 306 which can be used to align and connect to another, adjacent implant segment 300. Further, FIG. 3D depicts another embodiment of an insertion-facilitating mechanism 404 to assist in the insertion of the implant segment 300 into the target disc space. In the illustrated embodiment, the insertion-facilitating mechanism 304 comprises a female-threaded hole to receive a threaded instrument that can be used to guide, and in some embodiments lock, the modular disc implant segments into the target disc space. FIG. 3E depicts additional details on the embodiment described in connection with FIGS. 3A-3D. The exterior dimensions of FIGS. 3D and 3E are exemplary for the different segment embodiments. In embodiments, intermediate implant segments have particular ones of the exterior dimensions identified and that are deducible from the drawings, that are with 10% plus or minus those portrayed in FIGS. 3D and 3E. In embodiments, intermediate implant segments have particular ones of the exterior dimensions identified and that are deducible from the drawings, that are with 25% plus or minus those portrayed in FIGS. 3D and 3E.

[0112] FIG. 4 depicts a representative manner in which the modular disc implant segments may be implanted into the annulus fibrosus 401. The representative implant tool 400 can couple to the modular disc implant segments 402 to guide them through an access orifice 404 created in the annulus fibrosus 401 and facilitate interconnection and/or interlocking an adjacent modular disc implant segment. In such a manner, the target disc space 406 can be equipped with a unitary intervertebral disc nucleus prosthesis as described herein.

[0113] FIG. 5 depicts a representative process in which a surgeon can implement the teachings herein to implant a unitary intervertebral disc nucleus prosthesis. In such an embodiment, the surgeon can utilize modular disc implant segments, each having structural voids to enable compression of the modular disc implant segments in response to an external force, and where each are constructed of a material configured to return towards its original geometric shape in response to diminution of the external force. The process includes implanting a first modular disc implant segments, and in connection with implanting a second modular disc implant segment, the surgeon can connect the second modular disc implant segment to the first modular disc implant using a connection mechanism provided on each of the first and second modular disc implant segments. The last of the modular disc implant segments is then implanted to form an aggregate intervertebral disc prosthesis in situ in the patient.

[0114] The present disclosure solves numerous problems of the prior art, including insertion and biomaterial problems. In one embodiment, a solution is provided by using a single well known, biocompatible, thermoplastic material with a unique design that takes advantage of this material's excellent flexion fatigue characteristic to provide a compression modulus for the motion segment similar to the native nucleus pulposus in all ranges of motion, while also having a compression modulus of the material similar to bone.

[0115] Such an embodiment will allow the surgeon to reestablish the normal disc height and re-tense the annulus fibrosus fibers to establish a physiologic load sharing between the annulus and the nucleus pulposus.

[0116] Embodiments set forth herein include a simple yet robust attachment system to make implantation for the modules fast, reproducible, easily learned and secure.

[0117] As noted herein, the inventive information includes the various representative embodiments disclosed herein, which those skilled in the art can appreciate other embodiments from the teachings provided herein. Other representative/exemplary embodiments are set forth herein.

[0118] In one representative embodiment, a disc nucleus replacement apparatus is provided that implements a leaf spring arrangement to provide the necessary compressibility to mimic the native nucleus pulposus to allow motion between adjacent vertebrae.

[0119] In another particular embodiment, such a disc nucleus replacement apparatus (also referred to herein as an implant) includes a non-elastomeric material configured with one or more moveable leaves, (connected but separated from the body of the implant by an open channel) such that the implant as a whole is compressible. In a more specific representative embodiment, two or more leaf springs are configured in each module. In another more specific embodiment, the material comprises polyether ether ketone (PEEK), and in some embodiments the material is made entirely of PEEK.

[0120] In yet another embodiment of such a disc nucleus replacement apparatus, the material comprises a thermoplastic material, where in other embodiments the material comprises an elastomer, where in still other embodiments the material comprises a composite of elastomer and thermoplastic. In still other embodiments the material comprises a metal, where in yet other embodiments the material comprises a composite of metal and polymer (e.g., elastomeric or thermoplastic).

[0121] In another particular embodiment of such a disc nucleus replacement apparatus, the material has a hardness or compression modulus similar to bone.

[0122] In another particular embodiment, the implant includes two or more modules to allow insertion through a pathway in the annulus fibrosus. In a more specific embodiment, the modules include channels configured in a Z configuration with the open end on the upper channel facing posterior, and the open end of the lower channel facing anterior. In an alternative specific embodiment, the modules include channels configured in a Z configuration with the open end on the upper channel facing anterior, and the open end of the lower channel facing posterior. In yet other embodiments, the implant is inserted through a sequential dilator and distraction instrument(s), while in other embodiments the open anterior channel ends posteriorly in an enlarged, generally circular space to improve the compressibility of the leaf element. In another embodiment, the open posterior channel ends posteriorly in an enlarged, generally circular space to improve the compressibility of the leaf element.

[0123] In another embodiment, such a disc nucleus replacement apparatus is configured for insertion through Posterior Lumbar Interbody Fusion (PLIF), Transforaminal Lumbar Interbody Fusion (TLIF), and for lateral approaches.

[0124] Another embodiment includes a vertebral disc nucleus replacement apparatus comprising one or more structural voids within a substantially non-elastomeric component, where the structural voids facilitate compressibility of the substantially non-elastomeric component proximate the one or more structural voids when arranged within the vertebral disc as a replacement to an original nucleus pulposus.

[0125] The foregoing description of representative embodiments has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching without departing from the broader scope and spirit of the disclosure. Teachings in the specification and drawings are therefore regarded as illustrative, and not restrictive. The invention covers alternatives, modifications, and equivalents that come within the scope and spirit of the principles set out herein and/or in the appended claims.

[0126] The accompanying drawings forming a part of the disclosure show, by way of illustration and not of limitation, particular representative embodiments in which the disclosed concepts may be practiced. Therefore, this Detailed Description is not to be taken in a limiting sense, and the scope of various embodiments is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.

[0127] The embodiments of the innovative subject matter may be collectively or individually referred to herein as the invention for convenience, without intending to restrict the scope of this application to any single invention or inventive concept if multiple concepts are disclosed. Therefore, while specific embodiments have been illustrated and described herein, it should be understood that any arrangement designed to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure intends to encompass all adaptations or variations of various embodiments. Those skilled in the art will recognize combinations of the above embodiments and other embodiments not explicitly described herein upon reviewing the foregoing description.

[0128] The following United States patents are hereby incorporated by reference herein for all purposes: U.S. Pat. Nos. 5,888,220; 7,713,301; 8,038,718; 8,100,977; 8,123,750; 9,510,953; 10,195,048; and 11,246,714. Published U.S. Patent Applications: US2004/0247641; US2006/0111726; and US2008/0071379 are hereby incorporated by reference herein for all purposes. The above references to U.S. patents in all sections of this application are herein incorporated by references in their entirety for all purposes. Components, methods, tools, materials illustrated and/or disclosed in such patents may be utilized with embodiments herein. Incorporation by reference is discussed, for example, in MPEP section 2163.07(B).

[0129] The above references in all sections of this application are herein incorporated by references in their entirety for all purposes. All of the features disclosed in this specification (including the references incorporated by reference, including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

[0130] Each feature disclosed in this specification (including references incorporated by reference, any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0131] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. The above references in all sections of this application are herein incorporated by references in their entirety for all purposes.

[0132] Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following illustrative aspects. The above-described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention.