PARAXIAL REVISION ROD-TO-ROD CONNECTOR

Abstract

Disclosed herein are an orthopedic rod-to-rod connector and rod-to-rod connector assemblies for spinal fusion surgery. The rod-to-rod connector may include a first connector portion and a second connector portion. The first connector portion may have a first aperture configured to receive at least a portion of a bone-engaging screw and a first spinal rod. The second connector portion may be rotatably connected with the first connector portion and may include a second aperture to receive a second spinal rod. The second connector portion may be L-shaped and may include a set screw to control rotation of the first connector portion with respect to the second connector portion.

Claims

1. An orthopedic rod-to-rod connector comprising: a first connector portion with a first aperture configured to receive at least a portion of a tulip of a screw; and a second connector portion with a second aperture and a third aperture, the third aperture in communication with a channel for receiving a spinal rod, wherein the second connector portion is rotatably coupled with the first connector portion.

2. The connector of claim 1, wherein at least a portion of an external surface of the tulip is received within the first aperture.

3. The connector of claim 1, further comprising a first set screw placed through the first aperture and threadably coupled with the tulip, the first set screw having an extension portion extending through the first and second apertures and threadably coupled with a nut.

4. The connector of claim 1, further comprising a second set screw threadably coupled with the third aperture and extending into the channel

5. The connector of claim 3, wherein tightening of the nut prevents rotation of the first connector portion with respect to the second connector portion.

6. The connector of claim 1, wherein the second connector portion includes an L-shaped portion defining the channel and a fourth aperture and a depression in communication with the channel.

7. The connector of claim 6, wherein the L-shaped portion defines at least 3 points of contact on the spinal rod.

8. The connector of claim 1, wherein the first connector portion includes an extension received within the second aperture.

9. The connector of claim 8, wherein the extension is a circumferential extension.

10. An assembly comprising: a screw portion for engaging a bone; a tulip connected to the screw portion, the tulip having a first channel; a first connector portion with a first aperture receiving at least a portion of an external surface of the tulip; a second connector portion with a second aperture and a third aperture, the third aperture in communication with a second channel, the second connector portion rotatably coupled with the first portion; a first spinal rod disposed within the first channel; and a second spinal rod disposed within the second channel.

11. The assembly of claim 10, further comprising a first set screw placed through the first aperture and threadably coupled with the first channel, the first set screw having an extension portion extending through the first and second apertures and threadably coupled with a nut.

12. The assembly of claim 10, further comprising a second set screw threadably coupled with the third aperture and extending into the second channel that receives the second spinal rod.

13. The assembly of claim 11, wherein the tightening of the nut prevents the rotation of the first connector portion with respect to the second connector portion.

14. The assembly of claim 10, wherein the connector portion includes an L-shaped portion defining the second channel and a fourth aperture and a depression in communication with the second channel

15. The assembly of claim 14, wherein the L-shaped portion defines at least 3 points of contact on the spinal rod.

16. The assembly of claim 10, wherein the first connector portion includes an extension received within the second aperture.

17. The assembly of claim 10, wherein the tulip includes first and second arms defining the first channel.

18. The assembly of claim 10, wherein the first connector portion includes first and second legs that cooperate with the first and second arms.

19. The assembly of claim 10, wherein the tulip is polyaxially movable with respect to the screw portion.

20. An orthopedic rod-to-rod connector comprising: a first connector portion with a first aperture receiving at least a portion of an external surface of a tulip of a screw; and a second connector portion with a second aperture and a third aperture, the third aperture in communication with a channel for receiving a spinal rod, wherein the second connector portion is rotatably coupled with the first connector portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] A more complete appreciation of the subject matter of the present invention and of the various advantages thereof can be realized by reference to the following detailed description in which reference is made to the accompanying drawings in which:

[0017] FIG. 1 is a perspective view of a rod-to-rod connector according to one embodiment of the present invention connected with a pedicle screw.

[0018] FIG. 2 is another perspective view of the connector of FIG. 1.

[0019] FIG. 3 is an exploded view of the connector of FIG. 1.

[0020] FIG. 4 is a cross-sectional side view of the connector of FIG. 1 connected with a pedicle screw and two spinal rods in a first configuration.

[0021] FIG. 5 is a side view of construct of FIG. 4.

[0022] FIG. 6 is an enlarged view of the connector of FIG. 1.

[0023] FIG. 7 is a perspective view of the construct of FIG. 4 in a second configuration.

[0024] FIG. 8 is side view of the construct of FIG. 7 in the second configuration.

[0025] FIG. 9 is a perspective view of the construct of FIG. 4 attached to another pedicle screw.

[0026] FIG. 10 is a top view of the construct of FIG. 9.

[0027] FIG. 11A is a perspective view of the connector of FIG. 1 connected with a pedicle screw and two spinal rods in another configuration.

[0028] FIG. 11B is a perspective view of the construct of FIG. 11A with two rod-to-rod connectors.

DETAILED DESCRIPTION

[0029] In order to develop an appreciation of the principles of the invention, several embodiments as presented in FIGS. 1-10 will be described in the following written specification. The scope of the invention is not intended, however, to be restricted to the embodiments described below. It is also understood that the present invention includes alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention belongs.

[0030] As is shown in FIGS. 1 and 2, an orthopedic rod-to-rod connector 10 is disclosed as including two connector portions 12 and 14. The connector portions are rotatably coupled to each other, in the manner discussed more fully below. Connector portion 12 is designed to cooperate with a pedicle screw 1 having a first spinal rod 50 disposed therein, and connector portion 14 is designed to receive a second spinal rod 52. In many cases, this pedicle screw is an already implanted screw, but could be a screw implanted at the time of connector 10. For instance, connector 10 is specifically useful in a revision scenario where a series of pedicle screws (or in the case of the cervical spine, lateral mass screws) linked via a spinal rod are already present in the body, but additional level(s) of fixation are required. However, the connector may also be useful in connecting differently sized spinal rods, where required (e.g., across multiple regions of the spine). Connector 10 is shown in certain of the Figures cooperating with a pedicle screw 1. That device is typical of a standard pedicle or lateral mass screw and includes a screw portion 3 that is polyaxially coupled with a tulip 5, and the tulip also preferably includes a U-shaped channel 7 defined by upstanding threaded arms 9a, 9b. Of course, the present invention can be configured to cooperate with any known pedicle screw, lateral mass screw, hook or the like.

[0031] Connector portion 12 includes two legs 16a, 16b which are spaced apart a sufficient distance so as to receive a portion of tulip 5 and define a tulip receiving aperture 18. More particularly, legs 16a, 16b are configured to receive portions of arms 9a, 9b of tulip 5. The legs may include structures capable of cooperating with like structures of tulip 5, for instance, projections that extend into channels or the like. It is also noted that legs 16a, 16b are designed so as to create voids 17a, 17b that do not conflict with a rod extending through channel 7. The small voids 19a, 19b above voids 17a, 17b create space to properly fit in different tulip heads. Connector portion 12 also includes a set screw aperture 20 that is in communication with receiving aperture 18 and channel 7, as well as a circular extension 22 that facilitates the rotatable cooperation with connector portion 14 (best shown in FIG. 4).

[0032] Connector portion 14 includes an upper portion 30 that includes a connection aperture 32 and a set screw aperture 34. Connection aperture 32 is sized and shaped to receive extension 22 in a manner that enables the rotation of connector portions 12, 14 with respect to each other. Connection aperture 32 is in communication with set screw aperture 20, receiving aperture 18 and channel 7. This cooperation will be discussed more fully below. Set screw aperture 34 is threaded and extends over an L-shaped portion 36 that extends below upper portion 30. L-shaped portion 36 defines a channel 38 which is in communication with set screw aperture 34. Again, this will be discussed in more detail below. As is best shown in FIG. 6, L-shaped portion 36 includes surfaces 40a-c that define three points of contact with a rod 52 placed within channel 38. These three major points of intersection 40a, 40b and 40c between the spinal rod and the surface provide for a strong fixation of the rod within the channel. In this manner, a three-point fixation mechanism and a set screw 56 placed through set screw aperture 34 secures the spinal rod 52 in the channel 38. Additionally, L-shaped portion 36 defines a rod aperture 42 (best shown in FIGS. 1 and 2) that extends therethrough and allows for reception of the spinal rod 52 in a direction orthogonal to channel 38. Rod aperture 42 cooperates with a depression 44 formed in surface 40c so as to enable the orthogonal placement of the rod 52. Although orthogonal orientation of the rod with respect to channel 38 is facilitated in the design shown in the Figures, it is to be understood that it is within the scope of the present invention to allow for a different orientation. For instance, rod aperture 42 and depression 44 could be situated to allow for placement of a rod at any angle with respect to channel 38. Both the channel 38 and rod aperture 42 can be sized to accommodate rods of varying diameters such as 3.5 mm, 4.5 mm, 5.5 mm and 6.0 mm in the parallel and orthogonal alignments. In either configuration, the rods connected together via connector 10 can be of varying diameters. The connector 10 therefore, eases the implantation procedure of connecting two rods in a revision scenario or otherwise.

[0033] In addition to connector 10 and pedicle screw 1, a construct according to the present invention includes set screw 54 and a nut 58. This is best shown in FIGS. 4, 5 and 7-10. Spinal rod 50 is disposed within channel 7 and spinal rod 52 is disposed within channel 38 (either along the channel or orthogonal thereto). Set screw 54 is threaded with threaded arms 9a, 9b of tulip 4 and extends into channel 7 so as to contact spinal rod 50. As in a typical polyaxial pedicle or lateral mass screw design, tightening of set screw 54 bears on rod 50 which in turn prevents movement of screw portion 3 with respect to tulip 5. Set screw 54 also includes an extension portion that extends through apertures 20 and 32 and above upper portion 30 so as to be engageable with nut 58. Tightening of nut 58, not only ensures that connector 10 is held to the pedicle screws, but also prevents rotation of connector portions 12, 14 with respect to each other. As best seen in FIG. 5, a central longitudinal axis 60 of channel 7 and a central longitudinal axis 62 of channel 38 are offset by a distance 64. However, distance 64 can be adjusted by moving channel 38 or channel 7 such that the axes 60 and 62 may be co-planar along a transverse plane with respect to screw portion 3. Furthermore, longitudinal axis 62 of channel 38 can also be vertically varied as shown by arrow 66 to orient spinal rod 52 at any angle with respect to spinal rod 50. Vertical aligment flexibility is intended to allow rod alignment to match curvature of spine.

[0034] In one method of use, connector 10 is utilized in connection with the last pedicle (or lateral mass) screw in a previously implanted pedicle (or lateral mass) screw construct when another level or levels of fusion are desired (i.e., a revision procedure). In such a case, the connector is placed over the tulip of the pedicle (or lateral mass) screw, as described above. Given that there is often not a lot of rod overhand from the last pedicle (or lateral mass) screw in the initial assembly, engagement with the original rod is often difficult. Thus, placement of the connector over the pedicle (or lateral mass) screw itself eases performance of the procedure. The connector of the present invention also creates a strong connection point, which improves the overall stability of the resultant construct.

[0035] After placement of connector 10, one or more additional pedicle (or lateral mass) screws are then placed in the additional vertebral bodies that are desired to be fused to the previously fused bodies. Connector portion 14 is then rotated with respect to connector portion 12 so as to place it in the most suitable configuration for receiving a second spinal rod for the additional level(s). FIGS. 4 and 5 depict a first configuration in which the already implanted spinal rod and the new spinal rod extend along substantially parallel axes. In this configuration, a rod placed within channel 38 extends along the axis of the channel FIGS. 7 and 8 depict a second configuration in which the spinal rods again extend along substantially parallel axes, but the rod placed through aperture 42 extends orthogonal to the axis of the channel 38. The first and second configurations essentially allow for a different offset distance between the rods. FIGS. 9 and 10 depict a third configuration in which the rods extend at an angle with respect to each other. The rotatable nature of portions 12, 14 allows for this angle to vary, and the flexibility of the placement of a rod within channel 38 allows for further variations in the resultant construct. This is especially beneficial where pedicle (or lateral mass) screws are offset from each other along the spine. Connector 10 enables the rods to be placed even where these offsets may be significant.

[0036] Referring now to FIGS. 11A and 11B, there is shown another arrangement of connector 10, wherein connector 10 is located around an interior portion of two spinal rods 50 and 52 away from the ends of these spinal rods. As best shown in FIG. 11B, two connectors 10 and 10′ can also be used in a “quad rod” procedure, whereby two rods may be secured across vertebrae. A quad rod technique generally employs four rods instead of two rods across the vertebrae. A second rod is added to the main rod on each side of the spinous process and connected by rod-to-rod connectors to increase overall rigidity of the fixation assembly. As shown here, a second rod 52 may be added to a main rod 50 on each side of the spinous process and connected by two rod-to-rod connectors 10 and 10′ to perform a quad rod procedure. The rod-to-rod connectors may be oriented in opposite directions such that spinal rod 50 may be disposed in the first channel of connector 10 and the second channel 38′ of connector 10′ as shown in FIG. 11B. This allows for anchoring at least one screw portion 3 to each spinal rod. Other configurations may have the rod-to-rod connectors oriented in the same direction wherein spinal rod 52 may be disposed in the first channel of the first rod connector and the first channel of the second rod connector. While two rod-to-rod connectors are shown in FIG. 11B, other embodiments may have multiple rod-to-rod connectors attached to two or more spinal rods. Further connector 10 may be used in conjunction with spinal fixation assemblies comprising spinal rod loops, spinal rod connectors and spinal rod reinforcers disclosed in U.S. Provisional Application No. 62/362,690, the disclosure of which is hereby incorporated by reference herein.

[0037] The connector of the present invention is also useful in situations where vertebral bodies across different regions of the spine are being fused by a rod and screw construct. Typically, such constructs involve the use of tapering spinal rods that allow for placement of the rod in pedicle screws sized for the different regions (or in the case of the cervical spine, within lateral mass screws). For instance, a construct extending between the thoracic and lumbar regions of the spine will include a rod with a smaller diameter end for reception within the pedicle screws placed in the thoracic region and a larger diameter end for reception within the pedicle screws placed in the lumbar region. A problem that is often faced in such constructs is that the size and/or orientation of the vertebral bodies requires a level to be skipped. Such region spanning constructs have also been addressed by utilizing two differently sized rods that are connected via a different type of rod-to-rod connector that again often requires the skipping of a level. Use of the connector of the present invention negates the need for such level skipping. For instance, in the foregoing situations, connector 10 can be placed over a pedicle screw (or a lateral mass screw) in the construct and engaged with one of the differently sized rods. Thus, every level can be provided with a pedicle screw and none need to be skipped.

[0038] The various components of the present invention can be constructed of many different materials, preferably materials suitable for implantation in the body. Such components must also be able to withstand the forces typically present in a spinal fusion situation. For instance, it is contemplated to form the various portions of a metallic material, such as stainless steel or titanium. Of course, other materials may be utilized and different portions of the devices disclosed herein can be constructed of different materials from each other. It is also contemplated to provide connectors of varying sizes/configurations for use in connection with differently sized or configured pedicle (or lateral mass) screws and rods. The various connectors may be provided in a kit along with corresponding set screws, rods, etc. Of course, tools suitable for implantation and fixation of the connectors according to the present invention may also be provided. These may include drivers, clamps and other tools necessary to enable the proper application and use of the connectors.

[0039] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.