Bone fusion device

• US 10,016,283 B2
• Filed: 11/22/2016
• Issued: 07/10/2018
• Est. Priority Date: 04/13/2012
• Status: Active Grant

• Current Assignee: Neuropro Technologies Inc.
• Original Assignee: Neuropro Technologies Inc.
• Inventors: McLuen, Gary R., Baker, Daniel R., Remington, Benjamin J.
• Primary Examiner(s): Robert, Eduardo C
• Assistant Examiner(s): ECKMAN, MICHELLE CHRISTINE
• Application Number:
  US15/358,581
• Publication Number:
  US 20170071752A1
• Time in Patent Office: 595 Days
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/0256 for the spine
• CPC Class Codes: A61B 2090/032 pressure limiting, e.g. hydrostatic
• CPC Class Codes: A61B 2090/061 for measuring dimensions, e.g. length
• CPC Class Codes: A61B 2090/065 for measuring contact or contact pressure
• CPC Class Codes: A61B 2090/0807 Indication means
• CPC Class Codes: A61B 90/03 Automatic limiting or abutting means, e.g. for safety
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/441 made of inflatable pockets or chambers filled with fluid, e.g. with hydrogel
• CPC Class Codes: A61F 2/4465 having a circular or kidney shaped cross-section substantially perpendicular to the axis of the spine
• CPC Class Codes: A61F 2/447 substantially parallelepipedal, e.g. having a rectangular or trapezoidal cross-section
• CPC Class Codes: A61F 2/4601 for introducing bone substitute, for implanting bone graft implants or for compacting them in the bone cavity
• CPC Class Codes: A61F 2/4657 Measuring instruments used for implanting artificial joints for surgical instruments A61B90/06
• CPC Class Codes: A61F 2002/2839 Bone plugs or bone graft dowels
• CPC Class Codes: A61F 2002/30522 releasable, e.g. using a releasable ratchet
• CPC Class Codes: A61F 2002/30525 Worm gears
• CPC Class Codes: A61F 2002/30538 for adjusting angular orientation
• CPC Class Codes: A61F 2002/30556 for adjusting thickness
• CPC Class Codes: A61F 2002/30579 with mechanically expandable devices, e.g. fixation devices
• CPC Class Codes: A61F 2002/30581 having a pocket filled with fluid, e.g. liquid
• CPC Class Codes: A61F 2002/30601 : telescopic
• CPC Class Codes: A61F 2002/30617 : Visible markings for adjusting, locating or measuring
• CPC Class Codes: A61F 2002/448 : comprising multiple adjacent spinal implants within the same intervertebral space or within the same vertebra, e.g. comprising two adjacent spinal implants
• CPC Class Codes: A61F 2002/4661 : for measuring thickness
• CPC Class Codes: A61F 2002/4666 : for measuring force, pressure or mechanical tension

Abstract

A bone fusion device for insertion between bones that are to be fused together, such as, for example, the vertebrae of a spinal column. The bone fusion device comprises at least one extendable tab and one or more tab extension assemblies. Each tab extension assembly is able to be adjusted in order to individually control the extension or contraction of a side of the tab thereby enabling adjustment of the height and/or angle of the tab with respect to the body of the bone fusion device. Each tab extension assembly is able to be individually adjusted such that the side controlled by each assembly is raised or lowered until the desired tab angle is achieved. The tab is advantageously positioned and angled to correspond to the vertebrae to help brace the device until the bone has fused.

Claims

1. A method of implanting a bone fusion device into a desired location, the method comprising:

inserting the bone fusion device in the desired location, wherein the bone fusion device comprises a body having an interior cavity, a tab configured to fit within the interior cavity and selectively move from a retracted position within the interior cavity of the body to an extended position extending out of the body, a first extension assembly coupled to a first portion of the tab and comprising a first threaded drive mechanism and a first drive screw configured to move the first portion of the tab between the retracted position and the extended position, and a second extension assembly coupled to a second portion of the tab and comprising a second threaded drive mechanism and a second drive screw, non-coaxial to the first drive screw, and configured to move the second portion of the tab between the retracted position and the extended position; and

independently extending one or both of the first portion and the second portion of the tab from the retracted position within the interior cavity to a position at least partially outside the interior cavity by moving one or both of the first drive screw and the second drive screw.

2. The method of claim 1, further comprising adjusting the amount which one or more of the different portions of the tab are extended compared to the remainder of the different portions of the tab such that the angle of the tab with respect to the body is adjusted.

3. The method of claim 1, wherein each of the first and second threaded drive mechanisms comprise a worm gear operably coupled between the drive screw and a support jack such that rotation of the drive screw rotates the worm gear which retracts or extends the support jack into or out of the worm gear.

4. The method of claim 3, wherein at least one of the first and second drive screws is accessible through a first lateral side of the body and at least a second one of the drive screws is accessible through a second lateral side of the body.

5. The method of claim 3, wherein the device further comprises a support webbing positioned within the inner cavity of the body between one or more walls of the inner cavity and the exterior of the worm gears such that the support webbing resists lateral movement of the worm gears with respect to the walls of the inner cavity.

6. The method of claim 1, wherein the first and second extension assemblies are pivotably coupled to the different portions of the tab such that the tab is able to pivot about the extension assembly.

7. The method of claim 1, wherein the body has a bottom surface and an upper surface, wherein the upper surface is angled with respect to the bottom surface.

8. The method of claim 1, further comprising removably filling one or more holes with one or more plugs, wherein the body and the tab comprise the one or more holes, which extend from outside the device to the inner cavity and are configured to be removably filled by the plugs.

9. The method of claim 8, wherein the plugs comprise bone material.

10. The method of claim 1, wherein the tab comprises one or more tangs positioned along a perimeter of the top surface of the tab and fit within recesses in the top surface of the body when the tab is in the retracted position.

11. The method of claim 10, wherein one or more of the tangs extend from a perimeter of the tab to a perimeter of the body.

12. The method of claim 1, further comprising retracting the tab of the bone fusion device into the retracted position before inserting the bone fusion device into the desired location.

13. A method of implanting a bone fusion device into a desired location, the bone fusion device comprising a body having an interior cavity, a tab configured to fit within the interior cavity and comprising a first tab portion and a second tab portion, a first extension assembly coupled to a first portion of the tab and comprising a first threaded drive mechanism and a first drive screw configured to move the first portion of the tab between the retracted position and the extended position, and a second extension assembly coupled to a second portion of the tab and comprising a second threaded drive mechanism and a second drive screw, non-coaxial to the first drive screw, and configured to move the second portion of the tab between the retracted position and the extended position, the method comprising:

inserting the bone fusion device in the desired location; and

independently extending the first tab portion by moving the first drive screw of the first extension assembly and extending the second tab portion by moving the second drive screw of the second extension assembly.

14. The method of claim 13, further comprising adjusting an amount which the first tab portion and the second tab portion such that the angle of the tab with respect to the body is adjusted.

15. The method of claim 13, wherein the first extension assembly comprises a worm gear operably coupled between the first drive screw and a support jack such that rotation of the first drive screw rotates the worm gear which retracts or extends the support jack into or out of the worm gear.

16. The method of claim 15, wherein the first drive screw of the first extension assembly is accessible through a first lateral side of the body.

17. The method of claim 16, wherein the second drive screw of the second extension assembly is accessible through a second lateral side of the body.

18. The method of claim 15, wherein the device further comprises a support webbing positioned within the inner cavity of the body between one or more walls of the inner cavity and the exterior of the worm gears such that the support webbing resists lateral movement of the worm gears with respect to the walls of the inner cavity.

19. The method of claim 13, wherein the first extension assembly is pivotably coupled to the first tab portion such that the tab is able to pivot about the first extension assembly.

20. The method of claim 13, wherein the body has a bottom surface and an upper surface, wherein the upper surface is angled with respect to the bottom surface.

21. The method of claim 13, further comprising removably filling one or more holes with one or more plugs, wherein the body and the tab comprise the one or more holes, which extend from outside the device to the inner cavity and are configured to be removably filled by the plugs.

22. The method of claim 21, wherein the plugs comprise bone material.

23. The method of claim 13, wherein the tab comprises one or more tangs positioned along a perimeter of the top surface of the tab and fit within recesses in the top surface of the body when the tab is in the retracted position.

24. The method of claim 23, wherein one or more of the tangs extend from a perimeter of the tab to a perimeter of the body.

25. The method of claim 13, further comprising retracting the tab of the bone fusion device into a retracted position within the body before inserting the bone fusion device into the desired location.

26. A method of implanting a bone fusion device into a desired location, the bone fusion device comprising a body having an interior cavity, a tab configured to fit within the interior cavity and comprising a first tab portion and a second tab portion, a first extension assembly coupled to the first tab portion and a second extension assembly coupled to the second tab portion, the first extension assembly comprises a first worm gear operably coupled between a first drive screw and a first support jack such that rotation of the first drive screw rotates the first worm gear which retracts or extends the first support jack into or out of the first worm gear, and the second extension assembly comprises a second worm gear operably coupled between a second drive screw and a second support jack such that rotation of the second drive screw rotates the second worm gear which retracts or extends the second support jack into or out of the second worm gear, wherein the first drive screw of the first extension assembly is accessible through a first lateral side of the body and the second drive screw of the second extension assembly is accessible through a second lateral side of the body that is not opposite the first lateral side of the body, the method comprising:

inserting the bone fusion device in the desired location; and

independently extending the first tab portion by moving the first extension assembly and extending the second tab portion by moving the second extension assembly.

27. The method of claim 26, further comprising adjusting an amount which the first tab portion and the second tab portion such that the angle of the tab with respect to the body is adjusted.

28. The method of claim 26, wherein the first extension assembly is pivotably coupled to the first tab portion such that the tab is able to pivot about the first extension assembly.

29. The method of claim 26, wherein the body has a bottom surface and an upper surface, wherein the upper surface is angled with respect to the bottom surface.

30. The method of claim 26, further comprising removably filling one or more holes with one or more plugs, wherein the body and the tab comprise the one or more holes, which extend from outside the device to the inner cavity and are configured to be removably filled by the plugs.

31. The method of claim 30, wherein the plugs comprise bone material.

32. The method of claim 26, wherein the tab comprises one or more tangs positioned along a perimeter of the top surface of the tab and fit within recesses in the top surface of the body when the tab is in the retracted position.

33. The method of claim 32, wherein one or more of the tangs extend from a perimeter of the tab to a perimeter of the body.

34. The method of claim 26, wherein the device further comprises a support webbing positioned within the inner cavity of the body between one or more walls of the inner cavity and the exterior of the worm gears such that the support webbing resists lateral movement of the worm gears with respect to the walls of the inner cavity.

35. The method of claim 26, further comprising retracting the tab of the bone fusion device into a retracted position within the body before inserting the bone fusion device into the desired location.