Bone fusion device, apparatus and method

• US 10,092,422 B2
• Filed: 05/02/2016
• Issued: 10/09/2018
• Est. Priority Date: 08/09/2011
• Status: Active Grant

• Current Assignee: Neuropro Spinal Jaxx, Inc.
• Original Assignee: Neuropro Spinal Jaxx, Inc.
• Inventors: McLuen, Gary R., Remington, Benjamin J., Baker, Daniel R., Logan, Joseph N., Stalcup, Gregory C., Gerbec, Daniel E.
• Primary Examiner(s): Robert, Eduardo C
• Assistant Examiner(s): ECKMAN, MICHELLE CHRISTINE
• Application Number:
  US15/143,935
• Publication Number:
  US 20160242932A1
• Time in Patent Office: 890 Days
• Field of Search: 606 99, 623 1711- 1716
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/30965 Reinforcing the prosthesis by embedding particles or fibres during moulding or dipping
• CPC Class Codes: A61F 2/442 Intervertebral or spinal discs, e.g. resilient non-disc-shaped intervertebral inflatable pockets A61F2/441; non-disc-shaped intervertebral fusion implants A61F2/4455
• CPC Class Codes: A61F 2/4455 for the fusion of spinal bodies, e.g. intervertebral fusion of adjacent spinal bodies, e.g. fusion cages intervertebral discs A61F2/442
• CPC Class Codes: A61F 2/447 substantially parallelepipedal, e.g. having a rectangular or trapezoidal cross-section
• CPC Class Codes: A61F 2/4611 of spinal prostheses
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/3008 radio-opaque, e.g. radio-opaque markers
• CPC Class Codes: A61F 2002/30265 Flat parallelepipeds
• CPC Class Codes: A61F 2002/30365 with additional means for limiting said rotation
• CPC Class Codes: A61F 2002/30367 with additional means for preventing said rotation
• CPC Class Codes: A61F 2002/30372 with additional means for limiting said translation
• CPC Class Codes: A61F 2002/30373 with additional means for preventing said translation
• CPC Class Codes: A61F 2002/30395 with additional means for preventing or locking said rotation
• CPC Class Codes: A61F 2002/30397 Limited lateral translation of the rib within a larger groove
• CPC Class Codes: A61F 2002/30403 Longitudinally-oriented cooperating ribs and grooves on mating lateral surfaces of a mainly longitudinal connection
• CPC Class Codes: A61F 2002/30405 made by screwing complementary threads machined on the parts themselves
• CPC Class Codes: A61F 2002/3041 having threaded portions of different pitches
• CPC Class Codes: A61F 2002/30411 having two threaded end parts connected by a threaded central part with opposite threads at its opposite ends, i.e. for adjusting the distance between both end parts by rotating the central part
• CPC Class Codes: A61F 2002/30413 having threads of increasing height or depth
• CPC Class Codes: A61F 2002/30482 : using a locking cam
• CPC Class Codes: A61F 2002/30484 : Mechanically expandable devices located on the first prosthetic part for locking into or onto the second prosthetic part
• CPC Class Codes: A61F 2002/30507 : using a threaded locking member, e.g. a locking screw or a set screw
• CPC Class Codes: A61F 2002/30517 : using a locking plate
• CPC Class Codes: A61F 2002/3052 : unrestrained in only one direction, e.g. moving unidirectionally
• CPC Class Codes: A61F 2002/30522 : releasable, e.g. using a releasable ratchet
• CPC Class Codes: A61F 2002/30528 : Means for limiting said movement
• CPC Class Codes: A61F 2002/30579 : with mechanically expandable devices, e.g. fixation devices
• CPC Class Codes: A61F 2002/30593 : hollow
• CPC Class Codes: A61F 2002/30594 : slotted, e.g. radial or meridian slot ending in a polar aperture, non-polar slots, horizontal or arcuate slots
• CPC Class Codes: A61F 2002/30601 : telescopic
• CPC Class Codes: A61F 2002/30616 : Sets comprising a plurality of prosthetic parts of different sizes or orientations
• CPC Class Codes: A61F 2002/30777 : Oblong apertures
• CPC Class Codes: A61F 2002/30784 : Plurality of holes
• CPC Class Codes: A61F 2002/30827 : Plurality of grooves
• CPC Class Codes: A61F 2002/30841 : Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes
• CPC Class Codes: A61F 2002/30843 : Pyramidally-shaped
• CPC Class Codes: A61F 2002/30904 : serrated profile, i.e. saw-toothed
• CPC Class Codes: A61F 2002/3093 : for promoting ingrowth of bone tissue
• CPC Class Codes: A61F 2002/4622 : having the shape of a forceps or a clamp
• CPC Class Codes: A61F 2002/4627 : with linear motion along or rotating motion about the instrument axis or the implantation direction, e.g. telescopic, along a guiding rod, screwing inside the instrument
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys

Abstract

A bone fusion method, apparatus and device for insertion between bones that are to be fused together and/or in place of one or more of the bones, such as, for example, the vertebrae of a spinal column. The bone fusion device comprises one or more extendable plates having a central rib. The bone fusion device includes one or more support channels configured to receive an insertion instrument that is then secured to the bone fusion device via a coupling mechanism. As a result, the coupled device is able to be securely positioned between vertebrae using the insertion instrument with minimal risk of slippage.

Claims

1. A method of operation of a bone fusion system, the method comprising:

a. spreading fingers of an insertion instrument with a control mechanism of the insertion instrument, wherein one or more of the fingers comprise a fingertip that protrudes laterally from the finger;

b. sliding the fingers of the insertion instrument into one or more surface channels of a fusion body of a bone fusion device and inserting a drive mechanism of the insertion instrument into a positioning aperture of a positioning element of the bone fusion device, wherein each of the surface channels comprise a gripping aperture positioned within the surface channels for receiving the fingertip of the fingers and the fusion body has a front end and an interior cavity, and further wherein the channels are accessible from the front end and extend through a plane perpendicular to the front end;

c. contracting the fingers with the control mechanism such that the fingertips of the fingers move into gripping apertures of the surface channels and the insertion instrument is detachably coupled with the bone fusion device; and

d. positioning the bone fusion device into a desired position with the insertion instrument.

2. The method of claim 1, further comprising extending one or more extendable tabs of the bone fusion device by manipulating the control mechanism of the insertion instrument, wherein the control mechanism is mechanically coupled with the drive mechanism.

3. The method of claim 2, further comprising:

a. spreading the fingers with the control mechanism such that the fingertips of the fingers move out of the gripping apertures of the surface channels; and

b. sliding the fingers out of the surface channels of the bone fusion device and removing the drive mechanism from within the positioning aperture.

4. The method of claim 2, wherein controlling the spreading the fingers comprises pulling or pushing the control mechanism in or out of a shaft of the insertion instrument.

5. The method of claim 2, wherein extending the extendable tabs comprises rotating the control mechanism with respect to the fingers of the insertion instrument.

6. The method of claim 2, further comprising displaying data corresponding to the amount of rotation of the drive mechanism with an indicator on the insertion instrument.

7. The method of claim 6, wherein the data indicated by the indicator indicates the current position of the tabs relative to the body of the bone fusion device.

8. The method of claim 7, wherein the indicator is adjustable such that the indicator will indicate different data corresponding to the same amount of rotation of the drive mechanism based on the bone fusion device currently coupled to the insertion instrument.

9. The method of claim 2, wherein the surface channels are configured to receive the fingers and positioned along an exterior surface of the body.

10. The method of claim 9, wherein the positioning element is positioned through the front end and within the interior cavity of the body, and further wherein the positioning element is mechanically coupled with the extendable tabs such that moving the positioning element causes the extendable tabs to move with respect to the body.

11. The method of claim 10, wherein the surface channels are positioned along the exterior surface of the body on a plane perpendicular to the positioning aperture of the positioning element such that the fingers of the gripping apparatus are able to slide into the one or more surface channels by moving parallel to the plane.

12. The method of claim 11, wherein the insertion instrument is configured to prevent rotation of the drive mechanism if the fingers are not fully contracted.

13. The method of claim 12, wherein the insertion instrument comprises a locking mechanism that when activated by a trigger prevents rotation of the drive mechanism until the locking mechanism is deactivated by the trigger.

14. An insertion instrument for inserting a bone fusion device into a desired location, the instrument comprising:

a. an elongated body; and

b. a coupling mechanism partially housed by the elongated body and having a control mechanism, a plurality of blocking bodies, a plurality of pins and a plurality of fingers, wherein each of the plurality of fingers is configured to pivot about one of the pins in order to move between a closed position wherein the fingers are close together to a spread position, wherein the fingers are caused to pivot about the pins by the blocking bodies providing a force against angled sides of the fingers as the fingers are slid against the blocking bodies moved based on manipulation of the control mechanism.

15. The instrument of claim 14, wherein one or more of the fingers comprise a fingertip that protrudes laterally from the finger.

16. The instrument of claim 14, further comprising a drive mechanism mechanically coupled with the control mechanism and configured to rotate with respect to the elongated body.

17. The instrument of claim 16, wherein the control mechanism enables selective rotation of the drive mechanism.

18. The instrument of claim 17, further comprising a stopping mechanism that is configured to prevent rotation of the drive mechanism if the fingers are not in the closed position.

19. The instrument of claim 17, further comprising a locking mechanism that when activated by a trigger prevents rotation of the drive mechanism until the locking mechanism is deactivated by the trigger.

20. The instrument of claim 16, further comprising an indicator that indicates data corresponding to the amount of rotation of the drive mechanism.

21. The instrument of claim 20, wherein the data indicated by the indicator indicates the current position of extendable tabs of a bone fusion device coupled to the insertion instrument relative to a body of the bone fusion device.

22. The instrument of claim 21, wherein the indicator is adjustable such that the indicator will indicate different data corresponding to the same amount of rotation of the drive mechanism based on the bone fusion device currently coupled to the insertion instrument.