Bone fusion system, device and method including delivery apparatus

• US 10,213,321 B2
• Filed: 01/18/2017
• Issued: 02/26/2019
• Est. Priority Date: 01/18/2017
• Status: Active Grant

• Current Assignee: Neuropro Technologies Inc.
• Original Assignee: Neuropro Technologies Inc.
• Inventors: Knapp, Troy D., Stalcup, Gregory C., Williams, Kreigh R., Remington, Benjamin J.
• Primary Examiner(s): Philogene, Pedro
• Assistant Examiner(s): Comstock, David C
• Application Number:
  US15/409,423
• Publication Number:
  US 20180200077A1
• Time in Patent Office: 769 Days
• Field of Search: 623 1715, 623 1716, 606246, 606279, 606 92- 94, 606 99, 606102, 606 86 A, 604 27
• CPC Class Codes: A61F 2/447 substantially parallelepipedal, e.g. having a rectangular or trapezoidal cross-section
• CPC Class Codes: A61F 2/4603 for insertion or extraction of endoprosthetic joints or of accessories thereof
• CPC Class Codes: A61F 2/4611 of spinal prostheses
• CPC Class Codes: A61F 2/4657 Measuring instruments used for implanting artificial joints for surgical instruments A61B90/06
• CPC Class Codes: A61F 2002/30131 horseshoe- or crescent- or C-shaped or U-shaped
• CPC Class Codes: A61F 2002/30153 rectangular
• 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 2002/30515 using a locking wedge or block
• CPC Class Codes: A61F 2002/30523 by means of meshing gear teeth
• CPC Class Codes: A61F 2002/30556 for adjusting thickness
• CPC Class Codes: A61F 2002/30593 hollow
• 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 2002/4628 with linear motion along or rotating motion about an axis transverse to the instrument axis or to the implantation direction, e.g. clamping
• CPC Class Codes: A61F 2002/4635 using minimally invasive surgery
• CPC Class Codes: A61F 2002/4658 for measuring dimensions, e.g. length
• CPC Class Codes: A61F 2250/0009 for adjusting thickness

Abstract

A bone fusion method, system 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 tabs 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 bone fusion system for inserting material into a bone fusion device in a desired location, the system comprising:

a bone fusion device having a body with one or more device channels, a positioning element having a positioning aperture and one or more extendable tabs, wherein manipulation of the positioning element enables the tabs to be extended away from the body; and

a delivery apparatus comprising a docking rod and a delivery member having an elongated hollow shaft that leads to an exit aperture, wherein a tip of the docking rod detachably couples to the bone fusion device within the positioning aperture and the delivery member detachably couples with the docking rod such that the exit aperture aligns with one of the device channels when the rod is coupled to the bone fusion device,

wherein the delivery member includes a funneling chamber having a threaded chamber end, wherein the elongated hollow shaft provides a path from the funneling chamber to the exit aperture.

2. The system of claim 1, wherein the one of the device channels is along a side of the bone fusion device.

3. The system of claim 2, wherein the delivery member includes one or more coupling hoops that extend from the hollow shaft, and further wherein the delivery member detachably couples with the docking rod by sliding the docking rod through the coupling hoops.

4. The system of claim 3, wherein the delivery member includes a member handle having a handle channel that aligns with an axis of the coupling hoops, and further wherein the delivery member detachably couples with the docking rod by sliding the docking rod into the handle channel.

5. The system of claim 4, wherein, when the rod is coupled to the bone fusion device, fully inserted in to the handle channel and positioned through the coupling hoops, the exit aperture aligns with the one of the device channels.

6. The system of claim 5, wherein the delivery apparatus includes a rigid plunger comprising:

a plunger handle;

a plunger head;

a plunger rod having a first end coupled to the plunger handle and a second end coupled to the plunger head, wherein the plunger rod has a threaded portion between the plunger handle and the plunger head; and

a plunger hollow tubular cap having an opening at a first cap end, a wall including a screw aperture at a second cap end and a threaded inner tubular wall between the first cap end and the second cap end, wherein an inner surface of the screw aperture is threaded and the plunger hollow tubular cap is threaded onto threaded portion of the plunger rod in between the plunger handle and the plunger head.

7. The system of claim 6, wherein the plunger head has a circular outer perimeter sized such that, when slid into the funneling chamber, the circular outer perimeter abuts a circular inner surface of the funneling chamber.

8. The system of claim 6, wherein the plunger head has a circular outer perimeter sized such that, when slid into the elongated hollow shaft, the circular outer perimeter abuts a circular inner surface of the elongated hollow shaft.

9. The system of claim 8, wherein the delivery apparatus includes a flexible plunger comprising:

a handle;

a first flexible rod;

a second flexible rod; and

a sleeve coupled with the handle, wherein the sleeve holds the first flexible rod adjacent to the second flexible rod in an area such that the first and second flexible rods are held next to each other within the area, but able to flex away from each other outside of the area.

10. The system of claim 9, wherein the portion of the first flexible rod and the portion of the second flexible rod that extend out from the sleeve away from the handle have different lengths such that a distal tip of the first flexible rod is offset from a distal tip of the second flexible rod when both are fully extended away from the sleeve.

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

providing a bone fusion device having a body with one or more device channels, a positioning element having a positioning aperture and one or more extendable tabs, wherein manipulation of the positioning element enables the tabs to be extended away from the body;

detachably coupling a docking rod with the bone fusion device by inserting a tip of the docking rod within the positioning aperture of the device; and

detachably coupling a delivery member to the docking rod, wherein the delivery member has an elongated hollow shaft that leads to an exit aperture, and further wherein, when coupled to the docking rod, the exit aperture aligns with one of the device channels,

wherein the delivery member includes a funneling chamber having a threaded chamber end, wherein the elongated hollow shaft provides a path from the funneling chamber to the exit aperture.

12. The method of claim 11, wherein the one of the device channels is along a side of the bone fusion device.

13. The method of claim 12, wherein the delivery member includes one or more coupling hoops that extend from the hollow shaft and detachably coupling the delivery member to the docking rod comprises sliding the docking rod through the coupling hoops.

14. The method of claim 13, wherein the delivery member includes a member handle having a handle channel that aligns with an axis of the coupling hoops and detachably coupling the delivery member to the docking rod comprises the docking rod into the handle channel.

15. The method of claim 14, wherein, when the rod is coupled to the bone fusion device, fully inserted in to the handle channel and positioned through the coupling hoops, the exit aperture aligns with the one of the device channels.

16. The method of claim 15, further comprising pushing bone graft material from the funneling chamber through the elongated shaft out of the exit aperture and into the one of the channels of the bone fusion device with one or more plungers.

17. The method of claim 16, wherein one of the plungers is a rigid plunger comprising:

a plunger handle;

a plunger head;

a plunger rod having a first end coupled to the plunger handle and a second end coupled to the plunger head, wherein the plunger rod has a threaded portion between the plunger handle and the plunger head; and

a plunger hollow tubular cap having an opening at a first cap end, a wall including a screw aperture at a second cap end and a threaded inner tubular wall between the first cap end and the second cap end, wherein an inner surface of the screw aperture is threaded and the plunger hollow tubular cap is threaded onto threaded portion of the plunger rod in between the plunger handle and the plunger head.

18. The method of claim 17, wherein the plunger head has a circular outer perimeter sized such that, when slid into the funneling chamber, the circular outer perimeter abuts a circular inner surface of the funneling chamber.

19. The method of claim 17, wherein the plunger head has a circular outer perimeter sized such that, when slid into the elongated hollow shaft, the circular outer perimeter abuts a circular inner surface of the elongated hollow shaft.

20. The method of claim 19, wherein one of the plungers is a flexible plunger comprising:

a handle;

a first flexible rod;

a second flexible rod; and

a sleeve coupled with the handle, wherein the sleeve holds the first flexible rod adjacent to the second flexible rod in an area such that the first and second flexible rods are held next to each other within the area, but able to flex away from each other outside of the area.

21. The method of claim 20, wherein the portion of the first flexible rod and the portion of the second flexible rod that extend out from the sleeve away from the handle have different lengths such that a distal tip of the first flexible rod is offset from a distal tip of the second flexible rod when both are fully extended away from the sleeve.

22. A delivery apparatus for use in a bone fusion system, the delivery apparatus comprising:

an elongated hollow shaft having an entrance aperture, an exit aperture and one or more coupling hoops extending from an outer surface of the hollow shaft between the exit aperture and the entrance aperture;

a handle having a handle channel that aligns with an axis of the coupling hoops; and

a funneling chamber coupled to the entrance aperture of the elongated hollow shaft and having a threaded chamber end, wherein the elongated hollow shaft provides a path from the funneling chamber to the exit aperture.

23. The delivery apparatus of claim 22, further comprising a docking rod that detachably couples with the shaft by sliding through the coupling hoops.

24. The delivery apparatus of claim 23, wherein the exit aperture is defined by a cross-sectional cutout of a tip of the hollow shaft, wherein the cross-sectional cutout is parallel with the direction of the path provided by the shaft.

25. The delivery apparatus of claim 24, wherein the docking rod detachably couples with the handle by sliding into the handle channel such that the docking rod is concurrently positioned through the coupling hoops and the handle channel.

26. A rigid plunger for use in a bone fusion system, the rigid plunger comprising:

a plunger handle;

a plunger head;

a plunger rod having a first end coupled to the plunger handle and a second end coupled to the plunger head, wherein the plunger rod has a threaded portion between the plunger handle and the plunger head; and

a plunger hollow tubular cap having an opening at a first cap end, a wall including a screw aperture at a second cap end and a threaded inner tubular wall between the first cap end and the second cap end, wherein an inner surface of the screw aperture is threaded and the plunger hollow tubular cap is threaded onto threaded portion of the plunger rod in between the plunger handle and the plunger head.

27. The rigid plunger of claim 26, wherein the plunger head has a circular outer perimeter having a radius greater than the radius of the plunger rod and smaller than the inner radius of the threaded inner tubular wall of the hollow tubular cap.

28. The rigid plunger of claim 27, wherein the plunger head has a circular outer perimeter having a radius that is substantially equal to the radius of the plunger rod.