Expandable cage

• US 10,398,563 B2
• Filed: 05/08/2017
• Issued: 09/03/2019
• Est. Priority Date: 05/08/2017
• Status: Active Grant

• Current Assignee: Medos International Sarl (Johnson & Johnson)
• Original Assignee: Medos International Sarl (Johnson & Johnson)
• Inventors: Engstrom, Connor
• Primary Examiner(s): Plionis, Nicholas J
• Application Number:
  US15/589,209
• Publication Number:
  US 20180318101A1
• Time in Patent Office: 848 Days
• 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 2/4425 made of articulated components
• 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 2/4637 for connecting or disconnecting two parts of a prosthesis
• CPC Class Codes: A61F 2002/30387 Dovetail connection
• 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 2002/30507 using a threaded locking member, e.g. a locking screw or a set screw
• 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 2002/443 having two transversal endplates and at least one intermediate component
• CPC Class Codes: A61F 2002/4638 Tools for performing screwing, e.g. nut or screwdrivers, or particular adaptations therefor

Abstract

An intervertebral implant that iterates between collapsed and expanded configurations includes first and second plates spaced from one another along a first direction and defining bone-contacting surfaces facing away from each other along the first direction. An expansion assembly is positioned between the plates with respect to the first direction and includes a first support wedge that supports the first plate and defines a first ramp and a second support wedge that supports the second plate and defines second and third ramps. The expansion assembly includes an expansion wedge defining a fourth ramp. The first, second, third, and fourth ramps are each inclined with respect to a second direction that is substantially perpendicular to the first direction. At least one of the first and second support wedges is slidable along the respective supported first or second plate. The implant includes an actuator configured to apply a drive force to the expansion wedge so as to cause 1) the fourth ramp to ride along the third ramp so as to increase a distance between the bone-contacting surfaces along the first direction, and 2) the second ramp to ride along the first ramp, thereby further increasing the distance, thereby iterating the implant from the collapsed to the expanded configuration.

Claims

1. An intervertebral implant configured to iterate between a collapsed configuration and an expanded configuration, the implant comprising:

a first plate and a second plate spaced from one another along a first direction, the first plate defining a first bone-contacting surface, the second plate defining a second bone-contacting surface facing away from the first bone-contacting surface along the first direction;

an expansion assembly disposed between the first and second plates with respect to the first direction, the expansion assembly including;

a first support wedge supporting the first plate, the first support wedge defining a first ramp;

a second support wedge supporting the second plate, the second support wedge defining a second ramp and a third ramp; and

an expansion wedge defining a fourth ramp,

wherein each of the first, second, third, and fourth ramps is inclined with respect to a second direction that is substantially perpendicular to the first direction, and at least one of the first and second support wedges is slidable along the respective supported first or second plate; and

an actuator configured to apply a drive force to the expansion wedge so as to cause

     1) the fourth ramp to ride along the third ramp so as to increase a distance between the first and second bone-contacting surfaces along the first direction, and

     2) the second ramp to ride along the first ramp, thereby further increasing the distance, thereby iterating the implant from the collapsed configuration to the expanded configuration,

wherein the first and second support wedges and the expansion wedge are translatable relative to each other.

2. The implant of claim 1, wherein the distance increases at least by a factor of 2.0 between the collapsed and expanded configurations.

3. The implant of claim 1, wherein each of the first, second, third, and fourth ramps is inclined at an incline angle in the range of 10 degrees to 60 degrees.

4. The implant of claim 3, wherein the expansion wedge defines an additional ramp configured to ride along the first ramp responsive to the drive force, and the additional ramp is inclined at an angle in the range of 20 degrees to 50 degrees.

5. The implant of claim 1, wherein the actuator is rotatable about an axis oriented along the second direction, and the actuator drives the expansion wedge to translate along the second direction as the fourth ramp rides along the third ramp.

6. The implant of claim 1, wherein the actuator is threadedly coupled to the expansion wedge, such that rotation of the actuator about the axis causes the expansion wedge to threadedly translate along the actuator.

7. The implant of claim 1, wherein:

the expansion assembly is a first expansion assembly; and

the implant further comprises a second expansion assembly disposed between the first and second plates with respect to the first direction, the second expansion assembly spaced from the first expansion assembly along the second direction, the second expansion assembly including;

a third support wedge supporting the first plate, the third support wedge defining a fifth ramp;

a fourth support wedge supporting the second plate, the second support wedge defining a sixth ramp and a seventh ramp; and

a second expansion wedge defining an eighth ramp,

wherein each of the fifth, sixth, seventh, and eighth ramps is inclined with respect to the second direction, and at least one of the third and fourth support wedges is slidable along the respective supported first or second plate, and

the actuator is configured to apply a second drive force to the second expansion wedge so as to cause

     1) the eighth ramp to ride along the seventh ramp as the fourth ramp rides along the third ramp so as to collectively increase the distance between the first and second plates along the first direction, and

     2) the sixth ramp to ride along the fifth ramp as the second ramp rides along the first ramp so as to collectively further increasing the distance between the first and second plates along the first direction, thereby iterating the implant from the collapsed configuration to the expanded configuration.

8. The implant of claim 1, wherein the expanded configuration is a first expanded configuration, expansion assembly is a first expansion assembly, the distance is a first distance, and the implant further comprises:

a first side and a second side spaced from the first side along a third direction that is substantially perpendicular to the first and second directions, wherein the first distance is measurable at the first side of the implant;

a second expansion assembly disposed between the first and second plates with respect to the first direction, the second expansion assembly spaced from the first expansion assembly along the third direction, the second expansion assembly including;

a third support wedge supporting the first plate, the third support wedge defining a fifth ramp;

a fourth support wedge supporting the second plate, the second support wedge defining a sixth ramp and a seventh ramp; and

a second expansion wedge defining an eighth ramp,

wherein each of the fifth, sixth, seventh, and eighth ramps is inclined with respect to the second direction, and at least one of the third and fourth support wedges is slidable along the respective plate supported by the one of the third and fourth support wedges; and

a second actuator configured to apply a second drive force to the second expansion wedge so as to cause

     1) the eighth ramp to ride along the seventh ramp so as to increase a second distance between the first and second plates along the first direction, wherein the second distance is measurable at the second side, and

     2) the sixth ramp to ride along the fifth ramp so as to further increasing the second distance between the first and second plates along the first direction, thereby iterating the implant from the collapsed configuration to the second expanded configuration, wherein, in the second expanded configuration, the second distance is different than the first distance such that one of the first and second plates is tilted with respect to the other of the first and second plate.

9. An intervertabral implant configured to iterate between a collapsed configuration and an expanded configuration, the implant comprising:

a first plate and a second plate spaced from one another along a first direction, the first plate defining a first bone-contacting surface, the second plate defining a second bone-contacting surface facing away from the first bone-contacting surface along the first direction;

an expansion assembly disposed between the first and second plates with respect to the first direction, the expansion assembly including;

a first support wedge supporting the first plate, the first support wedge defining a first ramp;

the second support wedge supporting the second plate, the second support wedge defining a second ramp and a third ramp; and

an expansion wedge defining a fourth ramp,

wherein each of the first, second, third, and fourth ramps is inclined with respect to a second direction that is substantially perpendicular to the first direction, and at least one of the first and second support wedges is slidable along the respective supported first or second plate; and

an actuator configured to apply a drive force to the expansion wedge so as to cause

     1) the fourth ramp to ride along the third ramp so as to increase a distance between the first and second bone-contacting surfaces along the first direction, and

     2) the second ramp to ride along the first ramp, thereby further increasing the distance, thereby iterating the implant from the collapsed configuration to the expanded configuration,

wherein;

when the implant is in the collapsed configuration, an entirety of the first support wedge is spaced from an entirety of the expansion wedge with respect to the second direction, and at least a portion of the second support wedge is disposed between the first support wedge and the expansion wedge with respect to the second direction; and

when the implant is in the expanded configuration, the first support wedge underlies an entirety of the expansion wedge with respect to the first direction, and an entirety of the second support wedge is spaced from an entirety of the first support wedge with respect to the first direction.

10. The implant of claim 9, wherein the first plate defines a first channel elongate along the second direction, the second plate defines a second channel elongate along the second direction, the first and second channels are open toward one another and overly one another so as to define a compartment, and each of the wedges is housed within the compartment when the implant is in the collapsed configuration.

11. The implant of claim 10, wherein:

the first channel defines a first base surface extending along the second direction and a third direction that is perpendicular to the first and second directions;

the second channel defines a second base surface extending along the second and third directions, and the first and second base surfaces face one another;

the second support wedge defines a wedge base surface that is configured to slide along the second base surface during expansion of the implant between the collapsed configuration and the expanded configuration, and

the expansion wedge defines another wedge base surface that is configured to ride along the first base surface during expansion of the implant.

12. The implant of claim 11, wherein the expansion wedge further defines an additional ramp that is inclined with respect to the second direction, and the implant is configured such that, during a first phase of expansion of the implant:

the additional ramp is remote from the first ramp with respect to the second direction while the second ramp rides along the first ramp and;

the fourth ramp rides along the third ramp; and

the another wedge base surface rides along the first base surface.

13. The implant of claim 12, wherein the implant is configured such that, during a second phase of expansion of the implant, 1) the additional ramp rides along the first ramp, and 2) the second ramp is remote from the first ramp.

14. An implant for lateral insertion into an intervertebral space, the implant comprising:

an expansion mechanism disposed between a first endplate and a second endplate with respect to a vertical direction, the first endplate defining a first-bone contacting surface, the second endplate defining a second bone-contacting surface facing away from the first bone-contacting surface along the vertical direction, the expansion mechanism comprising;

an anterior actuation assembly arranged along a first axis; and

a posterior actuation assembly arranged along a second axis, the first and second axes each oriented along a longitudinal direction that is substantially perpendicular to the vertical direction, the first and second axes spaced from one another along a transverse direction that is substantially perpendicular to the vertical and longitudinal directions, wherein a first distance between the first and second bone-contacting surfaces along the vertical direction intersects the first axis, and a second distance between the first and second bone-contacting surfaces along the vertical direction intersects the second axis, the anterior and posterior actuation assemblies each comprising;

a first support wedge that supports the first endplate;

a second support wedge that supports the second endplate, the second support wedge slidable with respect to the first support wedge; and

an expansion wedge slidable with respect to the second support wedge; and

a drive shaft coupled to the expansion wedge, the drive shaft rotatable about the respective first or second axis so as to cause

     1) the expansion wedge to ride along the second support wedge, and

     2) the second support wedge to ride along the first support wedge, thereby varying the respective first or second distance;

wherein the drive shafts of the anterior and posterior actuation assemblies are rotatable independently of each other so as to provide a difference between the first and second distances.

15. The implant of claim 14, wherein each expansion wedge comprises a first member and a second member, the first member is rotatable with respect to the second member about the respective first or second axis, and the first member is configured to ride along the respective second support wedge responsive to rotation of the respective drive shaft, and the second member is configured to ride along the respective first support wedge responsive to rotation of the respective drive shaft.

16. The implant of claim 15, wherein:

each endplate defines an anterior guide feature and a posterior guide feature, each of the anterior and posterior guide features extending along the longitudinal direction,

each second support wedge includes a guide element configured to ride along the respective anterior or posterior guide feature of the second endplate; and

the second member of each expansion wedge includes a guide element configured to ride along the respective anterior or posterior guide feature of the first endplate.

17. The implant of claim 16, wherein each second support wedge further includes a guide feature, and the first member of each expansion wedge defines a guide element configured to ride within the guide feature of the respective second support wedge.

18. The implant of claim 17, wherein each first support wedge defines a guide feature, and the guide element of the respective second member is further configured to ride along the guide feature of the respective first support wedge.

19. The implant of claim 18, wherein each of the guide features is a guide slot, and each of the guide elements is a guide protrusion configured to extend within and ride along the associated guide slot.

20. The implant of claim 19, wherein:

the guide slots of the second endplate and the respective guide protrusions of the second support wedges are cooperatively shaped so as to rotationally interlock the second endplate to each of the second support wedges with respect to rotation about the respective first or second axis; and

the guide slots of the second support wedges and the respective guide protrusions of the first members are cooperatively shaped so as to rotationally interlock the second support wedges to the respective first members with respect to rotation about the respective first or second axis.

21. The implant of claim 20, wherein,

each first support wedge is fixed to the first endplate with respect to rotation about the respective first or second axis;

the guide protrusion of each second member and the respective guide slot of the first endplate are cooperatively shaped so as to rotationally interlock the first endplate to the associated second member when the guide protrusion of the associated second member extends within the respective guide slot; and

the guide protrusion of each second member and the guide slot of the respective first support wedge are cooperatively shaped so as to rotationally interlock each first support wedge to the associated second member when the guide protrusion of the associated second member extends within the guide slot of the associated first support wedge.