Zero-profile interbody spacer and coupled plate assembly

• US 10,433,976 B2
• Filed: 07/22/2016
• Issued: 10/08/2019
• Est. Priority Date: 11/07/2008
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Inventors: McDonough, William P., Strausbaugh, William L., Bonner, Christopher, Pepe, Thomas, Meili, Ralph, Hunziker, Markus, Jeger, Michael, Kueenzi, Thomas, Koch, David, Ponzer, Rainer, Richter, Joern, Berger, Roger
• Primary Examiner(s): Ku, Si Ming
• Application Number:
  US15/217,198
• Publication Number:
  US 20160324662A1
• Time in Patent Office: 1,173 Days
• Field of Search: 623 1711, 623 1716
• CPC Class Codes: A61B 17/1728 for holes for bone plates or plate screws
• CPC Class Codes: A61B 17/1757 for the spine
• CPC Class Codes: A61B 17/7059 Cortical plates A61B17/7007, A61B17/7058 take precedence
• CPC Class Codes: A61B 17/8033 having indirect contact with screw heads, or having contact with screw heads maintained with the aid of additional components, e.g. nuts, wedges or head covers
• CPC Class Codes: A61B 17/8042 the additional component being a cover over the screw head
• CPC Class Codes: A61B 17/8052 immobilised relative to screws by interlocking form of the heads and plate holes, e.g. conical or threaded
• CPC Class Codes: A61B 17/8057 the interlocking form comprising a thread
• CPC Class Codes: A61B 17/809 with bone-penetrating elements, e.g. blades or prongs bone staples A61B17/0642; intramedullary nails with a plate at an end A61B17/7233
• CPC Class Codes: A61B 17/86 Pins or screws or threaded wires; nuts therefor A61B17/72 take precedence
• CPC Class Codes: A61B 17/88 Osteosynthesis instruments; Methods or means for implanting or extracting internal or external fixation devices A61B17/7074 takes precedence
• CPC Class Codes: A61F 2/30965 Reinforcing the prosthesis by embedding particles or fibres during moulding or dipping
• 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 2/4465 having a circular or kidney shaped cross-section substantially perpendicular to the axis of the spine
• CPC Class Codes: A61F 2/4611 of spinal prostheses
• CPC Class Codes: A61F 2002/30387 Dovetail connection
• CPC Class Codes: A61F 2002/305 Snap connection
• CPC Class Codes: A61F 2002/30505 spring biased
• 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 2002/30576 with extending fixation tabs
• CPC Class Codes: A61F 2002/30593 : hollow
• CPC Class Codes: A61F 2002/30604 : modular
• CPC Class Codes: A61F 2002/30787 : inclined obliquely with respect to each other
• CPC Class Codes: A61F 2002/3079 : Stepped or enlarged apertures, e.g. having discrete diameter changes
• CPC Class Codes: A61F 2002/30841 : Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes
• 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 2002/4615 : of spacers
• CPC Class Codes: A61F 2220/0016 : with sharp anchoring protrusions, e.g. barbs, pins, spikes
• CPC Class Codes: A61F 2220/0025 : Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2230/0034 : D-shaped
• CPC Class Codes: A61F 2310/00017 : Iron- or Fe-based alloys, e.g. stainless steel
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 : Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00407 : Coating made of titanium or of Ti-based alloys
• CPC Class Codes: A61F 2310/00796 : Coating or prosthesis-covering structure made of a phosphorus-containing compound, e.g. hydroxy(l)apatite

Abstract

An implant for insertion into a disc space between vertebrae, wherein the implant includes a spacer portion, a plate portion coupled to the spacer portion, two bone fixation elements for engaging the vertebrae and a retention mechanism for preventing the bone fixation elements from postoperatively backing-out of the plate portion. The retention mechanism may be in the form of a spring biased snapper element that is biased into communication with the bone fixation elements so that once the bone fixation element advances past the snapper element, the snapper element is biased back to its initial position in which the snapper element interfaces with the bone fixation elements. Alternatively, the retention mechanism may be in the form of a propeller rotatable between a first position in which the bone fixation elements are insertable to a second position where the bone fixation elements are prevented from backing-out.

Claims

1. A plate configured to be coupled to a spacer to form an intervertebral implant, the plate comprising:

a trailing surface defining a first opening of a first bone fixation hole and a first opening of a second bone fixation hole, the first opening of the first bone fixation hole spaced from the first opening of the second bone fixation hole in a first direction, the first bone fixation hole configured to receive a first bone fixation element such that the first bone fixation element secures the plate to a first vertebra, the second bone fixation hole configured to receive a second bone fixation element such that the second bone fixation element secures the plate to a second vertebra that is spaced from the first vertebra;

a leading surface spaced from the trailing surface in a second direction that is substantially perpendicular to the first direction;

a top surface configured to face the first vertebra when the plate is implanted;

a bottom surface configured to face the second vertebra when the plate is implanted, the top surface spaced from the bottom surface in a third direction that is substantially perpendicular to both the first direction and the second direction, and the top surface facing in the third direction;

a stop that protrudes from the top surface in the third direction, the stop including a first surface and a second surface, the second surface spaced from the first surface in the second direction and the second surface facing in the second direction, the first surface defining a first width measured along the first direction at a first location, the second surface defining a second width measured along the first direction at a second location, the first location aligned with the second location along the second direction, and the second width is greater than the first width,

wherein the stop includes at least one projection that protrudes from the second surface in the second direction, the at least one projection configured to embed into the first vertebra to secure the plate to the first vertebra, and

wherein a portion of the top surface is positioned between the second surface and a second opening of the first bone fixation hole with respect to the second direction.

2. The plate of claim 1, wherein the second opening of the first bone fixation hole is partially defined by the top surface.

3. The plate of claim 1, wherein the second opening of the first bone fixation hole is partially defined by the leading surface.

4. The plate of claim 1, wherein the second opening of the first bone fixation hole is partially defined by the top surface, and the second opening of the first bone fixation hole is partially defined by the leading surface.

5. The plate of claim 1, wherein the second surface is devoid of any bone fixation holes configured to receive a bone fixation element.

6. The plate of claim 1, wherein the at least one projection includes a tooth.

7. The plate of claim 1, wherein the at least one projection includes a blade.

8. The plate of claim 1, wherein the stop is a first stop, and the plate includes a second stop that protrudes from the bottom surface in a direction opposite the third direction, the second stop including a third surface that faces in the second direction.

9. The plate of claim 8, wherein a portion of the bottom surface is positioned between the third surface and a second opening of the second bone fixation hole with respect to the second direction.

10. The plate of claim 9, wherein the portion of the top surface is a first portion of the top surface, the portion of the bottom surface is a first portion of the bottom surface, the first portion of the top surface is spaced in the third direction from the first portion of the bottom surface by a first distance measured in the third direction, a second portion of the top surface is spaced in the third direction from a second portion of the bottom surface by a second distance measured in the third direction, the second portion of the top surface and the second portion of the bottom surface both positioned between the first bone fixation hole and the second bone fixation hole with respect to the first direction, and the first distance is substantially equal to the second distance.

11. The plate of claim 1, wherein the stop is configured to abut the first vertebra during insertion of the plate to prevent over-insertion of the plate into an intervertebral disc space defined between the first vertebra and the second vertebra.

12. The plate of claim 1, wherein

the plate defines a first length measured from the trailing surface to the leading surface along the second direction, and

the stop defines a second length measured from the first surface to the second surface along the second direction, and the second length is less than half of the first length.

13. The plate of claim 12, wherein a portion of the top surface is positioned between the second surface and a second opening of the first bone fixation hole with respect to the second direction.

14. The plate of claim 12, wherein the stop is a first stop, the plate includes a second stop that protrudes from the bottom surface in a direction opposite the third direction, the second stop including a third surface that faces in the second direction, wherein an entirety of the third surface is:

1) between the leading surface and the trailing surface with respect to the second direction, and

     2) offset with each of the plurality of bone fixation holes configured to receive a respective bone fixation element such that the respective bone fixation element secures the plate to the first vertebra with respect to the first direction, and at least a portion of the third surface is offset from both the leading surface and the trailing surface with respect to the third direction.

15. The plate of claim 12, wherein a portion of the bottom surface is positioned between the third surface and a second opening of the second bone fixation hole with respect to the second direction.

16. The plate of claim 1, wherein the plate defines a first length measured from the trailing surface to the leading surface along the second direction, the stop defines a second length measured from the first surface of the second surface along the second direction, and the second length is less than half the first length.

17. The plate of claim 16, wherein the plate is devoid of a second stop that:

1) protrudes from the bottom surface, and

     2) includes a third surface that is aligned with the second surface with respect to the third direction such that a straight line in the third direction intersects both the second surface and the third surface.

18. A plate configured to be coupled to a spacer to form an intervertebral implant, the plate comprising:

a trailing surface defining a first opening of a first bone fixation hole and a second opening of a second bone fixation hole, the first opening spaced from the second opening in a first direction, the first bone fixation hole configured to receive a first bone fixation element such that the first bone fixation element secures the plate to a first vertebra, the second bone fixation hole configured to receive a second bone fixation element such that the second bone fixation element secures the plate to a second vertebra;

a leading surface spaced from the trailing surface in a second direction that is substantially perpendicular to the first direction, the leading surface configured to face the spacer when the plate is coupled to the spacer;

a top surface configured to face the first vertebra when the plate is implanted;

a bottom surface configured to face the second vertebra when the plate is implanted, the top surface spaced from the bottom surface in a third direction that is substantially perpendicular to both the first direction and the second direction, and the first bone fixation hole positioned between the top surface and the bottom surface with respect to the third direction; and

a stop that protrudes from the top surface in the third direction, the stop including a first surface that faces in the second direction, wherein the first surface is;

     1) between the leading surface and the trailing surface with respect to the second direction, and

     2) offset from both the leading surface and the trailing surface with respect to the third direction, the stop further including a second surface opposite the first surface, the second surface aligned with the first bone fixation hole with respect to the third direction, the stop defining a first thickness measured from a first location on the second surface to the first surface along a direction perpendicular to the second surface, the stop further defining a second thickness measured from a second location on the second surface to the first surface along the direction perpendicular to the second surface, the first location offset from the second location in the third direction, and the second thickness is greater than the first thickness,

wherein the plate is devoid of a second stop that;

     1) protrudes from the bottom surface, and

     2) includes a second surface that is aligned with the first surface with respect to the third direction such that a straight line in the third direction intersects both the first surface and the second surface.

19. The plate of claim 18, wherein the stop is a first stop, the plate further comprising a second stop that includes a third surface that:

1) faces in the second direction,

     2) is offset from both the leading surface and the trailing surface with respect to the second direction, and

     3) is offset from the first surface of the first stop with respect to the first direction.

20. The plate of claim 19, wherein the second surface is devoid of any bone fixation holes configured to receive a bone fixation element.

21. The plate of claim 18, wherein the first stop is devoid of any bone fixation holes configured to receive a bone fixation element.