Expandable intervertebral implant and associated method of manufacturing the same

• US 10,449,058 B2
• Filed: 12/05/2017
• Issued: 10/22/2019
• Est. Priority Date: 01/17/2008
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Inventors: Lechmann, Beat, Burkard, Dominique, Fierlbeck, Johann, Niederberger, Alfred
• Primary Examiner(s): Beccia, Christopher J
• Application Number:
  US15/831,870
• Publication Number:
  US 20180092755A1
• Time in Patent Office: 686 Days
• CPC Class Codes: A61F 2/30771 applied in original prostheses, e.g. holes or grooves
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/44 for the spine, e.g. vertebrae, spinal discs
• 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 2002/30462 retained or tied with a rope, string, thread, wire or cable
• CPC Class Codes: A61F 2002/30518 with possibility of relative movement between the prosthetic parts
• CPC Class Codes: A61F 2002/3055 for adjusting length
• 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 2002/30593 hollow
• CPC Class Codes: A61F 2002/30785 parallel
• CPC Class Codes: A61F 2002/30843 Pyramidally-shaped
• CPC Class Codes: A61F 2002/30904 serrated profile, i.e. saw-toothed
• CPC Class Codes: A61F 2002/4495 having a fabric structure, e.g. made from wires or fibres
• CPC Class Codes: A61F 2220/0016 with sharp anchoring protrusions, e.g. barbs, pins, spikes
• CPC Class Codes: A61F 2250/0009 for adjusting thickness
• CPC Class Codes: A61F 2250/009 for single use, e.g. having means for preventing re-use
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/34 : of powder characteristics, e.g. density, oxidation or flowability
• CPC Class Codes: B22F 12/41 : characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

An expandable intervertebral implant (10) includes superior (20) and inferior (30) bone contacting members and at least one vertical wire netting (50) interconnecting the superior and inferior bone contacting members. The superior and inferior bone contacting members include at least two bone contacting components interconnected via one or more lateral wire nettings such that the implant is vertically and laterally expandable in situ from a first insertion configuration to a second expanded configuration. The vertical and lateral wire netting are preferably constructed of a plurality of individual link members. The present invention also preferably relates to an associated method of manufacturing the intervertebral implant such that the intervertebral implant can be manufactured as an integral component or part.

Claims

1. An expandable intervertebral implant configured to be implanted in an intervertebral space between adjacent superior and inferior vertebral bodies, the implant comprising:

a first outer member having a first outer surface configured to face one of the superior and inferior vertebral bodies when the implant is disposed in the intervertebral space, and a first inner surface opposite the first outer surface along a first direction, the first outer member defining a plurality of openings that extend into the first inner surface towards the first outer surface; and

a second outer member having a second outer surface configured to face another one of the superior and inferior vertebral bodies when the implant is disposed in the intervertebral space, a second inner surface opposite the second outer surface along the first direction, and a plurality of protrusions, each protrusion extending from the second inner surface to a terminal end of the protrusion in a direction that is away from the second outer surface, wherein the first and second outer surfaces are opposite each other along the first direction,

wherein the implant is configured to expand from a collapsed configuration to an expanded configuration in response to expansion of a balloon that is disposed in an internal space of the implant, thereby increasing a height of the implant that is defined from the first outer surface to the second outer surface, such that the first and second outer surfaces bear against respective ones of the superior and inferior vertebral bodies, and

wherein the plurality of protrusions are disposed in the plurality of openings when the implant is in the collapsed configuration and are removed from the plurality of openings when the implant is in the expanded configuration such that the terminal ends of the protrusions are exposed within the internal space of the implant.

2. The expandable intervertebral implant of claim 1, wherein the implant has a first end and a second end that are spaced from one another along a longitudinal direction, perpendicular to the first direction, and first and second sides that are spaced from one another along a lateral direction, perpendicular to the both the first direction and the longitudinal direction.

3. The expandable intervertebral implant of claim 2, wherein some of the plurality of protrusions are spaced from one another along the longitudinal direction.

4. The expandable intervertebral implant of claim 3, wherein some of the plurality of protrusions are spaced from one another along the lateral direction.

5. The expandable intervertebral implant of claim 2, wherein the plurality of protrusions comprises first to fourth protrusions, wherein the first and second protrusions are offset from the third and fourth protrusions with respect to the longitudinal direction.

6. The expandable intervertebral implant of claim 5, wherein the first and third protrusions are offset from the second and fourth protrusions with respect to the lateral direction.

7. The expandable intervertebral implant of claim 2, wherein the implant is elongate along the longitudinal direction from the first end to the second end.

8. The expandable intervertebral implant as recited in claim 1, wherein each of the plurality of openings extends into the first inner surface towards the first outer surface along the first direction.

9. The expandable intervertebral implant as recited in claim 8, wherein each of the openings has a fully enclosed outer perimeter in a plane that is oriented perpendicular to the first direction.

10. The expandable intervertebral implant as recited in claim 9, wherein the fully enclosed outer perimeter defines a round surface in the plane.

11. The expandable intervertebral implant as recited in claim 10, wherein the round surface follows a circular path.

12. A system, comprising:

the expandable intervertebral implant of claim 1; and

the balloon, wherein the balloon is configured to bear against each of the first and second outer members as it expands.

21. The expandable intervertebral implant of claim 1, wherein the first and second outer members are coupled to one another when the implant is in the collapsed and expanded configurations.

13. An expandable intervertebral implant configured to be implanted in an intervertebral space between adjacent superior and inferior vertebral bodies, the implant comprising:

a first outer member having a first outer surface configured to face one of the superior and inferior vertebral bodies, and a first inner surface opposite the first outer surface, the first outer member defining a plurality of recesses that extend therein; and

a second outer member having a second outer surface configured to face another one of the superior and inferior vertebral bodies, a second inner surface opposite the second outer surface, first and second arms that extend from the second inner surface along a select direction, and a plurality of protrusions that extend from the first and second arms along the select direction such that each protrusion is configured to be at least partially inserted into a complementary one of the plurality of recesses,

wherein the implant is configured to expand from a collapsed configuration to an expanded configuration in response to expansion of a balloon that is disposed in an internal space of the implant, thereby increasing a height of the implant that is defined from the first outer surface to the second outer surface, such that the first and second outer surfaces bear against respective ones of the superior and inferior vertebral bodies.

14. The expandable intervertebral implant of claim 13, wherein the implant has a select configuration wherein a portion less than an entirety of each of the plurality of protrusions is received in the complementary one of the plurality of recesses.

15. The expandable intervertebral implant of claim 14, wherein the select configuration is between the collapsed configuration and the expanded configuration.

16. The expandable intervertebral implant of claim 13, wherein the implant has a first end and a second end that are spaced from one another along a longitudinal direction, and the implant is elongate along the longitudinal direction.

17. The expandable intervertebral implant of claim 16, wherein some of the plurality of protrusions are spaced from one another along the longitudinal direction.

18. The expandable intervertebral implant of claim 17, wherein the first and second outer surfaces are opposite each other along a first direction, and some of the plurality of protrusions are spaced from one another along a lateral direction that is perpendicular to each of the longitudinal direction and the first direction.

19. The expandable intervertebral implant of claim 13, wherein the plurality of protrusions comprises a first and second pairs of protrusions that are spaced from one another along the lateral direction, and the internal space is defined between the first and second pairs of protrusions with respect to the lateral direction.

20. A system, comprising:

the expandable intervertebral implant of claim 13; and

the balloon.