Woven orthopedic implants

• US 20020123750A1
• Filed: 02/25/2002
• Published: 09/05/2002
• Est. Priority Date: 02/28/2001
• Status: Active Grant

• Current Assignee: Warsaw Orthopedic Incorporated (Medtronic Plc)
• Original Assignee: SDGI Holdings Incorporated (Medtronic Plc)
• Inventors: Eisermann, Lukas, Ray, Eddie F. III
• Granted Patent: US 6,827,743 B2
• Time in Patent Office: Days
• US Class Current: 606/69
• CPC Class Codes: A61B 17/68 Internal fixation devices , including fasteners and spinal fixators, even if a part thereof projects from the skin bone staples A61B17/0642
• CPC Class Codes: A61B 17/7059 Cortical plates A61B17/7007, A61B17/7058 take precedence
• CPC Class Codes: A61B 17/8085 with pliable or malleable elements or having a mesh-like structure, e.g. small strips A61B17/8071, A61B17/8076 take precedence
• CPC Class Codes: A61B 17/842 Flexible wires, bands or straps A61B17/72, A61B17/82, A61B17/86 take precedence
• CPC Class Codes: A61B 2017/00557 inflatable A61B2017/22051 takes precedence
• CPC Class Codes: A61F 2/0077 Special surfaces of prostheses, e.g. for improving ingrowth A61F2/30767 takes precedence
• CPC Class Codes: A61F 2/08 Muscles; Tendons; Ligaments sutures A61B17/04
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/2846 Support means for bone substitute or for bone graft implants, e.g. membranes or plates for covering bone defects nets or sleeves applied to surface of endoprostheses A61F2/30907; bone plates A61B17/80; bone regeneration in dental surgery A61C8/0006
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/441 made of inflatable pockets or chambers filled with fluid, e.g. with hydrogel
• 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 2/446 having a circular or elliptical cross-section substantially parallel to the axis of the spine, e.g. cylinders or frustocones
• CPC Class Codes: A61F 2002/0086 for preferentially controlling or promoting the growth of specific types of cells or tissues
• CPC Class Codes: A61F 2002/2835 Bone graft implants for filling a bony defect or an endoprosthesis cavity, e.g. by synthetic material or biological material
• CPC Class Codes: A61F 2002/30004 the prosthesis being made from materials having different values of a given property at different locations within the same prosthesis
• CPC Class Codes: A61F 2002/30014 differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2002/3007 Coating or prosthesis-covering structure made of elastic material, e.g. of elastomer
• CPC Class Codes: A61F 2002/3008 radio-opaque, e.g. radio-opaque markers
• CPC Class Codes: A61F 2002/30092 : using shape memory or superelastic materials, e.g. nitinol
• 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 2002/30235 : tubular, e.g. sleeves
• CPC Class Codes: A61F 2002/30237 : partial tubes
• CPC Class Codes: A61F 2002/30433 : using additional screws, bolts, dowels, rivets or washers e.g. connecting screws
• CPC Class Codes: A61F 2002/30448 : using adhesives
• CPC Class Codes: A61F 2002/30461 : sutured, ligatured or stitched
• CPC Class Codes: A61F 2002/30583 : filled with hardenable fluid, e.g. curable in-situ
• CPC Class Codes: A61F 2002/30593 : hollow
• CPC Class Codes: A61F 2002/30599 : stackable
• CPC Class Codes: A61F 2002/30622 : Implant for fusing a joint or bone material
• CPC Class Codes: A61F 2002/30677 : Means for introducing or releasing pharmaceutical products, e.g. antibiotics, into the body
• CPC Class Codes: A61F 2002/30914 : Details of the mesh structure, e.g. disposition of the woven warp and weft wires
• CPC Class Codes: A61F 2002/3093 : for promoting ingrowth of bone tissue
• CPC Class Codes: A61F 2002/30971 : Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/4435 : Support means or repair of the natural disc wall, i.e. annulus, e.g. using plates, membranes or meshes
• 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 2210/0019 : operated at only one temperature whilst inside or touching the human body, e.g. constrained in a non-operative shape during surgery, another temperature only occurring before the operation
• CPC Class Codes: A61F 2210/0085 : hardenable in situ, e.g. epoxy resins
• CPC Class Codes: A61F 2220/0041 : using additional screws, bolts, dowels or rivets, e.g. connecting screws
• CPC Class Codes: A61F 2220/005 : using adhesives
• CPC Class Codes: A61F 2220/0075 : sutured, ligatured or stitched, retained or tied with a rope, string, thread, wire or cable
• CPC Class Codes: A61F 2230/0013 : Horseshoe-shaped, e.g. crescent-shaped, C-shaped, U-shaped
• CPC Class Codes: A61F 2230/0019 : rectangular
• CPC Class Codes: A61F 2230/0069 : cylindrical
• CPC Class Codes: A61F 2240/001 : Designing or manufacturing processes
• CPC Class Codes: A61F 2250/0014 : having different values of a given property or geometrical feature, e.g. mechanical property or material property, at different locations within the same prosthesis
• CPC Class Codes: A61F 2250/0018 : differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2250/0063 : Nested prosthetic parts
• CPC Class Codes: A61F 2250/0067 : Means for introducing or releasing pharmaceutical products into the body
• CPC Class Codes: A61F 2250/0098 : radio-opaque, e.g. radio-opaque markers
• 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 2310/00071 : Nickel or Ni-based alloys
• CPC Class Codes: A61F 2310/00161 : Carbon; Graphite
• CPC Class Codes: A61F 2310/00365 : Proteins; Polypeptides; Degradation products thereof
• CPC Class Codes: A61F 2310/00952 : Coating, pre-coating or prosthesis-covering structure made of bone cement, e.g. pre-applied PMMA cement mantle
• CPC Class Codes: A61F 2310/00958 : Coating or prosthesis-covering structure made of bone or of bony tissue
• CPC Class Codes: A61F 2310/0097 : Coating or prosthesis-covering structure made of pharmaceutical products, e.g. antibiotics
• CPC Class Codes: A61F 2310/00976 : Coating or prosthesis-covering structure made of proteins or of polypeptides, e.g. of bone morphogenic proteins BMP or of transforming growth factors TGF
• CPC Class Codes: A61F 2310/00982 : Coating made of collagen

Abstract

The present invention relates to orthopedic implants made from a mesh material. The mesh material can be treated in order to promote bone growth, to provide antibiotics, or to provide other beneficial treatment. Specific applications for the implants include, for example, a prosthetic ligament, a tension band, an interbody device, or a fixation device that extends across one or more joints or fractures.

Claims

1. An orthopedic implant comprising:

a bone fixating prosthesis comprising an interconnecting network of metallic fibers, and

one or more reinforcing elements secured to said network of metallic fibers, wherein said implant is adapted for promoting fusion between adjacent bone structures.

2. The implant of claim 1 comprising at least one of an ostoegenic material or a pharmaceutical agent.

3. The implant of claim 1 comprising fibers formed of one or more of:

stainless steel, cobalt-chrome alloy, titanium, titanium alloy, or nickel-titanium shape memory alloys.

4. The implant of claim 1 wherein the network of fibers is substantially nonelastic.

5. The implant of claim 1 wherein the network of fibers comprises a three dimensional array of fibers.

6. The implant of claim 1 wherein the network of fibers comprises a deformable sheet or fabric-like material.

7. The implant of claim 6 wherein at least a portion of the network of fibers is deformable to conform to a selected bone structure.

8. The implant of claim 1 comprising a second network of fibers formed of a material selected from the group consisting of:

biocompatible polymeric materials, nylon fibers, carbon fibers, glass fibers, collagen fibers, ceramic fibers, polyethylene fibers, poly(ethylene terephthalate), polyglycolides, polylactides, and combinations thereof.

9. The implant of claim 8 wherein the second network of fibers is biodegradable.

10. The implant of claim 1 comprising reinforcing elements formed of a material selected from the group of:

stainless steel, cobalt-chrome alloy, titanium, titanium alloy, or nickel-titanium shape memory alloys, biocompatible polymeric materials, nylon fibers, carbon fibers, glass fibers, collagen fibers, ceramic fibers, polyethylene fibers, poly(ethylene terephthalate), polyglycolides, polylactides, and combinations thereof.

11. The implant of claim 1 wherein said interconnecting network of fibers comprises a first set of fibers interwoven or bonded to a second set of fibers.

12. The implant of claim 1 adapted to secure to at least two adjacent vertebral bodies to promote spinal fixation.

13. The implant of claim 1 adapted to be inserted into a prepared disc space to promote spinal fusion.

14. The implant of claim 1 wherein at least a portion of the interconnecting network of fibers is impregnated with an osteogenic material.

15. The implant of claim 1 comprising a first interconnecting network of fibers overlayed with a second interconnecting network of fibers.

16. The implant of claim 15 wherein the first interconnecting network of fibers comprises a three dimensional array of fibers.

17. The implant of claim 15 wherein the implant is deformable to conform to a selected bone structure.

18. The implant of claim 15 wherein the first and second network of fibers are secured together using a securing element selected from the group consisting of:

an adhesive, a curable polymeric material, a suture, a staple, and combinations thereof.

19. The implant of claim 15 wherein the first and second network of fibers are secured together to provide a barrier sufficiently porous to permit interdiffusion of an osteogenic material therethrough.

20. The implant of claim 1 comprising a second set of fibers formed of a biocompatible polymeric material.

21. The implant of claim 1 wherein the reinforcing element is formed of a shape memory polymeric or metallic alloy material.

22. The implant of claim 1 wherein the reinforcing element is adapted to conform to a preselected bone structure.

23. The implant of claim 1 adapted to interconnect proximal bone structures as a prosthetic ligament, a tension band or an external fixation device.

25. The bone plate of claim 24 comprising fibers formed of a shape memory metallic alloy.

26. The bone plate of claim 24 comprising fibers formed of one or more of:

stainless steel, cobalt-chrome alloy, titanium, titanium alloy, or nickel-titanium shape memory alloys.

27. The bone plate of claim 24 wherein the network of metallic fibers comprises a three dimensional array of fibers.

28. The bone plate of claim 24 wherein the interconnecting network of metallic fibers is deformable to conform to a selected bone structure.

29. The bone plate of claim 24 wherein the bone fastener is a bone cement.

30. The bone plate of claim 24 wherein the bone fastener comprises at least one of:

a bone screw, a suture, or a staple.

31. The bone plate of claim 24 comprising one or more reinforcing elements formed of a material selected from the group of:

stainless steel, cobalt-chrome alloy, titanium, titanium alloy, or nickel-titanium shape memory alloys, biocompatible polymeric materials, nylon fibers, carbon fibers, glass fibers, collagen fibers, ceramic fibers, polyethylene fibers, poly(ethylene terephthalate), polyglycolides, polylactides, and combinations thereof.

24. A bone plate comprising:

an interconnecting network of metallic fibers providing a substantially nonelastic bone support;

an osteogeneic material impregnated on said fibers, and

a bone fastener.

32. An orthopedic implant for promoting bone fusion, said implant comprising:

a body including a wall portion formed of an interconnecting network of metallic fibers, said body defining an internal cavity; and

at least one reinforcing element connected to said fibers.

33. The implant of claim 32 comprising an ostoegenic material.

34. The implant of claim 32 comprising fibers formed of one or more of:

stainless steel, cobalt-chrome alloy, titanium, titanium alloy, or nickel-titanium shape memory alloys.

35. The implant of claim 32 wherein the network of metallic fibers is substantially nonelastic.

36. The implant of claim 32 wherein the network of fibers comprises a three dimensional array of fibers.

37. The implant of claim 32 comprising an opening through said wall portion into said internal cavity.

38. The implant of claim 32 comprising a core material disposed in the internal cavity.

39. The implant of claim 38 wherein the core material comprises an osteogenic material.

40. The implant of claim 38 wherein the core material is a curable material.

41. A method of treating a bone defect, said method comprising implanting an implant according to claim 35 proximal to a bone defect.

42. An orthopedic implant comprising:

a plurality of metallic fibers interconnected together at junctures to form a network;

two or more elongate members extending across a portion of the network adjacent said junctures, each of said elongate members provided to exhibit a tensile strength greater than a selected metallic fiber of the plurality of metallic fibers;

an osteogenic material impregnated in said network, wherein said implant is adapted to induce bone fusion between adjacent bone structures.

43. An orthopedic implant for promoting bone fusion, said implant comprising:

a body including a wall portion formed of an interconnecting network of metallic fibers, said body defining an internal cavity and having an opening through the wall portion into the internal cavity; and

at least one elongated member extending into said cavity, said elongate member provided to exhibit a tensile strength greater than a selected metallic fiber of the interconnecting network of metallic fibers wherein said implant is adapted to induce bone fusion between adjacent bone structures.

44. An orthopedic implant for connecting adjacent bone structures, said implant comprising:

an interconnecting network of metallic fibers each fiber joined to an adjacent fiber at a juncture;

said interconnecting network bounded by a reinforcing band;

two or more elongate members extending across a portion of the network adjacent said junctures, each of said elongate members provided to exhibit a tensile strength greater than a selected metallic fiber of the interconnecting network of metallic fibers;

an osteogenic material adhered to at least a portion of the implant, said implant adapted to promote bone ingrowth.

46. The method of claim 45 wherein said implant is a bone plate.

47. The method of claim 45 wherein said implant is a bone spacer.

48. The method of claim 45 wherein said implant comprises a body defining a cavity.

49. The method of claim 45 wherein said applying comprising applying the osteogenic material to the implant prior to implantation.

50. The method of claim 45 wherein said applying comprising applying the osteogenic material to the implant after implantation.

45. Method of treating a bone defect, said method comprising:

preparing a site of treatment to accept an orthopedic implant;

implanting proximal to said site an orthopedic implant comprising an interconnecting network of metallic fibers, and one or more reinforcing elements secured to said network of metallic fibers,

applying an osteogenic material to said implant or to said bone defect to promote bone fusion.