EXPANDABLE INTERVERTEBRAL IMPLANT AND ASSOCIATED METHOD OF MANUFACTURING THE SAME

• US 20100286783A1
• Filed: 01/21/2009
• Published: 11/11/2010
• Est. Priority Date: 01/17/2008
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Synthes USA LLC (Johnson & Johnson)
• Inventors: Burkard, Dominique, Lechmann, Beat, Niederberger, Alfred, Fierlbeck, Johann
• Granted Patent: US 8,551,173 B2
• Time in Patent Office: Days
• US Class Current: 623/17.12
• 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 comprising:

a superior bone contacting member including at least two bone contacting components interconnected via a first lateral wire netting;

an inferior bone contacting member including at least two bone contacting components interconnected via a second lateral wire netting; and

at least one vertical wire netting interconnecting the superior and inferior bone contacting members, wherein the first lateral wire netting, the second lateral wire netting and the vertical wire netting comprise a plurality of individual link members, the implant being expandable in situ from a first insertion configuration to a second expanded configuration, the implant having a first height and a first width in the first insertion configuration and a second height and a second width in the second expanded configuration, the second height being larger than the first height and the second width being larger than the first width.

2. The implant of claim 1, wherein the plurality of individual link members have a rectangular shape.

3. The implant of claim 1, wherein the plurality of individual link members have a trapezoidal shape.

4. The implant of claim 1, further comprising:

a cavity defined between the superior bone contacting member and the inferior bone contacting member; and

an expansion member insertable in the cavity, the expansion member capable of receiving a filling material so that injection of the filling material into the expansion member permits the vertical wire netting interconnecting the superior and inferior bone contacting members to expand, thereby moving the superior bone contacting member with respect to the inferior bone contacting member such that the implant vertically expands from the first height to the second height.

5. The implant of claim 4, wherein the at least two bone contacting components that form the superior and inferior bone contacting members include one or more bores for engaging a surgical instrument.

6. The implant of claim 1, wherein the at least two bone contacting components that form the superior and inferior bone contacting members include interconnecting projections and bores.

7. The implant of claim 1, wherein the superior bone contacting member, the inferior bone contacting member and the at least one vertical wire netting is constructed as an integral part via a layer-wise manufacturing process.

8. The implant of claim 7, wherein the layer-wise manufacturing process is a selective laser melting process.

9. The implant of claim 7, wherein the layer-wise manufacturing process is a selective laser sintering process.

10. A method of manufacturing an expandable intervertebral implant including superior and inferior bone contacting members interconnected by at least one wire netting, the superior and inferior bone contacting members including at least two bone contacting components interconnected via one or more lateral wire nettings such that the implant is laterally and vertically expandable from a first insertion configuration to a second expanded configuration, the at least one wire netting comprising a plurality of individual link members, the method comprising the steps of:

(a) applying a first layer of metal powder onto a moveable platform;

(b) melting the first layer of metal powder to define a first solid layer;

(c) lowering the platform by a defined layer height;

(d) applying a second layer of metal powder onto the moveable platform;

(e) melting the second layer of metal powder to define a second solid layer that is interconnected to the first solid layer;

(f) repeating steps (c)-(e) a plurality of times to form the expandable intervertebral implant having at least two continuous individual link members.

11. The method of claim 10, wherein the metal powder in steps (b) and (e) are melted by a laser beam.