COILED IMPLANTS AND SYSTEMS AND METHODS OF USE THEREOF

• US 20160324656A1
• Filed: 04/28/2016
• Published: 11/10/2016
• Est. Priority Date: 04/29/2015
• Status: Active Grant

• Current Assignee: The Institute of Musculoskeletal Science & Education
• Original Assignee: Institute For Musculoskeletal Science and Education Limited
• Inventors: Morris, Robert, Stauffer, Megan, Duffield, William, McShane, Edward
• Granted Patent: US 9,918,849 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61F 2/30744 End caps, e.g. for closing an endoprosthetic cavity
• 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 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/302 toroidal, e.g. rings
• CPC Class Codes: A61F 2002/30289 helically-coiled
• CPC Class Codes: A61F 2002/30593 hollow
• CPC Class Codes: A61F 2002/30622 Implant for fusing a joint or bone material
• CPC Class Codes: A61F 2002/30772 Apertures or holes, e.g. of circular cross section
• CPC Class Codes: A61F 2002/30774 internally-threaded
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30985 using three dimensional printing [3DP]
• CPC Class Codes: A61F 2002/4495 having a fabric structure, e.g. made from wires or fibres

Abstract

Implants, systems and methods of making and using thereof are described herein. The implants are formed from one or more coils, preferably a plurality of coils. Optionally the coils are included in a set or group of more than one coil. Optionally, the implant is symmetric about one or more planes. Typically an implant includes at least two coils (or sets or groups of coils) that are adjacent to each other intersect with each other at one or more intersection regions. Two or more coils may intersect at a plurality of intersection regions, optionally along an array of intersection regions, within the implant or on the outer side wall of the implant. Optionally, the implants include one or more plates to aid in fixation and/or insertion. The implants may be used in a variety of different spaces in the body that require bone growth.

Claims

1. An implant comprising a plurality of coils and an open space between and/or inside the coils.

2. The implant of claim 1, wherein at least two of the plurality of coils intersect with each other at one or more intersection regions.

3. The implant of claim 2, wherein the intersection regions are at regular intervals along the length of two or more adjacent coils.

4. The implant of claim 1, comprising a first set of two or more coils and a second set of two or more coils.

5. The implant of claim 1, further comprising a side wall defining the outside perimeter of the implant.

6. The implant of claim 5, wherein the side wall has a smooth outer surface and is in the form of a peripheral ring.

7. The implant of claim 1, further comprising a central support portion that connects with one or more of the coils, one or more portions of the side wall, or a combination thereof.

8. The implant of claim 1, wherein the implant is symmetric about a transverse plane (T), about a median plane (M), or both.

9. The implant of claim 8, wherein the implant comprises at least two levels,

wherein when the implant is divided about the transverse plane, at least a first level is located in the superior half and at least a second level is located in the inferior half, and

wherein each level comprises at least two exterior coils and at least two interior coils.

10. The implant of claim 7, wherein the central support portion comprises a base that lies in the median plane and connects at a first end with the anterior end of the implant and at a second end with the posterior end of the implant.

11. The implant of claim 7, wherein the central support portion further comprises one or more support rings, wherein the support rings intersect with the base at one or more connection ends.

12. The implant of claim 2, wherein the implant contains a superior outer surface, an inferior outer surface, and one or more outer side walls, and wherein the one or more intersection regions are located inside the outer surfaces of the implant, connect with the one or more outer side walls, or a combination thereof.

13. The implant of claim 1, wherein the shape of at least one of the coils is different than the shape of at least another of the one or more coils.

14. The implant of claim 13, wherein the diameter (D1, D2, or both) of at least one of the one or more coils varies within the coil or is different than the diameter (D1, D2, or both) of at least another of the one or more coils.

15. The implant of claim 13, wherein a largest dimension (α

) of the cross section of at least one of the one or more coils is different than the largest dimension (α

) of the cross section of at least another of the one or more coils.

16. The implant of claim 1, wherein the open space is configured to allow bone growth inside the implant.

17. The implant of claim 1, wherein one or more surfaces of the implant contain a texture or are porous.

18. The implant of claim 17, wherein the surfaces that contain a texture or are porous are selected from the group consisting of surfaces on the inside of the implant, surfaces configured to contact bony anatomy, and a combination thereof.

19. The implant of claim 5, wherein the side wall is a smooth peripheral ring, optionally with an anterior plate and or a posterior plate attached thereto, and wherein the smooth peripheral ring, and optional plates attached thereto, does not contain a textured surface and is non-porous.

20. The implant of claim 1, wherein the implant further comprises a bone graft or a bone graft substitute inside at least a portion of the opening.

21. The implant of claim 1, wherein the implant comprises side walls, a superior outer surface and an inferior outer surface,

wherein the side walls, superior outer surface and inferior outer surface are formed from the plurality of coils.

22. The implant of claim 1, wherein the implant contains a plurality of levels of coils or sets of coils, wherein each level contains two or more coils or sets of coils.

23. The implant of claim 1, further comprising one or more plates, wherein the one or more plates are integral with the side walls.

24. The implant of claim 1 in the form of an interbody fusion spacer.

25. The implant of claim 1, wherein volume of the open space (void volume) comprises at least 40% of the total volume of the implant.

26. A method of using the implant of claim 1, comprising inserting the implant in a site adjacent to a bony structure in a patient.

27. The method of claim 26, wherein the site is between two adjacent vertebrae.

28. The method of claim 26, wherein the site is the site of a bone fracture or bone void.

29. The method of claim 26, wherein the site is in a joint.

30. A method of making the implant of claim 1, comprising forming the implant by 3-D printing.