Non-metallic implant devices and intra-operative methods for assembly and fixation

• US 7,172,593 B2
• Filed: 08/05/2003
• Issued: 02/06/2007
• Est. Priority Date: 10/25/2000
• Status: Expired due to Term

• Current Assignee: Warsaw Orthopedic Incorporated (Medtronic Plc)
• Original Assignee: SDGI Holdings Incorporated (Medtronic Plc)
• Inventors: Sherman, Michael C., Justis, Jeff R., Trieu, Hai H., Drewry, Troy D., Coates, Bradley J., Estes, Bradley T.
• Primary Examiner(s): Philogene; Pedro
• Application Number:
  US10/634,245
• Publication Number:
  US 20040030342A1
• Time in Patent Office: 1,281 Days
• Field of Search: 606/69, 606/70, 606/71, 606/228, 606/232, 606/220, 606/73, 606/61
• US Class Current: 606/281
• CPC Class Codes: A61B 17/7059 Cortical plates A61B17/7007, A61B17/7058 take precedence
• 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 17/8085 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 17/866 Material or manufacture
• CPC Class Codes: A61B 2017/00004 (bio)absorbable, (bio)resorbable or resorptive
• CPC Class Codes: A61F 2/0811 Fixation devices for tendons or ligaments

Abstract

This invention relates to orthopedic implants and to methods of treating bone defects. More specifically, but not exclusively, the present invention is directed to non-metallic implants and to methods for intra-operative assembly and fixation of orthopedic implants to facilitate medical treatment. The non-metallic implant assembly can be secured to underlying tissue by a fastener, such as a bone screw, that is capable of swelling on contact with fluid in the underlying tissue. Alternatively, the non-metallic implant assembly can be assembled intra-operatively using a fastener that is adhesively bonded to a bone plate or the bone plate can be deformed using heat, force, or solvents to inhibit withdrawal of the fastener. In preferred embodiments, both the fastener and the bone plate are formed of biodegradable material.

Claims

1. A method of fixedly securing a fastener to a bone plate, said method comprising:

surgically preparing bone tissue in need of repair for receipt of a bone plate;

placing a bone plate proximal to said bone tissue in need of repair, said bone plate having at least one opening therethrough; and

inserting a bone screw through the at least one opening and into the bone tissue, wherein at least one of the fastener and the bone plate include an adhesive to fixedly secure the fastener to the bone plate, wherein said inserting comprises deforming a portion of the bone plate or the fastener with a solvent.

2. The method of claim 1 comprising applying said adhesive to the fastener.

3. The method of claim 1 comprising applying said adhesive to the bone plate.

4. An orthopedic implant assembly comprising:

a bone plate comprising at least one opening therethrough; and

a fastener formed of a non metallic material and comprising a head and an opposite tissue engaging portion, wherein said fastener is received through the at least one opening and bonded to the bone plate, wherein the fastener is solvent bonded to the bone plate.

5. The implant assembly of claim 4 wherein the bone plate comprises a first polymeric material, and wherein the fastener comprises a second polymeric material that is intermixed with the first polymeric material of the bone plate.

6. An implant assembly comprising:

a bone plate having at least one opening extending therethrough, and

a fastener received within said opening and having a proximal head, a distal bone-engaging portion, and a shaft therebetween, wherein at least one of the fastener and the bone plate include an adhesive to fixedly interengage the fastener to the bone plate, wherein at least one of the bone plate and the fastener includes a pressure sensitive adhesive.

7. The implant assembly of claim 6 wherein the bone plate is flexible to allow articulation of adjacent bone structures.

8. The implant assembly of claim 6 wherein the bone plate is configured to connect to adjacent vertebrae bodies.

9. The implant assembly of claim 6 wherein at least one of the bone plate and the fastener are formed of a biodegradable material.

10. The implant assembly of claim 6 wherein the fastener is formed of a polymeric material from the group consisting of homopolymers, co-polymers, and oligomers of:

polyhydroxy acids, polyesters, polyorthoesters, polyanhydrides, polydioxanone, polydioxanediones, polyesteramides, polyaminoacids, polyamides, polycarbonates, polylactide, polyglycolide, tyrosine-derived polycarbonate, polyanhydride, polyorthoester, polyphosphazene, polyethylene, polyester, polyvinyl alcohol, polyacrylonitrile, polyamide, polytetrafluorethylene, poly-paraphenylene terephthalamide, polyaryletherketones, polyetherketones, cellulose, carbon fiber reinforced composite, and mixtures thereof.

11. The implant assembly of claim 6 wherein at least one of the fastener and the bone plate are formed of a polymer comprising monomeric repeating units derived from the group consisting of d-lactic acid, l-lactic acid, glycolic acid, caprolactone, hydroxy buteric acid, hydroxy valeric acid, and mixtures thereof.

12. The implant assembly of claim 6 wherein the bone plate comprises a metallic material.

13. The implant assembly of claim 6 wherein the bone plate comprises a first polymeric material.

14. The implant assembly of claim 13 wherein the fastener comprises a second polymeric material that is intermixed with the first polymeric material of the bone plate.

15. The implant assembly of claim 6 wherein the bone plate comprises a composite material.

16. An implant assembly comprising:

a bone plate having at least one opening extending therethrough, and

a fastener received within said opening and having a proximal head, a distal bone-engaging portion, and a shaft therebetween, wherein at least one of the fastener and the bone plate include an adhesive to fixedly interengage the fastener to the bone plate, wherein the adhesive is selected from the group consisting of epoxies, acrylates, cyanoacrylates, polyesters, polyolefins, polyurethanes, silicone adhesives, and mixtures thereof.

17. The implant assembly of claim 16 wherein at least one of the bone plate and the fastener are formed of a biodegradable material.

18. The implant assembly of claim 16 wherein the fastener is formed of a polymeric material from the group consisting essentially of homopolymers, co-polymers, and oligomers of:

polyhydroxy acids, polyesters, polyorthoesters, polyanhydrides, polydioxanone, polydioxanediones, polyesteramides, polyaminoacids, polyamides, polycarbonates, polylactide, polyglycolide, tyrosine-derived polycarbonate, polyanhydride, polyorthoester, polyphosphazene, polyethylene, polyester, polyvinyl alcohol, polyacrylonitrile, polyamide, polytetrafluorethylene, poly-paraphenylene terephthalamide, polyaryletherketones, polyetherketones, cellulose, carbon fiber reinforced composite, and mixtures thereof.

19. The implant assembly of claim 16 wherein at least one of the fastener and the bone plate are formed of a polymer comprising monomeric repeating units derived from the group consisting of d-lactic acid, l-lactic acid, glycolic acid, caprolactone, hydroxy buteric acid, hydroxy valeric acid, and mixtures thereof.

20. The implant assembly of claim 16 wherein the bone plate comprises a metallic material.

21. The implant assembly of claim 16 wherein the bone plate comprises a first polymeric material.

22. The implant assembly of claim 21 wherein the fastener comprises a second polymeric material that is intermixed with the first polymeric material of the bone plate.

23. The implant assembly of claim 16 wherein the bone plate comprises a composite material.

24. An implant assembly comprising:

.

a bone plate having at least one opening extending therethrough, and

a fastener received within said opening and having a proximal head, a distal bone-engaging portion, and a shaft therebetween, wherein at least one of the fastener and the bone plate include an adhesive to fixedly interengage the fastener to the bone plate, wherein the adhesive is a two-part adhesive and wherein a first part of the adhesive is provided on the bone plate and a second part of the adhesive is provided on the fastener, whereby contact of the bone plate with the fastener combines the first part and the second part of the adhesive.

25. The implant assembly of claim 24 wherein at least one of the bone plate and the fastener are formed of a biodegradable material.

26. The implant assembly of claim 24 wherein the fastener is formed of a polymeric material from the group consisting essentially of homopolymers, co-polymers, and oligomers of:

polyhydroxy acids, polyesters, polyorthoesters, polyanhydrides, polydioxanone, polydioxanediones, polyesteramides, polyaminoacids, polyamides, polycarbonates, polylactide, polyglycolide, tyrosine-derived polycarbonate, polyanhydride, polyorthoester, polyphosphazene, polyethylene, polyester, polyvinyl alcohol, polyacrylonitrile, polyamide, polytetrafluorethylene, poly-paraphenylene terephthalamide, polyaryletherketones, polyetherketones, cellulose, carbon fiber reinforced composite, and mixtures thereof.

27. The implant assembly of claim 24 wherein at least one of the fastener and the bone plate are formed of a polymer comprising monomeric repeating units derived from the group consisting of d-lactic acid, l-lactic acid, glycolic acid, caprolactone, hydroxy buteric acid, hydroxy valeric acid, and mixtures thereof.

28. The implant assembly of claim 24 wherein the bone plate comprises a metallic material.

29. The implant assembly of claim 24 wherein the bone plate comprises a first polymeric material.

30. The implant assembly of claim 29 wherein the fastener comprises a second polymeric material that is intermixed with the first polymeric material of the bone plate.

31. The implant assembly of claim 24 wherein the bone plate comprises a composite material.

32. A method of fixedly securing a fastener to a bone plate, said method comprising:

surgically preparing bone tissue in need of repair for receipt of a bone plate;

placing a bone plate proximal to said bone tissue in need of repair, said bone plate having at least one opening therethrough; and

inserting a bone screw through the at least one opening and into the bone tissue, wherein at least one of the fastener and the bone plate include an adhesive to fixedly secure the fastener to the bone plate, wherein the adhesive is a pressure-sensitive adhesive.

33. The method of claim 32 comprising applying said adhesive to the fastener.

34. The method of claim 32 comprising applying said adhesive to the bone plate.

35. The method of claim 32 wherein said adhesive is pre-applied.

36. The method of claim 32 wherein said adhesive is applied during or immediately before a surgical procedure including said preparing, placing and inserting steps.

37. A method of fixedly securing a fastener to a bone plate, said method comprising:

surgically preparing bone tissue in need of repair for receipt of a bone plate;

placing a bone plate proximal to said bone tissue in need of repair, said bone plate having at least one opening therethrough; and

inserting a bone screw through the at least one opening and into the bone tissue, wherein at least one of the fastener and the bone plate include an adhesive to fixedly secure the fastener to the bone plate, wherein the adhesive is selected from the group consisting of;

epoxies, acrylates, cyanoacrylates, polyesters, polyolefins, polyurethanes, silicones, and mixtures thereof.

38. The method of claim 37 comprising applying said adhesive to the fastener.

39. The method of claim 37 comprising applying said adhesive to the bone plate.

40. The method of claim 37 wherein said adhesive is pre-applied.

41. The method of claim 37 wherein said adhesive is applied during or immediately before a surgical procedure including said preparing, placing and inserting steps.

42. An orthopedic implant assembly comprising:

a bone plate comprising at least one opening therethrough; and

a fastener formed of a non metallic material and comprising a head and an opposite tissue engaging portion, wherein said fastener is received through the at least one opening and bonded to the bone plate, wherein at least one of the bone plate and the fastener includes a pressure sensitive adhesive.

43. The implant assembly of claim 42 wherein at least one of the bone plate and the fastener are formed of a biodegradable material.

44. The implant assembly of claim 42 wherein the fastener is formed of a polymeric material from the group consisting essentially of homopolymers, co-polymers, and oligomers of:

polyhydroxy acids, polyesters, polyorthoesters, polyanhydrides, polydioxanone, polydioxanediones, polyesteramides, polyaminoacids, polyamides, polycarbonates, polylactide, polyglycolide, tyrosine-derived polycarbonate, polyanhydride, polyorthoester, polyphosphazene, polyethylene, polyester, polyvinyl alcohol, polyacrylonitrile, polyamide, polytetrafluorethylene, poly-paraphenylene terephthalamide, polyaryletherketones, polyetherketones, cellulose, carbon fiber reinforced composite, and mixtures thereof.

45. The implant assembly of claim 42 wherein at least one of the fastener and the bone plate are formed of a polymer comprising monomeric repeating units derived from the group consisting of d-lactic acid, l-lactic acid, glycolic acid, caprolactone, hydroxy buteric acid, hydroxy valeric acid, and mixtures thereof.

46. The implant assembly of claim 42 wherein the bone plate comprises a metallic material.

47. The implant assembly of claim 42 wherein the bone plate comprises a first polymeric material.

48. The implant assembly of claim 47 wherein the fastener comprises a second polymeric material that is intermixed with the first polymeric material of the bone plate.

49. The implant assembly of claim 42 wherein the bone plate comprises a composite material.

50. An orthopedic implant assembly comprising:

a bone plate comprising at least one opening therethrough; and

a fastener formed of a non metallic material and comprising a head and an opposite tissue engaging portion, wherein said fastener is received through the at least one opening and bonded to the bone plate, wherein at least one of the bone plate and the fastener includes an adhesive, and said adhesive is selected from the group consisting of;

epoxies, acrylates, cyanoacrylates, polyesters, polyolefins, polyurethanes, silicone adhesives, and mixtures thereof.

51. The implant assembly of claim 50 wherein at least one of the bone plate and the fastener are formed of a biodegradable material.

52. The implant assembly of claim 50 wherein the fastener is formed of a polymeric material from the group consisting essentially of homopolymers, co-polymers, and oligomers of:

polyhydroxy acids, polyesters, polyorthoesters, polyanhydrides, polydioxanone, polydioxanediones, polyesteramides, polyaminoacids, polyamides, polycarbonates, polylactide, polyglycolide, tyrosine-derived polycarbonate, polyanhydride, polyorthoester, polyphosphazene, polyethylene, polyester, polyvinyl alcohol, polyacrylonitrile, polyamide, polytefrafluorethylene, poly-paraphenylene terephthalamide, polyaryletherketones, polyetherketones, cellulose, carbon fiber reinforced composite, and mixtures thereof.

53. The implant assembly of claim 50 wherein at least one of the fastener and the bone plate are formed of polymer comprising monomeric repeating units derived from the group consisting of d-lactic acid, l-lactic acid, glycolic acid, caprolactone, hydroxy buteric acid, hydroxy valeric acid, and mixtures thereof.

54. The implant assembly of claim 50 wherein the bone plate comprises a metallic material.

55. The implant assembly of claim 50 wherein the bone plate comprises a first polymeric material.

56. The implant assembly of claim 55 wherein the fastener comprises a second polymeric material that is intermixed with the first polymeric material of the bone plate.

57. The implant assembly of claim 50 wherein the bone plate comprises a composite material.

58. An orthopedic implant assembly comprising:

a bone plate comprising at least one opening therethrough; and

a fastener formed of a non metallic material and comprising a head and an opposite tissue engaging portion, wherein said fastener is received through the at least one opening and adhesively bonded to the bone plate, wherein the adhesive is a two-part adhesive and wherein a first part of the adhesive is provided on the bone plate and a second part of the adhesive is provided on the fastener, whereby contact of the bone plate with the fastener combines the first part and the second part of the adhesive.

59. The implant assembly of claim 58 wherein at least one of the bone plate and the fastener are formed of a biodegradable material.

60. The implant assembly of claim 58 wherein the fastener is formed of a polymeric material from the group consisting essentially of homopolymers, co-polymers, and oligomers of:

polyhydroxy acids, polyesters, polyorthoesters, polyanhydrides, polydioxanone, polydioxanediones, polyesteramides, polyaminoacids, polyamides, polycarbonates, polylactide, polyglycolide, tyrosine-derived polycarbonate, polyanhydride, polyorthoester, polyphosphazene, polyethylene, polyester, polyvinyl alcohol, polyacrylonitrile, polyamide, polytetrafluorethylene, poly-paraphenylene terephthalamide, polyaryletherketones, polyetherketones, cellulose, carbon fiber reinforced composite, and mixtures thereof.

61. The implant assembly of claim 58 wherein at least one of the fastener and the bone plate are formed of a polymer comprising monomeric repeating units derived from the group consisting of d-lactic acid, l-lactic acid, glycolic acid, caprolactone, hydroxy buteric acid, hydroxy valeric acid, and mixtures thereof.

62. The implant assembly of claim 58 wherein the bone plate comprises a metallic material.

63. The implant assembly of claim 58 wherein the bone plate comprises a first polymeric material.

64. The implant assembly of claim 63 wherein the fastener comprises a second polymeric material that is intermixed with the first polymeric material of the bone plate.

65. The implant assembly of claim 58 wherein the bone plate comprises a composite material.

66. An implant assembly comprising:

a bone plate having at least one opening extending therethrough;

a fastener received within said opening and having a proximal head, a distal bone-engaging portion, and a shaft therebetween; and

an adhesive applied to at least one of the fastener and the bone plate, wherein said adhesive acts to fixedly attach said fastener to said bone plate, wherein said adhesive has a first adhesive part applied to said plate and a second adhesive part applied to said fastener.

67. The implant assembly of claim 66 wherein at least one of the bone plate and the fastener are formed of a biodegradable material.

68. The implant assembly of claim 66 wherein the fastener is formed of a polymeric material from the group consisting essentially of homopolymers, co-polymers, and oligomers of:

polyhydroxy acids, polyesters, polyorthoesters, polyanhydrides, polydioxanone, polydioxanediones, polyesteramides, polyaminoacids, polyamides, polycarbonates, polylactide, polyglycolide, tyrosine-derived polycarbonate, polyanhydride, polyorthoester, polyphosphazene, polyethylene, polyester, polyvinyl alcohol, polyacrylonitrile, polyamide, polytetrafluorethylene, poly-paraphenylene terephthalamide, polyaryletherketones, polyetherketones, cellulose, carbon fiber reinforced composite, and mixtures thereof.

69. The implant assembly of claim 66 wherein at least one of the fastener and the bone plate are formed of a polymer comprising monomeric repeating units derived from the group consisting of d-lactic acid, l-lactic acid, glycolic acid, caprolactone, hydroxy buteric acid, hydroxy valeric acid, and mixtures thereof.

70. The implant assembly of claim 66 wherein the bone plate comprises a metallic material.

71. The implant assembly of claim 66 wherein the bone plate comprises a first polymeric material.

72. The implant assembly of claim 71 wherein the fastener comprises a second polymeric material that is intermixed with the first polymeric material of the bone plate.

73. The implant assembly of claim 66 wherein the bone plate comprises a composite material.

74. The implant assembly of claim 66, wherein said first and second adhesive parts are intermixed on bringing said plate and said fastener together.