Impacted orthopedic bone support implant

• US 7,537,616 B1
• Filed: 10/20/2000
• Issued: 05/26/2009
• Est. Priority Date: 10/20/1999
• Status: Expired due to Term

• Current Assignee: SDGI Holdings Incorporated (Medtronic Plc)
• Original Assignee: Warsaw Orthopedic Incorporated (Medtronic Plc)
• Inventors: Ray, Eddie III, White, John L., Estes, Bradley T., Branch, Charles L.
• Primary Examiner(s): Prebilic; Paul
• Application Number:
  US10/312,174
• Time in Patent Office: 3,140 Days
• Field of Search: 623 1711- 1716, 623/23.26, 623/23.33, 623/23.44, 606/70, 606/74
• US Class Current: 623/17.16
• CPC Class Codes: A61B 17/14 Surgical saws A61B17/1637 takes precedence; tooth saws A61C3/12 ; Accessories therefor
• CPC Class Codes: A61B 17/1604 Chisels; Rongeurs; Punches; Stamps
• 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 2/30965 Reinforcing the prosthesis by embedding particles or fibres during moulding or dipping
• 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 2/4455 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 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 2/4603 for insertion or extraction of endoprosthetic joints or of accessories thereof
• CPC Class Codes: A61F 2/4611 of spinal prostheses
• 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 2002/2839 Bone plugs or bone graft dowels
• CPC Class Codes: A61F 2002/30112 Rounded shapes, e.g. with rounded corners
• CPC Class Codes: A61F 2002/30138 Convex polygonal shapes
• CPC Class Codes: A61F 2002/30153 rectangular
• CPC Class Codes: A61F 2002/30154 square
• CPC Class Codes: A61F 2002/30156 triangular
• CPC Class Codes: A61F 2002/30235 tubular, e.g. sleeves
• CPC Class Codes: A61F 2002/30261 parallelepipedal
• CPC Class Codes: A61F 2002/30324 differing in thickness
• CPC Class Codes: A61F 2002/30593 : hollow
• CPC Class Codes: A61F 2002/30616 : Sets comprising a plurality of prosthetic parts of different sizes or orientations
• CPC Class Codes: A61F 2002/30774 : internally-threaded
• CPC Class Codes: A61F 2002/30777 : Oblong apertures
• CPC Class Codes: A61F 2002/30785 : parallel
• CPC Class Codes: A61F 2002/30787 : inclined obliquely with respect to each other
• CPC Class Codes: A61F 2002/30789 : perpendicular with respect to each other
• CPC Class Codes: A61F 2002/3082 : Grooves
• CPC Class Codes: A61F 2002/30836 : knurled
• CPC Class Codes: A61F 2002/30879 : Ribs
• CPC Class Codes: A61F 2002/30912 : made of expanded metal, e.g. diamond mesh or metal nets having lozenge-shaped apertures
• CPC Class Codes: A61F 2002/3097 : using laser
• CPC Class Codes: A61F 2002/4649 : Bone graft or bone dowel harvest sites
• CPC Class Codes: A61F 2002/4681 : by applying mechanical shocks, e.g. by hammering
• CPC Class Codes: A61F 2230/0004 : Rounded shapes, e.g. with rounded corners
• CPC Class Codes: A61F 2230/0017 : Angular shapes
• CPC Class Codes: A61F 2230/0019 : rectangular
• CPC Class Codes: A61F 2230/0021 : square
• CPC Class Codes: A61F 2230/0023 : triangular
• CPC Class Codes: A61F 2230/0069 : cylindrical
• CPC Class Codes: A61F 2230/0082 : parallelepipedal
• CPC Class Codes: A61F 2250/0036 : differing in thickness
• 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 2310/00179 : Ceramics or ceramic-like structures

Abstract

This invention relates to a porous bone implant (10, 110, and 210), a method of manufacturing the implant and a method of orthopedic treatment. The mesh implant can be manufactured using extrusion techniques and a variety of cutting and machining processes to provide the implant with the desired structural features and in the required dimensions to be matingly received within the bone defect or cavity. The implant can be used to strengthen bone structures and support bone tissue adjacent to a defect of cavity. Thus, the implant can be used to provide improved treatment of patients having bone defects or diseases with decreased postoperative pain and a shorter recovery time.

Claims

1. An orthopedic implant comprising an impacted mesh body defining an interior chamber, said body comprising:

a first end including a first support band extending about a first axis and defining a first opening into said interior chamber and defining a first end surface; and

a second end opposite said first end and including a second support band extending about the first axis and defining a second opening into said interior chamber and defining a second end surface; and

a longitudinal wall extending along a second axis substantially orthogonal to the first axis and between opposite transverse end walls, said longitudinal wall integral with said first and second support bands to define a one-piece, unitary body, said unitary body having a cross-sectional thickness measured orthogonal to the first axis at said first and second support bands that is greater than a cross-sectional thickness of said longitudinal wall, said longitudinal wall including an exterior surface extending between said first end surface and said second end surface, and wherein said first and second support bands provide the implant with an uninterrupted support band surface extending continuously about an outer perimeter of said first and second ends and flush with said exterior surface of said longitudinal wall and which does not extend beyond said exterior surface of said longitudinal wall in a direction orthogonal to the first axis, said longitudinal wall including a plurality of openings formed therethrough defining a grid pattern; and

wherein said first end surface defined by said first support band and said second end surface defined by said second support band each comprise an arcuate end surface having a convex curvature extending along the second axis and between said opposite transverse end walls, said arcuate end surfaces of said first and second support bands defining a maximum height of the implant along the first axis positioned between said opposite transverse end walls that is greater than a height of a bone cavity to inhibit expulsion of the implant from the bone cavity.

2. The implant of claim 1 wherein the impacted, mesh body comprises a substantially rectangular prism body including a planar wall portion having a planar surface extending between said first end and said second end.

3. The implant of claim 2 wherein the longitudinal wall includes a first wall section having a first planar surface extending between said first end and said second end, and a second wall section having a second planar surface extending between said first end and said second end;

and

wherein said first and second planar surfaces are substantially parallel.

4. The implant of claim 1, wherein said first opening or said second opening is rectangular.

5. The implant of claim 1 wherein said plurality of openings define a plurality of equilateral or isosceles triangular openings.

6. The implant of claim 1 wherein said cross-sectional thickness of said longitudinal wall is selected to withstand impaction into a cavity between adjacent bone structures.

7. The implant of claim 1 wherein the longitudinal wall has an open area of at least about 50% based on the total exterior surface area of the longitudinal wall.

8. The implant of claim 1 wherein at least one of said opposite transverse end walls includes a tool engaging portion.

9. The implant of claim 3 wherein the at least one of said opposite transverse end walls includes a tool engaging portion.

23. The implant of claim 1 wherein said exterior surface of said longitudinal wall is substantially planar.

26. The implant of claim 1 wherein said longitudinal wall includes a first longitudinal wall and an opposite second longitudinal wall, each of said first and second longitudinal walls defining said grid pattern and being planar.

27. The implant of claim 1 wherein each of said opposite transverse end walls includes a first bearing surface and an opposite second bearing surface, each of first and second bearing surfaces including a substantially planar surface defining one or more anti-expulsion features.

28. The implant of claim 27 wherein said anti-expulsion features comprise a plurality of teeth.

35. The implant of claim 1 wherein said convex curvature of said arcuate end surfaces extends continuously between said opposite transverse end walls.

10. An orthopedic implant comprising an impacted mesh body defining an interior chamber, said body comprising:

a first end defining a first opening into said interior chamber and including a first support band extending about a first axis and positioned peripherally about said first opening and defining a first end surface, said first support band defining a lip or abutment projecting toward the interior chamber;

a second end opposite said first end and defining a second opening into said interior chamber and including a second support band extending about the first axis and positioned peripherally about said second opening and defining a second end surface; and

a longitudinal wall extending along a second axis substantially orthogonal to the first axis and between opposite transverse end walls and between said first and second ends, said longitudinal wall integral with said first and second support bands to define a one-piece, unitary body, said unitary body having a cross-sectional thickness measured orthogonal to the first axis at said first and second support bands that is greater than a cross-sectional thickness of said longitudinal wall, said longitudinal wall including an exterior surface extending between said first end surface and said second end surface, and wherein said first and second support bands provide the implant with an uninterrupted support band surface extending continuously about an outer perimeter of said first and second ends and flush with said exterior surface of said longitudinal wall and which does not extend beyond said exterior surface of said longitudinal wall in a direction orthogonal to the longitudinal first axis, said longitudinal wall including a plurality of openings formed therethrough defining a grid pattern, and wherein said unitary body exhibits a rectangular cross-sectional shape orthogonal to the first axis; and

wherein said first end surface defined by said first support band and said second end surface defined by said second support band each comprise an arcuate end surface having a convex curvature extending along the second axis and between said opposite transverse end walls, said arcuate end surfaces of said first and second support bands defining a maximum height of the implant along the first axis positioned between said opposite transverse end walls that is greater than a height of a bone cavity to inhibit expulsion of the implant from the bone cavity.

11. The implant of claim 10 wherein the said first and second support bands each define a lip or abutment projecting toward the interior chamber.

12. The implant of claim 10 wherein the longitudinal wall includes a first wall section having a first planar surface extending between said first end and said second end, and a second wall section having a second planar surface extending between said first end and said second end.

13. The implant of claim 12 wherein said first and second planar surfaces are substantially parallel.

14. The implant of claim 12 comprising a tool engaging portion on at least one of said opposite transverse end walls.

15. The implant of claim 10 comprising an osteogenic material within the interior chamber.

24. The implant of claim 10 wherein said exterior surface of said longitudinal wall comprises a substantially planar surface.

29. The implant of claim 10 wherein said longitudinal wall includes a first longitudinal wall and an opposite second longitudinal wall, each of said first and second longitudinal walls defining said grid pattern and being planar.

30. The implant of claim 10 wherein each of said opposite transverse end walls includes a first bearing surface and an opposite second bearing surface, each of first and second bearing surfaces including a substantially planar surface defining one or more anti-expulsion features.

31. The implant of claim 30 wherein said anti-expulsion features comprise a plurality of teeth.

36. The implant of claim 10 wherein said convex curvature of said arcuate end surfaces extends continuously between said opposite transverse end walls.

16. An orthopedic implant defining an interior chamber, comprising:

a first end including a first support band extending about a first axis and defining a first end surface;

an opposite second end including a second support band extending about the first axis and defining a second end surface;

a wall portion extending generally along a second axis substantially orthogonal to the first axis and extending between opposite transverse end walls and between said first end and said second end, said wall portion integral with said first and second support bands to define a one-piece, unitary body, said unitary body having a cross-sectional thickness measured orthogonal to the first axis at said first and second support bands that is greater than a cross-sectional thickness of said wall portion, said wall portion including an exterior surface extending between said first end surface and said second end surface, and wherein said first and second support bands provide the implant with an uninterrupted support band surface extending continuously about an outer perimeter of said first and second ends and flush with said exterior surface of said wall portion and which does not extend beyond said exterior surface of said wall portion in a direction orthogonal to the first axis, said wall portion defining a plurality of openings communicating with said interior chamber; and

wherein said first end surface defined by said first support band and said second end surface defined by said second support band each comprise an arcuate end surface having a convex curvature extending along the second axis and between said opposite transverse end walls, said arcuate end surfaces of said first and second support bands defining a maximum height of the implant along the first axis positioned between said opposite transverse end walls that is greater than a height of a bone cavity to inhibit expulsion of the implant from the bone cavity.

17. The implant of claim 16 wherein at least one of said first and second ends defines an end opening communicating with said interior chamber.

18. The implant of claim 17 wherein said support band extends entirely about said end opening.

19. The implant of claim 16 wherein said plurality of openings in said wall portion define a grid pattern.

20. The implant of claim 16 wherein said plurality of openings in said wall portion are triangular-shaped.

21. The implant of claim 16 wherein said wall portion has a substantially rectangular cross-sectional configuration.

22. The implant of claim 16 wherein said wall portion includes a first planar wall section, and an opposite second planar wall section arranged substantially parallel with said first planar wall section.

25. The implant of claim 17 wherein said exterior surface of said wall portion comprises a substantially planar surface.

32. The implant of claim 16 wherein said wall portion includes a first longitudinal wall and an opposite second longitudinal wall, each of said first and second longitudinal walls defining said plurality of openings and being planar.

33. The implant of claim 16 wherein each of said opposite transverse end walls includes a first bearing surface and an opposite second bearing surface, each of first and second bearing surfaces including a substantially planar surface defining one or more anti-expulsion features.

34. The implant of claim 33 wherein said anti-expulsion features comprise a plurality of teeth.

37. The implant of claim 16 wherein said convex curvature of said arcuate end surfaces extends continuously between said opposite transverse end walls.