Expandable intervertebral spacers and methods of use

• US 7,708,779 B2
• Filed: 05/01/2006
• Issued: 05/04/2010
• Est. Priority Date: 05/01/2006
• Status: Active Grant

• Current Assignee: Warsaw Orthopedic Incorporated (Medtronic Plc)
• Original Assignee: Warsaw Orthopedic Incorporated (Medtronic Plc)
• Inventors: Edie, Jason A., Cooper, Lloyd Guyton Bowers, Walker, Don Byron II, Windham, Jerrod Bradley, Dawson, John Caleb
• Primary Examiner(s): Barrett; Thomas C
• Assistant Examiner(s): Yang; Andrew
• Application Number:
  US11/415,042
• Publication Number:
  US 20070255415A1
• Time in Patent Office: 1,464 Days
• Field of Search: 606/61, 606/99, 606/279, 623 1711- 1716, 254/12, 254/13, 254/84, 254/85, 254/103, 254/424, 254/425
• US Class Current: 623/17.15
• 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 2/4465 having a circular or kidney shaped cross-section substantially perpendicular to the axis of the spine
• CPC Class Codes: A61F 2/4611 of spinal prostheses
• CPC Class Codes: A61F 2002/30331 made by longitudinally pushing a protrusion into a complementarily-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2002/30471 connected by a hinged linkage mechanism, e.g. of the single-bar or multi-bar linkage type
• CPC Class Codes: A61F 2002/30523 by means of meshing gear teeth
• CPC Class Codes: A61F 2002/30538 for adjusting angular orientation
• CPC Class Codes: A61F 2002/3055 for adjusting length
• CPC Class Codes: A61F 2002/30601 telescopic
• CPC Class Codes: A61F 2002/4627 with linear motion along or rotating motion about the instrument axis or the implantation direction, e.g. telescopic, along a guiding rod, screwing inside the instrument
• CPC Class Codes: A61F 2220/0025 Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2220/0033 made by longitudinally pushing a protrusion into a complementary-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2220/0091 connected by a hinged linkage mechanism, e.g. of the single-bar or multi-bar linkage type
• CPC Class Codes: A61F 2250/0006 for adjusting angular orientation
• CPC Class Codes: A61F 2310/00796 Coating or prosthesis-covering structure made of a phosphorus-containing compound, e.g. hydroxy(l)apatite
• 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

Abstract

An intervertebral spacer is inserted between vertebral members in a compact configuration and expanded post-insertion to contact the adjacent vertebral members. The intervertebral spacer comprises a first member and a second member movable with respect to the first member between retracted and extended positions.

Claims

1. An intervertebral spacer comprising:

first and second members having respective contact surfaces to contact adjacent vertebral bodies, said first and second members being movable with respect to one another between a retracted position and an extended position, one of said first and second members being a plate;

said first and second members configured to engage an insertion tool when said first and second members are in a retracted position, and to release said tool when said first and second members are moved to an extended position; and

a jack mechanism to move said first and second members between said retracted and extended positions, said jack mechanism including a threaded shaft that extends outward from one of the first and second members and terminates at a distal end, a ring gear with a threaded opening that receives the threaded shaft, the distal end of said threaded shaft remains within said ring gear when said spacer is in the retracted position;

the ring gear further including outwardly-extending gear teeth that extend radially outward from an exterior surface, and a drive gear with a helical extension that engages with the gear teeth, said jack mechanism configured for rotation of the drive gear in a first direction moving the first and second members towards the retracted position and rotation in a second direction moving the first and second members towards the extended position;

each of said first and second members includes a tool-engaging element to capture a head of an insertion tool by moving said first and second members from an extended position to the retracted position.

2. The intervertebral spacer of claim 1 wherein said tool-engaging element on said first and second members comprises an opening to receive the head of said insertion tool.

3. The intervertebral spacer of claim 1 wherein said tool engaging elements are configured to permit rotation of said intervertebral spacer about an axis.

4. The intervertebral spacer of claim 1 further comprising a guide member fixed to one of said first and second members to maintain alignment of said first and second members.

5. The intervertebral spacer of claim 4 wherein said guide member comprises a guide rod fixed to one of said first and second members, said guide member configured for insertion into a guide channel formed in the other of said first and second members.

6. The intervertebral spacer of claim 1 wherein at least one of the first and second members includes a portion that is porous to promote in-growth of bone into the intervertebral spacer.

7. The intervertebral spacer of claim 1 wherein the contact surface on at least one of said first and second members includes a texture to grip an adjacent intervertebral body.

9. The intervertebral spacer of claim 1 further comprising a guide member extending outward from an inner surface of said plate opposite from the contact surface of said plate to engage with a guide channel in said first member to maintain alignment of said first member and said plate.

10. The intervertebral spacer of claim 9 wherein said guide member comprises a guide rod fixed to said plate and configured for insertion into the guide channel formed in the said first member.

11. The intervertebral spacer of claim 1 wherein said first member and said plate are configured to engage an insertion tool when said plate is in a retracted position, and to release said insertion tool when said plate is moved to an extended position.

12. The intervertebral spacer of claim 11 wherein said first member and said plate each include an opening for engagement by said insertion tool when said plate is in the retracted position.

13. The intervertebral spacer of claim 12 wherein said intervertebral spacer is rotatable relative to said insertion tool when it is engaged by said insertion tool.

14. The intervertebral spacer of claim 1 wherein at least one of the first member and said plate includes a portion that is porous to promote in-growth of bone into the intervertebral spacer.

15. The intervertebral spacer of claim 1 wherein the contact surface on at least one of said first member and said plate includes a texture to grip an adjacent intervertebral body.

8. An intervertebral spacer comprising:

a first member and a plate each having respective flattened contact surfaces to contact adjacent vertebral bodies, said plate being movable with respect to the first member between a retracted position and an extended position, the first member including sidewalls that form a main cavity, the sidewalls positioned to be spaced away from the vertebral bodies when the contact surfaces are in contact with the vertebral bodies;

a screw jack interposed between said first member and said plate, said screw jack comprising a screw shaft fixed to said plate and extending transversely away from the contact surface of the plate and terminating at a bottom end, an internally threaded ring gear nested in the main cavity and meshed with said screw shaft such that rotation of said ring gear in a first direction moves said plate away from said first member, and such that rotation of said ring gear in a second direction moves said plate towards said first member, said bottom end of said screw shaft remains within said ring gear when said plate is in said extended and retracted positions; and

a drive gear including a helical thread that extends along a length of an exterior surface, said drive gear mounted in said first member with the helical thread meshed with teeth on an outer surface of said ring gear, said drive gear accessible to a surgeon post-insertion to actuate said screw jack to move said plate between said retracted and extended positions;

a centerline of the drive gear being spaced away from a centerline of the ring gear such that the centerlines do not intersect.

16. A method of inserting an intervertebral spacer between two vertebral members, said method comprising:

inserting an intervertebral spacer having first and second members into an intervertebral space, said intervertebral spacer including a screw jack for moving said first and second members relative to one another between a retracted position and an extended position, said screw jack comprising a screw shaft fixed to one of said first and second members, and an internally threaded ring gear meshed with said screw shaft such that rotation of said ring gear in a first direction moves said second member away from said first member, and such that rotation of said ring gear in a second direction moves said second member towards said first member;

expanding the intervertebral spacer post-insertion by rotating a worm gear with a helical thread meshed with said ring gear and rotating the ring gear while the ring gear is nested in a main cavity of one of the first and second members and while maintaining the ring gear against a floor of the main cavity to spread apart the first and second members; and

expanding the intervertebral spacer and moving a guide rod fixed to one of the first and second members within a guide channel in the other of the first and second members, the guide rod being spaced away from the screw shaft.