Cervical plate system

• US 7,736,380 B2
• Filed: 12/21/2005
• Issued: 06/15/2010
• Est. Priority Date: 12/21/2004
• Status: Active Grant

• Current Assignee: Rhausler, Inc
• Original Assignee: Rhausler, Inc
• Inventors: Geisler, Fred, Johnston, Terry
• Primary Examiner(s): Barrett; Thomas C
• Assistant Examiner(s): BOLES, SAMEH RAAFAT
• Application Number:
  US11/313,317
• Publication Number:
  US 20060167456A1
• Time in Patent Office: 1,637 Days
• Field of Search: 606/86, 606/87, 606/96, 606/98, 606/280, 606/281, 606/323, 606902-906, 606/915
• US Class Current: 606/280
• CPC Class Codes: A61B 17/1728 for holes for bone plates or plate screws
• CPC Class Codes: A61B 17/1757 for the spine
• CPC Class Codes: A61B 17/8038 the additional component being inserted in the screw head
• CPC Class Codes: A61B 17/861 specially shaped for gripping driver
• CPC Class Codes: Y10S 606/902 Cortical plate specifically adapted for a particular bone
• CPC Class Codes: Y10S 606/903 Cranial and facial plate
• CPC Class Codes: Y10S 606/904 Jaw plate
• CPC Class Codes: Y10S 606/905 Rib or sternum plate
• CPC Class Codes: Y10S 606/906 Small bone plate
• CPC Class Codes: Y10S 606/915 Toolkit for installing or removing cortical plate

Abstract

A device, system and method for securing a plate to a bone. An anchor device has a screw (with a head portion) and a locking disc. The head portion includes a slotted wall defining a plurality of petals disposed around a central opening. The screw further includes an internal bore. The locking disc is rotatably disposed within the central opening, such that in a first rotational position the petals may flex inwardly, and in a second rotational position the petals are substantially prevented from flexing inwardly. A tool for manipulating the anchor device has a shaft with its end configured to mate with the internal bore of the screw to permit selective rotation of the screw, and a sleeve member rotatably and slideably mounted on the shaft having an end that mates with the locking disc to permit selective rotation of the disc.

Claims

1. An anchor device for securing to a bone a plate having an upper surface and a lower surface and apertures extending from the upper surface to the lower surface, the apertures having inside concave edge walls spaced apart a given inner diameter and having an upper surface opening and a lower surface opening, each having a diameter smaller than the inner diameter, comprising:

a screw including a head portion and a threaded shank with a distal tip and a central longitudinal axis, the head portion having a central opening exposed at the proximal end of the screw and an annular wall around the central opening, the annular wall having an inner and an outer surface, the outer surface having a relaxed outer diameter substantially equal to the inner diameter of the aperture, and the annular wall having a plurality of slots that separate the annular wall into a plurality of petals, wherein the inner surface of the annular wall includes a plurality of shallow recesses and a plurality of deep recesses, wherein at least one of the petals has an inner surface of the annular wall having at least two of the shallow recesses, the screw further including an internal surface of defined shape originating in the central opening for engagement by a matingly-configured screw driving tool for driving the screw into the bone; and

a locking disc rotatably disposed within the central opening and having a periphery of defining a plurality of extending protrusions, the locking disc rotatable between a first rotational position and second rotational position;

wherein the shallow recesses, the deep recesses, and the protrusions are configured so that when the locking disc is in the first rotational position, the protrusions are disposed in the deep recesses in the inner surface of the annular wall with a clearance permitting the petals to flex inwardly to insert the screw head into the aperture past the upper surface opening, and when the locking disc is rotated to the second rotational position two of the protrusions are disposed in and engage with a corresponding two of the shallow recesses formed on the inner surface of at least one of the petals to establish a corresponding two engagements when the petal substantially is at its free relaxed state to prevent the petal from flexing inwardly, whereby the head is selectively captured within the concave edge walls of the plate aperture.

2. The device of claim 1, wherein the screw'"'"'s internal surface comprises a bore extending distally from the central opening along the central longitudinal axis of the shank.

3. The device of claim 2, wherein the locking disc has a central aperture that surrounds the bore, thereby permitting access to the bore by the screw driving tool.

4. The device of claim 2, wherein the bore has a hexagonal cross-section.

5. The device of claim 2, wherein the bore has a cross-sectional shape selected from among the following:

slotted, triangular, square, rectangular, pentagonal or octagonal.

6. The device of claim 1, wherein the plurality of slots comprises four slots and the plurality of petals comprises four petals, and wherein the periphery of the locking disc defines eight protrusions.

7. The device of claim 6, wherein at the first rotational position of the locking disc each of a first four of the eight protrusions is aligned with and engaged within a corresponding one of the four deep recesses that are aligned with the four slots, and each of a second four of the eight protrusions is aligned with and engaged within a corresponding one of the four deep recesses.

8. The device of claim 1, wherein the number of shallow recesses and the number of deep recesses are each equal to the number of protrusions.

9. The device of claim 1, wherein the locking disc includes at least a pair of proximally opening notches configured for engagement by a tool to effectuate rotation of the disc from the first rotational position to the second rotational position.

10. The device of claim 1, wherein the distal tip of the screw is self-tapping.

11. The device of claim 1, wherein the locking disc, at the first and at the second of the rotational positions, is fully nested within the central opening and does not protrude beyond the proximal end of the screw.

12. The device of claim 1, wherein the number of shallow recesses is equal to the number of deep recesses, and the shallow recesses and the deep recesses are arranged in an alternating pattern along the inner surface of the annular wall.

13. The device of claim 12, wherein the inner surface of each of said petals has two shallow recesses and has one deep recess between the two shallow recesses.

14. The device of claim 13, wherein the shallow recesses are equally spaced.

15. The device of claim 14, wherein the slots are formed so that the petals have a common width and are equally spaced.

16. The device of claim 15, wherein the inner surface of the annular wall includes one of the deep recesses aligned with each of the slots.

17. The device of claim 1, wherein the shallow recesses are equally spaced.

18. The device of claim 1, wherein the slots are formed so that the petals have a common width and are equally spaced.

19. The device of claim 1, wherein the inner surface of the annular wall includes one of the deep recesses aligned with each of the slots.

20. A system for securing a bone to a plate having an upper surface and a lower surface and apertures extending from the upper surface to the lower surface, the apertures having inside concave edge walls spaced apart a given inner diameter and having an upper surface opening and a lower surface opening, each having a diameter smaller than the inner diameter, comprising:

a screw including a head portion and a threaded shank with a distal tip and a central longitudinal axis, the head portion having a central opening exposed at the proximal end of the screw and an annular wall around the central opening, the annular wall having an inner and an outer surface, the outer surface having a relaxed outer diameter substantially equal to the inner diameter of the aperture and having a plurality of slots that separate the annular wall into a plurality of petals, wherein the inner surface of the annular wall includes a plurality of shallow recesses and a corresponding plurality of deep recesses, wherein at least one of the petals has an inner surface of the annular wall having at least two of the shallow recesses, the screw further including an internal surface of defined shape originating in the central opening for engagement by a matingly-configured screw driving tool for driving the screw into the bone; and

a locking disc rotatably disposed within the central opening and having a periphery of defining a plurality of extending protrusions, the locking disc rotatable between a first rotational position and second rotational position, the locking disc having a central aperture that surrounds the internal bore of the screw to permit access to the internal bore, and at least a pair of proximally opening notches configured for engagement to effectuate rotation of the disc; and

a tool with a handle, a shaft extending from the handle and having a distal end configured to mate with the internal bore of the screw to permit selective rotation of the screw, and a sleeve member axially slideable along and rotatable about the shaft and having a distal end with structure that mates with the pair of proximally opening notches in the locking disc to permit selective rotation of the disc;

wherein the shallow recesses, the deep recesses, and the protrusions are configured so that when the locking disc is in the first rotational position, the protrusions are disposed in the deep recesses with a clearance permitting the petals to flex inwardly to insert the screw head into the aperture past the upper surface opening, and when the locking disc is rotated to the second rotational position two of the protrusions are disposed in and engage with a corresponding two of the shallow recesses formed on the inner surface of at least one of the petals, to establish a corresponding two engagements with the petal substantially at its free relaxed state, to prevent the petal from flexing inwardly, whereby the head is selectively captured within the concave edge walls of the plate aperture.

21. The system of claim 20, wherein the internal bore has a hexagonal cross-section and the distal end of the tool shaft has a mating hexagonal configuration.

22. The system of claim 20, wherein the internal bore has a cross-sectional shape selected from among slotted, triangular, square, rectangular, pentagonal or octagonal, and the distal end of the tool shaft has a correspondingly mated configuration.

23. The system of claim 20, wherein the plurality of slots comprises four slots and the plurality of petals comprises four petals, and wherein the periphery of the locking disc defines eight protrusions.

24. The device of claim 23, wherein at the first rotational position of the locking disc each of a first four of the eight protrusions is aligned with and engaged within a corresponding one of the four deep recesses that are aligned with the four slots, and each of a second four of the eight protrusions is aligned with and engaged within a corresponding one of the four deep recesses.

25. The system of claim 20, wherein the number of protrusions is twice the number of petals, and the protrusions are configured with respect to the shallow recesses such that upon rotation of the locking disc to the second rotational position at least two protrusions engage a corresponding at least of the two shallow recesses on the inside surface of each petal.

26. The system of claim 20, wherein the locking disc, at the first and at the second of the rotational positions, is fully nested within the central opening and does not protrude beyond the proximal end of the screw.

27. The system of claim 20, wherein the sleeve of the tool further includes a flange member, whereby, when the distal ends of the shaft and the sleeve are engaged, respectively, with the screw and the locking disc, a user may maintain the rotational position of the screw by grasping the tool handle and simultaneously rotate the flange and the sleeve and thus also the disc.

28. The system of claim 20, further comprising a screw aligning device having a guide block and a manipulation arm, the guide block including at least one bore through which the screw can pass and which holds the screw in a desired angular position as it is being driven into the bone.

29. The system of claim 20, wherein the number of shallow recesses is equal to the number of deep recesses, and the shallow recesses and the deep recesses are arranged in an alternating pattern along the inner surface of the annular wall.

30. The system of claim 29, wherein the inner surface of each of said petals has two shallow recesses and has one deep recess between the two shallow recesses.

31. The system of claim 30, wherein the shallow recesses are equally spaced.

32. The system of claim 31, wherein the slots are formed so that the petals have a common width and are equally spaced.

33. The system of claim 32, wherein the inner surface of the annular wall includes one of the deep recesses aligned with each of the slots.

34. The system of claim 20, wherein the inner surface of each of said petals has two shallow recesses and has one deep recess between the two shallow recesses.

35. The system of claim 20, wherein the shallow recesses are equally spaced.

36. The system of claim 20, wherein the slots are formed so that the petals have a common width and are equally spaced.

37. The system of claim 20, wherein the inner surface of the annular wall includes one of the deep recesses aligned with each of the slots.

38. A method of securing to a bone a plate having an upper surface and a lower surface and apertures extending from the upper surface to the lower surface, the apertures having inside concave edge walls spaced apart a given inner diameter and having an upper surface opening and a lower surface opening, each having a diameter smaller than the inner diameter, comprising:

positioning a selected aperture of the plate adjacent a desired location on the bone;

aligning a bone screw through the selected aperture and into contact with the bone at a desired angular orientation, the screw including

a threaded shank with a distal tip,

a head portion having a central opening exposed at the proximal end of the screw and an annular wall around the central opening, the annular wall having an inner and an outer surface, the outer surface having a relaxed outer diameter substantially equal to the inner diameter of the aperture and having a plurality of slots that separate the annular wall into a plurality of petals, wherein the inner surface of the annular wall includes a plurality of spaced shallow recesses and a plurality of deep recesses, wherein at least one of the petals has at least two of the shallow recesses,

an internal bore of defined shape originating in the central opening for engagement by a driving tool, and

a locking disc rotatably disposed within the central opening and having a periphery of defining a plurality of extending protrusions, the locking disc rotatable between a first rotational position and a second rotational position, the locking disc having a central aperture that surrounds the internal bore of the screw to permit access to the internal bore, and at least a pair of proximally opening notches configured for engagement to effectuate rotation of the disc, wherein the shallow recesses, the deep recesses, and the protrusions are configured so that when the locking disc is in the first rotational position at least one of the petals is flexible inwardly to permit inserting the screw head into the aperture past the upper surface opening, and when the locking disc is rotated to the second rotational position the two of the protrusions are disposed in and engage with a corresponding two of the shallow recesses formed on the inner surface of at least one of the petals, with the petal substantially at its free relaxed state, to establish a corresponding two engagements to prevent the petal from flexing inwardly;

engaging the internal bore of the screw with a driving tool having a handle and a shaft with a distal end configured to mate with the internal bore, driving the distal tip of the screw against the bone and selectively rotating the screw until it penetrates the bone to a desired depth, the driving tool further including

a sleeve member axially slideable along and rotatable about the shaft, the sleeve member including a flange for effectuating movement of the sleeve relative to the shaft, and a distal end with structure that mates with the pair of proximally opening notches in the locking disc; and

manipulating the flange first to slide the sleeve into mating engagement with the pair of proximally opening notches in the locking disc and second to rotate the locking disc from the first rotational position to the second rotational position, whereupon the head is captured by the concave wall edges of the plate aperture.

39. The method of claim 38, further comprising the step of simultaneously maintaining the rotational position of the screw by grasping the tool handle while manipulating the flange to effectuate rotation of the locking disc.

40. The method of claim 38, further comprising the step of employing a screw aligning device having a guide block and a manipulation arm, the guide block including at least one bore through which the screw can pass and which maintains the screw in the desired angular orientation as it is being driven into the bone.

41. The method of claim 38, wherein the step of engaging the internal bore of the screw with a driving tool having a handle and a shaft with a distal end configured to mate with the internal bore, driving the distal tip of the screw against the bone and selectively rotating the screw further comprises rotating the locking disc to the first position, and wherein the selectively rotating the screw until it penetrates the bone to a desired depth includes rotating the screw until screw head the screw head is in the aperture, past the upper aperture opening, by the rotating urging the outer surface of the petals against the upper surface aperture opening to flex the petals inward and continuing urging the screw head until the petals pass the upper surface aperture opening and return to the free, relaxed state within the concave wall edges of the aperture.

42. The method of claim 38, wherein the number of shallow recesses is equal to the number of deep recesses, and the shallow recesses and the deep recesses are arranged in an alternating pattern along the inner surface of the annular wall.

43. The method of claim 42, wherein the inner surface of each of said petals has two shallow recesses and has one deep recess between the two shallow recesses.

44. The method of claim 43, wherein the shallow recesses are equally spaced.

45. The method of claim 44, wherein the slots are formed so that the petals have a common width and are equally spaced.

46. The method of claim 45, wherein the inner surface of the annular wall includes one of the deep recesses aligned with each of the slots.

47. The method of claim 38, wherein the inner surface of each of said petals has two shallow recesses and has one deep recess between the two shallow recesses.

48. The method of claim 38, wherein the shallow recesses are equally spaced.

49. The method of claim 38, wherein the slots are formed so that the petals have a common width and are equally spaced.

50. The method of claim 38, wherein the inner surface of the annular wall includes one of the deep recesses aligned with each of the slots.

51. A bone plate system, comprising:

a plate having an upper surface and a lower surface and an aperture extending from the upper surface to the lower surface, the aperture having inside concave edge walls spaced apart a given inner diameter and having an upper surface opening and a lower surface opening, each having a diameter smaller than the inner diameter;

a screw including a head portion at a proximal end and a threaded shank with a distal tip, the head portion having a mating structure exposed through a central opening at the proximal end, for engaging a matingly-configured screw driving tool for driving the screw, and having an annular wall around the central opening, the annular wall having an inner and an outer surface, the inner surface including a plurality of shallow recesses and a plurality of deep recesses, the annular wall having a plurality of slots that separate the annular wall into a plurality of petals such that each petal has a portion of the inner surface having at least two of the shallow recesses, the outer surface having a relaxed outer diameter substantially equal to the inner diameter of the aperture and; and

a locking disc rotatable within the central opening and having a periphery defining a plurality of protrusions, each protrusion having a high point configured for selective engagement within one of the shallow and one of the deep recesses,

wherein the shallow recesses, the deep recesses, and the protrusions are configured so that when the locking disc is in a first rotational position, the protrusions engage with the deep recesses in the inner surface of the annular wall with a clearance to enable inward flex of the petals of the screw head sufficient for insertion through the upper surface aperture opening into the aperture, and when the locking disc is in a second rotational position, the respective high point of least two of the protrusions engage with a corresponding at least two of the shallow recesses formed on the inner surface of each of the petals, to establish a corresponding two engagements preventing the petals from flexing inwardly, thereby preventing the screw head from being compressed sufficiently to pass through the upper aperture opening, thereby providing for capturing the head within the concave edge walls of the plate aperture.

52. The bone plate system of claim 51, wherein the number of shallow recesses is equal to the number of deep recesses, and the shallow recesses and the deep recesses are arranged in an alternating pattern along the inner surface of the annular wall.

53. The bone plate system of claim 52, wherein the inner surface of each of said petals has two shallow recesses and has one deep recess between the two shallow recesses.

54. The bone plate system of claim 51, wherein at least one of said apertures of at least one of said plates is an elongated slot aperture, the elongated aperture having a width equal to said inner diameter, and having an upper surface elongated aperture opening and a lower surface elongated aperture opening, the upper surface elongated aperture opening having a width smaller than the inner diameter and the lower surface elongated aperture opening having a width smaller than the inner diameter, and wherein at least one of the screws has its plurality of petals configured so that when its locking disc is rotated to the second rotational position the screw head of said screw is captured by the elongated slot aperture and, concurrent with said capture, the screw head is movable along a length of the elongated slot aperture.

55. The bone plate system of claim 51,

wherein the annular wall includes four slots separating the annular wall into four petals,

wherein the locking disc includes eight protrusions, and

wherein at the first rotational position of the locking disc each of a first four of the eight protrusions is aligned with and engaged within a corresponding one of the four deep recesses that are aligned with the four slots, and each of a second four of the eight protrusions is aligned with and engaged within a corresponding one of the four deep recesses.

56. The bone plate system of claim 55, wherein at the second rotational position of the locking disc each of the eight protrusions is aligned with and engaged within a corresponding one of the two shallow recesses.