Bone fusion device and methods

• US 7,799,056 B2
• Filed: 12/31/2007
• Issued: 09/21/2010
• Est. Priority Date: 12/31/2007
• Status: Active Grant

• Current Assignee: Kyphon SARL (Medtronic Plc)
• Original Assignee: Warsaw Orthopedic Incorporated (Medtronic Plc)
• Inventors: Sankaran, Meera
• Primary Examiner(s): Robert; Eduardo C
• Assistant Examiner(s): NEGRELLIRODRIGUEZ, CHRISTINA
• Application Number:
  US11/967,780
• Publication Number:
  US 20090171390A1
• Time in Patent Office: 995 Days
• Field of Search: 606/60, 606/103, 606154-264, 606/279, 623 1711- 1716
• US Class Current: 606/246
• 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 2/4611 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 2002/30224 cylindrical
• CPC Class Codes: A61F 2002/30235 tubular, e.g. sleeves
• CPC Class Codes: A61F 2002/30451 soldered or brazed or welded
• CPC Class Codes: A61F 2002/30538 for adjusting angular orientation
• CPC Class Codes: A61F 2002/30545 for adjusting a diameter
• CPC Class Codes: A61F 2002/30579 with mechanically expandable devices, e.g. fixation devices
• CPC Class Codes: A61F 2002/30601 telescopic
• CPC Class Codes: A61F 2002/30607 Kits of prosthetic parts to be assembled in various combinations for forming different prostheses
• CPC Class Codes: A61F 2002/30841 Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes
• CPC Class Codes: A61F 2002/448 comprising multiple adjacent spinal implants within the same intervertebral space or within the same vertebra, e.g. comprising two adjacent spinal implants
• 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 2002/4629 connected to the endoprosthesis or implant via a threaded connection
• CPC Class Codes: A61F 2220/0058 soldered or brazed or welded
• CPC Class Codes: A61F 2230/0069 cylindrical
• CPC Class Codes: A61F 2250/0006 for adjusting angular orientation
• CPC Class Codes: A61F 2250/001 for adjusting a diameter
• CPC Class Codes: A61F 2250/0062 : Kits of prosthetic parts to be assembled in various combinations for forming different prostheses

Abstract

A bone fusion device, system, kit, and/or method can include an elongated structure including at least two anchor portions and at least one deformable segment connected on each end to one of the at least two anchor portions. Each deformable segment can include a plurality of spaced apart deformable members deformable from an unexpanded configuration to an expanded configuration. The bone fusion device may be implanted between two bone structures in the unexpanded configuration utilizing a minimally invasive surgical procedure. The deformable members can be compressed along a longitudinal axis of the device to deform the deformable members to the expanded configuration into contact with the two bone structures. A bone growth promoting material can be placed in the anchor portion lumen and in the interior of each deformable segment to promote bone in-growth between the bone structures.

Claims

1. A bone fusion device comprising:

an elongated structure extending along a longitudinal axis and comprising at least two anchor portions and at least one deformable segment connected on each end to one of the at least two anchor portions,

each deformable segment comprising a plurality of spaced apart deformable members deformable from an unexpanded configuration to an expanded configuration, each of the deformable members individually having an outer cross section in the shape of a circle extending axially along the longitudinal axis of the device from a first of the anchor portions to a second of the anchor portions, the device being implantable between two bone structures in the unexpanded configuration,

wherein compression of the deformable members along the longitudinal axis of the device deforms the deformable members to the expanded configuration into contact with the two bone structures.

2. The device of claim 1, wherein the expanded configuration of each deformable segment comprises a predetermined configuration.

3. The device of claim 1, further comprising at least two deformable segments, wherein one of the deformable segments is deformable to a first expanded configuration, and another one of the deformable segments is deformable to a second expanded configuration different from the first expanded configuration.

4. The device of claim 1, further comprising the device being implantable utilizing a minimally invasive surgical procedure.

5. The device of claim 1, wherein the at least one deformable segment is deformable at least vertically along an intervertebral disc space height.

6. The device of claim 1, wherein the elongated structure comprises a tubular structure in the unexpanded configuration and the at least two anchor portions comprise tube portions.

7. The device of claim 1, wherein the deformable members comprise wire having a wire gauge.

8. The device of claim 1, wherein in the unexpanded configuration the deformable members are parallel to the longitudinal axis of the device.

9. The device of claim 1, wherein the deformable members further comprise surface projections for securely engaging the two bone structures.

10. The device of claim 1, wherein at least one of the anchor portions has a hollow lumen and each deformable segment has a hollow interior, the device further comprising a bone growth promoting material in the anchor portion lumen and in the interior of each deformable segment.

11. The device of claim 1, wherein one end of the at least one deformable segment connected to a proximal anchor portion at a proximal end of the elongated structure and another end of the at least one deformable segment connected to a distal anchor portion at a distal end of the elongated structure;

an internal rod extending through the elongated structure along the longitudinal axis and detachably attached to the distal anchor; and

a pushing tube slidable about the internal rod and detachably attached to the proximal anchor portion,

wherein translation of the pushing tube and the proximal anchor portion along the inner rod toward a fixed position of the distal anchor portion compresses the deformable members so as to deform each deformable segment to the expanded configuration.

13. The device of claim 1, further comprising:

an internal rod extendable through the elongated structure along the longitudinal axis of the device and detachably attachable to a distal anchor portion at a distal end of the elongated structure; and

a pushing tube slidable about the internal rod and detachably attachable to a proximal anchor portion at a proximal end of the elongated structure,

wherein translation of the pushing tube and the attached proximal anchor portion along the internal rod toward a fixed position of the distal anchor portion attached to the internal rod compresses the deformable members along the longitudinal axis so as to deform each deformable segment to the expanded configuration into contact with the two bone structures.

14. The device of claim 1, wherein the deformable members comprise wire members extending axially along the longitudinal axis from the first anchor portion to the second anchor portion.

12. A bone fusion device comprising:

an elongated structure comprising at least two anchor portions and at least one deformable segment connected on each end to one of the at least two anchor portions;

each deformable segment comprising a plurality of spaced apart deformable members deformable from an unexpanded configuration to an expanded configuration;

the device being implantable between two bone structures in the unexpanded configuration;

wherein compression of the deformable members along a longitudinal axis of the device deforms the deformable members to the expanded configuration into contact with the two bone structures; and

one end of the at least one deformable segment connected to a proximal anchor portion at a proximal end of the elongated structure and another end of the at least one deformable segment connected to a distal anchor portion at a distal end of the elongated structure;

an internal rod extending through the elongated structure along the longitudinal axis and detachably attached to the distal anchor; and

a pushing tube slidable about the internal rod and detachably attached to the proximal anchor portion;

wherein translation of the pushing tube and the proximal anchor portion along the inner rod toward a fixed position of the distal anchor portion compresses the deformable members so as to deform each deformable segment to the expanded configuration;

wherein the internal rod is detachably attached to the distal anchor portion with mating threads and the pushing tube is detachably attached to the proximal anchor portion with identically sized mating threads, and

wherein the internal rod and the pushing tube are detachable from the anchor portions by simultaneously rotating the internal rod and the pushing tube.

15. A bone fusion device comprising:

an elongated structure extending along a longitudinal axis and comprising at least two anchor portions and at least one deformable segment connected on each end to one of the at least two anchor portions;

each deformable segment comprising a plurality of spaced apart deformable members deformable from an unexpanded configuration to an expanded configuration, each of the deformable members having a circular cross section extending axially along the longitudinal axis of the device from a first of the anchor portions to a second of the anchor portions;

the device being implantable between two bone structures in the unexpanded configuration;

wherein compression of the deformable members along the longitudinal axis of the device deforms the deformable members to the expanded configuration into contact with the two bone structures; and

wherein the deformable members comprise wire members extending axially along the longitudinal axis from the first anchor portion to the second anchor portion; and

wherein each of the wire members has the same wire gauge.

16. The device of claim 15, wherein the circular cross section of each of the deformable members has a uniform outer diameter.

18. The device of claim 15, wherein the first and second anchor portions each comprise a tubular shaped disc, and

wherein the deformable members are attached to oppositely facing end surfaces of the tubular shaped discs.

17. A bone fusion device comprising:

an elongated structure extending along a longitudinal axis and comprising at least two anchor portions and at least one deformable segment connected on each end to one of the at least two anchor portions;

each deformable segment comprising a plurality of spaced apart deformable members deformable from an unexpanded configuration to an expanded configuration, each of the deformable members having a circular cross section extending axially along the longitudinal axis of the device from a first of the anchor portions to a second of the anchor portions;

the device being implantable between two bone structures in the unexpanded configuration;

wherein compression of the deformable members along the longitudinal axis of the device deforms the deformable members to the expanded configuration into contact with the two bone structures;

wherein the circular cross section of at least one of the deformable members has a first outer diameter, and

wherein the circular cross section of at least one other of the deformable members has a second outer diameter different from the first outer diameter.

19. A bone fusion device comprising:

an elongated structure extending along a longitudinal axis and comprising at least two anchor portions and at least one deformable segment connected on each end to one of the at least two anchor portions;

each deformable segment comprising a plurality of spaced apart deformable members deformable from an unexpanded configuration to an expanded configuration, each of the deformable members having a circular cross section extending axially along the longitudinal axis of the device from a first of the anchor portions to a second of the anchor portions;

the device being implantable between two bone structures in the unexpanded configuration; and

wherein compression of the deformable members along the longitudinal axis of the device deforms the deformable members to the expanded configuration into contact with the two bone structures; and

wherein the first and second anchor portions each comprise a tubular shaped disc; and

wherein the deformable members are attached to oppositely facing end surfaces of the tubular shaped discs; and

wherein the deformable members are welded to the oppositely facing end surfaces of the tubular shaped discs.

20. A bone fusion device comprising:

an elongated structure comprising at least two anchor portions and at least one deformable segment connected on each end to one of the at least two anchor portions;

each deformable segment comprising a plurality of spaced apart deformable members deformable from an unexpanded configuration to an expanded configuration, wherein the deformable members comprise wire, wherein each of the deformable members has the same wire gauge,

the device being implantable between two bone structures in the unexpanded configuration;

wherein compression of the deformable members along a longitudinal axis of the device deforms the deformable members to the expanded configuration into contact with the two bone structures.

21. The device of claim 20, wherein each of the deformable members has a circular cross section extending axially along the longitudinal axis of the device from a first of the anchor portions to a second of the anchor portions.

22. A bone fusion device comprising:

an elongated structure comprising at least two anchor portions and at least one deformable segment connected on each end to one of the at least two anchor portions;

each deformable segment comprising a plurality of spaced apart deformable members deformable from an unexpanded configuration to an expanded configuration;

the device being implantable between two bone structures in the unexpanded configuration;

wherein compression of the deformable members along a longitudinal axis of the device deforms the deformable members to the expanded configuration into contact with the two bone structures; and

one end of the at least one deformable segment connected to a proximal anchor portion at a proximal end of the elongated structure and another end of the at least one deformable segment connected to a distal anchor portion at a distal end of the elongated structure;

an internal rod extending through the elongated structure along the longitudinal axis and detachably attached to the distal anchor; and

a pushing tube slidable about the internal rod and detachably attached to the proximal anchor portion;

wherein translation of the pushing tube and the proximal anchor portion along the inner rod toward a fixed position of the distal anchor portion compresses the deformable members so as to deform each deformable segment to the expanded configuration;

wherein the internal rod has external threads that are threadedly engaged with internal threads defined by the distal anchor portion, and

wherein the pushing tube has internal threads that are threadedly engaged with external threads defined by the proximal anchor portion.

23. A bone fusion device comprising:

an elongated structure extending along a longitudinal axis and comprising at least two anchor portions and at least one deformable segment connected on each end to one of the at least two anchor portions;

each deformable segment comprising a plurality of spaced apart deformable members deformable from an unexpanded configuration to an expanded configuration, each of the deformable members having a circular cross section extending axially along the longitudinal axis of the device from a first of the anchor portions to a second of the anchor portions;

the device being implantable between two bone structures in the unexpanded configuration;

wherein compression of the deformable members along the longitudinal axis of the device deforms the deformable members to the expanded configuration into contact with the two bone structures;

an internal rod extendable through the elongated structure along the longitudinal axis of the device and detachably attachable to a distal anchor portion at a distal end of the elongated structure; and

a pushing tube slidable about the internal rod and detachably attachable to a proximal anchor portion at a proximal end of the elongated structure;

wherein translation of the pushing tube and the attached proximal anchor portion along the internal rod toward a fixed position of the distal anchor portion attached to the internal rod compresses the deformable members along the longitudinal axis so as to deform each deformable segment to the expanded configuration into contact with the two bone structures;

wherein the internal rod is threadedly engaged with the distal anchor portion by a first set of mating threads, and

wherein the pushing tube is threadedly engaged with the proximal anchor portion by a second set of mating threads.

24. The device of claim 23, wherein the first set of mating threads is identical to the second set of mating threads, and

wherein the internal rod and the pushing tube are detachable from the distal and proximal anchor portions by simultaneously rotating the internal rod and the pushing tube.

25. The device of claim 23, wherein the first set of mating threads comprises external threads defined by the internal rod and internal threads defined by the distal anchor portion, and

wherein the second set of mating threads comprises internal threads defined by the pushing tube and external threads defined by the proximal anchor portion.