Minimally invasive surgical system

• US 8,192,439 B2
• Filed: 08/23/2007
• Issued: 06/05/2012
• Est. Priority Date: 02/23/2005
• Status: Expired due to Fees

• Current Assignee: Pioneer Surgical Technology Incorporated (Surgalign Holdings, Inc.)
• Original Assignee: Pioneer Surgical Technology Incorporated (Surgalign Holdings, Inc.)
• Inventors: Songer, Matthew N., Gephart, Matthew P., Berman, Philip, Lynch, Bobby Steven, Corrao, Ernie N.
• Primary Examiner(s): Robert, Eduardo C
• Assistant Examiner(s): COTRONEO, STEVEN J
• Application Number:
  US11/844,259
• Publication Number:
  US 20080039839A1
• Time in Patent Office: 1,748 Days
• Field of Search: 606/99, 606/190, 606246-279, 606/86.A, 606/100, 606/86.B, 606/106, 606/138, 606/207, 606/208, 606/210, 606/205, D28/55, D24/143
• US Class Current: 606/86.A
• CPC Class Codes: A61B 17/7002 Longitudinal elements, e.g. rods
• CPC Class Codes: A61B 17/7004 with a cross-section which varies along its length A61B17/7019 takes precedence
• CPC Class Codes: A61B 17/701 Longitudinal elements with a non-circular, e.g. rectangular, cross-section A61B17/7005, A61B17/7007 take precedence
• CPC Class Codes: A61B 17/7011 Longitudinal element being non-straight, e.g. curved, angled or branched adjustable length longitudinal elements A61B17/7014; A61B17/7019 takes precedence, e.g. coil springs
• CPC Class Codes: A61B 17/7032 Screws or hooks with U-shaped head or back through which longitudinal rods pass
• CPC Class Codes: A61B 17/7037 wherein pivoting is blocked when the rod is clamped
• CPC Class Codes: A61B 17/708 with tubular extensions coaxially mounted on the bone anchors
• CPC Class Codes: A61B 17/7085 for insertion of a longitudinal element down one or more hollow screw or hook extensions, i.e. at least a part of the element within an extension has a component of movement parallel to the extension's axis
• CPC Class Codes: A61B 17/7086 Rod reducers, i.e. devices providing a mechanical advantage to allow a user to force a rod into or onto an anchor head other than by means of a rod-to-bone anchor locking element; rod removers
• CPC Class Codes: A61B 17/7091 for applying, tightening or removing longitudinal element-to-bone anchor locking elements, e.g. caps, set screws, nuts or wedges
• CPC Class Codes: A61B 2017/0256 for the spine

Abstract

A minimally invasive surgical system for implanting pedicle screw assemblies to be connected by a spinal rod is disclosed. In one form, the system includes a plurality of holding mechanisms for the pedicle screw assemblies, each holding mechanism for being inserted through an incision and configured to receive tools along an axis thereof for driving a screw anchor of the pedicle screw assembly into a vertebra and securing the spinal rod thereto and a rod inserter that is configured to adjustably hold the rod and insert the rod through a common incision with one of the holding mechanism for being fed into position in an initial direction that is transverse to the axes of the holding mechanisms.

Claims

1. A spinal rod insertion system, the spinal rod insertion system comprising:

an elongate spinal rod body having opposite end portions;

attachment structure of the spinal rod body at one of the end portions of the spinal rod body;

an elongate inner shaft having opposite end portions;

a pair of opposing resilient prongs at one of the end portions of the inner shaft rigidly connected thereto and configured to grip the attachment structure of the spinal rod body so that the elongate inner shaft does not translate relative to the spinal rod body; and

an elongate outer control sleeve having opposite end portions and a cylindrical configuration at one of the end portions thereof that is not connected to the spinal rod body with the cylindrical end portion sized to surround the inner shaft, the elongate outer control sleeve and the elongate inner shaft being axially shiftable relative to each other to a predetermined blocking position where the outer control sleeve extends about the prongs and the spinal rod body attachment structure so that the cylindrical end portion covers the prongs and the spinal rod body attachment structure gripped therebetween to keep the spinal rod body securely fixed to the inner shaft against movement relative thereto and to a predetermined release position with the sleeve cylindrical end portion disposed back up along the inner shaft beyond the resilient prongs to allow the prongs to resiliently flex apart for releasing the spinal rod body attachment structure.

2. The rod insertion tool in accordance with claim 1 wherein the prongs of the inner shaft are adapted to pivotably engage the spinal rod body attachment structure about a pivot axis;

and

a stop is provided on the inner shaft to limit pivoting of the spinal rod body in one direction while permitting pivoting of the spinal rod body in the opposite direction.

3. The rod insertion tool in accordance with claim 1 wherein the opposing prongs are configured for pivotably clasping the spinal rod body attachment structure therebetween.

4. The rod insertion tool in accordance with claim 3 wherein one of the pair of opposing prongs and the spinal rod body attachment structure has a pair of protuberances for pivotably engaging recesses on the other of the pair of opposing prongs and the spinal rod body attachment structure.

5. The rod insertion tool in accordance with claim 1 wherein a lock is selectively engageable to prevent shifting of the control sleeve from the blocking position to the release position.

6. The rod insertion tool in accordance with claim 1 wherein a handle is attached to the other of the end portions of the inner shaft.

7. The spinal rod insertion system of claim 1 further comprising an opening of the spinal rod body attachment structure;

and

a clamp boss of each of the prongs configured to extend into the opening of the spinal rod body attachment structure with the prongs clamped tightly against the attachment structure.

8. The spinal rod insertion system of claim 1 wherein the outer control sleeve is shiftable along the inner shaft to a predetermined unblocking position with the sleeve cylindrical end portion extending about the prongs and being spaced from the attachment structure of the spinal rod body along the inner shaft.

9. The spinal rod insertion system of claim 1 wherein the spinal rod body has a cylindrical outer surface extending between the opposite end portions thereof;

and

the cylindrical end portion of the outer control sleeve extends over the cylindrical outer surface of the spinal rod body with the outer control sleeve in the blocking position.

10. A spinal rod insertion system, the spinal rod insertion system comprising:

an elongate spinal rod body having opposite end portions;

attachment structure of the spinal rod body at one of the end portions thereof;

an elongate inner shaft having opposite end portions;

a pair of opposing resilient prongs at one of the end portions of the inner shaft configured to grip the attachment structure of the spinal rod body;

an elongate outer control sleeve having opposite end portions and a cylindrical configuration at one of the end portions thereof with the cylindrical end portion sized to surround the inner shaft and being shiftable along the inner shaft to a predetermined blocking position where the outer control sleeve extends about the prongs and the spinal rod body attachment structure therebetween so that the prongs are clamped tightly against the spinal rod body attachment structure to keep the spinal rod body securely fixed to the inner shaft against movement relative thereto and to a predetermined release position with the sleeve cylindrical end portion shifted back up along the inner shaft beyond the resilient prongs to allow the prongs to resiliently flex apart for releasing the spinal rod body attachment structure;

wherein a lock is selectively engageable to prevent shifting of the control sleeve from the blocking position to the release position; and

wherein the lock includes at least one locking member positionable in an aperture of the outer control sleeve and a blocking recess of the inner shaft to prevent shifting of the outer control sleeve from the blocking position to the release position.

11. A rod insertion tool for positioning a spinal rod relative to two or more pedicle screws, the rod insertion tool comprising:

an inner shaft having an end portion adapted to pivotably engage a spinal rod about a pivot axis;

an outer control sleeve surrounding at least a portion of the inner shaft and having an end portion shiftable between a blocking position covering the pivot axis to restrict pivoting of the spinal rod about the pivot axis and an unblocking position spaced from the pivot axis to permit pivoting of the spinal rod about the pivot axis;

the end portion of the inner shaft has a pair of opposing prongs for pivotably clasping the spinal rod therebetween;

the outer control sleeve is shiftable between the unblocking position and a release position whereby the outer control sleeve is sufficiently spaced from the pair of opposing prongs of the inner shaft to permit the prongs to flex outwardly relative to each other to release the spinal rod;

a lock is selectively engageable to prevent shifting of the control sleeve from the blocking position to the unblocking position;

the lock includes at least one locking member positionable in an aperture of the outer control sleeve and a blocking recess of the inner shaft to prevent shifting of the outer control sleeve from the blocking position to the unblocking position; and

wherein a shifting assembly is slidable along the outer sleeve, the shifting assembly having an internal slot facing the outer control sleeve with a narrow portion and a wide portion with an inclined ramp extending therebetween, the locking member preventing shifting of the control sleeve from the blocking position to the unblocking position when positioned in the narrow portion of the slot and extending between the aperture of the outer control sleeve and the blocking recess of the inner shaft and permitting shifting of the control sleeve from the blocking position to the unblocking position when positioned in the wide portion of the slot.

12. The rod insertion tool in accordance with claim 11 wherein the locking member is positionable in the aperture of the outer control sleeve and an unblocking recess of the inner shaft to prevent shifting of the outer control sleeve from the unblocking position to the blocking position, and the locking member preventing shifting of the control sleeve from the unblocking position to the blocking position when positioned in the narrow portion of the slot and in the aperture and permitting shifting of the control sleeve from the unblocking position to the blocking position when positioned in the wide portion of the slot.

13. The rod insertion tool in accordance with claim 12 wherein the locking member is positionable in the aperture of the outer control sleeve and a release recess of the inner shaft to prevent movement of the outer control sleeve from the release position to the unblocking position, and the locking member preventing movement of the control sleeve from the release position to the unblocking position when positioned in the narrow portion of the slot and in the aperture and permitting movement of the control sleeve from the release position to the unblocking position when positioned in the wide portion of the slot.

14. The rod insertion tool in accordance with claim 13 wherein the unblocking recess is positioned between the release recess and the blocking recess.

15. The rod insertion tool in accordance with claim 11 wherein the shift assembly is biased away from an end of the outer control sleeve and toward the pivot axis to bias the locking member into the narrow portion of the internal slot and into the blocking recess.

16. A spinal rod insertion system, the spinal rod insertion system comprising:

an elongate spinal rod having opposite end portions;

a main body portion of the spinal rod extending between the opposite end portions and having a generally cylindrical outer surface with a predetermined diameter thereof;

an attachment structure at one of the end portions of the spinal rod and having a width thereacross smaller than the diameter of the spinal rod cylindrical outer surface;

a proximal section of the spinal rod main body portion adjacent to the attachment structure;

a shaft assembly having a longitudinal axis;

an inner elongate rod holding member of the shaft assembly extending along the axis of the shaft assembly, the inner elongate rod holding member having an end portion including a pair of prongs configured to releasably engage the attachment structure of the spinal rod;

an outer shaft member of the shaft assembly concentrically disposed about the inner elongate rod holding member and extending along the axis of the shaft assembly; and

a pivot connection of the inner elongate rod holding member for pivotally connecting the spinal rod to the prongs of the inner elongate rod holding member, the outer shaft member of the shaft assembly being moveable relative to the inner elongate rod holding member between a predetermined blocking position where the outer shaft member is shifted downwardly along the inner elongate rod holding member with a distal end portion of the outer shaft member extending beyond the pivot connection and down along the proximal section of the spinal rod main body portion adjacent thereto to surround and cover the pivot connection and the adjacent proximal section of the spinal rod main body portion which fixes the spinal rod in a coaxial orientation along the longitudinal axis of the shaft assembly, and a predetermined unblocking position where the outer shaft member is shifted back up along the inner elongate rod holding member so that the pivot connection and the proximal section of the spinal rod main body portion are uncovered which permits pivoting of the spinal rod about the pivot connection to extend transversely to the longitudinal axis of the shaft assembly with the prongs of the inner elongate rod holding member pivotally engaged with the attachment structure of the spinal rod.

17. The spinal rod insertion system of claim 16 wherein the outer shaft member extends around an upper portion of the prongs with the outer shaft member in the predetermined unblocking position.

18. The spinal rod insertion system of claim 16 wherein the attachment structure of the spinal rod has an opening therein;

and

distal end portions of the prongs each have a clamp boss that extends into the opening of the spinal rod attachment structure with the prongs releasably engaged to the attachment structure.

19. The spinal rod insertion system of claim 18 wherein the clamp bosses of the prong distal end portions define a pivot axis for the spinal rod extending through the opening of the spinal rod attachment structure.

20. The spinal rod insertion system of claim 16 further comprising a predetermined release position of the outer shaft member whereby the outer shaft member is sufficiently spaced from the pair of opposing prongs of the inner elongate rod holding member that the outer shaft member permits the prongs to flex outwardly relative to each other to release the spinal rod.

21. The spinal rod insertion system of claim 20 wherein the predetermined unblocking position of the outer shaft member is disposed between the predetermined release position and the predetermined blocking position along the inner elongate rod member.

22. The spinal rod insertion system of claim 16 wherein the inner elongate rod holding member has a stop to limit pivoting of the spinal rod in one direction while permitting pivoting of the spinal rod in the opposite direction.