Expandable intervertebral implant and associated method of manufacturing the same

• US 8,551,173 B2
• Filed: 01/21/2009
• Issued: 10/08/2013
• Est. Priority Date: 01/17/2008
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Inventors: Lechmann, Beat, Burkard, Dominique, Fierlbeck, Johann, Niederberger, Alfred
• Primary Examiner(s): Truong, Kevin T
• Assistant Examiner(s): BECCIA, CHRISTOPHER J
• Application Number:
  US12/812,146
• Publication Number:
  US 20100286783A1
• Time in Patent Office: 1,721 Days
• Field of Search: 606/60, 606246-279, 623 1711- 1716
• US Class Current: 623/17.12
• CPC Class Codes: A61F 2/30771 applied in original prostheses, e.g. holes or grooves
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• 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 2/4425 made of articulated components
• 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 2002/30462 retained or tied with a rope, string, thread, wire or cable
• CPC Class Codes: A61F 2002/30518 with possibility of relative movement between the prosthetic parts
• CPC Class Codes: A61F 2002/3055 for adjusting length
• CPC Class Codes: A61F 2002/30556 for adjusting thickness
• CPC Class Codes: A61F 2002/30579 with mechanically expandable devices, e.g. fixation devices
• CPC Class Codes: A61F 2002/30593 hollow
• CPC Class Codes: A61F 2002/30785 parallel
• CPC Class Codes: A61F 2002/30843 Pyramidally-shaped
• CPC Class Codes: A61F 2002/30904 serrated profile, i.e. saw-toothed
• CPC Class Codes: A61F 2002/4495 having a fabric structure, e.g. made from wires or fibres
• CPC Class Codes: A61F 2220/0016 with sharp anchoring protrusions, e.g. barbs, pins, spikes
• CPC Class Codes: A61F 2250/0009 for adjusting thickness
• CPC Class Codes: A61F 2250/009 for single use, e.g. having means for preventing re-use
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/34 : of powder characteristics, e.g. density, oxidation or flowability
• CPC Class Codes: B22F 12/41 : characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

An expandable intervertebral implant (10) includes superior (20) and inferior (30) bone contacting members and at least one vertical wire netting (50) interconnecting the superior and inferior bone contacting members. The superior and inferior bone contacting members include at least two bone contacting components interconnected via one or more lateral wire nettings such that the implant is vertically and laterally expandable in situ from a first insertion configuration to a second expanded configuration. The vertical and lateral wire netting are preferably constructed of a plurality of individual link members. The present invention also preferably relates to an associated method of manufacturing the intervertebral implant such that the intervertebral implant can be manufactured as an integral component or part.

Claims

1. An expandable intervertebral implant defining a superior bone contacting surface, an inferior bone contacting surface spaced apart from the superior bone contacting surface along a vertical direction, the expandable intervertebral implant comprising:

a first bone contacting member;

a second bone contacting member positioned relative to the first bone contacting member along the vertical direction or a lateral direction that is substantially perpendicular to the vertical direction; and

at least one expandable wire netting that connects the first bone contact member to the second bone contacting member,

the at least one expandable wire netting comprising a plurality of interconnected individual link members, wherein adjacent link members are moveable relative to each other such that the bone contacting members are moveable relative to each other along at least the vertical direction or the lateral direction to expand the implant from a first insertion configuration to a second expanded configuration.

2. The implant of claim 1, wherein the plurality of individual link members have a rectangular shape.

3. The implant of claim 1, wherein the plurality of individual link members have a trapezoidal shape.

4. The implant of claim 1, wherein the first bone contacting member is a superior bone contacting member and the second bone contact member is an inferior bone contacting member spaced from the superior bone contacting member along the vertical direction, the implant further comprising:

a cavity defined between the superior bone contacting member and the superior bone contacting member; and

an expansion member insertable in the cavity, the expansion member capable of receiving a filling material so that injection of the filling material into the expansion member permits the wire netting interconnecting the superior and inferior bone contacting members to expand, thereby moving the superior bone contacting member with respect to the inferior bone contacting member such that the implant vertically expands from the first height to the second height.

5. The implant of claim 4, wherein the superior and inferior bone contacting members include one or more bores for engaging a surgical instrument.

6. The implant of claim 4, wherein the superior and inferior bone contacting members include interconnecting projections and bores.

7. The implant of claim 1, wherein the first and second bone contacting members and the at least one expandable wire netting are constructed as an integral part via a layer-wise manufacturing process.

8. The implant of claim 7, wherein the layer-wise manufacturing process is a selective laser melting process.

9. The implant of claim 7, wherein the layer-wise manufacturing process is a selective laser sintering process.

10. The implant of claim 1, wherein the at least one expandable wire netting is configured so that the first bone contacting member is separable from the second bone contacting member along the vertical direction.

11. The implant of claim 1, wherein the at least one wire netting is a first lateral wire netting, and wherein the first bone contacting member comprises at least two superior bone contacting components interconnected along the lateral direction via the first lateral wire netting.

12. The implant of claim 11, wherein the second bone contacting member comprises at least two inferior bone contacting components interconnected along the lateral direction via a second lateral wire netting, wherein each of the at least two inferior bone contacting components and the at least two superior bone contact components are independently moveable relative to each other.

13. The implant of claim 12, wherein the first lateral wire netting is configured so that the at least two superior bone contacting components can separate from each other along the lateral direction, and wherein the second lateral wire netting is configured so that the at least two inferior bone contacting components can separate from each other along the lateral direction.

22. The implant of claim 1, wherein the first and second bone contacting members are two superior components interconnected along the lateral direction.

23. The implant of claim 1, wherein the first and second bone contacting members are two inferior components interconnected along the lateral direction.

24. The implant of claim 1, wherein the first bone contacting members are two superior components interconnected along the lateral direction via a first lateral wire netting, wherein the second bone contacting member comprises two inferior components interconnected along the lateral direction via a second lateral wire netting, the first and second lateral wire nettings configured such that the two superior components and the two inferior bone components are independently separable along the lateral direction.

25. The implant of claim 1, wherein the first bone contacting member and the second bone contacting member can pivot relative to each other.

14. An expandable implant device configured for insertion in an intervertebral space disposed between adjacent vertebral bodies, the expandable implant device comprising:

superior vertebra contacting components;

inferior vertebra contacting components spaced from the superior bone contacting component along a vertical direction;

a first expandable wire netting that connects along the vertical direction the two superior components to the two inferior components; and

a second expandable wire netting that connects along the lateral direction either

     1) at least two of the superior components, or

     2) at least two of the inferior components, wherein each of the superior and inferior vertebra contacting components are separately moveable relative to each other along the respective vertical direction and the lateral direction, wherein the expandable implant device is expandable from a first insertion configuration to a second expanded configuration.

15. An expandable implant device of claim 14, wherein the first expandable wire netting is configured such that the superior vertebra contacting components are separable from the inferior vertebra contacting components.

16. The expandable implant device of claim 15, wherein the second expandable wire netting is configured such that at least two superior vertebra contacting components or at least two inferior vertebra contacting components are separable along the lateral direction.

17. The expandable implant device of claim 15, wherein the second expandable wire netting connects the at least two superior vertebra contacting components, the device further comprising a third expandable wire netting that connects along the lateral direction the at least two of the inferior vertebra contacting components.

18. The expandable implant device of claim 15, wherein the first and second expandable wire nettings are configured to enable 1) each of the superior vertebra contacting components to separately conform to the superior vertebra when the expandable implant device is in the second expanded configuration, and 2) each of the inferior vertebra contacting components to separately conform to the inferior vertebra when the expandable implant device is in the second expanded configuration.

19. The expandable implant device of claim 14, wherein at least one the superior bone contacting components and at least one of the inferior bone contacting components can pivot relative to each other.

20. The expandable implant device of claim 14, wherein at least two of the superior bone contacting components can pivot relative to each other.

21. The expandable implant device of claim 14, wherein at least two of the inferior bone contacting components can pivot relative to each other.

26. An expandable intervertebral implant defining a superior bone contacting surface, an inferior bone contacting surface spaced apart from the superior bone contacting surface along a vertical direction, the expandable intervertebral implant comprising:

a superior bone contacting member;

an inferior bone contacting member positioned relative to the superior contacting member along the vertical direction; and

at least one expandable wire netting that connects along the vertical direction the superior bone contact member to the inferior bone contacting member, the at least one expandable wire netting comprising a plurality of individual links arranged in at least a first row of links and a second rows of links moveably connected to the first row of links, the first row of links moveable along a vertical direction relative to the second row of links such that the bone contacting members are moveable relative to each other along at least the vertical direction to expand the implant from a first insertion configuration to a second expanded configuration.

27. The implant of claim 26, wherein the plurality the individual links are moveable in a vertical direction and at least a second direction that is angularly offset with the respect to the vertical direction.

28. The implant of claim 26, further comprising:

a cavity defined between the superior bone contacting member and the inferior bone contacting member; and

an expansion member insertable in the cavity, the expansion member capable of receiving a filling material so that injection of the filling material into the expansion member permits the wire netting interconnecting the superior and inferior bone contacting members to expand, thereby moving the superior bone contacting member with respect to the inferior bone contacting member such that the implant vertically expands from the first height to the second height.

29. The implant of claim 26, wherein the at least one expandable wire netting is a vertically expandable wire netting, and wherein the superior bone contacting member comprise at least two superior bone contacting components that are connected along a lateral direction that is perpendicular to the vertical direction by a first laterally expandable wire netting.

30. The implant of claim 29, wherein the inferior bone contacting member comprises at least two inferior bone contacting components that are connected along the lateral direction by a second laterally expandable wire netting.

31. The implant of claim 30, wherein the vertically expandable wire netting, and the first and second laterally expandable wire nettings are configured such that each of the at least two inferior bone contacting components and the at least two superior bone contact components are independently moveable relative to each other so as to conform to the vertebral bodies when the implant is disposed in the intervertebral space.