Hybrid bone fixation element and methods of using the same

• US 8,556,949 B2
• Filed: 11/13/2008
• Issued: 10/15/2013
• Est. Priority Date: 11/14/2007
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Inventors: Teisen, Jacques, Stucki, Simon
• Primary Examiner(s): Hammond, Ellen C
• Application Number:
  US12/270,573
• Publication Number:
  US 20090125028A1
• Time in Patent Office: 1,797 Days
• Field of Search: 606/60, 606/246, 606/264, 606/62, 606/63, 606/65, 606/67, 606/68, 606/286, 606/300, 606/301, 606/304, 606/309, 606/310, 606/313, 606/326, 606/327, 606/328, 606/331, 606/86.R
• US Class Current: 606/327
• CPC Class Codes: A61B 17/68 Internal fixation devices , including fasteners and spinal fixators, even if a part thereof projects from the skin bone staples A61B17/0642
• CPC Class Codes: A61B 17/7032 Screws or hooks with U-shaped head or back through which longitudinal rods pass
• CPC Class Codes: A61B 17/7283 with special cross-section of the nail
• CPC Class Codes: A61B 17/744 the longitudinal elements coupled to an intramedullary nail
• CPC Class Codes: A61B 17/80 Cortical plates , i.e. bone plates; Instruments for holding or positioning cortical plates, or for compressing bones attached to cortical plates
• CPC Class Codes: A61B 17/86 Pins or screws or threaded wires; nuts therefor A61B17/72 take precedence
• CPC Class Codes: A61B 17/8625 Shanks, i.e. parts contacting bone tissue
• CPC Class Codes: A61B 17/863 with thread interrupted or changing its form along shank, other than constant taper
• CPC Class Codes: A61B 2017/8655 with special features for locking in the bone
• 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 2/4455 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 2002/30579 with mechanically expandable devices, e.g. fixation devices

Abstract

The present invention is directed to a hybrid bone fixation element including a threaded proximal cortical bone contacting portion for threadably engaging the cortical portion of a human bone and a non-threaded expandable distal cancellous portion for engaging the cancellous portion of the human bone. The hybrid bone fixation element can be used, for example, as a pedicle screw, a bone screw or in any other type of bone fixation application.

Claims

1. A hybrid bone fixation element for engaging a patient'"'"'s bone including a cortical outer portion surrounding an inner cancellous portion;

the hybrid bone fixation element comprising;

a threaded proximal cortical bone contacting portion for threadably engaging the cortical outer portion of a patient'"'"'s bone, the threaded proximal cortical bone contacting portion having a cannulated bore formed therein; and

a non-threaded expandable distal cancellous bone contacting portion for engaging the inner cancellous portion, the non-threaded expandable distal cancellous bone contacting portion including a plurality of closed periphery holes;

wherein the threaded proximal cortical bone contacting portion comprises an externally threaded shaft having a radial diameter, the threaded shaft coupled to the non-threaded expandable distal cancellous bone contacting portion along a longitudinal axis, the non-threaded expandable distal cancellous bone contacting portion has a first unexpanded radial diameter in a first unexpanded state substantially equal to or less than the radial diameter of the externally threaded shaft, and the non-threaded expandable distal cancellous bone contacting portion has a second expanded radial diameter in a second expanded state at least twice the radial diameter of the externally threaded shaft; and

an elongated head portion integral with the externally threaded shaft along the longitudinal axis, the head portion comprising a drive surface.

2. The hybrid bone fixation element of claim 1, wherein the closed periphery holes are formed by intersecting helices.

3. The hybrid bone fixation element of claim 2, wherein the intersecting helices are attached at intersections.

4. The hybrid bone fixation element of claim 3, wherein the intersections are integrally formed by perforations.

5. The hybrid bone fixation element of claim 4, wherein the expandable distal cancellous bone contacting portion is an expandable stent coupled to the threaded proximal cortical bone contacting portion.

6. The hybrid bone fixation element of claim 5, wherein the expandable stent is configured for expansion from a first insertion configuration to a second expanded configuration via a balloon-catheter inserted into the expandable stent.

7. The hybrid bone fixation element of claim 6, wherein the first insertion position has a first surface area and the second expanded configuration has a second surface area, the second surface area being larger than the first surface area.

8. The hybrid bone fixation element of claim 6, wherein the first insertion position has a first radial diameter and the second expanded configuration has a second radial diameter, the second radial diameter being larger than the first radial diameter.

9. The hybrid bone fixation element of claim 1, wherein the closed periphery holes are formed by at least one of holes or perforations extending through a wall of the expandable distal cancellous bone contacting portion.

10. A hybrid bone fixation element for engaging a bone having a longitudinal axis comprising:

an enlarged head having a drive surface;

at least one externally threaded shaft portion having a diameter, a proximal end and a distal end; and

an expandable stent coupled to the externally threaded shaft portion, the expandable stent having a first unexpanded diameter substantially equal to or less than the diameter of the externally threaded shaft, and a second expanded diameter at least twice the diameter of the externally threaded shaft;

wherein the expandable stent includes a plurality of closed periphery holes; and

wherein the expandable stent is coupled to the distal end of the externally threaded shaft portion and the enlarged head is coupled to the proximal end of the externally threaded shaft portion,

wherein the externally threaded shaft comprises a cannulated bore formed therein.

11. The hybrid bone fixation element of claim 10, wherein the externally threaded shaft comprises a substantially continuous outer surface having a screw thread formed thereon.

12. The hybrid bone fixation device of claim 10, wherein the stent portion in its expandable state increases in size along the longitudinal axis of the device.

13. The hybrid bone fixation element of claim 10, wherein the closed periphery holes are formed by a plurality of at least one of holes or perforations extending through a wall of the expandable distal cancellous bone contacting portion.

14. The hybrid bone fixation element of claim 10, wherein the expandable stent includes intersecting helices.

15. A hybrid bone fixation device for engaging bone having a longitudinal axis comprising:

an enlarged head having a proximal end, a distal end and a drive surface, the enlarged head having a bore formed therethrough from the proximal end to the distal end;

a shaft having a proximal end, a distal end and a continuous outer surface between the proximal and distal ends defining a cross-section, the outer surface having an external thread, the proximal end of the shaft coupled integrally as a monolith with the distal end of the enlarged head along the longitudinal axis, the shaft having a cannulation formed thereon in communication with the bore of the head and extending from the proximal end to the distal end of the shaft; and

an expandable stent having a proximal end, a distal end and a first cross-section in the unexpanded state that is substantially equal to the cross-section of the shaft and an expanded state having a second cross-section that is different than the first cross-section, the proximal end of the expandable stent coupled to the distal end of the shaft along the longitudinal axis;

wherein the expandable stent includes a plurality of closed periphery holes.

16. The hybrid bone fixation device of claim 15, wherein the expandable stent includes intersecting helices with opposite orientation and wherein the holes are defined between the helices.