Zero-profile interbody spacer and coupled plate assembly

• US 9,192,419 B2
• Filed: 11/06/2009
• Issued: 11/24/2015
• Est. Priority Date: 11/07/2008
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Inventors: McDonough, William P., Strausbaugh, William L., Bonner, Christopher, Pepe, Thomas, Meili, Ralph, Hunziker, Markus, Jeger, Michael, Kueenzi, Thomas, Koch, David, Ponzer, Rainer, Richter, Joern, Berger, Roger
• Primary Examiner(s): Isabella, David
• Assistant Examiner(s): NELSON, CHRISTINE L
• Application Number:
  US12/613,866
• Publication Number:
  US 20100145459A1
• Time in Patent Office: 2,209 Days
• Field of Search: 606289-296, 623 1711- 1716
• US Class Current: 1/1
• 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 17/7059 Cortical plates A61B17/7007, A61B17/7058 take precedence
• CPC Class Codes: A61B 17/8033 having indirect contact with screw heads, or having contact with screw heads maintained with the aid of additional components, e.g. nuts, wedges or head covers
• CPC Class Codes: A61B 17/8042 the additional component being a cover over the screw head
• CPC Class Codes: A61B 17/8052 immobilised relative to screws by interlocking form of the heads and plate holes, e.g. conical or threaded
• CPC Class Codes: A61B 17/8057 the interlocking form comprising a thread
• CPC Class Codes: A61B 17/809 with bone-penetrating elements, e.g. blades or prongs bone staples A61B17/0642; intramedullary nails with a plate at an end A61B17/7233
• CPC Class Codes: A61B 17/86 Pins or screws or threaded wires; nuts therefor A61B17/72 take precedence
• CPC Class Codes: A61B 17/88 Osteosynthesis instruments; Methods or means for implanting or extracting internal or external fixation devices A61B17/7074 takes precedence
• CPC Class Codes: A61F 2/30965 Reinforcing the prosthesis by embedding particles or fibres during moulding or dipping
• 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 2/4465 having a circular or kidney shaped cross-section substantially perpendicular to the axis of the spine
• CPC Class Codes: A61F 2/4611 of spinal prostheses
• CPC Class Codes: A61F 2002/30387 Dovetail connection
• CPC Class Codes: A61F 2002/305 Snap connection
• CPC Class Codes: A61F 2002/30505 spring biased
• CPC Class Codes: A61F 2002/30507 using a threaded locking member, e.g. a locking screw or a set screw
• CPC Class Codes: A61F 2002/30517 using a locking plate
• CPC Class Codes: A61F 2002/30576 with extending fixation tabs
• CPC Class Codes: A61F 2002/30593 : hollow
• CPC Class Codes: A61F 2002/30604 : modular
• CPC Class Codes: A61F 2002/30787 : inclined obliquely with respect to each other
• CPC Class Codes: A61F 2002/3079 : Stepped or enlarged apertures, e.g. having discrete diameter changes
• 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 2002/4615 : of spacers
• CPC Class Codes: A61F 2220/0016 : with sharp anchoring protrusions, e.g. barbs, pins, spikes
• CPC Class Codes: A61F 2220/0025 : Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2230/0034 : D-shaped
• CPC Class Codes: A61F 2310/00017 : Iron- or Fe-based alloys, e.g. stainless steel
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 : Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00407 : Coating made of titanium or of Ti-based alloys
• CPC Class Codes: A61F 2310/00796 : Coating or prosthesis-covering structure made of a phosphorus-containing compound, e.g. hydroxy(l)apatite

Abstract

An implant for insertion into a disc space between vertebrae, wherein the implant includes a spacer portion, a plate portion coupled to the spacer portion, two bone fixation elements for engaging the vertebrae and a retention mechanism for preventing the bone fixation elements from postoperatively backing-out of the plate portion. The retention mechanism may be in the form of a spring biased snapper element that is biased into communication with the bone fixation elements so that once the bone fixation element advances past the snapper element, the snapper element is biased back to its initial position in which the snapper element interfaces with the bone fixation elements. Alternatively, the retention mechanism may be in the form of a propeller rotatable between a first position in which the bone fixation elements are insertable to a second position where the bone fixation elements are prevented from backing-out.

Claims

1. An implant for insertion into an intervertebral disc space between superior and inferior vertebral bodies, the implant comprising:

a spacer portion including a top surface configured to face the superior vertebral body, and a bottom surface configured to face the inferior vertebral body;

a plate portion coupled to the spacer portion, the plate portion including a top surface, and a bottom surface, the plate portion further including a first bone fixation hole configured to receive a first bone fixation element along a first insertion direction, the plate portion further including a first borehole intersecting with the first bone fixation hole; and

a first spring biased snapper element disposed at least partially in the first borehole, the first spring biased snapper element configured to prevent the first bone fixation element from backing-out of the first bone fixation hole along a first back-out direction that is opposite the first insertion direction when the first bone fixation element is inserted into the first bone fixation hole, the first spring biased snapper element including a first end that defines a tapered top surface and a flat bottom surface;

wherein the first spring biased snapper element is moveable to a position such that at least a portion of the first end protrudes into the first bone fixation hole so that when the first bone fixation element is inserted into the first bone fixation hole the flat bottom surface of the first spring biased snapper element at least partially is aligned with the first bone fixation element along the first back-out direction.

2. The implant of claim 1, wherein a height of the plate portion is substantially equal to a height of the spacer portion and a width of the plate portion is substantially equal to a width of the spacer portion.

3. The implant of claim 1, wherein the spacer portion includes a first side surface, a second side surface, a first recess formed in the first side surface and a second recess formed in the second side surface, the first and second recesses configured to engage first and second projections, respectively, extending from the plate portion.

4. The implant of claim 1, wherein the spacer portion further includes a centralized region comprising a first material concentrically surrounded by a portion comprising a second material that is different from the first material.

5. The implant of claim 4, wherein the centralized region extends from the top surface to the bottom surface.

6. The implant of claim 4, wherein the first material is more porous than the second material.

7. The implant of claim 1, wherein the first bone fixation hole is angled such that when the first bone fixation element is received within the first bone fixation hole the first fixation element engages the superior vertebral body.

8. The implant of claim 1, wherein the first spring biased snapper element is biased to the position.

9. The implant of claim 1, wherein:

the plate portion further includes a second bone fixation hole configured to receive a second bone fixation element along a second insertion direction, the plate portion further including a second borehole intersecting with the second bone fixation hole; and

a second spring biased snapper element disposed at least partially within the second bore hole, the second spring biased snapper element configured to prevent the second bone fixation element from backing-out of the second bone fixation hole along a second back-out direction that is opposite the second insertion direction, when the second bone fixation element is inserted into the second bone fixation hole, the second spring biased snapper element including a first end that includes a tapered top surface and a flat bottom surface;

wherein the second spring biased snapper element is moveable to a position such that at least a portion of the first end of the second spring biased snapper element protrudes into the second bone fixation hole so that when the second bone fixation element is inserted into the second bone fixation hole the flat bottom surface of the second spring biased snapper element at least partially covers the second bone fixation element with respect to the second back-out direction.

10. The implant of claim 9, wherein each of the first and second spring biased snapper elements includes a spring and a snapper element, the snapper element including the first end that protrudes into the first and second bone fixation holes, and a second end configured to interact with the spring.

11. The implant of claim 10, wherein the first and second spring biased snapper elements are secured within the first and second boreholes, respectively, via first and second pins, respectively.

12. The implant of claim 9, wherein the position of the first and second spring biased snapper elements is a first position, and insertion of the first and second bone fixation elements causes the first and second spring biased snapper elements to move from their respective first positions to respective second positions in which the first and second spring biased snapper elements are removed from the first and second bone fixation holes.

13. The implant of claim 9, wherein the position of the first and second spring biased snapper elements is a first position, and insertion of the first and second bone fixation elements causes a head portion of the first and second bone fixation elements to contact the first and second spring biased snapper elements, respectively, to cause the first and second spring biased snapper elements to recoil from their first positions to respective second positions.

14. The implant of claim 13, wherein further insertion of the first and second bone fixation elements causes the head portions of the first and second bone fixation elements to move distally of the first and second spring biased snapper elements resulting in the first and second snapper elements automatically moving from their second position to their first positions.

15. The implant of claim 9, further comprising first and second stops configured to prevent over-insertion of the implant during implantation and configured to assist in securing a position of the implant during insertion of the first and second bone fixation elements, the first stop extending superiorly of the top surface of the plate portion such that the first stop is configured to contact the superior vertebral body, the second stop extending inferiorly of the bottom surface of the plate portion such that the second stop is configured to contact the inferior vertebral body.

16. The implant of claim 15, wherein the first and second stops are integrally formed with the plate portion.

17. The implant of claim 15, wherein the first and second stops each include a distal surface that is configured to at least partially embed into the respective superior or inferior vertebral body.

18. The implant of claim 17, wherein the distal surface of each of the first and second stops includes a pyramid shaped projection or tooth configured to at least partially embed into the respective superior or inferior vertebral body.

19. The implant of claim 17, wherein the distal surface of each of the first and second stops includes a plurality of projections or teeth configured to at least partially embed into the respective superior or inferior vertebral body.

20. The implant of claim 17, wherein the distal surface of each of the first and second stops includes a vertical blade type projection configured to at least partially embed into the respective superior or inferior vertebral body.

21. The implant of claim 17, wherein the distal surface of each of the first and second stops includes transverse blade type projection configured to at least partially embed into the respective superior or inferior vertebral body.

22. The implant of claim 9, wherein the plate portion further includes a thread blocking mechanism that is configured to permit the advancement of the respective first or second bone fixation element into the respective first or second bone fixation hole to a desired depth, and once the respective first or second bone fixation element has reached the desired depth the thread blocking mechanism inhibits the respective first or second bone fixation element from backing out of the respective first or second bone fixation hole.

23. The implant of claim 22, wherein the desired depth is the point at which a distal surface of the thread blocking mechanism contacts a proximal side of the proximal most thread.

24. The implant of claim 22, wherein the thread blocking mechanism comprises a raised ridge.

25. The implant of claim 22, wherein the thread blocking mechanism comprises an interrupted ring.

26. The implant of claim 6, wherein the first material comprises porous PEEK and the second material comprises conventional PEEK.

27. The implant of claim 9, wherein the second bone fixation hole is angled such that when the second bone fixation element is received within the second bone fixation hole the second bone fixation element engages the inferior vertebral body.

28. The implant of claim 9, further comprising a mechanism configured to be actuated from a first configuration to a second configuration, such that when the mechanism is in the first configuration the mechanism is located at least partially within the first or second borehole to secure the respective first or second snapper element within the first or second borehole, and when the mechanism is in the second configuration the first or second snapper element is capable of being inserted into or removed from the respective first or second borehole.

29. The implant of claim 9, wherein the first and second spring biased snapper elements are biased to their respective positions.

30. An implant for insertion into an intervertebral disc space between superior and inferior vertebral bodies, the implant comprising:

a spacer portion including a top surface configured to face the superior vertebral body, and a bottom surface configured to face the inferior vertebral body;

a plate portion coupled to the spacer portion, the plate portion including a top surface, and a bottom surface, the plate portion further including a first bone fixation hole, a first borehole, and a second borehole, the first bone fixation hole configured to receive a first bone fixation element, the first borehole intersecting with the first bone fixation hole, and the second borehole being offset and open to the first borehole, the plate portion further including a second bone fixation hole, a third borehole, and a fourth borehole, the second bone fixation hole configured to receive a second bone fixation element, the third borehole intersecting with the second bone fixation hole, and the fourth borehole being offset and open to the third borehole;

a first spring biased snapper element positioned in the first borehole such that the first spring biased snapper element is moveable from a first position wherein a portion of the first spring biased snapper element protrudes into the first bone fixation hole to prevent the first bone fixation element from backing out of the first bone fixation hole, to a second position wherein the portion of the first spring biased snapper element is removed from the first bone fixation hole;

a second spring biased snapper element positioned in the third borehole such that the second spring biased snapper element is moveable from a first position wherein a portion of second the spring biased snapper element protrudes into the second bone fixation hole to prevent the second bone fixation element from backing out of the second bone fixation hole, to a second position wherein the portion of the second spring biased snapper element is removed from the second bone fixation hole;

a first mechanism that is located at least partially within the second borehole, the first mechanism moveable with respect to the first spring biased snapper element and configured to be positioned at least partially within the first borehole such that the first mechanism;

     1) permits movement of the first spring biased snapper element between the first and second positions; and

     2) prevents the first spring biased snapper element from exiting the first borehole entirely; and

a second mechanism that is located at least partially within the fourth borehole, the second mechanism moveable with respect to the second spring biased snapper element and configured to be positioned at least partially within the third borehole such that the second mechanism;

     1) permits movement of the second spring biased snapper element between the first and second positions; and

     2) prevents the second spring biased snapper element from exiting the third borehole entirely;

wherein the first and second spring biased snapper elements each include a first end that has a tapered top surface and a flat bottom surface such that when the first and second spring biased snapper elements are in their respective first positions and the first and second bone fixation elements are inserted into the first and second bone fixation holes, respectively,

     1) the flat bottom surface of the first spring biased snapper element faces a head of the first bone fixation element such that back out of the first bone fixation element is prevented, and

     2) the flat bottom surface of the second spring biased snapper element faces a head of the second bone fixation element such that back out of the second bone fixation element is prevented.

31. An implant for insertion into an intervertebral disc space between superior and inferior vertebral bodies, the implant comprising:

a spacer portion including a top surface configured to face the superior vertebral body, and a bottom surface configured to face the inferior vertebral body;

a plate portion coupled to the spacer portion, the plate portion including a top surface, and a bottom surface, the plate portion further including a first bone fixation hole, a first borehole, and a second borehole, the first bone fixation hole configured to receive a first bone fixation element, the first borehole intersecting with the first bone fixation hole, and the second borehole being offset and open to the first borehole, the plate portion further including a second bone fixation hole, a third borehole, and a fourth borehole, the second bone fixation hole configured to receive a second bone fixation element, the third borehole intersecting with the second bone fixation hole, and the fourth borehole being offset and open to the third borehole;

a first spring biased snapper element positioned in the first borehole such that the first spring biased snapper element is moveable from a first position wherein a portion of the first spring biased snapper element protrudes into the first bone fixation hole to prevent the first bone fixation element from backing out of the first bone fixation hole, to a second position wherein the portion of the first spring biased snapper element is removed from the first bone fixation hole;

a second spring biased snapper element positioned in the third borehole such that the second spring biased snapper element is moveable from a first position wherein a portion of second the spring biased snapper element protrudes into the second bone fixation hole to prevent the second bone fixation element from backing out of the second bone fixation hole, to a second position wherein the portion of the second spring biased snapper element is removed from the second bone fixation hole;

a first mechanism comprising a spring or a set screw, the first mechanism located at least partially within the second borehole, the first mechanism moveable with respect to the first spring biased snapper element and configured to be positioned at least partially within the first borehole such that the first mechanism;

     1) permits movement of the first spring biased snapper element between the first and second positions; and

     2) prevents the first spring biased snapper element from exiting the first borehole entirely; and

a second mechanism comprising a spring or a set screw, the second mechanism located at least partially within the fourth borehole, the second mechanism moveable with respect to the second spring biased snapper element and configured to be positioned at least partially within the third borehole such that the second mechanism;

     1) permits movement of the second spring biased snapper element between the first and second positions; and

     2) prevents the second spring biased snapper element from exiting the third borehole entirely.