Expandable intervertebral implant and associated method of manufacturing the same

• US 9,295,562 B2
• Filed: 09/20/2013
• Issued: 03/29/2016
• Est. Priority Date: 01/17/2008
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Inventors: Lechmann, Beat, Burkard, Dominique, Fierlbeck, Johann, Niederberger, Alfred
• Primary Examiner(s): BECCIA, CHRISTOPHER J
• Application Number:
  US14/032,231
• Publication Number:
  US 20140025169A1
• Time in Patent Office: 921 Days
• Field of Search: 623 1711- 1716, 606246-279
• US Class Current: 1/1
• 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 that extends along a longitudinal axis, the expandable intervertebral implant comprising:

a superior bone contacting member including at least a first superior bone contacting component, a second superior bone contacting component spaced from the first superior bone contacting component in a lateral direction that is perpendicular to the longitudinal axis, and a first expandable lateral component interconnected between the first and second superior bone contacting components along the lateral direction;

an inferior bone contacting member spaced from the superior bone contacting member in a vertical direction that is perpendicular to both the lateral direction and the longitudinal axis, the inferior bone contacting member including at least a first inferior bone contacting component, a second inferior bone contacting component spaced from the first inferior bone contacting component in the lateral direction, and a second expandable lateral component interconnected between the first and second inferior bone contacting components along the lateral direction; and

at least one expandable vertical component interconnected between the superior and inferior bone contacting members along the vertical direction, wherein the implant is expandable in situ in both the vertical direction and the lateral direction from a first insertion configuration to a second expanded configuration, whereby

     1) the first expandable lateral component expands in the lateral direction as the first superior bone contacting component and the second superior bone contacting component move away from each other in the lateral direction,

     2) the second expandable lateral component expands in the lateral direction as the first inferior bone contacting component and the second inferior bone contacting component move away from each other in the lateral direction, and

     3) the at least one expandable vertical component expands in the vertical direction as the superior bone contacting member and the inferior bone contacting member move away from each other in the vertical direction, and

wherein the implant is expandable from the first insertion configuration to the second expanded configuration without causing the implant to change in length along the longitudinal axis.

2. The implant of claim 1, wherein at least one of the first expandable lateral component, the second expandable lateral component, and the expandable vertical component includes a wire netting, the wire netting comprises a plurality of individual link members, and the plurality of individual link members have a rectangular shape.

3. The implant of claim 1, wherein at least one of the first expandable lateral component, the second expandable lateral component, and the expandable vertical component includes a wire netting, the wire netting comprises a plurality of individual link members, and the plurality of individual link members have a trapezoidal shape.

4. The implant of claim 1, 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 expandable vertical component 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 expands in the vertical direction from the first insertion configuration to the second expanded configuration.

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

6. The implant of claim 1, wherein the superior and inferior bone contacting members include interconnecting projections and bores.

7. The implant of claim 1, wherein the superior bone contacting member, the inferior bone contacting member, and the at least one expandable vertical component is 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 implant comprises a first terminal end and a second terminal end spaced from the first terminal end so as to define a full length of the implant along the longitudinal axis, and at least one of the first and second terminal ends is expandable in the lateral and vertical directions.

11. The implant of claim 10, wherein both the first and second terminal ends are expandable in the lateral and vertical directions.

12. The implant of claim 1, wherein:

each of the superior bone contacting member and the inferior bone contacting member comprises at least one abutment surface;

in the first insertion configuration, the at least one abutment surface of the superior bone contacting member abuts the at least one abutment surface of the inferior bone contacting member; and

in the second expanded configuration, the at least one abutment surface of the superior bone contacting member is spaced from the at least one abutment surface of the inferior bone contacting member.

13. The implant of claim 12, wherein:

each of the first and second superior bone contacting components comprises at least one other abutment surface and each of the first and second inferior bone contacting components comprises at least one other abutment surface;

in the first insertion configuration, the at least one other abutment surface of the first superior bone contacting component abuts the at least one other abutment surface of the second superior bone contacting component, and the at least one other abutment surface of the first inferior bone contacting component abuts the at least one other abutment surface of the second inferior bone contacting component; and

in the second expanded configuration, the at least one other abutment surface of the first superior bone contacting component is spaced from the at least one other abutment surface of the second superior bone contacting component, and the at least one other abutment surface of the first inferior bone contacting component is spaced from the at least one other abutment surface of the second inferior bone contacting component.

14. The implant of claim 1, wherein the longitudinal axis is oriented in a longitudinal direction, and:

the first superior bone contacting component defines a first inner surface and a first outer surface opposite the first inner surface along the lateral direction, and the second superior bone contacting component defines a second inner surface and a second outer surface opposite the second inner surface along the lateral direction, wherein the first and second inner surfaces face each other,

the first expandable lateral component extends from the first inner surface to the second inner surface,

in the second expanded configuration, the implant defines

     1) a first straight line that is oriented along the lateral direction, and extends from the first outer surface to the first inner surface a first distance,

     2) a second straight line that is oriented along the lateral direction, is inline with the first line, and extends from the first inner surface to the second inner surface a second distance, and

     3) a third straight line that is oriented along the lateral direction, is inline with the first and second lines, and extends from the second inner surface to the second outer surface a third distance, and

a sum of the first and third distances is greater than the second distance.

15. The implant of claim 1, wherein the at least one expandable vertical component comprises a first expandable vertical component interconnected between the first superior bone contacting component and the first inferior bone contacting component, and the implant further comprises a second expandable vertical component interconnected between the second superior bone contacting component and the second inferior bone contacting component, whereby the first and second expandable vertical components are expandable in the vertical direction as the superior bone contacting member and the inferior bone contacting member move away from each other in the vertical direction.

16. An expandable intervertebral implant that extends along a longitudinal axis that is oriented in a longitudinal direction, the expandable intervertebral implant comprising:

a superior bone contacting member, and an inferior bone contacting member spaced from the superior bone contacting member in a vertical direction that is perpendicular to the longitudinal direction, wherein one of the superior and inferior bone contacting members includes a first bone contacting component and a second bone contacting component spaced from the first bone contacting component in a lateral direction that is perpendicular to both the vertical direction and the longitudinal direction;

an expandable lateral component interconnected between the first and second bone contacting components along the lateral direction; and

an expandable vertical component interconnected between the superior and inferior bone contacting members along the vertical direction,

wherein the implant is expandable in situ in both the vertical direction and the lateral direction from a first insertion configuration to a second expanded configuration, whereby

     1) the expandable lateral component expands in the lateral direction as the first bone contacting component and the second bone contacting component move away from each other in the lateral direction, and

     2) the expandable vertical component expands in the vertical direction as the superior bone contacting member and the inferior bone contacting member move away from each other in the vertical direction, and

wherein at least one of the superior and inferior bone contacting members defines opposed terminal ends that are separated from each other along a length in the longitudinal direction, and the length defines a full length of the implant when the implant is in the collapsed configuration, and the length between the opposed terminal ends remains constant as the implant expands from the first insertion configuration to the second expanded configuration.

17. The implant of claim 16, wherein:

the superior bone contacting member comprises a first superior bone contacting component and a second superior bone contacting component spaced from the first superior bone contacting component in the lateral direction; and

the inferior bone contacting member comprises a first inferior bone contacting component and a second inferior bone contacting component spaced from the first inferior bone contacting component in the lateral direction.

18. The implant of claim 17, wherein:

the expandable lateral component is interconnected between the first and second superior bone contacting components along the lateral direction; and

the implant comprises a second expandable lateral component interconnected between the first and second inferior bone contacting components along the lateral direction, wherein when the implant is expanded from the first insertion configuration to the second expanded configuration, the second expandable lateral component expands in the lateral direction as the first inferior bone contacting component and the second inferior bone contacting component move away from each other in the lateral direction.

19. The implant of claim 17, wherein:

the expandable vertical component is interconnected between the first superior bone contacting component and the first inferior bone contacting component; and

the implant comprises a second expandable vertical component that is interconnected between the second superior bone contacting component and the second inferior bone contacting component, wherein when the implant is expanded from the first insertion configuration to the second expanded configuration, the second expandable vertical component expands in the vertical direction as the second superior bone contacting component and the second inferior bone contacting component move away from each other in the vertical direction.