Bone fusion device, apparatus and method

• US 9,358,123 B2
• Filed: 08/09/2012
• Issued: 06/07/2016
• Est. Priority Date: 08/09/2011
• Status: Active Grant

• Current Assignee: Neuropro Spinal Jaxx, Inc.
• Original Assignee: Neuropro Spinal Jaxx, Inc.
• Inventors: McLuen, Gary R., Remington, Benjamin J., Baker, Daniel R., Logan, Joseph N., Stalcup, Gregory C., Gerbec, Daniel E.
• Primary Examiner(s): Robert, Eduardo C
• Assistant Examiner(s): ECKMAN, MICHELLE CHRISTINE
• Application Number:
  US13/571,265
• Publication Number:
  US 20130211525A1
• Time in Patent Office: 1,398 Days
• Field of Search: 623 1711- 1716, 606/99, 606/105, 606/86.B
• US Class Current: 1/1
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/30965 Reinforcing the prosthesis by embedding particles or fibres during moulding or dipping
• 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 2/447 substantially parallelepipedal, e.g. having a rectangular or trapezoidal cross-section
• CPC Class Codes: A61F 2/4611 of spinal prostheses
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/3008 radio-opaque, e.g. radio-opaque markers
• CPC Class Codes: A61F 2002/30265 Flat parallelepipeds
• CPC Class Codes: A61F 2002/30365 with additional means for limiting said rotation
• CPC Class Codes: A61F 2002/30367 with additional means for preventing said rotation
• CPC Class Codes: A61F 2002/30372 with additional means for limiting said translation
• CPC Class Codes: A61F 2002/30373 with additional means for preventing said translation
• CPC Class Codes: A61F 2002/30395 with additional means for preventing or locking said rotation
• CPC Class Codes: A61F 2002/30397 Limited lateral translation of the rib within a larger groove
• CPC Class Codes: A61F 2002/30403 Longitudinally-oriented cooperating ribs and grooves on mating lateral surfaces of a mainly longitudinal connection
• CPC Class Codes: A61F 2002/30405 made by screwing complementary threads machined on the parts themselves
• CPC Class Codes: A61F 2002/3041 having threaded portions of different pitches
• CPC Class Codes: A61F 2002/30411 having two threaded end parts connected by a threaded central part with opposite threads at its opposite ends, i.e. for adjusting the distance between both end parts by rotating the central part
• CPC Class Codes: A61F 2002/30413 having threads of increasing height or depth
• CPC Class Codes: A61F 2002/30482 : using a locking cam
• CPC Class Codes: A61F 2002/30484 : Mechanically expandable devices located on the first prosthetic part for locking into or onto the second prosthetic part
• 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 2002/3052 : unrestrained in only one direction, e.g. moving unidirectionally
• CPC Class Codes: A61F 2002/30522 : releasable, e.g. using a releasable ratchet
• CPC Class Codes: A61F 2002/30528 : Means for limiting said movement
• 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 2002/30594 : slotted, e.g. radial or meridian slot ending in a polar aperture, non-polar slots, horizontal or arcuate slots
• CPC Class Codes: A61F 2002/30601 : telescopic
• CPC Class Codes: A61F 2002/30616 : Sets comprising a plurality of prosthetic parts of different sizes or orientations
• CPC Class Codes: A61F 2002/30777 : Oblong apertures
• CPC Class Codes: A61F 2002/30784 : Plurality of holes
• CPC Class Codes: A61F 2002/30827 : Plurality of grooves
• CPC Class Codes: A61F 2002/30841 : Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes
• CPC Class Codes: A61F 2002/30843 : Pyramidally-shaped
• CPC Class Codes: A61F 2002/30904 : serrated profile, i.e. saw-toothed
• CPC Class Codes: A61F 2002/3093 : for promoting ingrowth of bone tissue
• CPC Class Codes: A61F 2002/4622 : having the shape of a forceps or a clamp
• CPC Class Codes: A61F 2002/4627 : with linear motion along or rotating motion about the instrument axis or the implantation direction, e.g. telescopic, along a guiding rod, screwing inside the instrument
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys

Abstract

A bone fusion method, apparatus and device for insertion between bones that are to be fused together and/or in place of one or more of the bones, such as, for example, the vertebrae of a spinal column. The bone fusion device comprises one or more extendable plates having a central rib. The bone fusion device includes one or more support channels configured to receive an insertion instrument that is then secured to the bone fusion device via a coupling mechanism. As a result, the coupled device is able to be securely positioned between vertebrae using the insertion instrument with minimal risk of slippage.

Claims

1. A bone fusion system for inserting a bone fusion device into a desired location, the system comprising:

a. an insertion instrument comprising an elongated body having a central axis and a coupling mechanism partially housed by the elongated body and having a control mechanism and a plurality of fingers configured to move between a closed position wherein the fingers are close together to a spread position wherein the fingers are farther apart based on manipulation of the control mechanism and further wherein one or more of the fingers comprise a fingertip that protrudes laterally from the finger; and

b. a bone fusion device having a fusion body, a first extendable tab and a second extendable tab, wherein the fusion body of the bone fusion device comprises a front end, an interior cavity and one or more surface channels having sufficient size to receive the fingers within the channels and positioned along an exterior surface of the fusion body and further wherein the channels are accessible from the front end and extend through a plane perpendicular to the front end, and is detachably coupled to the insertion instrument by the coupling mechanism, wherein the channels are dimensioned and located on the fusion body such that when the fingers are within the channels the central axis of the elongated body is perpendicular to a smallest profile of the bone fusion device, and further wherein each of the surface channels comprise a gripping aperture positioned within the surface channels for receiving the fingertip of the fingers.

2. The system of claim 1, wherein the bone fusion device further comprises a positioning element having a positioning aperture and positioned through the front end and within the interior cavity of the fusion body, and further wherein the positioning element is mechanically coupled with the first and second extendable tabs such that moving the positioning element causes the first and second extendable tabs to move with respect to the fusion body.

3. The system of claim 2, wherein the surface channels are positioned along the exterior surface on a plane perpendicular to the positioning aperture of the positioning element such that the fingers of the gripping apparatus are able to enter the one or more surface channels by moving parallel to the plane.

4. The system of claim 3, wherein the insertion instrument further comprises a drive mechanism configured to engage with and selectively rotate the positioning aperture when the insertion instrument is coupled to the bone fusion device.

5. The system of claim 4, wherein the control mechanism is coupled with the drive mechanism such that the drive mechanism is able to be rotated by manipulating the control mechanism.

6. The system of claim 5, wherein the insertion instrument is configured to prevent rotation of the drive mechanism if the fingers are not in the closed position.

7. The system of claim 6, wherein the insertion instrument comprises a locking mechanism that when activated by a trigger prevents rotation of the drive mechanism until the locking mechanism is deactivated by the trigger.

8. The system of claim 7, wherein the insertion instrument comprises an indicator that indicates data corresponding to the amount of rotation of the drive mechanism.

9. The system of claim 8, wherein the data indicated by the indicator indicates the current position of the tabs relative to the fusion body of the bone fusion device.

10. The system of claim 9, wherein the indicator is adjustable such that the indicator will indicate different data corresponding to the same amount of rotation of the drive mechanism based on the bone fusion device currently coupled to the insertion instrument.

11. A bone fusion system for inserting a bone fusion device into a desired location, the system comprising:

a. an insertion instrument comprising a coupling mechanism having a control mechanism and a plurality of fingers configured to move between a closed position wherein the fingers are close together to a spread position wherein the fingers are farther apart based on manipulation of the control mechanism and further wherein one or more of the fingers comprise a fingertip that protrudes laterally from the finger; and

b. a bone fusion device having a body and a plurality of extendable tabs movably coupled to the body such that the entirety of each of the extendable tabs is able to move with respect to the body, the plurality of extendable tabs positioned parallel to each other, wherein the body of the bone fusion device comprises a front end, an interior cavity and one or more surface channels having sufficient size to receive the fingers within the channels and positioned along an exterior surface of the body of the bone fusion device and further wherein the channels are accessible from the front end and extend through a plane perpendicular to the front end, and is detachably coupled to the insertion instrument by the coupling mechanism, wherein the surface channels are positioned along the exterior surface on a plane perpendicular to a positioning aperture of a positioning element such that the fingers of the gripping apparatus are able to enter the one or more surface channels by moving parallel to the plane and further wherein each of the surface channels comprise a gripping aperture for receiving the fingertip of the fingers of the gripping apparatus positioned within the surface channels.

12. The system of claim 11, wherein the insertion instrument further comprises a drive mechanism configured to engage with and selectively rotate the positioning aperture when the insertion instrument is coupled to the bone fusion device.

13. A bone fusion system for inserting a bone fusion device into a desired location, the system comprising:

a. an insertion instrument comprising an elongated body and a coupling mechanism partially housed by the elongated body and having a control mechanism and a plurality of fingers configured to move between a closed position wherein the fingers are close together to a spread position wherein the fingers are farther apart based on manipulation of the control mechanism, wherein the insertion instrument further comprises a drive mechanism configured to engage with and selectively rotate the positioning aperture when the insertion instrument is coupled to the bone fusion device, and further wherein the control mechanism is coupled with the drive mechanism such that the drive mechanism is able to be rotated by manipulating the control mechanism, wherein the insertion instrument prevents rotation of the drive mechanism if the fingers are not in the closed position and further wherein the insertion instrument comprises a locking mechanism that when activated by a trigger prevents rotation of the drive mechanism until the locking mechanism is deactivated by the trigger; and

b. a bone fusion device having a fusion body and a plurality of extendable tabs movably coupled to the fusion body such that the entirety of each of the extendable tabs is able to move with respect to the fusion body, the plurality of extendable tabs positioned parallel to each other, wherein the fusion body of the bone fusion device comprises one or more surface channels having sufficient size to receive the fingers within the channels and positioned along an exterior surface of the fusion body, and is detachably coupled to the insertion instrument by the coupling mechanism, wherein the surface channels are positioned along the exterior surface on a plane perpendicular to a positioning aperture of a positioning element such that the fingers of the gripping apparatus are able to enter the one or more surface channels by moving parallel to the plane.

14. The system of claim 13, wherein the insertion instrument comprises an indicator that indicates data corresponding to the amount of rotation of the drive mechanism.

15. The system of claim 14, wherein the data indicated by the indicator indicates the current position of the tabs relative to the fusion body of the bone fusion device.

16. The system of claim 15, wherein the indicator is adjustable such that the indicator will indicate different data corresponding to the same amount of rotation of the drive mechanism based on the bone fusion device currently coupled to the insertion instrument.

17. A bone fusion system for inserting a bone fusion device into a desired location, the system comprising:

a. an insertion instrument comprising an elongated body having a central axis and a coupling mechanism partially housed by the elongated body and having a control mechanism and a plurality of fingers configured to move between a closed position wherein the fingers are close together to a spread position wherein the fingers are farther apart based on manipulation of the control mechanism; and

b. a bone fusion device having a fusion body and one or more extendable tabs, wherein the fusion body of the bone fusion device comprises a first surface channel positioned on a first side of the bone fusion device above a horizontal midline of the bone fusion device between the extendable tabs and a second surface channel positioned on a second side of the bone fusion device below the horizontal midline, the first and second surface channels having sufficient size to receive the fingers within the channels and detachably coupled to the insertion instrument by the coupling mechanism.