Methods and apparatus for expandable medical device employing flexure members

• US 9,445,917 B2
• Filed: 12/08/2014
• Issued: 09/20/2016
• Est. Priority Date: 12/31/2008
• Status: Active Grant

• Current Assignee: Octagon Spine LLC
• Original Assignee: EX Technology, LLC
• Inventors: Jimenez, Omar F., Powley, Nicholas Ransom
• Primary Examiner(s): Yang, Andrew
• Application Number:
  US14/563,660
• Publication Number:
  US 20150272745A1
• Time in Patent Office: 652 Days
• US Class Current: 1/1
• 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 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 2/482 Electrical means
• CPC Class Codes: A61F 2002/30485 plastically deformable
• CPC Class Codes: A61F 2002/30507 using a threaded locking member, e.g. a locking screw or a set screw
• CPC Class Codes: A61F 2002/30523 by means of meshing gear teeth
• CPC Class Codes: A61F 2002/30538 for adjusting angular orientation
• 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 2002/30601 telescopic
• CPC Class Codes: A61F 2002/30904 serrated profile, i.e. saw-toothed
• CPC Class Codes: A61F 2002/443 having two transversal endplates and at least one intermediate component
• 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 2220/0025 Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: E05D 1/02 made of one piece
• CPC Class Codes: E05D 1/04 : with guide members shaped as circular arcs
• CPC Class Codes: E05F 1/00 : Closers or openers for wings, not otherwise provided for in this subclass
• CPC Class Codes: F16C 11/12 : incorporating flexible connections, e.g. leaf springs
• CPC Class Codes: F16F 1/025 : characterised by having a particular shape F16F1/04, F16F1/14, F16F1/18, F16F1/32, F16F1/34 take precedence
• CPC Class Codes: F16M 11/38 : by folding , e.g. pivoting or scissors tong mechanisms
• CPC Class Codes: Y10T 403/45 : Flexibly connected rigid members
• CPC Class Codes: Y10T 403/54 : Flexible member is joint component

Abstract

Improved methods and apparatuses for expandable medical devices in accordance with various embodiments of the present invention employ flexure members. Flexure members connect a plurality of structural members to end plates on one end and blocks on another end. A drive screw or similar mechanism can be actuated to drive expansion blocks closer together, which causes flexure members to deflect, resulting in expansion of the structural members and distraction of the end plates.

Claims

1. A medical device capable of being distracted from a collapsed configuration to an expanded configuration, comprising:

a first end plate;

a second end plate; and

at least two struts extending between first and second end plates, each strut comprising first and second structural members and a block, wherein each structural member is connected at one end to one of the end plates with a flexure member and at an opposed end to the respective block with a flexure member,

wherein each end plate provides at least a pair of backstops, the pair of backstops being continuous and symmetrical with each other, each backstop configured to provide a rolling contact for a different flexure connecting one of the structural members to the respective backstop that guides a curvature of the flexure to conform to a shape of the backstop as the first end plate and the second end plate are moved relative to each other from a compressed configuration to an expanded configuration.

2. The medical device of claim 1, wherein the first end plate, the second end plate and the at least two struts comprise a one piece unitary body.

3. The medical device of claim 1, wherein the device includes at least two struts on a first side of the device and at least two struts on an opposing side of the device.

4. The medical device of claim 3, wherein the device includes three struts on the first side and three struts on the opposing side.

5. The medical device of claim 1, wherein the backstops are each concave.

6. The medical device of claim 1, wherein the backstops are each convex.

7. The medical device of claim 1, wherein the backstops are each flat.

8. The medical device of claim 1, wherein, as the device is moved from the compressed configuration to the expanded configuration, an increasing portion of each flexure disposed between one of the structural members and one of the end plates conforms to the shape of the respective backstop.

9. The medical device of claim 1, wherein in the compressed configuration the flexure members disposed between the block and the structural members conform to a shape of end wrapping surfaces of the structural member and in the expanded configuration the flexure members disposed between the first end plate and second end plate and the structural members conform to a shape of the backstop of the respective end plate.

19. The medical device of claim 1, wherein the intermediate blocks include apertures enabling operable access to an expansion tool such that actuation of the expansion tool causes the device to move between the compressed configuration and the expanded configuration.

10. A medical device capable of being distracted from a collapsed configuration to an expanded configuration, comprising:

a first end plate having an outer surface and an inner surface opposite the outer surface including at least one backstop;

a second end plate having an outer surface and an inner surface opposite the outer surface including at least one backstop; and

a plurality of struts extending between the inner surface of the first end plate and the inner surface of the second end plate, each strut comprising;

an intermediate block having a first surface and an opposing second surface;

a first structural member disposed between the first surface of the intermediate block and the inner surface of the first end plate and a second structural member disposed between the second surface of the intermediate block and the inner surface of the second end plate, each structural member including opposing end wrapping surfaces; and

a flexure member disposed on each end wrapping surface of each structural member, the flexure members connecting each structural member to a respective one of the first and second surfaces of the intermediate block and to the inner surface of a respective one of the first end plate and the second end plate,

wherein each structural member is rotatable with respect to the first end plate and the second end plate to move the first end plate and the second end plate relative to each other between a compressed configuration and an expanded configuration, and

wherein in the compressed configuration the flexure members disposed between the intermediate block and the structural members conform to a shape of the end wrapping surfaces of the structural members and in the expanded configuration the flexure members disposed between the first end plate and the second end plate and the structural members conform to a shape of the backstop of the respective end plate.

11. The medical device of claim 10, wherein the first end plate, the second end plate, and the plurality of struts comprise a one piece unitary body.

12. The medical device of claim 10, wherein the device includes at least two struts on a first side of the device and at least two struts on an opposing side of the device.

13. The medical device of claim 12, wherein the device includes three struts on the first side and three struts on the opposing side.

14. The medical device of claim 10, wherein the backstops are each concave.

15. The medical device of claim 10, wherein the backstops are each convex.

16. The medical device of claim 10, wherein the backstops are each flat.

17. The medical device of claim 10, wherein each end plate provides at least a pair of backstops, the pair of backstops being continuous and symmetrical with each other, each backstop configured to provide a rolling contact for a different flexure.

18. The medical device of claim 10, wherein as the device is moved from the compressed configuration to the expanded configuration an increasing portion of each flexure disposed between one of the structural members and one of the end plates conforms to the shape of the respective backstop.