Expandable intervertebral implant

• US 9,526,625 B2
• Filed: 03/06/2015
• Issued: 12/27/2016
• Est. Priority Date: 04/05/2008
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Inventors: Cain, Christopher Marden John
• Primary Examiner(s): Ramana, Anu
• Application Number:
  US14/640,220
• Publication Number:
  US 20150173916A1
• Time in Patent Office: 662 Days
• Field of Search: 623 1711- 1716
• 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 2/447 substantially parallelepipedal, e.g. having a rectangular or trapezoidal cross-section
• CPC Class Codes: A61F 2/4611 of spinal prostheses
• CPC Class Codes: A61F 2002/2835 Bone graft implants for filling a bony defect or an endoprosthesis cavity, e.g. by synthetic material or biological material
• CPC Class Codes: A61F 2002/30405 made by screwing complementary threads machined on the parts themselves
• CPC Class Codes: A61F 2002/30462 retained or tied with a rope, string, thread, wire or cable
• CPC Class Codes: A61F 2002/30471 connected by a hinged linkage mechanism, e.g. of the single-bar or multi-bar linkage type
• CPC Class Codes: A61F 2002/30495 using a locking ring
• CPC Class Codes: A61F 2002/305 Snap connection
• CPC Class Codes: A61F 2002/3052 unrestrained in only one direction, e.g. moving unidirectionally
• CPC Class Codes: A61F 2002/30537 adjustable
• CPC Class Codes: A61F 2002/30538 for adjusting angular orientation
• CPC Class Codes: A61F 2002/3055 for adjusting length
• CPC Class Codes: A61F 2002/30579 with mechanically expandable devices, e.g. fixation devices
• 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 2002/30841 Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes
• CPC Class Codes: A61F 2002/30884 Fins or wings, e.g. longitudinal wings for preventing rotation within the bone cavity
• CPC Class Codes: A61F 2002/4415 elements of the prosthesis being arranged in a chain like manner
• 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 2002/4485 : comprising three or more adjacent spinal implants
• 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 2002/4628 : with linear motion along or rotating motion about an axis transverse to the instrument axis or to the implantation direction, e.g. clamping
• CPC Class Codes: A61F 2220/0025 : Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2220/0075 : sutured, ligatured or stitched, retained or tied with a rope, string, thread, wire or cable
• CPC Class Codes: A61F 2220/0091 : connected by a hinged linkage mechanism, e.g. of the single-bar or multi-bar linkage type
• CPC Class Codes: A61F 2250/0006 : for adjusting angular orientation
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys

Abstract

An expandable intervertebral implant is provided for insertion into an intervertebral space defined by adjacent vertebrae. The expandable intervertebral implant includes a pair of outer sleeve portions and an inner core disposed between the outer sleeve portions. Movement of the inner core relative to the outer sleeve portions causes the outers sleeve portions to deflect away from each other, thereby engaging the expandable intervertebral implant with the vertebrae and adjusting the height of the intervertebral space.

Claims

1. An expandable intervertebral implant insertable into an intervertebral disc space defined between an upper vertebra and a lower vertebra, the expandable intervertebral implant comprising:

an outer sleeve defining an internal void, the outer sleeve including

     1) an upper sleeve portion having a) an upper cross beam that defines an upper vertebral engagement surface configured to abut the upper vertebra when the implant is disposed in the intervertebral disc space, and b) a pair of upper legs that each project down from laterally outer ends of the upper cross beam, and

     2) a lower sleeve portion having a) a lower cross beam that defines a lower vertebral engagement surface spaced in its entirety from an entirety of the upper vertebral engagement surface along a transverse direction, the lower vertebral engagement surface configured to abut the lower vertebra when the implant is disposed in the intervertebral disc space, and b) a pair of lower legs that each project up from the lower cross beam toward the upper cross beam; and

an inner core translatable in the internal void along a longitudinal direction so as to expand the implant from an initial position to an expanded position, the longitudinal direction perpendicular to the transverse direction, wherein the inner core defines upper and lower engagement surfaces that are sloped in the transverse direction as they extend along the longitudinal direction, whereby translation of the inner core in the internal void along the longitudinal direction causes

     1) the upper and lower engagement surfaces to ride along the upper and lower sleeve portions, respectively, so as to urge an entirety of each of the upper and lower sleeve portions to move away from the other of the upper and lower sleeve portions along the transverse direction, and

     2) each of the upper and lower sleeve portions to expand along a lateral direction that is perpendicular to each of the transverse direction and the longitudinal direction, whereby

     1) the legs of the pair of upper legs move away from each other along the lateral direction, and

     2) the legs of the pair of lower legs move away from each other along the lateral direction

wherein the upper vertebral engagement surface is oriented parallel to the lower vertebral engagement surface both when the implant is in the initial position and when the implant is in the expanded position.

2. The expandable intervertebral implant as recited in claim 1, wherein the inner core defines laterally outer engagement surfaces that are configured to ride along respective pairs of the legs of the pairs of upper and lower legs so as to cause both 1) the legs of the upper pair of legs to move away from each other along the lateral direction, and 2) the legs of the lower pair of legs to move away from each other along the lateral direction.

3. The expandable intervertebral implant as recited in claim 2, wherein the laterally outer engagement surfaces of the inner core are sloped along the lateral direction.

4. The expandable intervertebral implant as recited in claim 3, wherein the outer sleeve defines a generally rectangular outer surface.

5. The expandable intervertebral implant as recited in claim 1, wherein each of the upper and lower cross beams is discontinuous along the lateral direction.

6. The expandable intervertebral implant as recited in claim 1, wherein the legs of the pair of upper legs abut respective ones of the legs of the pair of lower legs when the implant is in the initial position.

7. The expandable intervertebral implant as recited in claim 1, further comprising a member that attaches the upper sleeve portion to the lower sleeve portion.

8. An expandable intervertebral implant insertable into an intervertebral disc space defined between an upper vertebra and a lower vertebra, the expandable intervertebral implant comprising:

an outer sleeve defining an upper vertebral engagement surface configured to abut the upper vertebra when the implant is disposed in the intervertebral disc space, and a lower vertebral engagement surface configured to abut the lower vertebra when the implant is disposed in the intervertebral disc space, wherein the outer sleeve defines an internal void; and

an inner core translatable in the internal void along a longitudinal direction, wherein the inner core defines

     1) a first pair of engagement surfaces spaced from each other along a transverse direction that is perpendicular to the longitudinal direction, the engagement surfaces of the first pair sloped along the transverse direction as they extend along the longitudinal direction, and

     2) a second pair of engagement surfaces spaced from each other along a lateral direction that is perpendicular to both the longitudinal direction and the transverse direction, each of the engagement surfaces of the second pair sloped along the lateral direction as they extend along the longitudinal direction;

wherein translation of the inner core in the internal void along the longitudinal direction causes

     1) each of the first pair of engagement surfaces to ride along opposed transverse inner surfaces of the outer sleeve so as to cause the outer sleeve to expand along the transverse direction and

     2) each of the second pair of engagement surfaces to ride along opposed lateral inner surfaces of the outer sleeve so as to cause the outer sleeve to expand along the lateral direction, and

wherein the opposed lateral inner surfaces define an orientation relative to each other prior to translation of the inner core in the internal void along the longitudinal direction, and the opposed lateral inner surfaces maintain the orientation relative to each other after to translation of the inner core in the internal void along the longitudinal direction.

9. The expandable intervertebral implant as recited in claim 8, wherein the outer sleeve comprises an upper cross beam and a pair of upper legs that each project down from laterally outer ends of the upper cross beam, the outer sleeve further comprises a lower cross beam and a pair of lower legs that each project up from the lower cross beam, the upper cross beam defines the upper vertebral engagement surface, and the lower cross beam defines the lower vertebral engagement surface.

10. The expandable intervertebral implant as recited in claim 9, wherein translation of the inner core in the internal void along the longitudinal direction causes 1) an upper one of the first pair of engagement surfaces to ride along the upper cross beam, and 2) a lower one of the first pair of engagement surfaces to ride along the lower cross beam so as to urge the upper and lower cross beams away from each other along the transverse direction.

11. The expandable intervertebral implant as recited in claim 10, wherein translation of the inner core in the internal void along the longitudinal direction causes a first one of the second pair of engagement surfaces to ride along a first one of the pair of upper legs, and a second one of the second pair of engagement surfaces to simultaneously ride along a second one of the pair of upper legs.

12. The expandable intervertebral implant as recited in claim 11, wherein translation of the inner core in the internal void along the longitudinal direction further causes the first one of the second pair of engagement surfaces to ride along a first one of the pair of lower legs, and the second one of the second pair of engagement surfaces to simultaneously ride along a second one of the pair of lower legs.

13. The expandable intervertebral implant as recited in claim 12, wherein the upper cross beam is discontinuous at a location between the legs of the upper sleeve portion with respect to the lateral direction, and the lower cross beam is discontinuous at a location between the legs of the lower sleeve portion with respect to the lateral direction.

14. The expandable intervertebral implant as recited in claim 8, wherein the inner core is translatable in the internal void in an expansion direction oriented along the longitudinal direction so as to cause the outer sleeve to expand along the transverse direction and the lateral direction, the engagement surfaces of the first pair of engagement surfaces converge toward each other in the expansion direction, and the engagement surfaces of the second pair of engagement surfaces converge toward each other in the expansion direction.

15. The expandable intervertebral implant as recited in claim 8, wherein the opposed transverse inner surfaces define a respective orientation relative to each other prior to translation of the inner core in the internal void along the longitudinal direction, and the opposed transverse inner surfaces maintain the respective orientation relative to each other after to translation of the inner core in the internal void along the longitudinal direction.

16. An expandable intervertebral implant insertable into an intervertebral disc space defined between an upper vertebra and a lower vertebra, the expandable intervertebral implant comprising:

an outer sleeve that defines a generally rectangular outer surface, the generally rectangular outer surface including an upper vertebral engagement surface that is configured to abut the upper vertebra when the implant is disposed in the intervertebral disc space, the generally rectangular surface further including an upper inner surface that is opposite the upper vertebral engagement surface, the generally rectangular outer surface further including a lower vertebral engagement surface that is spaced in its entirety from an entirety of the upper vertebral engagement surface along a transverse direction, and the generally rectangular outer surface further including a lower inner surface opposite the lower vertebral engagement surface, the lower vertebral engagement surface configured to abut the lower vertebra when the implant is disposed in the intervertebral disc space, the generally rectangular outer surface further including opposed outer lateral surfaces that are spaced in their respective entireties from each other along a lateral direction that is perpendicular to the transverse direction, wherein the outer sleeve defines an internal void;

an inner core translatable in the internal void along a longitudinal direction that is perpendicular to each of the transverse direction and the lateral direction,

wherein translation of the inner core in the internal void along the longitudinal direction causes the inner core to ride along the outer sleeve so as to cause the upper and lower vertebral engaging surfaces to move away from each other along the transverse direction, and to further cause the opposed outer lateral surfaces to move away from each other along the lateral direction, and

wherein the upper inner surface and the lower inner surface define an orientation relative to each other prior to translation of the inner core in the internal void along the longitudinal direction, and the upper inner surface and the lower inner surface maintain the orientation relative to each other after translation of the inner core in the internal void along the longitudinal direction.

17. The expandable intervertebral implant as recited in claim 16, wherein the generally rectangular outer sleeve comprises:

an upper sleeve portion including an upper cross beam that is oriented in a plane defined by a longitudinal direction and a lateral direction that is perpendicular to the longitudinal direction, wherein the upper cross beam defines the upper vertebral engagement surface, the upper sleeve portion further having a pair of upper legs that project down from laterally outer ends of the upper cross beam along the transverse direction; and

a lower sleeve portion having a lower cross beam that is oriented in a plane defined by a longitudinal direction and a lateral direction that is perpendicular to the longitudinal direction, wherein the lower cross beam defines the lower vertebral engagement surface, and the lower sleeve portion further includes a pair of lower legs that project up from laterally outer ends of the lower cross beam along the transverse direction,

wherein the legs of the pair of upper legs and the pair of lower legs, in combination, define the opposed outer lateral surfaces.

18. The expandable intervertebral implant as recited in claim 17, wherein translation of the inner core in the internal void along the longitudinal direction causes the inner core to ride along 1) the upper and lower cross beams thereby causing the upper sleeve portion and the lower sleeve portion to move away from each other along the transverse direction, and 2) the legs of the upper and lower pairs of legs, thereby causing the upper and lower sleeve portions to expand along the lateral direction.

19. The expandable intervertebral implant as recited in claim 17, wherein the inner core defines 1) a first pair of sloped engagement surfaces spaced from each other along the transverse direction, and 2) a second pair of sloped engagement surfaces spaced from each other along the lateral direction, and

wherein translation of the inner core in the internal void along the longitudinal direction causes the sloped engagement surfaces of the first pair of sloped engagement surfaces to ride along respective ones of the upper and lower cross beams so as to urge the upper and lower sleeve portions to move away from each other along the transverse direction, and further causes the sloped engagement surfaces of the second pair of sloped engagement surfaces to ride along respective pairs of legs of the pairs of upper and lower legs so as to urge the upper and lower sleeve portions to expand along the lateral direction.

20. The expandable intervertebral implant as recited in claim 19, wherein translation of the inner core in the internal void along the longitudinal direction causes the sloped engagement surfaces of the second pair of sloped engagement surfaces to ride along respective inner surfaces of the pairs of legs of the pairs of upper and lower legs,

wherein the inner surfaces of the upper legs and the inner surfaces of the lower legs define a respective orientation relative to each other prior to translation of the inner core in the internal void along the longitudinal direction, and the inner surfaces of the upper legs and the inner surfaces of the lower legs maintain the respective orientation relative to each other after translation of the inner core in the internal void along the longitudinal direction.

21. The expandable intervertebral implant as recited in claim 19, wherein translation of the inner core in the internal void along the longitudinal direction causes a first one of the second pair of engagement surfaces to ride along a first leg of the pair upper legs, and a second one of the second pair of engagement surfaces to simultaneously ride along a second leg of the pair upper legs.

22. The expandable intervertebral implant as recited in claim 21, wherein translation of the inner core in the internal void along the longitudinal direction causes the first one of the second pair of engagement surfaces to also ride along a first one of the pair lower legs, and the second one of the second pair of engagement surfaces to also simultaneously ride along a second one of the pair of lower legs.

23. The expandable intervertebral implant as recited in claim 16, wherein the inner core defines 1) a first pair of sloped engagement surfaces that are spaced from each other along the transverse direction and are sloped along the transverse direction as they extend along the longitudinal direction, each of the first pair of sloped engagement surfaces configured to ride along the outer sleeve so as to cause the upper and lower vertebral engaging surfaces to move away from each other along the transverse direction, and 2) a second pair of sloped engagement surfaces that are spaced from each other along the lateral direction and are sloped along the lateral direction as they extend along the longitudinal direction, each of the second pair of sloped engagement surfaces configured to ride along the outer sleeve so as to cause the opposed outer lateral surfaces to move away from each other along the lateral direction.

24. An intervertebral implant kit comprising:

an expandable intervertebral implant insertable into an intervertebral disc space defined between an upper vertebra and a lower vertebra, the expandable intervertebral implant including

     1) an outer sleeve that defines an internal void, and

     2) an inner core configured to translate in the internal void along a longitudinal direction, wherein the inner core defines an internal bore;

a rod configured to extend into the internal bore; and

an abutment member supported by the rod, the abutment member defining an abutment surface that is configured to face the inner core, such that a force applied to the abutment member along the longitudinal direction drives the inner core to translate in the internal void along the longitudinal direction with respect to the outer sleeve, thereby causing the implant to expand from an initial position to an expanded position whereby the outer sleeve expands along both a transverse direction that is perpendicular to the longitudinal direction, and a lateral direction that is perpendicular with respect to both the transverse direction and the longitudinal direction.

25. The intervertebral implant kit as recited in claim 24, wherein the outer sleeve includes an upper sleeve portion that defines an upper vertebral engagement surface configured to abut the upper vertebra when the implant is disposed in the intervertebral disc space, and the sleeve further includes a lower sleeve portion that defines a lower vertebral engagement surface configured to abut the lower vertebra when the implant is disposed in the intervertebral disc space, wherein the outer sleeve defines an internal void, and

wherein inner core is configured to ride in the internal void along the upper sleeve portion and the lower sleeve portion so as to urge the implant to expand along the transverse direction.

26. The intervertebral implant kit as recited in claim 25, wherein 1) the upper sleeve portion further includes an upper cross beam that defines the upper vertebral engagement surface, and the upper sleeve portion further includes an pair of upper legs that extend down from the upper cross beam toward the lower sleeve portion, 2) the lower sleeve portion further includes a lower cross beam that defines the lower vertebral engagement surface, and the lower sleeve portion further includes pair of lower legs that extend up from the lower cross beam toward the upper sleeve portion, and 3) the inner core is configured to translate in the internal void such that the inner core rides along the upper cross beam, the pair of upper legs, the pair of lower legs, and the lower cross beam, so as to cause the implant to expand from the initial position to the expanded position.

27. The intervertebral implant kit as recited in claim 25, wherein 1) the outer sleeve defines a generally rectangular outer surface that includes the upper and lower vertebral engagement surfaces, 2) the inner core defines a first pair of engagement surfaces that are spaced from each other along the transverse direction and are sloped along the transverse direction as they extend in the longitudinal direction, 3) the engagement surfaces of the first pair of engagement surfaces ride along respective ones of the upper and lower sleeve portions as the inner core translates in the internal void along the longitudinal direction, so as to move an entirety of each of the upper and lower sleeve portions away from each other along the transverse direction, thereby causing the outer sleeve to expand along the transverse direction, 4) the inner core defines a second pair of engagement surfaces that are spaced from each other along the lateral direction and are sloped along the lateral direction as they extend in the longitudinal direction, and 5) the engagement surfaces of the second pair of engagement surfaces ride along the outer sleeve as the inner core translates in the internal void along the longitudinal direction, thereby causing the outer sleeve to expand along the lateral direction.