Expandable spinal implant apparatus and method of use

• US 9,603,715 B2
• Filed: 04/30/2015
• Issued: 03/28/2017
• Est. Priority Date: 05/06/2009
• Status: Active Grant

• Current Assignee: Stryker European Operations Holdings, LLC (Stryker Corporation)
• Original Assignee: Stryker European Holdings I, LLC (Stryker Corporation)
• Inventors: Thibodeau, Lee L.
• Primary Examiner(s): Hammond, Ellen C
• Application Number:
  US14/700,554
• Publication Number:
  US 20150230930A1
• Time in Patent Office: 698 Days
• US Class Current: 1/1
• CPC Class Codes: A61F 2/30771 applied in original prostheses, e.g. holes or grooves
• CPC Class Codes: A61F 2/44 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 2/4455 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 2002/2835 Bone graft implants for filling a bony defect or an endoprosthesis cavity, e.g. by synthetic material or biological material
• CPC Class Codes: A61F 2002/30133 kidney-shaped or bean-shaped
• CPC Class Codes: A61F 2002/30281 wedge-shaped
• CPC Class Codes: A61F 2002/30354 Cylindrically-shaped protrusion and recess, e.g. cylinder of circular basis
• CPC Class Codes: A61F 2002/30367 with additional means for preventing said rotation
• CPC Class Codes: A61F 2002/3037 Translation along the common longitudinal axis, e.g. piston
• CPC Class Codes: A61F 2002/30372 with additional means for limiting said translation
• CPC Class Codes: A61F 2002/30387 Dovetail connection
• CPC Class Codes: A61F 2002/30507 using a threaded locking member, e.g. a locking screw or a set screw
• CPC Class Codes: A61F 2002/30518 with possibility of relative movement between the prosthetic parts
• CPC Class Codes: A61F 2002/3052 unrestrained in only one direction, e.g. moving unidirectionally
• CPC Class Codes: A61F 2002/30535 Special structural features of bone or joint prostheses not otherwise provided for
• 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 2002/30604 : modular
• CPC Class Codes: A61F 2002/30774 : internally-threaded
• CPC Class Codes: A61F 2002/30782 : inclined obliquely
• CPC Class Codes: A61F 2220/0025 : Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2220/0033 : made by longitudinally pushing a protrusion into a complementary-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2230/0015 : Kidney-shaped, e.g. bean-shaped
• CPC Class Codes: A61F 2230/0086 : Pyramidal, tetrahedral, or wedge-shaped
• CPC Class Codes: A61F 2250/0009 : for adjusting thickness

Abstract

A spinal implant apparatus that is an expandable spacer including features to minimize or eliminate spacer cant or offset during and after completing the expansion process. The spacer includes a top component, a base component in engagement with the top component, and an expansion mechanism arranged to change the top component'"'"'s position with respect to the base component. The mechanism for causing expansion may be a screw, a cam, a wedge or other form of distracting device. In one embodiment, the expandable spacer includes a base component with a set of towers and a top component with a set of corresponding silos, where the towers and silos are configured to minimize or eliminate tilt of the top component as it extends upwardly from the base component. In another embodiment, the spacer may include a stepped arrangement around the perimeter of the top component and the base component for engagement during height expansion with minimal canting or slippage. In another embodiment, the spacer may include texturing modification at the opposite ends of the longitudinal axis of the spacer to prevent tilting, slipping, or canting. Additionally, a portion of one or more exterior surfaces of the spacer may be textured, sawtoothed, dovetailed or the like to increase frictional intervertebral contact. The spacer may contain one or more passageways of selectable shape/dimension for bone growth through the spacer.

Claims

1. A method of implanting a spinal spacer into an intervertebral space of a patient, comprising:

engaging a tip of an insertion tool to a threaded on-axis interface of the spacer substantially parallel to a longitudinal axis of the spacer;

inserting a front end of the spacer into the intervertebral space along an insertion direction substantially parallel to the longitudinal axis of the spacer;

continuing to insert the spacer so that the front end of the spacer turns until the longitudinal axis of the spacer is non-parallel to the insertion direction;

further inserting the spacer into the intervertebral space while the insertion tool is non-parallel to the longitudinal axis of the spacer; and

actuating an expansion mechanism to expand the spacer by increasing a distance between a top surface of the spacer and a bottom surface of the spacer, the expansion mechanism being angled with respect to the longitudinal axis of the spacer;

wherein the insertion tool includes a shaft configured for positioning outside the intervertebral space while the spacer is within the intervertebral space, the shaft of the insertion tool being non-pivotable with respect to the tip of the insertion tool, the tip configured to be threadedly coupled to the spacer during the step of actuating the expansion mechanism.

2. The method of claim 1, further comprising disengaging the insertion tool from the spacer.

3. The method of claim 2, further comprising removing the insertion tool from the intervertebral space.

4. The method of claim 1, further comprising at least partially filling an opening in the spacer with bone grafting material.

5. The method of claim 4, wherein the step of at least partially filling an opening in the spacer with bone grafting material includes inserting the bone grafting material into a graft window in the spacer after the step of actuating the expansion mechanism to expand the spacer.

6. The method of claim 1, wherein the step of actuating the expansion mechanism further comprises driving a screw to increase the distance between the top and bottom surfaces of the spacer.

7. The method of claim 1, wherein the step of actuating the expansion mechanism further comprises driving a wedge to increase the distance between the top and bottom surfaces of the spacer.

8. The method of claim 1, wherein the step of actuating the expansion mechanism further comprises driving a cam to increase the distance between the top and bottom surfaces of the spacer.

9. The method of claim 1, further comprising disengaging the insertion tool from the on-axis interface prior to the step of further inserting the spacer into the intervertebral space.

10. The method of claim 9, further comprising engaging the insertion tool to an off-axis interface after the step of inserting a front end of the spacer into the intervertebral space and before the step of further inserting the spacer into the intervertebral space.

11. The method of claim 10, further comprising packing bone grafting material into the spacer through the on-axis interface after the step of actuating the expansion mechanism to expand the spacer.

12. The method of claim 10, further comprising packing bone grafting material into the spacer through the off-axis interface after the step of actuating the expansion mechanism to expand the spacer.

13. The method of claim 1, wherein the step of actuating the expansion mechanism to expand the spacer is performed such that the top surface of the spacer does not tilt with respect to the bottom surface of the spacer.

14. The method of claim 13, wherein the step of actuating the expansion mechanism to expand the spacer includes driving a top component of the spacer away from a base component of the spacer, the top component of the spacer remaining in contact with the base component during the actuating step.

15. The method of claim 14, wherein the step of actuating the expansion mechanism to expand the spacer includes sliding at least one silo in the top component along at least one tower in the base component.

16. The method of claim 14, wherein the step of actuating the expansion mechanism to expand the spacer includes sliding at least one tower in the top component along at least one silo in the base component.

17. The method of claim 1, wherein the inserting steps are performed so that, after insertion of the spacer is completed, the longitudinal axis of the spacer is rotated approximately 90 degrees with respect to the insertion direction.

18. A method of implanting an expandable spinal spacer into an intervertebral space of a patient, comprising:

providing the expandable spacer including a top component, a base component, and an expansion mechanism arranged to change a position of the top component respect to a position of the base component;

providing a tool including a shaft and a tip;

engaging the tip of the tool to a threaded tool interface of the spacer substantially parallel to a longitudinal axis of the spacer;

inserting the spacer at least partially into the intervertebral space by moving the tool substantially along an insertion direction, the insertion direction being substantially parallel to the longitudinal axis of the spacer;

turning a front end of the spacer as the spacer is being inserted at least partially into the intervertebral space; and

inserting the spacer further into the interverterbral space by moving the tool substantially along the insertion direction, such that the longitudinal axis of the space is angled with respect to the insertion direction;

wherein the shaft of the tool is configured for positioning outside the intervertebral space while the spacer is within the intervertebral space and the tip is coupled to the spacer, the shaft of the tool being non-pivotable with respect to the tip of the tool, the tip configured to be threadedly coupled to the spacer while the top component of the spacer is moved away from the base component of the spacer.

19. The method of claim 18, further comprising actuating the expansion mechanism to a distance between the top component of the spacer and the base component of the spacer, the expansion mechanism being angled with respect to the longitudinal axis of the spacer.

20. The method of claim 19, wherein the expansion mechanism is substantially parallel to the insertion direction during the step of actuating the expansion mechanism.