Rod coupling systems and devices and methods of making and using the same

• US 9,855,076 B2
• Filed: 05/06/2016
• Issued: 01/02/2018
• Est. Priority Date: 12/31/2012
• Status: Active Grant

• Current Assignee: Globus Medical, Inc.
• Original Assignee: Globus Medical, Inc.
• Inventors: Nichols, Jeff, Harderbrook, Fred, Ingalhalikar, Aditya, Fromhold, Mark
• Primary Examiner(s): Philogene, Pedro
• Assistant Examiner(s): Comstock, David C
• Application Number:
  US15/148,333
• Publication Number:
  US 20160317189A1
• Time in Patent Office: 606 Days
• Field of Search: 606246, 606264-272, 606278, 606279, 606328
• CPC Class Codes: A61B 17/7002 Longitudinal elements, e.g. rods
• CPC Class Codes: A61B 17/7004 with a cross-section which varies along its length A61B17/7019 takes precedence
• CPC Class Codes: A61B 17/7032 Screws or hooks with U-shaped head or back through which longitudinal rods pass
• CPC Class Codes: A61B 17/7037 wherein pivoting is blocked when the rod is clamped

Abstract

Provided are rod coupler devices, systems, kits and methods, which include at least one saddle having a concave configuration that either abuts a bone fastener and/or a locking cap and is shaped so as to contact the rod in two or more lines of contact, which reduces pressure on the rod, and therefore permits use of a rod having various materials, such as PEEK, without significant deformation of the rod. Also provided is the saddle itself and integrated locking caps that include a saddle, the locking cap and a set screw. Also provided are elongate rods having advantageous shapes, configurations, and/or compositions for rod coupler devices, systems and methods. Further provided are screw and cap devices and systems that themselves include a concave configuration so as to contact a rod in two or more lines of contact, which reduces pressure on the rod.

Claims

1. An integrated locking cap comprising:

a saddle having a first side configured to abut an elongate rod and a second side opposite the first side;

a locking cap contacting the second side of the saddle, wherein when the saddle is turned 90 degrees relative to the locking cap, the saddle is attached to the locking cap; and

a set screw disposed through the locking cap.

2. The integrated locking cap of claim 1, wherein the saddle is attached to the locking cap by a ledge on a top portion of the saddle that fits within a groove of the locking cap.

3. The integrated locking cap of claim 1, wherein the locking cap includes two opposed wings configured to engage a coupling body.

4. The integrated locking cap of claim 1, wherein the first side of the saddle has a concave portion.

5. The integrated locking cap of claim 1, wherein the first side of the saddle has at least two lines of contact between the saddle and the elongate rod.

6. An integrated locking cap comprising:

a saddle having a first side configured to abut an elongate rod and a second side opposite the first side;

a locking cap contacting the second side of the saddle, wherein in a first assembled position, the saddle is attached to the locking cap, and in a second assembled position, the saddle is not attached to the locking cap; and

a set screw disposed through the cap.

7. The integrated locking cap of claim 6, wherein the saddle is attached to the locking cap by a ledge on a top portion of the saddle that fits within in a groove of the locking cap.

8. The integrated locking cap of claim 6, wherein the locking cap includes two opposed wings configured to engage a coupling body.

9. The integrated locking cap of claim 6, wherein the first side of the saddle has a concave portion.

10. The integrated locking cap of claim 6, wherein the first side of the saddle has at least two lines of contact between the saddle and the elongate rod.

11. A rod coupler system comprising:

a coupling body;

an elongate rod configured to be received in the coupling body;

an integrated locking cap configured to be received in the coupling body and secure the elongate rod therein, the integrated locking cap comprises;

a saddle having a first side configured to abut the elongate rod and a second side opposite the first side;

a cap contacting the second side of the saddle, wherein when the saddle is turned 90 degrees relative to the cap, the saddle is attached to the cap; and

a set screw disposed through the cap.

12. The rod coupler system of claim 11, wherein the set screw applies a downward pressure on the elongate rod to lock the elongate rod in position.

13. The rod coupler system of claim 11, wherein the locking cap includes a threaded opening and the set screw is threadedly received in the threaded opening.

14. The rod coupler system of claim 11, wherein the coupling body has a bone fastener disposed therethrough.

15. The rod coupler system of claim 14, wherein the bone fastener comprises a pedicle screw.

16. The rod coupler system of claim 11, wherein the elongate rod is formed of PEEK.

17. The rod coupler system of claim 11, wherein the saddle is attached to the locking cap by a ledge on a top portion of the saddle that fits within in a groove of the locking cap.

18. The rod coupler system of claim 11, wherein the locking cap includes two opposed wings configured to engage a coupling body.

19. The rod coupler system of claim 11, wherein the first side of the saddle has a concave portion.

20. The rod coupler system of claim 11, wherein the first side of the saddle has at least two lines of contact between the saddle and the elongate rod.