Coiled implants and systems and methods of use thereof

• US 9,918,849 B2
• Filed: 04/28/2016
• Issued: 03/20/2018
• Est. Priority Date: 04/29/2015
• Status: Active Grant

• Current Assignee: The Institute of Musculoskeletal Science & Education
• Original Assignee: Institute For Musculoskeletal Science and Education Limited
• Inventors: Morris, Robert, Duffield, William, McShane, Edward, Stauffer, Megan
• Primary Examiner(s): Philogene, Pedro
• Assistant Examiner(s): Comstock, David C
• Application Number:
  US15/141,655
• Publication Number:
  US 20160324656A1
• Time in Patent Office: 691 Days
• Field of Search: 623 1711- 1716
• CPC Class Codes: A61F 2/30744 End caps, e.g. for closing an endoprosthetic cavity
• 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 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/302 toroidal, e.g. rings
• CPC Class Codes: A61F 2002/30289 helically-coiled
• CPC Class Codes: A61F 2002/30593 hollow
• CPC Class Codes: A61F 2002/30622 Implant for fusing a joint or bone material
• CPC Class Codes: A61F 2002/30772 Apertures or holes, e.g. of circular cross section
• CPC Class Codes: A61F 2002/30774 internally-threaded
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30985 using three dimensional printing [3DP]
• CPC Class Codes: A61F 2002/4495 having a fabric structure, e.g. made from wires or fibres

Abstract

Implants, systems and methods of making and using thereof are described herein. The implants are formed from one or more coils, preferably a plurality of coils. Optionally the coils are included in a set or group of more than one coil. Optionally, the implant is symmetric about one or more planes. Typically an implant includes at least two coils (or sets or groups of coils) that are adjacent to each other intersect with each other at one or more intersection regions. Two or more coils may intersect at a plurality of intersection regions, optionally along an array of intersection regions, within the implant or on the outer side wall of the implant. Optionally, the implants include one or more plates to aid in fixation and/or insertion. The implants may be used in a variety of different spaces in the body that require bone growth.

Claims

1. An implant comprising a plurality of coils and an open space between and/or inside the plurality of coils;

wherein the implant includes a superior outer surface, the superior outer surface formed by at least a portion of the plurality of coils; and

wherein the plurality of coils have a substantially circular cross-sectional shape;

wherein the plurality of coils include a plurality of flattened surfaces; and

wherein the plurality of flattened surfaces collectively form at least a portion of the superior outer surface of the implant.

2. The implant of claim 1, wherein at least two of the plurality of coils intersect with each other at one or more intersection regions.

3. The implant of claim 2, wherein the intersection regions are at regular intervals along the length of two or more adjacent coils.

4. The implant of claim 2, wherein the implant further comprises an inferior outer surface and one or more outer side walls;

and

wherein the one or more intersection regions are located inside the outer surfaces of the implant.

5. The implant of claim 2, wherein the implant further comprises an inferior outer surface and one or more outer side walls;

and

wherein the one or more intersection regions connect with the one or more outer side walls.

6. The implant of claim 1, further comprising a side wall defining the outside perimeter of the implant.

7. The implant of claim 6, wherein the side wall has a smooth outer surface and is in the form of a peripheral ring.

8. The implant of claim 6, further comprising a central support portion that connects with the side wall.

9. The implant of claim 6, wherein the implant further includes an anterior plate attached to the side wall;

and

wherein the anterior plate is non-textured and non-porous.

10. The implant of claim 6, wherein the implant further includes a posterior plate attached to the side wall;

and

wherein the posterior plate is non-textured and non-porous.

11. The implant of claim 1, further comprising a central support portion that connects with one or more portions of the plurality coils.

12. The implant of claim 1, wherein the implant is symmetric about a transverse plane;

and

wherein the implant comprises at least two levels, wherein when the implant is divided about the transverse plane, at least a first level is located in the superior half and at least a second level is located in the inferior half; and

wherein each level comprises at least two exterior coils and at least two interior coils.

13. The implant of claim 1, further comprising a central support portion;

and

wherein the central support portion comprises a base that lies in a median plane and connects at a first end with the anterior end of the implant and at a second end with the posterior end of the implant.

14. The implant of claim 13, wherein the central support portion further comprises one or more support rings, wherein the support rings intersect with the base at one or more connection ends.

15. The implant of claim 1, further including an additional coil;

wherein the shape of the additional coil is different than the shape of the plurality of coils.

16. The implant of claim 1, wherein the diameter of at least one of the plurality of coils varies within the coil.

17. The implant of claim 1, wherein a largest dimension of the cross section of at least one of the plurality of coils is different than the largest dimension of the cross section of at least another coil of the plurality of coils.

18. The implant of claim 1, wherein the open space is configured to allow bone growth inside the implant.

19. The implant of claim 1, wherein one or more surfaces of the implant include a texture.

20. The implant of claim 1, wherein one or more surfaces of the implant are porous.

21. The implant of claim 1, wherein the diameter of at least one of the plurality of coils is different than the diameter of at least another of the plurality of coils.

22. The implant of claim 1, wherein the implant contains a plurality of levels of coils or sets of coils, wherein each level contains two or more coils or sets of coils.

23. The implant of claim 1, further comprising one or more plates, wherein the one or more plates are integral with the side walls.

24. The implant of claim 1 in the form of an interbody fusion spacer.

25. The implant of claim 1, wherein volume of the open space comprises at least 40% of the total volume of the implant.

26. The implant of claim 1, wherein the substantially circular cross-sectional shape of the plurality of coils is spaced from the superior outer surface;

and

wherein the plurality of coils transitions from the substantially circular cross-sectional shape to the plurality of flattened surfaces proximate the superior outer surface.

27. The implant of claim 1, further comprising at least one of an anterior plate and a posterior plate;

and

wherein at least one coil of the plurality of coils includes an end that connects to at least one of the anterior plate and the posterior plate.

28. The implant of claim 27, wherein the at least one coil is integrally formed together with at least one of the anterior plate and the posterior plate.

29. An implant comprising a plurality of coils and an open space between and/or inside the plurality of coils;

wherein the implant includes an inferior outer surface, the inferior outer surface formed by at least a portion of the plurality of coils; and

wherein the plurality of coils have a substantially circular cross-sectional shape;

wherein the plurality of coils include a plurality of flattened surfaces; and

wherein the plurality of flattened surfaces collectively form at least a portion of the inferior outer surface of the implant.

30. The implant of claim 29, wherein the substantially circular cross-sectional shape of the plurality of coils is spaced from the inferior outer surface;

and

wherein the plurality of coils transitions from the substantially circular cross-sectional shape to the plurality of flattened surfaces proximate the superior outer surface.

31. The implant of claim 29, further comprising at least one of an anterior plate and a posterior plate;

and

wherein at least one coil of the plurality of coils includes an end that connects to at least one of the anterior plate and the posterior plate.

32. The implant of claim 31, wherein the at least one coil is integrally formed together with at least one of the anterior plate and the posterior plate.

33. An implant comprising:

a plurality of coils;

an open space between and/or inside the plurality of coils; and

at least one of an anterior plate and a posterior plate; and

wherein at least one coil of the plurality of coils includes an end that connects to at least one of the anterior plate and the posterior plate;

wherein the plurality of coils have a substantially circular cross-sectional shape;

wherein the plurality of coils include a plurality of flattened surfaces; and

wherein the plurality of flattened surfaces collectively form at least a portion of the outer surface of the implant.

34. The implant of claim 33, wherein the at least one coil is integrally formed together with at least one of the anterior plate and the posterior plate.

35. The implant of claim 33, wherein the outer surface is a superior outer surface or an inferior outer surface of the implant.