U.S. patent application number 12/465172 was filed with the patent office on 2009-09-10 for break-off screw extensions.
This patent application is currently assigned to DEPUY SPINE, INC.. Invention is credited to Timothy Beardsley, Douglas Bireley, Anthony R. Carlone, James J. Roveda, Christopher Sicvol.
Application Number | 20090228052 12/465172 |
Document ID | / |
Family ID | 39430284 |
Filed Date | 2009-09-10 |
United States Patent
Application |
20090228052 |
Kind Code |
A1 |
Beardsley; Timothy ; et
al. |
September 10, 2009 |
BREAK-OFF SCREW EXTENSIONS
Abstract
The present invention provides minimally invasive devices and
methods for delivering a spinal connector to one or more spinal
anchor sites in a patient's spinal column. In one embodiment, a
spinal implant and access device is provided that includes a
U-shaped receiver member, a bone-engaging member, and an extension
member. The U-shaped receiver member can have a recess formed
therein that is adapted to seat a spinal connector. The
bone-engaging member can extend distally from the receiver member
and it can be adapted to engage bone to thereby mate the receiver
member to bone. The extension member can extend proximally from the
receiver member and it can include a frangible portion formed
thereon that is adapted to break when a predetermined force is
applied thereto thereby allowing at least a portion of the
extension member to be separated from the receiver member.
Inventors: |
Beardsley; Timothy;
(Kingston, MA) ; Bireley; Douglas; (Barrington,
RI) ; Roveda; James J.; (North Attleboro, MA)
; Sicvol; Christopher; (Boston, MA) ; Carlone;
Anthony R.; (Bristol, RI) |
Correspondence
Address: |
NUTTER MCCLENNEN & FISH LLP
WORLD TRADE CENTER WEST, 155 SEAPORT BOULEVARD
BOSTON
MA
02210-2604
US
|
Assignee: |
DEPUY SPINE, INC.
Raynham
MA
|
Family ID: |
39430284 |
Appl. No.: |
12/465172 |
Filed: |
May 13, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11561455 |
Nov 20, 2006 |
|
|
|
12465172 |
|
|
|
|
Current U.S.
Class: |
606/305 ;
606/328 |
Current CPC
Class: |
A61B 17/7091 20130101;
A61B 17/7032 20130101; A61B 2017/0256 20130101; A61B 17/8863
20130101; A61B 2090/037 20160201; A61B 17/1757 20130101; A61B
17/7085 20130101; A61B 17/708 20130101; A61B 17/7037 20130101 |
Class at
Publication: |
606/305 ;
606/328 |
International
Class: |
A61B 17/86 20060101
A61B017/86; A61B 17/88 20060101 A61B017/88 |
Claims
1-21. (canceled)
22. A pedicle screw assembly comprising: a screw having a threaded
shaft and a head; a body coupled to the screw head and having a
channel adapted to receive a spine rod therein; at least one tab
projecting upwardly from the body; and a frangible joint joining
the at least one tab to the body such that the tab is adapted to be
separated from the body at the frangible joint.
23. The pedicle screw assembly of claim 22, further comprising: a
pair of the tabs; a pair of the frangible joints; and a pair of
spaced arms extending upwardly from the body, the channel being
defined between the spaced arms and each of the tabs being coupled
to one of the arms along one of the frangible joints.
24. The pedicle screw assembly of claim 23, wherein the pair of
tabs are spaced from one another and form a pair of slots there
between, each of the slots being in communication with the
channel.
25. The pedicle screw assembly of claim 22, wherein the body is a
polyaxial body adapted to be positioned in a plurality of
orientations relative to a longitudinal axis of the screw
shaft.
26. The pedicle screw assembly of claim 22 further comprising: a
set screw adapted to threadably engage the body and capture a rod
in the channel.
27. The pedicle screw assembly of claim 22, wherein the at least
one tab is elongate and adapted to extend percutaneously from the
body when the screw assembly is inserted into a patient's
vertebrae.
28. The pedicle screw assembly of claim 22, further comprising: a
collar adapted to releasably mate with the at least one tab
extending from the body.
29. A pedicle screw assembly comprising: a screw having a threaded
shaft and a head; a polyaxial body coupled to the screw head being
adapted to be positioned in a plurality of orientations relative to
a longitudinal axis of the screw shaft; a pair of spaced arms
extending upwardly from the body, a channel being defined between
the spaced arms and adapted to receive a spine rod therein; a pair
of elongate tabs each projecting upwardly from the polyaxial body
and adapted to extend percutaneously from the body when the screw
assembly is inserted into a patient's vertebrae; a pair of slots
formed between the pair of tabs, each of the slots being in
communication with the channel; a pair of the frangible joints each
joining one of tabs to the polyaxial body such that the tab is
adapted to be separated from the body at the frangible joint; and a
set screw adapted to threadably engage the body and capture the rod
in the channel.
30. The pedicle screw assembly of claim 29, further comprising: a
collar adapted to releasably mate with the at least one tab
extending from the body.
31. A method of installing a spinal fixation construct onto a
patient's spine, the method comprising the steps of: making a first
incision in the patient's skin proximate selected vertebrae of the
patient; inserting first and second screw assemblies into first and
second vertebra, respectively, each screw assembly having a tab
extending percutaneously from the patient when the screw assembly
is inserted into the associated vertebra to retract patient tissue
proximate the first incision; inserting a rod through the first
incision proximate the tab of at least one of the screw assemblies;
seating the rod in a channel in each of the screw assemblies;
securing the rod in the channel of each of the screw assemblies;
and removing each of the tabs from the associated screw
assembly.
32. The method of claim 31, further comprising: making a second
incision spaced from the first incision; wherein the first and
second screw assemblies are inserted through the first and second
incisions, respectively.
33. The method of claim 31, further comprising: prior to the
seating and the securing steps, forming the rod into a desired
configuration based on the relative positions of the tabs extending
percutaneously from the first and second screw assemblies.
34. The method of claim 31, further comprising: making a second
incision spaced from the first incision and extending proximate the
second and a third vertebra; wherein the first and second screw
assemblies are inserted through the first and second incisions,
respectively, into the associated vertebrae; inserting a third
screw assembly through the second incision; and inserting the third
screw assembly into the third vertebra.
35. The method of claim 31, further comprising: coupling a collar
to selected screw assemblies such that a portion of each collar is
positioned percutaneously.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/561,455 filed on Nov. 20, 2006 and entitled
"Break-Off Screw Extensions," which is hereby incorporated by
reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to tools for use in spinal
surgery, and in particular to minimally invasive methods and
devices for introducing a spinal connector to one or more spinal
anchor sites within a patient's spine.
BACKGROUND OF THE INVENTION
[0003] For a number of known reasons, spinal fixation devices are
used in orthopedic surgery to align and/or fix a desired
relationship between adjacent vertebral bodies. Such devices
typically include a spinal connector, such as a relatively rigid
fixation rod, that is coupled to adjacent vertebrae by attaching
the connector to various anchoring devices, such as hooks, bolts,
wires, or screws. The connector can have a predetermined contour
that has been designed according to the properties of the target
implantation site, and once installed, the instrument holds the
vertebrae in a desired spatial relationship, either until healing
or spinal fusion has taken place, or for some longer period of
time.
[0004] Spinal connectors can be anchored to specific portions of
the vertebrae. Since each vertebra varies in shape and size, a
variety of anchoring devices have been developed to facilitate
engagement of a particular portion of the bone. Pedicle screw
assemblies, for example, have a shape and size that is configured
to engage pedicle bone. Such screws typically include a threaded
shank that is adapted to be threaded into a vertebra, and a head
portion having a receiving element, usually in the form of a
U-shaped head. A set-screw, plug, or similar type of fastening
mechanism is used to lock the spinal connector, e.g., a spinal rod,
into the receiving head of the pedicle screw. In use, the shank
portion of each screw is threaded into a vertebra, and once
properly positioned, a rod is seated through the receiving member
of each screw and the rod is locked in place by tightening a cap or
other fastener mechanism to securely interconnect each screw and
the spinal rod.
[0005] Minimally invasive devices and methods for implanting spinal
fixation devices are advantageous because such devices and methods
utilize few incisions for introducing and implanting anchoring
devices and spinal connectors at a target site within a patient's
spine. Such procedures offer advantages over invasive techniques
because they reduce the amount of damage to surrounding tissue and
muscle and the amount of time required to complete the
procedure.
[0006] Accordingly, there is a need for improved minimally invasive
devices and methods for introducing a spinal connector into a
patient's spine.
SUMMARY OF THE INVENTION
[0007] The present invention provides minimally invasive devices
and methods for implanting a spinal anchor in bone, for
percutaneously delivering various tools and implants to the spinal
anchor through an extension coupled thereto, and for removing the
extension coupled to the spinal anchor. In one embodiment, a spinal
implant and access device is provided that includes a U-shaped
receiver member, a bone-engaging member, and an extension member.
The U-shaped receiver member can have a recess formed therein that
is adapted to seat a spinal connector, such as a spinal rod. In one
exemplary embodiment, the receiver member can have a maximum outer
diameter that is substantially the same as a maximum outer diameter
of the extension member. The bone-engaging member can extend
distally from the receiver member and it can be adapted to engage
bone to thereby mate the receiver member to bone. A variety of
configurations are available for the bone-engaging member, for
example, in one embodiment the bone-engaging member can be a
threaded shank such as a bone screw.
[0008] As indicated above, the access device can include an
extension member. The extension member can extend proximally from
the receiver member and it can have a lumen extending therethrough.
Although a variety of shapes and sizes are available for the
extension member in an exemplary embodiment, the extension member
has a length that is adapted to span through a skin surface in a
patient to the U-shaped receiver member when the bone engaging
member is implanted in a vertebra. The extension member can also
include a frangible portion formed thereon that is adapted to break
when a predetermined force is applied thereto thereby allowing at
least a portion of the extension member to be separated from the
receiver member. In one embodiment, the extension member can
include a proximal end and a distal end that is coupled to the
receiver member. The frangible portion can be formed adjacent to
the distal end.
[0009] The extension member can also have a variety of
configurations. For example, in one embodiment, the extension
member can include first and second opposed extension arms that
extend proximally from the U-shaped receiver member and that are
separated by opposed slots that extend between the arms. The
opposed slots can extend from the proximal end to the distal end or
the first and second extension arms can be coupled to one another
at least one location located proximal to the frangible portion. In
another embodiment, the extension member can be a hollow elongate
tube. The hollow elongate tube can include opposed slots that
extend from a distal end of the tube and that terminate distal to a
proximal end of the tube. Various configurations are also available
for the frangible portion of the extension member. For example, in
one embodiment, the frangible portion can include an annular groove
formed around the extension member.
[0010] In another embodiment, a removal tool is provided. Although
a variety of configurations are available for the removal tool, in
an exemplary embodiment the tool can include an elongate member
having a proximal portion that is adapted to be positioned adjacent
to a skin incision and a distal portion that is adapted to be
positioned adjacent to a vertebra and to be received within a lumen
formed in an extension member of a spinal anchor. The distal
portion can include an engagement mechanism that is adapted to
engage an inner surface of the extension member of the spinal
anchor and to apply a radially directed force to the extension
member disposed therearound to break at least a portion of the
extension member apart from the spinal anchor. The engagement
mechanism can have a variety of configurations. For example, in one
embodiment, the engagement mechanism can be a cam formed on a
distal portion of the elongate member. In another embodiment, the
engagement mechanism can be a set screw formed on a distal portion
of the elongate member. The set screw can have a proximal threaded
portion with an outer diameter that is greater than an outer
diameter of a distal threaded portion. The removal tool can also
include a handle disposed on a proximal portion that is adapted to
rotate the elongate member to cause the engagement mechanism to
apply a radially directed force to an extension member that is
disposed therearound.
[0011] Exemplary spinal systems are also provided. In one
embodiment, system can include a spinal anchor and a removal tool.
The spinal anchor can be adapted to be implanted in bone and it can
have a receiver member with a recess formed therein for seating a
spinal connector. An extension member can be frangibly coupled to
the receiver member and it can be adapted to span through a skin
surface in a patient to the receiver member when the receiver
member is coupled to a vertebra. A variety of configurations are
available for the extension member and the removal tool, including
those discussed above.
[0012] Methods for implanting a spinal anchor and removing a
percutaneous access device from a spinal anchor are also provided.
In one embodiment, the method can include percutaneously delivering
a spinal anchor to a vertebra, advancing a spinal connector through
an extension member that is frangibly attached to the spinal
anchor, and separating the extension member from the spinal anchor.
Advancing the spinal connector through the extension member can
generally include advancing the connector in a first orientation
substantially parallel to a longitudinal axis of the extension
member and manipulating the connector to extend in a second
orientation angled with respect to the first orientation to
position the connector in relation to the spinal anchor. In one
embodiment, the spinal connector can extend substantially parallel
to a patient's spinal column in the second orientation. A variety
of techniques can be used to separate the extension member from the
spinal anchor. For example, removing the percutaneous access device
from the spinal anchor can generally include inserting an elongate
member into a lumen formed through the percutaneous access device
and actuating the elongate member to cause the elongate member to
apply a radially directed force to an inner surface of the access
device to break at least a portion of the device away from the
spinal anchor. In one exemplary embodiment, actuating the elongate
member can include rotating the elongate member such that an
engagement mechanism disposed on a distal portion of the member
engages and applies the radially directed force to an inner surface
of the access device. The elongate member can be rotated by
applying a force to a handle disposed on a proximal end of the
elongate member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will be more fully understood from the
following detailed description taken in conjunction with the
accompanying drawings, in which:
[0014] FIG. 1A is a perspective view of a spinal implant and access
device having an extension frangibly coupled to a spinal anchor
according to one embodiment of the present invention;
[0015] FIG. 1B is an enlarged perspective view of the frangible
portion of the spinal implant and access device shown in FIG.
1A;
[0016] FIG. 1C is a cross-sectional view of a portion of the spinal
implant and access device of FIG. 1A;
[0017] FIG. 1D is a perspective view of another embodiment of an
extension member having a closed configuration for use with a
spinal anchor and access device;
[0018] FIG. 1E is a perspective view of another embodiment of an
extension member having an open configuration for use with a spinal
anchor and access device;
[0019] FIG. 1F is a perspective view of another embodiment of a
proximal end of an extension member having threads formed therein
and flats formed on an external surface thereof;
[0020] FIG. 2A is a perspective view of a removal tool according to
one embodiment of the present invention;
[0021] FIG. 2B is an enlarged perspective view of a distal end of
the removal tool shown in FIG. 2A;
[0022] FIG. 2C is a cross-sectional view of the tool shown in FIG.
2B;
[0023] FIG. 3A is a perspective view of a removal tool according to
another embodiment of the present invention;
[0024] FIG. 3B is a cross-sectional view of the removal tool shown
in FIG. 3A disposed within the extension member of the device of
FIG. 1A;
[0025] FIG. 3C is a cross-sectional view of the removal tool and
extension member shown in FIG. 3B showing the tool applying a force
to an inner surface of the extension member;
[0026] FIG. 4A is a perspective view of another embodiment of a
removal tool having first and second breaker arms, showing the tool
coupled to the device of FIG. 1A;
[0027] FIG. 4B is a perspective view of a distal portion of another
embodiment of an extension member;
[0028] FIG. 5A is an illustration showing the device of FIG. 1A
implanted in adjacent vertebra, and showing a spinal rod about to
be inserted therethrough;
[0029] FIG. 5B is an illustration showing the spinal rod of FIG. 5A
being passed through the slots in the extension members of the
devices of FIG. 5A;
[0030] FIG. 5C illustrates the rod of FIG. 5B positioned within the
spinal anchor of the devices of FIG. 5B;
[0031] FIG. 6A is an illustration showing a driver tool being used
to apply a fastening element to the spinal anchor of FIG. 5C to
lock the rod within the anchor;
[0032] FIG. 6B is an illustration of one embodiment of a torque
driver and a stabilizer to facilitate tightening of the fastening
element of FIG. 6A;
[0033] FIG. 7A is an illustration showing another embodiment of a
technique for removing the extension arms from the spinal anchor of
the device of FIG. 1A, showing a removal tool in an initial
position;
[0034] FIG. 7B is an illustration showing the removal tool of FIG.
7A in a final position;
[0035] FIG. 8 is an illustration showing one embodiment of a jig
and a targeting device in use with the spinal anchor and access
device of FIG. 1A;
[0036] FIG. 9 is an illustration showing one embodiment of a
distractor device in use with the spinal anchor and access device
of FIG. 1A; and
[0037] FIG. 10 is an illustration showing one embodiment of a
technique for using the spinal anchor and access device of FIG. 1A
to correct a spinal deformity.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Certain exemplary embodiments will now be described to
provide an overall understanding of the principles of the
structure, function, manufacture, and use of the devices and
methods disclosed herein. One or more examples of these embodiments
are illustrated in the accompanying drawings. Those of ordinary
skill in the art will understand that the devices and methods
specifically described herein and illustrated in the accompanying
drawings are non-limiting exemplary embodiments and that the scope
of the present invention is defined solely by the claims. The
features illustrated or described in connection with one exemplary
embodiment may be combined with the features of other embodiments.
Such modifications and variations are intended to be included
within the scope of the present invention.
[0039] The present invention provides minimally invasive methods
and devices for introducing a spinal connector into a surgical site
in a patient's spinal column. In general, a spinal implant and
access device is provided for creating a minimally invasive pathway
from a skin incision to a spinal anchor site for delivering various
tools and devices to the spinal anchor site. In an exemplary
embodiment, the access device can be in the form of an extension
member that is mated to or formed on and extends proximally from a
spinal anchor. The extension member can be used to implant the
spinal anchor, and, once the anchor is implanted, to manipulate the
spinal anchor from outside of the patient's body as well as to
provide a pathway through a skin surface to the spinal anchor for
introducing various tools and spinal system components, such as
spinal connectors, fasteners, installation tools, and removal
tools. The extension member can also be adapted to be easily
detached from or broken off of the spinal anchor once the procedure
is complete. Such a configuration eliminates the steps of
assembling, disassembling, and cleaning which are currently
required for conventional screw extensions.
[0040] FIG. 1A illustrates one exemplary embodiment of a spinal
implant and access device 10 having an extension member 12 that is
mated to a spinal anchor 14. As shown, the anchor 14 includes a
U-shaped receiver member 16 and a bone-engaging member 14b that
extends distally from the receiver member 16. The U-shaped receiver
member 16 can have a recess 16a formed therein that is adapted to
seat a spinal connector, such as a spinal rod. The bone-engaging
member 14b can extend distally from the receiver member 16 and it
can be adapted to engage bone such that it is effective to mate the
receiver member 16 to bone. The extension member 12 can include a
distal end 12b that is mated to and extends proximally from the
receiver member 16. In use, the extension member 12 can define a
pathway from a skin incision in a patient to the spinal anchor,
which can be implanted in a vertebra of a spine. In an exemplary
embodiment, the extension member 12 can be removably mated to the
receiver member 16 to allow at least a portion of the extension
member 12 to be separated from the receiver member 16.
[0041] The anchor can have a variety of configurations. In the
embodiment shown in FIG. 1A, the anchor 14 is in the form of a
spinal screw. As shown, the spinal screw 14 includes a distal
bone-engaging member 14b, e.g., a threaded shank, and a proximal
U-shaped receiver member 16 that is adapted to seat a spinal
connector, such as a rigid or dynamic spinal rod. The U-shaped
receiver member 16 can include opposed arms 16b, 16c having
cut-outs 16d, 16e formed therein that define the U-shaped recess
16a. The bone-engaging member 14b can be fixedly attached to the
receiver member 16 to form a monoaxial screw, or alternatively the
bone-engaging member 14b can be configured as a polyaxial screw
that is rotatably disposed through an opening formed in the distal
end of the receiver member 16 to allow rotation of the
bone-engaging member 14b with respect to the receiver member 16. A
variety of techniques known in the art can be used to allow
rotation of the receiver member 16 with respect to the
bone-engaging member 14b. A person skilled in the art will
appreciate that a variety of other anchors can be used with the
devices and methods of the present invention, including, for
example, spinal hooks, bolts, and wires.
[0042] The extension member 12 that is coupled to the anchor 14 can
also have a variety of configurations. In the illustrated
embodiment, the extension member 12 extends proximally from the
receiver member 16 and defines a lumen 17 extending therethrough.
In particular, a distal end of opposed arms 12c, 12d of the
extension member 12 can be mated to or integrally formed with and
can extend proximally from a proximal end of the opposed arms 16b,
16c of the receiver member 16. As will be discussed in more detail
below, this will allow opposed slots 13a, 13b in the extension
member 12 to align with the opposed cut-outs 16d, 16e in the
receiver member 16. The inner lumen 17 of the extension member 12
can define a longitudinal axis L that extends between proximal and
distal ends 12a, 12b of the extension member 12. The size of the
extension member 12 can vary depending on the intended use, but in
an exemplary embodiment it has a length that allows the proximal
end 12a of the extension member 12 to be positioned outside the
patient's body, while the distal end 12b of the extension member 12
is coupled to the spinal anchor 14 which is implanted in a vertebra
in a patient's spine. More particularly, the extension member 12
can have a length that allows the extension member 12 to span
through the skin surface to the receiver member 16 when the bone
engaging member is fully implanted in a vertebra, and the receiver
member 16 is positioned adjacent to the vertebrae, e.g., the bottom
surface of the receiver member 16 is in contact with or within
about 1 mm to 2 mm of the vertebra. Such a configuration is
particularly advantageous as it allows the extension member 12 to
be used to introduce and facilitate positioning of various tools
and devices therethrough, and it also allows the extension member
12 to be used to manipulate the anchor from outside of the
patient's body. The length l.sub.e of the extension member 12 is
illustrated in FIG. 1A, and is measured from the proximal-most end
of the extension member 12 to the proximal end of the receiver
member 16, i.e., to a frangible portion 18 that couples the
extension member to the U-shaped receiver member 16 as will be
discussed in more detail below. In an exemplary embodiment, the
length l.sub.e is greater than about 25 mm, and more preferably is
greater than about 55 mm. Thus, in such embodiments, the length of
the extension member 12 and the receiver member 16 (which can be
approximately 15 mm from the proximal-most end to the bottom or
distal end), can be greater than about 40 mm, and more preferably
greater than about 70 mm. Exemplary lengths l.sub.e of the
extension member 12 range from 85 mm to 185 mm (100 mm to 200 mm
with the receiver member), and more preferably from 135 mm to 175
mm (150 mm to 190 mm with the receiver member). In certain
exemplary embodiments, the extension member can have a length
l.sub.e of about 145 mm (160 mm with the receiver member) where the
extension member has an open configuration, as will be discussed in
more detail below, and a length l.sub.e of about 165 mm (180 mm
with the receiver member) where the extension member has a closed
configuration.
[0043] The extension member 12 can also be adapted to provide a
minimally invasive pathway for the delivery of various implants and
devices. In an exemplary embodiment, shown in FIG. 1C, the
extension member 12 has inner and outer diameters d.sub.i, d.sub.o
that are substantially the same as the inner and outer diameters
d.sub.ri, d.sub.ro of the receiver member 16. The matching inner
diameters will allow spinal connectors, fasteners, and other
implants and devices to be inserted therethrough and coupled to the
receiver member 16, and the matching outer diameters will allow a
relatively small incision to be used to introduce the spinal
implant and access device 10 into the body. It will also allow the
extension member 12 and the anchor 14 to be introduced through a
cannula or other access port, if necessary.
[0044] As indicated above, the extension member 12 can also include
cut-outs or slots to facilitate the introduction of tools, spinal
connectors, and other implants therethrough. A variety of
configurations are available for the cut-outs. For example, as
shown in FIG. 1A, the extension member 12 can include opposed slots
13a, 13b that extend between and separate the first and second
opposed extension arms 12c, 12d that extend proximally from the
U-shaped receiver member 16. The opposed slots 13a, 13b can extend
from the proximal end 12a to the distal end 12b, such that the
extension member 12 has an open configuration, or the first and
second extension arms 12c, 12d can be coupled to one another at one
or more locations along the length thereof, such that the extension
member 12 has a closed configuration. FIGS. 1A and 1C illustrate
the extension having a closed configuration, in which the first and
second extension arms 12c, 12d are coupled to one another by a web
or connector 15 located distal to the midpoint of the extensions
12c, 12d and proximal to a frangible portion 18, which will be
discussed in more detail below. In use, the slot(s) 13a, 13b can be
configured to allow various implants and devices to be passed
therethrough. Thus, each slot 13a, 13b preferably has a width that
is sufficient to accommodate the size of an implant or device to be
passed therethrough. In another embodiment of an extension having a
closed configuration, as shown in FIG. 1D, the first and second
extension arms 12c', 12d' can be coupled to one another at the
proximal end 12a' of the extension member 12'. Such a configuration
resembles a hollow elongate tube having slots 13a', 13b' formed in
the sidewalls thereof and extending proximally from the distal end
12b' thereof and terminating distal to the proximal end 12a' of the
extension member 12'.
[0045] Alternatively, the extension member can have an open
configuration. This is illustrated in FIG. 1E, which shows an
extension member 12'' having first and second extension arms 12c'',
12d'' that are separated by slots 13a'', 13b'' that extend from the
distal end 12b'' of the extension member 12'' and that extend
through the entire proximal portion of the extension member 12''
such that the proximal end 12a'' of each arm 12c'', 12d'' is
separated from one another. Accordingly, the quantity, shape, and
size of the slot(s) 13a, 13b can vary. A person skilled in the art
will appreciate that the extension member 12 can include any number
of sidewall openings having any shape that is sufficient to allow
desired implants and devices to be passed therethrough.
[0046] The extension member 12 can also include other features to
facilitate use of the device. For example, in another embodiment,
shown in FIG. 1F, the extension member 12''' includes threads
12t''' formed in a proximal portion of the extension member 12'''
for mating with corresponding threads formed on a driver tool,
reduction device, or other delivery device. The threads 12t''' will
facilitate advancement of the delivery device through the extension
member 12'''. For example, the threads 12t''' can mate with
corresponding threads on a rod reduction device to allow the rod
reduction device to reduce a spinal rod or other spinal connector
into the receiver member of the anchor. While FIG. 1F illustrates
threads 12t''' formed within the proximal end of the extension
member 12''', the threads 12t''' can be formed at any location
along the length of the extension member 12'''. For example,
threads can be formed within the connector 15 (FIG. 1C) and around
the circumference of the inner lumen of the extension member 12. As
further shown in FIG. 1F, the extension member 12''' can also or
alternatively include one or more flats 12f'' formed on an external
surface thereof for use with external devices, such as a rod
stabilizer. A person skilled in the art will appreciate that the
extension member can have various other configurations to
facilitate use with other delivery tools and/or fastening
elements.
[0047] Referring back to FIGS. 1A-1C, as indicated above the
extension member 12 can be removably coupled to the receiver member
16. In an exemplary embodiment, the distal end 12b of the extension
member 12 is integrally formed with the receiver member 16, i.e.,
the extension member 12 and receiver member 16 have a unitary
configuration. A frangible portion 18, best shown in FIG. 1A, can
be formed on the extension member 12 to allow the extension member
12 to be frangibly separated from the receiver member 16. The
frangible portion can be formed at various locations along the
extension member 12, but in an exemplary embodiment the frangible
portion 18 is located adjacent to the distal end 12b of the
extension member 12. The frangible portion 18 can be adapted to
break when a predetermined force is applied thereto thereby
allowing at least a portion of the extension member 12 to be
separated from the receiver member 16. A variety of techniques can
be used to form a frangible portion 18. For example, in one
embodiment shown in FIGS. 1A-1B, the frangible portion 18 can be
formed by a reduced diameter region or thinned region of material
formed between the extension member 12 and the receiver member 16.
Other configurations for the frangible portion 18 can include
webbing, an annular grooved formed in an outer or inner surface of
the extension member 12, or other techniques known in the art. A
variety of materials, including both plastics and metals, can be
used for the frangible portion 18, and the frangible portion 18
need not be made from the same material used for the anchor 14 or
extension member 12. By way of non-limiting example, the anchor 14
can be made from a metallic material, such as stainless steel, and
the frangible portion 18 and extension member 12 can be formed from
a plastic. Such a configuration allows the extension member 12 and
frangible portion 18 to act as insulators during neuromonitoring.
In use, the frangible portion 18 can provide a weak spot in the
extension member 12 to allow the extension member 12 to be
separated from the receiver member 16 when a predetermined force is
applied thereto.
[0048] Several techniques can be used to apply the predetermined
force to the frangible portion 18 of the extension member 12. For
example, a removal tool 20 can be inserted through a lumen 17 of
the percutaneous access device 12 or extension member 12 and it can
be actuated to apply a radially directed force to an inner surface
18c of the extension member 12 to break the extension member 12
away from the spinal anchor 14. A variety of configurations are
available for the removal tool 20. FIG. 2A illustrates one
exemplary removal tool 20 that generally includes an elongate
member 22 having a proximal end 22a that is adapted to remain
outside the body and a distal end 22b that is adapted to be
inserted through the lumen 17 of the extension member 12 and to be
positioned adjacent to the spinal anchor 14. The distal portion 22b
can include an engagement mechanism 24 that is adapted to engage an
inner surface 18c of the extension member 12 and to apply an
outward or radially directed force to the extension member 12
disposed therearound to break at least a portion of the extension
member 12 apart from the spinal anchor 14. The removal tool 20 can
also include a handle 26 disposed on the proximal end 22a of the
elongate member 22. The handle 26 can be used to manipulate the
device, as will be discussed in more detail below.
[0049] The engagement mechanism 24 can have a variety of
configurations, and the size and shape of the engagement mechanism
24 can vary depending on the configuration of the extension member
12. For example, in the embodiment shown in FIGS. 2A-2C, the
engagement mechanism 24 is in the form of a set screw or other
threaded member formed on a distal portion 22b of the elongate
member 22 and adapted to engage the complementary threads formed in
the distal end of the extension portion 12. As shown in FIGS. 2B
and 2C, the engagement mechanism 24 has a proximal threaded portion
24a with an outer diameter that is greater than an outer diameter
of a distal threaded portion 24b. In other words, the thread on the
proximal portion is oversized relative to the thread on the distal
portion. The proximal threaded portion 24a can be sized to engage
threads formed within the extension portion 12, and the distal
threaded portion 24b can be configured to engage threads formed in
the receiver member 16. FIG. 1B illustrates threads 12t formed on
inner surface of the extension member 12 just proximal to the
frangible portion 18, and threads 16t formed on an inner surface of
the receiver member 16 just distal to the frangible portion 18. The
proximal threaded portion 24a on the engagement mechanism 24 can
also have a size that is configured to apply a radially directed
force to the threads 12t on the extension member 12 to break the
frangible portion 18 and thereby separate the extension member 12
from the receiver member 16. This can be achieved using various
techniques. For example, a distal-most portion of the extension
member 12, i.e., the portion located adjacent to or at the
frangible portion 18, can be tapered such that the threaded portion
24a will apply a radially directed force thereto to cause the
frangible portion 18 to break. Alternatively, the threads on the
proximal threaded portion 24a can have an increasing diameter to
cause the proximal threaded portion 24a to apply a radially
directed force to the extension member 12. The distal threaded
portion 24b, on the other hand, can have threads that complement
the threads 16t within the receiver member 16 to allow the two
portions to mate to one another. In use, the distal threaded
portion 24b can thus function as a locking mechanism for locking a
spinal connector, such as a spinal rod, within the receiver member
16.
[0050] The engagement mechanism 24, or a portion thereof, can also
optionally be frangibly mated to the distal end 22b of the elongate
member 22. This will allow the elongate member 22 to be detached
from the engagement mechanism 24, thus allowing the engagement
mechanism 24, or a portion thereof, to remain mated to the receiver
member 16 of the anchor 14. The frangible portion can be formed at
various locations on the removal tool 20. For example, FIG. 2C
illustrates a frangible portion 22f formed within the engagement
mechanism 24 at a location that is between the proximal and distal
threaded portions 24a, 24b. In other embodiments, the proximal and
distal threaded portions 24a, 24b can be frangibly mated to one
another, thus allowing the proximal threaded portion 24a to be
separated from the distal threaded portion 24b and removed from the
body.
[0051] In use, the removal tool 20 can be actuated by inserting the
elongate member 22 through the extension member 12 to position the
engagement mechanism 24 within the distal end 12b of the extension
member 12. The distal threaded portion 24b can pass through the
threads 12t formed within the distal end 12b of the extension
member 12, as they will have a size that is less than a size of the
threads 12t formed within the extension member 12. The tool 20 can
then be rotated with respect to the extension member 12, using, for
example, the handle 26. As the tool 20 is rotated, the proximal
threaded portion 24a will engage the threads 12t formed in the
extension portion while the distal threaded portion 24b engages the
threads 16t formed within the receiver member 16. Continued
rotation will cause the proximal threaded portion 24a to apply a
radially directed force to the extension member 12, thereby
breaking the frangible portion 18 formed between the extension
member 12 and the receiver member 16. The extension member 12 can
thus be removed from the patient's body, leaving the spinal anchor
14 implanted in bone.
[0052] In another embodiment, the engagement mechanism can be in
the form of a cam, wedge, or other inclined surface formed on a
distal portion of an elongate shaft of a removal tool. FIGS. 3A-3C
illustrate a distal end 22b' of an elongate shaft 22' of a removal
tool having an engagement mechanism 24' in the form of a cam having
first and second fins 30a', 30b' disposed on opposed sides of and
extending radially outward from the shaft 22'. Each fin 30a', 30b'
can have a length l that is configured to correspond to a width of
the slots 13a, 13b formed in the arms 12c, 12d of the extension
member 12 to allow the fins 30a', 30b' to be slidably received
therein during insertion of the removal tool through the extension
member 12. Each fin 30a', 30b' can also have height h that
increases radially to form a ramped surface such that the fins
30a', 30b' can apply a radially directed force to the arms 12c, 12d
of the extension member 12. In particular, after the tool is
inserted to position the fins 30a', 30b' within the slots 13a, 13b
and adjacent to the distal end of the extension member 12, as shown
in FIGS. 3A and 3B, the removal tool can be rotated to cause the
fins 30a', 30b' to move in between and into alignment with the arms
12c, 12d of the extension member 12, as shown in FIG. 3C. The
increasing height h of each fin 30a', 30b' will apply a radially
directed force to an inner surface 18c of each arm 12c, 12d,
thereby causing the frangible portion to break thereby separating
the extension member 12 from the receiver member 16 of the spinal
anchor 14.
[0053] In another embodiment, the removal tool shown in FIGS. 3A-3C
can include first and second arm members (not shown) that extend
along the length of the elongate shaft. The fins can be rotated
with respect to the first and second arm members to cause the fins
to move in between and into alignment with the arm members. Similar
to the removal tool described above, the increasing height of each
fin will apply a radially directed force to an inner surface of
each arm member, thereby causing the first and second arm members
to apply a radially directed force to an inner surface of the
extension member. The frangible portion will thus break thereby
separating the extension member from the receiver member of the
spinal anchor.
[0054] In another embodiment, shown in FIG. 4A, the removal tool
20'' can include first and second breaker arms 21a'', 21b'' that
are configured to engage the proximal end of the first and second
arms 12c, 12d of the extension member 12. Various techniques can be
used to engage the arms 12c, 12d, but as shown in FIG. 4A the
breaker arms 21a'', 21b'' each include a U-shaped member for
receiving a proximal end of the arms 12c, 12d on the extension
member 12. Each breaker arm 21a'', 21b'' can also include a handle
23a'', 23b'' formed thereon, and once the breaker arms 21a'', 21b''
are engaged with the arms 12c, 12d on the extension member 12, the
handles 23a'', 23b'' can be rotated in opposite directions to break
the arms 12c, 12d of the extension member 12 away from the receiver
member 16 of the spinal anchor 14. In another embodiment, in order
to facilitate removal of the arms of the extension member, the arms
can have complementary features formed therein that allow the arms
to pass through one another. For example, FIG. 4B illustrates a
distal end of first and second extension arms 11a, 11b having
cut-outs 11c formed therein and offset from one another such that
one arm, e.g., arm 11a, can pass through the other arm, e.g., arm
11b as the arms 11a, 11b are rotated by the breaker arms 21a'',
21b''.
[0055] Exemplary methods for implanting a spinal anchor 14 and
delivering various tools and devices are also provided. In one
exemplary embodiment, the procedure can begin by forming a
minimally invasive percutaneous incision through tissue located
adjacent to a desired implant site. The incision can be a
relatively small incision having a length that is less than a
diameter or width of the device being inserted therethrough, a
spinal anchor and access device. Once the incision is made, a
spinal anchor and access device, such as device 10, can be
delivered to the anchor site. In particular, the anchor 14 can be
inserted through the incision with the extension member 12
frangibly attached thereto and extending through the skin incision
and outside of the patient's body. The bone-engaging member 14b of
the anchor 14 can be driven into bone using a tool, such as a
driver, that is passed through the extension member 12. While not
shown, the extension member 12 can optionally include threads
formed therein for mating with corresponding threads formed on the
driver tool, thus facilitating advancement of the driver through
the extension member 12 to drive the bone-engaging member 14b into
bone. When the spinal anchor 14 is fully implanted, the
bone-engaging member 14b will be fully disposed within bone and the
receiver member 16 will be located adjacent to the bone such that
it is either in contact with the bone or relatively close to the
bone, i.e., 1 mm to 2 mm away from the bone. The extension member
12 will extend from the receiver member 16 and through the skin
incision, thereby providing a pathway that spans through the skin
incision to the anchor 14. Additional spinal anchor and access
devices can be implanted in adjacent vertebrae using the same
technique, or using other techniques known in the art.
[0056] Once the anchor 14 is implanted, the extension member 12 can
be used to deliver various spinal connectors, fasteners, and other
tools and devices to the implant site. For example, a spinal
connector, such as a spinal rod, can be introduced through the
extension member and positioned within the spinal anchor 14, and
optionally within one or more additional spinal anchors implanted
in adjacent vertebrae. FIGS. 5A-5C illustrate one exemplary method
for inserting a spinal rod 40. The rod 40 is introduced through the
extension member 12 in a first orientation, shown in FIG. 5A, in
which the rod 40 is substantially parallel to the longitudinal axis
of the extension member 12. The spinal rod 40 can then be
manipulated to extend at an angle with respect to the first
orientation, such that the rod 40 extends in a direction
substantially transverse to the longitudinal axis L of the
extension member 12, for example, in a direction that is
substantially parallel to the patient's spine, as shown in FIG. 5C.
Since the length of the spinal rod 40 will necessarily be greater
than the inner diameter of the extension member 12, the slots 13a,
13b in the extension member 12 will allow the spinal rod 40 to
pivot and pass therethrough while being transitioned from the first
orientation to the second orientation, as shown in FIG. 5B. A
person skilled in the art will appreciate that the exact position
of the spinal rod 40 with respect to the longitudinal axis L of the
extension member 12 will of course vary depending on the
configuration of the spinal rod 40 or other spinal connector. As
further shown in FIGS. 5A-5C, movement of the spinal rod 40 can be
achieved using a manipulator or driver device 50. The manipulator
device can have a variety of configurations, but it should be
effective to allow controlled movement of the rod 40.
[0057] Once the spinal rod 40 is properly positioned and fully
seated in the receiver member 16, a closure mechanism or fastener
can be inserted through the extension member 12 and applied to lock
the rod 40 in place. A variety of closure mechanisms and tools for
delivering closure mechanisms are known in the art, and they can be
used with the present invention. By way of non-limiting example,
FIG. 6A illustrates a driver tool 60 for delivering a set screw 62
to the spinal anchor 14 to lock the spinal rod 40 within the
receiver member 16 of the spinal anchor 14. As shown, the set screw
62 is coupled to the distal end of the driver tool 60, which is
passed through the inner lumen of the extension member 12. The
illustrated driver tool 60 includes threads 60t formed on the shaft
thereof for mating with corresponding threads (not shown) formed
within the extension member 12. The threaded connection facilitates
distal movement or advancement of the driver tool 60 through the
extension member 12, thereby allowing the set screw 62 to reduce
the rod 50 into the U-shaped recess in the receiver member 16.
Final tightening of the set screw 62 can optionally be accomplished
using a standard torque driver 64 along with a stabilizer 66 to
prevent the receiver member 16 from rotating, as shown in FIG. 6B.
The stabilizer 66 can interface with flats formed on the external
surface of the extension member 12, as previously discussed with
respect to FIG. 1F.
[0058] While not shown, removal tool 20 previously described herein
can optionally be used to deliver the engagement mechanism 24,
which includes a distal threaded portion 24b that functions as a
set screw. Once the engagement mechanism 24 is mated to the
receiver member 16, the elongate member 22, and optionally the
proximal threaded portion 24a of the engagement mechanism 24, can
be frangibly detached from the distal threaded portion 24b to allow
the removal tool 20 to be removed from the extension member 12
while the distal threaded portion 24b remains mated to the receiver
member 16. This step can be repeated for adjacent spinal anchor(s).
A person skilled in the art will appreciate that the spinal
connector does not need to be directly attached to each anchor, and
that it can be indirectly attached to the anchors using, for
example, a band clamp, a slotted offset connector, or other
techniques known in the art.
[0059] Where the removal tool is not configured to simultaneously
deliver a fastening element while breaking the extension member 12
away from the receiver member 16, the extension member 12 can be
detached from the anchor 14 by inserting a removal tool through the
extension member 12 to apply a force to the frangible portion 18
formed between the extension member 12 and the spinal anchor 14.
FIGS. 7A and 7B illustrate one exemplary method for breaking the
extension member 12 away from the receiver member 16 of the spinal
anchor 14 using the cam-type engagement mechanism 24' shown in
FIGS. 3A-3C. As shown in FIGS. 7A and 7B, the removal tool 20' is
passed through the extension member 12 to position the engagement
mechanism (not shown) within the distal end of the extension member
12. The first and second fins on the engagement mechanism can be
passed through the slots 13a, 13b formed in the extension member
12. The tool 20' is then rotated to cause the fins to pass between
the arms 12c, 12d of the extension member 12, thereby applying a
radially directed force to the arms 12c, 12d to break the frangible
portion 18. The extension member 12 can thus be removed from the
patient, leaving the spinal anchor 14 implanted in bone. As further
shown in FIGS. 7A and 7B, a stabilizing tool 76 can optionally be
passed through at least a portion of the extension member 12 for
stabilizing the extension member 12 while the removal tool 20' is
rotated.
[0060] In other embodiments, one or more spinal anchor and access
devices can be implanted in adjacent vertebrae, and the extension
member on each device can be used to perform other procedures, such
as pedicle targeting, anchor alignment, distraction, deformity
correction, etc. For example, the extension member 12 can also be
used to manipulate the receiver member 16 coupled thereto. For
example, the proximal end 12a of the extension member 12 can be
grasped by a user and angularly oriented to thereby move the
receiver member 16 relative to the bone-engaging member 14b. Where
the anchor 14 is a monoaxial bone screw, movement of the extension
member 12 will move the vertebra that the anchor 14 is implanted
in. FIG. 8 illustrates a jig 70 mated to one or more extension
members implanted in adjacent vertebrae. The jig 70 can be used,
for example, to guide a pedicle targeting tool 72 and aid in the
alignment of adjacent anchors. In yet another embodiment, as shown
in FIG. 9, a distractor 80 can be mated to the extension member to
facilitate the distraction of adjacent vertebrae. In another
embodiment, shown in FIG. 10, multiple spinal anchor and access
devices can be implanted in adjacent vertebrae and they can be used
to correct a spinal deformity. For example, as shown in FIG. 10,
the extension member of each device can aid in the placement of an
extra long spinal rod 100, and insertion of the rod 100 through
each extension member can move the extension members to thereby
move the adjacent vertebrae into a desired orientation relative to
one another. Separate instruments can optionally be used to further
distract and/or manipulate the adjacent vertebrae. A person skilled
in the art will appreciate that a variety of other tools and
devices can be mated to and used in conjunction with the extension
member disclosed herein.
[0061] One skilled in the art will appreciate further features and
advantages of the invention based on the above-described
embodiments. Accordingly, the invention is not to be limited by
what has been particularly shown and described, except as indicated
by the appended claims. All publications and references cited
herein are expressly incorporated herein by reference in their
entirety.
* * * * *