U.S. patent application number 16/930229 was filed with the patent office on 2021-01-07 for method and devices for intracorporeal bonding of implants with thermal energy.
The applicant listed for this patent is P Tech, LLC. Invention is credited to Justin E. Beyers, Peter M. Bonutti, Matthew J. Cremens.
Application Number | 20210000515 16/930229 |
Document ID | / |
Family ID | |
Filed Date | 2021-01-07 |
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United States Patent
Application |
20210000515 |
Kind Code |
A1 |
Bonutti; Peter M. ; et
al. |
January 7, 2021 |
Method and Devices for Intracorporeal Bonding of Implants with
Thermal Energy
Abstract
A system for dynamically controlling a weld profile includes a
generator, and end effector, a sensor, and a computer. The
generator is configured to supply energy based on the weld profile.
The end effector operatively connected to the generator and
configured to apply vibratory energy and pressure to an object. The
sensor configured to provide an output with respect to the object.
The computer configured to monitor the output and change the weld
profile of the generator based on the output.
Inventors: |
Bonutti; Peter M.;
(Manalapan, FL) ; Cremens; Matthew J.; (Effingham,
IL) ; Beyers; Justin E.; (Effingham, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
P Tech, LLC |
Effingham |
IL |
US |
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|
Appl. No.: |
16/930229 |
Filed: |
July 15, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15208939 |
Jul 13, 2016 |
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16930229 |
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11671556 |
Feb 6, 2007 |
9421005 |
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15208939 |
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60810080 |
Jun 1, 2006 |
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60784186 |
Mar 21, 2006 |
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60765857 |
Feb 7, 2006 |
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Current U.S.
Class: |
1/1 |
International
Class: |
A61B 17/72 20060101
A61B017/72; A61B 17/70 20060101 A61B017/70; A61B 17/80 20060101
A61B017/80; A61B 17/82 20060101 A61B017/82; G06F 21/10 20060101
G06F021/10; A61B 17/68 20060101 A61B017/68; A61B 17/86 20060101
A61B017/86; A61B 17/88 20060101 A61B017/88; A61F 2/40 20060101
A61F002/40; A61B 17/04 20060101 A61B017/04 |
Claims
1. A system for dynamically controlling a weld profile, the system
comprising: a generator configured to supply energy based on the
weld profile; an end effector operatively connected to the
generator and configured to apply vibratory energy and pressure to
an object; a sensor configured to provide an output with respect to
the object; and a computer configured to monitor the output and
change the weld profile of the generator based on the output.
2. The system of claim 1, wherein the sensor includes a position
sensor configured to change the weld profile of the generator based
on a position of the end effector.
3. The system of claim 1, wherein the sensor includes a force
sensor configured to change the weld profile of the generator based
on a force applied relative to the object.
4. The system of claim 1, wherein a transducer is configured to
provide vibratory energy to the end effector and an electrical
property of the transducer is used to monitor a force applied
relative to the object.
5. The system of claim 1, further comprising a second sensor
configured to measure collapse of the object.
6. The system of claim 1, further comprising a second sensor
including at least one of an optic, laser, or hall-effect
sensor.
7. The system of claim 1, further comprising a mechanical stop
configured to prevent collapse of the object after a predetermined
point.
8. The system of claim 1, wherein the change in the weld profile
includes a change in wave amplitude.
9. The system of claim 1, wherein the weld profile is based on a
preset weld current.
10. The system of claim 1, wherein the weld profile is based on a
preset weld time.
11. A system for dynamically controlling a weld profile, the system
comprising: a generator configured to supply energy based on the
weld profile; an end effector operatively connected to the
generator and configured to apply vibratory energy and pressure to
an object; a position sensor configured to translate a position of
the end effector into an output; and a computer configured to
monitor the output and change the weld profile of the generator
based on the output.
12. The system of claim 11, wherein the output is indicative of an
amount of collapse of the object.
13. The system of claim 11, further comprising a mechanical stop
configured to prevent collapse of the object after a predetermined
point.
14. The system of claim 11, wherein the position sensor includes a
linear variable displacement transducer.
15. The system of claim 11, further comprising a force sensor.
16. The system of claim 11, further comprising a sensor including
at least one of an optic, laser, or hall-effect sensor.
17. The system of claim 11, wherein the change in the weld profile
includes a change in wave amplitude.
18. The system of claim 11, wherein the weld profile is based on a
preset weld current.
19. The system of claim 11, wherein the weld profile is based on a
preset weld time.
20. A system for dynamically controlling a weld profile,
comprising: a generator configured to supply energy based on weld
profile associated with a material type of an object to be welded;
an end effector operatively connected to the generator and
configured to apply vibratory energy and pressure to an object; and
a computer configured to provide a parameter set to the generator
associated with the type of polymer.
21. The system of claim 20, wherein the parameter set includes at
least one of time, power, pressure, frequency, or wavelength.
22. The system of claim 20, further comprising a position
sensor.
23. The system of claim 20, further comprising a force sensor.
24. The system of claim 20, wherein the computer is configured to
change the weld profile of the generator based on a change in
impedance of the generator.
25. The system of claim 20, further comprising a sensor including
at least one of an optic, laser, or hall-effect sensor.
26. The system of claim 20, further comprising a mechanical stop
configured to prevent collapse of the object after a predetermined
point.
27. The system of claim 20, wherein the change in the weld profile
includes a change in wave amplitude.
28. The system of claim 20, wherein the weld profile is based on a
preset weld current.
29. The system of claim 20, wherein the weld profile is based on a
preset weld time.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the following U.S.
Provisional Applications: 60/765,857 filed Feb. 7, 2006; 60/784,186
filed Mar. 21, 2006; and 60/810,080 filed Jun. 1, 2006. This
application also claims pliority to co-pending application U.S.
patent application Ser. No. 11/416,618 filed May 3, 2006. The
entirety of these related applications are incorporated by
reference.
FIELD OF THE INVENTION
[0002] The invention relates to fixation of tissues and implants
within the body, such as the fixation of two different tissue
types, the fixation of an implant to tissue, or the fixation of an
implant to another implant. This may involve using an energy source
to weld biocompatible materials intracorporeally to stabilize
tissue within a patient's body, such as a fractured bone.
BACKGROUND OF THE INVENTION
[0003] Body tissue often requires repair and stabilization
following trauma such as a fractured bone, torn ligament or tendon,
ripped muscle, or the separation of soft tissue from bone. For
example, trauma to the rotator cuff usually results in a portion,
if not all, of the ligament being torn away from bone. To repair
such an injury, the rotator cuff must be repositioned to its
anatomically correct location and secured to the bone.
[0004] One method of repairing a damaged rotator cuff is through
the use of a bone anchor and a suture. A hole is drilled in the
bone near where the rotator cuff will be reattached to the bone.
Then, an instrument is used to place a mattress stitch with a
suture in the detached portion of the rotator cuff. The suture is
slideably positioned through the anchor, and the anchor is placed
in the bone hole using an insertion instrument. This instrument
includes an anvil and mandrel placed in contact with the anchor so
that when the anvil and mandrel are moved in opposite directions
relative to each other, the anchor is deformed. The deformation
locks the anchor within the bone. Thereafter, the suture is
tensioned drawing the rotator cuff toward the anchor. A suture lock
is then activated by the insertion instrument to thereby pinch the
suture between the anchor and suture lock.
[0005] In another example, fractured bones are a common injury seen
in trauma centers. Sports activities, vehicle accidents,
industrial-type incidents, and slip and fall cases are just a few
examples of how bones may become fractured. Surgeons in trauma
centers frequently encounter many different types of fractures with
a variety of different bones. Each bone and each fracture type may
require unique procedures and devices for repairing the bone.
Currently, a one-solution-fixes-all device is not available to
repair fractured bones. Instead, surgeons may use a combination of
bone screws, bone plates, and intramedullary rods.
[0006] Bone plates may be positioned internal to the skin, i.e.
positioned against the fractured bone, or may be positioned
external to the skin with rods connecting the bone and plate.
Conventional bone plates are particularly well-suited to promote
healing of the fracture by compressing the fracture ends together
and drawing the bone into close apposition with other fragments and
the bone plate. However, one drawback with plates and screws is
that with the dynamic loading placed on the plate, loosening of the
screws and loss of stored compression can result.
[0007] To reduce the potential of loosening, locking screws and a
locking bone plate may be used. U.S. Pat. No. 5,085,660 to Lin
discloses a locking plate system. The system has multiple locking
pins, each with one end formed as a screw to lock in the pending
fixation bones or vertebral tubercles, with another end defining
rectangular or similarly shaped locking post having a threaded
locking end. Near the locking post end, there is formed a stopping
protrusion. A plate defines multiple locking bores disposed at one
side to be placed over the locking post end until the plate reaches
the stopping protrusion on the locking pin. The plate defines
multiple threaded screwing bores near the other side to receive
locking pin screw. Multiple locking devices fix the side of the
plate having locking bores to the locking post end or its locking
pins. Multiple screwing pins each have one end formed as a pin to
be used for penetrating the threaded screwing bore to lock into the
bone or the vertebral tubercle. Another end which forms a head is
for holding against the threaded screwing bore of the plate.
Threads are provided near the head for the screwing pins to be
screwed within the threaded screwing bore of the plate.
[0008] An example of an external bone plate system is disclosed in
U.S. Pat. No. 6,171,307 to Orlich. Orlich teaches an apparatus and
procedure for the external unilateral fracture fixation, fracture
compression or enlargement of osseous tissue with a metal or
equivalent material slotted forked stick to hold and position the
threaded pins in its length, inserted in the bone with multiple
fastening slidable screws and their bolts to attach the pins to the
slotted forked stick, a solid slidable cube to hold and position
the slotted forked stick, a supporting axial bar, and an axial
threaded bar. A preferred embodiment includes at least three
slotted forked sticks that hold and fix, with the use of
compression screws and their bolts, threaded pins that penetrate
the proximal and distal fragments of the bone through both
corticals. Another preferred embodiment includes slotted forked
sticks that adapt to the threaded pins, introduced in the bone, at
any degree of inclination or orientation that these pins might have
with respect to the bone.
[0009] In addition to internal or external bone plates, surgeons
sometimes use intramedullary rods to repair long bone fractures,
such as fractures of the femur, radius, ulna, humerus, fibula, and
tibia. The rod or nail is inserted into the medullary canal of the
bone and affixed therein by screws or bolts. After complete healing
of the bone at the fracture site, the rod may be removed through a
hole drilled in the end of the bone. One problem associated with
the use of today's intramedullary rods is that it is often
difficult to treat fractures at the end of the long bone. Fastener
members, such as bolts, are positioned through the cortical bone
and into threaded openings in the rod. However, the number and
positioning of the bolt/screw openings are limited at the tip of
the rod because of the decreased surface area of the rod and the
reduced strength at the tip of the rod. Therefore, fractured bone
sections at the distal end of a femur, for example, may not be
properly fastened to the intramedullary rod.
[0010] Various inventions have been disclosed to repair tissue and
fasten implants to tissue. U.S. Pat. No. 5,120,175 to Arbegast et
al. discloses a fastener having an elongated shank formed of a
shape memory alloy, a head at the upper end of the shank, and an
annular segment at the lower end of said shank having a deformed
cross-sectional shape suitable for insertion into an opening
extending through adjacent workpieces. The annular segment has a
frusto-conical trained shape that is larger than this opening. The
annular segment radially flares from the deformed shape to an
approximation of the trained shape when heated above a critical
transformation temperature, thereby securing the fastener in place
with respect to the workpieces. Alternatively, a sleeve made of a
different material (e.g. aluminum) extending over a portion or the
entire length of the fastener can be added for improved
deformational characteristics, by providing the same frusto-conical
shape through axial contraction of the shank.
[0011] U.S. Pat. No. 5,290,281 to Tschakaloff teaches a surgical
system including a thermoplastic, body absorbable, bodily tissue
fixation plate having a plurality of formations and a plurality of
through-bores arranged in alternating relation along with plate.
The body absorbable fasteners are adapted for insertion into the
through-bores to secure the plate to underlying bodily tissue. The
heating apparatus includes a wand having a heating tip of a
configuration adapted to substantially matingly cooperate with the
formations to facilitate heating and bending of the plate into
conformance with the underlying bodily tissue.
[0012] U.S. Pat. No. 5,941,901 to Egan discloses an expandable soft
tissue fixation assembly for use in anchoring soft tissue to bone.
The assembly includes a tab connected to an anchor, a sleeve
adapted to surround the anchor, and a flange adapted to hold a soft
tissue segment next to a bone. The sleeve is inse lied into a blind
hole in a bone, and a section of soft tissue is placed over the
hole next to the bone. Energy is applied to the flange while a
predetermined axial tension is applied to the tab to compress a
flared portion of the anchor against the sleeve. An upper tube
portion of the anchor and the flange are bonded together, and the
applied axial force on the tab separates it from the anchor,
leaving the assembly anchored in the bone and the soft tissue
section anchored in place between the flange and the bone.
[0013] U.S. Pat. No. 7,018,380 to Cole discloses a femoral
intramedullary rod system. The rod system is capable of treating a
variety of femoral bone fractures using a uniform intramedullary
rod design. The system generally comprises an intramedullary rod
defining an opening having an upper surface and a transverse member
including a bone engaging portion and a connection portion defining
a thru-hole with the nail sized to pass therethrough. A pin is
selectively coupled to the transverse member to rigidly assemble
the transverse member to the nail when the nail is passed through
the thruhole and the pin is received within the opening. In an
alternative design, an epiphyseal stabilizer is joined to the nail
by a locking member.
[0014] Also, U.S. Pat. No. 6,228,086 to Wahl et al. discloses a
modular intramedullary nail. The intramedullary nail apparatus
comprises a nail having a proximal portion, a middle portion and a
distal portion. The proximal portion has a longitudinal slot
adapted to receive at least one fixing element and the distal
portion has at least one transverse bore. The proximal portion has
a longitudinal axial bore. The apparatus further includes a set of
inserts, each of which is adapted to be inserted in the
longitudinal bore. Each insert has at least one guiding bore, the
orientation and position of which is different for each of the
inserts.
[0015] Another assembly and method to fasten tissue is disclosed in
U.S. Pat. 6,056,751 to Fenton et al. Fenton teaches a soft tissue
fixation assembly comprising an anchor element which is installed
in a bone or other tissue, and a joiner element which mates with
the anchor element to define a tissue capture region between them.
A section of soil tissue is held within the tissue capture region,
and energy is transmitted into the joiner element to cause relative
vibratory motion between the respective components and localized
melting of the contacting portions of the respective components to
establish a welded joint. The soft tissue segment is thus fixed to
the bone without sutures or other fasteners.
[0016] U.S. Pat. No. 6,080,161 to Eaves, III et al. teaches a
fastener for securing an osteosynthesis plate to a plurality of
bone segments is provided. The fastener in the form of a fastener
blank includes an elongated shank adapted for insertion through an
opening in the plate and into a hole formed in the bone. The upper
end of the shank forms a head that serves to secure the plate to
the bone. The elongated shank is constructed of a material which
when heated will deform to form a tight fit within the hole drilled
in the bone. The fastener is preferably made of a resorbable
material. The invention also provides a method for securing a plate
to a bone using the fasteners of the invention. A fastener blank is
positioned into the hole so that a portion of the blank extends
into the hole provided in the bone and another portion overlies the
plate. The blank is heated to raise the temperature of the blank
above the transition temperature of the material from which it is
made and deform the blank into a tight fit within the hole.
[0017] U.S. Pat. No. 6,605,090 to Trieu et al. discloses orthopedic
implants and methods of treating bone defects. More specifically,
but not exclusively, the present invention is directed to
non-metallic implants and to methods for intra-operative assembly
and fixation of orthopedic implants to facilitate medical
treatment. The non-metallic implant assembly can be secured to
underlying tissue by a fastener, such as a bone screw, that is
capable of swelling on contact with fluid in the underlying tissue.
Alternatively, the non-metallic implant assembly can be assembled
intra-operatively using a fastener that is adhesively bonded to a
bone plate or the bone plate can be deformed using heat, force or
solvents to inhibit withdrawal of the fastener. In preferred
embodiments, both the fastener and the bone plate are formed of
biodegradable material.
[0018] Also, U.S. Patent Publication No. 2004/0030341 to
Aeschlimann et al. teaches implants at least partially consist of a
material that can be liquefied by means of mechanical energy.
Particularly suitable materials of this type are thermoplastics
(e.g. resorbable thermoplastics) or thixotropic materials. The
implants are brought into contact with the tissue part, are
subjected to the action of ultrasonic energy and are simultaneously
pressed against the tissue part. The liquefiable material then
liquefies and is pressed into openings or surface asperities of the
tissue part so that, once solidified, it is positively joined
thereto. The implantation involves the use of an implantation
device comprising a generator, an oscillating clement and a
resonator, whereby the generator causes the oscillating element to
mechanically oscillate, and the element transmits the oscillations
to the resonator. The resonator is used to press the implant
against the tissue part whereby causing oscillations to be
trmlsmitted to the implant. The implants are, for example,
pin-shaped or dowel-shaped and are used in lieu of screws for
forming connections with bone tissue, whereby the bone tissue is
optionally pre-bored for positioning the implant. By viliue of the
fact that it is unnecessary to transmit any torsional forces to the
implants, these implants can be provided with a design that is
weaker, i.e. slimmer than that of known screws made of the same
material, and they can be implanted more quickly.
[0019] Existing systems and techniques for repairing tissue, like
the ones previously described, can be complex, time consuming, lack
the characteristic of being employed with precision, be damaging to
tissue, and/or fail to provide a robust fixation of tissue.
Therefore, there is a need for an apparatus and method for the
fixation of tissue that involves reduced technical ability, fewer
medical instruments, less time to complete, greater strength and
precision, and preservation of living tissue. There is a need for a
system that involves the precise application of energy to
thermoplastic material to affix tissue and implants within the
body.
SUMMARY OF THE INVENTION
[0020] The present invention provides devices and methods for the
fixation of tissue or implants during a surgical procedure. The
system includes devices and methods for intracorporeal bonding of
thermoplastic material. An energy source welds the thermoplastics
to polymers, metals, ceramics composites, and tissue. The energy
source may be resistive heating, radiofrequency, ultrasound
(vibratory), microwave, laser, electromagnetic, electro shockwave
therapy, plasma energy (hot or cold), and other suitable
sources.
[0021] In one embodiment of the invention, a fixation device
includes a tissue-piercing cap positionable in the anchor. Hard and
soil tissue may be fastened so that tissue-function may be at least
partially restored and the operation region may be stabilized for
enhanced healing. This could be ligament repair, tendon repair,
muscle repair, bone repair, cartilage repair, and repair of any
other tissue type. Ligaments may be fastened to ligaments;
ligaments to bones; bones to bones; ligaments to muscles; muscles
to muscles; tissue grafts to bone; tissue grafts to ligaments;
grafts to grafts; and any other combination of tissue and
implants.
[0022] Another embodiment of the invention is directed to a trauma
welding system that helps stabilize tissue or implants. In some
embodiments, the system may include devices and methods for
intracorporeal bonding of thermoplastic material. An energy source
welds the thermoplastics to polymers, metals, ceramics, composites,
and tissue. The energy source may be resistive heating,
radiofrequency, ultrasound (vibratory), microwave, laser,
electromagnetic, electro shockwave therapy, plasma energy (hot or
cold), and other suitable sources. The energy source also may
enable at least part of the implanted material to be foamed.
[0023] Several embodiments of the invention involve a trauma
welding system that utilizes material that can be welded within the
human body. This material has requires the characteristic of
becoming soft and tacky with the application of energy. The energy
and techniques used to weld the material within the body are
preferably selected to avoid or minimize the likelihood of tissue
necrosis. Such material may include polymers and some ceramics,
composites, and metals. The present invention contemplates the use
of any of these materials; however, based on testing, it is
believed that polymeric material, such as PEEK and PLLA, are
preferred weldable materials. PEEK and PLLA are advantageous
because of their desirable characteristics of being softened,
reheated, molded and remolded. These characteristics are believed
to exist even with the use of ultrasonic energy as the energy
source to weld the material. The use of solder and ultrasonic
energy are preferred when welding electrical or electronic wires
and components intracorporeally.
[0024] In accordance with one aspect of the present invention,
there is provided a method for stabilizing a fractured bone. The
method includes the steps of positioning an elongate rod in the
medullary canal of the fractured bone and forming a passageway
through the cortex of the bone. The passageway extends from the
exterior surface of the bone to the medullary canal of the bone.
The method also includes creating a bonding region on the elongate
rod where the bonding region is generally aligned with the
passageway of the cortex, positioning a fastener in the passageway
of the cortex and on the bonding region of the elongate rod, and
thermally bonding the fastener to the bonding region of the
elongate rod while the fastener is positioned in the passageway of
the cortex.
[0025] In accordance with another aspect of the present invention,
another method for stabilizing a fractured bone includes
positioning an elongate plate on the exterior surface of a
fractured bone, forming a passageway extending through the elongate
plate and into the bone, positioning a fastener in the passageway,
and thermally bonding the fastener to the bone while the fastener
is positioned in the passageway.
[0026] Yet another embodiment of the invention involves stabilizing
a fractured bone by positioning an elongate rod in the medullary
canal of the fractured bone and positioning an elongate plate on
the exterior surface of the bone such that the cortex of the bone
is positioned between the elongate rod and plate. This method may
also include forming a passageway through the elongate plate and
the cortex of the bone. The passageway extends from the exterior
surface of the elongate plate to the medullary canal of the bone.
The method may further include creating a bonding region on the
elongate rod where the bonding region is generally aligned with the
passageway, positioning a fastener in the passageway and on the
bonding region of the elongate rod, and thermally bonding the
fastener to the bonding region of the elongate rod while the
fastener is positioned in the passageway.
[0027] The elongate rod, elongate plate, and fastener may include
thermoplastic material such as PEEK. Ultrasonic energy may be used
to thermally bond fasteners to the bonding region of the elongate
rod and/or elongate plate. The bonding region may be a roughened
surface, an indentation, a channel (blind hole), or a thru-hole in
the plate/rod.
[0028] When bonding the fastener to the plate/rod, the fastener may
also be thermally welded to one or more cortex areas (cortical bone
portions) of the bone whereby the fastener resists movement between
the bone and plate/rod. Also, the fastener and implants such as
bone plates and IM rods may be thermally contoured to conform to an
adjacent surface or configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] A more complete understanding of the present invention, and
the attendant advantages and features thereof, will be more readily
understood by reference to the following detailed description when
considered in conjunction with the accompanying drawings
wherein:
[0030] FIG. 1 is a perspective view of an exemplary ultrasound
welding device;
[0031] FIGS. 2A and 2B illustrate exemplary cartridge heaters of
the present invention;
[0032] FIGS. 3A-3K show exemplary embodiments of a welding
horn;
[0033] FIGS. 4A-4C illustrate a three-function welding horn;
[0034] FIG. 5 shows the input parameters of a welding control
unit;
[0035] FIG. 6 illustrates a manual welding control box;
[0036] FIG. 7 shows a control box having pre-set welding
parameters;
[0037] FIG. 8A illustrates an automatic welding control unit;
[0038] FIG. 8B is a photograph of an ultrasonic welding control
unit;
[0039] FIG. 8C is a graph showing a welding profile having varying
wattage;
[0040] FIG. 9 is a flowchart showing the steps for adjusting the
welding device;
[0041] FIG. 10 is a diagram showing an electrical circuit for
checking the welding device;
[0042] FIGS. 11A and 11B illustrate a physical positive feedback
device;
[0043] FIGS. 12A-12F show various embodiments of thermoplastic
fasteners;
[0044] FIGS. 13A and 13B illustrate bonding regions of
implants;
[0045] FIGS. 14A-14D show more embodiments of thermoplastic
fasteners;
[0046] FIGS. 15A and 15B illustrate notched plates and rods for
stabilizing bones;
[0047] FIGS. 16A and 16B show a wedge-shaped expandable
thermoplastic fastener;
[0048] FIGS. 17A and 17B illustrate a bulge-shaped expandable
fastener;
[0049] FIGS. 18A and 18B show a mesh expandable fastener;
[0050] FIGS. 19A and 19B illustrate a tube-shaped expandable
fastener;
[0051] FIGS. 20A-20E show triangulation fasteners;
[0052] FIG. 21 is a welding horn for a triangulation fastener;
[0053] FIGS. 22A and 22B illustrate a thermoplastic implant removal
device;
[0054] FIGS. 23A-23D show the repair of a fractured bone with a
thermoplastic rod;
[0055] FIGS. 24A and 24B illustrate the repair of a fractured head
of a bone;
[0056] FIGS. 25A and 25B show the repair of a fractured bone with a
thermoplastic plate;
[0057] FIGS. 26A and 26B illustrate the repair of a.fractured bone
with a combination of a thermoplastic rod and plate;
[0058] FIGS. 27A -27C show a bone plate of the present
invention;
[0059] FIGS. 28A-28D illustrate exemplary fasteners for use with a
bone plate or other implant;
[0060] FIG. 29 shows modular assembly of a spinal implant;
[0061] FIG. 30 illustrates sequential welding of an intramedullary
rod;
[0062] FIGS. 31A and 31B show the stabilization of the spine using
thermoplastic implants;
[0063] FIG. 32 illustrates an exemplary embodiment of a pedicle
implant;
[0064] FIG. 33 shows stabilization of the spinal column with
thermoplastic implants;
[0065] FIGS. 34A and 34B illustrate a pedicle fastener
apparatus;
[0066] FIGS. 35A and 35B show a thermoplastic bone fixation
assembly;
[0067] FIGS. 36A and 36B illustrate a thermoplastic suture
tensioning device;
[0068] FIG. 37 shows the tensioning device of FIGS. 36A and 36B in
use to stabilize the spine;
[0069] FIGS. 38A, 38B, and 38C each illustrates a thermoplastic
glenoid repair component;
[0070] FIG. 39 shows a thermoplastic cross pin;
[0071] FIG. 40 illustrates a jig device for use with the cross pin
of FIG. 39;
[0072] FIG. 41 shows cauterization of tissue using ultrasonic
energy;
[0073] FIG. 42 illustrates cauterization of tissue using energy and
gelatin;
[0074] FIG. 43 shows the repair of tissue with a periosteal
flap;
[0075] FIGS. 44A and 44B illustrate a method of bonding a
thermoplastic fastener in bone.
[0076] FIG. 45 illustrates a perspective view of one embodiment of
a fixation device of the present invention;
[0077] FIG. 46 illustrates an exemplary process for ultrasonic
welding;
[0078] FIG. 47A shows a side view of the fixation device of FIG. 45
with a cap positioned in the anchor and an energy source deposited
within the cap and anchor;
[0079] FIG. 47B is a cross-sectional view of FIG. 47A;
[0080] FIG. 48 illustrates the fixation device of FIG. 45 with a
pusher means positioned against the cap;
[0081] FIG. 49 shows the fixation device of FIG. 45 employed to
fasten tissue;
[0082] FIG. 50 is a cross-sectional view of another embodiment of a
fixation device being free of a mechanical locking means;
[0083] FIG. 51 shows yet another embodiment of a fixation device
having a threaded cap;
[0084] FIG. 52 illustrates a further embodiment of a fixation
device having a plurality of post ribs:
[0085] FIG. 53 is a cross-sectional view of another embodiment of a
fixation device having an expandable anchor with radially extending
projections;
[0086] FIG. 54 illustrates the fixation device of FIG. 53 in an
expanded configuration;
[0087] FIG. 55 shows yet another embodiment of a fixation device
having an expandable anchor with a substantially smooth exterior,
tissue-contacting surface;
[0088] FIG. 56 illustrates the fixation device of FIG. 55 in an
expanded configuration;
[0089] FIG. 57A-D are perspective views illustrating the steps of
deploying the fixation device of the present invention;
[0090] FIG. 58 illustrates a use of a fixation device to stabilize
a fractured bone;
[0091] FIG. 59 shows another embodiment of a fixation device having
a suture positioned therethrough:
[0092] FIG. 60 is a perspective view illustrating an embodiment of
the fixation device having an integrated suture therein;
[0093] FIG. 61 shows yet another embodiment having a suture
positioned in a channel and groove of the anchor;
[0094] FIG. 62 illustrates a different embodiment of the fixation
device in which the anchor has a post and the cap has a post
bore;
[0095] FIGS. 63A and 63B show a fixation device having a plurality
of caps connectable to a plurality of anchor posts;
[0096] FIGS. 64A and 64B illustrate an embodiment having an anchor
with a plurality of bores in which a plurality of cap posts is
positionable;
[0097] FIGS. 65A and 65B are perspective views of another
embodiment of a fixation device having an anchor with friction ribs
and slots;
[0098] FIG. 66 shows a fixation device having an anchor with a
substantially smooth outer surface and a plurality of slots
disposed in the anchor wall;
[0099] FIG. 67 is a perspective view of a triangulation fixation
device;
[0100] FIG. 68 is a side view of the triangulation device of FIG.
67;
[0101] FIG. 69 is a perspective view of another embodiment of a
triangulation fixation device;
[0102] FIG. 70 is a side view of the triangulation device of FIG.
69;
[0103] FIG. 71 is another exemplary embodiment of a fixation device
having helical threads and a retaining ring disposed on the cap
post;
[0104] FIG. 72 is a perspective view of a further embodiment of a
fixation device having an anchor post and a tissue piercing
pin;
[0105] FIG. 73 illustrates the device of FIG. 72 in use
[0106] FIGS. 74A and 74B show an exemplary fastener having four
biasing prongs;
[0107] FIGS. 75A and 75B illustrate a fastener having lockable
barbs;
[0108] FIGS. 76A and 76B show an exemplary fastener having two
biasing prongs;
[0109] FIGS. 77A and 77B illustrate a fastener having slideable
hooks;
[0110] FIGS. 78A and 78B show an exemplary fastener having folding
arms;
[0111] FIGS. 79A and 79B illustrate a fastener having biasing
prongs and a tapered cap;
[0112] FIGS. 80A and 80B show an exemplary fastener having biasing
prongs and a macrotexture welding region;
[0113] FIG. 81 is a cross sectional view of a fastener with a
metallic core;
[0114] FIG. 82 is a cross sectional view of a fastener with a
composite/polymer core;
[0115] FIGS. 83A and 83B show a balloon fastener of the present
invention;
[0116] FIGS. 84A and 84B illustrate a living hinge fastener;
[0117] FIGS. 85A and 85B show a dual living hinge fastener;
[0118] FIGS. 86A and 86B illustrate a dual living hinge fastener
with a retaining sheath;
[0119] FIG. 87 is photograph of a thermoplastic fastener positioned
in bone;
[0120] FIG. 88 is a photograph of a biasing prong fastener disposed
in bone;
[0121] FIG. 89 is a photograph showing thermoplastic fasteners
welded into simulated bone;
[0122] FIG. 90 is a photograph of metallic core fasteners disposed
in a thermoplastic rod;
[0123] FIG. 91 is an x-ray image of the fasteners and rods of FIG.
90;
[0124] FIGS. 92A and 92B are photographs of thermoplastic fasteners
disposed in bone;
[0125] FIG. 93 shows a thermoplastic mesh sheet of the present
invention;
[0126] FIG. 94 illustrates a helically wrapped mesh sheet;
[0127] FIG. 95 shows a thermoplastic mesh cylinder;
[0128] FIG. 96 illustrates a thermoplastic mesh cylinder thermally
shaped into a curved mesh tube;
[0129] FIG. 97 shows a mesh cylinder positioned about an aneurysm
of a vessel;
[0130] FIG. 98 illustrates a mesh cylinder disposed around an
anastomosis surgery area;
[0131] FIG. 99 shows an ultrasonic generator control unit and a
handpiece positioned adjacent tissue;
[0132] FIG. 100 illustrates modular implants for revision
surgery;
[0133] FIG. 101A shows a thermally welded layered implant;
[0134] FIG. 101B illustrates a plyweld having metallic components
welded together with thermoplastics;
[0135] FIG. 101C shows a plyweld having polymeric components welded
together with thermoplastics;
[0136] FIG. 101D illustrates a plyweld having various components
welded together;
[0137] FIGS. 102A-102D illustrate various microtextures for use
with welding;
[0138] FIGS. 103A-103F show various macrotextures for use during
welding;
[0139] FIG. 104 illustrates a tibial tray component of the present
invention;
[0140] FIG. 105 shows a tibia implant secured with thermoplastic
fasteners;
[0141] FIG. 106 illustrates the repair of the proximal end of the
tibia;
[0142] FIG. 107 shows bone filler components and a tibia implant
secured to bone;
[0143] FIG. 108 illustrates a bone filler component and an
acetabular implant fastened to bone;
[0144] FIGS. 109A and 109B show impact fracture repair using
thermoplastic and metallic components and ultrasonic energy;
[0145] FIGS. 110A and 110B illustrate an acetabular implant of the
present invention;
[0146] FIGS. 111A and 111B show implantation and repair of
electrical components intracorporeally;
[0147] FIGS. 112A and 112B illustrate modular metallic stents;
[0148] FIGS. 113A and 113B show modular bifurcated metallic
stents;
[0149] FIG. 114 illustrates welded bone filler and an implant;
[0150] FIGS. 115A and 115B show a thermally bonded suture knot;
[0151] FIG. 116 illustrates a shrinkable suture;
[0152] FIGS. 117A and 117B show thermally sealed implantable
sacs;
[0153] FIGS. 118A and 118B illustrate tissue bonded with
thermoplastic material;
[0154] FIGS. 119A and 119B show a composite fastener of the present
invention;
[0155] FIG. 120 illustrates an exemplary thermoplastic fastener
used for testing weld parameters;
[0156] FIG. 121 is a photograph showing the apparatus used for
determining the fail strength of thermoplastics;
[0157] FIG. 122 is a photograph of thermoplastic fastener of the
present invention:
[0158] FIG. 123 is a photograph of neoprene (used as a tissue
model) held by the fastener of FIG. 122;
[0159] FIG. 124 is a photograph of another fastener of the present
invention;
[0160] FIG. 125 is a photograph of neoprene held by the fastener of
FIG. 124;
[0161] FIG. 126 is a photograph of a test specimen with PEEK
fasteners welded therein;
[0162] FIG. 127 is a photograph showing a PEEK fastener extending
through a test specimen;
[0163] FIG. 128 is a photograph of a PEEK fastener welded into a
blind hole;
[0164] FIG. 129 is a photograph showing a PEEK bone plate and PEEK
fasteners used to repair a fractured bone test specimen;
[0165] FIG. 130 is a side view photograph of FIG. 129;
[0166] FIG. 131 is a photograph of a PEEK anchor which is
mechanically locked and thermally locked into a test specimen;
[0167] FIG. 132 is a photograph showing various PEEK fasteners and
stabilization plates;
[0168] FIG. 133 is a photograph of a carbon reinforced PEEK
specimen and fasteners;
[0169] FIG. 134 is a partial close-up photograph of FIG. 133;
[0170] FIG. 135 is a perspective view of an exemplary fastener and
anchor;
[0171] FIG. 136 is a perspective view of an apparatus used during
thermoplastic weld testing;
[0172] FIG. 137 is a table showing test results for PEEK ultrasonic
weld samples;
[0173] FIG. 138 is a table showing test results for Acrylic heat
stake samples;
[0174] FIG. 139 is a perspective view of an exemplary ultrasound
welding device;
[0175] FIG. 140 is perspective view of a fastener and an end
effector of the device of FIG. 139;
[0176] FIG. 141 is a perspective view of the fastener disposed
against the end effector of FIG. 140
[0177] FIG. 142 is a perspective view showing an energy source horn
in contact with a thermoplastic fastener which is disposed in a
tissue anchor;
[0178] FIGS. 143A and 143B illustrate an exemplary cartridge heater
of the present invention;
[0179] FIGS. 144A-144K show exemplary embodiments of a welding
horn;
[0180] FIGS. 145A and 145B show a thermoplastic anchor welded in
tissue;
[0181] FIG. 146 illustrates the repair of a fractured bone with
thermoplastics and energy;
[0182] FIG. 147 shows a thermoplastic fastener and anchor used to
repair a fracture in a bone;
[0183] FIG. 148 illustrates a triangulation device used to repair a
fractured bone;
[0184] FIG. 149 shows multiple thermoplastic fasteners and an
anchor used to fix a broken bone;
[0185] FIGS. 150A and 150B illustrate the welding of a
thermoplastic component to a non-thermoplastic component;
[0186] FIGS. 151A and 151B show a thermoplastic component welded
into a cavity of a non-thermoplastic component;
[0187] FIG. 152 shows dynamic spinal stabilization using
thermoplastics and cables;
[0188] FIG. 153 illustrates thermal welding of a disc replacement
component;
[0189] FIG. 154 shows rigid and one-plane stabilization of the
spine;
[0190] FIG. 155 is a perspective view of a vertebral body
replacement implant that may be assembled using thermal
bonding;
[0191] FIGS. 156A-1 56F illustrate various embodiments of
thermoplastic fasteners;
[0192] FIG. 157 shows knee repair and stabilization using the
surgical welding system of the present invention;
[0193] FIG. 158 is a perspective view of a total knee replacement
implant having thermoplastic stabilizers welded thereon;
[0194] FIG. 159 illustrates implant tethering using
thermoplastics;
[0195] FIGS. 160A-160C show various embodiments of heat shrinkable
implant pouches;
[0196] FIG. 161 illustrates thermal bonding of acetabulum
implants;
[0197] FIG. 162 shows thermoplastic material functioning as a
bearing surface;
[0198] and
[0199] FIG. 163 illustrates thermoplastic material used to bond
bearing surface material in a hip replacement implant.
DETAILED DESCRIPTION OF THE INVENTION
[0200] As indicated above, the invention relates to devices and
methods that help stabilize tissue or implanted materials in a
patient's body. As will be explained in greater detail below, the
invention can be utilized in several ways to achieve different
desired results, including the fixation of two different tissue
types, the fixation of an implant to tissue, or the fixation of an
implant to another implant.
[0201] The methods and devices disclosed herein may be used in
conjunction with any surgical procedure of the body. The fastening
and repair of tissue or an implant may be performed in connection
with surgery of a joint, bone, muscle, ligament, tendon, cartilage,
capsule, organ, skin, nerve, vessel, or other body parts. For
example, tissue may be repaired during intervertebral disc surgery,
knee surgery, hip surgery, organ transplant surgery, bariatric
surgery, spinal surgery, anterior cruciate ligament (ACL) surgery,
tendon-ligament surgery, rotator cuff surgery, capsule repair
surgery, fractured bone surgery, pelvic fracture surgery, avulsion
fragment surgery, shoulder surgery, hernia repair surgery, and
surgery of an intrasubstance ligament tear, annulus fibrosis,
fascia lata, flexor tendons, etc.
[0202] Also, an implant may be inserted within the body and
fastened to tissue with the present invention. Such implant
insertion procedures include, but are not limited to, partial or
total knee replacement surgery, hip replacement surgery, shoulder
replacement surgery, bone fixation surgery, etc. The implant may be
an organ, partial organ grafts, tissue graft material (autogenic,
allogenic, xenogenic, or synthetic), collagen, a malleable implant
like a sponge, mesh, bag/sac/pouch, collagen, or gelatin, or a
rigid implant made of metal, polymer, composite, or ceramic. Other
implants include breast implants, biodegradable plates, porcine or
bovine patches, metallic fasteners, compliant bearing for medial
compartment of the knee, nucleus pulposus prosthetic, stent, tissue
graft, tissue scaffold, biodegradable collagen scaffold, and
polymeric or other biocompatible scaffold. The scaffold may include
fetal cells, stem cells, embryonic cells, enzymes, and
proteins.
[0203] Thus, the invention may be utilized as a trauma welding
system for the stabilization of damaged tissue, such as fractured
bones. In this application, the system may include devices and
methods for intracorporeal bonding of thermoplastic material. An
energy source can be used to weld the material in place. The energy
source may be resistive heating, radiofrequency, ultrasound
(vibratory), microwave, laser, electromagnetic, electro shockwave
therapy, plasma energy (hot or cold), and other suitable sources.
Likewise, the energy source may enable a portion of material to be
foamed or expanded such that two components of the welding system
are secured together. Other energy sources, surgical procedures,
and medical instruments which may be used with the present
invention are disclosed in U.S. Provisional Patent Applications
Nos. 60/765,857 filed Feb. 7, 2006; 60/784,186 filed Mar. 21, 2006;
and 60/810,080 filed Jun. 1, 2006, as well as U.S. patent
application Ser. No. 11/416,618 filed May 3, 2006. The contents of
these documents are incorporated by reference herein in their
entirety.
[0204] The trauma welding system and other embodiments of the
present invention contemplates the use of any biocompatible
material weldable within the human body. The materials used may
include, but are not limited to, degradable, biodegradable,
bioerodible, bioabsorbable, mechanically expandable, hydrophilic,
bendable, deformable, malleable, riveting, threaded, toggling,
barded, bubbled, laminated, coated, blocking, pneumatic, one-piece,
multi-component, solid, hollow, polygon-shaped, pointed,
self-introducing, and combinations thereof. Also, the devices may
include, but are not limited to, metallic material, polymeric
material, ceramic material, composite material, body tissue,
synthetic tissue, hydrophilic material, expandable material,
compressible material, heat bondable material, and combinations
thereof.
[0205] Preferably, this material can become gel-like, tacky, or
soft with the application of energy. The energy source and the
technique used to weld the material within the body can be selected
to minimize or avoid damage to surrounding body tissue. Exemplary
materials that may be used may include polymers, ceramics,
composites, and metals, although other materials may also be
suitable for use with the invention. While the present invention
contemplates the use of any of these materials in any of the
following embodiments, polymeric material is used in the following
examples and description simply to illustrate how the invention may
be used.
[0206] Generally, there are two types of polymers: thermoset and
thermoplastic. Thermoplastics may be used with the present
invention because they can be softened, reheated, molded and
remolded. Thermoplastics are generally classified as either
amorphous or semi crystalline. Some semi crystalline polymers have
some amorphous structure while other semi crystalline polymers may
be more crystalline than others. Examples of amorphous polymers are
poly carbonate (LEXAN), polystyrene, polysulfone (ULDALL), and
acrylics polycarbonate (ABS and styrenes). Examples of semi
crystalline polymers include acetyl (DELRIN), nylon, polyester,
polyethylene, polyether ether ketone, poly propylene,
polyvinylchloride (PVC), and Caprolactam. Biodegradable semi
crystalline polymers may include polylactic acid and polyglycolic
acid. Copolymers of PGA and PLA may also be used. These copolymers
may ultrasonically bond better than pure PGA and PLA. Other
polymers which may be used with the present invention, either as a
thermoplastic or non-thermoplastic, are polyethylene glycol
(PEG)-copolymers and D,L-lactide-co-glycolide polyesters.
[0207] Some semi crystalline materials have an amorphous structure
or an amorphous region within them. These materials are
particularly suitable for surgical welding, especially ultrasonic
welding. Examples of such materials include PEEK and PEAK. With
these special semi crystalline materials, the amorphous content of
the polymer makes the material more conducive to ultrasonic
welding, and therefore a better bond is achieved. Also, a lower
amount of energy is needed to bond these materials.
[0208] The semi crystalline materials without an amorphous
structure or region have a rigid or fixed melting point. A high
level of energy it required to breakdown the crystalline structure
before the melting occurs. Once the melting starts, the material
very rapidly moves through the transition area from a solid to a
flowable substance, i.e. a liquid. Also, the molecular structure of
semi crystalline materials absorbs vibrational energy making it
more difficult to transmit the vibrational energy from an
energy-producing instrument to the interface of the parts being
welded. For example, polylactic acid reaches its melting point and
goes through its transition region rapidly which causes it to flow
in the tissue. This rapid heating and complete, or nearly complete,
melting of the material weakens the overall structure and causes
tissue necrosis. When this material is used in surgical screws,
plates, rods, etc., care must be taken to avoid over melting and
weakening of the implant. The temperature, time, and pressure must
be closely monitored and controlled with semi crystalline materials
or the implant will fail.
[0209] The polymers used in the present invention, such as PEEK and
PLLA , have randomly arranged molecules allowing vibrational energy
to pass through the material with little attenuation. As such, the
material requires relatively little ultrasonic energy to make the
material soften and become tacky. This small amount of energy or
heat needed to bond PEEK and PLLA helps avoid or minimize the
likelihood of tissue necrosis. The transition period is longer in
duration and therefore, when applying energy, the material
gradually softens, passing from a rigid state through a transition
state to a rubbery state and then to a flowable gel-like state. The
amorphous features of these materials make them ultrasonically
weldable with lower temperature and better welding points. To bond
these materials, the true melting point does not need to be reached
or exceeded, so there is less risk to surrounding body tissue. PEEK
and PLLA are also useful with the welding system of the present
invention because it has a modulus of elasticity very close to
bone. Also, some grades of PEEK and PLLA have a hydrophilic
component which permits hydrophilic interlocking when placed in the
body.
[0210] The temperature, time, pressure, and other parameters of the
welding process may be closely monitored and controlled to achieve
an effective weld. Also, because the material does not
substantially melt (only the welding region softens and becomes
tacky) the holding strength of the thermoplastic during and after
welding is not jeopardized. That is, a fastener made of a
thermoplastic which melts, like those in the prior art, cannot
maintain a compressive force against a component or implant during
the welding process. This is because the material of the fastener
becomes liquefied, and a fastener in liquid form cannot maintain a
compressive or tension force. The present invention contemplates
implants made of PEEK or PLLA which bond by softening or making
tacky the polymer material at the bonding region. The remaining
PEEK or PLLA material does not flow and therefore retains its
ability to maintain a compression or tension force.
[0211] When bonding two thermoplastic components together, it is
optimal that the components be chemically compatible to create a
molecular bond. Similar thermoplastics may be compatible if their
melt temperature is within about 6 degrees Celsius or if they have
similar molecular structures. Generally, amorphous polymers may be
welded to each other. In the present invention, PEEK may be bonded
to PEEK. Biodegradable polymers may be bonded to biodegradable
polymers. Biostable polymers may be bonded to biostable polymers.
Biodegradable polymers may be bonded to biostable polymers.
[0212] When two dissimilar materials need to be bonded together,
the welding may be performed outside the body, such as during the
manufacturing process or within the operating room. This is done to
avoid damage to surrounding tissue caused by the heat required to
weld the dissimilar materials to each other. Then, once implanted,
further welding may be done within the body to bond like
thermoplastics creating the desired implant configuration. For
example, a spacer made of PEEK may be bonded to a metallic implant
outside the body. The spacer and implant may be placed in the body,
and the PEEK may be welded with another PEEK element inside the
body so that there is a PEEK to PEEK bond. The metal implant may be
the load bearing surface or the bearing point, while the PEEK to
PEEK weld provides for the fastening and stabilization of the
implant.
[0213] There are several factors that effect welding of
thermoplastic materials. One is hydroscopicity, the tendency of a
material to absorb moisture. If too much fluid gets between the
welded parts it can decrease the bond or create a foam which
prevents proper bonding of the materials. Therefore, the welding of
thermoplastics may be performed under vacuum/suction, or a hermetic
seal may be placed around the thermoplastic during the welding
process. Also, the welding may be performed using a cannula which
prevents fluid from entering the welding area. Furthermore,
pressure, such as air pressure or compression force may be applied
during welding to prevent entry of moisture or liquid.
[0214] In addition to or in place of reducing moisture from the
welding area, certain agents can be used to aid in the bonding
process. Such agents may include filler material, glass filler,
glass fiber, talc, and carbon. The agents may be placed at the bond
site as a temporary welding enhancement means or may be a permanent
agent to enhance the bonding. For example, the agent may be placed
within the bonding region of PEEK or PLLA. The agent may be left in
place to bond or could be removed. It is contemplated that any
amount of agent may be used to enhance the bond strength of the
thermoplastics. In an exemplary embodiment, the amount of agent may
be about 10 to 20 percent.
[0215] Moisture may further be eliminated or prevented from
entering the thermoplastic material through the use of desiccants.
Desiccants may be added prior to or during the welding process.
Also, the thermoplastic material may be stored using desiccant
material to prevent change in thermal properties. It is
contemplated that this moisture reducing means may be applied to
any polymeric material.
[0216] Another factor effecting the welding of thermoplastic
material is pigments, especially white and black coloring. In many
materials used in medical applications, white pigment is added to
the polymer to make it appear sterile. Some pigments negatively
affect the welding characteristics of the material. In the present
invention, pigment-free thermoplastics, such as PEEK, are thermally
welded for proper bonding of the material.
[0217] Mold release agents also affect the welding properties of
thermoplastics. Polymeric components are usually formed in a mold
to create a desired configuration. The component is easily removed
from the mold because a release agent is placed between the mold
and polymer. These agents, lubricants, plasticizers, and flame
retardants can negatively affect the bonding ability of the
polymer. Thus, it is preferred in the present invention that PEEK,
PLLA, and other thermoplastics used for welding are substantially
free of these substances.
[0218] In addition to avoiding release agents, pigments, and
moisture, the bonding of thermoplastic materials may be further
enhanced by adding minute metallic material to the polymer. The
metallic material may be metal flakes or metal dust. Examples of
such metal include iron particles, chromium, cobalt, or other
suitable metals. The metal may be embedded within the polymeric
material to enhance the thermal properties. Alternatively, or in
addition, the metal may be applied to the bonding surfaces of the
polymeric material. Energy applied to the polymer would heat both
the polymeric and metallic material providing a faster and more
uniform weld. It is contemplated that glass fillers, carbon
fillers, talc, or combination thereof may also be used in addition
to or in lieu of the metallic material.
[0219] Other factors affecting the welding of thermoplastics
include size, thickness, surface geometry, material properties of
the thermoplastic, and the type of host tissue involved in the
weld, i.e. soft, hard, dry, wet, or moist tissue. These and other
factors are explained in more detail with reference to FIG. 5.
[0220] Furthermore, how the thermoplastic is welded is an important
characteristic of obtaining a robust thermal bond. The type of
energy used is one way to control the welding process. As
previously mentioned, various energy sources may be used to weld
polymers. In an exemplary embodiment and as used primarily
throughout the invention, ultrasound energy is used to create
vibrations within the polymeric material thereby exciting and
heating the molecules to transition to a tacky state. Two or more
different types of energy may also be used. For example, ultrasound
may be used to weld a polymeric component to another component,
while resistive heating may be used to contour the surface or
change the geometry of the materials. The surface of the component
may be smoothed out or sculpted using resistive heating.
[0221] The intensity and duration of the energy source impacts the
quality of the weld. For instance, the amount of power or watts
used affects the weld. Therefore, the watts may be controlled by
the operator depending on the component to be welded. A switch,
dial, or other control may be placed in connection with the energy
source to vary the intensity of the energy applied to the weld. For
example, the amount of current supplied to the instrument may be
varied or controlled. In an exemplary embodiment, the ultrasound
power may be varied, for example, between 80 and 100 watts. The
amount of time the energy is applied affects the weld as well. The
time may be varied from milliseconds to hundredths of seconds to
actual seconds depending on the desired weld. Thus, controlling the
time of exposure to the energy source can be used to limit the
amount and the degree of thermoplastic material which softens and
becomes tacky. In an exemplary embodiment, energy may be applied
from 0.1 seconds to 3 seconds, such as approximately 0.3 seconds.
In case of RF and ultrasonic energy, the wavelength of the energy
may be varied to affect the softening or melting of the
thermoplastic. It is also contemplated that the amount of time that
energy is applied may be controlled not only by the operator but
also via radiofrequency, optical, radiowave, etc. A computer or
other microprocessor may send signals to the energy emitter to turn
the energy on and off
[0222] Pulsing of the energy source may likewise be used to
intermittently apply energy to the weld site or to vary
characteristics of the energy source over time, such as the power,
frequency, or pressure, to enhance bonding and avoid tissue
necrosis. That is, the energy may be emitted, then relaxed, then
emitted, etc.
[0223] Controlling the pressure applied to the thermoplastic
material also may be used to affect the welding process. During
welding, a handpiece, an anvil, a horn, end effector, or
combinations thereof may be used to apply controlled force against
the welded component. After welding, while the welded material is
cooling, the force may continue to be applied to ensure proper
bonding of the materials. The handpiece, anvil, horn, and end
effector may be made of aluminum, titanium, or other suitable
material. Also, the pressure may be varied, increased or decreased,
during the welding process. In an exemplary embodiment, the
pressure may be applied by the operator or may be applied with a
spring. A sensor, spring, and/or piezoelectric device may be used
to monitor and control the amount of pressure applied. In another
exemplary embodiment, the welding horn may apply ultrasound energy
and pressure to a polymeric implant being attached to bone. The
bone may act as the anvil eliminating the need for an anvil
instrument. Also, a hard implant or another polymeric material may
function as the anvil.
[0224] Furthermore, the placement of the energy source on the
thermoplastic affects the weld. The energy may be applied to one
side of the polymer, through the center of the polymer, to two or
more sides of the polymer, or to generally the outer surface of the
polymer.
[0225] Controlling collapse is another factor in achieving an
effective thermoplastic weld. For instance, the weld time and
material collapse may be monitored to ensure a proper weld. A
measurement of the change of the material being welded may be made
to determine when bonding is complete. This may be accomplished by
using micro-switches to provide precise binary control of the mold.
Also, by using a linear variable displacement transducer (LVDT),
the control system can monitor the weld more precisely. Because a
LVDT translates position to voltage, the weld profile can be
dynamically controlled. For example, the initial energy delivered
can be a higher wattage, then when the material starts co collapse
the amplitude of the wave can be decreased.
[0226] By being able to monitor the position of the collapse,
different weld profiles can be programmed into the system. In
addition, to control how far the material collapses on the anchor
during a weld, a combination of weld current and time preset in the
generator control system could be used. This can also be coupled
with a defined force applied during the weld. Furthermore, collapse
may be controlled or monitored through the use of a mechanical stop
on the fixation device itself or on the welding instrumentation.
The mechanical stop would prevent collapse after a predetermined
point. It is also contemplated that the collapse could be monitored
by other methods such as optics, laser, or even a hall-effect
sensor.
[0227] All of the above-mentioned welding parameters may be
monitored and controlled by a computer. The discussion relating to
FIGS. 5-8, among others, illustrate instruments that may be used
for controlling weld parameters. Feedback may be provided by the
computer to vary, start, and stop the various parameters of
welding. The feedback and control of the computer may be programmed
based on the type of polymer being welded and the type of material
the polymer is being welded to. For example, for PEEK to PEEK
welds, the computer may apply a set of parameters (time, power,
pressure, frequency, wavelength, etc.) to achieve a desired or
effective weld. Other parameters may be established or preset for
other polymers, other weld materials, or for welding dissimilar
materials.
[0228] Any known energy emitting instrument may be used with the
surgical welding system of the present invention. The instrument
may produce energy such as resistive heating, radiofrequency,
ultrasound (vibratory), microwave, laser, electromagnetic, electro
shockwave therapy, plasma energy (hot or cold), and other suitable
energy. FIG. 1 illustrates an exemplary welding instrument 100 that
may be used with the present invention. The welding instrument 100
may be an ultrasonic handpiece with a sheath 102 to cover and
protect the end effector 104 and hold a fastener. As will be
discussed in greater detail below, the welding instrument may be
used to weld a cap of an implanted device to an anchor, or likewise
may be used to weld other components together.
[0229] The sheath 102 may have a small counter bore at its tip to
cover a portion of the cap. There also may be a bushing at a nodal
point of the ultrasonic signal to prevent the end effector 104 from
contacting the sheath 102. The tip of the end effector 104 has a
small post 106 sticking out of the welding face which presses into
a bore in the cap of the fastener. This can help align the fastener
post into the anchor bore and keep the cap tight against the end
effector face. The end effector 104 may be removable to allow it to
be replaced or cleaned after welding.
[0230] The post 106 on the end effector 104 may be threaded or have
a Morse taper to mate with the cap. Alternatively, the end effector
104 has a bore that the top of the cap mates into. The mating of
the components could also be by threads or a Morse taper along with
a straight post. Furthermore, the post could be roughened on the
outside surface for better adhesion.
[0231] Another exemplary instrument is illustrated in FIGS. 2A and
2B. A small cartridge heater 110 may be used to deliver thermal
energy. The heater 110 may be a SUNROD 1/8 inch cartridge heater.
To prevent heat build up of the outside shaft 112, an insulating
region 114 may be formed between the welding horn 116 and the shaft
112. In FIG. 2A, four set screws 118 are used to create the
insulating region 114, which in this example is an air barrier,
while in FIG. 2B, a single set screw 118 is used.
[0232] Referring to FIGS. 3A-3K, energy emitting instruments may
include various horn or end effector configurations. In FIG. 3A,
the horn 120A emits energy to the top surface of the implant as
well as the central core via an elongate extension 122A. The horn
120B of FIG. 3B is recessed to hold the thermoplastic implant
during welding. In FIG. 3C, the horn 120C is concave to provide a
rounded surface to the implant after welding. The horn 120D of FIG.
3D is concave and includes a central extension 122D to deliver
energy throughout the implant. In FIG. 3E, the horn 120E includes a
spike 124E which may be disposed within an implant. The horn 120F
of FIG. 3F includes a threaded pin 126F which may be received by a
bore in the implant. In FIG. 3G, the horn 120G includes dual spikes
124G. The distal portion of the horn 120H of FIG. 3H may be
dimensioned to fit within the thermoplastic implant. In FIG. 31, a
sleeve 128I is disposed about the horn 120I and implant. A
side-weld horn 120J is shown in FIG. 3J. In FIG. 3K, a dual horn
welder 120K is used to simultaneously weld two fasteners 130.
[0233] In FIGS. 4A-4C, a welding instrument 140 is shown which
includes three different horn or end effector configurations in one
design. The instrument 140 can be configured to have a
bonding-surface horn (FIG. 4A), a welding horn (FIG. 4B), and a
contouring horn (FIG. 4C). FIG. 4A shows the instrument 140 in the
bonding-surface horn configuration. The center shaft 142 is
extended distally from the instrument 140, and the outer shaft 144
which slides over the center shaft 142 is also extended distally.
In FIG. 4B the outer shaft 144 has been retracted into the welding
instrument, leaving only the center shaft 142 extended. In this
position, the instrument 140 is in the welding horn configuration.
Finally, FIG. 4C shows both the center and outer shafts 142 and 144
retracted into the instrument. The sheath 146 which surrounds the
instrument 140 has also been retracted. In this position, the
instrument 140 is in the contouring horn configuration. The distal
surface 148 of the contouring horn may be used to reshape a
thermoplastic implant, such as the head of a fastener.
[0234] In use, the instrument of FIGS. 4A-4C may be reconfigured
quickly by the operator during a welding operation. In the
bonding-surface configuration, the instrument is positioned such
that the distal portion of the extended center and outer shafts
142, 144 come in contact with a thermoplastic component or implant.
Energy, such as ultrasonic energy, may be emitted from the center
and outer shafts to create a roughened surface on the implant, to
create an indentation or blind hole in the implant, or to create a
through hole in the implant. The type of fixation desired and the
intended fastener to be used will determine how deep the
bonding-surface horn should be moved into the implant. With the
bonding surface formed, the outer shaft 144 is retracted into the
instrument (FIG. 4B).
[0235] The distal portion of a fastener may be placed in or on the
bonding surface of the implant, and the end effector may be placed
on the fastener with the center shaft extending into a bore in the
fastener. Using the desired welding parameters, the operator emits
ultrasonic energy from the end effector to bond the fastener to the
implant. Once welded, the fastener may be contoured or reshaped or
resized with the contouring-horn of the instrument by retracting
the center shaft and optionally retracting the sheath around the
instrument (FIG. 4C).
[0236] As previously mentioned, monitoring and controlling the
welding parameters ensures proper bonding of thermoplastics. FIG. 5
illustrates the various parameters that may be monitored and
controlled for the trauma welding system of the present invention.
The parameters include, but are not limited to, the type of energy
to emit, type of thermoplastic material, the size and configuration
of the implant, the thickness of the implant, implant surface
geometry, the aqueous environment, weld time, weld power, frequency
and wavelength of the energy, amount of pressure applied to the
implant during and after welding, the geometry of the weld horn,
the impedance of the welding horn, the density of the implant, the
amount of collapse of the thermoplastic material, the depth into
tissue the implant is to be inserted, and the type and amount of
any therapeutic agent that may be delivered.
[0237] FIG. 6 shows a manual welding control box 150. A surgeon
determines the optimum or desired welding parameters and may then
enter them into the control box 150 prior to or during welding. In
FIG. 7, an automatic control box 152 may be provided with pre-set
weld parameters. For example, preset 1 may be for implant A which
has a known material, size, etc. to be welded in a dry environment.
Preset 2 may be for implant A in a moist environment. Preset 3 may
be for implant A in a wet environment. Preset 4 may be for implant
B using energy source X. Preset 5 may be for implant C using energy
source Y. Preset 6 may be implant D using energy source Z. It is
contemplated that any combination of weld parameters may be preset
into the control box.
[0238] The control box 154 of FIG. 8A is automatic. A sensor on the
end effecter 156 determines the weld parameters when the horn is
placed adjacent the thermoplastic material. The sensor 156 picks up
material type, humidity of the environment, and any other
parameter, then sends the data to the control box. The control box
154 automatically selects the energy source, time, wattage, and any
other parameters. FIG. 8B illustrates an ultrasonic energy control
box which may be used with the surgical welding systems of the
present invention.
[0239] The exemplary energy control units described herein may be
used to select and vary any of the welding parameters. In FIG. 8C
for example, the power or wattage of the welding horn is varied
over time. During a first period of welding, a large amount of
energy is delivered to overcome heat sink. In the second period,
the energy is reduced. In a subsequent period, the energy is
maintained at an appropriate level to thermal weld an implant.
[0240] Other variations of the use of a control box may likewise be
used. For instance, a computer may be used to query or receive data
about the surgical procedure. The physician may enter an implant
manufacturer, for instance, and then select or enter an implant
model, size, etc. Based on the entered information, the computer
may assist the physician by instructing which energy source(s),
weld horns, or other parameters may be recommended for the
procedure. While the control box or computer may automatically
select and apply a weld profile based on expected input weld
parameters, the control box or computer may also allow a physician
to alter or override the expected input or otherwise select a
different weld profile. The ability to allow varying degrees of
manual control of the welding instrument may also be provided.
[0241] The exemplary energy control units previously described may
be used to select and vary any of the welding parameters. For
example, the power or wattage of the welding horn may be varied
over time. During a first period of welding, a large amount of
energy may be delivered to overcome heat sink. In the second
period, the energy may be reduced. In a subsequent period, the
energy may be maintained at an appropriate level to thermal weld an
implant.
[0242] To help ensure a properly executed weld, the welding
instrument of the present invention may provide a positive feedback
system. One way to provide user feedback is by measuring and
controlling the impedance (resistance) of the end effector or weld
horn. This feedback system is based on the fact that the load
placed on the end effector affects the impedance of the system.
That is, the pressure put on the end effector by the object to be
welded changes the resistance of the end effector. To determine the
handpiece or end effector impedance, the drive voltage and current
through the end effector may be monitored during the weld. By using
Ohm's Law V=TR, the impedance, R, may be calculated from the
voltage, V, and current, I.
[0243] FIG. 9 illustrates one method of ensuring a consistent or
desired weld. By first transmitting a low power ultrasonic signal
through the end effector, the impedance of the handpiece can be
measured with no pressure. This establishes a baseline impedance
for the end effector. Then, the end effector may be subjected to
known pressures, and the voltage and current may be measured to
calculate the impedance for each pressure. Therefore, when a
surgeon or other operator applies pressure from the end effector to
a thermoplastic implant to be welded, the actual amount of pressure
can be fed back to the operator because the pressure can be
correlated to a known impedance. The surgeon may increase or
decrease the pressure on the end effector until the desired
pressure is achieved. In one embodiment, the welding instrument may
provide audible and/or visual signals that indicate when a surgeon
is applying too much, too little, or an adequate amount of
pressure. With the correct pressure applied, the surgeon may
activate the handpiece and emit ultrasonic energy in accordance
with the calculated weld profile.
[0244] In another exemplary embodiment for providing positive
feedback, the pressure and impedance of the end effector may be
monitored throughout the weld profile. In the previously described
method, the proper pressure based on impedance was achieved by the
surgeon using a low power signal, and then the ultrasonic energy
was emitted from welding. In this method, the pressure and
impedance is measured during the weld. When pressure on the end
effector is applied and the weld is started, for example by a hand
control or footswitch, the current may be measured and the
impedance calculated by a microprocessor. When the impedance is too
high or too low or outside an acceptable range indicating an
incorrect applied pressure, the microprocessor may send an audible
or visual signal to the surgeon.
[0245] Alternatively, or in addition to the signal, the
microprocessor can stop energy emission until the correct pressure
and impedance is achieved, then the welding may be resumed either
automatically by the microprocessor or manually by the surgeon. If
inadequate pressure is being exerted, the welding instrument may
operate in a pulse mode to maintain material in a near-weld state.
This may allow the welding to more rapidly continue when adequate
pressure is once again being applied.
[0246] Referring FIG. 10, because the drive signal is sinusoidal,
V.sub.monitor and V.sub.current must be sampled at a rate that is
at least twice the frequency of the ultrasonic waveform. For
example, if the waveform is a 41 kHz sinusoid, then samples may be
taken at 328 kHz, or one sample every 3 .mu.s. In this example,
solving for the impedance, the handpiece would be 500 .OMEGA..
[0247] Also, by monitoring handpiece impedance, changes to the weld
environment, such as moisture, ambient temperature, aqueous
conditions, etc., may be automatically compensated for by adjusting
the drive waveform of the ultrasonic energy. For example, if for a
certain material it is determined that 80W of power is required for
a 400 ms period to achieve a consistent weld, then the waveform can
be adjusted o ensure that this amount of energy is constantly
delivered. Power is calculated using P=IV, but because the signal
from the waveform is sinusoidal, the root mean square (RMS) voltage
as V==(1/ 2)A must be used.
[0248] As the impedance, R, of the handpiece changes, the total
power delivered also changes. By increasing or decreasing the drive
voltage to compensate for the change in the impedance, a constant
power can be delivered.
[0249] In another exemplary method, seat collapse may be monitored,
such as by the use of SONAR. Seal collapse is the distance a
thermoplastic fastener or implant shrinks in height when ultrasonic
energy is applied. Generally, thermoplastic fasteners may shrink
about 20 percent in height and increase 30 percent in width when
welded. For fasteners having two pieces, such as a cap and an
anchor, the attenuation of the reflected ultrasonic waves changes
as the two piece fastener becomes one piece. This change in
attenuation may be monitored to alert the surgeon or operator when
the weld is complete. Furthermore, an ultrasonic transducer could
be used in conjunction with the end effector to detect the change
in acoustic impedance/attenuation of the weld site. This signal may
be monitored by a microprocessor/controller or data signal
processor (DSP) and data may be automatically interpreted to
indicate whether the weld was successful.
[0250] Another way of providing feedback of an effective weld is to
monitor the Eddy currents created by the movement of the end
effector. As the end effector vibrates, the linear motion creates a
change in the magnetic field. By monitoring the travel of the end
effector, the amount of collapse can be determined.
[0251] It is also contemplated that the material being welded may
be translucent or transparent, and a visual indicator within the
material could indicate when the weld is complete. For example, a
pigment, dye, or other substance may be impregnated into the
thermoplastic which when subjected to ultrasonic energy the pigment
or dye would be released indicating that the weld is complete.
Alternatively, the material of the thermoplastic may have the
characteristic of changing color as heat, vibrations, or ultrasonic
energy is applied for a predetermined time and a predetermined
frequency and wattage.
[0252] The previously described methods for providing positive
feedback to the weld operator included the use of measurements
and/or computers. Another positive feedback system is provided
which relies on physical force. When two objects are fastened to
each other, it is common for the technician or mechanic to pull or
tug on the assembly to ensure the parts are securely fastened. This
common technique may apply to the thermoplastic welding system of
the present invention. Once a fastener or other implant is
ultrasonically welded, the surgeon can apply a quick tug on the
assembly to verify the weld was completed as intended.
[0253] FIGS. 11A and 11B illustrate a feedback instrument 160 for
performing such a physical positive feedback check. An end effector
162 includes a post 164 which emits ultrasonic energy. A
thermoplastic fastener 166 is placed on the end effector 162 with
the post 164 in a bore or receptacle 168 of the fastener 166. After
emitting ultrasonic energy and welding the fastener to an implant
or tissue, the surgeon may actuate a biasing prong or prongs 170
from the post 164 of the end effector while the post 164 is still
in the fastener 166. In a stored configuration, the prongs 170 are
positioned within the post 164. In a deployed configuration, the
prongs 170 extend radially from the post 164 by the activation of a
handle, switch, or button. The extended prongs 170 dig slightly
into the material of the fastener 166 so that the surgeon may now
pull or tug on the instrument 160 proximally to verify that the
fastener 166 is securely welded in place. Additionally, the prongs
170 and/or post 164 may include a strain gauge or other force
measuring device to measure and display to the surgeon how many
pounds of pull strength is being put on the fastener.
[0254] Some exemplary fasteners of the present invention are
illustrated in FIGS. 12A-12F. The fastener 180A of FIG. 12A is made
entirely of a thermoplastic material such as PEEK. In FIG. 12B, the
fastener 180B includes one type of thermoplastic material in the
lid 182 and a different type of thermoplastic material in the post
184. Each material may have different welding properties. FIG. 12C
shows a fastener 180C with only a proximal portion 186 made of
PEEK, while FIG. 12D illustrates a fastener 180D with only a distal
portion 188 made of PEEK. In FIG. 12E, the fastener 180E includes a
rigid metallic core 190 which is enclosed by a thermoplastic 192.
The fastener 180F of FIG. 12F has a polymeric core 194 surrounded
by PEEK 196. Although not illustrated in these examples, the
fasteners may include a central bore for receiving the post of the
end effector.
[0255] FIGS. 13A and 13B show a bone plate or rod 200 for use with
the trauma welding system of the present invention. Plate or rod
200 may be free of holes or may include pre-drilled thru-holes 202
or edge-holes 204 for positioning fasteners therethrough. The holes
may be formed by the manufacturer at the factory or by the surgeon
in the operating room. The plate or rod 200 may include a roughened
surface 206 in some areas or over the entire surface. The roughened
areas 206 provide a bonding region for fasteners or other
thermoplastic implants. Additionally, the plate 200 may include
blind holes 208 for securing a fastener therein. The blind hole 208
is an indentation in the surface of the plate 200 which extends
only partially into the plate 200. The thru-hole, roughened area,
and blind hole are bonding regions. In FIG. 13B, a thermoplastic
fastener 210 is positioned in an edge-hole 204 of the plate 200.
The distal end of the fastener 210 may be seated in another implant
or tissue, such as bone. Because the plate includes the edge-hole,
the fastener may be first at least partially implanted, then the
edge-hole of the plate may be positioned around the fastener. Once
properly aligned, the plate 200 and fastener 210 may be welded
together and the proximal end or head 212 of the fastener 210 may
be contoured as desired.
[0256] In addition to the fasteners described in FIGS. 12A-12F,
other fastener configurations are illustrated FIGS. 14A-14D. In
FIG. 14A, the fastener 220A includes a mechanical locking mechanism
in addition to thermal bonding. The fastener 220A includes
thermoplastic material and includes helical threads 222 disposed on
the outer surface thereof. In
[0257] FIG. 14B, the fastener 220B includes longitudinally
extending edges 224. These longitudinal edges 224 may function as
energy directors to focus the ultrasonic energy along the edges
providing a secure bond to tissue or an implant. FIG. 14C
illustrates a wedge shaped or Morse taper fastener 220C. The
fastener 220D of FIG. 14D includes an angled shoulder 226 which may
be seated against an implant or tissue and thermally bonded in
place.
[0258] The combination of thermoplastic material and ultrasonic
energy of the present invention is advantageous for modifying and
preparing implants while the implants are in the body. In FIG. 15A,
a plate 230 may be positioned against bone to stabilize a fractured
bone or damaged vertebrae. With the plate 230 in place, a notch or
nest 232 may be cut using heat energy or other mechanical means
such as a drill or saw. The notches 232 are dimensioned and
configured to receive a rod 234 or fastener. Therefore, implanting
and thermally bonding a rod in the notch 232 creates a desired
geometric shape with the plate 230 and rod 234 extending generally
perpendicular to each other. In this configuration, the assembly
may be used to stabilize the spinal column or may function as a
combination internal-external fracture bone stabilizer. In the
latter case, a first plate may be positioned against the fractured
bone, while an exterior plate may be bonded to one or more rods
extending from the notches of the first plate. The first plate
provides internal fixation, and the exterior plate provides
external fixation. The rods bonded between the two plates function
as pins passing through the skin and other soft tissue. To further
secure a rod within the notch of the plate, a fastener 236 may be
inserted as shown in FIG. 15B. The plate 230, rod 234, and fastener
236 may be thermally welded at several bonding regions 238.
[0259] The thermoplastic fasteners of the present invention may
also be expandable. FIGS. 16A and 16B illustrate one embodiment of
a fastener 240 which includes a cap 242 and an expandable anchor
244. The anchor 244 is generally V-shaped or conical, convex
shaped. The anchor 244 may include a tissue-piercing distal tip 246
to penetrate into and through tissue and implants, such as plates
or rods. As seen in FIG. 16A, the anchor 244 includes a bore 248
that may taper down from the proximal end to the distal end. The
bore 248 is dimensioned and configured to expand when receiving the
post 250 of the cap 242. Therefore, the post 250 tapers from the
proximal end or head down to the distal tip. The distal tip of the
post 250 may also include a tissue-piercing end. In an exemplary
method of use, the expandable anchor 244 is inserted through a
layer of tissue 252. A plate or other implant 254 (or other tissue)
is placed adjacent the tissue 252. The post 250 of the cap 242 is
moved distally through the plate 254 and tissue 252 and into the
bore 248 of the anchor 244 causing the anchor to expand outwardly
or radially, as shown in FIG. 16B. With the head 256 of the cap 242
pressing the plate 254 against the tissue 252, the cap 242 is
ultrasonically welded to the anchor 244. The anchor is prevented
from being removed from the tissue because the expanded wall
portions of the anchor contact the underside of the tissue.
[0260] FIGS. 17A and 17B illustrate another expandable fastener 260
embodiment. The principle of insertion and expansion are similar to
the fastener of FIGS. 16A and 16B. However, in this embodiment, the
anchor 262 is generally cylindrical in shape. The anchor 262 has a
cylindrical bore therein. The cap 264 includes a post 266 which is
generally cylindrical and has a widened portion disposed between a
proximal portion and a distal portion. The diameter of the distal
portion of the post 266 is configured for initial insertion in the
bore 268 of the expandable anchor 262. The diameter of the widened
portion is configured such that it expands the walls of the anchor
262 radially outward as the cap 264 is moved distally into the
anchor 262. In a seated configuration, the cap 264 is
ultrasonically welded to the anchor 262 and the head 270 of the cap
264 holds a plate or tissue 272 against lower tissue 274. The
expanded walls of the anchor contact the lower tissue preventing
the fastener from being pulled out.
[0261] Referring to FIGS. 18A and 18B, the fastener 280 includes a
cap 282 and an anchor 284 which is configured as a tubular mesh.
The tubular mesh 284 has an unexpanded diameter and an expanded
diameter. The post 286 of the cap 282 is dimensioned to fit ,
within the lumen of the tubular mesh 284 to expand the mesh to its
expanded diameter. The post 286 may include ridges or ring-like
structures 288 disposed thereon to aid in the expansion of the
tubular mesh anchor 284. In an exemplary method of use, the anchor
284, in its unexpanded diameter, is positioned in tissue 290. A
hole 292 may be drilled into the tissue 290 for receiving the
anchor 284 if desired. A bone plate or other implant 294 is placed
adjacent the bone 290. The cap 282 is moved through the plate 294
and tissue 290 and into the lumen of the mesh 284.
[0262] The mesh achieves its expanded diameter in at least one of
two ways. First, the insertion of the post (with ridges) into the
mesh causes the mesh to expand thereby preventing the anchor from
pulling out of the tissue. Alternatively, the post with or without
ridges may be inserted into the lumen of the mesh while the mesh
maintains its unexpanded diameter. Ultrasonic energy and pressure
from the welding horn may be applied to the cap causing it to swell
thereby locking the anchor into the tissue. It is also contemplated
that a combination of expansion methods may be used. That is, the
post with ridges may be inserted into the lumen of the mesh causing
the anchor to expand. Then, ultrasonic energy may be applied to the
fastener to further expand the mesh and bond the cap to the
anchor.
[0263] Another embodiment of an expandable fastener 300 is
illustrated in FIGS. 19A and 19B. A top or bottom view of the
anchor 302 is shown in FIG. 19A. The anchor 302 includes two or
more arced members or longitudinal portions of a tube 304. When
placed together as in FIG. 19A, the anchor 302 is in an unexpanded
configuration. The cap 306 includes a post 308 and lid 310. To
fasten a bone plate or other implant 312 to tissue 314, the anchor
302 in its unexpanded configuration is inserted into the tissue
314. The post 308, which may include a tissue-piercing point, is
inserted through the plate and tissue. As the post 308 enters the
anchor 302, the arced members 304 are moved outwardly or radially.
This is possible because the inner bore diameter of the anchor 302
in its unexpanded configuration is smaller than the diameter of the
post 308 of the cap 306. Once the cap 306 is pressed into the
anchor 302, it is ultrasonically welded to the anchor 302. The
anchor and fastener are prevented from being pulled out of the
tissue because the proximal ends of the expanded arced members of
the anchor contact the tissue. The lid of the cap holds the bone
plate firmly against the tissue.
[0264] The trauma welding system of the present invention also
provides fasteners configured as triangulation staples. Examples of
these staples are illustrated in FIGS. 20A-20E. In FIG. 20A, the
staple 320A includes first and second nails or braids 322A. The
nails 322A include a long post and a head disposed on the proximal
end of the post. The head may be slanted, angled, or pivotable to
allow the head to seat flush against an implant or tissue. The
distal end of the post includes a tissue-piercing tip 328A. The
nails 322A may include a central bore configured for receiving an
end effector. As shown, the fastener 320A includes two nails;
however, it is contemplated that the triangulation staples of the
present invention may include three or more nails. The staple 320A
of FIG. 20A is shown holding two bone plates or other implants 330A
and 332A against each other at their edges. The first nail 322A is
inserted through the first plate 330A near the edge of the first
plate. The first nail 322A is angled generally between 30 and 60
degrees with respect to vertical. A second nail 322A is inserted
through the second plate 332A near the edge of the second plate.
The second nail 322A is also angled such that the distal tips 328A
of the first and second nails contact each other. Ultrasonic energy
is applied to the nails 322A to bond the distal tips 328A together
to form a bonding area 334A. The nails 322A may also be welded to
the plates 330A and 332A where the nails passed through the plates.
Additionally, the edges of the bone plates may be ultrasonically
welded together. When implanted, the staple 320A securely holds the
two plates 330A and 332A together and fastens the plates to tissue,
such as bone.
[0265] In FIG. 20B, the triangulation staple 320B includes two
nails 322B with a suture or cable 324B connected with the heads of
the nails. In an exemplary use of this staple configuration, an
implant 330B is positioned adjacent another implant or tissue 332B.
The first nail 322B of the staple is inserted into the tissue 332B
on one side of the implant 330B. The second nail 322B is inserted
into the tissue 332B on another side of the implant 330B. The cable
324B, spanning between the nails, contacts the implant 330B. As the
nails 322B are driven further into the tissue 332B, the cable 324B
tensions and presses the implant 330B against the tissue 332B.
Also, with the nails firmly implanted in the tissue, the distal
tips 328B of the nails 322B contact each other. Ultrasonic energy
may be used to weld the distal tips 328D together to form a bonded
region.
[0266] The triangulation staple 320C of FIG. 20C is a one-piece
design. The first and second nails 322C are connected to each other
by a cross member 326C attached at the proximal ends of the nails.
The nails 322C may be rotatable or pivotable from their connection
with the cross member 326C. The distal ends of the nails may
include tissue-piercing tips 328C. In a pre-implantation
configuration, the nails 322C extend generally perpendicular to the
cross member 326C. In use, the staple 320C is inserted through
tissue, an implant, or both. The staple is inserted with the nails
322C being generally perpendicular to the cross member. Once
positioned, the nails 322C may be pivoted such that the distal tips
of the nails contact each other. The rotation of the nails 322C may
be performed by an instrument designed to angle the nails, for
example by using the central bore therein. With the tips in
contact, the nails 322C may be ultrasonically welded together to
form a secure fixation of the implant and/or tissue.
[0267] In FIGS. 20D and 20E the staple 320D includes a cross member
326D which has channels for allowing the nails 322D to slide
therein. The channels have a central axis which intersect below the
cross member 326D such that when the nails 322D are moved distally
through the channels, the distal tips 328D of the nails connect
each other, similar to the previously described embodiments. As
seen in FIG. 21E, the cross member 326D includes one thru-channel
338D and one edge-channel 340D. This configuration allows the nails
322D to be inserted sequentially (not at the same time, if
desired). In an exemplary method of use, the first nail 322D is
partially positioned in the implant (or tissue) to be fastened. The
first nail 322D is angled relative to vertical at an angle
generally equal to angles of the channels of the cross member 326D.
Then, the edge-hole 340D of the cross member 326D is positioned
around the first nail 322D. The second nail 322D is inserted into
the thru-hole 338D of the cross member 326D, and both nails 322D
are fully inserted into the implant/tissue. The distal tips 328D of
the nails 322D may be ultrasonically welded together, and the nails
322D may be ultrasonically welded to the cross member 326D.
[0268] An exemplary staple welding horn 350 is shown in FIG. 21.
The horn 350 includes two elongate horn shafts 352 disposed in
channels in a horn base 354. The horn shafts 352 may be slideable
within the channels. Both the horn shafts 352 and the horn base 354
may emit ultrasonic energy for welding the thermoplastic material,
such as PEEK, of the above described staples. In use, the horn
shafts 352 are retracted proximally. The horn 350 is placed over
the staple such that the horn shafts 352 align with the central
bore in the nails. It should be noted that the nails of the staples
previously described may include longitudinally extending bores not
only to receive the ultrasonic horn but also to receive an
instrument for positioned the nails in implant and/or tissue. With
the horn 350 properly aligned, the horn shafts 352 may be distally
extended into the channels of the nails. Ultrasonic energy and a
desired weld profile may be used to thermally bond the staple.
[0269] Referring now to FIGS. 22A and 22B, a thermoplastic removal
instrument 360 is shown. The instrument 360 includes an ultrasonic
welding horn shaft 362. The distal portion of the shaft 362 is
generally conical and tapers inward toward the distal tip. An
elongate pin 364 extends from the distal tip. The distal portion of
the shaft 362 includes helical threads 366 disposed on the outer
surface thereof. It is contemplated that besides having helical
threads 366, the distal portion of the shaft may include any
engagement means such as barbs, prongs, or other similar
configurations. To remove a thermoplastic component, the elongate
pin 364 of the instrument 360 is inserted into a channel of the
component. The channel may already exist in the component or may
need to be created with a drill and bit. With the pin 364 in the
channel, the instrument 360 is moved further distally until the
distal portion of the shaft 362 contacts the component. The distal
portion is then threaded into the component with the helical
threads 366. Ultrasonic energy may then be emitted from the pin 364
to soften the thermoplastic material of the component. As the
material is softened, the instrument 360 may be pulled proximally,
and the distal portion of the shaft 362 may begin to pull the
component out. The softened thermoplastic material adjacent the pin
364 can be reshaped as the component is pulled from the
implant/tissue.
[0270] In FIGS. 22A and 22B, a PEEK fastener 368 is holding a bone
plate 370 to bone 372. The fastener 368 may be removed from the
bone 372 with the method just described. In FIG. 22A, with the
fastener 368 in place, the distal portion of the fastener 368 is
thick thereby locking the fastener 368 in the bone 372. In FIG.
22B, as the fastener 368 is pulled proximally, the distal portion
thins or narrows as it is pulled from the bone 372 and plate 370.
Because the fastener 368 is only softened and not liquefied, the
removal instrument 360 is able to remove substantially all, if not
entirely all, of the thermoplastic material from the bone 372.
[0271] FIGS. 23A-23D illustrate a method of stabilizing a fracture
bone with the devices of the present invention. In FIG. 23A a femur
380 is shown with a fracture 382. An intramedullary rod 384 may be
placed within the medullary canal of the femur 380, as seen in FIG.
23B. The rod 384 may be made of thermoplastic material, such as
PEEK. The rod 384 is positioned in the bone such that it spans the
fracture on each side. In FIG. 23C, a plurality of channels are
created in the femur 380. The channels are dimensioned to receive a
fastener of the present invention. A first channel 386 is created
in cortical bone of the femur 380. The first channel 386 creates a
passage from the exterior of the femur to the IM rod 384. A second
channel 388 is created in the cortical bone and slightly into the
IM rod 384. The second channel 388 forms an indentation or nest in
the rod 384. A third channel 390 is formed entirely through the
femur 380 and IM rod 384. The third channel 390 is a thru-hole
which extends through the cortex (both cortical sides) of the femur
380. A fourth channel 392 is created in cortical bone and partially
into the IM rod 384. The fourth channel 392 forms a blind-hole in
the rod 384. The channels may be formed by any means known to
surgeons, such as by a drill and bit, a guidewire, a reamer, or
other similar instrument. It is contemplated that any number of
channels and any combination of channel types may be created in the
bone and IM rod.
[0272] In FIG. 23D fasteners are positioned in the channels and
ultrasonically welded in place. Before a first fastener 394 is
placed in the first channel 386, the surface of the IM rod 384
exposed by the channel requires preparation for bonding. The
surface may be roughened in situ using any suitable instrument.
Alternatively, the surface may be roughened by the manufacture or
the surgeon before implantation in the bone. With the bonding
surface prepared, the first fastener 394 is placed in the first
channel 386 such that the distal end of the fastener 394 contacts
the bonding surface of the rod 384. An energy source, such as
ultrasonic energy, may be applied to the fastener to thermally bond
the first fastener 394 with the IM rod and femur. A second fastener
396 is placed in the second channel 388 with the distal end of the
second fastener 396 positioned in the indentation in the rod 384.
The second fastener 396 may then be ultrasonically welded to the
rod and femur. A third fastener 398 is placed in the thru-hole of
the third channel 390. The leading end of the third fastener 398 is
configured for insertion through the channel, while the trailing
end of the fastener may include a cap or head. The third fastener
398 is ultrasonically welded to the IM rod and femur. The leading
end of the third fastener 398 may be contoured or flattened to form
a leading end head. A fourth fastener 400 is placed in the fourth
channel 392 and within the blind hole in the rod. The fourth
fastener 400 is thermally welded, and the cap or head is contoured
to conform to the outer surface of the femur. It is contemplated
that the three-horn instrument of FIGS. 4A-4C may be used to create
the bonding regions, to weld the fasteners, and to contour the
thermoplastic implants.
[0273] Referring now to FIGS. 24A and 24B, the devices and methods
of the present invention are used to repair an end portion of a
bone 410 having a plurality of fractures 412. Like the repair of
the fractured femur of FIGS. 23A-23D, a PEEK intramedullary rod 414
is placed in the medullary canal of the bone 410. A plurality of
channels is created through the end portion of the bone 410 and
into the IM rod 414. Any channel type previously described may be
used in this method. A plurality of thermoplastic fasteners 416 are
placed in the channels and are ultrasonically welded to the rod
414. Multiple (three or more) fasteners 416 may be welded to the
end portion of the IM rod 414 without reducing the strength of the
rod. Since the fasteners and rod are made of PEEK, the thermally
bonded fasteners within the rod enhance the strength of the rod.
Therefore, many fasteners may be bonded with the rod without losing
structural support from the channels created in the rod.
[0274] Another method and apparatus for repairing a fractured bone
is illustrated in FIGS. 25A and 25B. Instead of an intramedullary
rod being placed in the bone canal, a bone plate 420 is positioned
against the fractured femur 422 on the exterior side of the bone.
The bone plate 420 is made of thermoplastic material such as PEEK.
A first channel 424 is created through the plate 420 and through
the bone 422 to form a thru-hole. A second channel 426 is drilled
through the bone plate 420, across the fracture 428, and through
the bone 422. A third channel 430 is formed through the plate 420
and partially into the femur 422. Additional channels may be
created as desired. In FIG. 25B, PEEK fasteners 432 are placed in
the channels and ultrasonically welded to the femur 422 and bone
plate 420. The fastener type and method of welding each fastener
may be similar to previously described embodiments.
[0275] FIGS. 26A and 26B show a combination configuration for
repairing a fractured bone. The combination includes an IM rod 440
positioned in the medullary canal of the bone 442 and a bone plate
444 positioned against the exterior surface of the bone 442. The
rod and plate may be made of PEEK. In FIG. 26A, a plurality of
channels 446 are created through the plate, bone, and/or rod. PEEK
fasteners, shown in FIG. 26B, are positioned in the channels 446
and ultrasonically welded to the plate, bone, and rod. A first
fastener 448 is welded to a bonding region 450 on the surface of
the rod 440. A second fastener 452 is welded in an indentation in
the rod 440. A third fastener 454 extends through the plate, bone,
and rod. The third fastener 454 includes a mushroomed or contoured
head on its distal end, and on the proximal end, no head is needed
since the fastener bonds directly to the bone plate 444. A fourth
fastener 456 is positioned in a blind hole in the rod 440. The
fourth fastener 456 is also free of a proximal head or cap. As seen
in FIG. 26B, the bone plate 444 is contoured to conform to the
exterior surface of the femur 442. This may be performed with
ultrasonic energy, resistive heating, or other suitable energy
source.
[0276] An exemplary bone plate 460 of the present invention is
shown in FIGS. 27A-27C. Some previously described bone plates and
IM rods included no pre-fabricated holes. Instead, the surgeon
formed channels in the plates and rods to insert fasteners. In the
embodiment of FIG. 27A, the bone plate 460 includes a plurality of
openings. Some openings are threaded while others are free of
treads. FIG. 27B is a cross sectional view of a threaded opening
462 of the plate 460. FIG. 27C is a cross sectional view of an
unthreaded opening 464. The plate 460 is made of thermoplastic
material such as PEEK.
[0277] Shown in FIGS. 28A-28D are exemplary fasteners for affixing
the bone plate to a bone. The fasteners are made of PEEK and may
include a central channel configured for receiving a welding horn.
FIG. 28A shows a PEEK fastener 470A having a threaded head 472A and
a threaded shaft 474A. The threaded head 472A is dimensioned to be
threaded into one of the threaded openings 462 of the bone plate
460. The thread shaft 474A is configured for insertion in tissue.
FIG. 28B shows a fastener 470B with a smooth, unthreaded head 476B
and a threaded shaft 474B. The unthreaded head 476B is configured
for insertion in one of the unthreaded openings 464 of the bone
plate 460. FIG. 28C shows a fastener 470C having a threaded head
472C and smooth shaft 478C. FIG. 28D shows a fastener 470D with a
smooth head 476D and smooth shaft 478D. In use, the bone plate is
positioned on a fractured bone. Fasteners of FIGS. 28A-28D are
positioned through the openings in the plate and into the bone. The
fasteners are ultrasonically welded to the plate and bone. The
smooth head or smooth shaft of a fastener is thermally bonded to
the plate or tissue, while the threaded head or threaded shaft is
mechanically secured and thermally bonded to the plate and/or
tissue.
[0278] The trauma welding system also provides for the modular
assembly of implants intracorporeally. In FIG. 29, spinal cages 480
include thermoplastic material which may be welded to vertebral
body replacement components 482. The use of ultrasonic energy to
weld the assembly together in the body prevents damage to
surrounding tissue since the vibration energy creates just enough
heat to soften and make tacky the thermoplastic material. FIG. 30
illustrates a modular IM rod 484 and a modular bone plate 486. The
IM rod 484 includes a first portion 484A welded to a second portion
484B at a bonding region 488. The second portion 484B is welded to
a third portion 484C at another bonding region 488. In this
embodiment, the smaller portions of the rod may be implanted using
minimally invasive techniques. Each portion may be welded to an
adjacent portion intracorporeally. The bone plate 486, likewise,
includes a plurality of modular portions 486A, 486B, 486C which may
be thermally bonded together in the body. It is also contemplated
that the small portions of the rod, plate, or other implant may be
assembled by the surgeon in the operating room prior to
implantation. This way, the implant manufacture can produce small
portions of an implant allowing the surgeon to select the size and
number of portions to assembly to create a custom tailored implant.
It is contemplated that intracorporeally sequential welding applies
to other types of implants as well, such as modular stents, modular
acetabular component, modular spacers, and modular wedges.
[0279] In a further embodiment of the present invention shown in
FIGS. 31A and 31B, the trauma welding system may be used to
stabilize joints of the spine such as intervertebral joints and
facet joints. Stabilization of the spine is achieved by attaching
rigid rods, plates, spacers, or wedges 490 between two or more
vertebrae. Fasteners 492, such as pedicle screws, are inserted into
the vertebrae, and plates/rods 490 are connected to the screws 492.
The spinal rods, plates, fasteners, etc. may include thermoplastic
material, such as PEEK. The implants may be biodegradable or
biostable. In FIG. 31B, PEEK pedicle screws 492 are inserted into
vertebral bodies using the methods described herein. PEEK
stabilizing plates 490 span the pedicle screws 492 and are
ultrasonically bonded with the screws. Stabilizing cross bars 494
are thermally welded to the stabilizing plates at bonding regions
496. It is contemplated that any combination of fasteners, rods,
plates, and wedges may be ultrasonically welded to stabilize joints
of the spine.
[0280] In FIG. 32, a spacing fastener 500 is shown. The fastener
500 includes an anchor 502 and a cap 504. The anchor 502 is
generally a cylindrical shaft with a head 506 disposed on the
proximal end of the shaft 508. The shaft 508 may include helical
threads 510 for mechanical locking into tissue 512. The anchor 502
includes a bore extending along the central axis of the anchor. The
fastener 500 further includes a cap 504 having a post 514 and a lid
516 attached to the proximal end of the post. The post 514 is
dimensioned and configured for insertion into the bore of the
anchor 502. Both the cap and anchor may be made of thermoplastic
material such as PEEK. In an exemplary method of use, the anchor
502 is implanted in tissue 512 as shown in FIG. 32. The anchor 502
may be mechanically and/or thermally bonded in the tissue. A bone
plate or rod 518 is placed over the head 506 of the anchor 502. A
pre-drilled passageway 520 formed in the plate by the manufacturer
is aligned with the bore of the anchor. Alternatively, a passageway
520 may be formed by the surgeon and aligned with the bore. The cap
504 is inserted through the passageway 520 of the plate 518 and
into the bore of the anchor 502. The cap, plate, and anchor may be
thermally bonded together with ultrasonic energy. In the implanted
configuration, the head 506 of the anchor 502 acts as a spacer
between the tissue 512 and plate 518. The spacing fastener 500 of
FIG. 32 may be used as a pedicle screw separating a stabilizing
plate from vertebral bodies.
[0281] In a further embodiment, the trauma welding system may be
utilized to provide flexible stabilization of the spine, or any
other joint or bone of the body. The soft tissue around and near a
joint may become weakened over time, and the range of motion of the
joint usually increases thereby allowing excessive tissue laxity.
Also, instability of a joint may be caused by structural changes
within the joint as a result of trauma, degeneration, aging,
disease, or surgery. An unstable spinal joint may be rigidly
stabilized as previously explained or may be dynamically stabilized
to allow some range of motion of the spinal joints. Fasteners,
screws, plates, rods, etc. made of PEEK may be implanted between
two or more vertebrae. The plates and rods are configured and
dimensioned to permit some flexing and/or bending. The amount of
flexibility of these PEEK implants may be adjusted by the surgeon
in the operating room using energy, such as ultrasound, resistive
heating, etc. and by varying the weld parameters.
[0282] As seen in FIG. 33, a plate or rod 530 may be configured to
lock with a fastener 532 in one direction, but would allow movement
in another direction. For example, the plate 530 and fastener 532
permits superior and inferior motion of the spine but would prevent
lateral motion. Also, the plate 530 and fastener 532 may permit
motion in one plane and restrict motion in a different plane. The
fasteners and plates of FIG. 33 may be made of PEEK and may be
ultrasonically bonded to stabilize the spine.
[0283] FIGS. 34A and 34B illustrate another embodiment to stabilize
a joint such as a joint of the spine. The swivellable pedicle screw
assembly 540 may be used to connect a longitudinal bar 542 to a
pedicle screw 544 thereby forming a spine stabilization device. The
assembly 540 includes a body 546 having an upper end, a lower end,
a hole 548 which is open at least towards the bottom and has an
axis, and a through hole positioned perpendicular to the axis. The
assembly 540 also has a collet chuck 550 mounted coaxially on the
inside of the body 546 in such a way that it can slide along the
axis. The collet chuck 550 has a through hole 552 which is flush
with the through hole of the body 546, and a chamber which faces at
least downwards and is defined by tongues spring-mounted against
the cylinder axis. When the collet chuck 550 is inserted in the
body, the through holes 552 align to allow insertion of the
longitudinal bar 542. The head 554 of a pedicle screw 544 can be
clicked into the chamber from below by spring-action. The assembly
540 allows for the pedicle screw 544 to be inclined within a
certain range. The assembly may be made of thermoplastic material
such as PEEK. Ultrasonic energy may be used to thermally bond the
head 554 of the pedicle screw 544 within the chamber of the collet
chuck 550 and to bond the longitudinal bar 542 with the pedicle
screw 544.
[0284] It is contemplated that a simple ball and socket assembly
may be used to stabilize the spine as well. The ball is the head of
the pedicle screw as described above. The socket includes a chamber
for receiving the ball. The socket may include an attachment means,
such as a thru-hole or a thermal bonding region, for receiving and
affixing a plate or rod. The ball, socket and plate/rod may be
ultrasonically welded together to form a spine stabilizing
configuration.
[0285] FIGS. 35A and 35B illustrate a bone fixation assembly 560
for securing a bone plate to bone. The assembly 560 includes the
fixation device 562, a bushing 564, a fastening screw 566, and a
locking screw 568. The bushing 564 is seated within a through hole
in the fixation device 562 and can rotate within the through hole
and has a sidewall with a bore. The sidewall has at least one slot
for allowing outward expansion of the sidewall against the through
hole to thereby lock the bushing 564 at a selected angle relative
to the axis of the through hole. The fastening screw 566 has a
threaded shaft 570 for insertion through the bore of the bushing
564 and threads into bone to secure the bushing 564 and fixation
device 562 to bone. The head of the fastening screw 566 fits in the
bushing and includes a radial wall and open end defining a recess.
The radial side wall has at least one slit for allowing outward
expansion of the radial wall thereby outwardly expanding the
sidewall of the bushing 564. The locking screw 568 has a body that
threads in the head of the fastening screw 566 to thereby outwardly
expand the radial wall of the fastening screw 566. The assembly
components may be made of PEEK. In an alternative embodiment, a
fastening member 572, made of PEEK, replaces the fastening screw
566 and locking screw 568. In this embodiment, the fastening member
572 is inserted through the bore of the bushing 564 and into the
bone. The fastening member 572 may be ultrasonically welded to the
bushing 564 and the bushing 564 may be thermally bonded to the
fixation device 562. The fastening member 572 is ultrasonically
bonded to the bone using the welding methods described herein.
[0286] Referring now to FIGS. 36A and 36B, a cable tensioning
fastener 580 is illustrated. The fastener 580 includes a post 582
and a cap 584 disposed on the proximal end of the post. The post
582 is configured for winding a suture or cable 586 thereon. The
suture 586 may be attached to the post 582 by applying heat to PEEK
material of the post, setting the suture into the softened PEEK,
and allowing the PEEK to harden. Alternatively, a small channel may
extend radially through the post. The suture 586 may be threaded
through the channel. In a simple configuration, the suture 586 may
be wrapped over itself on the post 582, like a spool of string. In
an exemplary method of use as shown in FIGS. 36A and 36B, the
suture or cable 586 is placed through or around tissue 588 such as
a rotator cuff. The suture 586 is attached to the post 582 of the
fastener 580 as previously described. The fastener 580 is then
rotated to coil up the suture 586 on the post 582 and draw the
rotator cuff 588 in close to the fastener 580. To secure the
assembly, the fastener 580 is inserted into tissue such as bone
590. Ultrasonic energy is applied to the fastener 580 to bond the
fastener to the tissue 590 and bond the suture 586 to the post 582
of the fastener 580. In this position, the rotator cuff is securely
fastened to the bone.
[0287] FIG. 37 illustrates another exemplary use of the cable
tensioning fastener 580 of FIGS. 36A and 36B. A first tensioning
fastener 580 is positioned in a vertebral body 592. A second
fastener 580 is positioned in an adjacent vertebral body 592. A
cable 586 spans between the posts of the first and second
fasteners. One or both fasteners are rotated to tension the cable,
and the fasteners are implanted in the vertebrae and ultrasonically
welded in place. Third and fourth fasteners are implanted in
spinous processes 594. A tensioned cable 586 is connected with the
fasteners 580. The embodiment of FIG. 37 provides controlled
stabilization of the spine by affixing flexible or non-flexible
cables between vertebrae. Flexible cables provide dynamic
stabilization, while non-flexible cables provide rigid
stabilization.
[0288] The present invention also provides a glenoid replacement
component 600A, shown in FIG. 38A. The inner side is configured for
placement on the scapula 602, and the outer side is configured for
articulation of the head 604 of the humerus 606. Thermoplastic
fasteners 608 secure the component 600 to bone. In FIG. 38B, a
glenoid replacement component 600B is shown having prongs 610
extending from the inner side. The prongs 610 may be inserted into
pre-drilled holes in the scapula and ultrasonically welded therein.
FIG. 38C illustrates another embodiment of a glenoid replacement
component 600C. The component 600C includes two thru-holes 612
extending from the outer to the inner side of the component. PEEK
fasteners may be used to secure the replacement component to bone.
The caps or heads of the fasteners may be contoured and flattened
so as to not interfere with the head of the humerus.
[0289] Referring now to FIG. 39, a thermoplastic cross pin 620 is
illustrated. The pin 620 may be made of PEEK. The cross pin 620 is
used to stabilize and strengthen the neck 622 and head 624 of the
femur 626. To implant the pin, the pin 620 is positioned in a
channel extending into the neck 622 and head 624. The pin 620 may
be mechanically locked within the channel and/or may be thermally
bonded within the channel. Thermoplastic fasteners 628 are placed
through the cortical bone of the femur 626 and into contact with a
bonding region on the pin 620. As previously described, the bonding
region may be a roughened surface, an indentation, a blind- hole,
or a thru-hole. The fasteners 628 are then ultrasonically welded to
the pin 620 and bone to secure the pin 620 within the femur 626.
FIG. 40 illustrates a cross pin jig 630 to be used during
implantation of the pin 620. The jig 630 includes a shaft 632 and a
series of pivoting arms 634 connected with the shaft 632. At the
end of the pivoting arms 634 is an insertion guide 636. The guide
636 has a passageway 638 configured for guiding a fastener. The
arms 634 pivot in one plane with respect to the shaft 632 such that
the passageway 638 of the insertion guide 636 is always aligned
with the shaft 632. In use, the shaft 632 of the jig 630 is
inserted into the drilled channel extending into the neck and head
of the femur. The insertion guides 636 are positioned adjacent the
surface of the bone. A drill and bit is placed in the guide 636 and
a hole is created through the cortical bone terminating in the
channel. A plurality of holes may be formed in the bone to receive
a plurality of fasteners. Once the holes have been drilled, the jig
630 is removed and the cross pin 620 is inserted into the channel.
Fasteners are then placed through the holes and into contact with
the cross pin 620. Ultrasonic welding bonds the fasteners, cross
pin, and bone together. In an alternative embodiment, the shaft of
the jig has a diameter which slides into a central passageway of
the cross pin. In this embodiment, the cross pin may be implant in
the channel, then the jig may be placed in the cross pin.
[0290] In a related invention, FIG. 41 shows a tissue cauterization
device 640. A cut or opening 642 is formed in soft tissue such as
skin 644. To stop bleeding at the cut, ultrasonic energy may be
applied to the tissue. An energy horn 640, similar to those
previously described, may be placed in contact with bleeding tissue
644. Ultrasound energy emitted from the horn stops the flow of
blood by hemostasis. In FIG. 42, ultrasound from an energy horn 640
is applied to gelatin 648 within a joint 650. The gelatin 648 binds
to the tissue and stops bleeding. Gelatin, or other suitable
substance, may also be used with the tissue cauterization device of
FIG. 41.
[0291] FIG. 43 illustrates a periosteal flap 660 used to repair a
damaged bone 662. The flap 660 is fastened to the bone 662 using
thermoplastic fasteners 664 and methods previously described.
Tissue grafts may also secured intracorporeally using PEEK
fasteners and ultrasonic energy.
[0292] It is also contemplated that metal may be ultrasonically
welded to PEEK. For example, a fastener may be made of metal. By
placing the metallic fastener on the end effector of the welding
instrument, the fastener functions as an extension of the end
effector. Therefore, applying pressure from an ultrasound-emitting
metallic fastener to a PEEK implant drives the fastener into the
implant and thereby secures the fastener to the implant. It is
further contemplated that a thermoplastic fastener may be bonded
with a metallic implant. Accordingly, the devices and methods
described throughout may utilize metallic fasteners bonded to
thermoplastic implants and thermoplastic fasteners bonded to
metallic implants.
[0293] In a further embodiment of the present invention, a method
for securing a thermoplastic fastener 670 into tissue 672 is
provided. FIGS. 44A and 44B illustrate the method. In FIG. 44A, a
channel 674 is drilled in tissue such as bone 672. The fastener 670
includes a post 676 and a lid 678, similar to other fasteners
disclosed herein. The diameter of the post 676 is greater than the
diameter of the channel 674 in the bone 672 such that the fastener
670 does not freely slide into the channel 674. In FIG. 44B, an end
effector 680 is placed in and on the fastener 670. Ultrasonic
energy is emitted from the end effector 680 to soften the
thermoplastic material of the fastener 670. Simultaneously,
downward pressure is applied to the end effector 680 and fastener
670 so that the softened material conforms to the smaller diameter
of the channel 674. The fastener 670 is moved distally until it is
fully seated in the bone 672. After energy is no longer emitted,
the thermoplastic material re-hardens thereby securely bonding the
fastener 670 to the bone 672.
[0294] In another application of the present invention,
thermoplastic fasteners may be used to lock a drug delivery system
to an implant or to tissue. For example, a reservoir, balloon, or
bladder may be placed within the body and filled with a
pharmaceutical substance, gene therapy, or cell therapy. Using PEEK
or other thermoplastic, the reservoir may be sealed and stabilized
in the body. The contents of the reservoir may leach out or elute
out from pores or openings in the reservoir material.
Alternatively, the thermoplastic may be biodegradable to allow the
contents to escape from the reservoir and into the body. It is
contemplated that other drug delivery systems may be used with the
present invention. Also, the pharmaceutical agents may include
antibiotics, hydroxyapatite, anti-inflammatory agents, steroids,
antibiotics, analgesic agents, chemotherapeutic agents, bone
morphogenetic protein (BMP), demineralized bone matrix, collagen,
growth factors, autogenetic bone marrow, progenitor cells, calcium
sulfate, immo suppressants, fibrin, osteoinductive materials,
apatite compositions, germicides, fetal cells, stem cells, enzymes,
proteins, hormones, cell therapy substances, gene therapy
substances, bone growth inducing material, osteoinductive
materials, apatite compositions with collagen, demineralized bone
powder, or any agent previously listed . U.S. Provisional Patent
Application No. 60/728,206 entitled "Drug Eluting Implant"
discloses means for delivering therapeutic agents. The
above-mentioned provisional application is incorporated by
reference herein in its entirety.
[0295] The welding system of the present invention may further
include the process of welding collagen similar to the way PEEK is
bonded. Collagen fibers may be infused within a biodegradable
polymer or gelatin to enhance welding properties. An energy source,
such as ultrasonic energy, may be used to weld the collagen. As
previously described the quality of weld depends upon the welding
parameters of time, energy time, wattage, frequency, pulsation,
pressure, etc. In an exemplary embodiment, collagen is placed in
biodegradable polyglycolic acid. Once implanted, the polymer would
biodegrade leaving the collagen fibers to heal surrounding tissue.
Also, imbedded in the polymer may be cells, antibiotics, keratin,
tissue inductive factors, or other pharmaceutical agents disclosed
herein.
[0296] Alternatively, the collagen fibers may be packed very
densely and may be desiccated. The fibers may be welded together or
an interfacial material such as talc, glass, graphite, or protein
may be added to harden the fibers to a gelatin. In an exemplary
embodiment, collagen fibers may be combined with denatured porcine
collagen cells. The two substances may be welded together to form a
unitary implant. The implant may be fastened within the body for
cell therapy, gene therapy, or for the delivery of pharmaceutical
agents.
[0297] Another welding technique that may be utilized with the
present invention is plasma welding. Generally, there are four
states of matter in physics: solid, liquid, gas, and plasma. Plasma
is a gas in which atoms have been ionized. Therefore, plasma has
magnetic and electrical fields that move unpredictably, altering
the environment. As the environment changes, so does the plasma.
These ionized gases or plasma can be used to fuse bone or weld
material within the body. Plasma welding may be controlled similar
to the way thermal welding is controlled as previously described. A
plasma stream may be used for polymeric welding, protein welding,
or collagen welding. When welding intracorporeally, cold plasma
welding may be used to prevent tissue necrosis. Cold plasma can
weld tissue, polymers, metals, ceramics, and composites to each
other and to one another. Cold plasma may also be used to debride
wounds in surgery, to selectively kill bacteria, to roughen the
surface of tissue to make it more receptive to pharmaceutical
agents, or to prepare a surface of a bone for a joint replacement
component. It can also be used to shrink tissue and polymers,
ablate tissue, or smooth out wrinkles for plastic surgery either on
the surface of the skin or under the skin. Cold plasma welding may
be performed through a cannula in a straight line or
curved/deflected to reach a target site within the body. The plasma
energy may be altered by accelerating electrical charges or
electromagnetic fields.
[0298] In a related invention, welding of thermoplastics, tissue,
implants, etc. described herein may be performed utilizing suction
or negative pressure. For example, suction may be applied to a bone
to pull a cartilage graft or plate to the surface of the bone. A
tube may be placed within the bone to create a negative pressure.
This would temporarily hold the implant and contour it to the
surface while an energy source is used to weld the graft to the
bone with or without traditional or thermoplastic fasteners. Also,
suction may be used to stabilize an implant during welding or while
an adhesive is curing. Examples of biocompatible adhesives include
mollusk adhesive, protein adhesive, fibrin adhesive,
cyanoacrylates, or other known adhesives.
[0299] The present invention also may be used in other ways for the
fixation or securing of tissue and/or implants during a surgical
procedure. The use of the invention in such a procedure may assist
in restoring at least partial tissue-function in a treated area. In
this scenario, the fixation device may include a tissue-penetrating
cap positionable in an anchor. Tissue may be fastened so that
tissue-function is at least partially restored and the operation
region is stabilized for enhanced healing.
[0300] The fixation devices of at this and other embodiments of the
invention may be used in combination with fasteners in the prior
art. Examples of fasteners, implants and their methods of
employment may be found in U.S. Pat. Nos. 5,163,960; 5,403,348;
5,441,538; 5,464,426; 5,549,630; 5,593,425; 5,713,921 ; 5,718,717;
5,782,862; 5,814,072; 5,814,073; 5,845,645; 5,921 ,986; 5,948,002;
6,010,525; 6,045,551; 6,086,593; 6,099,531; 6,159,234; 6,368,343;
6,447,516; 6,475,230; 6,592,609; 6,635,073; and 6,719,765. Other
fastener types are disclosed in U.S. patent application Ser. Nos.
10/102,413; 10/228,855; 10/779,978; 10/780,444; and 10/797,685. The
above cited patents and patent applications are hereby incorporated
by reference in their entirety.
[0301] FIG. 45 illustrates an exemplary embodiment of a fixation
device 682 of the present invention, where the fixation device
includes a cap 684 and an anchor 686. The anchor 686 is generally
cylindrical in shape and includes a bore 688 disposed in a first
end of the anchor 686. A second end of the anchor may be
substantially conical although as explained in greater detail below
the second end may have other shapes as well. The central
longitudinal axis of the bore 688 may be congruent with a central
longitudinal axis of the anchor 686. The bore 688 may extend only
partially into or completely through the anchor 686. The anchor of
FIG. 45 includes threads 690 in a helical pattern disposed on the
exterior surface. The helical threads 690 are configured to allow
the anchor 686 to be inserted in tissue similar to the way a screw
is inserted into wood, with or without a pre-drilled hole.
[0302] The cap 684 of the fixation device 682 includes a lid 692
and a post 694. The post 694 is generally cylindrical in shape and
is dimensioned to fit within the bore 688 of the anchor 686, while
the lid 692 is generally disk shaped. The proximal end of the post
694 is connected with the underside of lid 692 to form a fastener
configuration similar to a nail. The cap 684 may be cannulated,
i.e. a channel may extend through the longitudinal axis of the cap.
The channel may be dimensioned for the positioning of a guide wire,
insertion tool, and/or energy source therein. The distal portion of
the post 694 may be chamfered to form a pointed tip 696. The
chamfered surfaces of the distal portion may extend from the distal
opening of the channel to the outer surface of the post 694. The
chamfered post tip 696 allows the cap 684 to penetrate through
tissue without substantial tearing.
[0303] The post 694 of the cap 684 and bore 688 of the anchor 686
may further include one or more mechanical locks that may be used
to help hold the cap 684 and anchor 686 together when desired. For
example, a mechanical lock can be used to hold the cap tip 696,
post 694, or other portions of the cap 684 within the anchor 686
when the device is being employed to secure tissue and/or an
implant. Examples of mechanical locks may include one or more
projection 698 disposed on the outer surface of the post 694. FIG.
45 illustrates one example of a projection where the cap post 694
has a circumferential ridge 698. One or more corresponding
indentation(s) or grooves may likewise be provided in the surface
of the anchor bore. Alternatively, one or more projections may be
provided on the anchor bore, and the cap post may have one or more
indentations or grooves.
[0304] Other mechanical locks may also be used with this and other
embodiments of the invention. For example, a mechanical lock may
utilize a mechanically, outwardly expanding post and/or a
mechanically inwardly expanding anchor/bore; a hydrophilically,
outwardly expanding post and/or a hydrophilically, inwardly
expanding anchor/bore; helical threads on the post and
corresponding threads in the bore; and biocompatible adhesive
disposed in the bore of the anchor and/or on the post of the cap.
Examples of adhesives may include cyanoacrylate adhesives, hydrogel
adhesives, monomer and polymer adhesives, fibrin, polysaccharide,
Indermil.RTM. or any other similar adhesive. Other exemplary
mechanical locks discussed in greater detail herein may also be
applied to many embodiments of the invention.
[0305] Alternatively, the cap 684 may be secured to the anchor 686
by thermal fastening. As previously explained, certain materials of
the cap 684 and anchor 686 may have the characteristic of becoming
melted, tacky, and/or flowable when energy such as heat is applied
to the fixation device. The material may be resorbable by the body
or non-resorbable. Such material may include polylactic acid
(PLLA), polyglycolic acid (PGA), a co-polymer of PLLA and PGA,
resins, polyetheretherketone (PEEK), polyethylene (PE),
ultra-high-molecular- weight-polycarbonate (PC), acetal (Delrin),
and other suitable polymers. The thermally bonding material may be
dispersed within the cap and anchor and/or may be coated on the
surface of the cap and anchor. Additionally, the cap and the anchor
may be made entirely from the thermally bonding material.
[0306] In an exemplary embodiment, the fixation device is made of
PEEK which is a suitable thermally bondable material. Also, an
implant in which the fixation device fastens to tissue may include
a thermally bondable material. For example, a plate, rod, spacer,
wedge or other implants disclosed herein may be secured to tissue.
An energy source, such as ultrasound or resistive heating, may be
used to secure the cap to the anchor and to secure the implant to
the fixation device. The energy source also may heat the implant
which may include thermally deformable material, such as PEEK. The
implant may also be deformable or conformable to adjacent
tissue.
[0307] To bond the cap 684 and anchor 686 of the fixation device
682 together, an energy source may be applied to one of or both of
the cap 684 and anchor 686. Suitable energy sources may include
ultrasonic; RF; laser; heat transmitted through conduction,
convection, or radiation; resistive heating; microwave;
electromagnet; ultraviolet; infrared; electro-shockwave; or other
known energy sources. The cap 684 and anchor 686 may also be
coupled by protein welding. Preferably, when the cap 684 and anchor
686 are designed to be thermally coupled, at least a portion of
both the cap and anchor include, or are made of a thermally
bondable polymer, such as those previously described. The use of
energy to bond the cap 684 and anchor 686 which have similar
polymeric material allows the melting of the material to occur
consistently or uniformly throughout welded area of the fixation
device 682. This helps reduce the risk of necrosis to the
surrounding tissue and also is believed to provide better control
of welding conditions. If the thermally bondable material is metal,
magnetic pulse welding could used to bond the cap and anchor of the
fixation device.
[0308] To apply an energy source to the fixation device 682, the
energy producing instrument may include a projection, such as an
arm, which is positionable within the cannulated cap 684 and anchor
bore 688. In this configuration, energy may be emitted from the
projection and into the cap 684 and anchor 686. Since the
projection extends through the cannulated cap and anchor, the
fixation device 682 is subjected to energy along its longitudinal
length. Therefore, the material of the cap 684 and anchor 686 may
be bonded in a consistent, even, and/or uniform manner.
[0309] It is also contemplated that the fixation device 682 may
include energy focusing material. The energy focusing material may
be particles or chips disposed within the material of the cap 684
and/or anchor 686. The energy focusing material also may be a
sleeve or particles disposed in the channels of the cannulated cap
684 and anchor bore 688. The energy focusing material may also be
dispersed in rings or discs disposed within the material of the
device 682. The rings may be positioned generally perpendicular to
the longitudinal axis of the device. Furthermore, the energy
focusing material may be disposed in bars or rods positioned
generally parallel to the long axis of the device. The energy
focusing material may be metallic, ceramic, polymeric, composite,
or other suitable material. For example, iron oxide may be used.
The energy focusing material may help capture energy from an energy
source and/or emit energy for bonding the cap and anchor to each
other.
[0310] An exemplary process for ultrasonic welding is illustrated
in FIG. 46. The welding process begins by either pushing the
generator footswitch or using the control on the hand piece. Upon
starting, the generator may first perform a system check. The
software may also check for proper patient grounding, ground offset
issues, as well as other vital circuits. If there are errors with
the system or the grounding, the generator can give a visual or
audible indication that an error has occurred, and the ultrasonic
signal generator may be disabled to prevent inadvertent use.
[0311] If no errors are detected, the system may then sweep a
frequency range, such as from about 38.5 kHz to about 43.5 kHz, to
tune the circuit. Current measurements may be used to find the
resonate frequency of the system, which in some embodiments may be
close to 41 kHz. The ultrasonic signal is then sent to the hand
piece where a resonator turns the waveform into linear
movement.
[0312] Welding of the fixation device of the present invention
could also be done using thermal energy. The process for thermal
welding is similar to the one used for ultrasonic, except that it
may not be necessary to tune the system. The energy signal sent to
the weld can be either AC or DC. To allow for longer heater life, a
pulse width modulated (PWM) signal could be used. The PWM signal
allows for the energy to be rapidly switched on and off with a
varying duty cycle proportional to the total system energy needed
for the weld environment.
[0313] Another way to connect the cap and anchor of the fixation
device may be through the combination of mechanical locking and
welding. For example, the outer surface of the cap post 694 may
include a circumferential ridge 698 and the interior surface of the
anchor bore 688 may include a corresponding circumferential groove.
Both the cap 684 and anchor 686 could include, or be made of, a
biocompatible, thermally bonding polymer. The mechanical lock of
the fastener could hold the cap 684 in the anchor 686 while an
energy source, like an ultrasonic welder, is used to melt and bond
the cap 684 and anchor 686 together. In this configuration, the
mechanical lock may act as a temporary hold until the cap 684 and
anchor 686 are permanently welded together. This configuration
allows a surgeon to temporarily connect the cap 684 and anchor 686
and then inspect the assembly and tissue or implant to confirm it
is in a desired position.
[0314] Alternatively, the fixation device 682 may include a more
permanent mechanical lock in combination with thermal bonding. For
example, the cap post 694 may include helical threads and the
anchor bore 688 may include corresponding helical threads 690. In
this configuration the cap post 694 may be screwed into the anchor
686 to securely connect the cap and anchor. The holding power of
the cap and anchor may then be enhanced by thermally bonding the
material of the cap and anchor together.
[0315] As previously described, the anchor 686 of the fixation
device 682 may be screwed into a pre-drilled passageway in bone.
The helical threads 690 disposed on the outer wall of the anchor
allow the anchor to be screwed into and secured in the drilled
passageway. Another way to implant the anchor 686 is by providing a
self-penetrating or self-tapping helical thread configuration. In
this configuration, the leading tip of the anchor 686 includes
sharp edges, similar to the distal end of a drill bit, to allow the
anchor to penetrate hard tissue as the anchor is being rotated.
Such an anchor may include rigid threads and/or a rigid exterior
wall on which the threads are disposed. The rigid exterior surface
may include metal or ceramic material which functions as a shell.
Within the rigid shell may be a polymer inner core including
thermally bondable material. The benefits of this anchor design are
that it is self-tapping requiring no pre-drilled passageway in bone
and that the cap post and anchor may still be thermally bonded
together.
[0316] Furthermore, the fixation device of the present invention
may include therapeutic substances to promote healing. These
substances could include antibiotics, hydroxyapatite,
anti-inflammatory agents, steroids, antibiotics, analgesic agents,
chemotherapeutic agents, bone morphogenetic protein (BMP),
demineralized bone matrix, collagen, growth factors, autogenetic
bone marrow, progenitor cells, calcium sulfate, immo suppressants,
fibrin, osteoinductive materials, apatite compositions, germicides,
fetal cells, stem cells, enzymes, proteins, hormones, cell therapy
substances, gene therapy substances, and combinations thereof.
These therapeutic substances may be combined with the materials
used to make the device. Alternatively, the therapeutic substances
may be impregnated or coated on the device. Time-released
therapeutic substances and drugs may also be incorporated into or
coated on the surface of the device. The therapeutic substances may
also be placed in a bioabsorbable, degradable, or biodegradable
polymer layer or layers.
[0317] The therapeutic agents may also be placed within one or more
cavities disposed in a fixation device of the present invention.
Different agents may be disposed in different cavities of the
device to specifically tailor the implant for a particular patient.
Dosages of the therapeutic agent may be the same or different
within each of cavities as well. The cavities may include a cover
which may release the agent in a controlled or timed manner. The
cover may be biodegradable or bioerodible to allow the agent to
release to surrounding tissue. Examples of suitable therapeutic
agents include bone growth inducing material, bone morphogenic
proteins, osteoinductive materials, apatite compositions with
collagen, demineralized bone powder, or any agent previously
listed. U.S. Provisional Patent Application No. 60/728,206 entitled
"Drug Eluting Implant" discloses means for delivering therapeutic
agents. The above-mentioned provisional application is incorporated
by reference herein in its entirety.
[0318] FIG. 47A shows a cap 700 inserted within an anchor 702. The
post 704 of the cap 700 is positioned in the bore of the anchor
702. A gap 706 is shown between the bottom of the cap lid 708 and
the trailing end or proximal end of the anchor. When the fixation
device is in use, the tissue and/or implant to be fastened may be
placed in the gap 706 to thereby squeeze the tissue between the lid
708 and anchor 702.
[0319] In FIG. 47B, the interior configurations of the cap 700,
anchor 702, and heater 710 are illustrated. The anchor 702 includes
a bore 712 and channel 714. The bore 712 is dimensioned to receive
the post 704 of the cap 700. The channel 714 may be dimensioned to
receive the distal portion of the heater 710. The channel 704 may
also be dimensioned to receive a guide wire to assist in more
precise placement of the anchor 702 in tissue and placement of the
cap 700 within the bore 712 of the anchor 702. The cap 700 also may
have a bore 716 and a channel. The cap bore 716 may be dimensioned
to receive an intermediate portion of the heater 710, while the cap
channel may be dimensioned to receive the distal portion of the
heater 710 and/or a guide wire.
[0320] To lock the cap 700 and anchor 702 of FIG. 47B together, the
cap post 704 is inserted into the anchor bore and a lock 718 is
actuated to temporarily resist inadvertent separation of the cap
700 from the anchor 702. Preferably, the lock 718 prevents the cap
700 and anchor 702 from moving relative to each other. The heater
710 may be inserted through the cap bore 716, cap channel, anchor
bore 712, and anchor channel 714. The heater 710 may include a
curved or angled edge 720 a part of a transition between the
intermediate portion and distal portion of the heater 710. The
heater 710 may be inserted until the edge 720 contacts the cap bore
716. The portion of the cap bore 716 that contacts edge 720 may be
curved, angled, or otherwise configured to have a surface that
corresponds to the contact area of the edge 720. The cap angled
edge may form the transition between the cap bore and cap channel.
The contact between the cap and heater allows for the transmission
of forces from the heater to the cap and to the anchor. The applied
force helps create a snug fit between the cap post and anchor bore
while the heater applies energy to the fixation device for thermal
bonding.
[0321] FIG. 48 illustrates another embodiment of a fixation device
722. In this embodiment, the cap 724 includes a channel but does
not include a bore. The anchor 726 includes both a bore 728 and a
channel 730. As shown, the heater 732 has a cap-contacting surface
734 between its proximal portion and distal portion. In FIG. 47B,
the force was applied from the heater 710 to the cap 700 through
the angled edges of the heater and cap bore. However, in the
embodiment illustrated in FIG. 48 forces applied to the heater 732
may be transferred to the top surface of the cap 724. While the
force is applied, energy from the heater 732 may be released to
thermally bond the cap 724 and anchor 726. The cap 724 and anchor
726 may also include one or more temporary or permanent locks 736
as previously described.
[0322] Referring now to FIG. 49, another embodiment of a fixation
device of the present invention is employed to secure a first
tissue type or implant 740, such as a rotator cuff, to a second
tissue type, such as bone 742. Alternatively, a plate 740, such as
a bone plate, may be fastened to a fractured bone. Although a plate
740 is shown and described, other implants, such as a mesh, can be
used. The anchor 744 is inserted into a drilled passageway in bone
742. In this embodiment, the anchor 744 includes external helical
threads 746; therefore, the anchor 744 may be screwed into the bone
passageway. It is contemplated that such an anchor 744 having
helical threads 746 would also be configured to permit screwing of
the anchor 744 into the drilled passageway. For example, a groove
may be disposed on the bottom of the anchor bore. The groove may be
configured to receive a tool, such as a flat-head type screw
driver, for rotating the anchor into the bone; the bore itself may
be configured to receive an Allen-type wrench; or the trailing end
of the anchor may include a groove(s) to receive a fiat-head or
Phillips-head type tool. In one alternative embodiment, there may
be no structural feature of the anchor itself for insertion, but
rather a tool may be inserted and mechanically expanded within the
anchor bore to permit rotation of the anchor into tissue.
[0323] Insertion of the anchor 744 into the bone 742 may be further
performed with a guide wire 748 or other similar surgical
instrument. The wire 748 may be placed in the bone at the desired
location for the fixation device. The passageway in the bone may be
formed by moving a cannulated drill bit along the guide wire 748.
Then the anchor 744 may be slideably disposed over the guide wire
748 in the anchor channel and inserted into the drilled passageway.
The cap 750 is also slideably disposed over the guide wire 748 and
is moved through the soft tissue, such as the rotator cuff, and
into the anchor 744. The distal tip of the cap post 752 may be
chamfered to permit the post to penetrate through the soft tissue
without significantly damaging the tissue. The cap post 752 may be
further aided during insertion through the soft tissue by the use
of the distal tip of the guide wire 748 or the distal tip of an
energy source, such as the one described in FIG. 48. The post 752
shown in FIG. 49 may include a chamfered leading tip having no
blunt surface. A blunt-free tip and the use of a pointed guide wire
or pointed energy source may allow the cap to more easily penetrate
the soft tissue in stages. That is, first the guide wire 748 or
energy source may be used to create a small hole in the soft
tissue. Then, the blunt-free, chamfered tip of the post 752 may
stretch or widen the hole to a larger diameter without significant
tearing of or damage to the soft tissue.
[0324] With the cap 750 disposed in the soft tissue, the cap post
752 is inserted into the anchor bore. A mechanical lock 754 may be
utilized to hold the cap 750 and anchor 744 together while an
energy source is used to weld the cap and anchor together. In this
final configuration, the soft tissue is sandwiched between, and
preferably is held firmly against the bone by the underside of the
cap lid 756.
[0325] FIG. 50 shows another exemplary embodiment ofr a fixation
device. The anchor 760 is similar in construction to the anchor of
FIG. 49. However, the anchor bore 762 and the cap post 764 do not
have a mechanical lock. Instead, fastening of the cap and anchor is
provided by thermal bonding only. Preferably, both the cap 766 and
anchor 760 include, or are made of, the same or similar
biocompatible polymer so that the two components of the fixation
device may be easily welded together. With the cap post 764 being
free of any mechanical lock, the cap 766 is able to be positioned
anywhere within the bore 762 of the anchor 760. Therefore. if the
tissue or implant to be fastened to the bone is thin, the cap 766
may be inserted fairly deeply into the anchor 760 and welded. If
the tissue or implant is thick, the same length cap may still be
used with the anchor; however, the cap post 764 is just not
inserted as far into the anchor bore 762 prior to welding.
Alternatively, a plurality of caps having differing length cap
posts may also be provided so that the surgeon may select a cap of
desired length according to the type of tissue or implant used in
the treated area. If two or more caps of differing lengths are
provided, the different sizes may be indicated on the caps, such as
by molding a size or other indicator onto the cap lid 768.
[0326] One notable feature of the embodiment of FIG. 50 and other
embodiments described herein is the lack of energy directors
required for welding the cap to the anchor. Some prior art
fasteners designed for thermal welding require projections disposed
between the two parts of the fasteners. Often, these directors take
the form of longitudinal ridges disposed on the outer surface of a
male fastener section or disposed on the inner surface of a female
fastener section. The purpose of the directors is to concentrate
the energy thereon to weld the fastener sections together. As seen
in FIG. 50, no directors are disposed between the cap and anchor.
When an energy source, such as an ultrasonic welder, is placed in
the cap 766, substantially all, and preferably the entire exterior
surface of the cap that is in contact with the anchor bore may be
welded to the anchor. This produces a uniform bond between the cap
and anchor. Alternatively, because the cap is cannulated, the
distal tip of the energy source may be positioned adjacent the
contact location of the distal end of the cap post and the distal
end of the anchor bore. This allows the energy source to weld the
cap and anchor at that contact location.
[0327] As previously mentioned, the cap and anchor of the fixation
device may be held together by a mechanical lock, by thermal
bonding, or by a combination of mechanical locking and thermal
bonding. The embodiment of FIG. 51 includes an example of a
fixation device 770 having a permanent type of mechanical lock.
With a permanent type of mechanical locking, thermal welding may
not be necessary to hold the cap and anchor together because the
mechanical lock may provide sufficient holding strength on its own.
The anchor 772, as shown, is similar to the anchors previously
described. However, in this embodiment, the anchor bore 774
includes helical threads 776 disposed in the wall of the bore 774.
The bore threads 776 are configured to receive threads 778 disposed
on the exterior surface of the cap post. The cap 780 is insertable
within the anchor by screwing the cap post 778 into the anchor bore
774. In addition, to enhance the holding power of the fixation
device, the cap 780 and anchor 772 may include a biocompatible
polymer which bonds together with the application of energy, such
as ultrasonic energy.
[0328] It is also contemplated that a washer or spacer may be
utilized with the fixation device of FIG. 51. The washer may be
placed over the cap post 778 and positioned against the bottom side
of the cap lid 782. Therefore, as the cap 780 is being screwed into
the anchor 772, the washer prevents the spinning cap 782 lid from
damaging the tissue. The washer would remain stationary relative to
the tissue, while the cap lid 782 would spin against the washer. As
illustrated in FIG. 50, the surface of the washer that contacts
tissue or an implant may be configured with a plurality of
projections that can help grip the tissue or implant material.
[0329] Like the embodiment described above, the fixation device 790
of FIG. 52 includes a permanent type of mechanical locking. The
anchor 792, as shown, is similar to the anchors previously
described; however, the anchor bore 794 includes a plurality of
circumferential grooves 796 disposed in the wall of the bore. The
bore grooves 796 are configured to receive circumferential ribs 798
disposed on the exterior surface of the cap post. The cap 800 is
insertable within the anchor 792 by pushing the cap post into the
anchor bore 794. In addition, to enhance the holding power of the
fixation device 790, the cap 800 and anchor 792 may include a
biocompatible polymer which bonds together with the application of
energy, such as ultrasonic energy. The configuration of the
mechanical lock of this embodiment may he altered so that the cap
post has a plurality of groves or indentations, which the anchor
bore has a plurality of projections or ribs.
[0330] FIGS. 53 and 54 illustrate yet another embodiment of a
fixation device 802 of the invention. The anchor 804 may include a
material which is polymeric, hydrophilic, expandable, compressible,
or combinations thereof. The anchor 804 may be made of such
material or the material may be mixed within or coated on the
anchor. For example, the anchor may include, or be made of, a
hydrophilic material which expands when it comes in contact with
liquid. The hydrophilic material may be desiccated body tissue,
foam, or a polymer. A hydrophilic anchor 804 is shown in FIG. 53 in
a normal, non-expanded configuration. Body fluid is absorbed by the
anchor 804, and it swells to a larger diameter or greater size. The
expansion of the anchor results in an interference fit between the
anchor 804 and the bone, tissue or material 806 in which it is
disposed, thereby providing frictional forces on the outer surface
of the anchor to increase its gripping force. Projections 808 may
be disposed on the outer surface of the anchor 804 to further
increase the frictional forces that hold the expanded anchor in
place.
[0331] In its initial, non-expanded configuration, the anchor 804
and projections 808 may fit within the bore of the anchor. In the
expanded or swelled configuration, the projections 808 may be
forced into the surrounding tissue to thereby help lock the anchor
804 to the tissue 806. The projections 808 may be small pointed
nubs, angled ramps, raised ridges, spikes, circumferential rings,
and similar configurations. The projections 808 illustrated in
FIGS. 53 and 54 are angled ramps oriented in opposite directions so
that the proximal ramps prevent the anchor from being pulled out of
the tissue while the distal ramps prevent the anchor from being
pushed further into the tissue.
[0332] In another example, the anchor 804 may include, or be made
of, a compressible-expandable material, such as foam, gel, or a
polymer. Prior to insertion of the anchor 804 into the drilled
passageway in the tissue, the anchor and projections may be
compressed into a smaller diameter or size. The compressed anchor
804 may be positioned in the tissue as shown in FIG. 53 and then
allowed to expand to its normal, expanded configuration as seen in
FIG. 54.
[0333] It should be noted that regardless of whether the anchor
includes a hydrophilic material or a compressible-expandable
material, the cap 810 may be secured to the anchor 804 by a
mechanical lock, by thermal bonding, or by a combination of
mechanical locking and thermal bonding. Also, the cap 810 may be
secured to the anchor 804 by the expanding feature of the anchor
804. Not only may the anchor expand radially outward to increase
overall diameter size, but it may also expand radially inward into
the cap post 812 thereby enhancing the locking strength between the
cap and anchor. This inward expansion of the anchor 804 against the
cap 810 may be the sole means for fastening the cap 810 and anchor
804 or may be utilized in conjunction with mechanical locking or
thermal bonding as described herein.
[0334] For example, an anchor 804 of the present invention may be
made of a material which expands hydrophilically or inherently
after compression and which can be thermally welded to a polymer in
the cap. The expansion of the anchor 804 locks the anchor to tissue
806 and provides additional holding power of the cap 810 and anchor
804 in conjunction with a thermal weld. As another example, the
anchor 804 could have a coating which expands hydrophilically or
inherently after compression. The coating may be placed over a
polymer material which may not expand but which may be thermally
weldable to the cap 810. In this example, the anchor 804 may not
expand inwardly against the cap 810; but instead a thermal weld,
and if desired a mechanical lock, may be used to secure the cap and
anchor.
[0335] As best seen in FIG. 54, an energy source is positioned
through the cannulated cap 810 and anchor 804. Energy, such as
ultrasound, heat, or RF, is transmitted to the fixation device to
bond the cap and anchor. The energy source 814 shown in FIG. 54
includes a lid-contacting surface 816. Therefore, because the
anchor 804 includes projections 808 to help prevent the anchor 804
from being pushed further into the tissue, a force can be applied
to the cap lid 818 through the energy source to thereby firmly
squeeze or pinch the tissue or implant 820 between the cap lid 818
and bone 806.
[0336] FIGS. 55 and 56 illustrate an exemplary embodiment of the
fixation device having an expandable anchor 822 without projections
disposed on the outer surface of the anchor. Instead, the anchor
822 has a substantially smooth exterior surface and a non-expanded
diameter which is equal to or slightly less than the diameter of
the drilled passageway 824 in the bone 826. As seen in FIG. 55, the
anchor 822 in its non-expanded configuration is inserted into the
bone 826 such that the trailing end or proximal end of the anchor
822 is positioned at or slightly distal to the bottom surface of
the cortical bone 828. In this orientation, the anchor 822 can
expand into the cancellous bone 826, and the trailing end of the
expanded anchor 822 will be adjacent to the underside of the
cortical bone 828. In FIG. 56, an overlap region 830 is shown where
the expanded anchor 822 and cortical bone 828 overlap each other.
With the anchor 822 expanded and orientated in this way, the anchor
822 is held firmly in the bone thereby preventing the anchor from
being pulled out.
[0337] To secure the cap 832 to the lid 834, an energy source 836
may be positioned through the cannulated cap and anchor. Energy,
such as ultrasound, heat, or RF, may be transmitted to the fixation
device to bond the cap 832 and anchor 822 when the fixation device
includes a thermally bondable material. Alternatively, or
additionally, the exterior surface of the cap post 838 and the
inside wall of the anchor bore may include a mechanical lock.
Alternatively, or additionally, the anchor may expand inwardly to
hold the cap relative to the anchor.
[0338] FIGS. 57A-57D illustrate an exemplary method of implanting
the fixation device to secure tissue to bone. Shown in FIG. 57A, an
anchor 840 is inserted into a drilled passage 842 in a bone,
tissue, or implant 844. The anchor 840 includes helical threads 846
to form a mechanical lock between the anchor 840 and bone, tissue,
or implant 844. To further stabilize the anchor 840, at least a
portion of the anchor 840 may be expanded within the bone passage.
The tissue 848 may be speared with a cap post 850 and an insertion
instrument 852 which may be disposed in the cannulated cap. As
previously described, the insertion instrument 852 or guide wire
may have a pointed distal tip which helps create a small hole in
the tissue. Because the cap post 850 includes a chamfered distal
portion, the insertion of the cap post 850 through the tissue 848
stretches the small hole created by the insertion tool and presents
undesired excessive tearing of the tissue 848.
[0339] In FIG. 57B, the cannulated cap 854 and insertion instrument
852 are aligned with the anchor 840, and the cap post 850 is
inserted into the anchor bore. The insertion tool 852 is pushed
distally to squeeze the tissue 848 between the cap lid 856 and
anchor/bone. The cap post 850 may be inserted partially into the
anchor bore if thick tissue is being fastened, or the cap post 850
may be inserted further toward the bottom of the anchor bore when a
thin piece of tissue 848 is being fastened. In the latter
configuration, the anchor 810 may include a channel extending
between the distal tip and the bottom of the bore to accommodate
the pointed distal tip of the insertion instrument 852. Regardless
of the depth of insertion of the cap 854 into the anchor 840, a
mechanical lock may be engaged to temporarily or permanently secure
the cap 854 to the anchor 840.
[0340] Precise depth placement of the cap in the anchor may be
required for certain applications. For example, in rotator cuff
repair, the typical thickness of a healthy rotator cuff is 5 to 10
mm. Therefore, to provide a secure fixation of the rotator cuff to
the bone, a gap between the lid and anchor/bone may be about 2 to 3
mm. To obtain a consistent gap, the anchor depth adjustment on the
insertion instrument could be manually set. The instrument could
have gradations that correspond to the depth of the anchor's top
surface into the bone. Also, the depth that the cap may be inserted
may be controlled with the insertion tool by adjusting the spacing
of the end effector and sheath covering the end effector. The
sheath may be marked with indicia or have a window through which
the cap can be seen. Furthermore, the cap itself may have a
mechanical stop preventing the cap from progressing too deep into
the anchor. The mechanical stop may be a stepped post shaft.
[0341] Moreover, the use of a mechanical lock, such as
circumferential ribs and corresponding grooves may be strategically
placed on the fixation device such that each locking or snapping of
a rib in a groove represents a known distance the cap has traveled
in the anchor. By knowing the distance the cap has been inserted in
the anchor, the gap distance can be determined. The desired gap
distance may also be preset into the energy source generator and
controlled with closed loop feedback by a position sensor such as
an LVDT. This could measure the amount the cap melts into the
anchor by stopping the energy when the desired gap is achieved.
Finally, for a mechanical locking cap, the cap insertion instrument
may include markings denoting depth of insertion.
[0342] The cap insertion tool 852 is removed in FIG. 57C and an
energy source 858 is inserted into the cannulated cap 854 and
anchor 840. Energy is applied to the fixation device to thermally
bond the cap and anchor together. Thermal bonding may be in
addition to mechanical locking or may be the sole means for bonding
the cap and anchor. FIG. 57D illustrates the fixation device
completely implanted. The tissue 848 is held firmly relative to the
bone 844. A portion of the tissue between the cap lid 856 and the
anchor 840 and bone 844 is being compressed.
[0343] Referring now to FIG. 58, two types of fixation devices of
the present invention are shown with a bone plate 860 to stabilize
a fractured bone 862. While the following example depicting a use
of the present invention involves only two devices and a plate, it
is contemplated that two or more fixation devices may be employed.
Also, instead of a bone plate 860, a tissue graft such as a bone
graft may be secured to a bone. As shown in FIG. 58, two anchors
864 are inserted into the bone 862. A bone plate 860 is positioned
adjacent the bone 862 with two holes in the plate aligning with the
two anchors 864. A cap 866 is then inserted through the bone plate
860 and into the each of the anchors 864. The caps 866 may be
secured to the anchors 864 by mechanical locks, by thermal bonding,
by expansion, or by combinations thereof
[0344] The design of the post of the cannulated cap permits the use
of a bone plate 860 which does not require pre-formed fastening
holes. Such a plate may be made from a polymeric material that is
strong enough to stabilize the bone, yet can still be penetrated by
the distal tip of the insertion tool and chamfered distal portion
of the cap post. In this embodiment, the location of the drilled
passageways in the bone for placement of the anchors does not need
to be aligned with pre-existing holes in the plate, giving the
physician greater discretion as to the placement of the fixation
devices.
[0345] Another embodiment of the present invention is illustrated
in FIG. 59. The anchor 870 and cap post 872 of this embodiment may
utilize any of the various structural features described herein.
The anchor 870 and cap post 872 may be secured together
mechanically, thermally, through expansion, or combinations
thereof. The cap lid 874 includes a lumen 876 extending radially
therethrough. The lumen 876 may be generally perpendicular to and
extend through the longitudinal axis of the cap. The lumen 876 may
be dimensioned to receive a portion of a suture, K-wire, cable, or
similar fastening member. The suture when placed through the lumen
of the lid provides for a secondary fixation of tissue and/or an
implant. For example, the cap may be inserted into the anchor 870
to secure a bone plate to a bone. For additional reinforcement, a
suture may be positioned through the lumen 876 of the lid, wrapped
around the bone and plate, and secured.
[0346] FIG. 60 shows yet another embodiment of the fixation device
of the present invention. Unlike a cap lid having a lumen for the
passage of a suture as described above for FIG. 59, the cap lid 880
of FIG. 60 includes a suture or wire 882 molded into or attached to
the lid 880. The suture 882 may be connected on a side surface or
the top surface of the lid. The suture 882 extends from the lid 880
and is positionable about tissue and/or an implant. A portion of
suture is also positionable between the underside of the lid 880
and the upper surface of the anchor 884. In this configuration, an
anchor 884 may be inserted into tissue and the cap 880 is then
positioned in the anchor bore but not yet welded to the anchor. A
portion of the suture 882 may be sandwiched between the cap lid 880
and anchor 884, then the cap is secured to the anchor either
mechanically, thermally, via expansion, or combinations thereof. As
seen in FIG. 60, the suture 882 may extends from one side of the
cap, can be looped around tissue or an implant, and may be returned
generally to the opposite side of the cap 880 to be pinched and
secured to the fixation device.
[0347] FIG. 61 depicts another embodiment of a fixation device 890
with a suture 892. A lumen 894 extends radially through the anchor
896 at a location intermediate between the leading and trailing
ends of the anchor. The lumen 894 may extend perpendicular to and
through the central longitudinal axis of the anchor 896. A groove
898 disposed in the threads or outer surface of the anchor 896 runs
generally parallel to the longitudinal axis of the anchor and
extends from one end of the lumen 894 to the trailing or proximal
end of the anchor 896. Another groove 898 disposed in the threads
of the anchor also runs generally parallel to the long axis of the
anchor but extends from the other end of the lumen 894 to the
proximal end of the anchor 896. A suture 892 is positionable within
the lumen 894 and grooves 898 of the anchor 896. The cap 900 of the
fixation device 890 may be similar to the cap described in FIG. 52
which has a plurality of circumferential ridges disposed on the
post. The anchor bore may have a plurality of corresponding
circumferential grooves disposed in the wall of the bore. The cap
post 902 has the additional feature of a cut-out or notch 904
located at the distal tip. The notch 904 is dimensioned to receive
one or more sections of suture.
[0348] In use, a suture 892 is positioned through the radially
extending lumen 894 and grooves 898 in the anchor 896. The anchor
896 is then inserted in tissue such that two sections of the suture
892 extend from the anchor/tissue. The suture sections are secured
to or around tissue or an implant such that a portion of one or
both suture segments is positioned over the proximal opening of the
anchor bore. The cap 900 is aligned with the anchor bore, and the
notch of the cap 904 is placed about one or both of the suture
segments 892. The cap 900 is moved into the anchor bore while
maintaining the suture segment(s) in the notch 904 of the post.
When fully seated, the circumferential ridges of the post mate with
the circumferential grooves of the anchor bore, and one or both
suture segments are pinched/held between the cap post and the outer
wall of the anchor bore.
[0349] In FIG. 62, another exemplary embodiment of the present
invention is illustrated. The anchor 910 in this embodiment
includes a post 912 extending from the proximal or trailing edge of
the anchor. The post 912 may include a pointed proximal tip to
permit the post to penetrate through and/or extend beyond tissue or
an implant. Preferably, the proximal tip does not include a blunt
end so that the tissue or implant is not unnecessarily torn or
damaged. The cap 914 includes a lid 916 and post 918 like previous
embodiments. However, in this embodiment, the post 918 includes a
bore 920 which is configured to receive the anchor post 912. The
cap post 918 may include a chamfered leading edge for easy
penetration of the cap post through tissue or an implant. The cap
914 and anchor 910 may be cannulated to allow insertion of a guide
wire or an energy source.
[0350] The fixation device of FIG. 62 may be used for the fixation
of tissue or an implant as follows. The anchor 910 is inserted in
tissue, such as bone, with the anchor post 912 extending from the
bone. The anchor 910 may include external helical threads 922 which
permit the anchor 910 to be screwed into the bone. Additionally, or
alternatively, the anchor 910 may be held in the bone via expansion
of the anchor. Tissue or an implant is aligned over the anchor and
pressed over the anchor post 912. The cap 914 of the device holds
the tissue to the bone by placing the cap post bore 920 over and
about the anchor post 912. The cap 914 and anchor 910 may be
secured to each other by mechanical means, thermal bonding, via
expansion, or combinations thereof. It is further contemplated that
implantation of the device may be performed over a guide wire
positioned in the cannulated cap and anchor.
[0351] Referring to the embodiment shown in FIGS. 63A and 63B, the
anchor 930 includes two posts 932. The anchor 930, if desired, may
include two or more posts 932. The posts may be parallel to or at
an angle to the longitudinal axis of the anchor. In FIG. 63A, the
two posts 932 are angled away from each other. In this
configuration the fixation device may provide an enhanced
stabilization and fixation of tissue or an implant. The cap lid 934
may be designed to remain generally parallel to the top surface of
the anchor 930, or they can remain perpendicular to the cap post
936 and be at an angle relative to the top surface of the anchor
930. The method of implanting the embodiment of FIGS. 63A-B is
similar to the implantation of the fixation device of FIG. 62.
However, multiple caps are inserted onto the multiple anchor posts
by way of mechanical locks, thermal bonding, anchor expansion, or
combinations thereof
[0352] As shown in FIGS. 64A and 64B, another exemplary embodiment
includes an anchor 940 having two bores 942. The anchor 940, if
desired, may include two or more bores. The bores 942 may be
parallel to, at an angle to, and/or offset from the longitudinal
axis of the anchor 940. The cap 944 includes a post 946 connected
with a lid 948. The cap post 946 is configured for insertion into
one of the bores 942 of the anchor 940. The distal tip of the cap
post is pointed for penetration through tissue or an implant. The
cap lid 948 may be designed to remain generally parallel to the top
surface of the anchor, or it can remain perpendicular to the cap
post and be at an angle relative to the top surface of the anchor.
The method of implanting the embodiment of FIGS. 64A-B is similar
to the implantation of the fixation device of FIGS. 63A-B. However,
multiple cap posts that penetrate the tissue or implant, are
positioned in the anchor bores, and are secured to the anchor by
way of mechanical locking, thermal bonding, anchor expansion, or
combinations thereof.
[0353] Referring to FIG. 65A, another exemplary fixation device is
illustrated. The anchor 950 includes two slots 952 disposed in the
wall of the anchor. The slots 952 extend from the trailing end of
the anchor to an intermediate area between the trailing and leading
ends of the anchor 950. The slots 952 extend completely through the
anchor wall. The exterior surface of the anchor includes
protrusions 954 that increase the frictional forces between the
anchor and the engaging tissue. Any configuration or structure
described herein may be used to increase the frictional forces. As
illustrated in FIG. 65A-B, the protrusions 954 may comprise a
plurality of circumferential ribs. The cap 956 of the fixation
device includes a lid 958 and post 960. The cap post 960 is
connected with the lid 958 and tapers in diameter as the post
extends from the lid 960. The distal tip of the cap post 960
includes a chamfered point for piercing and stretching tissue.
[0354] In use, the anchor 950 is inserted in tissue such as bone or
in an implant material. The anchor 950 may be inserted in a
pre-drilled passageway in the bone or may be include a self-tapping
tip and not require a pre-drilled hole. Tissue or an implant may be
positioned over the anchor 950, and the cap 956 can be inserted
into the anchor bore 962 through the tissue or implant. As seen in
FIG. 65B, the cap post 960 is inserted into the bore of the anchor.
Because the cap post 960 is tapered, as it is pushed into the
anchor bore 962, portions of the anchor 950 are separated as the
slots bias outward. In this configuration, the anchor is locked
into the bone with the circumferential ribs and by the outwardly
biased anchor portions. If movement of the anchor wall is
restricted by bone, tissue, or an implant, then the resistive
forces may instead be increased at insertion of the cap post 960
imparts outward pressure on the anchor walls. The cap and anchor
may be bonded together by mechanically locking, thermal bonding,
via expansion, or combinations thereof. The cap 956 and anchor 950
may be cannulated to receive a guide wire, insertion tool, and/or
energy source.
[0355] In FIG. 66, an embodiment similar to FIGS. 65A-B is shown,
except the exterior surface of the anchor 964 is substantially
smooth. The anchor 964 also includes two or more slots 966 disposed
in the anchor wall. It is contemplated that the anchor may include
two, three, four, five, six, or more slots. In use, the anchor 964
is inserted in bone such that the trailing or proximal end of the
anchor is positioned just under the bottom surface of cortical
bone. The cap 968 is inserted through tissue or an implant. The
tapered cap post 970 is moved distally into the anchor bore 972
forcing the anchor segments separated by the slots to outwardly
bias. The biased anchor segments penetrate into the surrounding
cancellous bone, and the proximal ends of the anchor segments
overlap the cortical bone. In this configuration the anchor is
prevented from being pulled out of the bone since the proximal ends
of the anchor segments come in contact with the underside of the
cortical bone. The cap and anchor may be bonded together by
mechanical locking, thermal bonding, via expansion, or combinations
thereof. The cap and anchor may be cannulated to receive a guide
wire, insertion tool, and/or energy source.
[0356] Referring to FIGS. 67 and 68, a triangulation fixation
device includes two anchors 980, 982 with a suture, cable, or band
984 attached to the anchors. A primary anchor 980 is generally
cylindrical in shape and includes a channel extending therethrough
at an angle to the central longitudinal axis of the anchor. The
channel is configured for receiving a secondary anchor 982. The
secondary anchor 982 includes a tissue-piercing and
tissue-stretching leading tip. The anchors may be cannulated to
allow insertion of a guide wire, insertion tool, and/or energy
source. The band 984 is connected to both the primary and secondary
anchors 980, 982. The band 984 may be pivotably or rotatably
attached to the anchors so that the anchors can be inserted in
tissue without the band being twisted or tangled.
[0357] To implant the triangulation fixation device, a primary
passageway is drilled in tissue such as bone. The diameter, depth,
and angle of the primary passageway are predetermined based on the
configuration of the primary anchor 980. A secondary passageway is
drilled in the bone which intersects the first passageway. The
diameter, depth, and angle of the secondary passageway are
predetermined based on the configuration of the primary and
secondary anchors 980, 982. The primary anchor 980 is first
inserted into the primary passageway. The primary anchor 980 may be
secured within the passageway by helical threads 986, by expansion,
or by other suitable means disclosed herein. The secondary anchor
982 is moved through tissue with the leading tip and positioned in
the secondary passage. The secondary anchor 982 is inserted into
the channel of the primary anchor 980 and fastened to the primary
anchor 980 by a mechanical lock, thermal bonding, expansion, or
combinations thereof. Locking the anchors together tensions the
band interconnected between the anchors thereby fastening the
tissue 988 to the bone.
[0358] Another embodiment of a triangulation fixation device is
shown in FIGS. 69 and 70. This embodiment is similar to the one
previously described except the anchors 990, 992 do not have
threads disposed on their outer surfaces, i.e., the anchors have
smooth sides. A suture, band, or other flexible material 994 is
disposed between the primary and secondary anchors 990, 992. The
suture 994 may be attached to the trailing end or the side of each
anchor 990, 992. The primary anchor 990 is generally cylindrical in
shape and includes a pocket or receptacle therein at an angle to
the central longitudinal axis of the anchor. The pocket or
receptacle is configured for receiving a distal portion of the
secondary anchor 992. The secondary anchor includes a
tissue-piercing and tissue-stretching leading tip. The chamfered
leading portion of the secondary anchor may 992 also act as a
conical energy director to assist in thermal bonding. The anchors
may be cannulated to allow insertion of a guide wire, insertion
tool, and/or energy source. The cannulas in the anchors may be
congruent to the longitudinal axis of the anchors or offset from
the long axis of the anchors so as to not interfere with the suture
or band 994.
[0359] To implant the triangulation fixation device of FIGS. 69 and
70, a primary passageway is drilled in tissue such as bone. The
diameter, depth, and angle of the primary passageway are
predetermined based on the configuration of the primary anchor 990.
A secondary passageway is drilled in the bone which intersects the
first passageway. The diameter, depth, and angle of the secondary
passageway are predetermined based on the configuration of the
primary and secondary anchors 990, 992. The primary anchor 990 is
inserted into the primary passageway, and then the secondary anchor
992 is moved through tissue with the leading tip and positioned in
the secondary passage. Insertion of the anchors may be performed
with a suitable insertion instrument. The secondary anchor 992 is
inserted into the pocket or receptacle of the primary anchor and
fastened to the primary anchor by a mechanical locking, thermal
bonding, expansion, or combinations thereof. As shown, an
ultrasonic end effector may be used to bond the anchors together.
Locking the primary and secondary anchors together helps prevent
the anchors from being pulled out of the bone.
[0360] The triangulation fixation devices described above included
a primary anchor having a channel, pocket or receptacle in which
the secondary anchor is positioned and secured. It is also
contemplated that the anchors may be attached to each other by way
of hooks, loops, latches, or similar mechanical means. For example,
one anchor may have a hook on its distal end while the other anchor
may have a hook or loop at its distal end. The anchors may be
positioned in their respective drilled passageways in bone and are
connected to each other with the hook/loop combination. In another
example, the primary anchor may have a hook/loop at its midsection
while the secondary anchor may have a hook/loop at its distal end.
The primary and secondary anchors may be secured together by such a
mechanical means.
[0361] The suture or band of the triangulation fixation device may
be tensioned to provide fixation of tissue and/or an implant. An
energy source may be used to shrink the suture or band to an
appropriate tension or length. The energy source may be one
previously described. Alternatively, or additionally, the band (or
anchors) may include shape memory material, such as Nitinol.RTM..
As this material is heated with a thermal probe or with natural
body heat, the device could flex or bend to self-tighten or lock in
tissue.
[0362] Referring now to FIG. 71, another embodiment of a fixation
device is illustrated. The anchor 1000 may have helical threads
1002 disposed on its outer surface for holding the anchor in
tissue, such as bone. The cap 1004 includes a post 1006 attached to
a lid 1008. Helical threads 1010 are disposed on the exterior
surface of the cap post 1006. The threads on the cap post and
anchor may be the same or different size. Also, the threads on the
cap post and anchor may both be right-handed threads or may both be
left-handed threads. Furthermore, the threads on one may be
right-handed, while the threads on the other may be left- handed.
The cap also includes a snap ring 1012 that allows the cap 1004 to
be locked into the anchor 1000 preventing it from coming out after
being screwed into the anchor bore. The snap ring 1012 on the cap
post 1006 mates with a groove in the wall of the anchor bore. As
shown in FIG. 71, the snap ring 1012 may be a circumferential ring
that is tapered at its leading portion and has a shoulder at its
trailing portion. The snap ring 1012 may extend partially around or
entirely around the cap post 1006. The groove in the anchor bore
may have a corresponding configuration to receive the snap ring.
The tapered leading portion of the snap ring 1012 allows the ring
to snap into the groove, and the shoulder prevents the ring (and
cap) from being pulled out of the anchor.
[0363] The cap 1004 and anchor 1000 may be cannulated to receive a
guide wire, an insertion instrument, and/or an energy source. As
illustrated, an insertion tool is disposed in the cannulated cap.
The insertion tool 1014 may include a piercing tip 1016 for
penetration through tissue. The insertion tool 1014 may also
include a mating means for temporarily connecting the tool and the
cap. Examples of mating means between the insertion tool and cap
may include a flat-shaped, square-shaped, rectangular-shaped,
hexagonal-shaped, or octagonal- shaped projection and a
corresponding socket.
[0364] FIG. 72 illustrates another exemplary embodiment of a
fixation device utilizing features of the invention. The device
includes an anchor 1020 having a post 1022 connected with a body
1024. The anchor body 1024 may include means for securing the
anchor body to the bone, such as helical threads, expansion, or
other suitable means. The anchor post 1022 is generally cylindrical
and has a bore extending therethrough, at least through the
proximal end of the post. The anchor post 1022 may include a
retaining ring or snap ring 1026 disposed on the outer surface of
the anchor post. The retaining ring 1026 may be a circumferential
projection or rib. The device further includes a tissue-piercing
pin 1028 which may be insertable and removable from the anchor post
bore. The pin 1028 may have a distal portion configured for
insertion into the bore of the anchor post 1022. The proximal
portion of the pin may be generally conical and have a point at the
proximal tip. The tip and conical shape are designed to pierce and
stretch tissue. The pin 1028 may be made of or include a metallic,
composite, ceramic, or polymeric material. In FIG. 72, the pin 1028
shown is made of stainless steel. The device also includes a cap
1030 being generally disk shaped. The cap 1030 includes an orifice
disposed therethrough which is dimensioned to receive the anchor
post 1022. The orifice has a diameter which is equal to or slightly
greater than the diameter of the anchor post. However, the orifice
diameter is not greater than the diameter of the retaining ring on
the anchor post.
[0365] As illustrated in FIG. 73, the anchor is inserted in tissue
1032, such as bone. A passageway may be drilled in the bone and the
anchor body inserted therein. Or, the anchor 1020 may be
self-tapping and therefore not require a pre-drilled passageway.
The anchor 1020 may be secured to the bone 1032 by mechanical means
such as threads, expansion, or similar means. With the anchor post
1022 extending from the bone, the pin is placed in the anchor bore.
Tissue 1034, such a rotator cuff, or an implant, such as a bone
plate, may be positioned over the anchor above the pin. The tissue
or implant 1034 is moved toward the bone such that the pointed and
chamfered end of the pin pierces the tissue/implant and the anchor
post penetrates through the tissue/implant. The pin may be removed
from the anchor post bore by a magnetic instrument, graspers,
claws, or other suitable surgical tool. The cap 1030 may be placed
over the anchor post 1022. The cap 1030 is moved toward the anchor
body thereby squeezing and fastening the tissue/implant 1034 toward
the bone 1032. The cap 1030 may be held to the anchor post 1022 by
the retaining or snap ring 1026. Alternatively, or additionally,
the cap and anchor may be connected together by mechanical locking,
by expansion, by thermal bonding, or combinations thereof If
thermal bonding between the cap and anchor is desired, an energy
source, such as a resistive heater, ultrasonic staking instrument,
or other suitable energy sources, may be used.
[0366] The fixation device of FIGS. 72 and 73 can be used with a
guide wire or an insertion instrument as previously described with
other fixation device embodiments. The anchor, cap, and/or pin may
be cannulated to receive the wire or instrument. In this
configuration, the fixation device may be placed with precision
within tissue or an implant. Also, the fixation device of FIGS. 72
and 73 may be used with a suture. The suture may be used to fasten
tissue and/or implant and then inserted through the cap and
secured. The suture may be positioned between the cap and anchor to
be secured. Furthermore, the suture may be molded into and extend
from the cap and/or anchor. It is contemplated that the
descriptions and features of the fixation devices and sutures of
FIGS. 59-61 apply to the fixation device of FIGS. 72 and 73.
[0367] In a related invention, the fixation of tissue may be
accomplished by heating collagen in tissue under defined pressure
to create spot welds, i.e. tissue welding or protein welding. This
fixation may be in addition to or separate from the previously
described fixation devices. Heating of collagen in tissue may be
done with an energy source such as ultrasonic energy, thermal
energy, or other energy source previously mentioned. In addition,
metallic particles, such as iron oxide, may be placed on the tissue
to assist with heating.
[0368] In another related invention, laser tissue welding may be
used in conjunction with or separate from the fixation devices.
Laser tissue welding is a sutureless method of wound closure that
may be used on nerves, skin, muscles, ligaments, tendons, bone, and
arterial anastomoses. After heating generated by laser exposure, a
glue is formed between tissue edges that forms a weld upon cooling.
With the use of laser welding, there may be no foreign body
reaction and less scar formation. Laser welding when used with an
artificial biomaterial made mostly of elastin and fibrin to weld
tissue allows a broad surface area for welding. Also, the use of a
pulsed diode laser may be used to maintain thermal confinement and
therefore minimize excess heating.
[0369] In yet another related invention, tissue may be approximated
or manipulated with an instrument utilizing suction or negative
pressure. For example, a torn rotator cuff may require stretching
or repositioning back to its anatomically correct position then may
require fixation to bone using a fixation device described herein.
The manipulation of the rotator cuff to its correct location may be
achieved by placing the distal portion of an instrument against the
rotator cuff, activating a vacuum or sucking force at the distal
end of the instrument, and pulling the rotator cuff into position.
The distal end of the instrument may include a suction port, a
suction cup, a suction cup with a suction port therein, or other
similar negative pressure means.
[0370] The fixation devices and above-mention related devices may
be used in combination with each other. For example, a torn rotator
cuff may need to be refastened to bone, or cartilage within a
joint, such as the knee, may need to be repaired. The negative
pressure instrument may be used to grab and move the cuff/cartilage
into proper position. A fixation device may be implanted to
temporarily or permanently secure the tissue to bone. Tissue or
protein welding may be performed to provide a thorough bonding of
the cuff/cartilage and bone.
[0371] The present invention also may be used in additional types
of intracorporeal welding devices and methods. Referring now to
FIGS. 74A and 74B, a fastener 1040 includes a cap 1042 and anchor
1044. The fastener 1040 may be made of thermoplastic material. The
anchor 1044 is generally tubular shaped with a circular flange 1046
attached to the proximal end. Four slots 1048 (two shown) are
disposed longitudinally from the distal end of the anchor 1044. The
four slots 1048 divide the anchor into four biasing prongs 1050.
The prongs 1050 bias or hinge from generally the proximal end of
the anchor 1044. Each biasing prong 1050 includes an outwardly
projecting ridge 1052 and an inwardly projecting ridge 1054. The
cap 1042 includes a post 1056 and a lid 1058 connected to the
proximal end of the post 1056. Both the cap 1042 and anchor 1044
may include a tissue-piercing distal tip.
[0372] In use, the anchor 1044 may be placed in tissue, such as
bone. Initially, the prongs 1050 of the anchor 1044 may not be
biased outward during this step. Next, the cap post 1056 is
inserted through an implant or tissue and positioned within a bore
of the anchor 1044. When the cap post 1056 contacts the inwardly
projection ridges 1054 of the prongs 1050, the prongs will be urged
to move radially outward. The outwardly projecting ridges 1052 of
the prongs 1050 are driven into surrounding tissue to thereby
prevent the anchor from being pulled out of the bone. Once the cap
is seated in its desired position, ultrasonic energy may be applied
to the fastener 1040 to weld the anchor 1044 and cap 1042
together.
[0373] In FIGS. 75A and 75B, a fastener 1060 includes a cap 1062
and anchor 1064. The fastener 1060 may be made of thermoplastic
material, such as PEEK or PLLA. The anchor 1064 is generally
tubular shaped with circular flange 1066 attached to the proximal
end. Four slots 1068 may be disposed longitudinally from the
proximal end of the anchor 1064. Within each slot 1068 is a
longitudinal barb 1070. The distal end of each barb 1070 is
attached to the anchor 1064 while the proximal portion of the barb
is free from attachment to the anchor and can be angled generally
proximally and radially outward, i.e. between 30 and 60 degrees
from the centerline of the anchor. The cap 1062 includes a post
1072 and a lid 1074 attached to the proximal end of the post. The
post 1072 includes four wedge members 1076 attached to the exterior
surface and spaced around the post 1072 such that each wedge member
1076 aligns with a slot 1068 in the anchor 1064. Each wedge member
1076 includes an angled face which is angled about the same as the
proximal portions of the barbs 1070. Both the cap 1062 and anchor
1064 may include a tissue-piercing distal tip.
[0374] To implant the fastener of FIG. 75A and 75B, the anchor 1064
may be inserted in tissue, such as bone. During insertion, the
proximal portions of each barb 1070 which extend beyond the
exterior surface of the anchor will flex or bend until they are
forced radially inward a sufficient amount so that the anchor 1064
may fit within a passageway in the bone. The cap 1062 is then
inserted through an implant or tissue and positioned in the bore of
the anchor. The wedge members 1076 on the cap post 1072 may then
slide into the slots 1068 of the anchor 1064. As the cap 1062 is
seated, the wedge members 1076 of the cap force each longitudinal
barb 1070 radially outward moving the proximal portion of each barb
into surrounding tissue to secure the fastener in place. Ultrasonic
energy may be applied to the fastener 1060 to secure the cap and
anchor together.
[0375] FIGS. 76A and 76B illustrate another embodiment of a
fastener 1080 of the present invention. The fastener 1080 is
similar to the fastener of FIGS. 74A and 74B except that the anchor
1082 includes two slots 1084 and two biasing prongs 1086. The
method of implanting the fastener of FIGS. 76A and 76B is also
similar to the method of inserting the fastener of FIGS. 74A and
74B.
[0376] Referring now to FIGS. 77A and 77B, a fastener 1090 includes
a cap 1092 and anchor 1094. The fastener 1090 may be made of
thermoplastic material. The anchor 1094 is generally tubular shaped
with a circular flange 1096 attached to the proximal end. Two
slideable hooks 1098 may be disposed in the anchor 1094 and extend
from the bore of the anchor and through channels in the anchor
wall. The hooks 1098 are generally curved at least at the distal
ends. The cap 1092 includes a post 1100 and a lid 1102 connected to
the proximal end of the post. The post 1100 includes a shoulder
1104 formed by two different diameters of the post. The shoulder
1104 is configured for contact with the proximal ends of the hooks
1098 in the anchor 1094. Both the cap 1092 and anchor 1094 may
include a tissue-piercing distal tip.
[0377] In use, the anchor 1094 may be placed in tissue, such as
bone. The slideable hooks 1098 are substantially disposed in the
anchor, i.e. little if any of the hook 1098 extends beyond the
exterior wall of the anchor 1094 during insertion. Next, the cap
post 1100 is inserted through an implant or tissue and positioned
within the bore of the anchor 1094. When the shoulder 1104 of the
post 1100 contacts the proximal ends of the hooks 1098, the hooks
are moved distally and outwardly into surrounding tissue preventing
the anchor 1094 from being pulled out of the bone. Once the cap
1092 is seated in its desired position, ultrasonic energy may be
applied to the fastener to weld the anchor and cap together.
[0378] The fastener 1110 illustrated in FIGS. 78A and 78B also
includes a cap 1112 and anchor 1114. The fastener 1110 may be made
of thermoplastic material. The anchor 1114 is generally tubular
shaped with a circular flange 1116 attached to the proximal end.
Two or four slots 1118 may be disposed in the anchor wall and
extend from the proximal end of the anchor. A folding member is
disposed in the bore of the anchor and through the slots. The
folding member includes a proximal ring 1120, a distal ring 1122,
and two or four crimping arms 1124 connected between the rings
1120, 1122. The folding member may be made of metal, thermoplastic,
or other suitable material. The cap 1112 includes a post 1126 and a
lid 1128 connected to the proximal end of the post. The cap post
1126 includes a shoulder 1130 formed by two different diameters of
the cap post 1126. The shoulder 1130 is configured for contact with
the proximal ring 1120 of the folding member. Both the cap 1112 and
anchor 1114 may include a tissue-piercing distal tip.
[0379] The anchor 1114 may be placed in tissue, such as bone.
During placement in bone, the crimping arms 1124 are substantially
straight and the proximal ring 1120 of the folding member is
located at the proximal end of the anchor bore. Next, the cap post
1126 is inserted through an implant or tissue and positioned within
the bore of the anchor. When the post shoulder 1130 contacts the
proximal ring 1120, the crimping arms fold 1124 or bend outwardly
into surrounding tissue preventing the anchor from being pulled out
of the bone. Once the cap 1112 is in its desired position,
ultrasonic energy may be applied to the fastener to weld the anchor
and cap together.
[0380] FIGS. 79A and 79B illustrate another embodiment of a
fastener of the present invention. The fastener 1140 is similar to
the fastener of FIGS. 76A and 76B except that the cap post 1142
includes a tapered portion 1144. The tapered portion 1144 of the
post 1142 is configured to be seated against a tapered ridge within
the bore of the anchor 1146. The method of implanting the fastener
1140 of FIGS. 79A and 79B is also similar to the method of
inserting the fastener of FIGS. 76A and 76B.
[0381] The fastener 1150 of FIGS. 80A and 80B is also similar to
the fastener of FIGS. 76A and 76B. However, the circular flange
1156 of the anchor 1152 includes a circular rise 1154, and the
underside of the cap lid 1158 includes a circular recess 1160
configured for receiving the circular rise 1154. The method of
implantation is similar to methods previously described. During
ultrasonic welding of the fastener 1150, however, the bonding
between the cap 1160 and anchor 1152 is enhanced by the increased
surface area provided by the circular rise 1154 and circular recess
1160.
[0382] FIGS. 81 and 82 illustrate another embodiment of the
invention. In FIG. 81, the fastener 1162 includes a rigid metallic
core 1164 which is enclosed by a thermoplastic. The fastener of
FIG. 82 has a polymeric core 1166 surrounded by PEEK. Although not
illustrated in these examples, the fasteners may include a central
bore for receiving the post of an end effector.
[0383] Referring now to FIGS. 83A and 83B, a balloon fastener 1170
is shown which includes an elongate body 1172 and one or more
balloons 1174 disposed on the exterior surface of the body 1172. A
passageway 1176 extends from the balloon(s) 1174 and through the
fastener lid 1178. The passageway 1176 provides open communication
between the interior of the balloon(s) and the exterior of the
fastener 1170. The body 1172 may include a tissue-piercing tip. To
implant the balloon fastener 1170, the balloon(s) may initially be
in a deflated configuration and substantially positioned up against
the exterior of the body. The fastener 1170 is positioned in tissue
with the proximal surface of the lid exposed for access by the
surgeon. Once placed in its desired position, the balloon(s) 1174
may be filled with air, gas, liquid, powder, etc. via the
passageway 1176. The balloon(s) expand against adjacent tissue to
thereby lock the fastener to the tissue. The passageway 1176 may be
closed and sealed with ultrasonic energy and thermoplastic
material.
[0384] FIGS. 84A-B, 85A-B and 86A-B illustrate living hinge
fasteners. In FIG. 84A, the fastener includes a main body 1180 and
a toggling body 1182 connected to each other with a living hinge
1184. A guide wire is slideably disposed through the main body 1180
and toggling body 1182 to maintain the bodies in general alignment.
As seen in FIG. 84B, with the guide wire removed, the living hinge
1184 normally biases the toggling body 1182 laterally from the main
body 1180. When inserted in tissue, the toggling body 1182 moves
into surrounding tissue to prevent the fastener from being pulled
out. An end effector 1186 may be placed in engagement with the
fastener to thermally bond the thermoplastic material of the main
body and toggling body together.
[0385] In FIG. 85A, the fastener includes two or more toggling
bodies 1190 connected to the main body 1192 with two or more living
hinges 1194. A single guidewire with a bifurcation 1196 or multiple
guidewires may be used to hold the normally outwardly biased
toggling bodies generally aligned with the main body 1192. FIG. 85B
shows the guidewire removed and the toggling bodies 1190 extended.
An end effector 1198 may be used to ultrasonically bond the main
body 1192 to the toggling bodies 1190.
[0386] The living hinge fastener of FIGS. 86A and 86B is similar to
the fastener of FIGS. 85A and 85B. However, instead of using a
guidewire to maintain the toggling bodies 1200 generally aligned
with the main body 1202, a sheath 1204 is disposed around the
exterior surface of the fastener. To deploy the fastener of FIGS.
86A and 86B, the fastener within the sheath 1204 in placed in
tissue. The sheath 1204 is removed and the toggling bodies 1200
normally extend outwardly into surrounding tissue. The toggling
bodies 1200 may be ultrasonically welded to the main body 1202.
[0387] FIG. 87 is a photograph of a fastener of the present
invention ultrasonically welded in bone. The fastener includes a
post and lid connected to the post. A hole is drilled in the bone
for insertion of the fastener. The diameter of the hole is less
than the diameter of the post. The lid includes a small bore for an
end effector. With the application of ultrasound and force, the
fastener flows into the hole in the bone. In FIG. 88 a fastener
includes an anchor and a cap. The anchor has slots which form a
plurality of biasing prongs. With the cap inserted within the bore
of the anchor, the prongs move radially outward and engage the bone
thereby locking the fastener to the bone. The cap and anchor are
ultrasonically welded together.
[0388] The photograph of FIG. 89 shows a cut away of thermoplastic
fasteners bonded within channels. The diameter of the channels is
less the diameter of the posts of the fasteners. With the
application of ultrasonic energy and pressure the thermoplastic
material flows into the channel, without the thermoplastic material
liquefying. In FIG. 90 metallic core- thermoplastic fasteners are
shown bonded to thermoplastic rods. The metallic cores can be seen
in the x-ray image of FIG. 91. In FIGS. 92A and 92B, PEEK and PLLA
fasteners are ultrasonically bonded in bone. The bone has been cut
in half to show the posts of the fasteners disposed in channels of
the bone.
[0389] Referring now to FIG. 93, a thermoplastic mesh sheet 1210 is
shown. The sheet may include openings therethrough for the passage
of body fluid. Alternatively, the sheet 1210 may be free from
openings to function as an impermeable membrane. The sheet may
include or may be made of thermoplastic material such as PEEK or
PLLA. One or more layers of material may form the sheet. For
example, an impermeable sheet may have a polymeric layer with no
openings and, additionally, may include a mesh layer on one or both
sides of the opening-free layer. A permeable sheet may include one,
two, three, or more mesh layers.
[0390] In FIG. 94, a mesh sheet 1212 is helically wrapped to form a
tube-like structure. The overlapping portions of the sheet 1212 may
be ultrasonically welded together to form a unitary structure. The
structure may be used as a prosthetic vessel, such as a blood
vessel or any other body conduit. It may also be used for tissue
repair by wrapping the structure around damaged tissue. FIG. 95
shows a cylindrical mesh sheet 1214. This configuration may also be
used for tissue repair and/or tissue stabilization. For example, a
fractured bone requires stabilization for proper healing. A mesh
sheet may be positioned about the fractured portion of the bone.
Ultrasonic energy may be used to bond the sheet to the bone.
Additional energy may be used to shrink the sheet in diameter to
apply a compressive force to the fractured bone.
[0391] The cylindrical mesh sheet 1216 of FIG. 96 has been shaped
using energy, such as ultrasound, resistive heating, etc. Shaping
of the sheet 1216 allows the surgeon to form a tailored implant. It
is contemplated that a non-cylindrical sheet may be shaped using
energy as well. A flat sheet may be contoured to conform to the
exterior surface of a body organ, such as the heart, stomach, the
skin, a bifurcated vessel, and other body parts like the knee,
elbow, or spine.
[0392] FIG. 97 illustrates a method of using a thermoplastic mesh
sheet 1218 to repair a blood vessel 1222. An aneurysm 1224 has
formed in the vessel wall. Instead of or in addition to treating
the aneurysm with an embolic coil or other known device, a mesh
sheet 1218 may be wrapped about the vessel 1222 over the aneurysm
region. A balloon 1220 may be positioned within the vessel 1222 to
provide structural rigidity to the vessel while ultrasonic energy
is applied to the mesh sheet. The sheet may be bonded to the vessel
and/or itself and shrunk in diameter to slightly compress the
aneurysm. In this example, the mesh sheet 1218 may include an
impermeable layer.
[0393] FIG. 98 shows another use of a thermoplastic mesh sheet
1230. An anastomosis is shown joining two vessels. The vessels may
be fastened together using known surgical techniques such a
suturing. Alternatively, or in addition, a thermoplastic mesh sheet
1230 may be placed between overlapping portions of the vessel or at
the ends of the vessels, and ultrasonic energy may be applied to
the sheet to bond the vessels together. Furthermore, a permeable or
impermeable mesh sheet 1230 may be used to wrap around the
anastomosis region. The sheet may be ultrasonically bonded to the
vessels and/or itself to create a fluid/blood tight seal at the
surgery site.
[0394] FIG. 99 shows a welding control box 1232. A surgeon
determines the optimum welding parameters and enters them into the
control box prior to welding. An ultrasonic end effector is located
on the distal end of the handpiece. Using different control
settings, such as wattage, frequency, time, etc., the end effector
may be used to flow thermoplastic material, clean tissue, and/or
cut tissue (i.e. osteotomy).
[0395] Welding of polymeric material to other material such as
metal or plastic may be useful in securing a tibial tray to a
tibial plate in a knee replacement component. As shown in FIG. 100,
a tibial bearing surface 1234 may be bonded to a metallic tibial
component 1236. Instead of having a manufacturer produce multiple
sizes of tibial replacement components, a single standard base 1236
may be made of metal and a bearing surface 1234 may be bonded to
the base to form a custom component. The size, thickness, and
configuration of the bearing component may be selected by a
physician based on the patient's needs. The bearing component 1234
may be ultrasonically welded into or onto the base tibial component
1236. As shown in FIG. 100, the base component 1236 may have
notches or channels 1238 in which the bearing component 1234 can
move into by the application of an energy source 1240, such as
heat. The bearing surface 1234 may be further contoured or sculpted
by an energy source 1240, such as resistive heat, to create a
customized surface tailored to meet the requirements of the
patient.
[0396] Alternatively, the base component 1236 may be metal with a
layer or areas of polymeric material disposed thereon/therein. In
this configuration, instead of the bearing component 1234 being
bonded directly to the metal, the bearing component 1234 may be
bonded to the polymer on the metal base 1236. Also, to achieve the
desired height of the tibial component, the surgeon may insert
polymeric shims above and/or below the bearing component. The shims
may be ultrasonically welded in place.
[0397] Additionally, polymeric components may be bonded to joint
replacement components supplied by different manufacturers. It
would be advantageous for a surgeon to be able to select individual
joint replacement component that best fit the needs of the patient,
regardless of manufacturer. Currently, joint replacement components
are supplied as a set and can not be interchanged, mixed and
matched. It is contemplated that the surgical welding systems of
the present invention would allow surgeons to select one component
from one manufacture, another component from another manufacturer,
tailor one or both components, and implant the components as a
customized set. For example, for a knee replacement system, a
surgeon could use a tibial base plate from manufacturer A and a
femoral component from manufacturer B. Using polymeric material and
thermal welding, a bearing surface/polyethylene may be thermally
bonded to the base plate 1236. The bearing surface 1234 may be
contoured and shaped to receive the femoral component. One or more
layers or inserts may be used to sequentially build up one or both
of the components. This system gives the surgeon more options in
selecting joint components and gives greater freedom in customizing
the components.
[0398] Furthermore, welding of polymeric components may be
performed in situ to repair or resurface a joint replacement
component, such as a shoulder, hip, knee, ankle, or intervertebral
disc. For example, the bearing surface 1234 of a knee component may
become worn out over time causing the patient pain. Instead of
removing the metallic component and implanting a new component
which may be expensive and cause the patient additional pain and
require longer rehabilitation, the existing bearing surface can be
rebuilt, restored, replaced or reshaped using thermoplastics and
thermal welding. In this revision joint replacement surgery, the
existing worn out bearing surface may be prepared by removing all,
some, or none of the polymeric surface. Then, a new polymeric
component may be welded intracorporeally onto the old bearing or
metallic component using ultrasound, radiofrequency, resistive
heating, etc. The new bearing surface component may be selected
based on the required thickness needed to restore the joint to its
anatomically correct configuration. Contouring of the bearing
surface may be performed intracorporeally or in the operating room
prior to welding the new bearing component intracorporeally.
[0399] In addition to revision surgery, it is contemplated that
ultrasonic energy and thermoplastics may be utilized with other
procedures, such as revision arthroplasty, osteomous correction,
fracture fixation, cementless fixation of an implant to
tissue/bone, and bone graft fixation.
[0400] If needed, multiple layers of polymeric material may be
added to the deteriorated joint component to build the joint up to
the proper height (FIG. 101A-D). Rather than having an inventory of
multiple inserts or components all varying in different
thicknesses, standard inserts may be manufactured with a given
thickness and welded together by the surgeon in the operating room
to obtain the needed implant height. For example, inserts may be
manufactured in 2 mm, 4 mm, and 8 mm thicknesses. A plurality of
these inserts may be selectively bonded together to form a single
insert. This may be done intracorporeally and/or within the
operating room.
[0401] FIGS. 101A-101D illustrates an implant 1242, such as a joint
replacement component, having a plurality of layers 1244 welded
together to create a customized implant. All the added layers 1244
may be made of polymeric material such as PEEK, PLLA, or
polyethylene. Alternatively, some of the layers may be made of a
metallic or ceramic material (FIG. 101B). The layers may alternate
between metallic/ceramic and polymeric material. In addition, the
layers also may alternate between different polymeric or
thermoplastic materials (FIG. 101C). Regardless of which material
(polymer, metal, ceramic) each layer includes, the layers can be
bonded to form a customized structure (see, e.g., FIG. 101D).
[0402] This structure is analogous to plywood where multiple layers
of material are bonded together to form one unit instead, in the
present invention, the "plyweld" is made of biocompatible layers of
material which are thermally bonded together either by spot welding
or full surface welding. Plyweld may be especially useful for
minimally invasive surgery and nanotechnology applications where
implants may be constructed intracorporeally to create a unitary
structure. Such structures may be advantageous for cell therapy,
gene therapy, drug delivery, bearing surface implants, and other
suitable applications.
[0403] At least one of the layers of the plyweld structure may have
an ingrowth surface. For example, a joint replacement component may
have a bearing surface on one side and an ingrowth surface on the
other side that, when implanted, is in contact with tissue. The
ingrowth surface may be porous, honeycomb, biodegradable,
biostable, or made from foam metal or foam titanium. The ingrowth
surface may include a therapeutic substance, such as tantalum, HA,
apatite, BMP, or other suitable agent.
[0404] In another embodiment of the present invention, joint
replacement components can be made with a hardened bearing surface
film bonded to a polymer. PEEK may be combined with a metallic or
ceramic film to create the bearing surface. Joint replacement
components generally employ metal on metal, such as cobalt chrome
against cobalt chrome, or ceramic on ceramic. In the present
invention, one or more bearing surfaces of a joint replacement
component could be made out of PEEK which may have a nano-metallic
or nano-ceramic film bonded to its articulating surface. For
example, a diamond crystal or aluminum crystal may be bonded to the
PEEK. The polymer may be a few microns to as much as 100 microns in
thickness. For minimally invasive surgery, this embodiment is
advantageous since the surgeon could introduce the implant bearing
surface of smaller components into the body through a small
incision. The components may be introduced through a cannula, under
endoscopic guidance, or under magnetic guidance. Once inserted, the
components may be welded together and attached to bone. It is
contemplated that intracorporeally welding applies to other types
of implants as well, such as modular stents, modular spinal cages,
modular acetabular component, modular bone plates, modular IM rods,
modular spacers, and modular wedges.
[0405] In addition to visualizing modular components during
implantation, the components (joint replacement, spinal,
intravascular) may be magnetically guided into and within the body.
Magnetic particles, such as iron oxide or iron particles, may be
placed within the polymeric components. A magnetometer or other
known energy source may be used to identify the location and
orientation of the modular components to aid in attaching the
components to each other and to tissue. The iron particles may also
enhance the thermal welding properties of the components. As
previously discussed, metallic particles disposed within or on the
surface of a thermoplastic material would aid in transferring
energy, such as vibratory or heat energy, thereby creating an
enhanced bonded interface.
[0406] Whether welding different layers together to form a plyweld
or ultrasonically welding to other implants together, the bonding
region between two components may be enhanced with textured surface
technology to increase the frictional characteristics of the
components. A texture on the surface, usually opposite the energy
director, increases weld strength, reduces flash and particulate
matter, and reduces the total amount of energy required to weld the
components. The components may include thermoplastic and/or
metallic material. Two components made of similar material may be
welded together using textured surfaces, or two components made
from different materials may be bonded using textured surfaces. A
microtextured surface may include small surface projections. For
example, FIG. 102A shows an implant with pebbles 1246. In FIG.
102B, the implant includes a scratched or roughened surface 1248.
FIG. 102C shows an implant with a grit blasted surface 1250, while
FIG. 102D illustrates an implant with fiber-like materials 1252
disposed on the surface.
[0407] Thermally weldable implants may additionally, or
alternatively, include a macrotextured surface. FIGS. 103A-103F
illustrate various embodiments of macrotextured surfaces. In FIG.
103A, one implant includes V-shaped projections 1254 and the
adjacent implant includes V-shaped grooves 1256. FIG. 103B shows
convex bulges 1258 and concave indentations 1260. FIG. 103C
illustrates a generally square projection 1262 and a square notch
1264. In FIG. 1030, the upper implant includes two square
projections 1266. The lower implant includes one square notch 1268
and a T-shaped notch 1270. The square projection 1266 thermally
welded into the T-shaped notch 1270 flows into the "T" to form a
locking bond between the layers.
[0408] FIG. 103E illustrates a textured fastener. The cap 1272 may
be made of thermoplastic material. The anchor 1274 may be made of
thermoplastic material and/or metallic material. The anchor 1274
includes a macrotextured surface on the inside of the anchor bore.
During ultrasonic welding, thermoplastic material of the cap 1272
flows into the grooves, notches or recesses of the macrotextured
anchor. In FIG. 103F, the anchor 1276 includes a macrotextured
surface at its proximal end or proximal surface. To this
configuration, thermoplastic material of the cap lid 1278 flows
into the notches, grooves, or recesses of the macrotextured anchor
surface.
[0409] In a related invention, FIG. 104 illustrates a tibial tray
1280 for implantation during knee replacement surgery. Typically, a
tibial tray implant is fastened to the proximal end of the tibia
with metal screws. Use of metal screws usually creates stress
risers and can limit tissue ingrowth. Also, the tibial tray may
subside slightly when secured with metal fasteners. To alleviate
these common problems, thermoplastic fasteners 1282 utilizing
features of the present invention may be used to implant tibial
trays 1280. The tray of FIG. 104 includes a plurality of channels
1284 configured for receiving a thermoplastic fastener 1282. Any
fastener disclosed herein or incorporated herein may be used to
fasten the tibial tray. The tray may be made of metal.
Alternatively, the tray may include both metallic and thermoplastic
material. For example, the main body of the tray 1280 may be made
of metal while the regions around the channels may be made of
thermoplastic materials. In this embodiment, a thermoplastic
fastener 1282 may be ultrasonically welded to bone and be bonded
with the thermoplastic material of the tibial tray.
[0410] FIG. 105 shows a tibial tray 1290 which is similar to the
tray of FIG. 104. However, the tray in this embodiment includes a
stem 1292. The stem 292 may be made of metal, thermoplastic, or a
combination thereof. The tibial tray 1290 is positioned on the
proximal end of the tibia 1294 with the stem 1292 disposed in the
medullary canal. Thermoplastic fasteners 1296 secure the tray to
the tibia. Additional thermoplastic fasteners 1298 may be used to
fasten the stem 1292 to the tibia 1294. The fasteners may include a
core as described in FIGS. 81 and 82, although other fastener
embodiments described herein may also be suitable.
[0411] In FIG. 106, a tibial tray 1300 includes a shortened stem
1302. As seen in the figure, the tibia is fractured in several
locations. Thermoplastic components may be used to reconstruct the
proximal end of the tibia. Initially, an intramedullary rod ("IM
rod") 1304 may be positioned in the intramedullary canal of the
tibia. The IM rod may be made of PEEK or other material suitable
for welding to other components. Existing metallic IM rods require
fasteners to be place through the cortical bone and into holes
disposed in the rod. This configuration is prone to create stress
risers. Therefore, using a weldable IM rod allows a surgeon to
implant the rod within the bone and use thermoplastic pins or
fasteners that can be welded to the rod. The pins may be placed
anywhere along the length of the rod including the ends of the rod
without the risk of creating stress risers. This PEEK rod and pin
combination allows unicortical or bicortical fixation to lock the
rod within the bone.
[0412] The tray 1300 is placed on the end of the tibia with the
shortened stem 1302 inserted in to a notch in the IM rod 1304. The
stem and rod may be ultrasonically bonded together. Thermoplastic
fasteners 1306, with or without cores, may be used to fasten the
tray to the bone and fasten the rod to the bone. Additional
fasteners may be utilized to secure a fragmented ligament to its
proper position as well as to secure a thermoplastic bone plate to
the tibia.
[0413] In another embodiment of the invention, bone filler implants
1310 are shown in FIGS. 107 and 108. In FIG. 107, two bone voids
exist at the proximal end of the tibia. To properly align and
secure a tibial replacement component, two bone filler implants
1310 are positioned in the voids. The filler implants 1310 may be
made of thermoplastic material and/or metal. Fasteners of the
present invention are used to secure the tibial tray and bone
filler implants to the tibia. Ultrasonic energy may be used to bond
the fasteners to the tray, filler implants, and bone and to bond
the filler implants to the tray and stem. FIG. 35 shows another
example of bone filler implants. An acetabular component and a
filler implant are thermally bonded to each other and are secured
to bone with one or more thermoplastic fasteners.
[0414] Referring now to FIGS. 109A and 109B, the present invention
may be used to repair an impact fracture. FIG. 109A shows a bone,
specifically a Femur, with multiple impact fractures. To repair
these fractures, a channel 1312 may be drilled through the bone and
into the impact region. Using appropriate instruments inserted
through the channel 1312, the impacted bone may be repositioned to
its anatomically normal position. Then, using ultrasonic energy,
flowable thermoplastic material 1314 is placed in the void of the
impact region. The thermoplastic material 1314 bonds to the bone
and provides structural support for the impact region.
[0415] In a related invention, an acetabular implant 1320 is shown
in FIGS. 110A and 110B. The implant 1320 is made of thermoplastic
material, such as PEEK or PLLA. A plurality of holes 1322 extends
through the walls of the implant and is configured for receiving a
thermoplastic fastener. With the application of ultrasonic energy
and pressure, the acetabular implant 1320 may be welded to bone,
and the fasteners may be thermally bonded to the implant and
bone.
[0416] In addition to using ultrasonic energy to flow thermoplastic
material in the body, ultrasonic energy may also be used to weld
metals and to melt solder intracorporeally. Other energy sources
may be used as well, such as laser and cool plasma. Using
intracorporeal metal welding and soldering, electrical and
electronic components can be implanted and repaired in the body.
For example, batteries from a pacemaker or other pump may be
replaced; temperature, pH, or pressure sensors may be connected or
reconnected; microprocessor or computer chips may be repaired; and
entire circuit board may be implanted and electrically connected.
These implanted electrical components may be encapsulated with
thermoplastic material to protect surrounding tissue from damage,
heat, shock, etc. and block body fluid from reaching the
components. FIG. 111A shows a patient with a pacemaker 1330.
Pacemakers usually have a limited service life and require
replacement after a certain period of time. With the method and
devices of the present invention, a pacemaker can be repaired or
upgraded in situ. Electrical connections may be detached and
reattached using ultrasonic energy and solder. A defibrillator made
be implanted and connected to an existing pacemaker. In FIG. 111B,
various electrical components 1332 may reside in an implant. These
components include diodes, transistors, transformers, rectifiers,
integrated circuits, resistors, capacitors, memory chips, etc.
These components may be repaired or replaced intracorporeally and
in situ.
[0417] Metal to metal welding may also be performed
intracorporeally using ultrasound, laser, and/or cold plasma. In
FIGS. 112A and 112B, two stents 1334 positioned in a vessel 1336
are welded together to form one unitary stent 1338. Both stents
1334 are made of metal and are welded to each other in situ. In
FIGS. 113A and 1 13B, multiple stents 1340 may be welded together
to form a desired configuration either in the operating room or
within the vessel. Where two vessels form a "T" or "Y"' in the
vasculature, a surgeon can thermally weld one stent 1340 to another
stent 1340 in a "T" or "V" configuration. Also, a plurality of
smaller stents may be built up within the body to form a larger
stent. This method of welding tubular structures using metallic
welding may also be applied to balloons and conduit /tubing for
medication pumps, diabetes insulin pumps, and pain pumps. Also,
electrodes to an electrical stimulation unit may be welded to
extend them or to seal them off.
[0418] In another example of metal to metal intracorporeal welding,
a metal implant may be bonded to a metallic bone filler implant.
FIG. 114 shows a metallic acetabular component implant 1342 in
bone. A metal filler implant 1344 is welded to the acetabular
component 1342. Fasteners 1346 disclosed herein may be used to
further secure the component and filler implant to bone.
[0419] The intracorporeal welding system of the present invention
also may include shrinkable materials for use in surgery.
Shrinkable materials provide a compressive force to tissue or
implants when energy is applied. For example, a fastener may be
implanted to secure an implant or tissue. The application of heat
to the polymeric material of fastener causes the fastener to
shorten or shrink thereby increasing the force provided by the
fastener. The fastener may be positioned through two portions of a
fractured bone then heated to shrink. The bone portions are
compressed together for proper healing. In addition to fasteners, a
suture, cerclage, wire, or cable may be made of shrinkable
material. A cable may be placed through tissue or bone, positioned
across a joint, or connected with an implant. When energy is
applied to the cable, it shortens thereby creating a tension force
and securing the object(s) to which is attached. A shrinkable cable
positioned adjacent to or across a joint provides rigid and/or
dynamic stabilization of the joint.
[0420] FIGS. 115A and 115B illustrate a thermally bendable suture.
In FIG. 115A, the suture is knotted 1352. Frequently, however,
knots creep and the suture loses tension. To solve this problem,
ultrasonic energy may be applied to the thermoplastic material of
the knot 1352. FIG. 115B shows the suture knot 1352 thermally
bonded/melted to itself to prevent creep. In FIG. 116, the suture
1350 is reduced in length/diameter using ultrasonic energy. FIGS.
117A and 117B illustrate heat shrinkable implant pouches 1354.
Implants placed in a pouch 1354 are sealed within. Applying energy
to the pouch shrinks it to firmly hold the implant therein.
Thermoplastic fasteners may be used to secure the pouch within the
body.
[0421] In another related invention, tissue may be bonded to tissue
using thermoplastic material and ultrasonic energy. As shown in
FIG. 118A, thermoplastic material, such as PEEK or PLLA may be
positioned between two pieces of tissue. In FIG. 118B, an
ultrasonic end effector and anvil 1360 is used to press the two
pieces of tissue 1362 and the thermoplastic material 1364 together.
The thermoplastic material 1364 bonds the tissue 1362. This method
may be performed intracorporeally or in the operating room outside
the body. The thermoplastic material 1364 may include a therapeutic
agent such as proteins, cells, growth inducer, or similar
substances. Other agents include antibiotics, hydroxyapatite,
anti-inflammatory agents, steroids, antibiotics, analgesic agents,
chemotherapeutic agents, bone morphogenetic protein (BMP),
demineralized bone matrix, collagen, growth factors, autogenetic
bone marrow, progenitor cells, calcium sulfate, immo suppressants,
fibrin, osteoinductive materials, apatite compositions, germicides,
fetal cells, stem cells, enzymes, hormones, cell therapy
substances, gene therapy substances, bone growth inducing material,
osteoinductive materials, apatite compositions with collagen, and
demineralized bone powder. U.S. Provisional Patent Application No.
60/728,206 entitled "Drug Eluting Implant" discloses means for
delivering therapeutic agents. The above-mentioned provisional
application is incorporated by reference herein in its
entirety.
[0422] Referring to FIG. 119A, a composite fastener 1370 is
illustrated. The composite fastener 1370 includes a metallic core
1372 with helical threads 1374 disposed on the distal position of
the core. A thermoplastic sleeve 1376 is positioned about and
secured to the middle portion of the core. The composite fastener
1370 is shown in FIG. 119B implanted in a bone 1378. Initially, an
IM rod 1380 may be positioned within the medullary canal or the
bone. A channel is then drilled through the bone and IM rod. The
composite fastener 1370 is inserted in the channel such that the
threads of the fastener engage the cortex of the bone and the
sleeve of the fastener engages the IM rod. Ultrasonic energy may be
applied to the fastener to thermally bond the sleeve and IM rod. A
bone plate may be positioned between the head of the fastener and
the bone.
[0423] In many of the experiments, tests, and examples described
below and elsewhere herein, ultrasound energy was used to weld
thermoplastic material. The bond between implantable components may
also be a chemical bond, covalent bond, ionic bond, or a bond using
Vanderwall forces. It is contemplated that any energy source
provided herein may be utilized.
Experiments and Testing
[0424] Testing of PEEK welding was performed with ultrasonic energy
from an ultrasound generator and handpiece. The end effector that
contacts the thermoplastic component was 0.180'' in diameter,
though other sizes may be used. During the welds, approximately 7-9
lbs of load was placed on the handpiece, which was delivered to the
cap of the component during the weld. Settings of current=170 and
time=3 second was initially used. The time corresponds to tenths of
a second, so the weld time was 0.3 seconds. The current value is on
a 0-255 scale.
[0425] The majority of samples welded had a seat cap (fastener)/
design as shown in FIG. 120. Seat caps 1380 that were tested were
made from Acrylic, Nylon, UHMWPE and PEEK. In most cases the
"anchor" in which the seat cap was welded into was a hole in a
small block of the same material. However, with the Nylon samples,
the anchor actually was threaded into a sawbone for welding and
testing. To simulate "tissue" 1/8'' thick neoprene was used as it
could compress a little. To test the weld, a stainless steel wire
or USP 5 suture was placed through the neoprene and force was
applied to the wire to try and break the weld. FIG. 121 illustrates
the apparatus used to test the welds.
[0426] The neoprene "tissue" stretched when tensioned and in some
tests the neoprene failed prior to the cap and weld failing. In
tests with Acrylic seats, the weld failed (rather than the neoprene
"tissue" failing) at around 30 lbs. With the Nylon seats, the
samples typically failed at loads of 30 lbs. UHMWPE samples did not
weld well and the welds were easy to break by hand. In five PEEK
seat tests, there were no weld failures, even at loads of 38 lbs
where the "tissue" failed.
[0427] Referring to FIG. 122, a fastener 1382 includes an anchor
1384 and a cap/post nail 1386. The fastener 1382 includes a
thermoplastic material such as PEEK. The anchor 1384 includes a
bore configured to receive the post 1388 of the nail. The anchor
1384 also includes helical threads 1390 disposed on the outer
surface thereon. Using the threads 1390, thermal welding, or both,
the anchor 1384 is lockable within tissue. The distal portion of
the post and the distal portion of the anchor include a tissue
piercing point 1392. In FIG. 123, a piece of neoprene 1394 is used
to simulate tissue. The neoprene is fastened between the cap 1396
and the anchor 1384. The post 1388 is thermally welded into the
anchor bore using ultrasonic energy or other energy source.
[0428] Another test fastener 1400 is shown in FIG. 124. The
fastener includes an anchor 1402 and a cap 1404. A distal portion
of the anchor 1402 is configured for placement in tissue. The
anchor 1402 may be mechanically locked in the tissue, thermally
welded in the tissue, or a combination of both securing techniques.
The anchor 1402 may have a pointed post 1406 which pierces the
tissue requiring repair. The disc shaped cap 1404 is then placed
over the anchor post 1408, and energy, such as resistive heating or
ultrasound, is emitted thereby staking the cap 1404 on the post
1408. The tip of the post may be contoured to a flattened
configuration to reduce its profile. In FIG. 125, a strip of
neoprene 1410, representing soft tissue, is held by the fastener
1400 of FIG. 124. During surgery, the distal portion of the
fastener would be anchored in tissue. The cap 1404 is welded to the
anchor post 1408, and the post is deformed to a flat
configuration.
[0429] Testing was performed on components fastened using resistive
heat. The simple prototypes were made from Acrylic and looked like
the component in FIG. 120. The post was attached to the anchor and
was 0.105'' in diameter. The outer diameter of the cap and anchor
was 0.236''. For this test, a thin foil heater was attached to a
handpiece and a board designed in-house. The board delivered a
pulse width modulation signal and 10 watts of power. During a
strength test the weld failed at about 30 lbs.
[0430] FIGS. 126 through 134 illustrate test samples of PEEK
components. FIG. 126 shows PEEK fasteners 1412 that were
ultrasonically welded to a PEEK rod placed inside the sawbone. The
holes drilled through the sawbone and into the rod were drilled at
the same time, as would be done in surgery. The small blind hole in
the rod provides a flat surface for the fastener tip to weld
against.
[0431] FIGS. 127 and 128 are of another PEEK rod with two different
types of PEEK fasteners 1414 ultrasonically welded to the rod 1416.
In FIG. 127, the fastener 1414 was designed to pass fully through
the rod 1416. In this case, the fastener 1414 is stepped and welds
to the rod at the mating of the hole entrance and the angled
fastener surface. In FIG. 128, there is a blind hole and the
tapered bottom of the fastener 1414 is welded at the bottom of the
drilled hole.
[0432] FIGS. 129-131 show a PEEK plate 1418 secured to a sawbone
1420 with thread-in PEEK fasteners 1422. The two fasteners 1422
were threaded into the sawbone 1420 on opposite sides of a fracture
1424. The plate 1418 was secured as a cap 1426 was welded to the
first fastener 1422, then the other was welded. The plate 1418 had
slots predrilled through it, but it is possible that it could be
drilled in surgery at the same time as the bone with the fastener
passed through the newly drilled plate hole, provided that the
welded cap 1426 is larger in diameter than the newly drilled
hole.
[0433] FIG. 132 shows a small PEEK plate 1430 with fasteners 1432
ultrasonically welded to the hole openings. FIGS. 133 and 134 show
30 percent carbon reinforced PEEK fasteners 1434 welded to a rod
1436 of the same material.
[0434] In all of the cases, the welds were made with an ultrasonic
handpiece and generator with a manual pressure applied by hand (in
the 6 to 9 lb. range) with a weld time of 0.3 seconds. All of the
welded specimens were tested by applying force with the hands. None
of the welds failed. While the test specimens shown in FIGS.
126-134 were all made of medical grade PEEK, it is contemplated
that other materials such as Acrylic, PMMA, polypropylene,
polycarbonate, acetal, and polyphenylsulfone (RADEL) may also be
used.
[0435] Further testing was performed with test samples made from
virgin PEEK (non medical grade). FIG. 135 shows the test fastener
1438 and anchor 1440 used. The anchor 1440 in these samples was
made so that it could be secured in a vise during welding and
tensile testing. The samples were ultrasonically welded with an
ultrasonic generator and handpiece. The weld time was 0.3 seconds,
and pressure of about 7-8 lbs. was applied to the fastener by hand
during welding.
[0436] FIG. 136 illustrates a fixture 1442 made for testing the
samples. The top section mounts to the ultrasound generator and the
bottom piece has a small hole in 0.040'' thick aluminum so that the
fastener post can pass through it. Samples were welded with this
plate between the fastener 1444 and anchor 1446 sections as tissue
would be. In the first set of testing, pull force was applied to
the fastener in the direction of the post and anchor bore axis. The
test was designed to preload the sample to 0.5 lbs, and then apply
further force at a loading rate of 1.25 mm/s. The results are
provided in Table 1, below.
TABLE-US-00001 TABLE 1 Tension Load Testing Results Number of
samples: 6 Average Failure Load: 46.0 lbs Standard Deviation: 18.1
lbs Maximum Failure Load: 75.5 lbs Minimum Failure Load: 20.3
lbs
[0437] A second set of testing dealt with placing a shear load on
the post in a direction perpendicular to the axis of the post and
anchor bore. This load may be similar to what would be applied by
tissue stretched over to be repaired. The preload and loading
conditions for this test are identical to the prior test set. The
orientation of the pull was the only difference. The results are
provided in Table 2, below.
TABLE-US-00002 TABLE 2 Shear Load Testing Results Number of
samples: 5 Average Failure Load: 76.6 lbs Standard Deviation: 10.5
lbs Maximum Failure Load: 91.7 lbs Minimum Failure Load: 62.9
lbs
[0438] In both tests, the PEEK prototypes had strength far
exceeding the strength of a knotted USP 2 suture, which would be
expected to be about 35 lbs.
[0439] Further results of PEEK and Acrylic testing are shown in
FIGS. 137 and 138. As seen in FIG. 137, the mean failure tension
load for PEEK ultrasonic weld samples was 46 lbs. while the mean
failure shear load was about 76 lbs. In FIG. 138, the mean failure
tension load for Acrylic heat stake samples was 29 lbs.
Exemplary Instruments
[0440] As previously discussed, a variety of energy emitting
instruments may be used with the surgical welding system of the
present invention. The instrument may produce energy such as
resistive heating, radiofrequency, ultrasound (vibratory),
microwave, laser, electromagnetic, electro shockwave therapy,
plasma energy (hot or cold), and other suitable energy. FIGS.
139-142 illustrate an exemplary instrument 1450 and fastener 1452
of the present invention. The instrument 1450 shown is an
ultrasonic handpiece with a sheath 1454 to cover and protect the
end effector 1456 and hold the fastener. The sheath 1454 has a
small counter bore at its tip to cover a portion of the cap 1458.
There is also a bushing at a nodal point of the ultrasonic signal
to prevent the end effector 1456 from contacting the sheath 1454.
The tip of the end effector 1456 has a small post 1460 sticking out
of the welding face which presses into a bore in the cap of the
fastener. This can help align the fastener post into the anchor
bore and keep the cap tight against the end effector face. After
welding, the end effector 1456 easily pulls off.
[0441] The post 1460 on the end effector 1456 could be threaded or
have a Morse taper to mate with the cap. Alternatively, the end
effector 1456 may have a bore that the top of the cap mates into.
The mating of the components could also be by threads or a Morse
taper along with a straight post. Furthermore, the pin could be
roughened on the outside surface for better adhesion.
[0442] Another exemplary instrument is illustrated in FIGS. 143A
and 143B. A small cartridge heater 1462 may be used to deliver
thermal energy. The heater 1462 may by a SUNROD 1/8 inch cartridge
heater. To prevent heat build up of the outside shaft 1464, an air
barrier may be formed between the heater and the shaft. In FIG.
143A, four set screws 1466 are used to create an air barrier, while
in FIG. 248, a single set screw 1466 is used.
[0443] Referring to FIGS. 144A-144K, energy emitting instruments
include various horn configurations. In FIG. 144A, the horn 1470
emits energy to the top surface of the implant as well as the
central core. The horn 1472 of FIG. 144B is recessed to hold the
thermoplastic implant 1474 during welding. In FIG. 144C, the horn
1476 is concave to provide a rounded surface to the implant 1478
after welding. The horn 1480 of FIG. 144D is concave and includes a
central extension 1482 to deliver energy throughout the implant
1484. In FIG. 144E, the horn 1486 includes a spike 1488 within
disposable within an implant 1490. The horn 1492 of FIG. 144F
includes a threaded pin 1494 which is received by a bore in the
implant 1496. In FIG. 144G, the horn 1498 includes dual spikes
1500. The distal portion of the horn 1502 of FIG. 144H is
dimensioned to fit within the thermoplastic implant 1504. In FIG.
1441, a sleeve 1506 is disposed about the horn 1508 and implant
1510. The side-weld horn 1512 is shown in FIG. 144J. In FIG. 144K,
a dual horn welder 1514 is used to simultaneously weld two
fasteners 1516.
Exemplary Applications
[0444] The following examples further illustrate the diversity of
the surgical welding system of the present invention. It is
contemplated that the above description regarding welding
parameters, thermoplastic material, and instruments may be used
with the following examples. This list of examples is not all
inclusive but rather shows some specific applications on how and
where thermal welding may be utilized during manufacture and/or
surgery.
[0445] FIGS. 145A and 145B illustrate one embodiment of the present
invention. An anchor 1520, which may be made of PEEK or other
suitable polymer, is placed into a predrilled passageway 1522 in
bone 1524. An end effector 1526 is pressed against a surface of the
anchor 1520 and ultrasonic energy is emitted from the effector. The
energy softens the polymer thereby deforming the polymer and
driving the anchor 1520 into the bone and locking the anchor within
the bone. No initial mechanical lock is required. However, as
previously discussed, the application of ultrasonic energy may be
in lieu of or in addition to a mechanical locking means, such as
threads.
[0446] In FIG. 146, a fractured bone has two sections 1530, 1532
which need to be rejoined and compressed for proper healing. The
anchor 1534 is locked in the bone as previously described. A
guidewire 1536 may be drilled from one bone section, through the
fracture, into the other bone section, and to the anchor 1534. A
cannulated drill 1538 may be used to create a bigger hole over the
guidewire. After the channel is created, the drill can be
removed.
[0447] Next, as shown in FIG. 147, a fastener 1540, which includes
a cap 1542 and post 1544, is attached to the anchor 1534 to secure
the tissue. The fastener 1540 may be slid through the drilled hole,
over the guidewire 1536, across the fracture, and at least
partially into the anchor. The post 1544 can then be welded into
the anchor 1534 to close the fracture with the cap 1542 placing
pressure against the outer surface of the bone to apply compressive
force to the fracture. Further energy may be applied to the cap to
deform or contour it to make it less obtrusive from the bone. Soft
tissue and/or a bone plate may be positioned under the cap of the
fastener.
[0448] In FIG. 148 a guide instrument 1546 is shown. The instrument
properly aligns the drill and fastener 1540 into the anchor 1534.
The instrument 1546 may be an aiming or alignment guide or some
type of triangulation device. The instrument 1546 may be adjustable
to fit various sized of bone/tissue or different angles of fastener
insertion. FIG. 149 shows an anchor 1534 with multiple fasteners
1540 disposed therein.
[0449] In the embodiments described in FIGS. 145-149, the post 1544
of the fastener 1540 may be threaded. That is, when drilling the
channel through the bone sections 1530, 1532 and across the
fracture, the drill may be extended into or through the anchor
1534. A tap may be used to create helical threads within the
channel in the anchor. Then, the threaded post of the fastener may
be inserted in the channel and screwed into the anchor to thereby
close the fracture. Energy may be used to further lock the fastener
to the anchor. Alternatively, the post 1544 may extend completely
through the anchor and extend out the opposite side of the anchor.
In this configuration, a threaded nut may be placed on the distal
end of the post. Furthermore, the distal end of the post may be
thermally flattened or contoured. In another related embodiment,
the cap 1542 of the fastener 1540 may be angled or may float or
pivot on the proximal end of the post. This could allow the cap to
lay flush against the tissue surface.
[0450] FIGS. 150A and 150B illustrate another application of the
surgical welding system. Ultrasonic energy may be used to bond a
metal/ceramic implant to a polymeric implant or a polymeric implant
to another polymeric implant. A polymer implant 1550 is positioned
against a metallic implant1552. An extension or spike 1554 may
extend from the polymer and be positioned through the metallic
implant. Using ultrasonic energy, the extension is excited and
formed by an ultrasonic horn 1556 or other energy source to soften
and move over the metal thereby securing the two implants to each
other.
[0451] Referring to FIGS. 151A and 151B, ultrasound energy may be
used to move a first, polymeric material 1560, such as PEEK, into a
second material 1562 that is more resistant to softening by an
energy source. The second material 1562 may have a higher melting
point, such as metal, ceramic, or a different thermoplastic
material. Alternatively, the second material may be formed of a
thermoset material. The polymer component may have energy directors
that fit into a passage in the second material. The second material
also may have undercuts or cavities 1564 for the polymer to move
into and fill. As the PEEK is excited by the ultrasound energy, it
moves into the voids of the second material. After the energy is
removed, the polymer cools to mechanically lock the two dissimilar
material components together.
[0452] In a further embodiment of the present invention shown in
FIGS. 152-155, the surgical welding system may be used to repair
and/or stabilize joints of the spine such as intervertebral joints
and facet joints. Stabilization of the spine is usually achieved by
attaching rigid rods 1570, plates 1572, spacers 1574, or wedges
1576 between two or more vertebrae. Fasteners 1578, such as screws,
are inserted into the vertebrae, and the plate 1572 and/or rod 1570
is mechanically connected to the fastener 1578. The spinal rods,
plates, fasteners, etc. may include thermoplastic material of the
present invention, such as PEEK or PEAK. The implants may be
biodegradable or biostable. For example, the fastener 1578 may be
made of metal, and the rod 1570 or plate 1572 may be made of PEEK.
The metal fasteners may be affixed to vertebrae, while polymeric
rods may be welded to the fastener using ultrasonic energy.
Alternatively, the fasteners 1578 may be made of PEEK, and the rods
may be made of metal. The fasteners may be implanted in the
vertebrae using energy, as previously disclosed. The rods/plates
may be aligned with fasteners, and the polymeric material of the
fasteners may be welded to the rods. Furthermore, both the
fasteners 1578 and rods 1570 or plates 1572 may be made of PEEK.
The fasteners are implanted in vertebrae by softening the PEEK with
energy. The rods are attached to the fasteners also with energy,
such as ultrasonic energy.
[0453] The fasteners and rods/plates also may include both PEEK and
metal. For example, the fasteners may have a distal portion made of
PEEK which thermally locks in bone by applying energy. The proximal
portion of the fastener may include metal which may mechanically
and/or thermally lock with a rod or plate. Alternatively, the
distal portion of the fastener is metal, and the proximal portion
is PEEK. Other embodiments of the invention using a composite of
materials may also be used. Likewise, the rod and/or plate may also
include both metal and thermoplastic material, such as PEEK. The
rod and/or plate may be made mostly of metal; however, the plate
may include PEEK where the fasteners attach to the rod/plate. It is
contemplated that the fasteners, plates, and rods described herein
may be made of PEEK, metal, ceramic, composite, or another
polymeric material.
[0454] FIG. 155 shows a modular vertebral body replacement system
1580. The thermoplastics and energy of the present invention may be
used to bond the components together intracorporeally. The CONSTRUX
system in FIG. 155 is designed to be mechanically locked together
during surgery. Using thermoplastics, the unit may be mechanically
and thermally locked together using welding processes described
herein.
[0455] Additional exemplary fasteners are illustrated in FIGS.
156A-156F. The fastener 1580 of FIG. 156A is made entirely of a
thermoplastic material such as PEEK . In FIG. 156B, the fastener
1582 includes two different thermoplastic materials 1584, 1586.
Each material may have different welding properties. FIG. 156C
shows a fastener 1588 with only a proximal portion 1590 made of
PEEK, while FIG. 156D illustrates a fastener 1594 with only a
distal portion 1598 made of PEEK. In FIG. 156E, the fastener 1600
includes a rigid metallic core 1602 which is enclosed by a
thermoplastic 1602, such as PEEK. The fastener 1606 of FIG. 156F
has a polymeric core 1608 surrounding by a thermoplastic 1610, such
as PEEK.
[0456] Moreover, thermal energy used to soften and bond PEEK may
also be used to contour and deform the fasteners, plates, and rods.
Energy, such as resistive heating, may be applied to the plates and
rods to shape them to a desired and anatomical configuration. Also,
the fasteners, rods, and plates may be deformed using energy and
positioned such that the combination produces compression or
tension between two or more vertebrae.
[0457] In a further embodiment, the surgical welding system may be
utilized to provide flexible stabilization of the spine, or any
other joint or bone of the body, as suggested in FIGS. 152-154. The
soft tissue around and near a joint may become weakened over time,
and the range of motion of the joint usually increases thereby
allowing excessive tissue laxity. Also, instability of a joint may
be caused by structural changes within the joint as a result of
trauma, degeneration, aging, disease, or surgery. An unstable
spinal joint may be rigidly stabilized as previously explained or
may be dynamically stabilized to allow some range of motion of the
spinal joints. Fasteners, screws, plates, rods, etc. made of PEEK
may be implanted between two or more vertebrae. The plates and rods
are configured and dimensioned to permit some flexing and/or
bending. The amount of flexibility of these PEEK implants may be
adjusted by the surgeon in the operating room using energy, such as
ultrasound, resistive heating, etc. and varying the weld
parameters.
[0458] Additionally, as seen in FIG. 154, a plate 1572 or rod 1570
may be configured to lock with a fastener 1578 in one direction,
but would allow movement in another direction. For example, the
plate and fastener permits superior and inferior motion of the
spine but would prevent lateral motion. Also, the plate and
fastener may permit motion in one plane and restrict motion in a
different plane. Other devices and methods for dynamic
stabilization of the spine and other joints and bones are disclosed
in U.S. patent application Ser. No. 11/258,795 entitled "Devices
and Methods for Stabilizing Tissue and Implants" filed Oct. 26,
2005. The contents of the aforementioned patent application are
incorporated herein by reference in its entirety.
[0459] In another embodiment, the welding system of the present
invention may be used to thermally weld a spinal spacer or spinal
cage to a bone. Currently, spinal cages are threaded into the spine
or mechanically locked into the spine with barbs, threads, etc. In
the present invention, the spinal cage may be made of PEEK and
could lock into tissue by the application of ultrasonic energy
and/or by the use of PEEK fasteners. The fasteners may extend from
the cage to adjacent vertebrae. The fasteners may function as
tension or compression bands to hold the cage in place.
Additionally energy, such as resistive heating, may be use to
contour the cage or spacer to a desired configuration such as to
conform with the geometry of adjacent vertebrae. If multiple cages
and/or spacers are required, the implants may be thermally welded
together before implantation in the operating room,
intracorporeally, or both.
[0460] In yet another embodiment of the present invention, the
surgical welding system may be used to repair and stabilize a knee
joint. For example, as seen in FIG. 157, a ligament (ACL), tendon,
or bone graft 1612 may be fastened into position using
thermoplastics and energy. Other polymers may be welded across the
joint to provide rigid and/or dynamic stabilization. Also, a joint
replacement component may be modified using thermoplastics and
energy. In FIG. 158, one or more stabilizers 1614 may be bonded to
the joint replacement component to provide stability between the
tibial and femoral components 1616, 1618. It is contemplated that
other joint replacement components, such as the hip, shoulder,
elbow, ankle, etc. may include thermoplastic stabilizers. As seen
in FIG. 158, the tray 1614 may be spot welded (or surface welded)
to the tibial base component 1616.
[0461] Furthermore, PEEK fasteners and PEEK material may be used to
stabilize or tether disc replacement components or other implants
such as an organ, partial organ grafts, tissue graft material
(autogenic, allogenic, xenogenic, or synthetic), collagen, a
malleable implant like a sponge, mesh, bag/sac/pouch, collagen, or
gelatin, or a rigid implant made of metal, polymer, composite, or
ceramic, breast implants, biodegradable plates, porcine or bovine
patches, metallic fasteners, compliant bearing for medial
compartment of the knee, nucleus pulposus prosthetic, stent, tissue
graft, tissue scaffold, biodegradable collagen scaffold, and
polymeric or other biocompatible scaffold. As illustrated in FIG.
159, fasteners 1620 may be attached to or placed around the implant
1622 and secured to adjacent tissue preventing the implant from
migrating. Other methods of tethering implants are disclosed in
U.S. patent application Ser. No. 11/258,795, previously mentioned
and incorporated by reference herein.
[0462] In another spinal application, a spinal implant may include
a thermoplastic material to which a bearing surface coating may be
applied. A nano-ceramic coating may be bonded to a spacer which is
used to change positions of bones of a joint. The coating may be
3-5 microns thick or could be as thick as 50 microns. The coating
may be alumina, Zirconia, or diamond type ceramic which is welded
to the spacer using ultrasound energy, resistive heating, or other
energy source. The spacer may be stabilized or tethered using PEEK
fasteners as previously described. In one embodiment, the spacer is
affixed to one vertebra with fasteners, and the other side of the
spacer which includes the bearing surface coating is free to
articulate against the adjacent vertebra. In addition to PEEK,
other polymers such as polyurethane, polyethylene, polyester, or
DELRIN may be used.
[0463] It is also contemplated that the welding system of the
present invention may be used with other surgical applications. For
example, cerclage wire may be made of PEEK. The wire could be used
to secure a cervical plate for unicortical or bicortical fixation.
Energy may be used to weld the wire and plate together. Energy may
also be used to change the angle of fixation and to contour the
plate. PEEK implants may be used to stabilize nucleus pulposus
replacement components or to repair the annulus. PEEK implants may
be used in a kyphoplasty. A balloon or mesh may be inserted into a
spinal void. The mesh may be filled with fluid or graft material to
expand the adjacent vertebral bodies. The mesh sack may then be
sealed and anchored into position to prevent migration. The mesh,
graft material, seal, and/or anchor may be made of PEEK and may be
biodegradable material.
[0464] In a further application of the invention, the surgical
welding system may be used with for intracranial and craniofacial
surgery. Thermoplastic implants may be used to stabilize
craniofacial plates. The plates may be contoured with energy to
obtain the desired shape. PEEK fasteners may be implanted in tissue
via mechanically, thermal welding, or both, and the plate may be
attached to the fasteners via mechanical means, thermal welding, or
a combination thereof. For face lifts, one or more PEEK fasteners
and a suture or cable may be used to create a sling to reposition
and tighten soft tissue such as skin. The fasteners may be secured
to bone or other tissue. The suture may be positioned through the
soft tissue using a magnetic suture passer and magnetic guidance
thereby achieving a minimally invasive facial support. The
fasteners and/or suture may be secured unicortically to the skull,
mandible, maxilla, or other bones of the head. Also, PEEK may be
used for sealing cerebrospinal fluid leaks. This may be performed
with a thermoplastic and energy source, with or without
vacuum/suction.
[0465] In another embodiment of the present invention, a fastener
includes multiple portions made from a different polymeric
material. For example, the fastener may have dual dermometry
properties. (see, e.g., FIGS. 156A-156F). For instance, the cap may
be made of one polymer while the post may be made of a different
polymer. The two polymers may have different temperature transition
regions. Therefore, one polymer would soften before the other
polymer. Also, if using ultrasonic energy, the two polymers may
soften at different frequencies, wattages, pressures, or other
welding parameters. Alternatively, the post may be made of a
polymer that softens with ultrasound, while the cap may be made of
a polymer that softens with resistive heating. It is contemplated
that any of the implants and devices disclosed herein may include
multiple polymers having different welding parameters.
[0466] In addition to PEEK and the other polymers described herein,
the implants, devices, and methods of the present invention may use
keratin, a naturally occurring polymer. Keratin may be
ultrasonically welded to itself, to other implants, or within
tissue. This may be performed in the operating room or
intracorporeally. Keratin may be bonded to collagen or to other
known polymers. In an exemplary application, keratin may be used to
fasten tissue to bone since keratin has BMP and tissue scaffold
properties. It is contemplated that any of devices and methods
disclosed herein may utilize keratin alone or in combination with
PEEK, polylactic acid, or other polymer. Keratin may be used to
make fasteners, disc replacements, joint replacement components,
stents, cell scaffolds, drug reservoirs, etc. Also, joint bearing
surfaces may include keratin with or without collagen or
chondrocytes. The bearing surfaces may be fastened to a joint
component using PEEK or PLA fasteners.
[0467] The surgical welding system also includes shrinkable
materials for use in surgery. Shrinkable materials provide a
compressive force to tissue or implants when energy is applied. For
example, a fastener may be implanted to secure an implant or
tissue. The application of heat to the polymeric material of
fastener causes the fastener to shorten or shrink thereby enhancing
the force provided by the fastener. The fastener may be positioned
through two portions of a fractured bone then heated to shrink. The
bone portions are compressed together for proper healing. In
addition to fasteners, a suture, cerclage, wire, or cable may be
made of shrinkable material. Cable may be placed through tissue or
bone, positioned across a joint, or connected with an implant. When
energy is applied to the cable, it shortens thereby creating a
tension force and securing the object(s) to which is attached. A
shrinkable cable positioned adjacent to or across a joint may
provide rigid and/or dynamic stabilization of the joint. FIGS.
160A-160C illustrate configurations and uses of heat shrinkable
implant pouches 1624. Implants 1626 may placed in a pouch are
sealed within. Applying energy to the pouch 1624 shrinks it to
firmly hold the implant 1626 therein. Thermoplastic fasteners may
be used to secure the pouch within the body.
[0468] In a further embodiment of the present invention,
thermoplastics and energy may be used to repair a hip joint. As
shown in FIG. 161, bearing surface implants 1628 may be bonded to
the acetabulum. Fasteners 1630 may also be used to secure the
implants 1628. In FIG. 162, a prosthetic femoral head 1632 is
attached to the femur with a fastener 1634. The head includes a
thermoplastic material 1636 bonded to the surface to function as a
bearing surface. The thermoplastic 1636 may articulate against
acetabulum implants. FIG. 163 shows PEEK 1638 disposed on the
surface of the femoral head. A bearing surface material 1640, such
as nano-metal or nano-ceramic is welded to the PEEK. On the
acetabulum, a bearing surface material is also welded to the bone
with PEEK. With the replacement components implanted, the bearing
surfaces articulate against each other.
[0469] It is contemplated the surgical welding system of the
present invention may be used with and integrated with the methods
and devices disclosed in U.S. Provisional Application No.
60/765,857 entitled "Surgical Fixation Device" filed on Feb. 7,
2006. In the '857 document, various thermoplastic fixation devices
are disclosed. The fixation devices may be, but are not limited to,
degradable, biodegradable, bioerodible, bioabsorbable, mechanically
expandable, hydrophilic, bendable, deformable, malleable, riveting,
threaded, toggling, barbed, bubbled, laminated, coated, blocking,
pneumatic, one-piece, multi-component, solid, hollow,
polygon-shaped, pointed, self-introducing, and combinations thereof
Also, the devices may include, but are not limited to, metallic
material, polymeric material, ceramic material, composite material,
body tissue, synthetic tissue, hydrophilic material, expandable
material, compressible material, heat bondable material, and
combinations thereof
[0470] The methods and devices disclosed in the '857 document may
be used in conjunction with any surgical procedure of the body. The
fastening and repair of tissue or an implant may be performed in
connection with surgery of a joint, bone, muscle, ligament, tendon,
cartilage, capsule, organ, skin, nerve, vessel, or other body
parts. For example, tissue may be repaired during intervertebral
disc surgery, knee surgery, hip surgery, organ transplant surgery,
bariatric surgery, spinal surgery, anterior cruciate ligament (ACL)
surgery, tendon-ligament surgery, rotator cuff surgery, capsule
repair surgery, fractured bone surgery, pelvic fracture surgery,
avulsion fragment surgery, shoulder surgery, hernia repair surgery,
and surgery of an intrasubstance ligament tear, annulus fibrosis,
fascia lata, flexor tendons, etc.
[0471] It is contemplated that the devices and methods of the
present invention be applied using minimally invasive incisions and
techniques to fasten muscles, tendons, ligaments, bones, nerves,
and blood vessels. A small incision(s) may be made adjacent the
damaged tissue area to be repaired, and a tube, delivery catheter,
sheath, cannula or expandable cannula may be used to perform the
methods of the present invention. U.S. Pat. No. 5,320,611 entitled
"Expandable Cannula Having Longitudinal Wire and Method of Use"
discloses cannulas for surgical and medical use expandable along
their entire lengths. The cannulas are inserted through tissue when
in an unexpanded condition and with a small diameter. The cannulas
are then expanded radially outwardly to give a full-size instrument
passage. Expansion of the cannulas occurs against the viscoelastic
resistance of the surrounding tissue. The expandable cannulas do
not require a full depth incision, or at most require only a
needle-size entrance opening.
[0472] U.S. Pat. Nos. 5,674,240; 5,961,499; and 6,338,730 also
disclose cannulas for surgical and medical use expandable along
their lengths. The cannula can be provided with a pointed end
portion and can include wires having cores which are enclosed by
jackets. The jackets are integrally formed as one piece with a
sheath of the cannula. The cannula may be expanded by inserting
members or by fluid pressure. An expandable chamber may be provided
at the distal end of the cannula. The above mentioned patents are
hereby incorporated by reference.
[0473] In addition to using a cannula with the present invention,
an introducer may be utilized to position implants at a specific
location within the body. U.S. Pat. No. 5,948,002 entitled
"Apparatus and Method for Use in Positioning a Suture Anchor"
discloses devices for controlling the placement depth of a
fastener. Also, U.S. patent application Ser. No. 10/102,413
discloses methods of securing body tissue with a robotic mechanism.
The above-mentioned patent and application are hereby incorporated
by reference. Another introducer or cannula which may be used with
the present invention is the VersaStep.RTM. System by Tyco.RTM.
Healthcare.
[0474] The present invention may also be utilized with minimally
invasive surgery techniques disclosed in U.S. patent application
Ser. No. 10/191,751 and U.S. Pat. Nos. 6,702,821 and 6,770,078.
These patent documents disclose, inter alfa, apparatus and methods
for minimally invasive joint replacement. The femoral, tibial,
and/or patellar components of a knee replacement may be fastened or
locked to each other and to adjacent tissue using fixation devices
disclosed herein and incorporated by reference. Furthermore, the
methods and devices of the present invention may be utilized for
repairing, reconstructing, augmenting, and securing tissue or
implants during and "on the way out" of a knee replacement
procedure. For example, the anterior cruciate ligament and other
ligaments may be repaired or reconstructed; quadriceps mechanisms
and other muscles may be repaired; a damaged rotator cuff may be
mended. The patent documents mentioned above are hereby
incorporated by reference.
[0475] Furthermore, it is contemplated that the present invention
may be used with bariatric surgery, colorectal surgery, plastic
surgery, gastroesophageal reflex disease (GERD) surgery, or for
repairing hernias. A band, mesh, or cage of synthetic material or
body tissue may be placed around an intestine or other tubular body
member. The band may seal the intestine. This method may be
performed over a balloon or bladder so that anastomosis is
maintained. The inner diameter of the tubular body part is
maintained by the balloon. The outer diameter of the body part is
then closed or wrapped with a band, mesh, or patch. The inner
diameter of the tubular body member may be narrowed or restricted
by the band. The band may be secured to the tubular body part or
surrounding tissue with the devices and methods described herein
and incorporated by reference.
[0476] It is further contemplated that the present invention may be
used in conjunction with the devices and methods disclosed in U.S.
Pat. No. 5,329,846 entitled "Tissue Press and System" and U.S. Pat.
No. 5,269,785 entitled "Apparatus and Method for Tissue Removal."
For example, an implant secured within the body using the present
invention may include tissue harvested, configured, and implanted
as described in the patents. The above-mentioned patents are hereby
incorporated by reference.
[0477] Additionally, it is contemplated that the devices and
methods of the present invention may be used with heat bondable
materials as disclosed in U.S. Pat. No. 5,593,425 entitled
"Surgical Devices Assembled Using Heat Bondable Materials." For
example, the implants of the present invention may include heat
bondable material. The material may be deformed to secure tissue or
hold a suture or cable. The fasteners made of heat bondable
material may be mechanically crimped, plastically crimped, or may
be welded to a suture or cable with RF (Bovie devices), laser,
ultrasound, electromagnet, ultraviolet, infrared,
electro-shockwave, or other known energy. The welding may be
performed in an aqueous, dry, or moist environment. The welding
device may be disposable, sterilizable, single-use, and/or
battery-operated. The above- mentioned patent is hereby
incorporated by reference.
[0478] Furthermore, the methods of the present invention may be
performed under indirect visualization, such as endoscopic
guidance, computer assisted navigation, magnetic resonance imaging,
CT scan, ultrasound, fluoroscopy, X-ray, or other suitable
visualization technique. The implants, fasteners, fastener
assemblies, and sutures of the present invention may include a
radiopaque material for enhancing indirect visualization. The use
of these visualization means along with minimally invasive surgery
techniques permits physicians to accurately and rapidly repair,
reconstruct, augment, and secure tissue or an implant within the
body. U.S. Pat. Nos. 5,329,924; 5,349,956; and 5,542,423 disclose
apparatus and methods for use in medical imaging. Also, the present
invention may be performed using robotics, such as haptic arms or
similar apparatus. The above-mentioned patents are hereby
incorporated by reference.
[0479] Moreover, the devices and methods of the present invention
may be used for the repair and reconstruction of a tubular pathway
like a blood vessel, intestine, urinary tract, esophagus, or other
similar body parts. For example, a blood vessel may be
intentionally severed during a surgical operation, or the blood
vessel may be damaged or torn as a result of an injury. Flexible
fixation of the vessel would permit the vessel to function properly
and also compress and stabilize the vessel for enhanced healing. To
facilitate the repair or reconstruction of a body lumen, a balloon
may be inserted into the lumen and expanded so the damaged,
severed, or torn portion of the vessel is positioned against the
outer surface of the inflated balloon. In this configuration, the
implants and methods described and incorporated herein may be used
to approximate the damaged portion of the vessel.
[0480] All references cited herein are expressly incorporated by
reference in their entirety.
[0481] It will be appreciated by persons skilled in the art that
the present invention is not limited to what has been particularly
shown and described herein above. In addition, unless mention was
made above to the contrary, it should be noted that all of the
accompanying drawings are not to scale. A variety of modifications
and variations are possible in light of the above teachings without
departing from the scope and spirit of the invention.
* * * * *