U.S. patent number RE47,470 [Application Number 15/191,385] was granted by the patent office on 2019-07-02 for vertebral body placement and method for spanning a space formed upon removal of a vertebral body.
This patent grant is currently assigned to Simplify Medical Pty Ltd. The grantee listed for this patent is Simplify Medical Pty Ltd. Invention is credited to Yves Arramon, David Hovda.
United States Patent |
RE47,470 |
Hovda , et al. |
July 2, 2019 |
Vertebral body placement and method for spanning a space formed
upon removal of a vertebral body
Abstract
A vertebral body replacement includes first and second end
plates, and a compliant connector section between the end plates
having one or more helical cuts to provide limited compliance
between the end plates. The compliant connector section can be
provided in a separate spacer that fits between the end plates or
directly in one or more of the end plates. The adjoining end plate
surfaces, and/or adjoining surfaces of the spacer, include a
rotational interlock to inhibit rotational motion between the
surfaces and allow a modular stacking assembly of the vertebral
body replacement to accommodate a wide range of patients.
Inventors: |
Hovda; David (Mountain View,
CA), Arramon; Yves (Sunnyvale, CA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Simplify Medical Pty Ltd |
Paddington |
N/A |
AU |
|
|
Assignee: |
Simplify Medical Pty Ltd
(AU)
|
Family
ID: |
40564282 |
Appl.
No.: |
15/191,385 |
Filed: |
June 23, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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60981665 |
Oct 22, 2007 |
|
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Reissue of: |
12255737 |
Oct 22, 2008 |
8758441 |
Jun 24, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61F
2/4465 (20130101); A61F 2/30771 (20130101); A61F
2/30771 (20130101); A61F 2/4465 (20130101); A61F
2310/00017 (20130101); A61F 2002/30904 (20130101); A61F
2310/00431 (20130101); A61F 2310/00976 (20130101); A61F
2310/00131 (20130101); A61F 2310/00179 (20130101); A61F
2310/00407 (20130101); A61B 17/86 (20130101); A61F
2002/30787 (20130101); A61F 2250/0032 (20130101); A61F
2002/30772 (20130101); A61F 2310/00407 (20130101); A61F
2310/0088 (20130101); A61F 2310/00604 (20130101); A61F
2002/30889 (20130101); A61F 2002/30884 (20130101); A61F
2002/449 (20130101); A61F 2310/00976 (20130101); A61F
2310/00796 (20130101); A61F 2002/30056 (20130101); A61F
2250/0032 (20130101); A61F 2310/00023 (20130101); A61F
2002/449 (20130101); A61F 2002/30056 (20130101); A61F
2310/00604 (20130101); A61F 2002/30899 (20130101); A61F
2310/0088 (20130101); A61F 2002/30884 (20130101); A61F
2002/30787 (20130101); A61F 2002/30904 (20130101); A61F
2310/00796 (20130101); A61F 2002/30772 (20130101); A61F
2310/00071 (20130101); A61F 2310/00029 (20130101); A61F
2310/00431 (20130101); A61B 17/86 (20130101) |
Current International
Class: |
A61F
2/44 (20060101); A61F 2/30 (20060101); A61B
17/86 (20060101) |
References Cited
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|
Primary Examiner: Wehner; Cary E
Attorney, Agent or Firm: Wilson Sonsini Goodrich &
Rosati
Claims
What is claimed is:
1. A vertebral body replacement for replacing at least one
vertebral body between remaining upper and lower vertebral bodies,
the vertebral body replacement comprising: a first end plate having
an upper surface configured to engage against a surface of the
upper remaining vertebral body, and a lower surface opposite the
upper surface spanning the first end plate; a second end plate
having a lower surface configured to engage against a surface of
the lower remaining vertebral body; a compliant connector section
between the first end plate lower surface and the second end plate
lower surface, the compliant connector section comprising a
plurality of separate stackable spacers each having at least one
helical cut configured and arranged to permit limited rotation
between the first end plate and the second end plate in an
anterior/posterior direction and a lateral direction; and a
rotational interlock on the first end plate lower surface and an
upper surface of at least one of the spacers, the rotational
interlock being configured and arranged to inhibit rotational
motion between the first end plate lower surface and the at least
one spacer upper surface, wherein the rotational interlock
comprises a first raised elongate portion extending in the
anterior/posterior direction or the lateral direction on one of the
first end plate lower surface or the at least one spacer upper
surface and a first complementary elongate recess in the opposite
surface.
2. The vertebral body replacement of claim 1, wherein the second
end plate includes an upper surface opposite the second end plate
lower surface and spanning the second end plate, the compliant
connector section located between the second end plate lower and
upper surfaces.
3. The vertebral body replacement of claim 2, wherein said
rotational interlock is a first rotational interlock, and further
comprising a second rotational interlock on the first end plate
lower surface and the second end plate upper surface, the second
rotational interlock configured and arranged to at least inhibit
rotational motion between the first end plate lower surface and the
second end plate upper surface.
4. The vertebral body replacement of claim 1, wherein the compliant
connector section is configured and arranged to limit motion to
less than 10 degrees between said remaining vertebral bodies.
5. The vertebral body replacement of claim 1, wherein the at least
one helical cut in each of the separate stackable spacers are
oppositely oriented.
6. The vertebral body replacement of claim 1, wherein said
rotational interlock is a first rotational interlock, wherein the
at least one spacer has a lower surface spanning the at least one
spacer, wherein the second end plate has an upper surface spanning
the second end plate, and further comprising: a second rotational
interlock on the second end plate upper surface and the at least
one spacer lower surface, the second rotational interlock
configured and arranged to at least inhibit rotational motion
between the second end plate upper surface and the at least one
spacer lower surface, wherein the second rotational interlock
comprises a second raised elongate portion extending in the
anterior/posterior direction or the lateral direction on one of the
second end plate upper surface or the at least one spacer lower
surface and a second complementary elongate recess in the opposite
surface.
7. The vertebral body replacement of claim 6, wherein the first and
second rotational interlocks are different.
8. The vertebral body replacement of claim 1, further comprising:
an adjustment mechanism between the first and second end plates,
the adjustment mechanism configured and arranged to selectively
move the first and second end plates towards and away from each
other.
9. The vertebral body replacement of claim 1, further comprising at
least one bone ingrowth hole in at least one of the first and
second end plates.
10. The vertebral body replacement of claim 1, wherein each of the
first and second end plates comprise a lateral surface, and wherein
the at least one bone ingrowth hole extends between said lateral
surface and said surface configured to engage against a surface of
a remaining vertebral body.
11. The vertebral body replacement of claim 1, wherein the
vertebral body replacement is sized and shaped to replace one or
more entire vertebral bodies of the human spine.
12. A vertebral body replacement for replacing at least one
vertebral body between remaining upper and lower vertebral bodies,
the vertebral body replacement comprising: a first end plate having
an upper surface configured to engage against a surface of the
upper remaining vertebral body, and a lower surface opposite the
upper surface spanning the first end plate; a second end plate
having a lower surface configured to engage against a surface of
the lower remaining vertebral body; a compliant connector section
between the first end plate lower surface and the second end plate
lower surface, the compliant connector section comprising a
plurality of separate stackable spacers each having at least one
helical cut configured and arranged to form a continuous spring
coil element; and a rotational interlock on the first end plate
lower surface and an upper surface of at least one of the spacers,
the rotational interlock being configured and arranged to inhibit
rotational motion between the first end plate lower surface and the
at least one spacer upper surface, wherein the rotational interlock
comprises a raised elongate portion extending in the
anterior/posterior direction or the lateral direction on one of the
first end plate lower surface or the at least one spacer upper
surface and a complementary elongate recess in the opposite
surface.
13. The vertebral body replacement of claim 12, wherein the
vertebral body replacement is sized and shaped to replace one or
more entire vertebral bodies of the human spine.
14. A vertebral body replacement for replacing at least one
vertebral body between remaining upper and lower vertebral bodies,
the vertebral body replacement comprising: a first end plate having
an upper surface configured to engage against a surface of the
upper remaining vertebral body, and a lower surface opposite the
upper surface spanning the first end plate; a second end plate
having a lower surface configured to engage against a surface of
the lower remaining vertebral body and an upper surface; a
compliant connector section between the first end plate lower
surface and the second end plate lower surface, the compliant
connector section comprising a plurality of separate stackable
spacers each having at least one helical cut configured and
arranged to form a continuous spring coil element; and a rotational
interlock on the second end plate upper surface and a lower surface
of at least one of the spacers, the rotational interlock being
configured and arranged to inhibit rotational motion between the
second end plate upper surface and the at least one spacer lower
surface, wherein the rotational interlock comprises a raised
elongate portion extending in the anterior/posterior direction or
the lateral direction on one of the second end plate upper surface
or the at least one spacer lower surface and a complementary
elongate recess in the opposite surface.
15. The vertebral body replacement of claim 14, wherein the
vertebral body replacement is sized and shaped to replace one or
more entire vertebral bodies of the human spine.
16. A vertebral body replacement for replacing at least one
vertebral body between remaining upper and lower vertebral bodies,
the vertebral body replacement comprising: a first end plate having
an upper surface configured to engage against a surface of the
upper remaining vertebral body, and a lower surface opposite the
upper surface spanning the first end plate; a second end plate
having a lower surface configured to engage against a surface of
the lower remaining vertebral body and an upper surface opposite
the lower surface and spanning the second end plate; a compliant
connector section between the first end plate lower surface and the
second end plate lower surface, the compliant connector section
comprising a plurality of separate stackable spacers each having at
least one helical cut configured and arranged to permit limited
rotation between the first end plate and the second end plate in an
anterior/posterior direction and a lateral direction; and a
rotational interlock on the second end plate upper surface and a
lower surface of at least one of the spacers, the rotational
interlock being configured and arranged to inhibit rotational
motion between the second end plate upper surface and the at least
one spacer lower surface, wherein the rotational interlock
comprises a raised elongate portion extending in the
anterior/posterior direction or the lateral direction on one of the
second end plate upper surface or the at least one spacer lower
surface and a complementary elongate recess in the opposite
surface.
17. The vertebral body replacement of claim 16, wherein the
compliant connector section is located between the second end plate
lower and upper surfaces.
18. The vertebral body replacement of claim 16, wherein the
compliant connector section is configured and arranged to limit
motion to less than 10 degrees between said remaining vertebral
bodies.
19. The vertebral body replacement of claim 16, wherein the at
least one helical cut in each of the separate stackable spacers are
oppositely oriented.
20. The vertebral body replacement of claim 16, wherein said
rotational interlock is a first rotational interlock, and further
comprising a second rotational interlock on the first end plate
lower surface and the second end plate upper surface, the second
rotational interlock configured and arranged to at least inhibit
rotational motion between the first end plate lower surface and the
second end plate upper surface.
21. The vertebral body replacement of claim 16, further comprising:
an adjustment mechanism between the first and second end plates,
the adjustment mechanism configured and arranged to selectively
move the first and second end plates towards and away from each
other.
22. The vertebral body replacement of claim 16, further comprising
at least one bone ingrowth hole in at least one of the first and
second end plates.
23. The vertebral body replacement of claim 16, wherein each of the
first and second end plates comprise a lateral surface, and wherein
the at least one bone ingrowth hole extends between said lateral
surface and said surface configured to engage against a surface of
a remaining vertebral body.
24. The vertebral body replacement of claim 16, wherein the
vertebral body replacement is sized and shaped to replace one or
more entire vertebral bodies of the human spine.
.Iadd.25. A vertebral body replacement for replacing at least one
vertebral body between remaining upper and lower vertebral bodies,
the vertebral body replacement comprising: a first end plate having
an upper surface configured to engage against a surface of the
upper remaining vertebral body and at least one elongated fin on
the upper surface configured to enter a slot cut in the upper
remaining vertebral body; a second end plate having a lower surface
configured to engage against a surface of the lower remaining
vertebral body and at least one elongated fin on the lower surface
configured to enter a slot cut in the lower remaining vertebral
body; a compliant connector section between the first end plate and
the second end plate, the compliant connector section comprising a
plurality of separate stackable spacers each having at least one
helical cut configured and arranged to permit limited rotation
between the first end plate and the second end plate in an
anterior/posterior direction and a lateral direction, wherein the
compliant connector section is configured and arranged to limit
motion to less than 10 degrees between said remaining
vertebrae..Iaddend.
.Iadd.26. The vertebral body replacement of claim 25, wherein the
upper and lower surfaces have less than 10 percent comprising
holes..Iaddend.
.Iadd.27. The vertebral body replacement of claim 25, further
comprising one or more holes in the first and second end plates
configured to receive screws extending through the plates and into
the bone..Iaddend.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. .sctn.119 to U.S.
Provisional Application No. 60/981,665 filed Oct. 22, 2007,
entitled "Method and Spacer Device Spanning Space Formed Upon
Removal of an Intervertebral Disc," the full disclosure of which is
incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to medical devices and methods. More
specifically, the invention relates to vertebral body replacements
and methods of spanning a space formed upon removal of an
intervertebral disc.
Back pain takes an enormous toll on the health and productivity of
people around the world. According to the American Academy of
Orthopedic Surgeons, approximately 80 percent of Americans will
experience back pain at some time in their life. In the year 2000,
approximately 26 million visits were made to physicians' offices
due to back problems in the United States. On any one day, it is
estimated that 5% of the working population in America is disabled
by back pain.
One common cause of back pain is injury, degeneration and/or
dysfunction of one or more intervertebral discs. Intervertebral
discs are the soft tissue structures located between each of the
thirty-three vertebral bones that make up the vertebral (spinal)
column. Essentially, the discs allow the vertebrae to move relative
to one another. The vertebral column and discs are vital anatomical
structures, in that they form a central axis that supports the head
and torso, allow for movement of the back, and protect the spinal
cord, which passes through the vertebrae in proximity to the
discs.
Another form of spinal injury involves injury or deformity of the
vertebra themselves. When one or more vertebrae is fracture or
deformed by tumor or other causes and results in pain and
discomfort, surgery is often required. Traditionally, surgical
procedures for vertebral replacement have involved removal of the
vertebra and fusion of the two vertebrae above and below the
missing vertebra. It is necessary to replace the removed vertebra
to maintain spacing of adjacent vertebrae. Oftentimes, pins, rods,
screws, cages and/or the like are inserted between the vertebrae to
act as support structures to hold the vertebrae and graft material
in place while they permanently fuse together. These vertebral body
replacement procedures generally focus on rigidly fusing the
adjacent vertebrae and preventing motion.
However, it would be desirable to achieve immobilization of the
vertebrae adjacent a removed vertebral body and maintain spacing
between the adjacent vertebrae without the complete rigidity of
traditional interbody fusion.
Another problem associated with the typical vertebral body
replacement procedure is the subsidence of the cage into the
vertebral body. The typical vertebral body replacement cage is
formed with a large percentage of open space to allow the bone to
grow through and form the bridging bone which immobilizes the
vertebrae. However, the large amount of open space means that the
load on each segment of the cage is significantly higher than if
the cage surface area was larger. This results in the cage
subsiding or sinking into the bone over time and allows the space
between the vertebrae to collapse.
Therefore, a need exists for improved vertebral body replacement
and method for spanning a space and maintaining spacing between two
vertebrae after removal of an intervertebral body. Such improved
method and intervertebral body replacement would avoid the need for
growth of bridging bone between the remaining vertebrae.
BRIEF SUMMARY OF THE INVENTION
Embodiments of the present invention provide a vertebral body
replacement with compliance or shock absorption and methods of
spanning a space formed upon removal of vertebral body.
In accordance with one of numerous aspects of the present
invention, a vertebral body replacement for replacing at least one
vertebral body between remaining upper and lower vertebral bodies,
the vertebral body replacement comprises a first end plate having
an upper surface configured to engage against a surface of the
upper remaining vertebral body, and a lower surface opposite the
upper surface spanning the first end plate, a second end plate
having a lower surface configured to engage against a surface of
the lower remaining vertebral body, and a compliant connector
section between the first end plate lower surface and the second
end plate lower surface, the compliant connector section comprising
at least one helical cut configured and arranged to permit limited
motion between the first end plate and the second end plate.
In accordance with another aspect of the invention, a method of
replacing at least one vertebral body comprises removing said at
least one vertebral body between two remaining vertebral bodies,
placing a vertebral body replacement between said two remaining
vertebral bodies, the vertebral body replacement comprising first
and second end plates and a compliant connector section between the
first and second end plates, the compliant connector section having
at least one helical cut and configured and arranged to limit
motion to less than 10 degrees between said remaining vertebral
bodies, and maintaining the space between the two remaining
vertebral bodies with the vertebral body replacement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a vertebral body replacement
according to one embodiment of the present invention;
FIG. 1A is an exploded, perspective view of the vertebral body
replacement of FIG. 1;
FIG. 2 is a perspective view of a vertebral body replacement
according to a second exemplary embodiment of the present
invention; and
FIG. 3 is a perspective view of a vertebral body replacement
according to a third exemplary embodiment of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
Various embodiments of the present invention generally provide for
a vertebral body replacement having upper and lower plates or
surfaces connected by a central connector portion which provides
some limited amount of axial compliance and/or rotational motion
between the upper and lower plates or surfaces. The compliant
vertebral body replacement according to the present invention can
maintain disc height and prevent subsidence with a large surface
area while improving outcomes by allowing some limited motion and
providing improved fixation. The compliance of the vertebral body
replacement also functions to reduce loading on the interface
between the bone and vertebral body replacement.
One example of a vertebral body replacement 10 for replacement of a
vertebral body and maintaining disc height between two adjacent
vertebral discs is shown in FIG. 1. The body 10 includes at least
one end plate 20 having a vertebral body contacting surface 24, a
second end plate or body end 30 opposite the end plate 20, and a
compliant connector or connector section 32 interposed between, or
interconnecting, the two ends 20, 30. As will be described below,
some limited rotational and axial motion may be provided between
the two plates or sections 20, 30 to reduce loading on the
interface between the adjacent vertebral bodies and the body 10.
According to an exemplary device embodying principles of the
present invention, the compliance of the connector 32, as well as
some small amount of translation and rotation, is provided by
lateral cuts or slots 70 extending into the connector 32. The body
10 when implanted between two vertebrae maintains a desirable space
between the two adjacent vertebrae similar to that provided by a
natural vertebra.
Although the body 10 has been shown as generally oblong in cross
section, other shapes may be used, including circular, oval,
elliptical, or rectangular. Although the connector section 32 has
been illustrated in FIG. 1 as integral with the end section 30,
according to other embodiments, the connector can include one or
more separate compliant connectors or spacers in other
configurations and at other locations. By way of example, a
compliant connector may be the same or substantially the same
diameter, size, and shape as the plates, multiple connectors can be
arranged in a rectangular pattern, or a hollow cylindrical
connector can be used. Further optionally, while the surfaces 24
are illustrated being perpendicular to the vertical axis of the
body 10, one or both of the surfaces 24 can be somewhat
wedge-shaped, formed with one or two lordosis angles, as well known
to those of ordinary skill in the art. The modular design of the
upper plate 20 and the lower plate section 30 allows the creation
of a complete bodies 10 of different sizes to correspond to the
particular space for each patient.
The upper plate 20 and the lower plate or plate section 30, and
connector 32, may be constructed from any suitable metal, alloy or
combination of metals or alloys, such as but not limited to cobalt
chrome alloys, titanium (such as grade 5 titanium), titanium based
alloys, tantalum, nickel titanium alloys, stainless steel, and/or
the like. They may also be formed of ceramics, biologically
compatible polymers including PEEK, UHMWPE (ultra high molecular
weight polyethylene) or fiber reinforced polymers. However, when
polymer is used for the body 10, the contacting surfaces 24 may be
coated or otherwise covered with metal for fixation. The upper
plate 20 and the lower plate or plate section 30, and connector 32,
may be formed of a one piece construction or may be formed of more
than one piece, such as different materials coupled together. When
the body 10 is formed of multiple materials, these materials are
fixed together to form a unitary one piece spacer without
separately moving parts.
Different materials may be used for different parts of the body 10
to optimize imaging characteristics. For example, the upper plate
20 and the lower plate or plate section 30 may be formed of
titanium, while the connector 32 is formed of cobalt chromium alloy
for improved imaging of the plates. Cobalt chrome molybdenum
alloys, when used for the plates 20, 30 may be treated with
aluminum oxide blasting followed by a titanium plasma spray to
improve bone integration. Other materials and coatings can also be
used such as titanium coated with titanium nitride, aluminum oxide
blasting, HA (hydroxylapatite) coating, micro HA coating, and/or
bone integration promoting coatings. Any other suitable metals or
combinations of metals may be used as well as ceramic or polymer
materials, and combinations thereof. Any suitable technique may be
used to couple materials together, such as snap fitting, slip
fitting, lamination, interference fitting, use of adhesives,
welding and/or the like.
In some embodiments, the outer surface 24 is planar. Oftentimes,
the outer surface 24 will include one or more surface features
and/or materials to enhance attachment of the body 10 to vertebral
bone. For example, as shown in FIG. 1, the outer surface 24 may be
machined to have serrations 40 or other surface features for
promoting adhesion of the plates 20, 30 to a vertebra. In the
embodiment shown, the serrations 40 are pyramid shaped serrations
extending in mutually orthogonal directions, but other geometries
such as teeth, grooves, ridges, pins, barbs or the like would also
be useful. When the bone integration structures are ridges, teeth,
barbs or similar structures, they may be angled to ease insertion
and prevent migration. These bone integration structures can be
used to precisely cut the bone during implantation to cause
bleeding bone and encourage bone integration. Additionally, the
outer surface 24 may be provided with a rough microfinish formed by
blasting with aluminum oxide microparticles or the like to improve
bone integration. In some embodiments, the outer surface may also
be titanium plasma sprayed or HA coated to further enhance
attachment of the outer surface 24 to vertebral bone.
The outer surfaces 24 may also carry one or more upstanding fins
50, 52 which also extend laterally in an anterior-posterior
direction. The fins 50, 52 are configured to be placed in slots in
the vertebral bodies. Preferably, the fins 50, 52 each have a
height greater than a width and have a lateral length greater than
the height. In one embodiment, the fins 50, 52 are pierced by
transverse holes 54 for bone ingrowth. The transverse holes 54 may
be formed in any shape and may extend partially or all the way
through the fins 50, 52. In alternative embodiments, the fins 50,
52 may be rotated away from the anterior-posterior axis, such as in
a lateral-lateral orientation, a posterolateral-anterolateral
orientation, or the like.
The fins 50, 52 provide improved attachment to the bone and prevent
rotation of the plates 20, 30 in the bone. In some embodiments, the
fins 50, 52 may extend from the surface 24 at an angle other than
90.degree.. For example, on one or more of the plates 20, 22 where
multiple fins 52 are attached to the surface 24, the fins may be
canted away from one another with the bases slightly closer
together than their edges at an angle such as about 80-88 degrees.
The fins 50, 52 may have any other suitable configuration including
various numbers angles and curvatures, in various embodiments. In
some embodiments, the fins 50, 52 may be omitted altogether. The
embodiment of FIG. 1 illustrates a combination of one plate with a
single fin 50 and another plate with a double fin 52. This
arrangement is useful for double level disc replacements and
utilizes offset slots in the vertebral body to prevent the rare
occurrence of vertebral body splitting by avoiding cuts to the
vertebral body in the same plane for multi-level implants. The
combination of the single fin 50 and double fin 52 can also assist
the surgeon in placement of the spacer in the correct
orientation.
The body 10 has been shown with the fins 50, 52 as the primary
fixation feature; however, the fins may also be augmented or
replaced with one or more screws extending through the plates and
into the bone. For example in the body 10 of FIG. 1, the upper fin
50 may be augmented or replaced with one or more screws (not
illustrated) while the two lower fins 52 remain. The plates 20, 30
can be provided with one or a series of holes 60 to allow screws to
be inserted at different locations at the option of the surgeon.
However, the holes 60 should not be of such size or number that the
coverage of the plate 20, 30 is decreased to such an extent that
subsidence occurs. Alternately, the screws can pass laterally
through one or more of the holes in the fins. When one or more
screws are provided, they may incorporate a locking feature to
prevent the screws from backing out. The screws may also be
provided with a bone integration coating.
Some limited holes may also be provided in the plate to allow bone
ingrowth. However, if the outer surfaces 24 have holes therein, the
holes advantageously cover less than 40 percent of the outer
surface 24 which contacts the bone to prevent subsidence of the
plates into the vertebral bodies. Preferably the holes will cover
less than 25 percent, and more preferably less than 10 percent of
the outer bone contacting surfaces. At the option of the surgeon,
when the small holes are present in the plates 20, 30, bone graft
can be placed in the holes to allow bone to grow through the
plates. The embodiments illustrated in FIGS. 1-3 also illustrate
the optional inclusion of countersunk screw holes 60 extending
between a lateral surface of the plates 20, 30 and the end surfaces
24, in which bone screws may optionally be inserted to further
stabilize the body 10. The holes 60 can alternatively extend
vertically through the end plates, or the end plates can include
combinations of vertical and angled holes.
The vertebral body replacement 10 shown herein is configured for
placement in the vertebral column from an anterior approach. It
should be understood that other approaches can be used, and the
particular shape of the vertebral body replacement would be
modified depending on the approach. For example, for a lateral
approach, the vertebral body replacement may be formed in a more
elongated, kidney bean, or banana shape with a transversely
oriented fin.
As shown in FIG. 1, the vertebral body replacement 10 is provided
with shock absorption or some other limited motion between the two
plates 20, 30 by providing a compliant connector 32. The limited
motion provided by the compliant connector 32 is designed to reduce
forces on the interface between the outer surfaces 24 and the bone
to improve long term fixation of the spacer. The compliance of the
connector 32 allows motion between the vertebral bodies to be
accommodated by the compliance in the body 10 rather than causing
one or both of the vertebral bodies to pull away from the plates
20, 30. The compliant connector 32 provides limited relative motion
between the plates, which may include compliance in a vertical
direction of up to about 6 mm, rotation in an anterior/posterior
direction, lateral direction, or axial rotation of less than about
10 degrees, and/or translation of up to about 1 mm.
In the vertebral body replacement 10 of FIG. 1, the compliance, as
well as some small amount of translation and rotation, is provided
by the cuts or slots 70 extending into the connector 32. In the
embodiment of FIG. 1, the slots 70 are spiral slots, however, other
shaped slots may also be used. The compliant connector 32 is
advantageously formed as a unitary member with at least one lateral
cut or slot 70 positioned between the upper and lower plates 20,
30, permitting the plates to move resiliently toward and away from
each other. The replacement 10 can also be formed as multiple parts
where different properties are desired from the different parts,
such as different radiopacities, different strengths, or different
flexibility properties and for flexibility in creating the size and
configuration of spacer suited to the patient. The lateral cuts 70
in the connector 32 allow the connector to function as a compliant
member without affecting the function of the upper and lower plates
of the body 10.
FIG. 2 illustrates an alternative embodiment of a body 10 having
multiple parts including end plates 20, 30 and spacers 90. The
spacers 90 include lateral cuts 70 in place of the spiral cuts of
FIG. 1. The material remaining after the cuts 70 are made is called
a column. A shallow cut, that is, one that extends laterally into
the connector a relatively small distance, and a large column
provides a stiffer spacer, while a deeper cut and smaller column
provides a more compliant spacer. In the embodiment shown in FIG.
2, the cuts 70 are at least 60% of the way through the spacer width
or diameter, and preferably at least 75% of the way through the
connector width.
Optionally, a variable stiffness shock absorbing connector 32 (FIG.
1) or spacer 90 (FIG. 2) can be constructed with lateral cuts 70
with tapering widths. For cuts with such tapering widths, the cut
70 is smallest where the cut terminates adjacent the column and is
largest at the edge of the connector 32 furthest from the column.
In this version, each of the lateral cuts 70 causes the connector
32 to act as a non linear spring providing progressively stiffer
behavior upon larger compression. This is due to the fact that
progressively more material on the sides of the cuts 70 is in
contact as the connector 32 or spacer 90 is compressed. The
non-linear spring can be incorporated in any of the other
embodiments described herein to provide a softer stop to the
compliant action of the core. The tapered width cuts 70 can provide
the additional benefit of providing a flushing action during
operation that moves any accumulated material out of the cuts.
The cuts 70 also advantageously include a stress relief 74 at the
end of the cuts which increases the fatigue life of the device by
reducing the stress concentration at the ends of the slots.
In the exemplary embodiments illustrated herein, a shock absorbing
connector 32 includes either one or more planar cuts 70 (FIG. 2),
or alternatively one or more spiral or helical cuts 70 (FIG. 1) to
form one or more continuous spring coil elements 72 which provide
compliance to the connector. Although the spiral cut connector 32
is illustrated in FIG. 1 with two spiral cuts, only one, or three
or more spiral cuts may also be employed. For example, two or more
spiral cuts 70 arranged in opposite directions can be formed in the
connector 32, as illustrated in FIG. 1. Furthermore, when more than
one spiral cut 70 is provided, the cuts can optionally be nested
one inside the other (not illustrated), as in the manner of a
multi-start thread, and/or can include combinations of both nested
and adjacent cuts (such as those illustrated in FIGS. 1-2). The
compression of a spiral cut connector 70 can result in some small
amount of relative rotation between the upper and lower surfaces
20, 30. In cases where it is desirable to eliminate this rotation,
a connector 32 having multiple spiral cuts in opposite directions
can be used. For example, a connector 32 can be formed with a first
spiral cut 70 at a top of the connector in a first direction and a
second spiral cut 70 at a bottom of the core in an opposite second
direction. The first and second spiral cuts can offset rotation of
each other resulting in a non rotating compliant connector. The
double spiral embodiment of the connector is also more stable in
shear than the single coil. Furthermore, coils 74 provide
significantly more surface area between the adjoining surfaces of
the cuts 70 than do planar cuts, which can be advantageous to allow
limited rotational motion. The spiral cuts 70 can be made parallel
to the end surfaces of the body 10 or can be angled, as in a cone
shape. When the spiral cuts 70 are angled to form a cone shaped
spring the cone shaped surfaces can limit the translational
movement of the spring.
In each of the shock absorbing connectors described herein, the
interconnected sections within the connector and the plate(s) are
designed for minimal or no motion between contacting parts to
prevent particulate generation. However, since the plates and
connectors are made entirely of hard materials such as metals, some
minimal rubbing contact may be accommodated. In the exemplary
embodiments illustrated in figures herein, a rotational interlock
80 is provided between the lower surface of the end plate 20 and
the adjoining upper surface of the connector section 32 of the end
plate 30. With reference to FIG. 2, the exemplary interlock 80
includes complementary portions 82, 84, formed on the adjoining
faces of the end plate 20 and the connector section 32, in the
exemplary body 10, taking the shape of simple raised portions or
ribs 84 which mate with correspondingly sized and shaped recesses
82. The rotational interlock 80 is not limited to the particular
shapes or orientations illustrated in the drawing figures, and can
take any shape or orientation which resists, and advantageously
prevents, the plate 20 and the connector section 32 from rotating
relative to each other. The rotational interlock 80 on the top and
bottom surface of a spacer 90 can be different to allow the
complete body 10 to be assembled only in a particular desired
configuration.
Further optionally, as illustrated in FIG. 1A, the body 10 can
include one or more blind cavities 86 extending vertically through
the connector section 32, which provides the interior side of the
spiral cut 70. The blind cavities 86 can also vary in cross
sectional size and shape to tailor the rigidity of the connector
section 32 in different directions. More specifically, the cavity
or cavities 86, only one of which is illustrated in FIG. 1A, when
left hollow, provides a less rigid connector 32. To increase the
rigidity of the connector section 32, other material can be used to
partially or completely fill the cavity 86, such as pins or rods
(not illustrated) inserted in the cavity.
When implanted between vertebrae, the shock absorbing connector 32
can resiliently absorb shocks transmitted vertically between upper
and lower vertebrae of the patient's spinal column. This shock
absorption is related to the material properties, design, and
dimensions of the connector. In general, an increased number and
width of the cuts 70 will increase absorption of shocks, with more
elastic, or springy compression between the vertebrae.
Preferably the connector 32 is made of metal such as titanium,
cobalt chromium alloy, stainless steel, tantalum, nickel titanium
or a combination thereof. These materials also can be designed to
provide a device which is deformable in the elastic region of the
stress/strain curve and will not plastically deform during
compression.
In the embodiments illustrated herein, the number, pitch, lead,
lead angle, handedness, and total vertical length of each of the
spiral cuts or slots 70, as well as the combination of multiple
cuts if provided, can be varied to change the amount of compliance
of the connector 32. When a load is applied to the upper and lower
plates 20, 30, the connector 32 will compress with each of the cuts
70 closing and the total amount of compression possible depending
on the number, arrangement, and height of the cuts. The cuts 70
form spiral coils 74 between the ends of the cut, which function
like springs to allow the connector 32 to be compressed. The cuts
70 may be modified to be non-uniform to provide preferential
deflection in one or more bending directions. Preferential
deflection is useful to provide increased anterior-posterior
compliance and less lateral compliance, or the other way
around.
According to one embodiment of the invention, the cuts 70 in the
shock absorbing connector 32 according to any of the embodiments
described herein may be manufactured by wire EDM (electrical
discharge machining), molding, laser cutting, or the like. A number
of cuts 70 can vary from 1 to about 50, preferably about 6 to about
20, for a vertebral body replacement. A width of the lateral cuts
70 in the direction of the height of the body 10 is about 0.01 mm
to about 2 mm, preferably about 0.05 to about 1 mm.
In one embodiment of the present invention, for a cervical
application, the maximum deformation of the shock absorbing body is
about 0.5 to about 4 mm, and is preferably about 1 to about 2 mm.
For a lumbar application, the maximum deformation of the shock
absorbing body is about 1 to about 6 mm, and is preferably about 1
to about 3 mm.
Although motion between the plates 20, 30 of the body 10 has been
described herein as provided by cuts 70, it should be understood
that this motion can be provided in a number of other known
manners, such as use of resilient materials, or movable joints as
long as the motion is limited to the small amount of motion
allowable in a patient requiring a fusion procedure including
compliance or vertical motion between the plates of up to about 6
mm, rotation between the plates of less than 10 degrees, and
translation between the plates of up to about 1 mm.
The body 10 can be provided in different sizes, with different
plate sizes, angles between plates, lordosis angles, and heights
for different patients or applications. In addition, the shock
absorbing connector section 32 can be provided in different
compliances for different patients. In addition, the compliance
and/or height of the body 10 can be adjustable, such as by rotating
an adjustment screw before or after implantation, and/or bonding
portions of one or more of the portions of a coil 74. The body 10
preferably is sized to provide substantial coverage of the
vertebral surfaces. For example, in an anterior procedure, the
plates 20, 30 are preferably sized to cover at least 50 percent of
the vertebral surface. In posterior or lateral procedures, the
coverage of the vertebral surface may be somewhat smaller due to
the small size of the access area, i.e., the posterior or lateral
spacers may cover about 40 percent or more of the vertebral surface
with a one or two part spacer.
Turning now to FIG. 2, a second exemplary embodiment of a body 10,
adhering to principles of the present invention, is illustrated. In
contrast to the embodiment illustrated in FIGS. 1 and 1A, the body
10 illustrated in FIG. 2 includes one or more separate compliant
connector spacers 90 positioned between plates 20, 30, rather than
a connector section 32 of a plate 30. Each of the spacers 90
includes one or more cuts 70, which can be either planar cuts or
forming one or more coils, as described above with reference to the
embodiment of FIGS. 1 and 1A. The adjoining surfaces of the plates
20, 30 and the spacers 90 are also provided with rotational
interlocks 80, as described herein; while FIG. 2 suggests that the
interlocks 80 are the same, differently configured interlocks can
alternatively be provided for different non-adjoining surfaces, for
example to prevent the spacers 90 from being assembled in a way
other than that designed for a body 10 configured for the
particular patient. By way of non-limiting example, a first
rotational interlock, formed of rectangular ribs and recesses on
adjoining surfaces of the end plates and/or the spacers, as
illustrated in FIG. 1A, can be provided on the adjoining surfaces
of the plate 20 and the adjacent first spacer 90; a second
rotational interlock, formed of vertically oriented cylindrical
pins, can be provided on the opposite face of the first spacer 90
and the adjoining surface of the adjacent spacer or plate 30.
Because the two interlocks 80 are incompatible and do not mate,
there is only a single configuration of the pieces that will permit
them to be assembled into a body 10.
FIG. 3 illustrates a third exemplary embodiment of a body 10,
adhering to principles of the present invention. In addition to the
features previously described with reference to FIGS. 1-2, the
embodiment illustrated in FIG. 3 includes a vertical adjustment
mechanism 100 for fine tuning of the vertical size of the body 10,
either prior to or after implantation of body 10 into a patient.
While numerous configurations of the adjustment mechanism 100 can
be provided, one exemplary embodiment includes a threaded post or
tube 102 extending from either an upper surface 106 of the end
plate 30 or a lower surface 104 of the section 32, which mates with
a correspondingly configured and threaded hole or post in the other
of the end plate 30 and section 32. Rotation of the post 102 causes
the two portions of the body 10 to move toward or away from each
other, and thus decreases or increases the vertical size of the
body 10, respectively. According to one version of the adjustable
height vertebral body replacement an adjustment mechanism with
oppositely threaded ends is inserted in the upper and lower parts
104, 106 and is adjustable after positioning in the patient.
According to one exemplary method adhering to principles of the
present invention, a patient in need of a vertebral body
replacement is prepped and surgical access is made to the
particular vertebral body to be removed. Access to the surgical
site is generally made anteriorly through the abdominal cavity for
a lumbar procedure. One or more target vertebral body or bodies is
removed in one of numerous manners known to those of ordinary skill
in the art, between upper and lower remaining vertebral bodies in
the patient's spine, and a vertebral body replacement 10, embodying
principles of the present invention, is selected based on the
measurement of the spacing for proper spinal alignment. The
vertebral body replacement 10 is assembled and implanted in the
space created by removal of the original vertebral body or bodies.
Optionally, one or more spacers 90 are assembled into the body 10,
prior to installation of the body 10 into the patient, and/or the
vertical length of the body 10 is adjusted to better fit in the
space. Further optionally, when the body 10 includes one or more
cavities 86, additional material is inserted into the cavity, prior
to implantation of the body, to tailor the rigidity of the body 10,
or for other purposes.
While the exemplary embodiments have been described in some detail,
by way of example and for clarity of understanding, those of skill
in the art will recognize that a variety of modifications,
adaptations, and changes may be employed. Hence, the scope of the
present invention should be limited solely by the appended
claims.
* * * * *
References