The present disclosure generally relates to devices and methods for securing one or more fasteners in a fixation plate. For example, a rotational locking mechanism may be provided to lock a bone screw positioned within a fixation plate.
Spinal fixation has become a common approach in treating spinal disorders, fractures, and for fusion of vertebrae, for example, in cases of trauma, tumors, and degenerative conditions. A common device used for spinal fixation is a bone fixation plate. A typical bone fixation plate includes a relatively flat, rectangular plate having a plurality of apertures therethrough. A corresponding plurality of fasteners, such as bone screws, are provided to secure the bone fixation plate to one or more bones, such as two adjacent spinal vertebrae.
A common problem associated with the use of such fixation plates, however, is the tendency of the bone screws to “back out” of the underlying bone under the stress of bodily movement. This problem occurs primarily due to the normal motion of the body, but may be particularly prevalent in areas of high stress, such as, for example, in the spine. Given the delicate nature of the spine, any post-operative fixation plate movement may not only frustrate the surgical goals, but may also raise patient safety concerns.
A number of various designs have been brought forth in attempts to lock the screws to the bone fixation plate, prevent screws from pulling away from the bone, or to prevent the screws from backing out or pulling away from the bone fixation plate. While there are many designs in this area, it is desirable to have improved locking devices and systems having locking features integrated with the bone plate, which have enhanced functionality and ease of use.
To meet this and other needs, devices, systems, and methods for locking one or more fasteners in a device, such as a fixation plate, are provided. In particular, a rotational locking mechanism is provided with a cam-style locking feature to provide secure locking of the fastener into the fixation plate. As the locking mechanism is rotated, engagement of the cam-style locking feature with a portion of the fastener (e.g., a plurality of threads) increases because the radius of the locking feature on the locking mechanism increases. The locking mechanism may also be constrained within the fixation plate to provide for enhanced attachment. The configuration of the fixation plate and locking mechanism allow for secure locking of the fastener to the plate.
According to one embodiment, an assembly for locking a fastener in a fixation plate is provided. The fastener has a plurality of threads. For example, the fastener may be in the form of a bone screw having a head and a shaft extending therefrom, the shaft may have the plurality of threads thereon. The assembly includes a locking element at least partially positioned in the fixation plate. The locking element has a base member and a head portion. The base member has an interlock portion configured to engage the threads of the fastener when in a locked position. The head portion extends from the base member, and the head portion is configured to be engaged by a driver to rotate the base member from an unlocked position to the locked position.
The interlock portion may include a cam-style locking feature. For example, the interlock portion may include a plurality of elongated protrusions having a recess positioned between adjacent protrusions. In one embodiment, the interlock portion includes three substantially parallel protrusions. The elongated protrusions may be angled such that they correspond substantially to the thread angle of the threads of the fastener (e.g., about 60 degrees). When in the unlocked position, there is no interference between the elongated protrusions and the fastener. When in the locked position, there is interference between the elongated protrusions and the shaft of the fastener. In particular, an outer surface of each of the plurality of elongated protrusions contacts the shaft of the fastener and the recesses positioned between adjacent protrusions receive a portion of the plurality of threads of the fastener.
The locking mechanism may also be constrained within the fixation plate. For example, base member and/or head portion of the locking mechanism may be positioned inside the fixation plate, for example, in a blind opening in the fixation plate. In one embodiment, the locking element includes a shaft between the base member and the head portion. The shaft may have a smaller diameter than the head portion of the locking element. The head portion and shaft may fit within a corresponding notch, recess, and/or ridge positioned inside the blind opening in the fixation plate. Alternatively, the locking mechanism may be threaded into the fixation plate.
According to another embodiment, a system for preventing a bone screw from backing out of a fixation plate includes a fastener, a locking element, and a fixation plate. The fastener has a plurality of threads. The locking element includes a base member and a head portion. The base member has an interlock portion configured to engage the threads of the fastener when in a locked position, and the head portion extends from the base member. The head portion is configured to be engaged by a driver to rotate the base member from an unlocked position to the locked position. The fixation plate has a bottom surface configured to engage a portion of the bone being fixated, an opposite top surface, an opening defined therethrough sized and configured to receive at least a portion of the fastener, and a blind opening for receiving the locking element positioned adjacent to the opening for receiving the fastener. The blind opening may include a ridge configured to prevent the locking element from being removed axially. The ridge may be configured to engage a bottom surface of the head portion, for example.
According to another embodiment, a method of locking a bone screw in a fixation plate may include: inserting a fastener through an opening in a fixation plate and into contact with bone, the fastener having a plurality of threads configured to engage the bone; and locking the fastener to the fixation plate by rotating a locking element in the fixation plate to a locked position such that an interlock portion on the locking element engages at least a portion of the plurality of threads of the fastener. For example, a driver may engage a recess in the locking element to rotate the locking element. The method may also include, before the fastener is inserted in the fixation plate, placing the locking element through the opening in the fixation plate and sliding the locking element over such that the locking element is seated in the blind opening in the fixation plate.
According to yet another embodiment, a method of manufacturing a fixation plate with an integrated locking element may include: providing a locking element having a base member with an interlock portion configured to engage the threads of a fastener when in a locked position, a head portion configured to be engaged by a driver to rotate the base member from an unlocked position to the locked position, and a shaft connecting the base member to the head portion; and inserting the locking element axially through a fastener opening in the fixation plate and sliding the locking element transversely into a blind opening in the fixation plate such that the locking element is seated in the blind opening in the fixation plate.
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:
Embodiments of the disclosure are generally directed to devices, systems, and methods for locking one of more fasteners, such as bone screws, in a fixation plate. Specifically, a cam-style locking feature may be disposed in the plate such that, when the locking feature is in a first position, the bone screw is able to traverse an opening in the fixation plate and engage adjacent bone; and when the locking feature is rotated into a second position, an interference between the locking feature and bone screw causes the bone screw to be secured firmly to the fixation plate.
Although described with reference to fixation plates, it will be appreciated that any suitable fixation device, such as interbody devices, frames, cages, spacers, standalone implants, and the like may also incorporate the locking features described herein. Similarly, although bone screws are exemplified in this document, it will also be appreciated that other suitable fasteners, such as shims, nails, and the like, may be adapted to mate with the locking features described herein. These devices may be suitable for fixation into areas along the spine, such as one or more vertebrae; a hip bone, such as an ilium; a leg bone, such as a femur; or a bone from an arm, such as a distal forearm bone or a proximal humerus; or any other bone in a mammal. When used in the spine, the fixation devices may be suitable for cervical, thoracic, lumbar, or sacral regions and may be surgically approached anteriorly, posteriorly, laterally, anterolaterally, or the like.
The embodiments of the disclosure and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and detailed in the following description. The features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiments of the disclosure. The examples used herein are intended merely to facilitate an understanding of ways in which the disclosure may be practiced and to further enable those of skill in the art to practice the embodiments of the disclosure. Accordingly, the examples and embodiments herein should not be construed as limiting the scope of the disclosure, which is defined solely by the appended claims and applicable law. Moreover, it is noted that like reference numerals represent similar features and structures throughout the several views of the drawings.
Referring now to the drawing,
As best seen in
The plate 20 may also include a blind hole or opening 28 for receiving the locking element 40. The blind opening 28 is positioned adjacent to the opening 26 for receiving the fastener 30. The blind opening 28 may extend from the top surface 22 to a distance in the fixation plate 20, but preferably does not extend completely through to the bottom surface 24 of the plate 20. The blind opening 28 is shaped and dimensioned to receive the locking element 40. The locking element 40 may be positioned in the blind opening 28 such that a top surface 62 of the locking element 40 may be flush with or recessed below the top surface 22 of the fixation plate 20. The blind opening 28 may be continuous with the fastener opening 26, for example, forming a single contiguous opening in the fixation plate 20. Although not shown, the plate 20 may include multiple fastener openings 26 with adjacent blind openings 28 for receiving locking elements 40 to lock each respective fastener 30 in the plate 20. Each fastener 30 may be provided with a separate locking element 40.
Any fastener 30 known in the art may be used. For example, the fastener 30 may include bone screws, shims, nails, or other fastening devices having at least one threaded portion 38. The fasteners 30 may be poly-axial screws, uniplanar screws, mono-axial screws, or the like based on their desired adjustability and functionality. The preferred fastener 30 has a plurality of threads 38. For example, the fastener 30 may be in the form of a bone screw having shaft 36 extending from the head 32. The plurality of threads 38 may extend from the base of head 32 to a distal tip of the shaft 36. Alternatively, the plurality of threads 38 may extend along a portion of the shaft 36. The head 32 may be conical, rounded, spherical, or the like. The head 32 may be enlarged relative to the shaft 36. Preferably, the head 32 is sized and dimensioned such that it lies flush with or is recessed in the top surface 22 of the plate 20. The head 32 may also include a recess 34 configured to receive a driving instrument (e.g., a hex driver), for example, to apply rotational force to the fastener 30 such that at least a portion of the shaft 36 can be secured into bone.
As shown in
One advantage of system 10 is that the interlock portion 50 of the locking element 40 can engage with the fastener 30 at any position along the length of the fastener 30. As the locking element 40 is rotated, a force is generated on the fastener 30 that is perpendicular to a longitudinal axis of the fastener 30, which may come from the interference between the interlock portion 50 and the shaft 36 of the fastener 30. The interlock portion 50 also interacts with the threads 38 of the fastener 30 to further tighten the fastener 30 to the plate 20.
As best illustrated in
The base member 42 of the locking element 40 extends from a top surface 44 to a bottom surface 46. One or more sidewalls may connect the top surface 44 to the bottom surface 46. The sidewalls may be curved, rounded, straight, or the like such that the base member 42 has a partially cylindrical shape or any other suitable shape. For example, the base member 42 may have a generally tear drop shape when viewed from a top-down view (
The base member 42 includes interlock portion 50 configured to engage the threads 38 and/or shaft 36 of the fastener 30 when in the locked position. The interlock portion 50 may include a cam-style locking feature. For example, the cam-style interlock portion 50 may have at least two relative positions. In a first orientation, where the locking element 40 is unlocked, the interlock portion 50 does not intermesh with the threads 38 of the fastener 30 although a portion of the threads 38 may be permitted to travel through at least a portion the interlock portion 50. In the first orientation, the fastener 30 is free to travel through the opening 26 in the plate 20. In a second orientation, where the locking element 40 is locked, the interlock portion 50 is intermeshed with the threads 38 and/or shaft 36 of the fastener 30 to cause interference between them. This prevents or minimizes any further rotation of the fastener 30, thereby preventing or inhibiting back out of the fastener 30 from the plate 20.
As seen in
As evident in
The cam-style outer surfaces 70 of each protrusion 52, for example, extending from beveled portion 72 to the second end 58 allow for translational and/or rotational movement of the locking element 40 into the locked position. Accordingly, when the locking element is translated, pivoted, or rotated into the locked position, at least a portion of the outer cam surface 70 (e.g., including second end 58 having a greater depth or thickness) of each of the plurality of elongated protrusions 52 contacts the shaft 36 of the fastener 38 and the recesses 54 fully receive the corresponding threads 38 of the fastener 30. This engagement may be best seen in
As best seen in
The interlock portion 50 can be translated, pivoted, or rotated between the locked and unlocked positions.
The locking element 40 may be constrained within or locked to the fixation plate 20. The locking element 40 may be at least partially positioned in the fixation plate 20. In an exemplary embodiment, the entire locking element 40 is positioned within the fixation plate 20. For example, base member 42 and/or head portion 60 of the locking element 40 may be positioned inside the fixation plate 20, for example, in the blind opening 28 in the fixation plate 20. As shown in
According to one method of locking the fastener 30 in the fixation plate 20, the fastener 30 is inserted through the opening 26 in the fixation plate 20 and into contact with bone. The fastener 30 is locked to the plate 20 by rotating the locking element 40 in the fixation plate 20 to the locked position such that the interlock portion 50 on the locking element 40 engages at least a portion of the plurality of threads 38 of the fastener 30. The locking element 40 may be engaged into locked mode, for example, by clockwise turning of the head portion 60 of the locking element. For example, a driver may engage the recess 66 in the head portion 60 of the locking element 40 to rotate the locking element 40 into position.
As depicted, for example, in
This cam-style locking element 40 provides for secure locking of the fastener 30 into the fixation plate 20. As the locking element 40 is rotated, engagement of the cam-style locking feature 50 with the threads 38 on the fastener 20 increases because the radius of the locking feature on the locking mechanism increases. The locking element 40 may also be constrained within the fixation plate 20 to provide for enhanced attachment. The configuration of the fixation plate 20, fastener 30, and locking element 40 allow for secure locking of the fastener 30 to the plate 20, thereby preventing or minimizing undesirable movement of the fastener 30.
Although the invention has been described in detail and with reference to specific embodiments, it will be apparent to one skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. Thus, it is intended that the invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. It is expressly intended, for example, that all ranges broadly recited in this document include within their scope all narrower ranges which fall within the broader ranges. It is also intended that the components of the various devices disclosed above may be combined or modified in any suitable configuration.
This application is a continuation of U.S. application Ser. No. 14/864,999, filed Sep. 25, 2015, now U.S. Pat. No. 10,130,402, which is hereby incorporated by reference in its entirety for all purposes.
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