Devices and methods for explantation of intervertebral disc implants

FIELD OF THE INVENTION

Embodiments of the invention relates to devices and methods for explantation of prosthetic spinal implants. More specifically, the embodiments relate to methods and devices for applying heat or a vibrating or reciprocating saw blade to prosthetic spinal implants to separate the implant into smaller pieces, and extracting the smaller pieces from the site.

DESCRIPTION OF RELATED ART

The intervertebral disc functions to stabilize the spine and to distribute forces between vertebral bodies. A normal disc includes a gelatinous nucleus pulposus, an annulus fibrosis and two vertebral end plates. The nucleus pulposus is surrounded and confined by the annulus fibrosis.

Intervertebral discs may be displaced or damaged due to trauma or disease. Disruption of the annulus fibrosis may allow the nucleus pulposus to protrude into the vertebral canal, a condition commonly referred to as a herniated or ruptured disc. The extruded nucleus pulposus may press on a spinal nerve, which may result in nerve damage, pain, numbness, muscle weakness and paralysis. Intervertebral discs also may deteriorate due to the normal aging process. As a disc dehydrates and hardens, the disc space height will be reduced, leading to instability of the spine, decreased mobility and pain.

One way to relieve the symptoms of these conditions is by surgical removal of a portion or the entire intervertebral disc. The removal of the damaged or unhealthy disc may allow the disc space to collapse, which would lead to instability of the spine, abnormal joint mechanics, nerve damage, and severe pain. Therefore, after removal of the disc, adjacent vertebrae are typically fused to preserve the disc space. Several devices exist to fill an intervertebral space following removal of all or part of the intervertebral disc in order to prevent disc space collapse and to promote fusion of adjacent vertebrae surrounding the disc space. Even though a certain degree of success with these devices has been achieved, full motion typically is never regained after such vertebral fusions. Attempts to overcome these problems have led to the development of disc replacement devices.

Disc replacement devices or intervertebral spinal disc implants or spinal implants are configured to be load bearing bodies of a size to be placed in an intervertebral disc space and intended to fully or partially replace the nucleus pulposus of mammals, particularly humans. Spinal disc implants are typically only prescribed when the natural nucleus pulposus becomes damaged or extruded.

Though replacement disc implant devices are available and generally work well for their prescribed use, they too may become damaged over time. In addition, prosthetic discs may be incorrectly sized for the intervertebral disc space that they occupy and therefore do not properly support the spinal column. This may lead to discomfort, pain, and other undesirable symptoms. To overcome this problem, the first prosthetic disc may need to be removed and replaced with a second prosthetic disc.

Spinal implants, especially those made from a gelatinous material such as a hydrogel, are typically implanted through a small defect or hole in the annulus fibrosis and are typically larger than the defect. For example, the implant may be inserted through a defect in the annulus fibrosis that initially allowed the natural nucleus pulposus to protrude. However, a defect in the annulus fibrosis that allows a natural nucleus pulposus to protrude also may allow a prosthetic spinal implant to protrude. Therefore, it is often favorable to keep any defect in the annulus fibrosis as small as possible. This is true when removing a natural nucleus pulposus and implanting or removing a prosthetic spinal implant.

U.S. Pat. No. 5,976,105 to Marcove (“the '105 patent”), U.S. Pat. Nos. 5,313,962 and 5,195,541 to Obenchain (“the '962 patent” and “the '541 patent,” respectively), and U.S. Pat. No. 4,678,459 to Onik (“the '459 patent”) all describe methods or instruments that relate to the removal of a natural nucleus pulposus. However, none of them relate to or disclose a method to remove a prosthetic spinal implant.

The '105 patent describes an intra-annular ultrasound disc apparatus and method. The patent aims to avoid unnecessary traumatization of the portions of the disc that are to be left intact. It further describes a method of inserting an ultrasonic probe inside the interior of the annular ligament, softening the tissue at the central region of the herniated disc, and inserting a discectomy instrument to remove the softened tissue.

Both the '962 patent and the '541 patent describe a method of performing laparoscopic lumbar discectomy, which is the excision, in part or whole, of an intervertebral disc. Specifically, both references describe penetrating the annulus and removing the herniated disc material.

Finally, the '459 patent discloses an irrigating, cutting, and aspirating system for percutaneous surgery. The patent further discloses a guillotine type cutting action to cut herniated disc tissue into small portions while the irrigation and vacuum means of the system aspirate the severed material. It also describes a means for cutting the nucleus pulposus of an intervertebral disc.

The cited references all describe means to remove a natural nucleus pulposus, typically using soft tissue shearing devices. In contrast to the natural nucleus pulposus, many spinal implants are hard polymeric plastic materials or even metal fusion cages. The soft tissue shearing devices used to remove the natural nucleus pulposus may be ineffectual in cutting the hard materials of a prosthetic implant. Other polymeric spinal implants are somewhat elastic, making them difficult to cut with conventional shearing devices. None of the disclosed methods of removing a nucleus pulposus, therefore, is entirely effective for removing a spinal implant.

The description herein of problems and disadvantages of known apparatus, methods, and devices is not intended to limit the invention to the exclusion of these known entities. Indeed, embodiments of the invention may include one or more of the known apparatus, methods, and devices without suffering from the disadvantages and problems noted herein.

SUMMARY OF THE INVENTION

A need exists for a device and method to remove a spinal implant through a relatively small opening in the annulus fibrosis—that is, through minimally invasive means. Therefore, it is a feature of an embodiment to provide for a method for explanting spinal implants using minimally invasive techniques. The method entails guiding a cutting tool, optionally positioned within a protective sleeve, to a spinal implant. The method further includes projecting the cutting tool into or around the spinal implant. The spinal implant then may be broken or melted into pieces and the pieces subsequently removed.

In another embodiment, there is provided a device for explantation of a spinal implant. The device comprises a cutting wire or blade positioned inside a protective sleeve, a power source, and a handle to which the cutting tool, protective sleeve, and power source are attached.

In an additional embodiment the method and device for explantation of a spinal implant include a retractable cutting wire or reciprocating saw blade positioned within a lumen. The cutting wire or blade is positioned on or around the spinal implant, and then energy is supplied to cause the wire to become hot, or the blade to reciprocate. The heat melts the areas of the implant in and around the points of contact with the wire, or the movement of the blade cuts the areas of the implant in and around the points of contact with the blade, and the wire or blade then is pulled back toward the lumen to cut through the impant. In an optional embodiment, an additional anchor is supplied and attached to the portion of the implant to be removed after it is severed from the remaining portion of the implant.

These and other objects and advantages of the present invention will be apparent from the description provide herein.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates a side view of a cross-section of a nucleus pulposus implant in an intervertebral disc space, bound by a superior vertebral body, an inferior vertebral body, and an annulus fibrosis with a defect.

FIG. 2 illustrates intervertebral space of FIG. 1, with a cutting tool accessing the spinal implant through the annular defect.

FIG. 3 illustrates the intervertebral space of FIG. 2, with the cutting tool unsheathed and piercing the spinal implant.

FIG. 4 illustrates the intervertebral space of FIG. 3, with the cutting tool extending into varying depths of the intervertebral space and accessing the space through the annular defect at different angles. FIG. 4 further illustrates the implant of the previous Figures having been cut into pieces.

FIG. 5 shows the implant of the previous Figures, having been cut into many small pieces, being removed through the protective sleeve.

FIG. 6 illustrates a variety of cutting tips for a spinal implant explantation device and method of embodiments of the invention.

FIG. 7 illustrates preferred spinal implant explantation devices of embodiments of the invention.

FIG. 8 illustrates another preferred spinal implant explantation device of embodiments of the invention.

FIG. 9 illustrates an explantation device and associated wire or blade capable of cutting through an implant.

FIG. 10 is an exploded view of the end portion of an explantation device and wire or blade.

FIG. 11, embodiments A and B illustrate an exemplary embodiment whereby an anchor is placed in a portion of an implant to be removed after severing from the remainder of the implant, and then removal of that portion attached to the anchor.

FIG. 12, embodiments A and B illustrate various anchor configurations in their initial and deployed states.

FIG. 13, embodiments A, B, and C illustrate an exemplary device in various stages of operation.

FIG. 14 is an exploded view of an exemplary device and wire or blade being advanced through or around an implant.

FIG. 15 is an exploded view of an exemplary device deploying anchors into an implant.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description is intended to convey a thorough understanding of the present invention by providing a number of specific embodiments and details involving explantation of spinal implants. It is understood, however, that the present invention is not limited to these specific embodiments and details, which are exemplary only. It is further understood that one possessing ordinary skill in the art, in light of known systems and methods, would appreciate the use of the invention for its intended purposes and benefits in any number of alternative embodiments.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention.

As used throughout this disclosure, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “a spinal implant” includes a plurality of such implants, as well as a single implant, and a reference to “a cutting tool or probe” is a reference to one or more cutting tools or probes and equivalents thereof known to those skilled in the art, and so forth.

Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. All publications mentioned herein are cited for the purpose of describing and disclosing the various spinal implants, methods of explanting natural nucleus pulposus, and other components that are reported in the publications and that might be used in connection with the invention. Nothing herein is to be construed as an admission that these publications are prior art to the instant claims, or that the invention is not entitled to antedate such disclosures by virtue of prior invention.

Throughout this description, the expressions “natural nucleus pulposus” refers to a nucleus pulposus that is naturally found in the intervertebral disc space of a mammal, particularly humans. The expression is used to differentiate between what is a natural, normal body part and that which is a man-made implant.

The terms “spinal implant” or “nucleus implant” shall be used to denote any man-made implant which is used to partially or fully replace the natural nucleus pulposus or intervertebral disc that is found in mammals, especially humans. Man-made spinal implants include implants made from natural sources (e.g. implanted autologous bones and tissues), implants made from synthetic sources (e.g. metals, polymers, and ceramics), and composites thereof (e.g. bone/polymer matrices).

Spinal implants can be made of a wide range of materials such as polymeric materials, metals, ceramics, and body tissues. Exemplary polymeric materials include, but are not limited to, thermoplastic polymers, thermoset polymers, elastomers, hydrogels, adhesives, sealants, and composites thereof. Polymeric spinal implants may be preformed implants, injectable/in situ formable implants, and combinations thereof. Preformed polymeric spinal implants may be in any shape, including implants shaped like a spiral, hockey puck, kidney, capsule, rectangular block, cylinder, implants such as those described in, for example, U.S. Pat. No. 6,620,196, the disclosure of which is incorporated herein by reference in its entirety, and the like. Spinal implants, especially polymeric implants, also may comprise supporting bands or jackets.

Spinal implants may be in any of numerous known forms, including, but not limited to, total disc prostheses, intervertebral fusion devices, stackable corpectomy devices, threaded fusion cages, and impacted fusion cages. Spinal implants also include implants wherein only the full or partial nucleus of the intervertebral disc is replaced, for example nucleus replacement implants and nucleus augmentation implants. Because the embodiments described herein are adept at removing a spinal implant through a small defect in the annulus fibrosis, it is preferred that the spinal implant be a nucleus replacement implant or nucleus augmentation implant wherein the natural annulus fibrosis is retained.

Exemplary implants include hydrogel implants that are injected into an evacuated disc space. The implant hardens into a implant shaped like the evacuated disc space, or shaped like a balloon type device that is filled by the injected hydrogel components prior to hardening. Such implants may be removed at a later time through practice of the embodiments if they are damaged, or to replace them with better functioning implants, such as preformed implants like the NAUTILUS® implant, available from Medtronic Sofamor Danek, Memphis, Tenn.

The phrase “opening in the annulus fibrosis” shall denote any opening, hole, or other defect in the annulus fibrosis. It is through an opening in the annulus fibrosis that the spinal implant preferably is removed. The opening in the annulus fibrosis preferably is less than about 20 mm in the largest dimension, and may be comprised of any shape, such an ellipse, circle, square, etc. In a more preferred embodiment, the opening in the annulus fibrosis preferably is less than 15 mm in the largest dimension. In a most preferred embodiment, the opening in the annulus fibrosis is less than 10 mm in the largest dimension. Because the invention provides for removal of spinal implants through small openings in the annulus fibrosis, the patient's natural annulus fibrosis preferably may be uninjured during the explantation procedure and may be retained after implant explantation.

“Disc space” means the volume occupied, or formerly occupied, by the spinal implant. The disc space may be the volume contained inside the annulus fibrosis. The disc space also may be the entire volume, including the annulus fibrosis, between two adjacent vertebral bodies.

An embodiment of the present invention provides a device for explantation of a spinal implant. The device may be referred to as an “explantation instrument.” The explantation instrument may comprise a cutting tool, a protective sleeve, a power source, and a handle to which the cutting tool, protective sleeve, and power source are attached.

The cutting tool may comprise a mechanical cutting element. The mechanical cutting element preferably is located at the tip of the cutting tool. The mechanical cutting element may comprise, for example, a flat blade, curved blade, saw blade, pointed probe, angle blade, saw tip, knife tip, hook tip, or C-tip. Exemplary mechanical cutting elements are illustrated in FIG. 6. Embodiment A illustrates a curved blade; embodiment B illustrates a saw blade; embodiment C illustrates a pointed probe; embodiment D illustrates an angle blade; embodiment E illustrates a saw tip; embodiment F illustrates a knife tip; embodiment G illustrates a hook tip; and embodiment H illustrates a C-tip. In other embodiments, the mechanical cutting element may comprise a drill bit, a heated wire element, a thin razor wire, or a reciprocating blade similar to circulating or reciprocating blades on a band saw.

One skilled in the art will appreciate the various configurations that the cutting element may take, and all such configurations and modifications thereof are considered within the scope of the invention. For example, the cutting elements may come in various sizes, lengths, thicknesses, shapes, and so forth. Preferably, the cutting element is sufficiently rigid to as to effect penetration and cutting of a spinal implant. In a preferred embodiment, the cutting element also is detachable and disposable so that the cutting element may be replaced with a new, sterile cutting element following an explantation procedure.

In a preferred embodiment, the explantation instrument may additionally comprise movement means to impart movement to the cutting element, such as a gyrating, rotating, oscillating, reciprocating, or reverberating movement. For example, if the mechanical cutting element is a saw blade, it may be preferred that the explantation instrument additionally comprise mechanical means to oscillate the saw blade back and forth so as to effect cutting of the spinal implant. Alternatively, the various knife tips also can be oscillated back and forth to effect cutting of the spinal implant or even rotated about their axis like a drill bit. Other movement means may be employed to advance the cutting element in and around the implant. One skilled in the art will appreciate the various mechanical means, for example electric motors and gear arrangements, that may be used to effect gyration, rotation, oscillation, reciprocation, reverberation, and so forth of the mechanical cutting element. Preferably, the mechanical means may be continuously adjusted between an off state and full power so as to control the gyration, rotation, oscillation, reciprocation, reverberation, and so forth of the mechanical cutting element.

The cutting tool may additionally or preferably alternatively comprise a heating element. The heating element preferably is located at the tip of the cutting tool. Any applicable source of thermal energy may be used as the heating element. The heating element may heat the spinal implant directly or may heat the mechanical cutting tool. Exemplary heating elements include, but are not limited to, electric resistance heaters, sources of ultrasonic vibrations, heated wires, and lasers. For example, the mechanical cutting element itself may be an electric resistance heater wherein electric current passes through the mechanical cutting element. In another embodiment, an electric heating element, for example a thin metallic wire, may be embedded in the mechanical cutting element. This is exemplarily illustrated in FIG. 6, embodiments A-H, where wire leads acting as heating elements are shown running through the exemplary mechanical cutting elements. In another embodiment, a source of laser energy may be disposed immediately adjacent to the mechanical cutting element of the cutting tool.

In a preferred embodiment, the heating element heats the mechanical cutting element to at least 100° C. In a more preferred embodiment, the heating element heats the mechanical cutting element to at least 150° C. In a most preferred embodiment, the heating element heats the mechanical cutting element to greater than 200° C. The temperature of the heating element may preferably be continuously adjusted between an off state and full power. Heating elements such as the exemplary heating elements described herein may be desirable to soften the spinal implant, thereby facilitating faster and easier disintegration of the spinal implant. Heating elements may be especially preferred when the spinal implants are made of polymeric materials that will soften relatively quickly in response to elevated temperature.

The cutting tool preferably may be adjustable to facilitate disintegration of the spinal implant. For example, the cutting tool or wire may be bendable so that the tool or wire can curve. This may be preferable because a spinal implant may be irregularly shaped and a bendable cutting tool is more likely to be able to reach all parts of the irregularly shaped spinal implant. The cutting tool also preferably may be steerable so that the user may direct the cutting tool to that portion of the spinal implant that is to be disintegrated. For example, the advancement means may enable the user to manipulate the cutting tool or wire or blade to its desired configuration prior to imparting energy to the cutting apparatus. The cutting tool also may preferably be extensible. One skilled in the art will appreciate other ways in which the cutting tool preferably may be adjustable in order to facilitate disintegration of the spinal implant.

A protective sleeve may surround the cutting tool in order to prevent unwanted contact between the cutting tool and tissues that are not to be excised or otherwise damaged during explantation of the spinal implant. The protective sleeve may be retractable so that, when desired, the protective sleeve may be retracted, thereby projecting the cutting tool into adjacent tissues and structures, such as the spinal implant. Additionally, the protective sleeve may be extensible so that, when desired, the protective sleeve again may be extended beyond the cutting tool, thereby shielding adjacent tissues and structures from the cutting tool. In this way, the cutting tool may be preferentially exposed for use in excision of tissue and explantation of the spinal implant. FIG. 7 illustrates an exemplary protective sleeve. Embodiment A illustrates the protective sleeve in a retracted position, exposing the cutting tool. Embodiment B illustrates the protective sleeve in an extended position, shielding the cutting tool.

In a preferred embodiment, the protective sleeve is electrically and thermally insulated. Electrical insulation may be desirable to prevent unwanted stray of the electrical current from the heating element. Additionally, electrical insulation is a safety feature in general to prevent unwanted electrical discharge from the device as a whole. Thermal insulation may be desirable to protect tissues and structures adjacent to the cutting tool from damage incurred due to heat radiated by the optional heating element. The protective sleeve may be made from any applicable polymeric, ceramic, metallic, and composite materials so as to achieve desirable thermal and electrical insulative qualities.

The protective sleeve may be detachable and disposable. A detachable protective sleeve may be desirable so that, upon explantation of the spinal implant, the sleeve may be detached from the rest of the explantation instrument. For example, the sleeve may be left in the body and the remainder of the explantation instrument may be removed. The sleeve then may function as a cannula for removal of the pieces of the spinal implant. Additionally, a detachable sleeve may thereby be disposable, so that a new, sterile sleeve may be used in subsequent procedures involving the explantation instrument. The protective sleeve, like the cutting tool, also preferably may be adjustable in that it may be bendable, extensible, and steerable. This may aid in directing the protective sleeve to the spinal implant through the tissues, vasculature, and structures of the body. Also, a bendable, extensible, and steerable protective sleeve may be preferable so that the sleeve may be steered inside the disk space during removal of the pieces of the spinal implant, for example by vacuum and irrigation.

In a preferred embodiment, a flexible scope or camera may be attached to the end of the protective sleeve. The scope or camera may be desirable to enable the user to more easily steer the protective sleeve and cutting tool to the spinal implant, and to visualize the removal process.

The power source may be any applicable source of electrical energy. In a preferred embodiment, the power source is a battery or power source attachable to a suitable electrical outlet. The battery may preferably be encased in the handle of the explantation instrument. The battery also may preferably be rechargeable so that it can be reused after the electrical capacitance of the battery is discharged. The battery may be any applicable type of battery, including, but not limited to, lithium batteries, alkaline batteries, fuel cells, nickel-cadmium batteries, and the like. It may be preferred that the battery, especially if it is not rechargeable, be removable so that the battery may be replaced with a new battery after it has been discharged. If the battery is rechargeable, it may still be preferred that the battery be removable so that it may be recharged in an external charger separate from the explantation instrument itself. One skilled in the art will appreciate the various configurations that the battery and other power sources may take, in accordance with the limitations herein.

The handle may be any applicable means for holding the explantation instrument. One skilled in the art will appreciate the various applicable configurations that the handle may take, including finger grips, various shapes, triggers to operate the explantation instrument, clips to attach other surgical tools and instruments, surface textures to ensure a good grip, and the like. All such configurations and modifications are understood to be within the scope of the invention. Preferably, the handle may include adjustable switches to control the temperature of the heating element and the mechanical actuation of the mechanical cutting element. In a preferred embodiment, the handle may include detachment means whereby the cutting tool and protective sleeve may be detachably connected to the handle of the explantation instrument. One skilled in the art will appreciate how this is to be done. If the explantation instrument comprises mechanical means to actuate the mechanical cutting means, it may be preferable that a portion of the means be located inside the handle.

FIG. 8 exemplarily illustrates a device for explantation of a spinal implant in accordance with the invention. The device comprises a cutting tool 81. The cutting tool comprises a mechanical cutting element and a heating element. Mechanical means 86 may gyrate, rotate, oscillate, or reverberate the mechanical cutting element. The cutting tool is internal to a protective sleeve 80 that may be preferentially extended and retracted to protect and expose the cutting tool. Detachment means 85 detachably connect the cutting tool and protective sleeve to the handle 84 of the instrument. The power source is a battery 83 that may be operated with a switch 82 to control the delivery of power to the heating element of the cutting tool 81 and mechanical means 86 to gyrate, rotate, oscillate, or reverberate the mechanical cutting element.

In another embodiment, the protective sleeve surrounding the cutting tool is guided to the spinal implant. The protective sleeve preferably may be extensible so that it may be elongated while being guided to the spinal implant. Guiding to the spinal implant may be accomplished by manipulating the handle of the explantation instrument to steer the protective sleeve and cutting tool to a position immediately adjacent to the spinal implant. The optional scope or camera preferably may aid in this process. The protective sleeve may be retracted to expose the cutting tool. The cutting tool may be projected into the spinal implant and manipulated so as to disintegrate the spinal implant. The optional mechanical means may aid in this process by causing the mechanical cutting element to gyrate, rotate, oscillate, or reverberate in such a manner as to facilitate disintegration of the spinal implant.

The cutting tool may disintegrate the spinal implant into pieces by cutting the spinal implant, melting the spinal implant, or a combination thereof. In this way, the spinal implant may be separated into smaller pieces that then may be more easily removed from the space formerly occupied by the spinal implant. When the spinal implant is satisfactorily disintegrated, the protective sleeve may be extended and the cutting tool retracted so as to again surround the cutting tool. In a preferred embodiment, the protective sleeve then may be detached from the explantation instrument, including the cutting tool. In a more preferred embodiment, the protective sleeve then may be allowed to remain in the body while the rest of the explantation instrument is removed. In this way, the protective sleeve will continue to afford access to the disc space without the obstruction of the internal cutting tool.

The pieces of the spinal implant may be removed from the space formerly occupied by the spinal implant in any applicable manner, as will be appreciated by one skilled in the art. For example, the pieces of the spinal implant may be removed by irrigating the disc space with water or saline solution. An irrigation solution may be supplied to the disc space through the protective sleeve. Alternatively, the irrigation solution may be supplied to the disc space through a separate cannula that is inserted to replace or in addition to the protective sleeve. Pieces of the spinal implant also may be removed by vacuuming the pieces of the spinal implant out of the disc space. Vacuum may be applied through the protective sleeve or a cannula inserted to replace or in addition to the protective sleeve. Pieces of the spinal implant also may be removed using tweezers, forceps, a pituitary ronguer, or other surgical tools as will be appreciated by one skilled in the art. This may be preferable for larger pieces that are more difficult to extract, for example through the opening in the annulus fibrosis. The pieces also may be removed by use of a suitable anchor means that anchors into the piece to be removed so that after cutting it away from the remainder of the implant, the anchor means can be retracted back into the device to extract the cut-away piece.

In a preferred embodiment, the cutting tool may be projected into the spinal implant through an opening in the annulus fibrosis. The spinal implant may be disintegrated into pieces smaller than the opening in the annulus fibrosis in order to facilitate easier removal of the spinal implant. In this way, a spinal implant may be removed without undue damage to the annulus fibrosis. In another preferred embodiment, the opening in the annulus fibrosis is not enlarged during explantation of the spinal implant.

In a more preferred embodiment, the opening in the annulus fibrosis through which the implant is to be removed was created prior to the explantation of the implant. For example, the opening in the annulus fibrosis may be created during implantation of the spinal implant. Rather than creating a new opening and further damaging the annulus fibrosis, the existing opening may be utilized to explant the spinal implant. Insertion of the cutting tool and removal of the implant pieces through an opening in the annulus fibrosis is especially preferred when the implant to be explanted is a nucleus replacement implant or nucleus augmentation implant. In this way, the annulus fibrosis retained during implantation of the spinal implant may not be further damaged during explantation of the spinal implant.

Embodiments of the invention will now be described in reference to FIGS. 1 to 5.

FIG. 1 illustrates a nucleus implant 30 between a superior vertebral body 21 and an inferior vertebral body 22. Preferably, the nucleus implant 30 is at least partially surrounded by the annulus fibrosis 20. The superior vertebral body 21, inferior vertebral body 22, and annulus fibrosis 20 define the boundaries of the intervertebral disc space that the implant 30 at least partially occupies. It is also preferable that the annulus fibrosis 20 has a defect or hole 23. It is further preferred that the defect 23 is a pre-existing condition, and was not caused by the performance of the present invention. Implant 30 also is preferably undersized, oversized, or damaged in some way and needs to be replaced. Throughout the description, the term “undersized” denotes that the implant is too small to properly support the axial loads of, or properly align the spinal column. Also throughout the description, the term “oversized” denotes that the implant is too large to properly support the axial loads of, or properly align the spinal column.

FIGS. 2, 3, and 4 depict a preferred embodiment of the invention that provides a probe 10 comprising a protective sleeve 11 housing a cutting tool 12 for insertion into a defect or hole 23 in the annulus fibrosis 20. The cutting tool 12 preferably comprises a heating element to melt, cut, and break down the implant material. Heated tips may be particularly effective when explanting a nucleus implant comprising elastic polymeric or thermoplastic materials, such as silicone-polyurethane based implants. The heat may be supplied by electric current, ultrasonic vibrations, laser energy, or other means known in the art. The cutting tool 12 also may preferably comprise a mechanical cutting element like a knife, a pointed tip like a needle, a blunt probe, or a reciprocating saw blade. Mechanical shearing without heat, such as with a knife edge or a reciprocating saw blade, also may be used, though mechanical shearing without heat may not be preferred if the spinal implant comprises elastic polymeric materials. In addition, the protective sleeve 11 preferably is insulated to protect the surrounding tissues and structures from being damaged by heat radiated from the heated cutting tool 12.

The probe 10 is guided through surrounding tissues and into the annular defect 23. Minimally invasive techniques to access the intervertebral disc space can be readily determined by those of ordinary skill in the art without undue experimentation. For example, fluoroscopic guidance may be used with the METRx® MicroDiscectomy System available from Medtronic Sofamor Danek. Once the probe 10 has reached the spinal implant 30, the protective sleeve 11 preferably is retracted and the cutting tool 12 preferably is extended into the intervertebral disc space and into the spinal implant 30, as illustrated in FIG. 3. Once inside the intervertebral disc space, the cutting tool 12 can be extended to varying depths and adjusted through varying angles about the annular defect 23 to disintegrate the spinal implant 30 into pieces 30a, as illustrated in FIG. 4.

Finally, after the implant 30 has been cut into sufficiently small pieces, the pieces 30a are removed. It is preferred that a vacuum is applied through the protective sleeve 11 to assist in removing the implant pieces 30a. The implant pieces 30a then are preferably removed by suction through the protective sleeve 11. It is also envisioned that the protective sleeve may be irrigated, thereby assisting in removing the implant pieces. The particular amount of vacuum and irrigation necessary to remove the implant pieces 30a can be easily determined by one of ordinary skill in the art without undue experimentation.

Additional embodiments are illustrated in FIGS. 9-15. These figures illustrate embodiments whereby a cutting tool, such as a wire or cutting blade, are advanced in and around an implant, energy is imparted to the cutting tool to activate it and cut through the implant, and then the cut-away pieces are removed from the disc space. The cut-away pieces may be removed by the same cutting tool or apparatus, or the cutting tool or apparatus may be removed and a removal instrument inserted to effect removal. Skilled artisans will appreciate the various means by which cut-away pieces of a spinal implant can be extracted using minimally invasive techniques.

As shown in FIG. 9, cutting tool 900 includes a longitudinal element that is used to access the disc space and cut-away a portion of a spinal implant 30. The longitudinal element preferably is an axial element having a wire or cutting blade positioned axially within its housing via bore 910. The wire or cutting blade 920 then can be advanced around the implant and then re-attached to the cutting tool 900. In this configuration, the wire or cutting blade 920 is “activated,” or ready to be activated by any suitable energy imparting mechanism to cut away a portion of the implant.

FIG. 10 illustrates an exploded view of the end portion of cutting tool 900, showing in particular the end portion of the longitudinal element 930. The wire or cutting blade 920 is illustrated in its activated position whereby it has been advanced through aperture 940 in longitudinal element 930, in and around the implant, and then back into aperture 950 in longitudinal element 930. Positioned within longitudinal element 930 are axial bores 910 to accommodate wire or blade 920. The arrow 960 is provided to illustrate the direction in which wire or blade 920 can be moved, once activated, to cut through the implant. That is, once activated, wire or blade 920 can be pulled toward longitudinal element 930, thereby passing through and consequently cutting away the implant.

Skilled artisans will appreciate that the cross-section of longitudinal element 930, as well as cutting tool 900 may differ from that shown in the exemplary embodiments of the figures. In addition, while FIG. 10 illustrates wire or blade 920 having a generally circular cross-section, the cross-section can be more planar in the event a reciprocating blade were employed.

FIG. 11 illustrates an exemplary method of explanting a cut-away portion of a spinal implant 30, after the cutting tool has cut through implant 30 at plane 110. In a preferred embodiment, an anchor 115 can be implanted into the portion of the implant 30 that is to be removed, designated in FIG. 11 as 30′. Anchor 115 can comprise any type of device capable of grasping implant portion 30′, including loops, fasteners, hooks, heated barbed elements, screws, spiral hooks, and the like. Anchor 115 typically is secured to implant portion 30′ prior to cutting, although it can be secured at any time (prior, during, or after cutting away implant portion 30′). For example, anchor 115 can be a relatively rigid rod or wire 117 with barbs 116 at the end that can be opened by either application of heat (e.g., a shape memory metal such as nitinol) or by a mechanical means such as rotating the rod or wire 117. After implantation, barbs 116 can be opened to secure anchor 115 to the implant portion 30′.

FIG. 11, embodiment A illustrates the implant 30 just after cutting at plane 110, with anchor 115 secured to implant portion 30′. Embodiment B of FIG. 11 illustrates the implant portion 30′ extricated from the remaining portion 30″ of the implant by advancing anchor 115 in the direction of arrow 960. Thus, pieces of implant 30 can be explanted sequentially from the disc space immediately after cutting. Alternatively, implant 30 can be dissected into a number of smaller portions 30′, etc., and then a series of anchors 115 (or anchor 115 applied sequentially) may be attached to the smaller portions to remove them from the disc space.

Anchors 115 can be inserted into the implant, or portions of the implant that have been cut away by any technique known to those skilled in the art. For example, anchor 115 may be inserted via simple forward piercing, stabbing, puncturing, etc., by use of force or pressure. Anchor 115 also can be inserted by use of a reciprocating forward and backward motion to pierce, stab, puncture, or otherwise enter implant. Anchor 115 also can be inserted by heating the anchor and melting away a portion of the implant as the anchor 115 is advanced into the implant. The heat can be removed and the melted material allowed to solidify, thereby anchoring anchor 115 into the implant. Heating can be separate from, or in conjunction with any of the afore-mentioned methods of insertion (e.g., forward force or pressure, reciprocation, etc.).

FIG. 12 illustrates a variety of anchors 115. FIG. 12, embodiment A illustrates anchor 115 with rod or wire 117 with barbs 116 at the end transforming from an insertion position (on the left) to an extraction position (on the right) whereby barbs 116′ now are opened and secured to the implant portion. Opening of barbs 116 (i.e., taking barbs 116 from an insertion position to extraction position 116′) can be effected using any of a number of techniques. Preferably, barbs 116 are opened by application of heat, or natural spring biasing action of barbs. In one embodiment, heat causes barbs 116 to expand and open up to the extraction position 116′. Barbs 116 can be fabricated from any of the well-known shape memory metal alloys so that application of external energy (e.g., heat or electricity) causes the barbs 116 to transform their shape into the extraction position 116′.

In another embodiment, barbs 116 are biased inward during insertion by virtue of the action of rod or wire 117 advancing through implant. Preferably, the barbs 116 and/or rod or wire 117 are heated to permit them to advance into the body of the implant. Upon implantation, the heated barbs 116 may melt away sufficient implant material that will allow them to spring back (or bias outward) naturally. Upon cooling, the barbs 116′ will be sufficiently anchored into the implant portion to enable extraction. In another embodiment, the barbs 116 can be activated into their extraction position 116′ by, for example, rotating rod or wire 117 to advance it into barb 116 and cause it to expand. Other means for activating barbs 116 will be readily apparent to those skilled in the art.

FIG. 12, embodiment B, illustrates for purposes of illustration only, other possible configurations of anchor 115, having different configurations for barbs 116 or rod or wire 117. For example, barbs 116 can be plate-like, or be comprised of relatively sharp narrow rods. Rod or wire 117 can be in the shape of a screw-type device enabling advancement into implant portion 30′ by rotating rod or wire 117.

FIG. 13, embodiments A, B, and C illustrate an exemplary device 130 in various stages of operation. The device 130 is one exemplary device showing the remaining portion of cutting tool 900, having longitudinal element 930 (FIG. 9). In embodiment A, the device has a trigger 131 attached near a handle portion 133, which preferably is positioned proximal to the remaining portion of device 130. Trigger 131 provides mechanical or electrical action or energy to device 130, depending on the position of indicator 135 (e.g., position A, B, or C). The device 130 also preferably has a distal end 132, which is similar to longitudinal element 930 depicted in FIG. 9.

Embodiment A illustrates the device whereby indicator 135 is in position A, or advancing mode. In this position, displacing trigger 131 (toward handle 133 in FIG. 13), advances wire or blade 920 from axial bore 910 in distal portion 132 of the device 130. The user can place the distal portion 132 of device 130 at or near spinal implant 30, and preferably at or near a hole or other aperture in implant 30 so that the advancing wire or blade 920 moves through the hole or aperture. Alternatively, the user may place the distal portion 132 of device 130 on an opposing side of an implant so that wire or blade 920 surrounds a portion of the implant 30. Those skilled in the art will be capable of designing a suitable device 130 so that when in advancing mode, the wire or blade 920 is capable of cutting a portion of the implant 30, depending on the shape and design of the implant 30.

Embodiment B illustrates the device whereby indicator 135 is in position B, or activating mode. Pulling trigger 131 further advances and attaches wire or blade 920 to the distal portion 132 of device 130 and primes the device for activation, whereby electrical or mechanical energy can be applied to wire or blade 920, respectively, to enable the wire or blade 920 to cut the implant. Once activated, indicator 135 may be advanced to position C, or cutting mode.

In cutting mode, depressing trigger 131 causes wire or blade 920 to be applied with electrical (heat) or mechanical energy, respectively, to enable wire or blade 920 to cut through implant 30. As wire or blade 920 is cutting through implant 30, further depressing trigger 131 causes wire or blade 920 to be displaced in the direction of arrow 136, thereby cutting a path or plane through implant 30. Device 130 could be designed so that trigger 131 can be depressed and released to allow wire or blade 920 to move longitudinally in the direction of arrow 136 when depressed, and in a direction opposite arrow 136 when released, or vice versa.

FIG. 14 is an exploded view of an exemplary device and wire or blade 920 being advanced through or around an implant 30. This would occur in the embodiment illustrated in FIG. 13, when the device 130 has indicator 135 in position A, or advancing mode. As shown in FIG. 14, longitudinal element 930 of the device includes a distal end 132 positioned near implant 30. Axially disposed within longitudinal element 930 is an axial bore 910, which could be in the form of a wire sheath, or longitudinal bore axially disposed within longitudinal element 930. Axial bore 910 can be advanced out of the distal end 132 and placed in an appropriate position such that wire or blade 920 can be expelled therefrom to encircle all or a portion of implant 30.

Arrow 145 indicates the direction wire or blade 920 will advance in or around implant 30 and back into the longitudinal element 930. FIG. 14 illustrates a particularly preferred embodiment whereby an additional element 140 is positioned within longitudinal element 930 that is capable of accepting the distal portion of wire or blade 920 after it has been advanced in or around all or a portion of implant 30. Element 140 preferably is capable of longitudinal displacement within longitudinal element 930 so that when the distal portion of wire or blade 920 is attached thereto, element 140 can be moved back-and-forth longitudinally to cut through implant 30.

FIG. 15 is an exploded view of an exemplary device deploying anchors 115 into an implant 30. The device may be the same as the cutting tool 900, or a different device. If cutting tool 900 were employed, anchors 115 would be advanced from the distal end 132 of longitudinal element 930 and into the implant. The implant 30 may have already been cut or may not have been cut, cutting of implant taking place along arrow 150, as described previously. It is preferred to insert anchors 115 prior to cutting so that the anchors can hold the implant portions in place while the cutting takes place. Anchors 115 can be advanced from distal end 132 by longitudinally displacing rod or wire 117 out of distal end until barbs 116 are sufficiently implanted and secured into implant 30 (insertion can be effected by any of the means discussed previously). After cutting of implant 30, rod or wire 117 then can be longitudinally displaced back toward and into distal end 132, together with the removed portion of the implant to which barb 116 is attached. This action will enable removal of the cut-away portions of implant 30 from the disc space.

After removal of the first cut-away portion of implant 30, the other anchor 115 remains in place in the remaining portions of implant 30. This anchor 115 can serve as a guide for the next cutting procedure. A surgeon need not re-locate the implant fluoroscopically or by other means, but rather need only rely on the placement of the anchor 115. The cutting tool can be rotated or the implant moved into a separate position, another anchor 115 inserted into the implant, and a second cutting procedure takes place to cut away a second portion of implant 30. After cutting away the second portion, anchor 115 inserted during, after or before the first cutting procedure, now preferably is seated within the second cut-away portion, and can be used to remove it from the disc space. This procedure then can be repeated until the entire implant is explanted.

The foregoing detailed description is provided to describe the invention in detail, and is not intended to limit the invention. Those skilled in the art will appreciate that various modifications may be made to the invention without departing significantly from the spirit and scope thereof.

	Number	Date	Country
Parent	10976893	Nov 2004	US
Child	11115230	Apr 2005	US

Devices and methods for explantation of intervertebral disc implants

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