The invention pertains to fully threaded screws as surgical implants for the distraction, compression, and/or fusion of vertebrae and other bones, joints, or bone segments.
Cervical surgery since the late 1950s and early 1960s has steadily transitioned from primarily posterior based to primarily anterior based. Posterior based surgery has the following major advantages: minimal critical structures in the surgical field, familiar anatomy, and access to multiple levels. However, posterior based surgery has the following major disadvantages: dissection or approach related post-operative pain and large or limited arthrodesis option (for example, lateral mass screws and surface area available for fusion). Anterior based cervical surgery addresses some of the deficits, particularly pain and infection rates. Thus, the trend in the United States has been a shift towards more anterior cervical surgery and towards less posterior cervical surgery.
However, certain unique risks still remain with anterior surgery: injury to esophagus, injury to trachea, dysphagia/dysphonia, injury to recurrent laryngeal nerves, carotid artery injury, internal jugular vein injury, vagus nerve injury, adjacent level disease, non-unions, implant failure, implant prominence, dural injury, spinal cord injury to name a few. Thus, there has been a reemergence of posterior based surgery, particularly minimally invasive posterior surgery, to address the issues that may arise with anterior surgery.
Common indications for posterior minimally invasive surgery (MIS) include anterior cervical non-unions, patients at a high risk for non-unions (for example, smokers), and/or isolated foraminal stenosis which may lead to radiculopathy. In theory, given that the facet surface area of the posterior spine is equal to or larger than the surface area of the disc space anteriorly, one could minimize the rate of cervical non-unions or even treat anterior non-unions via a posterior MIS. Also, if a stenosis is present at the foraminal segment, indirect decompression via a posterior MIS would elevate the facet joint and increase the foraminal height as has been shown in the literature rather than the alternative anterior approach. Given the minimal disruption of soft tissue with posterior MIS, the infection rates and post-operative pain issues should match that of anterior based surgery.
Several wedge-type implants have been developed for treatment of degenerative disc disease (DDD) of the cervical spine (C3-C7), including cervical pseudarthrosis, such as “CAVUX®” (referred to “DTRAX®” in some literature), “HONOUR® ORB,” “Valeo® II C”, “UNIFLEX® Cervical cage” and others. These devices all require some degree of malleting for insertion. Some of these devices can be used for either anterior or posterior approaches (Smith, et al. “Anterior Cervical Pseudarthrosis Treated with Bilateral Posterior Cervical Cages,” Oper Neurosurg (Hagerstown). 2018 Mar. 1; 14(3):236-242. doi: 10.1093/ons/opx103, PMID: 28637309)
An alternative fusion technique involves the use of lateral mass screws in a posterior approach. For example, this includes DePuy/Synthes SYNAPSE™ and the Stryker OASYS® system. The major issue with any of these implants, despite the length of the screws on average being 10-16 mm, is related to the approach or exposure: an extremely wide dissection is required which may increase post-operative pain/disability and may increase the risk of infection. Furthermore, the screws themselves are primarily anchored in softer cancellous bone.
Related devices are also used for other bones besides the spine. See e.g., US 2018/0206897 A1, disclosing compression screws for bones not in the spine. Other prior art bone screws for distraction, compression, or fusion of bones or bone fragments are described in US 2009/0043308 and WO 2017/123753 A1.
This disclosure addresses the shortcomings in the prior by providing a fully threaded screw implant intended for distraction or compression and fusion of the facet joints particularly for, but not limited to, the C3-C7 vertebrae, for the treatment of degenerative disc disease (DDD) of the cervical spine, stenosis, or pseudarthrosis. In addition, other bony fusions can be accomplished with the inventive implant.
In an embodiment, an implant is provided for the fusion of two adjacent bone structures or two adjacent bone fragments, comprising a fully threaded screw with a proximal end having a drive engagement feature and a distal end for insertion into bone or related tissue. In an embodiment, the screw has roughened surfaces throughout, and is fully coated with hydroxyapatite and/or tri-calcium phosphate, and is porous to allow for bone in-growth. In an embodiment, the proximal end of the screw is headless and the distal end to the head is flattened, rounded, or blunted. In an embodiment, the screw has uniform low pitch cortical threads, with with a major diameter of 3 mm to 7 mm, and an overall length of 5 mm to 65 mm; and the screw is made from titanium alloy or tantalum alloy with a similar modulus of elasticity to bone.
In an alternative embodiment, an implant for two adjacent bone structures or two adjacent bone fragments is provided, comprising a fully threaded screw with a proximal end having a drive engagement feature and a distal end for insertion into bone or related tissue. In an embodiment, the screw has roughened surfaces throughout, is fully coated with hydroxyapatite and/or tri-calcium phosphate and is porous to allow for bone in-growth. In an embodiment, the proximal end of the screw is headless and the distal end to the head is flattened, rounded, or blunted. In an embodiment, the screw has variable pitch threads, having low pitch cortical threads distal to the head, and larger pitch cancellous threads proximal to the head, In an embodiment, the screw has a uniform major diameter of 3 mm to 7 mm for the entire length of the screw, and an overall length of 5 mm to 65 mm. In an embodiment, wherein the screw is made from titanium alloy or tantalum alloy with a similar modulus of elasticity to bone.
In an alternative embodiment, an implant for fusion of two adjacent bone structures or two adjacent bone fragments is provided, comprising a fully threaded screw with a proximal end having a drive engagement feature and a distal end for insertion into bone or related tissue. In an embodiment, the screw has roughened surfaces throughout, is fully coated with hydroxyapatite and/or tri-calcium phosphate and is porous to allow for bone in-growth. In an embodiment, the proximal end of the screw is headless and the distal end to the head is flattened, rounded, or blunted. In an embodiment, the screw has variable pitch threads, having large pitch cancellous threads distal to the head, and low pitch cortical threads proximal to the head, In an embodiment, the screw has a uniform major diameter of 3 mm to 7 mm for the entire length, and an overall length of 5 mm to 65 mm. In an embodiment, the screw is made from titanium alloy or tantalum alloy with a similar modulus of elasticity to bone.
In an embodiment, the screw implants have a major diameter (major diameter) of 4 mm to 5 mm. In an embodiment, the screw implants have an overall length is selected from 10 mm, 12 mm, 15 mm, or any other length from 15 mm to 65 mm. In an embodiment, the screw implants are solid without a cannulation channel. In an embodiment, the screw implants are cannulated with a channel through the center to allow placement with a guidewire. In an embodiment, the screw implants have one or more fenestrations, with or without cannulation. The fenestrations may be slots or perforations to allow for bone grafting and bony through-growth.
In an embodiment, the implant is fully threaded screw-like implant with low pitch cortical threads with major diameter of 3 mm to 7 mm and a length of 5 mm to 65 mm. In an embodiment, the implant would have low-pitch threads (close threads) and low crests (to minimize difference between inner and outer diameters) similar to commonly seen set screws. In an alternative embodiment, the implant could have variable pitch threads to allow for distraction of the facet joints if placed across a joint line (low pitch threads distally and large pitch threads proximally). In another embodiment, the implant could have variable pitch threads to allow for compression of the facet joints if placed across a joint line (large pitch threads distally and low pitch threads proximally).
In an embodiment, the implant would have a leading end (distal) that is blunt and a trailing (proximal) end that allows for a driver to engage the implant, for example a hexagonal screwdriver.
In an embodiment, the implant is fully porous with pore sizes ranging in 100 to 900 μm to facilitate in-growth and have a porosity to mimic host cancellous bone.
In an embodiment, the implant is made of titanium or tantalum or an alloy thereof to match the modulus of elasticity of bone.
In an embodiment, the implant would be coated with HA (hydroxyapatite) and/or TCP (tri-calcium phosphate) to facilitate osteo-conduction.
In an embodiment, the implant is threaded to allow for simpler in-line insertion in between the facets and into the joint space. Alternatively, the implant insertion can be perpendicular to the joint line in the embodiment with variable threads to allow for joint distraction or compression.
In an embodiment, the implant may be cannulated to allow placement with a guidewire.
In an embodiment, the implant may have fenestrations or slots or perforations to allow for bone grafting and bony through-growth.
This invention provides an implant for fusion of cervical spinal vertebrae, wherein the implant is a fully threaded screw with a cylindrical body as shown in
The inventive implants may be used for distraction, fusion, and bone compression of adjacent bones or bone fragments, including vertebrae. In an embodiment, the screws are inserted into the posterior facet joint between two vertebrae. Alternatively, the screws can be inserted across a facet joint using a drilled hole and optionally a guide wire. In contrast to the prior art devices discussed above, such as the CAVUX®, HONOUR® ORB, Valeo® II C, UNIFLEX® Cervical cage, which require malleting or tamping during insertion, the inventive implants 100 are inserted by being screwed into position. All of the above referenced prior art devices are cages and have a boxy or wedge shape to some extent. All of the cage-like devices must be malleted into position. The inventive devices which are screwed into position for vertebral distraction afford a much greater degree of control for the surgeon. Malleting also has the disadvantage that fracturing or chipping of bone at the facet joint is a common adverse event. If this occurs, invasive remediation is required such as open or traditional fusion with screws and rods.
In another embodiment, the implants such as those illustrated in
The inventive device has significant advantages over the screws disclosed in US 2009/0312763 A1 (763) at FIGS. 39-47. The '763 devices do not have the osteoconductive hydroxyapatite or TCP coatings of the inventive implants and do not have porous surfaces and roughened surfaces.
The inventive devices have features to facilitate osseoincorporation or osseointegration of the implant into bone tissue. In an embodiment, the inventive implants are equipped with a roughened surface with a HA and/or TCP to facilitate bone ongrowth on the implant. (Jung Taek Kim, MD and Jeong Joon Yoo, “Implant Design in Cementless Hip Arthroplasty,” Hip Pelvis. 2016 June; 28(2): 65-75, doi: 10.5371/hp.2016.28.2.65 (see p. 65)) The porous surfaces facilitate bone ingrowth. Bone ingrowth refers to the formation of bone within an irregular surface of an implant, which improves the implant's integration into bone. The presence of a porous-coated implant evokes a cellular and physiological response that resembles the healing cascade of cancellous defects. In porous implants, the void spaces are filled with newly formed bone tissue when the implants are stable. Fenestrations promote bone through-growth, meaning bone growth through the fenestrations.
The insertion of the implants 100 may take two or more configurations. One embodiment is shown in
With either installation configuration, the width of the dissection can be narrower than is required with the DePuy/Synthes SYNAPSE™ and the Stryker OASYS® system.
In the embodiment shown in
The “major diameter” (Dmaj) is defined as the maximum outside diameter of the threads. The Dmaj, is the larger of two extreme diameters delimiting the height of the thread profile, as a cross-sectional view is taken in a plane containing the axis of the threads. The “minor diameter” (Dmin) is the diameter of the core of the implant, i.e., at the bottom of the threads. The Dmin is the lower extreme diameter of the thread. As used herein, the “core diameter” or “shaft diameter” is equivalent to the minor diameter. In an embodiment, the implant has a uniform major diameter for the entire length, except for the rounded, flattened, or blunted distal tip. “Thread height” is defined at Dmaj-Dmin. In an embodiment, the Dmin may vary, particularly in embodiments with variable thread pitches, in order to keep the Dmaj uniform. In such embodiments, the Dmin will be smaller in sections of the screw with larger cancellous threads than in sections of the screw with smaller cortical threads.
In an embodiment, the threads may have low crests, meaning shallow threads, that is, meaning the difference between the major and minor diameter will be smaller than a normal 1.25 mm to 1.75 mm pitch thread. This is similar to commonly used orthopedic set screws or cortex screws.
In an embodiment, the distal end 104 of implant 100 is flattened, rounded, or blunted. This is desirable to minimize damage during insertion and reduce the tolerance necessary to insert the implant without unnecessary damage at the implant site.
In an embodiment the proximal end 102 of the implant is headless and includes a drive engagement feature 120, such as a hexagonal head, star head, or Phillips head, for the insertion of a screwdriver to rotationally drive the implant into position. However, other shaped features are also contemplated (both male and female). For example, the drive engagement feature 120 can include a cruciate shape, square shape, six-point star shape, or the like. Where a hexagonal (or “hex”) feature is used (e.g., 120 in
In an embodiment, the implant 100 has no external head (headless), meaning the drive engagement feature 120 is recessed into the body of the implant and there is no portion of the device outside the shape of the cylinder or cone 106 (i.e., the minor diameter) needed to accommodate the drive engagement feature. This is important because in an embodiment, the inventive implant 100 may be driven entirely into the bone, with no portion of the screw exterior to the natural surface of the bone (
In the embodiment shown in
In an embodiment, the implant of
In an embodiment as shown in
In an embodiment, the device of
In an embodiment, the device of
The inventive implant may be equipped with features to enhance bone in-growth. In an embodiment, the implant may be fabricated from a porous material known to enhance bone in-growth. In an embodiment, the implant may have a uniformly roughened surface to enhance bone on-growth and provide a scratch fit or interference fit. The implant may also be coated with an osteoconductive coating and equipped with fenestrations.
In an embodiment, the device of
In an embodiment, the entire implant may be fabricated from a medically compatible tantalum, titanium, tantalum alloy, or titanium alloy. For example, an appropriate titanium alloy may be titanium 6AL4V and 6AL4V ELI (ASTM Standard F1472, https://www.astm.org/Standards/F1472.htm (see also https://en.wikipedia.org/wiki/Ti-6Al-4V)), which are alloys made with about 6% aluminum and 4% vanadium. An appropriate tantalum alloy may be tantalum alloyed with 2.5% to 10% tungsten, or 40% niobium. These materials are known to have good biocompatibility and match the modulus of elasticity of bone. In an embodiment, the implant may be manufactured from a titanium alloy in accordance with ASTM F136, or where exterior surfaces are coated with medical-grade commercially pure titanium (CP Ti) per ASTM F1580.
In an embodiment, titanium or tantalum alloys can be made with roughened and porous surfaces. See e.g., https://www.slideshare.net/sameerashar9/uncemented-femoral-stem and Vasconcellos L M et al. “Evaluation of bone ingrowth into porous titanium implant: histomorphometric analysis in rabbits,” Braz Oral Res. 2010 October-December; 24(4):399-405, DOI: 10.1590/s1806-83242010000400005.
In an embodiment, all surfaces of the implant may be roughened with a macro surface roughness. This may be accomplished with a technique such as grit blasting, acid etching, or plasma spray coating (also called thermal spray coating). The rough surfaces are indicated in the drawings by the random dot pattern shown throughout.
In an embodiment, all surfaces of the implant 100 are coated with hydroxyapatite (HA) and/or tricalcium phosphate (TCP). HA and TCP are well known as osteoconductive materials that encourage bone growth.
In an embodiment, the implant may be fabricated from a porous material known to enhance bone in-growth, for example with pore sizes ranging in 100 to 900 μm to facilitate in-growth and have a porosity of 60-65% to mimic cancellous bone. Porosity may be created by mechanical manipulation of the screws, such with micro-drilling or laser drilling in an uneven pattern. The porosity is shown in the figures by the larger surface imperfections depicted as triangles.
The combination of surface roughness, HA or TCP coating, and porosity will facilitate bone in-growth which is desirable for fusion.
This patent application claims the benefit of U.S. Patent Application 62/789,483 filed Jan. 7, 2019.
Filing Document | Filing Date | Country | Kind |
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PCT/US20/12602 | 1/7/2020 | WO | 00 |
Number | Date | Country | |
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62789483 | Jan 2019 | US |