Process of fabricating composite implants having integration surfaces composed of a regular repeating pattern

Abstract

Processes of fabricating a roughened surface topography on a composite interbody spinal implant including a body having a top surface, a bottom surface, opposing lateral sides, and opposing anterior and posterior portions; a first integration plate affixed to the top surface of the body; and an optional second integration plate affixed to the bottom surface of the body. At least a portion of the first integration plate, optional second integration plate, or both has a roughened surface topography including macro features, micro features, and nano features, without sharp teeth that risk damage to bone structures, adapted to grip bone through friction, inhibit migration of the implant, and promote bone growth. The process steps may include separate and sequential macro processing, micro processing, and nano processing steps.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional of U.S. patent application Ser. No. 13 / 558,390, filed on Jul. 26, 2012, which is a continuation-in-part of U.S. patent application Ser. No. 12 / 151,198, filed on May 5, 2008, and issued as U.S. Pat. No. 8,262,737, which is a continuation-in-part of U.S. patent application Ser. No. 11 / 123,359, filed on May 6, 2005, and issued as U.S. Pat. No. 7,662,186. The contents of all prior applications are incorporated by reference into this document, in their entirety and for all purposes.TECHNICAL FIELD[0002]The present invention relates generally to composite interbody spinal implants and methods of making such implants and, more particularly, to friction-fit composite spinal implants having a roughened integration surface with a repeating pattern of predetermined sizes and shapes.BACKGROUND OF THE INVENTION[0003]In the simplest terms, the spine is a column made of vertebrae and discs. The vertebrae provide the supp...

AI Technical Summary

Benefits of technology

[0007]The present invention provides for composite interbody spinal implants having a body and one or two integration plates. The integration plates include integration surfaces with fusion and biologically active surface geometry, for example, in regular repeating patterns. The composite body also allows for insertion of the implants without damaging critical bone structures during or after implantation. Various implant body shapes are provided to allow for implantation through various access paths to the spine through a patient's body.

[0008]In one embodiment, the present invention provides a composite interbody spinal implant comprising: a body having a top surface, a bottom surface, opposing lateral sides, opposing anterior and posterior portions, a substantially hollow center, and a single vertical aperture; a first integration plate affixed to the top surface of the body, the first integration plate having a top surface, a bottom surface, opposing lateral sides, opposing anterior and posterior portions, and a single vertical aperture extending from the top surface to the bottom surface and aligning with the single vertical aperture of the body, defining a transverse rim. The top surface of the first integration plate has a first roughened surface topography including macro features, micro features, and nano features, without sharp teeth that risk damage to bone structures, adapted to grip bone through friction generated when the implant is placed between two vertebrae and to inhibit migration of the implant. Optionally, the implant also includes a second integration plate affixed to the bottom surface of the body, the second integration plate having a top surface, a bottom surface, opposing lateral sides, opposing anterior and posterior portions, and a single vertical aperture extending from the top surface to the bottom surface and aligning with the single vertical aperture of the body, defining a transverse rim. The top surface of the optional second integration plate has a second roughened surface topography including macro features, micro features, and nano features, without sharp teeth that risk damage to bone structures, adapted to grip bone through friction generated when the implant is placed between two vertebrae and to inhibit migration of the implant.

Problems solved by technology

Over time, the discs may become diseased or infected, may develop deformities such as tears or cracks, or may simply lose structural integrity (e.g., the discs may bulge or flatten).

Impaired discs can affect the anatomical functions of the vertebrae, due to the resultant lack of proper biomechanical support, and are often associated with chronic back pain.

There are a number of problems, however, with traditional spinal implants including, but not limited to, improper seating of the implant, implant subsidence (defined as sinking or settling) into the softer cancellous bone of the vertebral body, poor biomechanical integrity of the endplates, damaging critical bone structures during or after implantation, and the like.

Such challenges include: (1) end-plate preparation; (2) implant difficulty; (3) materials of construction; (4) implant expulsion; (5) implant subsidence; (6) insufficient room for bone graft; (7) stress shielding; (8) lack of implant incorporation with vertebral bone; (9) limitations on radiographic visualization; and (10) cost of manufacture and inventory.

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