Expandable Interbody Implant

Abstract

To provide expandable fusion devices, systems and methods.SOLUTION: The expandable fusion implant may include an upper endplate and a lower endplate configured to engage adjacent vertebrae, an actuation gear configured to adjust a height of the upper endplate, an interface collar configured to attach to an inserter instrument at multiple orientations for a desired surgical approach, and an expansion and orientation lock configured to lock the orientation of the interface collar and lock the height of the upper endplate. The expandable fusion device is attachable to the inserter instrument to secure the interface collar and disengage the lock from the actuation gear to permit expansion of the upper endplate.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] The present disclosure relates to surgical devices, and more particularly to expandable fixation devices that can be deployed inside an intervertebral disc space and then expanded in height to maintain disc spacing, stabilize the spine, and / or facilitate interbody fusion. [Background technology]

[0002] A common treatment for addressing pain associated with degenerated intervertebral discs due to various factors, such as trauma or aging, is the use of intervertebral fusion devices to stabilize one or more adjacent vertebral bodies. Generally, to stabilize the adjacent vertebral bodies, the disc is first partially or completely removed. An interbody fusion device is then inserted between the adjacent vertebrae to maintain normal disc spacing and restore spinal stability, thereby facilitating interbody fusion.

[0003] Several fixation devices and methods exist for achieving interbody fusion. These may include solid bone implants, fixation devices that include cages or other implant mechanisms that may be packed with bone and / or bone growth inducers, and expandable implants. The implants are placed between adjacent vertebrae to fuse the vertebral bodies together, thereby reducing associated pain.

[0004] Interbody devices have been used to provide support and stability in the anterior column of the spine when treating a variety of spinal conditions, including degenerative disc disease and spinal stenosis with spondylolisthesis. Clinical treatment of spinal pathology with anterior interbody devices relies on accurate placement of the interbody device to restore normal anterior column alignment. Iatrogenic pathology can result from a lack of surgical access to the disc space, failure to accurately position the interbody over the hard cortical bone often found on the vertebral apophyseal rings, and / or failure to precisely control and restore normal anatomic spinal alignment.

[0005] Thus, there is a need for a fixation device that can be inserted into the disc space at a collapsed height and then axially expanded to restore lost disc space height, yet provides precise interbody placement, and can be inserted from multiple approaches to allow access to the spine without requiring an extensive set of implants with fixed approach-specific insertion features. Summary of the Invention

[0006] To meet this and other needs, and with its objectives in mind, the present application provides devices, systems, and methods for installing and expanding interbody implants and deploying integrated retention spikes. In particular, expandable fixation devices are provided that can be inserted from any approach that allows access to the spine. The expandable fixation devices may have the ability to adjust the orientation of attachment to the implant to accommodate various approaches, provide discrete orientation positions about the implant's central axis, and may have an internal auto-lock that automatically locks the device after insertion into the disc space, and / or may have the ability to expand in height when implanted to achieve a desired spacer height that provides a desired disc height.

[0007] According to one embodiment, the expandable implant includes upper and lower endplates configured to engage adjacent vertebrae, an actuation gear configured to adjust the height of the upper endplate and coupled to the lower endplate and engaged with the upper endplate, an interface collar configured to be attached to an insertion instrument in multiple orientations for a desired surgical approach and including a plurality of angled protrusions, and an expansion and orientation lock configured to lock the orientation of the interface collar and lock the height of the upper endplate, the lock being retained within the lower endplate and including a tapered outer surface having a plurality of notches defined therein configured to mate with the plurality of angled protrusions in the interface collar.

[0008] The expandable implant may include one or more of the following features: The interface collar can freely rotate about the central axis of the implant when not engaged by an inserter instrument or when engaged in the open position. The interface collar may be a split ring having a gap between opposing sides of the split ring. The interface collar may include a pair of eyelets defining a pair of openings through the interface collar. The lower endplate may include a plurality of snap-fit ​​posts arranged in pairs defining a space therebetween, and the lock may include a plurality of guide rail posts configured to fit into the spaces between the snap-fit ​​posts and thereby guide movement of the lock. Upper portions of the guide rail posts may protrude upward from the lock and be configured to interact with pockets below the actuation gear to constrain rotational movement of the actuation gear and prevent expansion and collapse of the implant. The lock may include a plurality of spring arms extending from a bottom surface of the lock, which, in a disengaged state, push the lock up and away from the bottom endplate. The actuation gear may include a disk with a plurality of teeth projecting radially outward therefrom and a threaded central opening configured to threadably mate with the upper endplate. The upper endplate may include an annular body with a bone-engaging surface and a downwardly-projecting cylinder configured to mesh with the actuation gear. The downwardly-projecting cylinder of the upper endplate may include external threads and a vertical slot bisecting the external threads, and the lower endplate may include a post receivable in the vertical slot.

[0009] According to one embodiment, an implantable system includes an expandable implant and an insertion instrument. The expandable implant includes an upper endplate configured to engage a superior vertebra, an actuation gear configured to adjust the height of the upper endplate, an interface collar configured to rotate about a central axis of the implant for a desired surgical approach, an expansion and orientation lock configured to lock the orientation of the interface collar and the height of the upper endplate, and an inferior endplate configured to engage a inferior vertebra. The insertion instrument has a mounting assembly configured to engage the interface collar and an expansion assembly configured to expand the implant. The insertion instrument is attachable to the interface collar in open, half, and full positions to control the position of the interface collar and the expansion of the implant.

[0010] The system may include one or more of the following features. The attachment assembly may include an attachment fork having a pair of prongs. The interface collar may include a pair of openings configured to receive the prongs of the attachment fork. In the open position, the insertion instrument is attached to the implant such that the attachment fork does not engage the interface collar, thereby allowing full rotation of the interface collar and the lock prevents expansion of the upper endplate. In the half position, the insertion instrument is attached to the implant such that the attachment fork engages the interface collar, thereby fixing the position of the interface collar and the lock prevents expansion of the upper endplate. In the full position, the insertion instrument is attached to the implant such that the attachment fork is engaged with the interface collar, thereby fixing the position of the interface collar and the lock disengages from the actuation gear to allow expansion of the upper endplate.

[0011] According to another embodiment, a method of installing an expandable implant includes: (a) providing an expandable implant including a superior endplate configured to engage a superior vertebra, an actuation gear configured to adjust the height of the superior endplate, an interface collar configured to rotate about a central axis of the implant for a desired surgical approach, an expansion and orientation lock configured to lock the orientation of the interface collar and lock the height of the superior endplate, and an inferior endplate configured to engage a inferior vertebra; and (b) attaching an insertion instrument to the interface collar, the insertion instrument configured to allow full rotation of the interface collar and move the interface collar to an open position where the lock prevents expansion of the superior endplate, a half position where the lock locks the position of the interface collar and prevents expansion of the superior endplate, or a full position where the lock locks the position of the interface collar and disengages from the actuation gear and allows expansion of the superior endplate. The insertion instrument may be attached to the interface collar to establish a desired trajectory, including a direct anterior, a direct lateral, or an unspecified oblique approach between direct anterior and direct lateral. The expandable implant may be positioned within the disc space in a collapsed position when the insertion instrument moves the interface collar to the half or full position and locks the position of the interface collar. When the insertion instrument moves the interface collar to the full position, the lock disengages from the actuation and the actuation gear can be rotated to adjust the height of the superior end plate.

[0012] Also provided are kits containing various types and sizes of implants, rods, tensioning instruments, insertion tools, and other components for performing the procedure. [Brief explanation of the drawings]

[0013] A more complete understanding of the present invention and its attendant advantages and features will be more readily appreciated by reference to the following detailed description when considered in conjunction with the accompanying drawings. [Figure 1A]10A-10C show insertion instruments attached to expandable implants for a direct anterior approach, an undefined oblique approach, and a direct lateral approach, respectively, according to one embodiment. [Figure 1B] 10A-10C show insertion instruments attached to expandable implants for a direct anterior approach, an undefined oblique approach, and a direct lateral approach, respectively, according to one embodiment. [Figure 1C] 10A-10C show insertion instruments attached to expandable implants for a direct anterior approach, an undefined oblique approach, and a direct lateral approach, respectively, according to one embodiment. [Figure 2] 1 illustrates an exploded view of an inserter tool, according to one embodiment. [Figure 3A] 3A and 3B show front and left side views, respectively, of the expandable fixation device of FIG. 2 at a collapsed starting height. [Figure 3B] 3A and 3B show front and left side views, respectively, of the expandable fixation device of FIG. 2 at a collapsed starting height. [Figure 4A] 3A and 3B show front and left side views, respectively, of the expandable fixation device of FIG. 2 fully expanded in height. [Figure 4B] 3A and 3B show front and left side views, respectively, of the expandable fixation device of FIG. 2 fully expanded in height. [Figure 5] FIG. 3 is a top view of one embodiment of the expandable fixation device of FIG. 2. [Figure 6A] 1A and 1B show a top view and a cross-sectional view, respectively, of an insertion tool attached to an expandable implant according to one embodiment. [Figure 6B] 1A and 1B show a top view and a cross-sectional view, respectively, of an insertion tool attached to an expandable implant according to one embodiment. [Figure 6C] 1A and 1B show a top view and a cross-sectional view, respectively, of an insertion tool attached to an expandable implant according to one embodiment. [Figure 7] 1 shows a partial top view (left) and partial cross-sectional view (right) of the insertion tool in a neutral open position where the implant is not engaged with the interface collar. [Figure 8A] 1A and 1B show a partial top view (left) and a partial cross-sectional view (right) and a side cross-sectional view, respectively, of the insertion tool positioned in a semi-locked position with the implant locking the implantation track but not unlocking the expansion gear. [Figure 8B] 1A and 1B show a partial top view (left) and a partial cross-sectional view (right) and a side cross-sectional view, respectively, of the insertion tool positioned in a semi-locked position with the implant locking the implantation track but not unlocking the expansion gear. [Figure 9A] 1A and 1B show a partial top view (left) and a partial cross-sectional view (right) and a side cross-sectional view of the insertion instrument positioned in a fully locked position with the implant to lock the implant trajectory and unlocking the expansion gear to allow expansion or contraction of the implant, respectively. [Figure 9B] 1A and 1B show a partial top view (left) and a partial cross-sectional view (right) and a side cross-sectional view of the insertion instrument positioned in a fully locked position with the implant to lock the implant trajectory and unlocking the expansion gear to allow expansion or contraction of the implant, respectively. DETAILED DESCRIPTION OF THE INVENTION

[0014] To restore height loss within the disc space and provide precise positioning between vertebral bodies, expandable implants may (1) have the ability to adapt the surgical approach to the implant to accommodate various surgical approaches, (2) provide distinct orientation positions around the implant's central axis, and internal automatic locking to automatically lock the device after insertion into the disc space, and (3) have the ability to expand in height when implanted to achieve a desired spacer height that provides the desired disc height. Accordingly, embodiments of the present application are generally directed to devices, systems, instruments, and methods for installing and expanding interbody implants. The terms implant, interbody, interbody implant, fixation device, spacer, and expandable device may be used interchangeably herein. While described with reference to interbody implants, it will be understood that the implants may also be used as corpectomy spacers, placed between non-adjacent vertebral bodies, or used in trauma or other suitable surgical applications.

[0015] 1A-1C, an expandable interbody fusion device or implant 10 and installation method according to one embodiment is shown. The expandable device 10 is configured to be inserted between two adjacent vertebrae 2. The expandable implant 10 is attached to an insertion instrument 12 to deploy the device 10 within the intervertebral disc space (the upper vertebrae are omitted from FIGS. 1A-1C for clarity). The inserter 12 may be suitable for use during a minimally invasive surgical (MIS) procedure, for example, such that the inserter 12 and attached implant 10 may be positioned through a guide tube or cannula to access and guide the implant 10 into the intervertebral disc space. The expandable implant 10 is inserted between the vertebral bodies 4 of the vertebrae 2 and inserted into the intervertebral disc space in a collapsed state.

[0016] The implant 10 is configured to adjust the orientation of the inserter 12 relative to the implant 10 to accommodate various surgical approaches to the spine. The ability to adjust the implant 10's implant orientation accommodates various approach angles and trajectories to the spine. Surgical approach angles and trajectories may include direct anterior, direct lateral, oblique, and subdivisions between direct anterior and direct lateral. FIG. 1A illustrates placement of the implant 10 via a direct anterior approach to the spine from the front of the body. When operating on the lumbar spine, this surgical technique is sometimes referred to as an anterior lumbar interbody fusion (ALIF). FIG. 1B illustrates placement of the implant 10 via an unspecified oblique approach (e.g., an angle between direct anterior and direct lateral). FIG. 1C illustrates placement of the implant 10 via a direct lateral approach to the spine from the side of the body. When operating on the lumbar spine, this surgical technique is sometimes referred to as a lateral lumbar interbody fusion (LLIF). It will be appreciated that the surgeon may determine the best surgical approach and placement of the expandable implant 10 pre-operatively or intra-operatively.

[0017] Once inserted into the disc space via the desired surgical approach, the implant 10 is then expanded in height to an expanded position to precisely restore normal spinal alignment and distribute loads across the vertebral endplates 6. The adjustable attachment interface allows the implant 10 to be oriented or tilted to better contact the natural endplate curvature of the vertebral bodies 4 above and below the disc space in which the device 10 is implanted. This can be particularly beneficial in cases of highly complex deformities where the vertebral bodies 4 may be rotated relative to two or more dimensional planes, thus requiring atypical surgical access approaches depending on the level the surgeon desires to treat.

[0018] Referring now to FIG. 2, a distractor and retractor system 10 is shown according to one embodiment. The implant 10 includes an upper endplate 20 for engaging the superior vertebral body 4, an inferior endplate 22 for engaging the inferior vertebral body 4, an expansion or actuation gear 24 for adjusting the height of the upper endplate 20, an orientation and interface collar 26 configured to attach the inserter 12 to the implant 10 at various orientations or angles for a desired surgical approach angle or trajectory, and an expansion and orientation lock 28 configured to lock the orientation of the interface collar 26 and / or automatically lock the height of the implant. The endplates 20, 22, actuation gear 24, interface collar 26, and lock 28 are aligned along a central longitudinal axis 30. The implant 10 can define a large central graft-retaining opening or window 32 configured to receive bone graft or other suitable bone growth-promoting material. As best seen in FIG. 5, the central graft window 32 can be generally cylindrical in shape with its central axis aligned with the central longitudinal axis 30.

[0019] The top or superior endplate 20 includes an annular body 34 having a downwardly protruding cylinder 36 configured to mate with the actuation gear 24. The annular body 34 may be a ring or circle that surrounds a portion of the central graft window 32. The annular body 34 has a thickness between an upper bone-engaging surface 38 and a bottom or inferior surface 40 of the annular body 34. As best seen in FIGS. 3A-3B and 4A-4B, the annular body 34 may be angled and / or the thickness between the upper surface 38 and the inferior surface 40 of the annular body 34 may be varied to accommodate a wide range of anatomical profiles and to match or restore lordosis when used in the lumbar spine.

[0020] The annular body 34 includes an upper bone-engaging surface 38 configured to engage the superior vertebral body 4. The upper bone-engaging surface 38 may be contoured to mimic the shape of the vertebral endplate 6. The upper bone-engaging surface 38 may include a plurality of teeth, protrusions, or other friction-enhancing surfaces configured to engage bone. In one embodiment, the upper endplate 20 includes a bone-like, ejection-resistant pattern or texture on its upper surface geometry for contacting the bone surface, which can be angled to match or restore lordosis when used in the lumbar spine. The bone-contacting surface 38 may further include a porous or porous structure to allow additional bone ingrowth into the spacer. The upper endplate 20 may be 3D printed, for example, to increase the potential for bone growth. It will be understood that the bone-engaging surface 38 may be modified to include one or more surface treatments, coatings, textures, or other features to enhance fusion.

[0021] The cylinder 36 extends from the bottom or lower surface 40 of the annular body 34. The protruding cylinder 36 defines one or more external threads 42 configured to mate with corresponding threads 50 inside the actuation gear 24. The external threads 42 may include a helical thread profile machined into the exterior surface of the cylinder 36. The external threads 42 may have any suitable attributes, including diameter, handedness, thread form, thread angle, lead, pitch, etc. The threads 42 may extend along the entire length of the cylinder 36 or an appropriate portion thereof. When the cylinder 36 is telescopically received into or out of the actuation gear 24, the upper end plate 20 is configured to increase or decrease in height, thereby adjusting the overall height of the implant 10. The slot 44 may extend the entire length or a portion of the length of the threads 42 and extend into the central graft window 32. The slot 44 may be vertically oriented and in fluid communication with the central graft window 32. The slot 44 may be positioned at an angle from directly anterior to allow access from various approach angles. The slot 44 may act as a backfill window and counter torque for expansion and collapse of the spacer.

[0022] The expansion gear or actuation gear 24 is configured to expand and collapse the implant 10. The actuation gear 24 has a central through opening 48 sized and dimensioned to telescopically receive the protruding cylinder 36 of the upper endplate 20. The central opening 48 has a central axis coaxial with the central longitudinal axis 30 of the implant 10. The central opening 48 defines one or more internal threads 50 cut into its inner diameter that are configured to mate with the external threads 42 of the upper endplate 20. The threaded engagement between the cylinder 36 and the threaded opening 48 allows the actuation gear 24 to adjust the height of the upper endplate 20 when rotated.

[0023] The outer periphery of the actuation gear 24 includes a plurality of cogs or teeth 52. In one embodiment, the actuation gear 24 may be a spur or straight gear having straight teeth 52 projecting radially from a cylinder or disc. The edges of each tooth 52 may be straight and aligned parallel to the axis of rotation. While a specific arrangement of beveled surfaces is shown, it is envisioned that the number, location, and configuration of the beveled surfaces may be varied or selected by one skilled in the art. When engaged by the insertion instrument 12, the actuation gear 24 may be rotated about the axis 30 to move the upper endplate 20 up or down, thereby adjusting the height of the implant 10.

[0024] The teeth 52 can extend between an upper surface 54 and an opposite lower surface 56 of the actuation gear 24. The upper surface 54 of the actuation gear 24 can be configured to contact the bottom surface 40 of the annular body 34 of the upper end plate 20 when the upper end plate 20 is fully folded (as shown in FIGS. 3A-3B). The lower surface 56 of the actuation gear 24 is configured to always contact or abut the upper surface 78 of the collar 26. The upper and lower surfaces 54, 56 of the actuation gear 24 can be generally flat and smooth.

[0025] The actuation gear 24 includes a snap-fit ​​lip 58 that protrudes downwardly and is configured to be retained by the bottom endplate 22. As best seen in FIG. 8B , the snap-fit ​​lip 58 may include a circular rim 60 defined by a circular groove above the rim 60. The circular rim 60 protrudes radially outward to engage the bottom endplate 22. The bottom or surface of the rim 60 may be angled or rounded to aid in the snap-fit ​​engagement. The underside 56 of the actuation gear 24 defines a plurality of pockets 62 configured to retain portions of the locks 28. The locks 28 are configured to interact with the pockets 62 in the underside 56 of the actuation gear 24 to constrain rotational movement of the expansion gear 24 and prevent both expansion and collapse of the implant 10.

[0026] The orientation and interface collar 26 is configured to mate with the inserter 12 for implantation. When not engaged by the inserter 12, the collar 26 is free to rotate about the axis 30. When engaged by the inserter 12 in a certain position, the collar 26 is locked in place relative to the inserter 12 for implantation for a desired approach or trajectory. The interface collar 26 includes a split ring body 66 having a gap 68 between opposite sides of the split ring 66. The interface collar 26 defines one or more openings 70 through an outer surface 72 of the outer diameter configured to mate with the inserter 12 for implantation. The outer surface 72 may be generally smooth, except for a pair of protruding oval eyelets 71 on either side of the gap 68. Each opening 70 may be defined through a respective eyelet 71.

[0027] The inner surface 74 of the interface collar 26 includes a plurality of angled protrusions 76. The angled protrusions 76 may include a series of alternating protrusions and grooves configured to mate with corresponding mating surfaces 94 on the lock 28. The angled protrusions 76 may define sides or angled surfaces configured to allow vertical translation of the lock 28 along the axis 30. The angled protrusions 76 may extend a distance from the upper surface 78 toward the lower surface 80, stopping short of the lower surface 80 to allow for a smooth area below the protrusions 76. In one embodiment, a first series of angled protrusions 76 extends a distance along the inner surface 74 from the first opening 70, and a second series of angled protrusions 76 extends a distance along the inner surface 74 from the second opening 70, with a smooth area along the inner surface 74 between the two series of protrusions 76. While a particular arrangement of angled surfaces is shown, it is envisioned that the number, location, and configuration of the angled surfaces may be varied or selected by one skilled in the art.

[0028] A rotatable interface collar 26 is positioned between the actuation gear 24 and the bottom end plate 22. The interface collar 26 may be retained within the bottom end plate 22 by overlapping lips 82, 120 on the collar 26 and the bottom end plate 22. The lip 82 on the interface collar 26 may include a downwardly projecting lip that continues into the body of the split ring 66 along the inner surface 74. It will be appreciated that the interface collar 26 may be retained within the bottom end plate 22 using any suitable mechanism that allows rotational movement of the collar 26 about the axis 30 when the collar 26 is not secured by the inserter 12.

[0029] When not engaged by the inserter 12, the interface collar 26 is free to rotate 360° about the central axis 30 of the implant core. The collar 26 can be engaged by the inserter 12 in multiple positions. In a first position, the angled protrusion 76 of the collar 26 interacts with the lock 28 to prevent the collar 26 from rotating, which locks the orientation of the implant 10 relative to the inserter 12 for implantation. In a second position, the collar 26 disengages the lock 28 from the actuation gear 24, thereby allowing expansion or collapse of the implant 10 and preventing rotation and reorientation of the collar 26.

[0030] The expansion and orientation lock 28 is configured to lock the orientation of the interface collar 26 and / or automatically lock the height of the implant 10. The outer diameter 92 of the lock 28 is tapered by angled shallow notches 94, which interact with and interface with the mating protrusions 72 on the interface collar 26. The lock 28 includes a ring-shaped body 86 that is angled or tapered from a top edge 88 to a bottom edge 90. The body 86 gradually increases in diameter around its circumference from the top edge 88 to the bottom edge 90, forming an outer cone-like shape. Thus, the top edge 88 has a smaller diameter than the bottom edge 90. The outer diameter of the lock 28 includes a plurality of shallow notches 94. The shallow notches 92 may be generally rectangular in shape extending perpendicularly from the top edge 88 to the bottom edge 90. The cuts 92 may have equal widths, may be equally spaced around the circumference of the lock 28, or may be otherwise configured to mate with corresponding protrusions 72 in the interface collar 26. The inner surface 96 of the lock 28 may be smooth.

[0031] The lock 28 has one or more guide rail posts 98 that interact with the bottom end plate 22, acting as a counter-torque means, so that the lock 28 can only move linearly up and down along the axis 30. Each guide rail post 98 can include a vertical rail that protrudes radially inward. For example, four guide rail posts 98 can be equally spaced around the inner surface 94 of the lock 28. It will be appreciated that any suitable number and configuration of guide rail posts can be used to guide the movement of the lock 28. The upper portions of the guide rail posts 98 protrude upward and are configured to interact with the pocket 62 below the actuation gear 24 to constrain the rotational movement of the actuation gear 24 and prevent expansion and collapse of the implant 10. The lock 28 can include one or more spring arms 102 extending from the bottom surface 90 of the lock 28 and each terminating in a free end. The spring arms 102 can include a curved beam or structure that bends downward with a convex lower profile. A spring arm 102 may be positioned below each guide rail post 98. Each spring arm 102 may be machined into the lock 28 such that in the disengaged state of the implant, the spring arm 102 pushes the lock 28 up and away from the bottom endplate 22.

[0032] The inferior endplate 22 includes an annular body 106 configured to receive the expansion and orientation lock 28, the interface collar 26, and the actuation gear 24. Similar to the superior endplate 20, the annular body 106 may be a ring or a circle that surrounds a portion of the central implant window 32. The annular body 106 has a thickness between a lower bone-engaging surface 108 and an upper edge 110 of the annular body 106. As best seen in FIGS. 3A-3B and 4A-4B, the annular body 106 may be angled and / or the thickness between the superior and inferior surfaces 108, 110 of the annular body 106 may be varied to accommodate a wide range of anatomical profiles and to match or restore lordosis when used in the lumbar spine.

[0033] The lower bone-engaging surface 108 of the lower endplate 22 is configured to engage the lower vertebral body 4. The lower bone-engaging surface 108 may be contoured to mimic the shape of the vertebral endplate 6. Similar to the upper bone-engaging surface 38, the lower bone-engaging surface 108 may include a plurality of teeth, protrusions, or other friction-enhancing surfaces configured to engage bone. In one embodiment, the bottom endplate 22 includes an aggregate-like, ejection-resistant pattern or texture on the lower surface geometry to contact the bone surface, which can be angled to match or restore lordosis when used in the lumbar spine. The lower bone-engaging surface 108 may further include a porous or porous structure to allow additional bone ingrowth into the spacer. The lower endplate 22 may, for example, be 3D printed to increase the potential for bone growth. It will be understood that the bone-engaging surface 108 may be modified to include one or more surface treatments, coatings, textures, ejection-resistant structures or geometries, or other features to enhance fusion.

[0034] Assembly, counter-torque, and mating features for the lock 28 are machined into the upper portion of the lower endplate 22. The expansion and orientation lock 28 resides nested within a pocket and groove 112 machined in the bottom endplate 22. The lower endplate 22 has an inner wall 114 defined by a portion of the central graft window 32. A plurality of snap-fit ​​posts 116 extend perpendicularly from the inner wall 114. The snap-fit ​​posts 116 are arranged in pairs with spaces 118 therebetween configured to receive respective guide rail posts 98 of the lock 28. In the illustrated embodiment, four pairs of snap-fit ​​posts 116 are evenly spaced around the inner wall 114, defining four respective spaces 118 for corresponding guide rail posts 98. The guide rail posts 98 interact with the spaces 118 between the snap-fit ​​posts 116 to guide the movement of the lock 28 linearly up and down along the axis 30. Although a particular number and configuration of posts 98, 116 are shown, it will be understood that another suitable configuration may be selected to guide the lock 28.

[0035] After the lock 28 is positioned within the inferior endplate 22, the interface collar 26 is positioned within the inferior endplate 22 such that the collar 26 surrounds and engages the lock 28. The interface collar 26 may be retained within the bottom endplate 22 by overlapping lips 82, 120 on the collar 26 and the bottom endplate 22. The collar 26 may be sized and dimensioned such that the outer surface 72 of the orientation collar 26 is generally flush with the outer periphery of the annular body 106 of the inferior endplate 22.

[0036] The actuation gear 24 may then be positioned on top of the orientation collar 26 and secured to the lower end plate 22. The lower surface 56 of the actuation gear 24 abuts the upper surface 78 of the interface collar 26. The actuation gear 24 may be sized and dimensioned such that the outer diameter of the gear 24 is generally flush with the outer surface 72 of the interface collar 26 and the outer periphery of the annular body 34 of the upper end plate 20. The lower surface 56 of the actuation gear 24 rests on top of snap-fit ​​posts 116 in the bottom end plate 22. The actuation gear 24 is retained within the bottom end plate 22 via the snap-fit ​​lips 60. Each free end of the snap-fit ​​posts 116 defines a protrusion or finger 122 configured to fit into a groove defining the circular rim 60 of the actuation gear 24. The snap fit post 116 may be configured to bend or flex slightly as the fingers 122 are inserted, thereby securely connecting the actuation gear 24 to the lower end plate 22 .

[0037] The upper endplate 20 is threadedly engaged with the actuation gear 24. A post 124 may protrude perpendicularly from the lower endplate 22 and is sized and configured to fit within the slot 44 in the cylinder 36 of the upper endplate 20. When in the fully collapsed position, the slot 44 and post 124 may act as a counter-torque means for the expansion and collapse of the spacer. When the implant 10 is fully collapsed, as shown in FIGS. 3A-3B, the bottom surface 40 of the annular body 34 of the upper endplate 20 may contact and abut the top surface 54 of the actuation gear 24. When the implant 10 is expanded, as shown in FIGS. 4A-4B, the annular body 34 of the upper endplate 20 lifts off the actuation gear 24 and the bottom surface 40 of the annular body 34 is spaced apart from the actuation gear 24.

[0038] The expandable fixation device 10 and its components can be fabricated from a number of biocompatible materials, including, but not limited to, titanium, stainless steel, titanium alloys, non-titanium metal alloys, polymeric materials, plastics, plastic composites, PEEK, ceramics, and elastomeric materials. The device or its components may be fabricated by additive processes, such as machining, three-dimensional (3D) printing, and / or subtractive processes.

[0039] 6A-9B, the implant 10 can be inserted into the intervertebral disc space using an inserter 12 via an agnostic approach. In other words, the surgeon can determine the trajectory or approach to the spine before or during the procedure and adjust the orientation of the implant 10 during the procedure to accommodate the desired surgical approach. The implant 10 is configured to be inserted from multiple approaches, eliminating the need for an extensive set of implants with fixed, approach-specific insertion characteristics. The ability of the implant 10 to be inserted from multiple approaches and trajectories can significantly reduce the number of implants required in a set list for a given procedure. The flexibility of the implant 10 also provides the surgeon with more options and greater control during the procedure, thereby resulting in better patient outcomes.

[0040] 6A-6C show an insertion tool 12 attached to an implant 10 according to one embodiment. The inserter 12 controls the position of the interface collar 26, the position of the lock 28, and the expansion height of the upper endplate 20 when properly attached. The post 12 extends along a central longitudinal axis from a proximal end 130 to a distal end 132. The proximal end 130 includes an attachment interface for connecting a handle (not shown) configured to be manipulated by a user. The distal end 132 is configured to attach to the interface collar 26 of the implant 10. The inserter 12 includes a main outer body 134 in the form of a hollow outer tube or cannula defining a central channel configured to receive an expansion assembly including an expansion drive shaft 136 configured to expand the implant 10 and an attachment assembly including a distal attachment fork 140 configured to engage the interface collar 26 at different locations.

[0041] The expansion assembly may include an expansion drive shaft 136, which is a cylindrical shaft that passes through the outer body 134 and is attached to a drive gear 138 configured to engage the actuation gear 24 of the implant 10. The proximal end 130 of the expansion drive shaft 136 is connectable to a handle (not shown) to enable rotation of the drive shaft 136. When the inserter 12 is engaged with the orientation collar 26 in the full position, rotating the expansion drive shaft 136 rotates the drive gear 138, which interacts with the actuation gear 24 to enable expansion or contraction of the upper endplate 20, thereby enabling adjustment of the height of the implant 10.

[0042] The mounting assembly may include a mounting fork 140, which includes a central body or base 142 with a pair of distal prongs 144 extending therefrom. The prongs 144 may be straight or curved and may be spaced to match the spacing of the mounting locations 70 along the interface collar 26. The prongs 144 may be configured to be slightly bent or flexed to engage with the interface collar 26 at different locations. The free end 146 of each prong 144 may be inserted into a respective opening 70 or may be contoured or shaped to engage with both sides of the opening 70. A sleeve 148 may be configured to pull the prongs 144 together or separately. An outer control knob 150 and an inner half nut 152 can be used to manipulate the prongs 144. For example, the control knob 150 can be rotated to translate the sleeve 148, drawing the prongs 144 together or spreading the prongs 144 apart. It will be appreciated that any suitable mechanism may be used to control the movement of the attachment fork 140 and prongs 144 .

[0043] FIG. 7 shows the inserter 12 attached to the implant 10 so that the attachment fork 140 does not engage the interface collar 26, thereby providing a neutral or open position. When the collar 26 is not engaged by the inserter 12, the collar 26 is free to rotate 360° around the central axis 30 of the implant core. The angled protrusion 76 of the interface collar 26 is not received within the shallow notch 94 of the lock 28. The open position occurs when the control knob 150 is twisted to position the attachment fork 140 so that the prongs 144 of the fork 138 do not engage the attachment points 70 on the interface collar 26. FIG. 7 shows the prongs 144 in the neutral position within the openings 70 of the interface collar 26, allowing the interface collar 26 to be fully rotated in the desired insertion direction.

[0044] When the collar 26 is engaged by the inserter 12, the angled protrusions 76 of the collar 26 interact with the angled shallow notches 94 on the lock 28. The collar 26 may be engaged by the inserter 12 in two different positions: a half position and a full position. FIGS. 8A-8B show the inserter 12 attached to the implant 10 in the half position. In the half position, the attachment fork 140 engages the interface collar 26, and the prongs 144 are positioned within the openings 70 of the interface collar 26 such that the prongs 144 move away from each other. When engaged in the half position by the inserter 12, the protrusions 76 of the interface collar 26 mate with the notches 94 on the lock 28, preventing the collar 26 from rotating, which in turn defines the orientation of the implant 10 relative to the inserter 12 for implantation. The half position occurs when the control knob 150 is twisted to bring the mounting fork 140 into a position where the prongs 144 of the fork 140 engage the angled interaction features on the interface collar 26 with the lock 28. The half position firmly defines the orientation of the interface collar 26 but does not unlock the expansion mechanism.

[0045] 9A-9B show the inserter 12 attached to the implant 10 in the full position. When engaged by the inserter 12 in the full position, the ramp feature of the interface collar 26 pushes into and over the lock 28, disengaging the rail post 98 from the underside of the gear 24 and allowing the implant 10 to expand or collapse and be implanted or removed. The full position also prevents rotation and reorientation of the collar 26. In the full position, the prongs 144 of the attachment fork 144 may be pulled toward each other to grasp the interface collar 26 so that the ends of the split ring 66 approach each other, thereby engaging the interface collar 26 with the lock 28. The full position occurs when the control knob 150 is twisted to bring the attachment fork 140 into a position where the prongs 144 of the fork 140 engage the interaction feature 76 on the interface collar 26 with the lock 28. In this manner, the interface collar 26 is firmly oriented, and the angled interaction feature 76 of the interface collar 26 pushes the lock 28 downward, away from the expansion gear 24. The upper end of the guide rail post 98 on the lock 28 disengages from the pocket 62 in the underside 56 of the actuation gear 24, thereby unlocking the implant 10.

[0046] Once in the full position, the upper endplate 20 can be raised or lowered. For example, rotating the expansion drive shaft 136 on the inserter 12 expands or contracts the spacer 10. The drive gear 138 engages the actuation gear 24, thereby allowing for adjustment of the height of the implant 10. Conversely, in the half or open position, rotating the expansion drive shaft 136 on the inserter 12 does not expand or contract the spacer 10 because the lock 28 is coupled with the expansion gear 24, thereby preventing this movement. Furthermore, when the inserter 12 is removed from the implant 10, the lock 28 automatically re-engages with the actuation gear 24 such that the spring 102 urges the lock 28 upward and the upper end of the guide rail post 98 re-enters the pocket 62 on the underside 56 of the actuation gear 24, thereby re-locking the implant 10 and preventing further expansion or contraction of the implant 10.

[0047] In one embodiment, robotic and / or navigational guidance may be used to assist in orienting and placing the implant 10 along one or more agnostic approaches. Further examples of surgical robotic and / or navigational systems can be found, for example, in U.S. Patent Nos. 10,675,094 and 9,782,229, which are incorporated by reference herein in their entireties for all purposes. The implant 10 may be implanted using one or more of the following steps: (1) determining the optimal implant location and positioning to optimize bone contact and desired correction; (2) using a robotic system and / or navigation system to determine potential trajectories that allow for optimal implant position and outcome; (3) optionally docking a cannula onto the disc space through an appropriate trajectory, including direct anterior, direct lateral, or an unspecified oblique approach between anterior and lateral; (4) inserting the expandable interbody 10 into the disc space in a collapsed position through the given trajectory; and (5) expanding the expandable interbody 10 heightwise to accurately restore disc height and spinal alignment (e.g., lordosis).

[0048] The implants and systems described herein may include one or more of the following advantages: (1) the ability to adjust the orientation of attachment to the implant to accommodate various approaches; (2) internal auto-locking that provides distinct orientation positions about the central axis of the implant and automatically locks the device after insertion into the disc space; and (3) the ability to expand in height when implanted to achieve a desired spacer height that provides a desired disc height.

[0049] The ability to adjust the implant orientation of the spacer relative to the sagittal angle accommodates a variety of approach angles and trajectories, including, but not limited to, direct anterior, direct lateral, oblique, and fine increments between direct anterior and direct lateral. The spacer has a retained interface collar that allows for free rotation around the device's central axis. By pivoting / rotating about the central axis, the device can be oriented to better interface with the natural endplate curvature of the vertebral bodies above and below the disc space in which it is implanted. This can be particularly beneficial in highly complex deformities where the vertebral bodies may be rotated relative to two or more dimensional planes, thus requiring atypical surgical access approaches to the level the surgeon desires to treat.

[0050] The auto-lock with discrete orientation positions serves the dual function of both automatically locking the implant to prevent expansion and collapse, and discretely orienting the implant on the inserter for implantation. The auto-lock feature reduces the steps required intraoperatively to successfully implant the device, potentially reducing cognitive load for the surgeon. The discrete orientations provided by the lock allow the surgeon to adapt to the approach that best suits the patient's anatomy.

[0051] Unlike static spacers, which only provide height restoration at discrete intervals, expandable implants are inserted into the disc space at a collapsed height and then expand axially to restore lost height within the disc space. The ability to expand in height upon implantation allows the surgeon to restore collapsed disc height at any height between the implant's starting height and its fully expanded height. Additionally, expandable interbody spacers maximize the volume within and around the device for graft material.

[0052] It should further be understood that various changes in the details, materials, and arrangements of parts described and illustrated to explain the nature of the invention may be made by those skilled in the art without departing from the scope of the invention as expressed in the claims. Those skilled in the art will appreciate that the above-described embodiments are non-limiting. It will also be understood that one or more features of one embodiment may be incorporated, in part or in whole, into one or more other embodiments described herein.

Claims

1. 1. An expandable intervertebral implant comprising: upper and lower major endplates configured to engage adjacent vertebrae; an actuation gear configured to adjust the height of the upper main endplate, the actuation gear coupled to the lower main endplate and engaged with the upper main endplate; an interface collar configured to be attached to an inserter instrument in multiple orientations for a desired surgical approach, the interface collar including multiple angled protrusions; an expansion and orientation lock configured to lock the orientation of the interface collar and lock the height of the upper major endplate, the lock being retained within the lower major endplate, the lock including a tapered outer surface having a plurality of notches defined therein configured to interface with the plurality of angled protrusions in the interface collar.

2. The expandable intervertebral implant of claim 1 , wherein the interface collar is free to rotate about a central axis of the expandable intervertebral implant.

3. The expandable intervertebral implant of claim 1 , wherein the interface collar is a split ring having a gap between opposing sides of the split ring.

4. The expandable intervertebral implant of claim 1 , wherein the interface collar includes a pair of eyelets defining a pair of openings therethrough.

5. 2. The expandable intervertebral implant of claim 1, wherein the lower major endplate includes a plurality of snap-fit ​​posts arranged in pairs defining a space therebetween, and the lock includes a plurality of guide rail posts configured to fit into the spaces between the snap-fit ​​posts, thereby guiding movement of the lock.

6. 6. The expandable intervertebral implant of claim 5, wherein an upper portion of the guide rail post protrudes upward from the lock and is configured to interact with a pocket below the actuation gear to constrain rotational movement of the actuation gear and prevent expansion and collapse of the expandable intervertebral implant.

7. 10. The expandable intervertebral implant of claim 1, wherein the lock includes a plurality of spring arms extending from a bottom surface of the lock, the spring arms urging the lock up and away from the lower major endplate in a disengaged state.

8. 2. The expandable intervertebral implant of claim 1, wherein the actuation gear includes a disk having a plurality of teeth projecting radially outward therefrom and a threaded central opening configured to threadably engage the upper major endplate.

9. The expandable intervertebral implant of claim 1 , wherein the upper major endplate includes an annular body having a bone-engaging surface and a downwardly projecting cylinder configured to mate with the actuation gear.

10. 10. The expandable intervertebral implant of claim 9, wherein the downwardly projecting cylinder of the upper major endplate includes an external thread and a vertical slot bisecting the external thread, and the lower major endplate includes a post receivable within the vertical slot.

Images