INTERVERTEBRAL DISC IMPLANTS AND METHODS FOR MANUFACTURING SAME

Description

[0001] The present invention relates generally to intervertebral disc implants.

[0002] As further background, a number of devices have been proposed for implantation within the spinal disc space. Many of these devices incorporate the use of an elastomeric material, for example a hydrogel. Such devices have also been proposed that can adopt a generally linear configuration for implantation through an aperture in the disc annulus, and a second, differing configuration once introduced into the disc space.

[0003] WO 03/028587, US 2002/0026244 and WO 03/051212 (the latter being prior art for the purposes of novelty only in accordance with Art. 54(3) EPC) all disclose intervertebral disc implants.

[0004] One challenge encountered in such devices is their ability to effectively transition to the desired conformation once implanted within the disc space. In addition, after taking on the desired conformation, the device must withstand the repeated loadings typically encountered in the spinal column. Aspects of the present invention address one or more of these and other needs for intervertebral disc implants.

[0005] The present invention differs from the prior art in accordance with Art. 54(3) EPC in that the implant has an elongate shape and a spiral-form relaxed configuration.

SUMMARY OF THE INVENTION

[0006] Accordingly, in one aspect, the present invention provides an intervertebral disc implant, comprising:

an elongate elastomeric polymer body sized for introduction into a disc space; and

an elongate superelastic element within the elastomeric body; wherein

the implant has a spiral-form relaxed configuration. In certain forms, such implants include an elongate hydrogel body having embedded therein an elongate superelastic metal element. The superelastic element can extend along substantially the entire length of the elongate body. In one specific embodiment, an implant is provided with an elongate core element comprised of a superelastic nickel-titanium alloy.

[0007] In another aspect of the invention there is provided a method for manufacturing an intervertebral disc implant, comprising:

providing an elongate superelastic element; and

incorporating the superelastic element within an elongate elastomeric polymer body sized for introduction within a spinal disc space; wherein the implant has a spiral-form relaxed configuration.

[0008] Methods of manufacturing an intervertebral disc implant may include providing a superelastic element, and providing a hydrogel or other similar elastomeric body around the element. Specific embodiments of these methods involve the manufacture of intervertebral disc implants as described herein.

BRIEF DESCRIPTION OF THE FIGURES

[0009] 

Figure 1 provides a perspective view of one intervertebral implant of the invention.

Figure 2 provides a perspective view of the implant of Figure 1 in a straightened configuration.

Figures 3A and 3B provide cross-sectional views of the implant of Figures 1 and 2 in a relatively non-swelled, and swelled state, respectively.

Figures 4-6 provide illustrations of steps that can be taken during introduction of intervertebral implants of the invention.

DETAILED DESCRIPTION

[0010] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to certain embodiments thereof and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations, further modifications and further applications of the principles of the invention as described herein being contemplated as would normally occur to one skilled in the art to which the invention relates.

[0011] As disclosed above, the present invention provides intervertebral disc implant devices and methods for their preparation.

[0012] In certain aspects of the invention, the body of the intervertebral implant can be formed of a hydrogel or other suitable elastomeric material. Water-soluble materials can be used, so that upon implantation with the disc space, the implant increases in volume.

[0013] As to hydrogel materials suitable for use in the invention, these include lightly cross-linked biocompatible homopolymers and copolymers of hydrophilic monomers such as 2-hydroxyalkyl acrylates and methacrylates, e.g., 2-hydroxyethyl methacrylate (HEMA); N-vinyl monomers, for example, N-vinyl-2-pyrrolidone (N-VP); ethylenically unsaturated acids, for example, methacrylic acid (MA) and ethylenically unsaturated bases such as 2-(diethylamino)ethyl methacrylate (DEAEMA). The copolymers may further include residues from non-hydrophilic monomers such as alkyl methacrylates, for example, methyl methacrylate (MMA), and the like. The cross-linked polymers are formed, by known methods, in the presence of crosslinking agents, such as ethyleneglycol dimethacrylate and methylenebis(acrylamide), and initiators such as 2,2-azobis (isobutyronitrile, benzoyl peroxide, and the like, and radiation such as UV and y-ray.

[0014] Methods for the preparation of these polymers and copolymers are well known to the art. The EWC of these hydrogels can vary, e.g., from about 38% for Polymacon^™ (poly HEMA) to about 79% for Lidofilcon^™ B (a copolymer of N-VP and MMA) under ambient conditions.

[0015] Another type of hydrogel, useful in the practice of the invention, is illustrated by HYPAN^™ and poly(vinyl alcohol) (PVA) hydrogels. These hydrogels, unlike the aforementioned hydrogels, are not cross-linked. Their insolubility in aqueous media is due to their partially crystalline structures. HYPANP^™ is a partially hydrolyzed polyacrylonitrile. It has a multiblock copolymer (MBC) structure comprising hard crystalline nitrile blocks, which provide the hydrogel with good mechanical properties, and soft amorphous hydrophilic blocks to provide the hydrogel with good water binding capability. The methods of preparing HYPAN^™ hydrogels of different water contents and mechanical properties have been disclosed in the U.S. Patents 4,337,327, 4,370,451, 4,331,783; 4,369,294; 4,420,589; 4,379,874 and 4,631,188. The pre-nuclear forms of this material, for use in this invention, can be prepared by melt processing using solvents such as DMF and DMSO, as melting aids or by solution processing.

[0016] One particular type of hydrogel useful in the practice of this invention is highly hydrolyzed crystalline poly(vinyl alcohol) (PVA). The amount of hydrolyzation may be between 95 and 100 percent depending on the desired EWC which will be from about 60% to about 90%. Generally, the final hydrogel water content increases with decreasing hydrolyzation of the initial PVA which results in decreased crystallinity.

[0017] Partially crystalline PVA hydrogels may be prepared, from commercially available PVA powders, by any of the methods known to the art. For example, they can be prepared by the method disclosed in the U.S. Patent 4,663,358, the teachings of which are incorporated herein by reference. Illustratively, 10-15% PVA powder can be mixed with a solvent, such as water, dimethyl sulfoxide (DMSO), ethylene glycol and mixtures thereof. The mixture is then heated at a temperature of about 100 to about 120°C, until a viscous solution is formed. The solution is then poured or injected into a tubular metal, glass or plastic mold and allowed to cool to below -10°C, preferably to about -20°C.

[0018] The solution is maintained at that temperature for several hours during which time crystallization and, therefore, gelation of the PVA occurs. The shaped gel is soaked with several portions of water which are periodically replaced, over a period of at least two days, until all the organic solvent in the gel has been replaced by water. The hydrated gel can then be partially or completely dehydrated for implantation. Hydrogels thus prepared can have EWC's between 60-90% and compressive strengths of at least 1 MNm^-2, preferably about 4 MNm^-2, when subject to the same constraints as the natural nucleus in an intervertebral disc.

[0019] Completion of the solvent exchange can be determined by known methods. For instance, when the solvent is DMSO its removal from the gel, is determined as follows: 50 µL of a 0.01 N KMnO₄ solution are added to 50 mL aliquots of the water which has been separated from the gels. The presence of DMSO in the water will be indicated by disappearance of the characteristic pink color of the KMnO₄. When the DMSO has been completely removed the pink color will not disappear. This method has a detection limit of 0.3 ppm, for DMSO, when compared to a blank and 0.3 ppm aqueous DMSO standard.

[0020] In general, any hydrogel that can be used for biomedical purposes can be used. In certain forms of the invention, the hydrogel will exhibit an EWC from about 30 to about 90% and a compressive strength of at least about 1 MNm^-2 preferably 4MNm^-2, when subjected to the constraints of the annulus and end plates of the disc. Shaped implants from these materials, e.g. a rod or tube, in a dehydrated form (xerogels), can be prepared either by cast molding or lathe cutting. In cast molding, the liquid monomer mixture, with initiator, is poured into a mold of predetermined shape and size, and cured. If desired, the casting mixture may include water, or another aqueous medium. Under those circumstances the resultant shaped article will be partially hydrated, i.e., a hydrogel. In the case of lathe cutting, the xerogel can be prepared, in a similar manner to the above, in the form of a block or rod which is larger than needed to form the prosthetic nucleus. The xerogel is then cut to the shape and size required for implantation into the disc cavity. In both cases, the hydrogel expansion factor, due to polymer swelling upon hydration, has to be taken into account in designing the mold or in cutting the block, rod or tube.

[0021] The invention provides implants that incorporate an internal or core element comprised of a superelastic material. In one illustrative example, such implants can be prepared by molding or casting the elastomeric (e.g. hydrogel) polymer body around the superelastic element.

[0022] Superelastic materials are known to exhibit unusual elasticity and flexibility. These materials also typically exhibit a shape memory effect. When plastically deformed from an original shape at one temperature, the materials will recover their original shape on being raised to a higher temperature.

[0023] Superelastic materials are known to undergo a transformation known as martensitic transformation, wherein they change from a high temperature form called austenite, to a low temperature form called martinsite. For a given superelastic alloy, the transformation between martinsite and austenite forms occurs at a predictable temperature, known as the transformation temperature.

[0024] As to these temperature dependent properties, to exhibit a shape memory effect, constructs of superelastic alloys must first be bent into a shape to be "memorized" at room temperature. The alloy element is then heated until it assumes a high temperature configuration called the beta or parent phase. In this phase, the crystal structure of the metal assumes its austenite form which it will "remember". Afterwards, the alloy is rapidly cooled such that the atoms in the alloy rearrange themselves into the crystal form of martensite. The alloy can then be bent into a new shape which it will maintain as long as the temperature remains below the transformation temperature. Subsequent heating of the element above its transformation temperature so that the alloy structure reverts to an austenite form will cause the element to recover its previously memorized shape.

[0025] Intervertebral implants of the invention can be manufactured so as to utilize these shape memory properties of superelastic materials. For instance, shape memory properties of the superelastic element can facilitate the transition of an intervertebral disc implant from a first configuration during introduction, to a second configuration after introduction and upon reaching the body temperature of the patient. Alternatively or in addition, these temperature-dependent shape memory properties can provide a residual force within the implant in its second, implanted configuration, to stabilize the implant in that configuration.

[0026] Illustratively, a superelastic material with a transformation temperature between a relatively lower temperature at which the implant will be introduced and a higher temperature of the patient's body can be used. A superelastic element (e.g. an elongate wire or similar element) can be shaped to the second, implanted configuration (e.g. a spiral), and heated until its the crystal structure assumes its austenite, "memorized" form. After cooling to form the martensite crystal form, the superelastic element can be bent to straighten it, and then the elastomeric body provided around the superelastic element, such as by molding or casting a hydrogel body around the element. Thereafter, upon introduction, the superelastic element will be heated by the patient's body heat to a temperature above its transformation temperature, and thus revert to its second, implanted configuration. It will be understood in this regard that such shape memory effects can also be used in conjunction with the superelastic, temperature-independent properties to facilitate transition between the first and second configurations.

[0027] In another illustrative embodiment using a superelastic material having an intermediate transformation temperature as described above, the superelastic element can be used to further stabilize the implant in its second, implanted configuration. For instance, for implanted configurations, such as spiraled or folded shapes, wherein two portions of the implant will contact one another, the shape memory properties of the superelastic element can be used to forcibly maintain that contact and thus stabilize the final configuration.

[0028] In a specific exemplary embodiment, an elongate superelastic element can be formed to a spiral somewhat tighter or more acute than that to be found in the final, implanted configuration, and then heated to introduce memory of that form, and cooled. The spiral element can then be bent to a less acute form approximating that desired in the implanted configuration, and then an elongate hydrogel body provided (e.g. molded or cast) around and following the spiral element. For introduction, the spiral-form implant can be forcible straightened. Upon introduction, the implant will relax to its implanted configuration with portions contacting one another, and then the superelastic element will be heated by the patient's body heat to a temperature above its transformation temperature, thus providing a residual, lasting force the maintain the contact points in the implant.

[0029] As noted above, superelastic materials also have useful temperature independent properties. Superelastic alloys exhibit significantly increased resiliency relative to non-superelastic materials, because the atoms of the memory metal shift back and forth between martinsite and austenite forms, and do not slip into new dislocated configurations as is the case with normal metals. In an alloy that has a beta phase capable of producing martinsite under stress, an unusual elastic property called superelasticity is observed. Typically alloys with this property exhibit normal elastic behavior under stress until a critical stress is reached, at which point martinsite molecular structures begin to form. With further stress, the element continues to elongate as if it were being physically deformed. Upon removal of the stress, the martinsite structure reverts to the parent phase, or austenite structure, and the metal contracts to its original dimensions, showing substantially no permanent deformation.

[0030] In a specific embodiment, the superelastic material can be a nickel-titanium alloy such as that commercially available as Nitinol.

[0031] With reference now to Figure 1, shown is a perspective view of one intervertebral disc implant of the present invention. Implant 11 includes elastomeric body 12 made of a polymeric material, particularly a hydrogel. Embedded within body 12 is a core element 13 made of a superelastic material, such as a superelastic nickel-titanium alloy. Implant 11 has a height H and a width W suitable for implantation within the disc space defined by a disc annulus.

[0032] With reference now to Figure 2, shown is implant 11 of Figure 1 in a linear or straightened configuration. As shown, both elastomeric body 12 and superelastic core element 13 are in a relatively linear configuration, rendering the device to a convenient state for passage through a cannula and into the disc space.

[0033] With reference to Figures 3A and 3B, shown are cross-sectional views of the device of Figure 2. In Figure 3, implant body 12 is formed of a hydrogel which is dehydrated or only partially hydrated, therefore having a relatively smaller cross-sectional dimension. Shown in Figure 4 is the same implant body 12 having a more or completely hydrated form and thus a larger cross-sectional dimension. As will be understood, the implant in the completely or partially dehydrated state as shown in Figure 3 will be more readily passed through a smaller cannula and smaller opening in the disc annulus, for delivery to the disc space. Thereafter, implant 11 will take up water and swell to a larger dimension.

[0034] With reference to Figures 4-6, generally shown are steps to be taken in one procedure of implantation In a first step, the disc annulus 20 is provided with one or more openings into the interior disc space 21. These openings can be provided, for example, by a cutting or dissecting instrument such as a scalpel. In addition, it will be understood that an access cannula, such as a tissue retraction cannula, and be provided extending to the one or more openings, through which other surgical instruments as discussed herein can be manipulated.

[0035] A tissue disrupting instrument 22 is used to disrupt nucleus tissue from within the disc space 21, which tissue can optionally be withdrawn under vacuum. An endoscope 23 or other visualization device extending through opening 25 in disc annulus 20 can be used to visualize the disc space. Referring to Figure 5, after any removal of material desired from the disc space 21, an introducer cannula 26 is inserted through opening 24, and implant 11 is passed through cannula 26 and delivered into the disc space 21. Referring now to Figure 6, shown is implant 11 having taken on its implanted configuration in a generally coiled or spiral shape. After introduction of the implant 11, delivery cannula 26 can be withdrawn, and endoscope 23 can also be withdrawn, along with any access cannula(s) utilized in the surgery. If desired, openings 24 and 25 in annulus 20 can be patched or sealed with suitable materials therefor.

[0036] In one embodiment of the invention, implant 11 is provided in a kit or system along with at least one other device for use in the disc surgery, for example, delivery cannula 26, visualization device 23, tissue disruption device 22, access cannula(s), etc. Any combination of some or all of these and/or other devices along with implant 11 can be incorporated into a surgical kit or system in accordance with the invention.

[0037] Further, implants of the invention can have one or more implant bodies having any of a wide variety of shapes or configurations. As several specific illustrations, superelastic core elements, e.g. corresponding to core element 13 disclosed herein, can be incorporated into the implant bodies and shapes disclosed in U.S. Patent No. 6,620,196 issued September 16, 2003 and assigned to SDGI Holdings Inc., and can be adapted to facilitate transition of the implants to an intended implanted configuration and/or stabilize the implants in such configuration.

[0038] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the scope of the invention as defined by the claims are desired to be protected.

Claims

1. An intervertebral disc implant, comprising:

an elastomeric polymer body (12) sized for introduction into a disc space; and

a superelastic element (13) within the elastomeric body;

wherein said elastomeric polymer body and said superelastic element are elongate and

the implant has a spiral-form relaxed configuration.

2. The intervertebral disc implant of claim 1, wherein the elastomeric polymer body is water-swellable.

3. The intervertebral disc implant of claim 2, wherein the elastomeric polymer body comprises a hydrogel.

4. The intervertebral disc implant of any of claims 1-3, wherein the superelastic element comprises a superelastic metal alloy.

5. The intervertebral disc implant of claim 4, wherein the superelastic metal alloy is a nickel-titanium alloy.

6. The intervertebral disc implant of claim 1, wherein the implant is forcibly configurable to a substantially straight configuration.

7. A method for manufacturing an intervertebral disc implant, comprising:

providing an elongate superelastic element (13); and

incorporating the superelastic element within an elongate elastomeric polymer body (12) sized for introduction within a spinal disc space; wherein the implant has a spiral-form relaxed configuration.

8. The method of claim 7, wherein the elastomeric polymer body is water-swellable.

9. The method of claim 8, wherein the elastomeric polymer body comprises a hydrogel.

10. The method of claim 9 , which comprises molding the hydrogel around the superelastic element.

11. The method of any of claims 7 to 10, wherein the superelastic element comprises a superelastic metal alloy.

12. The method of claim 11, wherein the superelastic metal alloy is a nickel-titanium alloy.

13. The method of claim 7, wherein the implant is forcibly configurable to a substantially straight configuration.

14. A system for treating an intervertebral disc, comprising:

an intervertebral disc implant according to any of claims 1 to 6; and

at least one additional device for treating the intervertebral disc.

15. The system of claim 14, wherein said additional device includes one or more of an endoscope, a tissue disrupting device, a tissue dissection device, and a tissue retraction cannula.

Ansprüche

1. Bandscheibenimplantat, umfassend:

einen elastomeren Polymerkörper (12), dimensioniert zur Einsetzung in einen Bandscheibenraum; und

ein superelastisches Element (13) in dem elastomeren Körper, wobei der elastomere Polymerkörper und das superelastische Element länglich sind und das Implantat eine spiralförmige entspannte Konfiguration aufweist.

2. Bandscheibenimplantat nach Anspruch 1, wobei der elastomere Polymerkörper in Wasser quellbar ist.

3. Bandscheibenimplantat nach Anspruch 2, wobei der elastomere Polymerkörper ein Hydrogel umfasst.

4. Bandscheibenimplantat nach einem der Ansprüche 1 bis 3, wobei das superelastische Element eine superelastische Metalllegierung umfasst.

5. Bandscheibenimplantat nach Anspruch 4, wobei die superelastische Metalllegierung eine Nickel-Titan-Legierung ist.

6. Bandscheibenimplantat nach Anspruch 1, wobei das Implantat mit Zwang in eine im Wesentlichen geradlinige Konfiguration konfigurierbar ist.

7. Verfahren zum Herstellen eines Bandscheibenimplantats, umfassend:

Bereitstellen eines länglichen superelastischen Elements (13); und

Einfügen des superelastischen Elements in einen länglichen elastomeren Polymerkörper (12), der zur Einführung in einen Bandscheibenraum dimensioniert ist, wobei das Implantat eine spiralförmige entspannte Konfiguration aufweist.

8. Verfahren nach Anspruch 7, wobei der elastomere Polymerkörper in Wasser quellbar ist.

9. Verfahren nach Anspruch 8, wobei der elastomere Polymerkörper ein Hydrogel umfasst.

10. Verfahren nach Anspruch 9, welches die Formung des Hydrogels um das superelastische Element herum umfasst.

11. Verfahren nach einem der Ansprüche 7 bis 10, wobei das superelastische Element eine superelastische Metalllegierung umfasst.

12. Verfahren nach Anspruch 11. wobei die superelastische Metalllegierung eine Nickel-Titan-Legierung ist.

13. Verfahren nach Anspruch 7, wobei das Implantat mit Zwang in eine im Wesentlichen geradlinige Konfiguration konfigurierbar ist.

14. System zum Behandeln einer Bandscheibe, umfassend:

ein Bandscheibenimplantat gemäß einem der Ansprüche 1 bis 6; und zumindest eine zusätzliche Vorrichtung zum Behandeln der Bandscheibe.

15. System nach Anspruch 14, wobei die zusätzliche Vorrichtung eines oder mehrere von Folgendem einschließt:

ein Endoskop, eine Gewebsdisruptionsvorrichtung, eine Gewebsdissektionsvorrichtung und eine Gewebsretraktionskanüle.

Revendications

1. Implant de disque intervertébral, comprenant :

- un corps polymère élastomère (12) dimensionné pour une introduction dans un espace de disque ; et

- un élément superélastique (13) à l'intérieur du corps élastomère, ledit corps polymère élastomère et ledit élément superélastique étant allongés et l'implant ayant une configuration relâchée en forme de spirale.

2. Implant de disque intervertébral selon la revendication 1, dans lequel le corps polymère élastomère est apte à gonfler dans l'eau.

3. Implant de disque intervertébral selon la revendication 2, dans lequel le corps polymère élastomère comprend un hydrogel.

4. Implant de disque intervertébral selon l'une quelconque des revendications 1-3, dans lequel l'élément superélastique comprend un alliage métallique superélastique.

5. Implant de disque intervertébral selon la revendication 4, dans lequel l'alliage métallique superélastique est un alliage nickel-titane.

6. Implant de disque intervertébral selon la revendication 1, dans lequel l'implant est configurable à force dans une configuration sensiblement droite

7. Procédé de fabrication d'un implant de disque intervertébral, comprenant les opérations consistant à : se procurer un élément superélastique allongé (13) ; et incorporer l'élément superélastique à l'intérieur d'un corps polymère élastomère allongé (12) dimensionné pour une introduction à l'intérieur d'un espace de disque spinal ; l'implant ayant une configuration relâchée en forme de spirale.

8. Procédé selon la revendication 7, dans lequel le corps polymère élastomère est apte à gonfler dans l'eau.

9. Procédé selon la revendication 8, dans lequel le corps polymère élastomère comprend un hydrogel.

10. Procédé selon la revendication 9, qui comprend le moulage de l'hydrogel autour de l'élément superélastique.

11. Procédé selon l'une quelconque des revendications 7 à 10, dans lequel l'élément superélastique comprend un alliage métallique superélastique.

12. Procédé selon la revendication 11, dans lequel l'alliage métallique superélastique est un alliage nickel-titane.

13. Procédé selon la revendication 7, dans lequel l'implant est configurable à force dans une configuration sensiblement droite.

14. Système de traitement d'un disque intervertébral comprenant :

- un implant de disque intervertébral selon l'une quelconque des revendications 1 à 6 ; et

- au moins un dispositif supplémentaire pour traiter le disque intervertébral.

15. Système selon la revendication 14, dans lequel ledit dispositif supplémentaire comprend l'un ou plusieurs parmi un endoscope, un dispositif de rupture de tissu, un dispositif de dissection de tissu, et une canule de rétractation de tissu.

Drawing