Minimally invasive vertebral anchor access system and associated method

[0001] This invention relates generally to spinal fixation devices and more specifically relates to a system and associated method for minimally invasive installation of vertebral anchors and connecting elements of spinal fixation constructs.

[0002] The human spinal column is a highly complex system of bones and connected tissues that provide support for the body and protects the delicate spinal cord and nerves. The spinal column includes a series of vertebrae stacked one atop the other. Each vertebral body includes a relatively strong cortical bone portion forming the outside surface of the body and a relatively weak cancellous bone portion forming the center of the body. An inter-vertebral disc is situated between each vertebral body that provides for cushioning and dampening of compressive forces applied to the spinal column. The vertebral canal containing delicate spinal cords and nerves is located just posterior to the vertebral bodies.

[0003] A variety of types of spinal column disorders may be caused by abnormalities, disease, trauma or the like and result in debilitating pain as well as diminished nerve function in many cases. One known technique to address many such spinal conditions is commonly referred to as spinal fixation. Surgical implants are used for fusing together and/or mechanically immobilizing adjacent vertebrae of the spine. Spinal fixation may also be used to improve the position of the adjacent vertebrae relative to one another so as to alter the overall alignment of the spine. Such techniques have been used effectively to treat many spinal conditions and to relieve pain suffered by the patient.

[0004] One particular spinal fixation technique includes immobilizing the spine by using orthopedic spine rods which run generally parallel to the spine. This is accomplished by exposing the spine posterially and fastening hooks or bone screws to the pedicles of the appropriate vertebrae. The vertebral anchors or screws are generally placed two per vertebrae, one at each pedicle on either side of the spinal column and serve as anchor points for the spine rods. The aligning influence of the rods forces the spine to conform to a more desirable shape. In many cases, the spine rods are bent to achieve the desired curvature of the spinal column.

[0005] Installation of such spinal fixation constructs conventionally requires a surgeon to prepare a long incision aligned with the spinal column of a patient. The pedicle screws, hooks or other vertebral anchors are then attached to a number of vertebrae after which the spine rod is located with respect to saddles or U-shaped channels attached to the vertebral anchors. The spine rod is then bent to match the relative position of the anchor heads. Visualization of the accuracy of the alignment of the spine rod and the anchor heads may be difficult because of visual interference from tissue and blood in the surgical field. Conventional surgical methods require a large midline incision and retraction of skin, muscle and other tissue to provide the surgeon with sufficient visualization of the pedicle bone structure.

[0006] The accuracy of the placement and configuration of the spine fixation elements are very important. In combination with the relatively long incision required for the installation of the fixation construct, extended surgical procedures and related difficulties or complications are generally recognized as major contributing influences for extended patient recovery and less than optimal spinal fixation results.

[0007] This invention addresses these and other shortcomings in the prior art. The devices and methods associated with this invention are used to aid in the surgery for vertebral stabilization using pedicle hooks, screws, anchors and fixation components.

[0008] According to various embodiments of this invention, vertebral anchors such as pedicle screws are inserted into the target vertebrae of a patient's spinal column. The pedicle screw may be cannulated for proper positioning and installation. In one aspect, this invention provides an access system which involves a pedicle screw with an extension member adapted to be coupled to the anchor and extend percutaneously from the spine. The surgical procedure associated with this invention involves making small, discrete incisions for the placement of select pedicle screws. The extension members on the pedicle screws retract soft tissue, muscle and the like to thereby provide the surgeon visibility and access to the head of the pedicle screw. Through the extension member, instrumentation such as a spine rod, set screw and other required hardware may be delivered to the pedicle screws.

[0009] In another aspect of this invention, a deformation arrangement is used to couple the extension member to the anchor head. In one embodiment, the deformation arrangement is a flange on one end of the extension member and one or more slits in the flange allow the flange to expand when being installed and removed from the anchor head.

[0010] Once the extension member is secured on the anchor, a restrictor is coupled to the flange to inhibit expansion of the deformation arrangement and maintain secure placement of the extension member on the anchor while the spinal fixation construct is being installed or serviced. The extension members for each pedicle screw extend beyond the surface of the skin (i.e., percutaneously) thereby retracting soft tissue and muscle enabling the surgeon to install the spinal fixation construct with smaller discrete incisions as opposed to an extended incision. As such, a more minimally invasive surgical procedure can be accomplished with this invention thereby allowing for visualization of the installation components during the surgery and promoting patient recovery post-surgery.

[0011] As a result of these and other aspects of this invention, increased efficiency and accuracy is provided for installation of a spinal fixation construct in a minimally invasive atmosphere thereby promoting patient recovery and optimum spinal surgery results.

[0034] Referring to the Figs., various embodiments of a minimally invasive spinal fixation construct 10 and associated installation method are shown. In FIG. 1, the spinal fixation construct 10 includes a number of vertebral anchors 12 which in one embodiment are each pedicle screw assemblies, each of which is inserted into selected vertebrae 14 of a patient. The pedicle screw assemblies 12 are joined together in the spinal fixation construct by a connecting element 16 which in one embodiment is a spine rod. The connecting element 16 may be something other than a rigid rod according to alternative embodiments of this invention. According to various aspects of this invention, the individual pedicle screw assemblies 12 may be inserted into the patient through discrete and often individual incisions 18 in the patient's skin 20. In certain instances, a single incision 18 may be available to provide installation of multiple pedicle screw assemblies 12 in adjacent vertebrae 14. The small, discrete incisions 18 provide the opportunity for insertion of a cannulated pedicle screw via a K-wire (not shown) inserted through the incision 18 to the precise location on the vertebrae 14 for proper installation of the pedicle screw 12. While cannulated and other pedicle screw assemblies are shown and described herein, one of ordinary skill in the art will appreciate that other types of vertebral anchors and vertebrae engaging mechanisms can be utilized such as hooks for anchoring the connecting element 16 to the patient's spinal column.

[0035] As shown generally in FIGS. 1 and 5-8, a vertebral anchor 12 according to one embodiment of this invention includes a pedicle screw 12 having a threaded shaft 20 and a distal tip 22 for insertion and stable positioning into the pedicle area of the patient's vertebrae 14. The pedicle screw 12 shown herein is a polyaxial pedicle screw in which a polyaxial body 24 mounted opposite from the distal tip 22 of the screw 12 to a screw head 26 provides for a variety of orientations of the polyaxial body 24 relative to longitudinal axis of the screw 12 as is common with many pedicle screw systems. The polyaxial body 24 coupled to the pedicle screw head 26 includes a saddle or U-shaped channel 28 (FIGS. 19-20) formed between a pair of spaced arms 30 extending upwardly. The polyaxial body 24 is adapted to receive the spine rod 16 in the saddle or U-shaped channel 28 and the spine rod 16 is securely retained by the polyaxial body 24 via a fastener such as a set screw 32 (FIG. 8) threadably received therein as is common with many known pedicle screw systems.

[0036] One aspect of various embodiments of this invention includes an extension member 34 projecting upwardly from the vertebral anchor head 24 as shown in FIGS. 1 and 5-8. Due to the relative position and configuration of the extension members 34 on the vertebral anchors 12 according to embodiments of this invention, slots 36 are provided and in communication with the U-shaped channel or saddle 28 of the anchor head 24. Advantageously, the extension members 34 project through the incision 18 such that a proximal end 38 of the members 34 is located percutaneously above the patient's skin when the anchor 12 is inserted into the vertebrae 14 as shown in FIG. 1.

[0037] One embodiment of an extension member 34 according to this invention is shown particularly in FIGS. 1-8. The extension member 34 is elongate and adapted to extend percutaneously from the body when the anchor 12 is secured to the patient's vertebrae 14. The elongate extension member 34 in this embodiment is an elongate tubular sleeve having a generally arcuate sidewall 40 with a generally circular cross-sectional configuration. The extension member 34 has a first more distal end 42 adapted to be coupled to the anchor head 24 and the second or proximal end 38 adapted to be positioned percutaneously for access to the anchor head 24 through a lumen 44 formed by the arcuate sidewall 40 of the extension member 34. The first end 42 of the extension member 34 includes a flange 46 having an enlarged diameter relative to the sidewall 40 of the extension member 34. As shown most clearly in FIGS. 2-4, the flange 46 has an upper and a lower portion 46a, 46b with a shoulder 48 formed in between them. A beveled rim 50 forms a transition from the flange 46 to the sidewall 40 of the extension member 34. As shown in FIGS. 2 and 3, the extension member 34 includes a full-length slot 36a and a distal slot 36b positioned diametrically opposite from the full-length slot 36a. Both of the slots 36a, 36b are in communication with the distal end 42 of the extension member 34.

[0038] Referring particularly to FIGS. 5 and 6, a socket 52 is formed on the interior of the flange 46 and is sized and configured to meet with the anchor head 24 when the extension member 34 is mounted to the anchor 12. In this embodiment of the invention, the socket 52 has a generally upwardly tapered configuration with a throat or entry region 54 being more narrow than the upper portion of the socket 52. This contour corresponds to the contour of the anchor head 24 thereby providing a snug and secure mating relationship as shown generally in FIG. 6.

[0039] One aspect of the extension member 34 according to this embodiment of the invention is one or more slits 56 in the flange 46 which allow the flange 46 to temporarily expand or deform while the extension member 34 is being coupled to or uncoupled from the anchor 12. As shown most clearly in FIGS. 2-4, the flange 46 includes a number of minor slits 56a which have a main portion 58 angled relative to the longitudinal axis of the extension member 34 and terminate in the lower portion 46b of the flange with a hook 60. One or more major slits 56b are also provided in the flange 46 and the major slits include a main portion 58 similar to the configuration of the minor slits. The major slits each also include an adjoining hook portion 60. The minor slits 56a terminate with the hook portion 60 whereas the major slits 56b include an angled portion 62 projecting from the hook portion 60. The angled portion 62 transitions the major slit 56b through the shoulder 48 of the flange 46. The major slit 56b terminates in a keyhole-shaped configuration 64 which is aligned generally with the longitudinal axis of the extension member 34 (FIG. 4). In alternative embodiments, any number and/or configuration of sized or shaped slits can be used to provide for the desired deflection characteristics.

[0040] The major and minor slits 56ab, 56a allow the flange 46 of the extension member 34 to temporarily expand as the throat 54 of the extension member 34 passes over the outwardly tapered proximal portion 66 of the anchor head 24. Continued downward movement of the extension member 34 as shown in FIG. 5 allows the larger diameter proximal portion 66 of the anchor head 24 to enter into the larger diameter portion of the socket 52 in the flange 46 and the reduced neck region 68 of the anchor head 24 seats within the reduced diameter throat 54 of the flange 46. The slits 56 allow the flange 46 to expand outwardly as shown in FIG. 5 until the anchor head 24 is seated within the socket 52 as shown in FIG. 6. At that time, the slits 56 allow the flange 46 on the extension member 34 to relax into a mating configuration with the anchor head 24.

[0041] While the portion 66 of the anchor head 24 and the socket 52 are shown and described as having tapered, mating configuration, other configurations and designs are envisioned within the scope of this invention to provide a retained fit between the extension member 34 and the anchor head 24.

[0042] Another aspect of this embodiment of the invention is a restrictor 70 which when selectively coupled to the extension member 34 inhibits deformation of the flange 46. In one embodiment, the restrictor 70 is an elongate collar which telescopically fits downwardly around the sidewall 40 of the extension member 34. As shown in FIG. 6, the collar or restrictor 70 includes an internal cavity 72 sized and configured to mate with the upper portion of the flange 46a and the lowermost edge 74 of the collar seats upon the shoulder 48 of the flange 46 as shown in FIG. 7. With the collar 70 mated onto the extension member 34, expansion of the flange 46 is restricted thereby adding to the secure mating relationship of the extension member 34 on the anchor 12. The collar 70 inhibits the flange 46 from expanding and restricts the slits 56 from expanding. The upper end of the collar 70 may extend percutaneously through the incision 18 as shown in FIG. 1. The collars 70 may include slots 76 corresponding to the orientation, size and configuration of the slots 36 in the extension members 34. When the collars 70 are telescopically mated with the extension members 34, the slots 36, 76 in the respective components are aligned.

[0043] Referring to FIGS. 9-21, a second embodiment of this invention is shown. This embodiment of the invention also includes an extension member 34 adapted to be coupled to the head 24 of the anchor 12 to provide access for the surgeon during installation of the spinal fixation construct 10. The extension member 34 of this embodiment also utilizes a restrictor 70 to inhibit expansion or deformation of the flange 46 on the extension member 34 coupled to the anchor head 12.

[0044] As shown in FIGS. 9-11, the extension member 34 includes the full-length slot 36a and two partial-length slots 36b, 36c each extending from opposite ends of the extension member 34 (FIG. 10). Moreover, the flange 46 according to this embodiment of the extension member includes the lower portion 46b and shoulder 48. However, the upper portion of the flange 46a does not extend around the entire circumference of the sidewall 40 and is formed in two diametrically opposite sections 46a, 46a which extend upwardly from the shoulder48 . A major slit 56b extends through each of the upper flange portions 46a as shown in FIGS. 9 and 11. Moreover, notches 78 are provided in the flange 46 to separate the flange 46 into downwardly projecting lugs 80 formed between the notches 78. The major slit 56b originates in one of the notches 78 and projects through the upper portion of the flange 46a and into the sidewall 40 of the extension member 34 as shown in FIGS. 9 and 11. The peripheral rim 50 of the upper portion of the flange 46a is undercut as shown most clearly in FIG. 10. The undercut rim 50 of the upper flange portion 46a extends around the entire perimeter of that component.

[0045] The restrictor 70 according to this embodiment of the invention is shown particularly in FIGS. 12 and 13. The restrictor 70 is provided in two distinct members, one identical with the other. The restrictor 70 has a generally L-shaped configuration with an upper tab 82 projecting generally perpendicular from the major body portion 84 of the restrictor 70. The restrictor 70 has a lower enlarged yoke portion 86 at an opposite end from the tab 82. The yoke portion 86 includes a U-shaped recess 88 providing a bifurcated configuration to the yoke 86. The U-shaped recess 88 is bounded by a sloped edge go which is sized and configured to mate with the tapered rim 50 of the upper portion of the flange 46a to form a dove tail or rabbet joint as shown in FIGS. 13-16. A pair of the restrictors 70 on diametrically opposite sides of the extension member 34 and are each aligned with the one of the upper flanges 46a, 46a and inserted downwardly as shown in FIG. 19 until the U-shaped recess 88 of each restrictor 70 is seated on the associated upper flange portion 46a of the extension member 34. The configurations of the rim of the upper flange 46b and the U-shaped recess edge go provide positive locking engagement in the form of a rabbet or miter joint (FIG. 14) to thereby inhibit expansion of the extension member 34 after it is seated upon the anchor head 24 as shown in FIG. 20. In alternative embodiments, the restrictors 70 may be modular relative to extension member 34 or integrated as a single functioning assembly or unit and may utilize a variety of mating geometries, not just a dovetail or rabbet joint.

[0046] Similar to other previous described embodiments of this invention, once the extension member 34 and restrictors 70 are seated on the anchor head 24, the connecting member 16 in the form of a spine rod may be inserted through the lumen 44 formed in the extension member 34 toward the anchor head 24 for installation onto the vertebral anchors 12 on the spinal fixation construct 10. The set screw 32 may subsequently be inserted through the lumen 44 for mating with the anchor 12 as shown in FIG. 21.

[0047] One advantage provided by this invention is shown generally in FIG. 1. With the pedicle screws 12 inserted into the appropriate vertebrae 14, the extension members 34 project from the screw assemblies 12 percutaneously. The enhanced visualization and access afforded by the percutaneous positioning of the extension members 34 in the general orientation of the associated anchors 12 is a significant advantage for the accurate and precise positioning of the spinal fixation components. Referring to FIGS. 8 and 21, the spine rod 16 may be inserted through the slots and into the saddles 28 of the anchors 12. This may be accomplished with incisions 18 which are adjacent to the pedicle screw assemblies 12 as shown in FIG. 1. The access slots provided in the extension member 34 and the restrictors 70 provide communication between the various adjacent pedicle screw assemblies 12 so that the spine rod 16 may be inserted into the saddles 28 of the anchor heads 24 in a minimally invasive and less disruptive procedure than previously realized.

[0048] Once the set screws 32 are installed in the anchor heads 24, the restrictors 70 and then the extension members 34 can be removed from the anchors 12 and out of the patient through the incisions 18. The slits 56 allow for expansion of the flange 46 once the restrictor 70 is removed to permit the anchor head 24 removal from the socket 52.

[0049] As a result, a more minimally invasive spinal fixation construct installation procedure is provided by the pedicle screw assemblies, collars and associated devices of this invention without the need for extended incision and associated difficulties. Moreover, increased visualization and minimally invasive disruption are realized with this invention.

[0050] From the above disclosure of the general principles of this invention and the preceding detailed description of at least one embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.