Rod to rod cross connector

[0001] The present invention relates generally to systems for stabilization and fixation the spine, and more particularly to an assembly for rigidly connecting two spinal rods together using one or more actuators in an arrangement that distributes clamping forces uniformly to the rods, and minimizes the transverse width of the assembly.

[0002] When performing a lateral or anterolateral corpectomy, the diseased or damaged vertebral body and adjacent disc are removed. Removal of the vertebral body and disc leaves a void in the spinal column. Therefore, a vertebral body replacement (VBR) device is placed into the void to provide support to the spinal column. Although the VBR device provides support, the spinal column can still be unstable, particularly in torsion or bending maneuvers. Therefore, surgeons often place a dual rod construct or other stabilization system over the affected level to provide additional stability. In a dual rod construct, pedicle screws are placed in the spine. Two rods are placed into the pedicle screws in parallel arrangement, and locked into the pedicle screws with set screws or other locking mechanisms.

[0003] The dual rod construct provides great stability in bending motions, but the spine can still be unstable in response to torsional movement. Therefore, additional devices are needed improve torsional stiffness. Various devices have been developed for rigidly connecting two spinal rods together to increase the stiffness of paired rods. These devices, sometimes referred to as rod to rod connectors, typically feature two or more set screws that must be tightened to connect the device to the rods. Each set screw must be tightened to connect the device to each rod. Tightening set screws can be tedious and time consuming, particularly when multiple rod to rod connectors are being connected to the rods.

[0004] U.S. Pat. No. 7,717,938 describes a rod to rod connector that utilizes a single set screw to connect both rods together. The rod to rod connector has an elongate body with two recesses for receiving rods. As the set screw is advanced into the elongate body, the set screw pushes two engagement members outwardly against the two rods. The set screw is advanced until the engagement members lock the rods in the recesses. The single set screw reduces the number of set screws on the connector by one, thereby reducing the amount of time and effort devoted to tightening set screws. Nevertheless, the device has a relatively large footprint due to the transverse width of the assembly. The elongate body must have a center portion large enough to contain not only the set screw, but also the two engagement members in a side by side fashion (see FIG. 1B). This adds to the overall transverse width of the assembly, which is not desirable. The placement of the engagement members inside the central body also limits the axial width of the engagement members, as they can only be as wide as the central body. If the central body is narrow, then the engagement members must be even narrower. If the engagement members are too narrow, they may not grip a large enough area of the rod to securely engage the rod.

[0005] The drawbacks of conventional rod to rod cross connectors are resolved in many respects by rod to rod cross connectors in accordance with the present invention. Rod to rod connectors in accordance with the invention may include a central body and one or more actuators. The central body may be coupled to a first lever and a second lever. The first lever may include a free end separated from the central body by a first channel. The second lever may also include a free end separated from the central body by a second channel. The one or more actuators may be operable to pivot the first and second levers into a relatively closed position. When the first and second levers are in the relatively closed position, the free ends of the first and second levers are moved toward one another and toward the central body to contract the first and second channels. Drawing the first and second levers toward one another reduces the transverse width of the assembly, resulting in a smaller footprint after it is implanted.

[0013] The term “axial”, as used herein, means a direction parallel to the longitudinal axis defining a rod receiving channel in a rod to rod connector. For example, dimensions 191A and 191B in FIG. 2 extend in the axial direction and are referred to as axial widths. The long dimensions of pins 190A and 190B in FIG. 1 are also examples of dimensions extending in the axial direction relative to rod to rod connector 100.

[0014] The term “transverse”, as used herein, means a direction perpendicular to the axial direction and parallel to a plane passing through the longitudinal axes of both rod channels. For example, dimension 121 in FIG. 3 extends in the transverse direction and is referred to herein as a transverse width.

[0015] Rod to rod cross connectors in accordance with the invention feature a central body and one or more clamping mechanisms that apply forces on rods to be connected. The clamping mechanism(s) apply forces on each rod in a direction toward the central body, so as to pull the rods into the central body, rather than push the rods outwardly and away from the central body. One or more actuators are used to engage the clamping mechanism(s) and apply force to the rods.

[0016] In a preferred embodiment, the cross connector may include a central body and one or more actuators. A first lever and a second lever may be coupled to the central body. The first lever may include a free end separated from the central body by a first channel. The second lever may also include a free end separated from the central body by a second channel. The one or more actuators may be operable to pivot the first and second levers into a relatively closed position. When the first and second levers are in the relatively closed position, the free ends of the first and second levers are moved toward one another and toward the central body to contract the first and second channels. Drawing the first and second levers toward one another reduces the transverse width of the assembly, as noted above.

[0017] The one or more actuators may consist of a single actuator. The central body may form a bore, and the actuator may be disposed in the bore. The actuator may include a first thread, and the bore may include a second thread. The actuator may be disposed in the bore with the first thread engaged with the second thread.

[0018] The actuator may include a shaft. In addition, the actuator may include a flange extending radially outwardly from the shaft. The actuator may also include a head extending radially outwardly from the shaft. The head and the flange may be separated from one another by an annular groove between the head and flange. The first and second levers may each comprise a tab extending into the groove between the head and the flange on the actuator. A deformable member may be seated on the flange and extend in the groove. The deformable member may be a compression spring, lock washer or other deformable component. The deformable member may be compressed between the tabs and the flange to absorb excess force after the first and second levers are pivoted to a relatively closed position.

[0019] The central body may include a recess in communication with the bore. The recess may receive at least a portion of the head of the actuator. The head of the actuator may include a socket for receiving the tip on a driver. The central body may feature a T-shaped configuration that includes a base portion and a wing portion extending outwardly from the base portion.

[0020] The base portion may include a first concave wall section that partially defines the first channel, and a second concave wall section that partially defines the second channel. The free end of the first lever may include a third concave wall section that partially defines the first channel. The free end of the second lever may include a fourth concave wall section that partially defines the second channel. When the first and second levers are in the relatively closed position, the first and third concave wall sections may align with one another along a cylindrical profile, and the second and fourth concave wall sections may align with one another along a cylindrical profile.

[0021] The first wall section has an axial width substantially equal to the third wall section, and the second wall section has an axial width substantially equal to the fourth wall section. Compression forces applied by the first and second levers onto rods are distributed substantially evenly along the rods. Each lever may include an arm having a first axial width and a compression block having a second axial width. The second axial width may be greater than the first axial width.

[0022] The wing portion may include a first pair of extensions separated by a first slot, and a second pair of extensions separated by a second slot. The first slot may receive the arm of the first lever, and the second slot may receive the arm of the second lever. Each compression block may extend in at least one axial direction from its associated arm, forming at least one shelf that slidably engages at least one extension on the wing portion. The first lever may be pivotally coupled to the wing portion of the central body by a first pin, and the second lever may be pivotally coupled to the wing portion of the central body by a second pin.

[0023] Referring to FIGS. 1 and 2, a cross connector 100 is shown in accordance with one exemplary embodiment. Cross connector 100 includes a central body 110 and a single actuator 180 that is operable to clamp the cross connector onto two spinal rods simultaneously. Central body 110 has a symmetrical shape.

[0024] Cross connector 100 includes a first lever 170A and a second lever 170B for clamping onto spinal rods. First lever 170A has a configuration that is identical to the configuration of second lever 170B. Therefore, features of first lever 170A will be described, with the understanding that identical features having the same description are present on second lever 170B. Features of first lever 170A are identified with reference numbers followed by the suffix “A”. Corresponding features on second lever 170B that are shown in the drawings are labeled with the same reference number followed by the suffix “B”. Some features of second lever 170B may be described, but any features of the second lever that are not expressly mentioned are nonetheless understood to be described by the description of the corresponding feature in first lever 170A.

[0025] First lever 170A and second lever 170B are pivotally coupled to central body. First lever 170A has an L-shaped body with a free end 172A. When first lever 170A is coupled to central body 110, free end 172A is separated from central body 110 by a first channel 192. Second lever 170B also has an L-shaped body with a free end 172B. When second lever 170B is coupled to central body 110, free end 172B is separated from central body 110 by a second channel 194. Actuator 180 is operable to pivot the first lever 170A and second lever 170B from a relative open position, shown in FIG. 3, to a relatively closed position, shown in FIG. 4. When first lever 170A and second lever 170B are in the relatively closed position, free end 172A of first lever 170A, and free end 172B of second lever 170B, are moved toward one another and toward the central body to contract the first channel 192 and second channel 194. Movement of the first and second levers toward one another reduces the transverse width of the assembly, resulting in a smaller footprint after it is implanted.

[0026] Central body 110 forms a bore 112 that extends through the midline of the central body as shown. Actuator 180 is disposed in bore 112, and has a first thread 182. Bore 112 includes a second thread 114. Actuator 180 is disposed in bore 112 with first thread 182 engaged with second thread 114. In this configuration, actuator 180 is displaceable through bore 112 in response to torque applied to the actuator. Actuator 180 includes a shaft 184 and a flange 186 extending radially outwardly from the shaft. A head 181 also extends radially outwardly from shaft 184. Head 181 and flange 186 are separated from one another by an annular groove 188 between the head and flange. First lever 170A has a tab 174A extending into groove 188 between the head and the flange on the actuator. Second lever 170B also has a tab 174B extending into groove 188. Tab 174A has an underside 178A, and tab 174B has an underside 178B. Flange 186 has a leading surface 187. Leading surface 187 is configured to apply force to undersides 176A and 176B when actuator 180 is reversed out of bore 112, as will be described in more detail below.

[0027] Torque is applied to the actuator to apply clamping force on the rods, as will be explained in more detail. Excessive torque can apply too much force to the rods and possibly damage the rods or create weakened areas. In addition, excessive torque applied to the actuator can cause damage to the threads on the actuator, the threads inside the clamping body, or other areas of the rod to rod connector. Therefore, it may be desirable to include one or more components that prevent damage to the rod and components of the rod to rod connector. For example, the rod to rod connector may include a deformable member between the actuator 180 and first and second levers 170A and 170B that absorbs excess forces before they are applied to the rods and inner engagement surfaces in the rod to rod connector. The deformable member may be in the form of one or more coil springs, spring washers or other compressible elements.

[0028] Referring to FIGS. 3 and 4, rod to rod connector 100 includes a deformable member in the form of a lock washer 189. Lock washer 189 is designed to provide a cushion between flange 186 and tabs 174A and 174B. When torque is applied to actuator 180, flange 186 bears upwardly against lock washer 189, tab 174A and tab 174B. The upward force on tab 174A pivots first lever 170A towards the relatively closed position, and the upward force on tab 174B pivots second lever 170B towards the relatively closed position. Once first lever 170A and second lever 170B reach the relatively closed position, the levers compress the rods against central body 110 in first and second rod channels 192 and 194.

[0029] The amount of torque applied to actuator 180 reaches a “threshold torque” once the first and second levers 170A and 170B are moved to the relatively closed position. Additional torque that is applied to the actuator beyond the threshold torque is excess torque. Lock washer 189 is compressible, allowing flange 186 and actuator 180 to continue moving in the bore in response to excess torque. As lock washer 189 is compressed, it absorbs the additional compression force created by the excess torque so that the additional force is not transferred to the rods.

[0030] The head 181 of actuator 180 has a disc shaped body that surrounds a central socket 183. Socket 183 is configured for receiving and mating with the tip of a torque applying tool, such as a driver. When central body 110 is coupled to first and second levers 170A and 170B, the central body and levers form a circular recess 116 in communication with bore 112. Recess 116 is configured and dimensioned to receive at least a portion of head 181. More preferably, recess 116 is configured and dimensioned to receive all of head 181 so that the head can be recessed inside central body 110. This provides a smooth, flat and continuous top surface 102 as shown in FIG. 3.

[0031] Central body 110 has a symmetrical T-shaped configuration featuring a base portion 120 and a wing portion 130 extending outwardly from the base portion. Base portion 120 includes a first concave wall section 122 that partially defines the first channel 192. Base portion 120 also includes a second concave wall section 124 that partially defines the second channel 194. Free end 172A of first lever 170A includes a third concave wall section 176A that partially defines the first channel 192. Free end 172B of second lever 170B includes a fourth concave wall section 176B that partially defines second channel 194. When first lever 170A and second lever 170B are in the relatively closed position, the first concave wall section 122 and third concave wall section 176A align with one another along a cylindrical profile 177. Similarly, second concave wall section 124 and fourth concave wall section 176B align with one another along a cylindrical profile 179.

[0032] Rod to rod connectors in accordance with the invention provide a distinct advantage over known rod to rod connectors, because of the ability to minimize the transverse width of the overall assembly. Rod to rod connector 100 applies inward clamping forces onto rods via the first and second levers 170A and 170B. Base portion 120 does not contain engagement members or other components that apply a clamping force outwardly to the rods. As such, the transverse width 121 of base portion 120 can be minimized, because the base portion and channel do not have to provide additional room to accommodate engagement components that move between the base portion and the rod channels. It should be understood that the transverse width of base portion 120, relative to the entire assembly, can be even smaller than what is shown in FIG. 3, because the walls around bore 112 can be made thinner. Smaller diameter actuators can also be selected to reduce the size of bore 112, and consequently, the transverse width of base portion 120.

[0033] Rod to rod connectors in accordance with the invention preferably distribute compression forces onto rods in an even, or substantially even, manner along each rod. Moreover, compression forces are preferably distributed over a wide section of each rod, rather than concentrated on small areas of the rod. Concentrated forces on small areas of a rod can create stress points on the rod. Applying forces over a larger area can increase the amount of frictional engagement between the rod to rod connector and the rods. To provide for greater distribution of force, levers in accordance with the invention preferably include sections having an enlarged axial width that applies force over a greater area of each rod. The enlarged axial width of each lever is preferably equal or substantially equal to the axial width of the central body.

[0034] For example, referring to FIG. 2, first concave wall section 122 has an axial width 123 equal to the axial width 191A of third concave wall section 176A. Second concave wall section 124 has an axial width 125 equal to the axial width 191B of fourth concave wall section 176B. In this configuration, the axial width of the rod engaged by central body 110 is the same as the axial width of rod engaged by the levers.

[0035] Rod to rod connectors in accordance with the invention preferably engage at least one half of the perimeter of each rod so as to distribute compression force over a large area of the rod. First concave wall section 122 and third concave wall section 176A collectively form a cylindrical engagement surface that spans an angle α of more than 180 degrees. Second concave wall section 124 and fourth concave wall section 176B also collectively form a cylindrical engagement surface spanning an angle β of more than 180 degrees. In this configuration, the walls of rod channel 192 and rod channel 194 each engage more than one half of the perimeter of a rod. This provides a secure frictional engagement and distributes compression force evenly over a relatively large area of each rod.

[0036] Lever 170A includes an arm 171A having a first axial width 175A. Lever 170A also includes a compression block 173A having a second axial width equal to axial width 191A of first concave wall section 122. Axial width 191A of compression block 173A is greater than first axial width 175A of arm 171A. Compression blocks 173A and 173B each extend outwardly from their respective arms in axial directions, forming shelves 195A and 195B. In this configuration, the compression blocks 173A and 173B have an enlarged axial width, as compared to the arms, to apply compression force over a greater area of each rod.

[0037] Wing portion 130 includes a first pair of extensions 132 separated by a first slot 134, and a second pair of extensions 136 separated by a second slot 138. First slot 134 receives arm 171A of first lever 170A, and second slot 138 receives arm 171B of second lever 170B. First lever 170A is pivotally coupled to wing portion 130 by a first pin 190A, and second lever 170B is pivotally coupled to the wing portion by a second pin 190B. Shelves 195A and 195B slidably engage extensions 132 and 134 on wing portion 130. Wing portion 130 preferably includes rounded edges 135 along the perimeter of each of the extensions 132 and 136.

[0038] FIG. 5 is a schematic illustration that shows how rod to rod connector 100 can be used in a spinal column SC after a corpectomy procedure. A vertebral body and disc material are removed from spinal column SC and replaced with a VBR implant V inside space S. VBR implant maintains the height of space S and is filled with bone graft or other osteogenic material to promote fusion of the adjacent vertebrae V1 and V2. To stabilize spinal column SC during fusion, a pair of rods R are secured to vertebral bodies V1 and V2 using pedicle screw implants P. Rods R are arranged parallel to one another, with each rod secured in two pedicle screw implants P. To enhance the stiffness of the rod construct, a pair of rod to rod connectors 100 are connected to rods R. Each rod to rod connector 100 extends with its long dimension generally perpendicular to rods R. Levers 170A and 170B of each rod to rod connector 100 are locked in the relatively closed position to clamp the rod to rod connectors to rods R. With this arrangement, rod to rod connectors 100 form transverse braces between rods R that increase the rigidity and stiffness of the rod pair.

[0039] A method of using rod to rod connector 100 will now be described. As noted above, first and second levers 170A and 170B are displaceable between the relatively open condition, shown in FIG. 3, and the relatively closed position, shown in FIG. 4. Each rod channel 192 and 194 spans an opening or “mouth” 196. The width of each mouth 196 increases as the levers are moved toward the relatively open position, and decreases as the levers are moved to the relatively closed position.

[0040] To connect two rods using rod to rod connector 100, first and second levers 170A and 170B are spread apart to the relatively open position. This can be done by applying torque to head 181 of actuator 180. Torque is applied to head 181 in a first direction to drive actuator 180 into bore 112. As actuator 180 is driven into bore 112, flange 186 is driven downwardly into a recess 117 in central body 110. Tabs 174A and 174B, which extend between head 181 and flange 186, are pushed downwardly by head 181, causing arms 171A and 171B to pivot and move compression blocks 173A and 173B upwardly and outwardly from central body 110. In this condition, the mouths 196 of each channel 192 and 194 are expanded so that the rods can easily slip into each channel.

[0041] Rod to rod connector 100 is lowered onto the two rods with base portion 120 positioned between the two rods, and levers 170A and 170B extending over the outside edges of the rods, as shown in FIG. 5. Once rod to rod connector 100 is seated on the rods, torque is applied to actuator 180 in a second direction opposite the first direction to drive the actuator in a reverse direction out of bore 112. As actuator 180 is reversed out of bore 112, flange 186 is driven upwardly out of recess 117 in central body. Tabs 174A and 174B are pushed upwardly by flange 186 and lock washer 189. This causes arms 171A and 171B to pivot and move compression blocks 173A and 173B downwardly and inwardly toward central body 110. Compression blocks 173A and 173B apply force to the rods in an inward direction, compressing the rods against central body 110 into a clamped condition. Torque is applied to actuator 180 in the second direction until the user detects resistance to further torque. Compressive force that results from excess torque is absorbed by lock washer 189, preventing possible damage to the rods.

[0042] Although the present invention has been described in connection with specific embodiments, it should be understood that the invention as claimed is not limited to the specific embodiments. The specific embodiments described herein are provided only as examples. Various modifications may be made to the devices and methods described herein, including but not limited to various substitutions and combinations of device components and method steps, without departing from the scope of the invention.

[0043] For example, rod to rod connectors in accordance with the invention may have more than one actuator for moving the levers between the relatively open position and the relatively closed position. Two actuators may be provided, with each lever being controlled by its own actuator. This may be desired where the user wishes to control the amount of force applied to each rod individually. FIG. 6 shows a rod to rod connector 1000 with two actuators 1800A and 1800B. Actuator 1800A is configured to move a first lever 1700A and actuator 1800B is configured to move a second lever 1700B. The transverse width of central body 1100 is increased somewhat to accommodate the two actuators. Nevertheless, the transverse width of central body can still be kept relatively narrow, because it only needs to be wide enough to accommodate the two actuators, and does not have to provide additional width for engagement elements in the central body.

[0044] Rod to rod connectors in accordance with the invention may also include different actuator and lever configurations. In cross connector 100, actuator 100 is configured to move levers 170A and 170B toward the relatively closed position as the actuator is reversed out of central body 110. Cross connectors in accordance with the invention may have a different configuration that moves the levers toward the relatively open position when the actuator is reversed out of the central body. For example, the central body may include gears, levers or linkages that are connected between the actuator and lever to convert downward motion of the actuator into inward movement of the levers, so that the levers are moved to the relatively closed position as the actuator is driven into the central body.

[0045] Accordingly, it is intended that the appended claims cover all such variations of the devices, components and methods described herein.