Fusion implant and method of making same

Abstract

The present invention provides an implant for use in fusing adjacent bony structures. The implant comprises at least one structural member combined with at least one flexible planar member to retain the at least one structural member to form the implant.

1 . An implant for use in fusing adjacent bony structures comprising at least one structural member combined with at least one flexible planar member to retain the at least one structural member to form the implant.  
   
   
       2 . The implant of  claim 1  wherein the at least one structural member comprises at least one shape selected from the group consisting of particles, strips, blocks, and beams.  
   
   
       3 . The implant of  claim 1  wherein the at least one structural member comprises at least one material selected from the group consisting of bone, metal, ceramic, carbon and polymer.  
   
   
       4 . The implant of  claim 1  wherein the at least one structural member comprises at least one material selected from the group consisting of polyethylene, polyester, polyglycolic acid, polylactic acid, polytetrafluroethylene, polyaryletherketone, and polyetheretherketone.  
   
   
       5 . The implant of  claim 1  wherein the at least one flexible planar member comprises at least one shape selected from the group consisting of sheet, block, foam, woven fabric, non-woven fabric, membrane, and mesh.  
   
   
       6 . The implant of  claim 1  wherein the at least one flexible planar member comprises at least one material selected from the group consisting of body tissue, resorbable polymer, nonresorbable polymer, and metal.  
   
   
       7 . The implant of  claim 1  wherein the at least one flexible planar member comprises at least one material selected from the group consisting of fascia, skin, pericardium, partially demineralized bone, fully demineralized bone, cartilage, tendon, and ligament.  
   
   
       8 . The implant of  claim 1  wherein the flexible planar member retains a plurality of structural members to maintain them in a predetermined form.  
   
   
       9 . The implant of  claim 1  wherein the structural member has a longitudinal axis and the flexible planar member retains the structural member with its axis in a predetermined orientation.  
   
   
       10 . The implant of  claim 1  wherein the at least one structural member comprises a plurality of pieces of bone.  
   
   
       11 . The implant of  claim 10  wherein the individual pieces of bone have less than a predetermined minimum load bearing capacity and the combined pieces form an implant that achieves a predetermined capacity greater than the predetermined minimum load bearing capacity.  
   
   
       12 . The implant of  claim 11  wherein the individual pieces of bone have a predetermined geometry outside of a predetermined standard associated with a unitary implant and the combined pieces form an assembled bone load-bearing implant that achieves the predetermined geometry.  
   
   
       13 . The implant of  claim 12  wherein the individual pieces of bone comprise cortical bone harvested from a donor bone having a longitudinal axis, the individual pieces of bone having a thickness, measured radially from the longitudinal axis of the donor bone, less than 2 mm thick.  
   
   
       14 . The implant of  claim 10  wherein the pieces of bone include at least one shape selected from the group consisting of particles, strips, blocks, and beams.  
   
   
       15 . The implant of  claim 10  wherein the pieces of bone comprise cortical bone for achieving a predetermined load-bearing capability in the implant.  
   
   
       16 . The implant of  claim 15  wherein the pieces of bone further comprise cancellous bone.  
   
   
       17 . The implant of  claim 16  wherein the individual pieces of bone are further interconnected by at least one means selected from the group consisting of chemical and mechanical means.  
   
   
       18 . The implant of  claim 17  wherein the individual pieces of bone are interconnected by at least one means selected from the group consisting of pinning, suturing, pressing, incorporating a binding agent, collagen crosslinking, and interlocking mechanical engagement.  
   
   
       19 . The implant of  claim 18  wherein the individual pieces of bone are interconnected with at least one material selected from the group consisting of fibrin glue, cyanoacrylate, epoxy, polymethylmethacrylate, and gelatin.  
   
   
       20 . The implant of  claim 10  wherein the at least one flexible planar member comprises at least one shape selected from the group consisting of sheet, block, foam, woven fabric, non-woven fabric, membrane, and mesh.