Polyaryletherketone Artificial Intervertebral Disc

Abstract

An intervertebral prosthesis for insertion between adjacent vertebrae, in one embodiment, includes upper and lower prosthesis plates and a movable core. The prosthesis plates and optionally the core are formed of polyaryletherketone (PAEK) for improved imaging properties. A metallic insert is provided on each of the PAEK prosthesis plates providing a bone ongrowth surface.

1 . An intervertebral disc comprising:
 an upper plate having an upper vertebra contacting surface and a lower bearing surface, wherein the upper plate is formed of polyaryletherketone (PAEK) with the upper surface formed at least in part from a metallic insert having a plurality of projections formed thereon for improving bone attachment;   a lower plate having a lower vertebra contacting surface and an upper bearing surface, wherein the lower plate is formed of PAEK with the lower surface formed at least in part from a metallic insert having a plurality of projections formed thereon for improving bone attachment; and   a core positioned between the upper and lower plates, the core having upper and lower surfaces configured to mate with the bearing surfaces of the upper and lower plates.   
   
   
       2 . The disc of  claim 1 , wherein the core is movable with respect to the upper and lower plates. 
   
   
       3 . The disc of  claim 1 , further comprising anchoring elements in the form of fins extending from the upper surface of the upper plate and from the lower surface of the lower plate. 
   
   
       4 . The disc of  claim 3 , wherein the fins each have a height greater than their width and a length greater than their height. 
   
   
       5 . The disc of  claim 3 , wherein the fin is formed of PAEK. 
   
   
       6 . The disc of  claim 3 , wherein the fin is formed is formed of PAEK and is covered with a metallic material. 
   
   
       7 . The disc of  claim 3 , wherein the fin is formed as a part of the metallic insert. 
   
   
       8 . The disc of  claim 1 , wherein the metallic inserts are formed of titanium. 
   
   
       9 . The disc of  claim 1 , wherein the metallic inserts are insert molded into the PAEK of the upper and lower plates. 
   
   
       10 . The disc of  claim 1 , wherein the metallic inserts having a thickness of about 0.1 to about 1.0 mm. 
   
   
       11 . The disc of  claim 1 , wherein the metallic inserts are attached to the PAEK of the upper and lower plates by a press fit connection. 
   
   
       12 . The disc of  claim 1 , wherein a portion of the upper surface of the upper plate and the lower surface of the lower plate include titanium plasma spray coating for bone attachment. 
   
   
       13 . The disc of  claim 1 , wherein the core is formed of PAEK. 
   
   
       14 . An intervertebral disc comprising:
 an upper plate having an upper vertebra contacting surface and a lower bearing surface, wherein the upper plate is formed of polyaryletherketone (PAEK) with the upper surface formed at least in part from a metallic insert having a thickness of at least 0.3 mm;   a lower plate having a lower vertebra contacting surface and an upper bearing surface, wherein the lower plate is formed of PAEK with the lower surface formed at least in part from a metallic insert having a thickness of at least 0.3 mm; and   a core positioned between the upper and lower plates, the core having upper and lower surfaces configured to mate with the bearing surfaces of the upper and lower plates.   
   
   
       15 . The disc of  claim 14 , wherein the core is movable with respect to the upper and lower plates. 
   
   
       16 . The disc of  claim 14 , further comprising anchoring elements in the form of fins extending from the upper surface of the upper plate and from the lower surface of the lower plate. 
   
   
       17 . The disc of  claim 16 , wherein the fins each have a height greater than their width and a length greater than their height. 
   
   
       18 . The disc of  claim 16 , wherein the fin is formed of PAEK. 
   
   
       19 . The disc of  claim 16 , wherein the fin is formed is formed of PAEK and is covered with a metallic material. 
   
   
       20 . The disc of  claim 16 , wherein the fin is formed as a part of the metallic insert. 
   
   
       21 . The disc of  claim 14 , wherein the metallic inserts are formed of titanium. 
   
   
       22 . The disc of  claim 14 , wherein the metallic inserts are insert molded into the PAEK of the upper and lower plates. 
   
   
       23 . The disc of  claim 14 , wherein the metallic inserts are attached to the PAEK of the upper and lower plates by a press fit connection. 
   
   
       24 . The disc of  claim 1 , wherein the core is formed of PAEK. 
   
   
       25 . The disc of  claim 1 , wherein the metallic inserts comprise stamped teeth. 
   
   
       26 . An intervertebral disc comprising:
 an upper plate having an upper vertebra contacting surface and a lower bearing surface, wherein the upper plate is formed of polyaryletherketone (PAEK) with the upper surface formed at least in part from a metallic insert having a plurality of projections formed thereon for improving bone attachment;   a lower plate having a lower vertebra contacting surface and an upper bearing surface, wherein the lower plate is formed of PAEK with the lower surface formed at least in part from a metallic insert having a plurality of projections formed thereon for improving bone attachment; and   wherein the upper and lower bearing surfaces are configured to allow articulation between the upper vertebra contacting surface and the lower vertebra contacting surface.   
   
   
       27 . The disc of  claim 26 , wherein the upper and lower bearing surfaces are configured to engage a movable core positioned between the upper and lower plates. 
   
   
       28 . The disc of  claim 26 , further comprising anchoring elements in the form of fins extending from the upper surface of the upper plate and from the lower surface of the lower plate. 
   
   
       29 . The disc of  claim 28 , wherein the fins each have a height greater than their width and a length greater than their height. 
   
   
       30 . The disc of  claim 28 , wherein the fins are formed of PAEK. 
   
   
       31 . The disc of  claim 26 , wherein the metallic inserts are formed of titanium. 
   
   
       32 . The disc of  claim 26 , wherein the metallic inserts are insert molded into the PAEK of the upper and lower plates. 
   
   
       33 . The disc of  claim 26 , wherein the metallic inserts having a thickness of about 0.1 to about 1.0 mm. 
   
   
       34 . The disc of  claim 26 , wherein the metallic inserts are attached to the PAEK of the upper and lower plates by a press fit connection. 
   
   
       35 . The disc of  claim 26 , wherein the metallic inserts are attached to the PAEK and cover at least 50% of bone contacting surface of the upper and lower plates. 
   
   
       36 . The disc of  claim 26 , wherein the PAEK comprises polyetheretherketone (PEEK). 
   
   
       37 . An intervertebral disc comprising:
 an upper plate formed of polyaryletherketone (PAEK) with a metallic insert fixed to the PAEK and configured to contact a first vertebra;   a lower plate formed of PAEK with a metallic insert fixed to the PAEK and configured to contact a second vertebra adjacent to the first vertebra; and   wherein the upper and lower plates are arranged to articulate in a anterior-posterior direction and in a lateral direction with respect to one another and to rotate with respect to one another.