Polyaxial pedicle screw having a threaded and tapered compression locking mechanism

Abstract

A polyaxial orthopedic device for use with rod implant apparatus includes a screw having a curvate head, a two-piece interlocking coupling element which mounts about the curvate head, and a rod receiving cylindrical body member having a tapered socket into which both the screw and the interlocking coupling element are securely nested. The interlocking coupling element includes a socket portion which is slotted and tapered so that when it is radially compressed by being driven downwardly into the tapered socket in the cylindrical body it crush locks to the screw. The securing of the rod in the body member provides the necessary downward force onto the socket portion through a contact force on the top of the cap portion. Prior to the rod being inserted, therefore, the screw head remains polyaxially free with respect to the coupling element and the body. In a preferred embodiment, the cap portion and the socket portion are formed and coupled in such a way that when the cap portion is compressed toward the socket portion, there is an additional inward radial force applied by the cap portion to the socket portion, thereby enhancing the total locking force onto the head of the screw.

We claim:  
     
       1. A polyaxial screw and coupling element assembly for use with orthopedic rod implantation apparatus, comprising: 
       a screw having a semi-spherical head;  
       a cylindrical body including an axial bore defining a bottom chamber portion at a bottom end thereof and a rod receiving channel at a top end thereof, said bottom chamber portion further defining a tapered lower portion and a constant diameter upper chamber portion, and said top end having a threading thereon;  
       a two-piece interlocking coupling element including  
       a socket portion having a semi-spherical interior volume for receiving therein the head of said screw, upper and lower sections, and vertical slots formed in said upper and lower sections, at least one of said slots rendering said interior volume expandable and contractable, said lower section having a tapered exterior surface for nesting in said tapered lower chamber portion of said cylindrical body such that forceable advancement of socket portion along the tapered lower chamber portion of the axial bore causes the at least one of said slots to narrow such that the semi-spherical interior volume contract, and  
       a cap portion having an opening in a bottom thereof and an interior chamber extending upwardly therefrom for joining with, and slideably retaining therein, the upper section of said socket portion, said cap portion initially seating with a portion thereof extending into a bottom portion of said rod receiving channel; and  
       a top locking nut, mateable with said threading, for locking a rod in said channel and for applying therethrough a downward force onto said cap portion,  
       wherein said semi-spherical head portion is rotationally freely mounted within the semi-spherical interior volume of the socket portion prior to said socket portion being forceably advanced into the tapered lower chamber portion of the axial bore, and  
       whereby downward compression of a rod in said channel portion of said body member, by said top locking nut, onto the cap portion causes the forceable advancement of the socket portion into the tapered lower chamber portion of the axial bore, and locks the screw, coupling element and body relative to one another.  
     
     
       2. The polyaxial screw as set forth in  claim 1 , wherein said semi-spherical head of said screw further includes a recess formed therein for receiving therein a screwdriving tool such that said screw may be threadably advanced into a vertebral bone. 
     
     
       3. The polyaxial screw as set forth in  claim 1 , wherein said threading on said top end is on the interior surface of said channel. 
     
     
       4. The polyaxial screw as set forth in  claim 3 , wherein said cap portion further includes a threading and wherein said cap portion needs to be threadably advanced along the threading to be seated in the bore into its initial position. 
     
     
       5. The assembly as set forth in  claim 1 , 
       wherein said socket portion further comprises a substantially constant diameter upper section having an outwardly annular extending lip at an extreme end thereof,  
       wherein said opening in the bottom of the cap portion comprises an inwardly directed annular lip, and  
       wherein at least one of said vertical slots in the upper section of said socket portion renders the upper section thereof to be expandable and contractable such that the upper section of the socket portion may be forceably inserted into the opening in the bottom of the cap portion so that it may be retained in the interior chamber therein by mutual interference engagement of the inwardly directed annular lip of the cap portion and the outwardly extending annular lip of the socket portion.  
     
     
       6. The assembly as set forth in  claim 5 , wherein the interior chamber of the cap portion comprises a tapered surface such that advancement thereof into the hole causes an inwardly directed force against the upper section of the socket portion, therein causing the at least one of said vertical slots in the upper section to narrow and causes the upper section to contract and further lock the head of the screw within the interior semi-spherical volume of the socket portion. 
     
     
       7. An orthopaedic implant apparatus having a rod and a plurality of screw and coupling element assemblies, comprising: 
       at least one screw having a semi-spherical head;  
       at least one cylindrical body including an axial bore defining a bottom chamber portion at a bottom end thereof and a rod receiving channel at a top end thereof, said bottom chamber portion further defining a tapered lower portion and a constant diameter upper chamber portion, and said top end having a threading thereon;  
       at least one corresponding two-piece interlocking coupling element including  
       a socket portion having a semi-spherical interior volume for receiving therein the head of said corresponding screw, upper and lower sections, and vertical slots formed in said upper and lower sections, at least one of said slots rendering said interior volume expandable and contractable, said lower section having a tapered exterior surface for nesting in said corresponding tapered lower chamber portion of said cylindrical body such that forceable advancement of socket portion along the tapered lower chamber portion of the axial bore causes the at least one of said slots to narrow such that the semi-spherical interior volume contract, and  
       a cap portion having an opening in a bottom thereof and an interior chamber extending upwardly therefrom for joining with, and slideably retaining therein, the upper section of said socket portion, said cap portion initially seating with a portion thereof extending into a bottom portion of said rod receiving channel; and  
       at least one corresponding top locking nut, mateable with said threading, for locking a rod in said channel and for applying therethrough a downward force onto said cap portion,  
       wherein said semi-spherical head portion is rotationally freely mounted within the semi-spherical interior volume of the socket portion prior to said socket portion being forceably advanced into the tapered lower chamber portion of the axial bore, and  
       whereby downward compression of a rod in said channel portion of said body member, by said top locking nut, onto the cap portion causes the forceable advancement of the socket portion into the tapered lower chamber portion of the axial bore, and locks the screw, coupling element and body relative to one another.  
     
     
       8. The apparatus as set forth in  claim 7 , wherein said threading on said top end is on the interior surface of said channel. 
     
     
       9. The apparatus as set forth in  claim 8 , wherein said cap portion further includes a threading and wherein said cap portion needs to be threadably advanced along the threading to be seated in the bore into its initial position. 
     
     
       10. The apparatus as set forth in  claim 7 , 
       wherein said socket portion further comprises a substantially constant diameter upper section having an outwardly annular extending lip at an extreme end thereof,  
       wherein said opening in the bottom of the cap portion comprises an inwardly directed annular lip, and  
       wherein at least one of said vertical slots in the upper section of said socket portion renders the upper section thereof to be expandable and contractable such that the upper section of the socket portion may be forceably inserted into the opening in the bottom of the cap portion so that it may be retained in the interior chamber therein by mutual interference engagement of the inwardly directed annular lip of the cap portion and the outwardly extending annular lip of the socket portion.  
     
     
       11. The apparatus as set forth in  claim 10 , wherein the interior chamber of the cap portion comprises atapered surface such that advancement thereof into the hole causes an inwardly directed force against the upper section of the socket portion, therein causing the at least one of said vertical slots in the upper section to narrow and causes the upper section to contract and further lock the head of the screw within the interior semi-spherical volume of the socket portion. 
     
     
       12. An orthopedic fixation assembly for securing an orthopedic rod implantation apparatus, comprising: 
       
         a cylindrical body including an axial bore extending therethrough, said body including a channel at a top end of said body, said axial bore defining a chamber portion at a bottom end of said body, said chamber portion having an upper chamber portion and a bottom chamber portion, said bottom chamber portion further including a retaining surface, and said top end of said body having a threading thereon;  
       
         a screw having a semi - spherical head, said semi - spherical head is mounted within said bottom chamber portion of said axial bore of said body;    
       
         a coupling assembly comprising:  
       
         a retaining portion having an inner surface for seating said semi - spherical head of said screw, said retaining portion further including a slot formed therein, said slot rendering a volume of said retaining portion to be adjustable, said retaining portion further being shaped to seat in said retaining surface of said bottom chamber of said axial bore of said cylindrical body, such that advancement of semi - spherical head against said retaining portion causes said head of said screw to be compression locked thereagainst,    
       
         a cap portion slidably located within said upper chamber portion and adapted for location between a rod and said top surface of said screw head; and  
       
       
         a top locking nut, mateable with said threading of said body,  
       
         wherein said semi - spherical head portion is freely rotational within said retaining portion prior to being compressed onto said retaining portion, and    
         whereby when the rod is in said channel, downward movement of said top locking nut onto the rod results in a force upon said cap portion causing forcible advancement of the semi - spherical head of said screw thereby locking said screw, said coupling assembly and said body relative to one another.    
     
     
       13. The orthopedic fixation assembly set forth in  claim 12 , wherein said axial bore has a substantially constant diameter at said upper chamber portion.  
     
     
       14. The orthopedic fixation assembly set forth in  claim 12 , wherein said semi- spherical head of said screw further includes a recess for receiving a screwdriving tool such that said screw may be threadably advanced into a vertebral bone.    
     
     
       15. The orthopedic fixation assembly set forth in  claim 12 , wherein said threading on said top end is on a surface of said axial bore.  
     
     
       16. The orthopedic fixation assembly set forth in  claim 15 , wherein said cap portion further includes a threading mating with said threading on said axial bore and wherein said cap portion is threadably advanced along said threading of said axial bore to be seated into said upper chamber portion.  
     
     
       17. The orthopedic fixation assembly set forth in  claim 12  wherein said channel extends through a top surface of said body creating at least one pair of upwardly extending members.  
     
     
       18. An orthopedic fixation assembly for use with an orthopedic rod implantation apparatus, comprising: 
       
         a body comprising an axial bore extending therethrough and a channel extending perpendicularly to said axial bore at a top end of said body, said axial bore having a threaded portion at said top end of said body member and a chamber portion at a bottom end of said body member, said chamber portion defining an upper chamber portion and a bottom chamber portion, said bottom chamber portion including a nesting surface defining a nesting volume;  
       
         a screw having a semi - spherical head, said semi - spherical head being located within said chamber portion of said body member;    
       
         a coupling element comprising:  
       
         a retaining portion having an inner surface which seats said semi - spherical head of said screw permitting angulation of said screw relative to said body, and an outer surface being seated within said nesting volume, said retaining portion further including a slot extending between said inner and outer surfaces, said slot rendering at least said outer surface of retaining portion to be deformable; and    
       
         a cap portion moveably located within said upper chamber portion and over said semispherical head of said screw; and  
       
       
         a locking nut having a threaded portion which is mateable with said threaded portion of said axial bore allowing a portion of said locking nut to advance into said axial bore;  
       
         wherein when a rod is placed in said channel, advancement of said locking nut produces a downward force on the rod translating into a downward movement of at least said cap portion and said screw causing deformation of said outer surface of said retaining portion within said nesting surface resulting in a locking force applied by said retaining portion against said semi - spherical head causing said screw to be compression locked within said body.    
     
     
       19. The orthopedic fixation assembly of  claim 18 , where said semi- spherical head of said screw further comprises a recess formed therein for receiving a screwdriving tool such that said screw may be threadably advanced into a vertebral bone.    
     
     
       20. The orthopedic fixation assembly of  claim 18 , wherein said axial bore has a constant diameter at said upper chamber portion.  
     
     
       21. The orthopedic fixation assembly of  claim 18 , wherein said cap portion further includes a threading and wherein said cap portion is threadably advanced along said threaded portion of said axial bore prior to seating in said chamber portion.  
     
     
       22. The orthopedic fixation assembly of  claim 18 , wherein said locking nut includes a post position which is seated in said axial bore, wherein when the rod is in said channel, a bottom surface of said post portion contacts the rod.  
     
     
       23. The orthopedic fixation assembly set forth in  claim 18  wherein said channel extends through a top surface of said body creating at least one pair of upwardly extending members.