US20090012525A1 - Devices and systems for delivering bone fill material - Google Patents

Abstract

The present invention relates in certain embodiments to medical devices, systems and methods for use in osteoplasty procedures, such as vertebral compression fractures. One device for delivering a bone fill material to a bone, such as a vertebra, includes an elongated introducer having a working end at a distal end of the introducer, the working end positionable within the bone and having at least one outlet opening configured to allow a bone fill material flow therethrough. An insulative coating is disposed on an external surface of the introducer, the coating being lubricious and configured to inhibit scratching of said external surface. One system for delivering a bone fill material to a bone includes such a device, a thermal energy emitter operably coupled to the introducer to apply energy to the bone fill material flowing through a channel of the introducer, and a controller in communication with the thermal energy emitter to control the operation of the thermal energy emitter.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application claims the benefit of U.S. Provisional Patent Application No. 60/788,755, filed Apr. 3, 2006, the entire contents of which is hereby incorporated by reference and should be considered a part of this specification.
BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• The present invention relates in certain embodiments to medical devices for osteoplasty treatment procedures, such as vertebral compression fractures. More particularly, embodiments of the invention relate to insulated devices and systems for delivering bone fill material into bone, such as vertebral bodies.
• 2. Description of the Related Art
• Osteoporotic fractures are prevalent in the elderly, with an annual estimate of 1.5 million fractures in the United States alone. These include 750,000 vertebral compression fractures (VCFs) and 250,000 hip fractures. The annual cost of osteoporotic fractures in the United States has been estimated at $13.8 billion. The prevalence of VCFs in women age 50 and older has been estimated at 26%. The prevalence increases with age, reaching 40% among 80-year-old women. Medical advances aimed at slowing or arresting bone loss from aging have not provided solutions to this problem. Further, the population affected will grow steadily as life expectancy increases. Osteoporosis affects the entire skeleton but most commonly causes fractures in the spine and hip. Spinal or vertebral fractures also cause other serious side effects, with patients suffering from loss of height, deformity and persistent pain which can significantly impair mobility and quality of life. Fracture pain usually lasts 4 to 6 weeks, with intense pain at the fracture site. Chronic pain often occurs when one vertebral level is greatly collapsed or multiple levels are collapsed.
• Postmenopausal women are predisposed to fractures, such as in the vertebrae, due to a decrease in bone mineral density that accompanies postmenopausal osteoporosis. Osteoporosis is a pathologic state that literally means “porous bones”. Skeletal bones are made up of a thick cortical shell and a strong inner meshwork, or cancellous bone, of with collagen, calcium salts and other minerals. Cancellous bone is similar to a honeycomb, with blood vessels and bone marrow in the spaces. Osteoporosis describes a condition of decreased bone mass that leads to fragile bones which are at an increased risk for fractures. In an osteoporosis bone, the sponge-like cancellous bone has pores or voids that increase in dimension making the bone very fragile. In young, healthy bone tissue, bone breakdown occurs continually as the result of osteoclast activity, but the breakdown is balanced by new bone formation by osteoblasts. In an elderly patient, bone resorption can surpass bone formation thus resulting in deterioration of bone density. Osteoporosis occurs largely without symptoms until a fracture occurs.
• Vertebroplasty and kyphoplasty are recently developed techniques for treating vertebral compression fractures. Percutaneous vertebroplasty was first reported by a French group in 1987 for the treatment of painful hemangiomas. In the 1990's, percutaneous vertebroplasty was extended to indications including osteoporotic vertebral compression fractures, traumatic compression fractures, and painful vertebral metastasis. Vertebroplasty is the percutaneous injection of PMMA (polymethylmethacrylate) into a fractured vertebral body via a trocar and cannula. The targeted vertebrae are identified under fluoroscopy. A needle is introduced into the vertebrae body under fluoroscopic control, to allow direct visualization. A bilateral transpedicular (through the pedicle of the vertebrae) approach is typical but the procedure can be done unilaterally. The bilateral transpedicular approach allows for more uniform PMMA infill of the vertebra.
• In a bilateral approach, approximately 1 to 4 ml of PMMA is used on each side of the vertebra. Since the PMMA needs to be is forced into the cancellous bone, the techniques require high pressures and fairly low viscosity cement. Since the cortical bone of the targeted vertebra may have a recent fracture, there is the potential of PMMA leakage. The PMMA cement contains radiopaque materials so that when injected under live fluoroscopy, cement localization and leakage can be observed. The visualization of PMMA injection and extravasion are critical to the technique—and the physician terminates PMMA injection when leakage is evident. The cement is injected using syringes to allow the physician manual control of injection pressure.
• Kyphoplasty is a modification of percutaneous vertebroplasty. Kyphoplasty involves a preliminary step consisting of the percutaneous placement of an inflatable balloon tamp in the vertebral body. Inflation of the balloon creates a cavity in the bone prior to cement injection. The proponents of percutaneous kyphoplasty have suggested that high pressure balloon-tamp inflation can at least partially restore vertebral body height. In kyphoplasty, some physicians state that PMMA can be injected at a lower pressure into the collapsed vertebra since a cavity exists, when compared to conventional vertebroplasty.
• The principal indications for any form of vertebroplasty are osteoporotic vertebral collapse with debilitating pain. Radiography and computed tomography must be performed in the days preceding treatment to determine the extent of vertebral collapse, the presence of epidural or foraminal stenosis caused by bone fragment retropulsion, the presence of cortical destruction or fracture and the visibility and degree of involvement of the pedicles.
• Leakage of PMMA during vertebroplasty can result in very serious complications including compression of adjacent structures that necessitate emergency decompressive surgery. See “Anatomical and Pathological Considerations in Percutaneous Vertebroplasty and Kyphoplasty: A Reappraisal of the Vertebral Venous System”, Groen, R. et al, Spine Vol. 29, No. 13, pp 1465-1471 2004. Leakage or extravasion of PMMA is a critical issue and can be divided into paravertebral leakage, venous infiltration, epidural leakage and intradiscal leakage. The exothermic reaction of PMMA carries potential catastrophic consequences if thermal damage were to extend to the dural sac, cord, and nerve roots. Surgical evacuation of leaked cement in the spinal canal has been reported. It has been found that leakage of PMMA is related to various clinical factors such as the vertebral compression pattern, and the extent of the cortical fracture, bone mineral density, the interval from injury to operation, the amount of PMMA injected and the location of the injector tip. In one recent study, close to 50% of vertebroplasty cases resulted in leakage of PMMA from the vertebral bodies. See Hyun-Woo Do et al, “The Analysis of Polymethylmethacrylate Leakage after Vertebroplasty for Vertebral Body Compression Fractures”, Jour. of Korean Neurosurg. Soc. Vol. 35, No. 5 (5/2004) pp. 478-82, (http://wwwjkns.or.kr/htm/abstract.asp?no=0042004086).
• Another recent study was directed to the incidence of new VCFs adjacent to the vertebral bodies that were initially treated. Vertebroplasty patients often return with new pain caused by a new vertebral body fracture. Leakage of cement into an adjacent disc space during vertebroplasty increases the risk of a new fracture of adjacent vertebral bodies. See Am. J. Neuroradiol. 2004 February; 25(2):175-80. The study found that 58% of vertebral bodies adjacent to a disc with cement leakage fractured during the follow-up period compared with 12% of vertebral bodies adjacent to a disc without cement leakage.
• Another life-threatening complication of vertebroplasty is pulmonary embolism. See Bernhard, J. et al, “Asymptomatic diffuse pulmonary embolism caused by acrylic cement: an unusual complication of percutaneous vertebroplasty”, Ann. Rheum. Dis. 2003; 62:85-86. The vapors from PMMA preparation and injection also are cause for concern. See Kirby, B, et al., “Acute bronchospasm due to exposure to polymethylmethacrylate vapors during percutaneous vertebroplasty”, Am. J. Roentgenol. 2003; 180:543-544.
• In both higher pressure cement injection (vertebroplasty) and balloon-tamped cementing procedures (kyphoplasty), the methods do not provide for well controlled augmentation of vertebral body height. The direct injection of bone cement simply follows the path of least resistance within the fractured bone. The expansion of a balloon applies also compacting forces along lines of least resistance in the collapsed cancellous bone. Thus, the reduction of a vertebral compression fracture is not optimized or controlled in high pressure balloons as forces of balloon expansion occur in multiple directions.
• In a kyphoplasty procedure, the physician often uses very high pressures (e.g., up to 200 or 300 psi) to inflate the balloon which crushes and compacts cancellous bone. Expansion of the balloon under high pressures close to cortical bone can fracture the cortical bone, typically the endplates, which can cause regional damage to the cortical bone with the risk of cortical bone necrosis. Such cortical bone damage is highly undesirable as the endplate and adjacent structures provide nutrients for the disc.
• Kyphoplasty also does not provide a distraction mechanism capable of 100% vertebral height restoration. Further, the kyphoplasty balloons under very high pressure typically apply forces to vertebral endplates within a central region of the cortical bone that may be weak, rather than distributing forces over the endplate.
• There is a general need to provide bone cements and methods for use in treatment of vertebral compression fractures that provide a greater degree of control over introduction of cement and that provide better outcomes. Embodiments of the present invention meet this need and provide several other advantages in a novel and nonobvious manner.
SUMMARY OF THE INVENTION
• Certain embodiments of the invention provide systems and methods for treating bone, such as a vertebra, by delivering bone fill material into the interior of the vertebra. One embodiment utilizes Rf energy or other energy sources to controllably elevate the temperature of bone fill material flows as the flows exit the working end of an introducer. A computer controller controls the bone fill material flow parameters and energy delivery parameters for selectively polymerizing the fill material inflow plume to thereby control the direction of flow and the ultimate geometry of a flowable, in-situ hardenable bone fill material. The system and method further includes means for sealing tissue in the interior of a vertebra to prevent migration of monomers, fat or emboli into the patient's bloodstream.
• Certain embodiments of the invention include a sensor system along a surface of the bone fill material introducer for sensing retrograde flows of a bone fill material, for example bone cement flows that can migrate along a fractured path toward a pedicle of a vertebra and risk leakage into the spinal canal. In one embodiment the sensing system is an impedance sensing system. In one embodiment, the physician is alerted of cement migration in a retrograde direction, such as one in which cement flow that can impinge on nerves or the spinal cord.
• In another embodiment, the sensing system includes a member with an electrosurgical surface or a sensing electrode surface and an insulative diamond-like surface coating or diamond nanostructure coating that can be insulative or conductive.
• In another embodiment, a controller is provided to control all parameters of bone fill material injection. For example, the controller can control bone fill material inflow parameters from, for example, a hydraulic mechanism. The controller can also control the sensing system and energy delivery parameters for selectively heating tissue or polymerizing bone fill material at both the interior and exterior of the introducer. The workload on a physician during an osteoplasty procedure can thus advantageously be reduced.
• In one embodiment, an apparatus for delivering a bone fill material to a vertebra is provided. The apparatus comprises an elongated introducer configured for introduction into a vertebral body, the introducer comprising a working end at a distal end of the introducer, the working end positionable within the vertebral body and having at least one outlet opening configured to allow a bone fill material flow therethrough. The apparatus also comprises an insulative coating disposed on an external surface of the introducer, the coating being lubricious and configured to inhibit the scratching of said external surface.
• In another embodiment, a system for delivering a bone fill material to a bone is provided. The system comprises an elongated introducer configured for insertion into a bone, the introducer defining a channel sized to allow a flow of a bone fill material therethrough, the introducer having at least one outlet opening in communication with the channel for delivering the bone fill material into the bone. An insulative coating is disposed on an exterior surface of the introducer, the coating being lubricious and having a high scratch resistance. The system also comprises a thermal energy emitter operably coupled to the introducer and configured to apply energy to the bone fill material flowing through the channel. The system also comprises a controller in communication with the thermal energy emitter and configured to control the operation of the thermal energy emitter.
• In still another embodiment, a method for delivering a bone fill material to a vertebra is provided. The method comprises providing an elongate introducer comprising an insulative coating disposed on an external surface of the introducer, the coating being lubricious and configured to inhibit the scratching of said external surface. The method also comprises inserting the elongated introducer into a vertebra and delivering bone fill material through the elongated introducer into the vertebra.
BRIEF DESCRIPTION OF THE DRAWINGS
• In order to better understand the invention and to see how it may be carried out in practice, some preferred embodiments are next described, by way of non-limiting examples only, with reference to the accompanying drawings, in which like reference characters denote corresponding features consistently throughout similar embodiments in the attached drawings.
• FIG. 1 is a schematic side view of a spine segment showing a vertebra with a compression fracture and an introducer, in accordance with one embodiment disclosed herein.
• FIG. 2A is a schematic perspective view of a system for treating bone, in accordance with one embodiment.
• FIG. 2B is a schematic perspective view of a working end of the introducer ofFIG. 2A.
• FIG. 3A is a schematic perspective view of a working end of an introducer, in accordance with one embodiment.
• FIG. 3B is a schematic perspective view of a working end of an introducer, in accordance with another embodiment.
• FIG. 3C is a schematic perspective view of a working end of an introducer, in accordance with yet another embodiment.
• FIG. 4 is a schematic cross-sectional side view of one embodiment of a working end of a probe, in accordance with one embodiment.
• FIG. 5A is a schematic side view of an introducer inserted into a vertebral body and injecting flowable fill material into the vertebral body.
• FIG. 5B is a schematic side view of the introducer inFIG. 5A injecting a relatively high viscosity volume of flowable fill material into the vertebral body, in accordance with one embodiment of the present invention.
• FIG. 6 is a schematic perspective view of a system for treating bone, in accordance with another embodiment.
• FIG. 7A is a schematic sectional view of a fill material, in accordance with one embodiment.
• FIG. 7B is a schematic sectional view of a fill material, in accordance with another embodiment.
• FIG. 8A is a schematic perspective view of a system for treating bone, in accordance with another embodiment.
• FIG. 8B is a schematic perspective view of the system inFIG. 8A, injecting an additional volume of fill material into a vertebral body.
• FIG. 9A is a schematic cross-sectional view of one step in a method for treating bone, in accordance with one embodiment.
• FIG. 9B is a schematic cross-sectional view of another step in a method for treating bone, in accordance with one embodiment.
• FIG. 9C is a schematic cross-sectional view of still another step in a method for treating bone, in accordance with one embodiment.
• FIG. 10A is a schematic cross-sectional view of a step in a method for treating bone, in accordance with another embodiment.
• FIG. 10B is a schematic cross-sectional view of another step in a method for treating bone, in accordance with another embodiment.
• FIG. 11A is a schematic perspective view of a system for treating bone, in accordance with another embodiment.
• FIG. 11B is a schematic perspective view of the system inFIG. 11A, applying energy to a fill material.
• FIG. 12 is a schematic perspective view of a system for treating bone, in accordance with another embodiment.
• FIG. 13 is a schematic view of another embodiment of a bone cement delivery system together with an aspiration source.
• FIG. 14A is a sectional view of a working end of an introducer as inFIG. 13 showing the orientation of a cement injection port in a vertebra.
• FIG. 14B is a sectional view of the working end ofFIG. 14A showing an initial inflow of bone cement.
• FIG. 14C is a sectional view of the working end ofFIG. 14B showing an additional inflow of bone cement to reduces a vertebral fracture.
• FIG. 15A is a sectional view of a vertebra depicting a first mode of operation wherein an initial flow of bone cement is provided under selected flow parameters that allow cement interdigitation into cancellous bone.
• FIG. 15B is a sectional view of a vertebra similar toFIG. 15A depicting a second mode of operation wherein cement flows are provided in a high acceleration pulse that disallows cement interdigitation into cancellous bone.
• FIG. 16 is a sectional schematic view of another embodiment of a bone cement delivery system.
• FIG. 17 is a schematic perspective view of another embodiment of a bone cement delivery system for treating osteoporotic bone or a fractured vertebra.
• FIG. 18A is a sectional view of a vertebra showing one step of a method for delivering bone cement to a vertebra, in accordance with one embodiment.
• FIG. 18B is a sectional view of the vertebra ofFIG. 18A showing another step of the method for delivering bone cement to a vertebra.
• FIG. 18C is a sectional view similar toFIGS. 18A-18B showing another step of the method for delivering bone cement to a vertebra.
• FIG. 19 is a perspective schematic view of another embodiment of a bone cement delivery system.
• FIG. 20 is a perspective schematic view of another embodiment of an injector with a thin wall sleeve and a sensor system.
• FIG. 21 is a perspective schematic view of another embodiment of a bone cement delivery system.
• FIG. 22 is a perspective schematic view of another embodiment of a bone cement delivery system.
• FIG. 23A is a sectional view of one embodiment of a bone cement injector having an energy emitter.
• FIG. 23B is a sectional view of another embodiment of a bone cement injector having an energy emitter.
• FIG. 24 is a perspective schematic view of another embodiment of a bone cement delivery system.
• FIG. 25 is a sectional schematic view of another embodiment of a bone cement injector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTSDefinitions
• “Bone fill material, infill material or composition” includes its ordinary meaning and is defined as any material for infilling a bone that includes an in-situ hardenable material, such as bone cement. The fill material also can include other “fillers” such as filaments, microspheres, powders, granular elements, flakes, chips, tubules and the like, autograft or allograft materials, as well as other chemicals, pharmacological agents or other bioactive agents.
• “Flowable material” includes its ordinary meaning and is defined as a material continuum that is unable to withstand a static shear stress and responds with an irrecoverable flow (a fluid)—unlike an elastic material or elastomer that responds to shear stress with a recoverable deformation. Flowable material includes fill material or composites that include a fluid (first) component and an elastic or inelastic material (second) component that responds to stress with a flow, no matter the proportions of the first and second component, and wherein the above shear test does not apply to the second component alone.
• An “elastomer” includes its ordinary meaning and is defined as material having to some extent the elastic properties of natural rubber wherein the material resumes or moves toward an original shape when a deforming force is removed.
• “Substantially” or “substantial” mean largely but not necessarily entirely. For example, substantially may mean about 10% to about 99.999%, about 25% to about 99.999% or about 50% to about 99.999%.
• “Osteoplasty” includes its ordinary meaning and means any procedure wherein fill material is delivered into the interior of a bone.
• “Vertebroplasty” includes its ordinary meaning and means any procedure wherein fill material is delivered into the interior of a vertebra.
Systems and Methods of Infill Material Delivery and Energy Application
• For the purpose of understanding the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and accompanying text that describe the invention. Further details on systems and methods for the delivery of bone cement can be found in U.S. patent application Ser. No. 11/165,652, filed Jun. 24, 2005, now U.S. Pub. No. 2006-0122623; U.S. application Ser. No. 11/196,045, filed Aug. 2, 2005, now U.S. Pub. No. 2006-0122624; U.S. application Ser. No. 11/208,448, filed Aug. 20, 2005, now U.S. Pub. No. 2006-0122621; and U.S. application Ser. No. 11/209,035, filed Aug. 22, 2005, now U.S. Pub. No. 2006-0122625, the entire contents of which are hereby incorporated by reference and should be considered a part of this specification.
• FIG. 1 illustrates one embodiment of the invention for treating a spine segment in which avertebral body90 has a wedge compression fracture indicated at94. In one embodiment, the systems and methods are directed to safely introducing a bone fill material into cancellous bone of the vertebra without extravasion of fill material in unwanted directions (i) to prevent micromotion in the fracture for eliminating pain, and (ii) to support the vertebra and increase vertebral body height. Further, systems and methods are provided for sealing cancellous bone (e.g., blood vessels, fatty tissues etc.) in order to prevent monomers, fat, fill material and other emboli from entering the venous system during treatment.
• FIG. 1 illustrates a fractured vertebra andbone infill system100 which includesprobe105 having ahandle end106 extending to anelongated introducer110A and workingend115A, shown inFIG. 2A. The introducer is shown introduced throughpedicle118 of the vertebra for accessing the osteoporotic cancellous bone122 (SeeFIG. 2A). The initial aspects of the procedure are similar to conventional percutaneous vertebroplasty wherein the patient is placed in a prone position on an operating table. The patient is typically under conscious sedation, although general anesthesia is an alternative. The physician injects a local anesthetic (e.g., 1% Lidocaine) into the region overlying the targeted pedicle or pedicles as well as the periosteum of the pedicle(s). Thereafter, the physician uses a scalpel to make a 1 to 5 mm skin incision over each targeted pedicle. Thereafter, theintroducer110A is advanced through the pedicle into the anterior region of the vertebral body, which typically is the region of greatest compression and fracture. The physician confirms the introducer path posterior to the pedicle, through the pedicle and within the vertebral body by anteroposterior and lateral X-Ray projection fluoroscopic views. The introduction of infill material as described below can be imaged several times, or continuously, during the treatment depending on the imaging method.
• It should be appreciated that the introducer also can be introduced into the vertebra from other angles, for example, alongaxis113 through the wall of thevertebral body114 as inFIG. 1 or in an anterior approach (not shown). Further, first and second cooperating introducers can be used in a bilateral transpedicular approach. Additionally, any mechanism known in the art for creating an access opening into the interior of thevertebral body90 can be used, including open surgical procedures.
• Now referring toFIGS. 2A and 2B, the end ofintroducer110A is shown schematically after being introduced intocancellous bone122 with an inflow of fill material indicated at120. The cancellous bone can be in any bone, for example in a vertebra. It can be seen that theintroducer110A and workingend115A comprise a sleeve or shaft that is preferably fabricated of a metal having aflow channel118 extending therethrough from the proximal handle end106 (seeFIG. 1). In one embodiment, the introducer shaft is astainless steel tube123 having an outside diameter ranging between about 3.5 and 4.5 mm, but other dimensions are possible. As can be seen inFIGS. 2A and 3A, theflow channel118 can terminate in a single distal opening oroutlet124ain the workingend115A, or there can be a plurality of flow outlets orports124barranged angularly about the radially outward surface of the workingend115A, as shown inFIG. 3B. The outlets in the working end thus allow for distal or radial ejection of fill material, or a working end can have a combination of radial and distal end outlets. As can be seen inFIG. 3C, the distal end of workingend115A also can provide an angleddistal end outlet124cfor directing the flow of fill material from the outlet by rotating the workingend115A.
• InFIGS. 2A and 2B, it can be seen thatsystem100 includes aremote energy source125A and acontroller125B that are operatively coupled to anenergy emitter128 in the workingend115A of theintroducer110A for applying energy to thefill material120 contemporaneous with and subsequent to ejection of thefill material120 from the workingend115A. In one preferred embodiment, theenergy source125A is a radiofrequency (Rf) source known in the art that is connected to at least one electrode (132aand132binFIG. 2B) in contact with injectedfill material120, which preferably carries a radiosensitive composition therein. It is equally possible to use other remote energy sources andemitters128 in the workingend115A which fall within the scope of the invention, such as (i) an electrical source coupled to a resistive heating element in the working end, (ii) a light energy source (coherent or broadband) coupled to an optical fiber or other light channel terminating in the working end; (iii) an ultrasound source coupled to an emitter in the working end; or a (iv) microwave source coupled to an antenna in the working end. In still another embodiment, theenergy source125A can be a magnetic source. Thefill material120 preferably includes an energy-absorbing material or an energy-transmitting material that cooperates with energy delivered from a selected energy source. For example, the energy-absorbing or energy-transmitting material can be a radiosensitive or conductive material for cooperating with an Rf source, chromophores for cooperating with a light source, ferromagnetic particles for cooperating with a magnetic source, and the like. In one embodiment, thefill material120 can include a composition having an energy-absorbing property and an energy-transmitting property for cooperating with theremote energy source125A. For example, the composition can absorb energy from theremote energy source125A for polymerizing the composite or transmit energy for heating tissue adjacent to the composite.
• As can be understood fromFIGS. 2A and 2B, theexemplary introducer110A is operatively coupleable to asource145 ofbone fill material120 together with a pressure source ormechanism150 that operates on the source offill material145 to deliver thefill material120 through theintroducer110A into a bone (see arrows). Thepressure source150 can comprise any type of pump mechanism, such as a piston pump, screw pump or other hydraulic pump mechanism. InFIG. 2B, the pump mechanism is shown as a piston orplunger152 that is slidable in thechannel118 ofintroducer110A. In one embodiment, thepressure source150 includes a controller150B that controls the pressure applied by thepressure source150. For example, where thepressure source150 is a piston pump or screw pump that is motor driven, the controller150B can adjust the motor speed to vary the pressure applied by thepressure source150 to the inflow of thebone fill material120. In one embodiment, the controller150B also controls the volume of thebone fill material120 that is introduced to a bone portion. In another embodiment, the controller150B, or a separate controller, can also control the volume ofbone fill material120 introduced into the bone portion. For example, the controller150B can operate a valve associated with the bone fillsource145 to selectively vary the valve opening, thus varying the volume ofbone fill material120 introduced to the bone portion.
• As shown inFIGS. 2A and 2B, theintroducer110A preferably has an electrically and thermally insulativeinterior sleeve154 that defines theinterior flow channel118. The sleeve can be any suitable polymer known in the art such as PEEK, Teflon™ or a polyimide. As can be seen inFIG. 2B,interior sleeve154 carries conductive surfaces that function asenergy emitter128, and more particularly comprise spaced apart opposingpolarity electrodes132aand132b. Theelectrodes132aand132bcan have any spaced apart configuration and are disposed about the distal termination ofchannel118 or about the surfaces ofoutlet124a. The electrode configuration alternatively can include a first electrode in the interior ofchannel118 and a second electrode on an exterior ofintroducer110A. For example, themetallic sleeve123 or a distal portion thereof can comprise one electrode. In a preferred embodiment, theelectrodes132aand132bare connected to theRf energy source125A andcontroller125B by anelectrical cable156 with (+) and (−)electrical leads158aand158btherein that extend through theinsulative sleeve154 to the opposing polarity electrodes. In one embodiment, theelectrical cable156 is detachably coupled to thehandle end106 ofprobe105 by male-female plug (not shown). Theelectrodes132aand132bcan be fabricated of any suitable materials known to those skilled in the art, such as stainless steels, nickel-titanium alloys and alloys of gold, silver platinum and the like.
• In one embodiment, not shown, the workingend115A can also carry any suitable thermocouple or temperature sensor for providing data tocontroller125B relating to the temperature of thefill material120 during energy delivery. One or more thermocouples may be positioned at the distal tip of the introducer, or along an outer surface of the introducer and spaced from the distal end, in order to provide temperature readings at different locations within the bone. The thermocouple may also be slideable along the length of the introducer. In another embodiment, the working end can have at least one side port (not shown) in communication with a coolant source, the port configured to provide the coolant (e.g., saline) therethrough into thecancellous bone122 to cool the cancellous bone in response to a temperature reading from the temperature sensor.
• Now turning toFIG. 4, the sectional view of workingend115A illustrates the application of energy to fillmaterial120 as it is being ejected fromoutlet124a. Thefill material120 in the proximal portion ofchannel118 is preferably a low viscosity flowable material such as a two-part curable polymer that has been mixed (e.g., PMMA) but without any polymerization having, for example, a viscosity of less than about 50,000 cps. Such a low viscosity fill material allows for simplified lower pressure injection through theintroducer110A. Further, the system allows the use of a lowviscosity fill material120 which can save great deal of time for the physician.
• In a preferred embodiment, it is no longer necessary to wait for the bone cement to partly polymerize before injection. As depicted inFIG. 4, energy delivery at selected parameters fromelectrodes132aand132bto fillmaterial120 contemporaneous with its ejection fromoutlet124aselectively alters a property of fill material indicated at120′. In one embodiment, the altered flow property is viscosity. For example, the viscosity of thefill material120′ can be increased to a higher viscosity ranging from about 100,000 cps or more, 1,000,000 cps or more, to 2,000,000 cps or more. In another embodiment, the flow property is Young's modulus. For example, the Young's modulus of thefill material120′ can be altered to be between about 10 kPa and about 10 GPa. In still another embodiment, the flow property can be one of durometer, hardness and compliance.
• Preferably, thefill material120 carries a radiosensitive composition for cooperating with theRf source125A, as further described below. At a predetermined fill material flow rate and at selected Rf energy delivery parameters, the alteredfill material120′ after ejection can comprise an increased viscosity material or an elastomer. At yet another predetermined fill material flow rate and at other Rf energy delivery parameters, the alteredfill material120′ after ejection can comprise a substantially solid material. In the system embodiment utilized for vertebroplasty as depicted inFIGS. 2A and 5B, thecontroller125B is adapted for delivering Rf energy contemporaneous with the selected flow rate offill material120 to provide a substantially highviscosity fill material120′ that is still capable of permeating cancellous bone. In other osteoplasty procedures such as treating necrosis of a bone, thesystem controller125B can be adapted to provide muchharder fill material120′ upon ejection fromoutlet124a. Further, the system can be adapted to apply Rf energy to the fill material continuously, or in a pulse mode or in any selected intervals based on flow rate, presets, or in response to feedback from temperature sensors, impedance measurements or other suitable signals known to those skilled in the art.
• In one embodiment, thecontroller125B includes algorithms for adjusting power delivery applied by theenergy source125A. For example, in one embodiment thecontroller125B includes algorithms for adjusting power delivery based on impedance measurements of thefill material120′ introduced to the bone portion. In another embodiment, thecontroller125B includes algorithms for adjusting power delivery based on the volume ofbone fill material120 delivered to the bone portion. In still another embodiment, thecontroller125B includes algorithms for adjusting power delivery based on the temperature of thebone fill material120′ introduced to the bone portion.
• FIGS. 5A and 5B are views of avertebra90 that are useful for explaining relevant aspects of one embodiment of the invention wherein workingend110A is advanced into the region of thefracture94 in thecancellous bone122.FIG. 5A indicatessystem100 being used to injectflow material120′ into the vertebra with the flow material having a viscosity similar to conventional vertebroplasty or kyphoplasty, for example having the consistency of toothpaste.FIG. 5A depicts the situation wherein high pressure injection of a low viscosity material can simply follow paths of least resistance along arecent fracture plane160 to migrate anteriorly in an uncontrolled manner. The migration of fill material could be any direction, including posteriorly toward the spinal canal or into the disc space depending on the nature of the fracture.
• FIG. 5B illustratessystem100 including actuation of theRf source125A by thecontroller125B to contemporaneously heat the fill material to eject alteredfill material120′ with a selected higher viscosity intocancellous bone122, such as the viscosities described above. With a selected higher viscosity,FIG. 5B depicts the ability of the system to prevent extravasion of fill material and to controllably permeate and interdigitate withcancellous bone122, rather than displacing cancellous bone, with aplume165 that engages cortical bonevertebral endplates166aand166b. The fill material broadly engages surfaces of the cortical endplates to distribute pressures over the endplates. In a preferred embodiment, the fill material controllably permeatescancellous bone122 and is ejected at a viscosity adequate to interdigitate with thecancellous bone122. Fill material with a viscosity in the range of between about 100,000 cps to 2,000,000 cps may be ejected, though even lower or higher viscosities may also be sufficient. The Rf source may selectively increase the viscosity of the fill material by about 10% or more as it is ejected from theintroducer115A. In other embodiments, the viscosity may be increased by about 20%, 50%, 100%, 500% or 1000% or more.
• Still referring toFIG. 5B, it can be understood that continued inflows of highviscosity fill material120′ and the resultant expansion ofplume165 will apply forces onendplates166aand166bto at least partially restore the vertebral height of thevertebra90. It should be appreciated that the workingend115A can be translated axially between about the anterior third of the vertebral body and the posterior third of the vertebral body during the injection offill material120′, as well as that the workingend115A, which can be any of the types described above and shown inFIGS. 3A-3C, can be rotated.
• FIG. 6 is a schematic view of an alternative embodiment ofsystem100 wherein theRf source125A and thecontroller125B are configured to multiplex energy delivery to provide additional functionality. In one mode of operation, the system functions as described above and depicted inFIGS. 4 and 5B to alter flow properties offlowable fill material120′ as it is ejected from workingend115A. As can be seen inFIG. 6, the system further includes a return electrode orground pad170. Thus thesystem100 can be operated in a second mode of operation whereinelectrodes132aand132b(seeFIG. 2B) are switched to a common polarity (or the distal portion ofsleeve123 can comprise such an electrode) to function in a mono-polar manner in conjunction with theground pad170. This second mode of operation advantageously creates high energy densities about the surface ofplume165 to thereby ohmically heat tissue at the interface of theplume165 and the body structure.
• InFIG. 6, the ohmically heated tissue is indicated at172, wherein the tissue effect is coagulation of blood vessels, shrinkage of collagenous tissue and generally the sealing and ablation of bone marrow, vasculature and fat within the cancellous bone. The Rf energy levels can be set at a sufficiently high level to coagulate, seal or ablate tissue, with the controller delivering power based, for example, on impedance feedback which will vary with the surface area ofplume165. Of particular interest, the surface ofplume165 is used as an electrode with an expanding wavefront withincancellous bone122. Thus, the vasculature within the vertebral body can be sealed by controlled ohmic heating at the same time that fillmaterial120′ is permeating the cancellous bone. Within the vertebral body are the basivertebral (intravertebral) veins which are paired valveless veins connecting with numerous venous channels within the vertebra (pars spongiosa/red bone marrow). These basivertebral veins drain directly into the external vertebral venous plexus (EVVP) and the superior and inferior vena cava. The sealing of vasculature and the basivertebral veins is particularly important since bone cement and monomer embolism has been frequently observed in vertebroplasty and kyphoplasty cases (see “Anatomical and Pathological Considerations in Percutaneous Vertebroplasty and Kyphoplasty: A Reappraisal of the Vertebral Venous System”, Groen, R. et al, Spine Vol. 29, No. 13, pp 1465-1471 2004). It can be thus understood that the method of using thesystem100 creates and expands a “wavefront” of coagulum that expands as theplume165 of fill material expands. Theexpandable coagulum layer172, besides sealing the tissue from emboli, contains and distributes pressures of the volume ofinfill material120′ about the plume surface.
• The method depicted inFIG. 6 provides an effective means for sealing tissue via ohmic (Joule) heating. It has been found that passive heat transfer from the exothermic reaction of a bone cement does not adequately heat tissue to the needed depth or temperature to seal intravertebral vasculature. In use, the mode of operation of thesystem100 in a mono-polar manner for ohmically heating and sealing tissue can be performed in selected intervals alone or in combination with the bi-polar mode of operation for controlling the viscosity of the injected fill material.
• In general, one aspect of the vertebroplasty or osteoplasty method in accordance with one of the embodiments disclosed herein allows for in-situ control of flows of a flowable fill material, and more particularly comprises introducing a working end of an introducer sleeve into cancellous bone, ejecting a volume of flowable fill material having a selected viscosity and contemporaneously applying energy (e.g., Rf energy) to the fill material from an external source to thereby increase the viscosity of at least portion of the volume to prevent fill extravasion. In a preferred embodiment, the system increases the viscosity by about 20% or more. In another preferred embodiment, the system increases the viscosity by about 50% or more.
• In another aspect of one embodiment of a vertebroplasty method, thesystem100 provides means for ohmically heating a body structure about the surface of the expandingplume165 of fill material to effectively seal intravertebral vasculature to prevent emboli from entering the venous system. The method further provides an expandable layer of coagulum about the infill material to contain inflow pressures and distribute further expansion forces over the vertebral endplates. In a preferred embodiment, the coagulum expands together with at least a portion of the infill material to engage and apply forces to endplates of the vertebra.
• Of particular interest, one embodiment offill material120 as used in the systems described herein (seeFIGS. 2A,4,5A-5B and6) is a composite comprising an in-situ hardenable orpolymerizable cement component174 and an electricallyconductive filler component175 in a sufficient volume to enable the composite to function as a dispersable electrode (FIG. 6). In one type of composite, the conductive filler component is any biocompatible conductive metal. In another type of composite, the conductive filler component is a form of carbon. The biocompatible metal can include at least one of titanium, tantalum, stainless steel, silver, gold, platinum, nickel, tin, nickel titanium alloy, palladium, magnesium, iron, molybdenum, tungsten, zirconium, zinc, cobalt or chromium and alloys thereof. The conductive filler component has the form of at least one of filaments, particles, microspheres, spheres, powders, grains, flakes, granules, crystals, rods, tubules, nanotubes, scaffolds and the like. In one embodiment, the conductive filler includes carbon nanotubes. Such conductive filler components can be at least one of rigid, non-rigid, solid, porous or hollow, withconductive filaments176aillustrated inFIG. 7A andconductive particles176bdepicted inFIG. 7B.
• In a preferred embodiment, the conductive filler comprises chopped microfilaments or ribbons of a metal as inFIG. 7A that have a diameter or a cross-section dimension across a major axis ranging between about 0.0005″ and 0.01″. The lengths of the microfilaments or ribbons range from about 0.01″ to 0.50″. The microfilaments or ribbons are of stainless steel or titanium and are optionally coated with a thin gold layer or silver layer that can be deposited by electroless plating methods. Of particular interest, thefill material120 ofFIG. 7A has an in situhardenable cement component174 than has a first low viscosity and the addition of the elongated microfilamentconductive filler component175 causes the composite120 to have a substantially high apparent viscosity due to the high surface area of the microfilaments and its interaction with thecement component174. In one embodiment, the microfilaments are made of stainless steel, plated with gold, and have a diameter of about 12 microns and a length of about 6 mm. The other dimensions provided above and below may also be utilized for these microfilaments.
• In another embodiment ofbone fill material120, the conductive filler component comprises elements that have a non-conductive core portion with a conductive cladding portion for providing electrosurgical functionality. The non-conductive core portions are selected from the group consisting of glass, ceramic or polymer materials. The cladding can be any suitable conductive metal as described above that can be deposited by electroless plating methods.
• In any embodiment of bone fill material that uses particles, microspheres, spheres, powders, grains, flakes, granules, crystals or the like, such elements can have a mean dimension across a principal axis ranging from about 0.5 micron to 2000 microns. More preferably, the mean dimension across a principal axis range from about 50 microns to 1000 microns. It has been found that metal microspheres having a diameter of about 800 microns are useful for creating conductive bone cement that can function as an electrode.
• In one embodiment, a conductive filler comprising elongated microfilaments wherein the fill material has from about 0.5% to 20% microfilaments by weight. More preferably, the filaments are from about 1% to 10% by weight of the fill material. In other embodiments wherein the conductive filler comprises particles or spheres, the conductive filler can comprise from about 5% of the total weight to about 80% of the weight of the material.
• In anexemplary fill material120, the hardenable component can be any in-situ hardenable composition such as at least one of PMMA, monocalcium phosphate, tricalcium phosphate, calcium carbonate, calcium sulphate or hydroxyapatite.
• Referring now toFIGS. 8A and 8B, an alternative method is shown wherein thesystem100 and method are configured for creating asymmetries in properties of the infill material and thereby in the application of forces in a vertebroplasty. InFIG. 8A, thepressure mechanism150 is actuated to cause injection of an initial volume or aliquot offill material120′ that typically is altered in viscosity in workingend115A as described above—but the method encompasses flows of fill material having any suitable viscosity. Thefill material120′ is depicted inFIGS. 8A and 8B as being delivered in a unilateral transpedicular approach, but any extrapedicular posterior approach is possible as well as any bilateral posterior approach. The system inFIGS. 8A-8B again illustrates a vertical plane through thefill material120′ that flows under pressure intocancellous bone122 with expanding plume or periphery indicated at165. Theplume165 has a three dimensional configuration as can be seen inFIG. 8B, wherein the pressurized flow may first tend to flow more horizontally that vertically. One embodiment of the method of the invention includes the physician translating the workingend115A of theintroducer110A slightly and/or rotating the workingend115A so thatflow outlets124aare provided in a selected radial orientation. In a preferred embodiment, the physician intermittently monitors the flows under fluoroscopic imaging as described above.
• FIG. 8B depicts a contemporaneous or subsequent energy-delivery step of the method wherein the physician actuates the Rfelectrical source125A andcontroller125B to cause Rf current delivery from the at least oneelectrode emitter128 to cause ohmic (Joule) heating of tissue as well as internal heating of theinflowing fill material120′. In this embodiment, the exterior surface ofsleeve123 is indicated as electrode oremitter128 with the proximal portion ofintroducer110A having aninsulator coating178. The Rf energy is preferably applied in an amount and for a duration that coagulates tissue as well as alters a flowability property ofsurface portions180 of the initial volume of fill material proximate the highest energy densities in tissue.
• In one preferred embodiment, thefill material120 is particularly designed to create a gradient in the distribution of conductive filler with an increase in volume of material injected under high pressure intocancellous bone122. This aspect of the method in turn can be used advantageously to create asymmetric internal heating of the fill volume. In this embodiment, thefill material120 includes a conductive filler of elongatedconductive microfilaments176a(FIG. 7A). The filaments are from about 2% to 5% by weight of the fill material, with the filaments having a mean diameter or mean sectional dimension across a minor axis ranging between about 0.001″ and 0.010″ and a length ranging from about 1 mm to about 10 mm, more preferably about 1 mm to 5 mm. In another embodiment, the filaments have a mean diameter or a mean dimension across a minor axis ranging between about 1 micron and 500 microns, more preferably between about 1 micron and 50 microns, even more preferably between about 1 micron and 20 microns. It has been found that elongatedconductive microfilaments176aresult in resistance to flows thereabout which causes such microfilaments to aggregate away from the most active media flows that are concentrated in the center of the vertebra proximate tooutlet124a. Thus, theconductive microfilaments176aattain a higher concentration in the peripheral orsurface portion180 of the plume which in turn will result in greater internal heating of the fill portions having such higher concentrations of conductive filaments. The active flows also are controlled by rotation ofintroducer110A to eject the material preferentially, for example laterally as depicted inFIGS. 8A and 8B rather that vertically. Thehandle106 of theprobe105 preferably has markings to indicate the rotational orientation of theoutlets124b.
• FIG. 8A depicts the application of Rf energy in a monopolar manner betweenelectrode emitter128 andground pad170, which thus causes asymmetric heating whereinsurface portion180 heating results in greater polymerization therein. As can be seen inFIG. 8A, the volume of fill material thus exhibits a gradient in a flowability property, for example withsurface region180 having a higher viscosity than inflowingmaterial120′ as it is ejected fromoutlet124a. In one embodiment, the gradient is continuous. Such heating at theplume periphery165 can create an altered, highlyviscous surface region180. This step of the method can transform the fill material to have a gradient in flowability in an interval of about 5 seconds to 500 seconds withsurface portion180 being either a highly viscous, flowable layer or an elastomer that is expandable. In preferred embodiments, the interval of energy delivery required less than about 120 seconds to alter fill material to a selected asymmetric condition. In another aspect of the invention, the Rf energy application for creating the gradient in flowability also can be optimized for coagulating and sealing adjacent tissue.
• The combination of theviscous surface portion180 and thetissue coagulum172 may function as an in-situ created stretchable, but substantially flow-impervious, layer to contain subsequent high pressure inflows of fill material. Thus, the next step of the method is depicted inFIG. 8B which includes injectingadditional fill material120′ under high pressure into the interior of the initial volume offill material120 that then has a highly viscous, expandable surface. The viscous, expandable surface desirably surrounds cancellous bone so that the subsequent injection of fill material can expand the fill volume to apply retraction forces on thevertebra endplates166aand166bto provide vertical jacking forces, distracting cortical bone, for restoring vertebral height, as indicated by the arrows inFIG. 8B. The system can generate forces capable of breaking callus in cortical bone about a vertebral compression fracture when the fracture is less than completely healed.
• In one embodiment, the method includes applying Rf energy to create highly viscous regions in a volume of fill material and thereafter injectingadditional fill material120 to controllably expand the fill volume and control the direction of force application. The scope of the method further includes applying Rf energy in multiple intervals or contemporaneous with a continuous flow of fill material. The scope of the method also includes applying Rf energy in conjunction with imaging means to prevent unwanted flows of the fill material. The scope of the invention also includes applying Rf energy to polymerize and accelerate hardening of the entire fill volume after the desired amount of fill material has been injected into a bone.
• In another embodiment, the method includes creating Rf current densities in selected portions of the volume offill material120 to create asymmetric fill properties based on particular characteristics of the vertebral body. For example, the impedance variances in cancellous bone and cortical bone can be used to create varied Rf energy densities infill material120 to create asymmetric properties therein. Continued injection offill material120 are thus induced to apply asymmetric retraction forces againstcortical endplates166aand166b, wherein the flow direction is toward movement or deformation of the lower viscosity portions and away from the higher viscosity portions. InFIGS. 9A-9C, it can be seen that in a vertebroplasty, the application of Rf energy in a mono-polar manner as inFIG. 6 naturally and preferentially creates more highly viscous, deeper “altered” properties in surfaces of the lateral peripheral fill volumes indicated at185 and185′ and less viscous, thinner altered surfaces in the superior andinferior regions186 and186′ offill material120. This effect occurs since Rf current density is localized about paths of least resistance which are predominantly in locations proximate to highly conductivecancellous bone122aand122b. The Rf current density is less in locations proximate to less conductive cortical bone indicated at166aand166b. Thus, it can be seen inFIG. 9B that the lateralperipheral portions185 and185′ of the first flows offill material120 are more viscous and resistant to flow and expansion than the thinner superior and inferior regions. InFIG. 9C, the asymmetrical properties of the initial flows offill material120 allows the continued flows to apply retraction forces in substantially vertical directions to reduce the vertebral fracture and increase vertebral height, for example from VH (FIG. 9B) to VH′ inFIG. 9C.
• FIGS. 10A and 10B are schematic views that further depict a method corresponding toFIGS. 9B and 9C that comprises expanding cancellous bone for applying retraction forces against cortical bone, e.g., endplates of a vertebra in a vertebroplasty. As can be seen inFIG. 10A, an initial volume offlowable fill material120 is injected into cancellous bone whereinsurface region180 is altered as described above to be highly viscous or to comprise and elastomer that is substantially impermeable to interior flows but still be expandable. Thesurface region180 surrounds subsequent flows offill material120′ which interdigitate with cancellous bone. Thereafter, as shown inFIG. 10B, continued high pressure inflow into the interior of the fill material thereby expands thecancellous bone122 together with the interdigitatedfill material120′. As can be seen inFIG. 10B, the expansion ofcancellous bone122 and fillmaterial120′ thus applies retraction forces to movecortical bone endplates166aand166b. The method of expanding cancellous bone can be used to reduce a bone fracture such as a vertebral compression fracture and can augment or restore the height of a fractured vertebra. The system thus can be used to support retract and support cortical bone, and cancellous bone. The method can also restore the shape of an abnormal vertebra, such as one damaged by a tumor.
• After utilizingsystem100 to introduce, alter and optionally hardenfill material120 as depicted inFIGS. 9A-9C and10A-10B, theintroducer110A can be withdrawn from the bone. Alternatively, theintroducer110A can have a release or detachment structure indicated at190 for de-mating the working end from the proximal introducer portion as described in co-pending U.S. patent application Ser. No. 11/130,843, filed May 16, 2005, now U.S. Pub. No. 2006-0100706, the entirety of which is hereby incorporated by reference and should be considered a part of this specification.
• Anothersystem200 for controlling flow directions and for creating asymmetric properties is shown inFIGS. 11A and 11B, wherein first andsecond introducers110A and110B similar to those described above are used to introduce first and secondindependent volumes202aand202boffill material120 in a bilateral approach. In this embodiment, the two fill volumes function as opposing polarity electrodes in contact withelectrodes205aand205bof the working ends. Current flow between the electrodes thus operates in a bi-polar manner with the positive and negative polarities indicated by the (+) and (−) symbols. In this method, it also can be seen that the highest current density occurs in the three dimensional surfaces ofvolumes202aand202bthat face one another. This results in creating the thickest,high viscosity surfaces208 in the medial, anterior and posterior regions and the least “altered” surfaces in the laterally outward regions. This method is well suited for preventing posterior and anterior flows and directing retraction forces superiorly and inferiorly since lateral flow are contained by the cortical bone at lateral aspects of the vertebra. The system can further be adapted to switch ohmic heating effects between the bi-polar manner and the mono-polar manner described previously.
• Now referring toFIG. 12, another embodiment is shown wherein atranslatable member210 that functions as an electrode is carried byintroducer110A. In a preferred embodiment, themember210 is a superelastic nickel titanium shape memory wire that has a curved memory shape. Themember210 can have abare electrode tip212 with a radiopaque marking and is otherwise covered by a thin insulator coating. InFIG. 12, it can be seen that the introducer can be rotated and the member can be advanced from aport214 in the workingend115A under imaging. By moving theelectrode tip212 to a desired location and then actuating RF current, it is possible to create a local viscous orhardened region216 offill material120. For example, if imaging indicates thatfill material120 is flowing in an undesired direction, then injection can be stopped and Rf energy can be applied to harden the selected location.
• FIG. 13 illustrates another embodiment of theintroducer110A which includes a transition in cross-sectional dimension to allow for decreased pressure requirements for introducing bone cement through the length of theintroducer110A. In the embodiment ofFIG. 13, theproximal handle end106 is coupled tointroducer110A that has a larger diameterproximal end portion218athat transitions to a smaller diameterdistal end portion218bconfigured for insertion into a vertebral body. Thedistal end portion218bincludesexterior threads220 for helical advancement and engagement in bone to prevent theintroducer110A from moving proximally when cement is injected into a vertebral body or other bone, for example to augment vertebral height when treating a VCF. The bore that extends through theintroducer110A similarly transitions from larger diameter boreportion224ato smaller diameter boreportion224b. The embodiment ofFIG. 13 utilizes a bore termination orslot225 in a sidewall of the workingend115A for ejecting bone cement at a selected radial angle from theaxis226 of the introducer for directing cement outflows within a vertebral body.
• Still referring toFIG. 13, theintroducer110A is coupled tobone cement source145 andpressure source150 as described previously that is controlled bycontroller125B. Further, anenergy source125A (e.g., Rf source) is coupled to an energy delivery mechanism in the workingend115A for applying energy to a cement flow withinbore224b. In the embodiment ofFIG. 13, theintroducer110A can be fabricated of a strong reinforced plastic such a polymide composite with asleeve electrode228 inbore224band inward of thebore termination slot225, similar toelectrode128 depicted inFIG. 3A. Theelectrode228 inFIG. 13 is coupled toRf source125A for operating in a mono-polar manner in cooperation with thereturn ground pad170. Thecontroller125B again is operatively connected to theRf source125A to adjust energy delivery parameters in response to feedback from athermocouple235 in thebore124bor in response to measuring impedance of the cement flow. InFIG. 13, thecontroller125B further is operationally connected to anaspiration source240 that is coupled to a needle-like introducer sleeve242 that can be inserted into a bone to apply suction forces to the interior of vertebra for relieving pressure in the vertebra and/or extracting fluids, bone marrow and the like that could migrate into the venous system. The use of such an aspiration system will be described further below.
• InFIG. 13, theintroducer110A has a larger diameter bore224athat ranges from about 4 mm to 10 mm, and preferably is in the range of about 5 mm to 6 mm. The smaller diameter bore224bcan range from about 1 mm to 3 mm, and preferably is in the range of about 1.5 mm to 2.5 mm. Theexterior threads220 can be any suitable height with single or dual flights configured for gripping cancellous bone. The thread height and length of the reduceddiameter section218bare configured for insertion into a vertebra so that theport225 can be anteriorly or centrally located in the vertebral body. The workingend115A further carries aradiopaque marking244 for orienting the radial angle of the introducer and boretermination port225. InFIG. 13, theradiopaque marking244 is elongated and surroundsport225 in the introducer sidewall. Thehandle106 also carries a marking245 for indicating the radial angle ofport225 to allow the physician to orient the port by observation of the handle.
• Now referring toFIGS. 14A-14C, the workingend115A of the introducer ofFIG. 13 is shown after being introduced intocancellous bone122 invertebra90.FIG. 14A illustrates a horizontal sectional view ofvertebra90 wherein thebore termination port225 is oriented superiorly to direct cement inflows to apply forces againstcancellous bone122 and the superiorcortical endplate248 of the vertebra. A method of delivering bone cement comprises providing a flow source250 (thepressure source150 andcement source145, in combination, are identified asflow source250 inFIG. 13) for bone cement inflows and acontroller125B for control of the bone cement inflows, and inflowing the bone cement into a vertebral body wherein thecontroller125B adjusts an inflow parameter in response to a measured characteristic of the cement. In one embodiment, the measured characteristic is temperature of the bone cement measured bythermocouple235 in the workingend115A. Thecontroller125B can be any custom computerized controller. In one embodiment, the system can utilize a commercially available controller manufactured by EFD Inc., East Providence, R.I. 02914, USA for flow control, wherein either a positive displacement dispensing system or an air-powered dispensing system can be coupled to theflow source250. In response to feedback fromthermocouple235 that is received by thecontroller125B, any inflow parameter of the bone cement flow can be adjusted, for example cement injection pressure, the inflow rate or velocity of the bone cement flows or the acceleration of a bone cement flow. Thecontroller125B also can preferably vary any inflow parameter with time, for example, in pulsing cement inflows to thereby reduce a vertebral fracture, or move cancellous or cortical bone (seeFIGS. 14A-14B). Thecement120 can be introduced in suitable volumes and geometries to treat fractures or to prophylactically treat a vertebra.
• In another method corresponding to the invention, theflow source250,controller125B andRf energy source125A are provided as shown inFIG. 13. Thecontroller125B again is capable of adjusting any bone cement delivery parameter in response to impedance and/or temperature. Thecontroller125B adjusts at least one cement delivery parameter selected from cement volume, pressure, velocity and acceleration of the inflowing cement. Thecontroller125B also can vary pressure of the inflowing cement or pulse the cement inflows. In this embodiment, thecontroller125B also is capable of adjusting energy delivered fromRf energy source125A to theinflowing cement120 in response to impedance, temperature, cement viscosity feedback or cement flow parameters to alter cement viscosity as described above. Cement viscosity can be calculated by thecontroller125B from temperature and pressure signals. Thecontroller125B also is capable of being programmed with algorithms to ramp-up and ramp down power in one or more steps, or can be programmed to pulse power delivery to the bone cement120 (FIGS.14A-14BA).
• As can be seen inFIGS. 14B and 14C, the inflowingcement120 can be directed to apply forces againstcancellous bone122 and the superiorcortical endplate248 of the vertebra, or the working end can be rotated to introducecement120 and apply forces in other directions. In this embodiment, the extension of the workingend115A in cancellous bone serves as a support for causing expansion pressures to be directed substantially in the direction of cement flows. The method of treating the vertebra includes translating (by helical advancement) and rotating theintroducer110A to thereby alter the direction of cement introduction. In another embodiment (not shown), theintroducer110A can comprise an assembly of first and second concentric sleeves wherein the outer sleeve hasthreads220 for locking the assembly in bone and the inner sleeve is rotatable to adjust the angular direction ofport225 wherein the sleeves are locked together axially. This embodiment can be used to intermittently angularly adjust the direction of cement outflows while helical movement of the outer sleeve adjusts the axial location ofport225 and the cement outflows.
• In another method of the invention, referring back toFIG. 14A, the aspiration introducersleeve242 can be inserted into thevertebral body90, for example through the opposing pedicle. Thecontroller125B can be programmed to alter aspiration parameters in coordination with any bone cement inflow parameter. For example, the cement inflows can be pulsed and the aspiration forces can be pulsed cooperatively to extract fluids and potentially embolic materials, with the pulses synchronized. In one method, the cement inflows are pulsed at frequency ranging between about 1 per second and 500 per second with an intense, high acceleration pulse which causes bone marrow, fat, blood and similar materials to become susceptible to movement while at the same time the aspiration pulses are strong to extract some mobile marrow etc into theaspiration sleeve242. InFIG. 14A, theaspiration sleeve242 is shown with single port in it distal end. It should be appreciated that anaspiration sleeve242 that has a plurality of inflow ports along the length of the sleeve, a sleeve that is curved or can be of a shape memory alloy (e.g., Nitinol) for introduction in a curved path in the anterior of posterior region of a vertebral body as indicated bylines260 and260′ inFIG. 14A, can also be used. In another embodiment, the aspiration sleeve can extend through theintroducer110A or can comprise an outer concentric sleeve around theintroducer110A.
• FIGS. 15A and 15B illustrates another embodiment of a method for delivering bone fill material wherein thecontroller125B andpressure source150 are configured to introduce a flowable cement into the interior of a vertebra under widely varying velocities and rates of acceleration to optionally (i) provide first slow flow rates to allow cement flow and interdigitation into and through cancellous bone, and (ii) provide second higher flow rates that disallow cement interdigitation and flow into and through cancellous bone. At suitable high acceleration and flow velocity, for example in a pulse of cement flow into bone, the accelerated flow apply forces to bone substantially across the surface of the cement plume which can displace cancellous bone rather than allowing the cement to flow into the cancellous bone.
• FIG. 15A illustrates the system ofFIG. 13 in a method of use wherein thecontroller125B andpressure source150 are actuated to cause a volume ofcement120 to flow intocancellous bone122 under a suitable low pressure to allow the cement to interdigitate with, and flow into, the cancellous bone. The flow of cement depicted inFIG. 15A can be accompanied by the application of aspiration forces as described above.
• FIG. 15B illustrates another aspect of the method wherein thecontroller125B andpressure source150 are actuated to flow cement with a high acceleration rate and velocity that disallows the cement from having time to flow into pores of the cancellous bone. The acceleration and velocity are selected to disallow cement interdigitation, which thereby causes the application of force to bone across the surface of the cement plume265 (FIG. 15B). The application of such forces across the surface ofcement plume265 is further enabled by providing a suitable high viscosity cement as described above, which includes selectively increasing cement viscosity by means of energy delivery thereto. The method of the invention can include one or more sequences of flowing cement into the bone to first cause cement interdigitation (FIG. 15A) and then to apply expansion forces to the bone by at least one high acceleration flow (FIG. 15B). Of particular interest, the method of using high acceleration flows, for example in pulses, causes the cement volume to apply forces to bone akin to the manner is which a mechanical expander or balloon expander would apply forces to bone. That is, expansion forces are applied across the entire surface ofcement plume265 similar to the manner in which mechanical instruments apply expanding forces across the bone engaging surface of the instrument. The methods are adapted for reducing a vertebral fracture and for selectively applying forces to move cancellous bone and cortical bone.
Retrograde Sensing Systems and Methods
• FIG. 16 illustrates another embodiment of anintroducer110A for safe introduction of bone cements into a vertebra that incorporates asensing system280. Thesensing system280 includes the introducer orcannula110A with at least onedistal port225 for injection of bone cement into avertebra90, as described previously with respect toFIGS. 13-15B. Thissensing system280 further includes at least one electrode carried about an otherwise insulativeexterior surface278 of the cannula orintroducer110A. In the illustrated embodiment, thesensing system280 has three electrodes orsensors280a,280b,280cdisposed about a surface of the introducer110A, but it can be appreciated that more or fewer such electrodes can be used. In the illustrated embodiment, theelectrodes280a,280b,280care ring electrodes, however other configurations are possible. Preferably, theelectrodes280a,280b,280care independently coupled to a lowvoltage power source285, which can be a DC or AC source, and to acontroller286 that allows for measurement of impedance between a pair of theelectrodes280a,280b,280cor between theelectrodes280a,280b,280cand another electrode288 (in phantom) located in a more proximal location on theintroducer110A that contacts tissue, or betweenelectrodes280a,280b,280cand a ground pad. Such impedance measurements can advantageously provide the physician with instant feedback that indicates whether there in aflow290 ofbone cement120 along thecannula110A (e.g., a retrograde flow). Retrograde flows of cement can be seen by imaging means, but imaging is typically not performed continuously during vertebroplasty. Further, the cannula itself may obscure clear imaging of a cement flow. Such retrograde cement flows, if unnoticed, could leak through a fracture to contact nerves and/or the spinal cord. Though thesensors280a,280b,280cin the illustrated embodiment are adapted to measure impedance, thesensors280a,280b,280ccan be adapted to measure other suitable electrical, chemical or mechanical parameters, such as temperature, voltage, and reflectance.
• InFIG. 16, it can be seen that theretrograde flow290 ofbone cement120 along thecannula110A passes by, and in one embodiment may contact, first andsecond electrodes280aand280b, which will alter the impedance (or other sensed parameter) measured between the first andsecond electrodes280a,280bfrom the normal tissue impedance. The control algorithms advantageously create a signal to notify the physician of the variation in impedance measurement. The signal can be a tone, a visual signal such as a light and or a tactile signal such as a vibrator in the handle of theintroducer110A. Thecontroller286 can preferably switch sensing between various electrodes (e.g., adjacent electrodes or non-adjacent electrodes) to indicate the location of any migrating cement. The cement delivery system may use a conductive bone cement, as described in U.S. application Ser. No. 11/209,035 filed Aug. 22, 2005, which will have a significantly different impedance than tissue to allow for easy detection of cement flows. It should be appreciated that any conventional bone cement will have a different impedance than bone tissue so that aretrograde flow290 of conventional bone cement can be detected. Thecontroller286 algorithms can be configured for any type of bone cement, wherein each type has a known impedance, reflectance, etc. For example, a bone cement formula can be provided for use with thecontroller286 to measure impedance and detect variations in impedance due to bone cement flow. In one embodiment, thecontroller286 preferably compares the sensed parameter (e.g., impedance) of the retrograde flow bone cement with a known value or value range for said parameter in bone tissue (e.g., vertebral tissue). The known values for the parameter can be stored in an algorithm or formulas stored in thecontroller286 or in a separate memory. In another embodiment, thecontroller286 can measure impedance (or other parameter values) of vertebral tissue adjacent at least one of theelectrodes280a,280band compare said measured impedance to a measured impedance of retrograde bone cement flow adjacent another of theelectrodes280a,280b.
• In another embodiment, the feedback from thesensing system280 ofFIG. 16 can be further adapted for actuating a control mechanism relating to operation of the vertebroplasty system. In one embodiment, as described inFIGS. 13-15B, the flow of bone cement is controlled by acontroller125B andpressure source150. Feedback from thesensors280a,280b,280cto thecontroller286, which are used to measure impedance, can be used to adjust or terminate the flow of bone cement from the pressurized source ofbone cement145.
• In another embodiment, the feedback from thesensing system280 ofFIG. 16 can be adapted to expand an expansion structure295 (in phantom) about the surface of the cannula to prevent further bone cement migration. The expansion structure can be a fluid filled balloon, a thermally expandable polymer that has resistive or Rf energy applied thereto, or an elastomeric structure that can be expanded by axially or rotationally moving concentric cannula sleeves.
• In another embodiment, thesensing system280 can include athermocouple282 for measuring temperature of media proximate theexterior surface278 of thecannula110A. Such a temperature sensor can be well insulated from the interior bore of the cannula which will carry exothermic cement. Thesensor system280 can also include a light sensor system that can measure and compare a tissue parameter and a bone cement parameter. For example, a fiber optic can be provided to emit and/or receive light at the electrode locations inFIG. 16. Various parameters are possible such as reflectance. Alternatively, the bone cement can be configured with signaling compositions to cooperate with light emitted from a light source.
• While thesensing system280 has been described with the sensors being proximal to thecement injection port225 of thecannula110A, the sensors also can be elsewhere along thecannula110A, for example at the distal end of thecannula110A, to detect cement flow in that direction, such as in an anterograde direction.
• FIG. 17, shows another embodiment of a bone fill introducer orinjector system310A for treatment of the spine, such as in a vertebroplasty procedure.Introducer system310A is used for placement a fill material fromsource145, wherein injection of the fill material is carried out by the pressure mechanism orsource150. Thepressure mechanism150 can be a manually operated syringe loaded with bone fill material, or a non-manual pressurized source of fill material. Thesource145 of fill material preferably includes a coupling or fitting314 for sealable locking to acorresponding fitting315 at aproximal end316 of an elongated introducer sleeve orcannula320. In one embodiment, the source offill material145 is coupled directly to fitting315 with a threaded coupling, a Luer lock or the like. In another embodiment as inFIG. 17, a flexible tube318 (phantom view) is used to couple thesource145 to theintroducer320.
• With continued reference toFIG. 17, the bone fillintroducer system310A includes theelongated sleeve320 withinterior channel322 extending alongaxis324, wherein thechannel322 terminates in anoutlet opening325. In the illustrated embodiment, theoutlet opening325 is disposed proximal the distal end of theelongated sleeve320 and faces a side of thesleeve320. In the illustrated embodiment, theoutlet opening325 is a single opening. In other embodiments, a plurality of outlet openings can be disposed on anoutward surface328 of thesleeve320 about a circumference of thesleeve320. In another embodiment, an outlet opening can be provided at thedistal tip330. In one embodiment, thedistal tip330 is blunt. In another embodiment, the distal tip can be sharp as with a chisel-like tip.
• As can be seen inFIG. 17, theexterior surface328 of theintroducer sleeve320 carries at least onesensor system344 adapted to sense the flow or movement of a fill material345 (seeFIGS. 18A-18C) proximate to thesensor system344. Theintroducer sleeve320 andsensor system344 are particularly useful in monitoring and preventing extravasion of afill material345 in a vertebroplasty procedure. In the illustrated embodiment, thesensor system344 comprises a plurality of spaced apart electrodes orsensors354a,354b,354ccoupled to theelectrical source125A via anelectrical connector356 preferably disposed at the proximal end of theintroducer320. Theelectrodes354a,354b,354care preferably spaced apart about the circumference of theintroducer320, as well as axially along the length of theintroducer320. Theelectrical source125A preferably carries a low voltage direct current, such as an Rf current, between the opposing potentials of spaced apart electrodes. The voltage is preferably between about 0.1 volts to about 500 volts, or from between about 1 volt to about 5 volts, and preferably creates a current path through the tissue between a pair of electrodes. The current can be continuous, intermittent and/or multiplexed between different electrode pairs or groups of electrodes.
• In one embodiment and method of use, referring toFIGS. 18A-18C, theintroducer sleeve320, as shown inFIG. 17, is used in a conventional vertebroplasty procedure with a single pedicular access through avertebra350. Alternatively, a bi-pedicular access can be used. Thefill material345 is preferably a bone cement, such as PMMA, that is injected intocancellous bone346 within the interior of acortical bone surface348 of thevertebra350.
• FIGS. 18A-18B show a progressive flow ofcement345 that exits theintroducer sleeve320 throughoutlet325 and into the interior of thevertebra350.FIG. 18C depicts a situation that is known to occur where bone is fractured along the entry path of theintroducer320, or where the pressurized cement finds the path of least resistance to be retrograde along the surface ofintroducer320. The retrograde flow of cement, as inFIG. 18C, if allowed to continue, could lead to cement extravasion into thespinal canal352. In one embodiment, thesensor system344 is actuated when thebone cement345 comes into contact with at least one of thesensors354a,354b,354cof thesensor system344. In another embodiment, thesensor system344 continually monitors the impedance adjacent thesensors354a,354b,354cof thesensor system344.
• The arrangement ofelectrodes354a,354b,354ccan be spaced apart angularly and axially as shown inFIG. 17, or the electrodes can be ring electrodes (seeFIG. 16), helically spaced electrodes, or the electrodes can be miniaturized electrodes as in thermocouples, MEMS devices or any combination thereof. The number of sensors or electrodes can range from about 1 to 100 and can be adapted to cooperate with a ground pad (e.g.,ground pad170 inFIG. 13) or other surface portion ofsleeve320. In one embodiment, the electrodes can include a PTC or NTC material (positive temperature coefficient of resistance or negative temperature coefficient of resistance) to thereby function as a thermistor to allow measurement of temperature, as well as functioning as a sensor. Thesensor system344 includes thecontroller125B, which measures at least one selected parameter of the current flow to determine a change in a parameter such as impedance. When the bone cement345 (e.g., a non-conductive bone cement material) contacts one or more electrodes of thesensor system344, thecontroller125B identifies a change in the selected electrical parameter and generates a signal to the operator. In another embodiment, thecontroller125B identifies a change in the selected parameter when thebone cement345 passes proximal one or more of the sensors of thesensor system344 and communicates a signal to the operator corresponding to said change in said selected parameter. Said selected parameter can be at least one electrical property, reflectance, fluorescence, magnetic property, chemical property, mechanical property or a combination thereof.
• Now referring toFIG. 19, another embodiment of abone fill system310B for vertebroplasty procedures is shown. Thebone fill system310B includes anintroducer320 with aproximal portion360athat is larger in cross-section than adistal portion360bthereof. This advantageously allows for lower injection pressures since the cement flow needs to travel a shorter distance through the smallest diameterdistal portion360bof theintroducer320. In one embodiment, thedistal portion360bof theintroducer385 can have a cross section ranging between about 2 mm and 4 mm with a length ranging between about 40 mm and 60 mm. Similarly, in one embodiment theproximal portion360aof theintroducer320 can have a cross section ranging between about 5 mm and 15 mm, or between about 6 mm and 12 mm. However the proximal anddistal portions360a,360bof theintroducer320 can have other suitable dimensions.
• With continued reference toFIG. 19, thebone fill system310B also includes asensing system365 for detecting a retrograde flow of bone cement along anouter surface366 of theintroducer320. In the illustrated embodiment, thesensing system365 includes a first and asecond electrode365a,365bin the form of spaced apart exposed flat wire surfaces that are disposed on thesurface366 of thedistal introducer portion360b, wherein theintroducer320 includes asurface insulator layer368. In one embodiment, theinsulator layer368 covers the entire surface of thedistal introducer portion360b, and more preferably the entire surface of theintroducer320, except where theelectrodes365a,365bare disposed. In another embodiment, thedistal introducer portion360bcan be a conductive metal introducer portion with a first polarity electrode that is exposed in cut-out portions ofinsulator layer368 and another opposing polarity electrode is disposed on the surface of theinsulator layer368. In the illustrated embodiment the electrodes orsensors365a,365bhave a helical shape and extend helically along theintroducer320. However, in another embodiment, theelectrodes365a,365bcan have other suitable shapes (e.g., ring electrodes). ThoughFIG. 19 shows twoelectrodes365a,365b, one of ordinary skill in the art will recognize that more or less than two electrodes can be provided.
• In the illustrated embodiment, theelectrodes365a,365bare preferably electrically connected to theenergy source125A andcontroller125B via lead lines (dashed lines). In one embodiment, theenergy source125A is an Rf electrical source capable of delivering sufficient Rf energy (i) to coagulate tissue which in turn will polymerize adjacent bone cement to create a dam to inhibit retrograde flows, or (ii) to deliver energy to aconductive bone cement345 to inhibit retrograde flows. The opposing polarity electrodes indicated by the (+) and (−) can be spaced apart any selected distance to thus operate in a bi-polar manner wherein the depth of tissue coagulation will depend, at least in part, on the approximate center-to-center or edge-to-edge dimensions of the positive and negative electrodes. Thus, any such electrode arrangement can be adapted to both sense retrograde flows and thereafter deliver energy to such flow in response to at least one feedback algorithm in thecontroller125B. Any suitable type of external thermal energy emitter that is linked to thesensor system365 for inhibiting retrograde flows can be used, such as theenergy emitter128 discussed above with respect toFIG. 2A. The exterior thermal energy emitter can be a resistively heated emitter, a resistive coil, a PTC heating element, a light energy emitter, an inductive heating emitter, an ultrasound source, a microwave emitter or any other electromagnetic energy emitter or Rf emitter that cooperates with the bone cement.
• FIG. 20 shows another embodiment of anintroducer system500 that includes a thin wall sleeve orsheath510 removably slidable over an injector or introducer520 (in phantom) used in conventional vertebroplasty procedures and adapted for ejection of bone fill material (e.g., bone cement) through an outlet opening522 (in phantom) at a distal end of theintroducer520. In the illustrated embodiment, thesheath510 has anopening515 formed at adistal end518 of thesheath510, wherein theopening515 preferably aligns with theopening522 of the of theintroducer520 when thesleeve510 is deployed over theintroducer520. In the illustrated embodiment, thesleeve510 is preferably a thin-wall flexible sleeve. For example, thesleeve510 can be fabricated of silicone, polyethylene, urethane, polystyrene, or any other suitable polymer. Thesleeve510 can be elastic and dimensioned for a substantially tight grip fit about theinjector520. In another embodiment, thesleeve510 can include a tacky or adhesive surface for engaging theinjector520. In another embodiment, thesleeve510 can be invertable with or without a self-stick surface to roll over the injector520 (e.g., as a condom). In another embodiment, thesleeve510 can comprise a heat shrink material to shrink over theinjector520. In another embodiment, thesleeve510 can be a thin-wall flexible sleeve that has a large diameter compared toinjector520 so that thesleeve510 fits loosely over theinjector520, where thesleeve510 is adapted to longitudinally fold about theinjector520 for inserting into a path in the cancellous bone. Upon any retrograde flow of cement, said thin wall material advantageously tends to crumple and engage the cancellous bone to form a mechanical dam to inhibit retrograde flows. In still another embodiment (not shown), the sleeve can be a thin-wall substantially rigid or rigid sleeve that can slip over theintroducer520, and be made of, for example, metal or a hard plastic.
• Thesystem500 preferably includes asensor system560, which includes a first and second spaced apartelectrodes565a,565b, similar to theelectrodes365a,365bdescribed above with respect toFIG. 19. Theelectrodes565a,565bare preferably disposed on anouter surface512 of thesleeve510. In the illustrated embodiment, the electrodes orsensors565a,565bhave a helical shape and extend helically along the length of thesleeve510. However, theelectrodes565a,565bcan have any suitable shape (e.g., ring electrodes). Additionally, any number ofelectrodes565a,565bcan be provided.
• With continued reference toFIG. 20, thesensor system560 includes anelectrical connector570 that connects to a proximal end514 of thesleeve510. Theconnector570 is configured for detachable coupling withelectrical leads572A,572B that extend to the electrical or energy source125a. The electrical leads572A,572B preferably are electrically connected to theelectrodes565a,565b. In one embodiment, theelectrodes565a,565bcan be used to sense a retrograde flow of bone cement, where the signals (e.g., of impedance as discussed above) are communicated to thecontroller125B, which in turn generates a signal (e.g., visual, tactile, auditory) to notify the operator of the retrograde flow, as discussed above. In another embodiment, thesensor system560 can operate as an energy-delivery system, where thecontroller125B controls the operation of theenergy source125A to control the delivery of electricity to theelectrodes565a,565bto, for example, polymerize bone cement proximal thesensors565a,565bor coagulate tissue proximal thesensors565a,565b, as discussed above.
Hydraulic Pressure Mechanism
• Returning toFIG. 19,system310B includes a container of fill material orsource145′ that is pressurized by apressure mechanism150′. Thepressure mechanism150′ can be a hydraulic source. For example, in one embodiment, the hydraulic source can include a syringe, or plurality of syringes, with a conduit containing a working fluid therein and connecting the syringe to a proximal end of thefill material source145′. The working fluid can transfer the force generated by the syringe onto a piston358 (e.g., a floating piston) that travels through asleeve145A of thefill material source145′ to eject fill material from thefill material source145′ into theintroducer320. In another embodiment the hydraulic source can comprise a plurality of syringes connected via conduits having working fluids therein, the force generated by one syringe transferred through the working fluid onto a piston of a downstream syringe, and eventually transferred to thepiston358 in thesleeve145A. In still another embodiment, the hydraulic mechanism can include a screw pump actuatable to transmit a force onto a working fluid in a conduit, which in turn transmits said force onto thepiston358 in thesleeve145A. However, thepressure mechanism150′ can comprise other suitable mechanisms.
Temperature Control Systems
• FIG. 21, shows another embodiment of a bonefill delivery system310C. Thesystem310C is similar to thesystem310B inFIG. 19, except as noted below. Thus, the reference numerals used to designate the various components of thesystem310C are identical to those used for identifying the corresponding components of thesystem310B, except as noted below.
• Thesystem310C can include a sensing system for detecting retrograde flows of bone cement, as discussed above. Further, thesystem310C preferably includes a cooling system ormechanism380, which is shown schematically inFIG. 21. In one embodiment, thecooling mechanism380 is carried within thecontainer145 that carries the fill material (e.g., PMMA bone cement or similar in-situ hardening cement) as shown inFIG. 22. In another embodiment, thecooling mechanism380 can be disposed about thecontainer145. As can be seen inFIG. 21, theelectrical source125A andcontroller125B are coupled to theintroducer320 via leads that are electrically connected to adetachable coupling382 coupleable to theintroducer320. Astylet384 is also provided, preferably having a sharp tip, for use in embodiments where theintroducer320 has a distalopen port325′.
• Thecooling system380 ofFIG. 21 advantageously maintains a volume of mixed bone cement at a pre-determined temperature to inhibit acceleration of the exothermic heating thereof, thus extending the working time of the cement. In one embodiment, as shown inFIG. 21, theintroducer320 is anindependent introducer320 sized and configured for introducing the bone cement345 (FIGS. 18A-18C) into thevertebra350. In the illustrated embodiment, thebone cement container145 has a fitting and optionalflexible sleeve connector388 for providing a substantially sealed and substantially pressure-tight coupling between thecontainer145 and theintroducer320 Theconnector388 preferably has a length of between about 10 mm and about 100 mm and can optionally include a cooling system disposed therein.
• Thecooling system380 preferably includes at least one of an active cooling system and a passive cooling system. In one embodiment, shown inFIG. 21, thecooling system380 includes a thermoelectric system with at least one element390 (e.g., a Peltier element) in contact with a thermallyconductive wall portion392 of thecontainer145. In another embodiment, thecooling system380 includes a chilled fluid circulation system withchannels394 disposed proximate thewall portion392 of container145 (SeeFIG. 22). In another embodiment (not shown) thecooling system380 includes a freon system with an expansion channel inside thewall portion392 of thecontainer145. However, thecooling system380 can include other suitable active cooling arrangements. In still another embodiment (not shown), thecooling system380 includes a heat pipe system with at least one elongate channel or concentric channel in thewall portion392 of thecontainer145, which wicks heat away from thecontainer145 to a heat exchanger component. In yet another embodiment (not shown), thecooling system380 is a passive system that includes an open cell graphite structure for conducting heat away from thecontainer145 to a heat exchanger component. In one embodiment, the open cell graphite is PocoFoam™ manufactured by Poco Graphite, Inc. 300 Old Greenwood Road, Decatur, Tex. 76234.
• With continued reference toFIG. 21, the bonefill injection system310C includes the pressure source ormechanism150′, as discussed above with respect toFIG. 19. In the illustrated embodiment, thepressure source150′ is a hydraulic mechanism coupled to thecontainer145 via flexible ordeformable tubing396 to drive thepiston358.
• As shown inFIG. 21, thecontroller125B can be further coupled to at least onesensing system440 for determining the viscosity of the bone cement in thecontainer145. Preferably, thesensing system440 is at least partially disposed in thecontainer145. Thecontroller125B preferably includes algorithms for preventing any flow of bone cement through theintroducer320 until the cement has reached a pre-determined viscosity.
• In one embodiment, thesensing system440 includes an electrical parameter sensing system for querying an electrical parameter of a polymerizable bone cement to thereby determine its viscosity. Such an electrical sensor can preferably measure at least one of capacitance, conductivity and impedance. Another embodiment ofsensing system440 includes a mechanical parameter sensing system for measuring a mechanical parameter of the bone cement. For example, the mechanical parameter sensing system can query the bone cement by applying an acoustic wave thereto. In still another embodiment, thesensing system440 includes an optical parameter sensing system for determining the viscosity of the bone cement by measuring an optical parameter of a polymerizing bone cement. For example, the optical parameter sensing system can measure reflectance of the bone cement. In another embodiment, the optical parameter sensing system can acquire an optical signature of a bone cement that carries a thermochromic composition. In another embodiment, thesensing system440 includes a temperature sensing system for determining the viscosity of the bone cement via a measured the temperature of a polymerizable bone cement in thecontainer145. In still another embodiment, thesensing system440 includes a strain gauge (not shown) disposed in thecontainer145 or drive system to determine the viscosity of the cement. In another embodiment, thesensing system440 uses a pressure sensor, such as a MEMS pressure sensor, to determine the viscosity of the bone cement. Any of the sensing systems described herein can be configured to query the parameter of the bone cement continuously or intermittently at any suitable rate.
• With continued reference toFIG. 21, the bonefill injection system310C optionally further includes a thermal energy emitter420 (SeeFIG. 23A) disposed within aninterior channel424 of theintroducer320 for heating a flow of bone cement exiting theintroducer320 through theoutlet opening325, as shown inFIG. 23A. In one embodiment, thethermal energy emitter420 is an Rf emitter adapted for heating a conductive bone cement as disclosed in the following co-pending U.S. Patent Applications: application Ser. No. 11/165,652 filed Jun. 24, 2005; application Ser. No. 11/165,651 filed Jun. 24, 2005, now U.S. Pub. No. 2006-0122622; application Ser. No. 11/196,045 filed Aug. 2, 2005; application Ser. No. 11/208,448 filed Aug. 20, 2005; and application Ser. No. 11/209,035 filed Aug. 22, 2005, the entire contents of which are hereby incorporated by reference and should be considered a part of this specification. In another embodiment, thethermal energy emitter420 delivers thermal energy to the bone cement via conduction in the distal region of theintroducer320. Thethermal energy emitter420 can be a resistive heat emitter, a light energy emitter, an inductive heating emitter, an ultrasound source, a microwave emitter and any other electromagnetic energy emitter to cooperate with the bone cement.
• In another embodiment, shown inFIG. 23B, the thermal energy emitter is aresistive heater420′ with aresistive heating element422. Theheating element422 preferably has a helical configuration, though other suitable configurations are possible, such as an axial configuration. Additionally, theheating element422 is preferably disposed in aninterior bore424 of theintroducer320 and can optionally be formed from (or coated with) a positive temperature coefficient material and coupled to a suitable voltage source to provide a constant temperature heater as is known in the art. Preferably, theheating element422 is carried within aninsulative coating426 on an interior surface of theintroducer320.
• In one embodiment, thethermal energy emitter420,420′ raises the temperature of the chilled bone cement to body temperature or within about 5° C. above or below body temperature. In another embodiment,thermal energy emitter420,420′ raises the temperature of the chilledbone cement345 to at least about 45° C., at least about 55° C. in another embodiment, at least about 65° C. in still another embodiment, and between about 45° C. and 95° C. in another embodiment to accelerate polymerization of thebone cement345 and increase the viscosity of a PMMA or similar bone cement. In another embodiment, thethermal energy emitter420,420′ raises the temperature of the chilledbone cement345 to between about 50° C. and 85° C., or between about 50° C. and 65° C. to accelerate polymerization ofbone cement345.
• In the embodiments illustrated inFIGS. 21,22 and23A-B, thecontroller125B preferably controls all parameters associated with cooling of the bone cement in thecontainer145, cement injection pressure and/or flow rate, energy delivery to cement flows in or proximate the distal end of theintroducer320, sensing of retrograde flows, and energy delivery to retrograde flows about the exterior surface of theintroducer320.
• FIG. 22 illustrates anothersystem310D for delivery of bone infill material. Thesystem310D is similar to thesystem310B inFIG. 19, except as noted below. Thus, the reference numerals used to designate the various components of thesystem310D are identical to those used for identifying the corresponding components of thesystem310B, except as noted below. In the illustrated embodiment, the arrangement of theelectrodes365a,365bcan be multiplexed between a bi-polar mode and a mono-polar mode using a remote return electrode (ground pad)170.
Injector Coatings
• FIGS. 24 and 25 show another embodiment of a bone infillmaterial delivery system600, which again comprises abone cement injector620 that extends to a workingend605 thereof. However, the features described below are applicable to any electrosurgical probe or other heated probe. Theinjector620 has ahandle portion640 and anextension portion642 with aflow passageway424 extending therethrough (SeeFIG. 25). Theextension portion642 is preferably sized and shaped for use in a vertebroplasty procedure.
• As shown inFIG. 24, theinjector620 has an exterior surface that includes acoating625. Thecoating625 preferably comprises a thin layer of a non-metallic material, such as an insulative amorphous diamond-like carbon (DLC) or a diamond-like nanocomposite (DCN). Such coatings advantageously inhibit scratching (e.g., have high scratch resistance), as well as have lubricious and non-stick characteristics that are useful in bone cement injectors configured for carrying electrical current for (i) impedance sensing purposes; (ii) for energy delivery to bone fill material; and/or (iii) ohmic heating of tissue, such as theinjectors110A,320,620 discussed herein. In a preferred embodiment, the coating has a scratch resistance of at least about 10 on the Mohs scale, or above about 12 on the Mohs scale in another embodiment, or above about 14 on the Mohs scale in still another embodiment. A surface of the injector can have a lubricious level represented by a static coefficient of friction of less than about 0.5 in one embodiment, less than about 0.2 in another embodiment, and less than about 0.1 in still another embodiment. In one embodiment, the DLC or DNC coatings can have an overlying layer of Teflon, or similar material, to provide the desired lubricious level. For example, when inserting a bone cement injector through the cortical bone surface of a pedicle and then into the interior of a vertebra, it is important that the exterior insulative coating portions do not fracture, chip or scratch to thereby ensure that the electrical current carrying functions of theinjector110A,320,620 are not compromised.
• With continued reference toFIG. 24, the source ofbone fill material145 is coupleable to theflow passageway424 of theintroducer620. In addition, thehandle portion640 of theinjector620 includes aconnector645A that allows for releasable connection of theinjector620 with anelectrical connector645B coupled to the electrical or energy source. Theextension portion642 is preferably sized and shaped for use in a vertebroplasty procedure and to thecontroller125B via anelectrical cable650. Theelectrical cable650 preferably carries current to the workingend605 of thebone cement injector620. In another embodiment, theelectrical cable650 can be integrated into and permanently attached to thehandle portion640 of theinjector620.
• As shown inFIG. 24, thesystem600 includes asensor system660 that includes a series ofelectrodes662 at the workingend605 of theintroducer620. In the illustrated embodiment, theelectrodes662 are ring-like electrodes, though other suitable configurations can be used (e.g., helical shaped electrodes). ThoughFIG. 24 shows fiveelectrodes662, thesensor system660 can have more or fewer electrodes. In the illustrated embodiment, theelectrodes662 are defined by circumferential rings of exposed surfaces of a metal cannula, where the amorphous diamond-like carbon coating has been removed, for example, by etching. In use, the low voltage current provide by theelectrical source125A is coupled to the ring-like electrodes662 from a second opposing polarity electrode in the working end605 (or a remote electrode such as a ground pad). As bone cement covers the ring-like electrodes660, impedance will change to thus allow a signal of retrograde bone cement migration, as described above, to be generated and communicated by thecontroller125B to the operator. In one embodiment, theelectrical source125A provides energy to theelectrodes662 for sensing a retrograde flow. In another embodiment, theelectrical source125B provides energy to theelectrodes662 for heating of bone cement (e.g., polymerization of bone cement0 or tissue.
• FIG. 25 shows a schematic partial cross-sectional view of theintroducer620. Theintroducer620 inFIG. 25 is similar to theintroducer320 inFIG. 23B, except as noted below. Thus, the reference numerals used to designate the various features of theintroducer620 are identical to those used for identifying the corresponding features of theintroducer320, except as noted below. In the illustrated embodiment, theintroducer620 includes the thermal energy embitter420′, which includes theresistive heating element422, coupled to theelectrical source125A andcontroller125B. The source offill material145 provides a flow of bone infill material (e.g., bone cement) through theflow passageway424, which extends through theintroducer620 to theoutlet opening325. As discussed above, theintroducer620 has thecoating625 disposed over an outer surface thereof. As shown inFIG. 25, theintroducer620 also has an amorphous diamond-like carbon (DLC) or a diamond-like nanocomposite (DCN) coating630 within theinterior passageway424 of thebone cement injector620, though the injector can be of any type described above.
• Suitable amorphous diamond-like carbon coatings and diamond-like nanocomposites are available from Bekaert Progressive Composites Corporations, 2455 Ash Street, Vista, Calif. 92081 or its parent company or affiliates. Further information on said coatings can be found at: http://www.bekaert.com/bac/Products/Diamond-like %20coatings.htm, the contents of which are incorporated herein by reference. The diamond-like coatings preferably comprise amorphous carbon-based coatings with high hardness and low coefficient of friction. The amorphous carbon coatings advantageously exhibit non-stick characteristics and excellent wear resistance. The coatings are preferably thin, chemically inert and have a very low surface roughness. In one embodiment, the coatings have a thickness ranging between about 0.001 mm and about 0.010 mm. In another embodiment, the coatings have a thickness ranging between about 0.002 mm and about 0.005 mm. The diamond-like carbon coatings are preferably a composite of sp2 and sp3 bonded carbon atoms with a hydrogen concentration of between about 0% and about 80%. Another suitable diamond-like nanocomposite coating (a-C:H/a-Si:O; DLN) is made by Bakaert and is suitable for use in the bone cement injector described above. The materials and coatings are known by the names Dylyn®Plus, Dylyn®/DLC and Cavidur®.
• In another embodiment, the metal-doped amorphous diamond-like carbon or diamond-like nanocomposite can be used in an electrosurgical surface of a blade, needle, probe, jaw surface, catheter working end and the like. In one embodiment, the surface of a probe or jaw can comprise a pattern of metal-doped amorphous diamond-like carbon portions and adjacent or surrounding insulative amorphous diamond-like carbon portions.
• In another embodiment, the amorphous diamond-like carbon or diamond-like nanocomposite can be used in a high temperature circuit board. Such a circuit board can comprise any insulative substrate together with an electrical circuit deposited thereon, wherein the circuit is of a metal-doped amorphous carbon or diamond-like nanocomposite. The circuit board can use depositions of the DLC or DLN that have a thickness ranging between about 1 micron and 10 microns. The width of the electrical circuit paths have a width of less than about 1000 microns; 100 microns; 10 microns and 1 micron.
• In one embodiment, theelectrodes280a,280b,280c,344,365,662 do not come in contact with adjacent tissue due to, for example, the presence of a coating on an external surface of theinjector110A,320,620, such ascoating625. Accordingly, theelectrodes280a,280b,280c,344,365,662 can preferably sense a retrograde flow without being in direct contact with bone cement or tissue, and can direct energy to said bone cement or tissue without being in direct contact with the same to, for example, coagulate tissue or polymerize bone cement.
• In another embodiment, energy can be delivered via theelectrodes280a,280b,280c,344,365,662 of the systems described above to heat surrounding tissue prior to introduction of bone cement into the vertebra. In another embodiment, energy can be delivered via theelectrodes280a,280b,280c,344,365,662 of the systems described above to heat surrounding tissue and bone cement prior to introduction of additional bone cement into the vertebra.
• The features described herein are further applicable to cure-on-demand fill materials that can be used for disc nucleus implants, wherein the conductive fill material is injected to conform to the shape of a space and wherein Rf current is then applied to increase the modulus of the material on demand to a desired level that is adapted for dynamic stabilization. Thus, the Rfconductive fill material120,345 can be engineered to reach a desired modulus that is less than that of a hardened fill material used for bone support. In this embodiment, the fill material is used to support a disc or portion thereof. The cure-on-demand fill material also can be configured as an injectable material to repair or patch a disc annulus as when a tear or herniation occurs
• The features described herein are further applicable to cure-on-demand fill materials that can be used for plastic surgery and reconstructive surgery wherein the conductive fill material is injected to conform to a desired shape, for example in facial plastics for chin implants, nasal implants, check implants or breast implants and the like.
• The features described herein are further applicable to cure-on-demand fill material that can be used for injection into a space between vertebrae for intervertebral fusion. The injection of fill material can conform to a space created between two adjacent vertebrae, or can be injected into notches or bores in two adjacent vertebrae and the intervening space, and then cured by application of Rf current to provide a substantially high modulus block to cause bone fusion.
• In any embodiment such as for intervertebral fusion or for bone support in VCFs, the system can further include the injection of a gas (such as carbon dioxide) into the fill material before it is injected from a high pressure source. Thereafter, the gas can expand to form voids in the fill material as it is cured to create porosities in the hardened fill material for allowing rapid bone ingrowth into the fill material.
• The systems described herein can use any suitable energy source, other that radiofrequency energy, to accomplish the purpose of altering the viscosity of thefill material120,345. The method of altering fill material can be at least one of a radiofrequency source, a laser source, a microwave source, a magnetic source and an ultrasound source. Each of these energy sources can be configured to preferentially deliver energy to a cooperating, energy sensitive filler component carried by the fill material. For example, such filler can be suitable chromophores for cooperating with a light source, ferromagnetic materials for cooperating with magnetic inductive heating means, or fluids that thermally respond to microwave energy.
• The features described herein are further applicable to additional filler materials, such as porous scaffold elements and materials for allowing or accelerating bone ingrowth. In any embodiment, the filler material can comprise reticulated or porous elements of the types disclosed in co-pending U.S. patent application Ser. No. 11/146,891, filed Jun. 7, 2005, titled “Implants and Methods for Treating Bone” which is incorporated herein by reference in its entirety and should be considered a part of this specification. Such fillers also can carry bioactive agents. Additional fillers, or the conductive filler, also can include thermally insulative solid or hollow microspheres of a glass or other material for reducing heat transfer to bone from the exothermic reaction in a typical bone cement component.
• Of course, the foregoing description is that of certain features, aspects and advantages of the present invention, to which various changes and modifications can be made without departing from the spirit and scope of the present invention. Moreover, the bone treatment systems and methods need not feature all of the objects, advantages, features and aspects discussed above. Thus, for example, those skill in the art will recognize that the invention can be embodied or carried out in a manner that achieves or optimizes one advantage or a group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. In addition, while a number of variations of the invention have been shown and described in detail, other modifications and methods of use, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is contemplated that various combinations or subcombinations of these specific features and aspects of embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the discussed bone treatment systems and methods.

Claims (21)

1. An apparatus for delivering a bone fill material to a vertebra, comprising:

an elongated introducer configured for introduction into a vertebral body, the introducer comprising a working end at a distal end of the introducer, the working end positionable within the vertebral body and having at least one outlet opening configured to allow a bone fill material flow therethrough; and

an insulative coating disposed on an external surface of the introducer, the coating being lubricious and configured to inhibit the scratching of said external surface.

2. The apparatus ofclaim 1, wherein the insulative coating has a scratch resistance of at least 10 on the Mohs scale, at least 12 on the Mohs scale, or at least 14 on the Mohs scale.

3. The apparatus ofclaim 1, wherein the insulative coating having a static coefficient of friction of less than about 0.5, less than about 0.2, or less than about 0.1.

4. The apparatus ofclaim 1, wherein the coating is configured to inhibit fracture, chipping or scratching thereof during introduction of the introducer into the vertebra.

5. The apparatus ofclaim 1, wherein the coating comprises at least one of an insulative amorphous diamond-like carbon and a diamond-like nanocomposite.

6. The apparatus ofclaim 1, wherein the at least one outlet opening is disposed at the distal end of the introducer.

7. The apparatus ofclaim 1, wherein the introducer comprises an interior surface defining a channel through which the bone fill material flows.

8. The apparatus ofclaim 7, wherein an insulative coating is disposed on the interior surface of the introducer.

9. The apparatus ofclaim 8, wherein the insulative coating on the interior surface comprises at least one of an insulative amorphous diamond-like carbon or a diamond-like nanocomposite.

10. The apparatus ofclaim 1 in combination with a source of bone fill material, the source being in communication with the elongated introducer for delivering bone fill material therethrough.

11. A system for delivering a bone fill material to a bone, comprising:

an elongated introducer configured for insertion into a bone, the introducer defining a channel sized to allow a flow of a bone fill material therethrough, the introducer having at least one outlet opening in communication with the channel for delivering the bone fill material into the bone, an insulative coating disposed on an exterior surface of the introducer, the coating being lubricious and having a high scratch resistance;

a thermal energy emitter operably coupled to the introducer and configured to apply energy to the bone fill material flowing through the channel; and

a controller in communication with the thermal energy emitter and configured to control the operation of the thermal energy emitter.

12. The system ofclaim 11, wherein the coating is configured to inhibit fracture, chipping or scratching thereof during introduction of the introducer into the vertebra.

13. The system ofclaim 11, wherein the coating comprises at least one of an insulative amorphous diamond-like carbon or a diamond-like nanocomposite.

14. The system ofclaim 11, wherein the at least one outlet opening is disposed at the distal end of the introducer.

15. The system ofclaim 11, wherein the introducer comprises an interior surface defining the channel through which the bone fill material flows.

16. The system ofclaim 15, wherein an insulative coating is disposed on the interior surface of the introducer.

17. The system ofclaim 16, wherein the insulative coating on the interior surface comprises at least one of an insulative amorphous diamond-like carbon or a diamond-like nanocomposite.

18. The system ofclaim 11, wherein the thermal energy emitter is disposed in the channel proximal the at least one outlet opening.

19. The system ofclaim 18, further comprising an insulative layer between the thermal energy emitter and an inner circumferential wall of the introducer.

20. The system ofclaim 11, wherein the thermal energy emitter is selected from the group consisting of an electromagnetic energy emitter, a radiofrequency energy emitter, a light energy emitter, a microwave emitter, a resistive heat emitter, an inductive heat emitter and an ultrasound source.

21. A method for delivering a bone fill material to a vertebra, comprising:

providing an elongated introducer comprising an insulative coating disposed on an external surface of the introducer, the coating being lubricious and configured to inhibit the scratching of said external surface;

inserting the elongated introducer into a vertebra; and

delivering bone fill material through the elongated introducer into the vertebra.

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