Abstract:
This disclosure provides a plate having at least a first aperture and a second aperture, and at least a first annulus adaptable to be disposed within the first aperture and at least a second annulus adaptable to be disposed within the second aperture. Further provided is at least a first screw adaptable to be disposed within the first annulus and at least a second screw adaptable to be disposed within the second annulus, wherein the first and second screws are each engageable with its respective first and second annulus.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This Non-Provisional U.S. patent application claims the benefit of and priority to the earlier-filed U.S. Provisional Patent Application Ser. No. 61/579,630, filed on Dec. 22, 2011, the entire contents of which is hereby incorporated by reference in full. 
    
    
     BACKGROUND OF THE INVENTION 
     The bones of vertebrates (including mammals such as humans) can break or fracture, due to injury, heredity, or combinations thereof. Prior apparatuses and methods for fixation or fusion of bones and joints to promote healing and/or reduce future injury are generally known. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       The present disclosure will be further explained with reference to the attached drawing figures, wherein like structures are referred to by like numerals throughout the several views. The drawing figures shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present disclosure. 
         FIG. 1  is an exploded view of an illustrative plate and screw apparatus of the present disclosure; 
         FIG. 2  is a perspective view an illustrative plate and screw apparatus of the present disclosure; 
         FIG. 3  is a top down view of the illustrative plate and screw apparatus of the  FIG. 2 ; 
         FIG. 4  is a cross-sectional view of the illustrative plate and screw apparatus of  FIGS. 2 and 3  taken along cut line  4 - 4  of  FIG. 3 ; 
         FIG. 5  is a side view of an illustrative plate of the present disclosure; 
         FIG. 6  is a top-down view of the illustrative plate of  FIG. 5 ; 
         FIG. 7  is a cross-sectional view of the illustrative plate of  FIGS. 5 and 6  taken along cut line  7 - 7  of  FIG. 6 ; 
         FIG. 8  is a cross-sectional view of the illustrative plate of  FIGS. 5 and 6  taken along cut line  8 - 8  of  FIG. 6 ; 
         FIG. 9  is a top-down view of an illustrative annulus of the present disclosure; 
         FIG. 10  is a side-view of the illustrative annulus of  FIG. 9 ; 
         FIG. 11  is a cross-sectional view of the illustrative annulus of  FIGS. 9 and 10  taken along cut line  11 - 11  of  FIG. 10 ; 
         FIG. 12  is a side view of an illustrative slide of the present disclosure; 
         FIG. 13  is a top-down view of the illustrative slide of  FIG. 12 ; 
         FIG. 14  is a cross-sectional view of the illustrative slide of  FIGS. 12 and 13  taken along cut line  14 - 14  of  FIG. 13 ; 
         FIG. 15  is a side view of an illustrative screw of the present disclosure; 
         FIG. 16  is an exploded view of an alternative illustrative plate and screw apparatus of the present disclosure; 
         FIG. 17  is a perspective view an illustrative alternative plate and screw apparatus of the present disclosure; 
         FIG. 18  is a top down view of the alternative illustrative plate and screw apparatus of the  FIG. 17 ; 
         FIG. 19  is a cross-sectional view of the illustrative plate and screw apparatus of  FIGS. 17 and 18  taken along cut line  19 - 19  of  FIG. 18 ; 
         FIG. 20  is a side view of an illustrative alternative screw of the present disclosure; 
         FIG. 21  is a top down view of an illustrative embodiment of a nut engaged with an alternative screw of the present disclosure; 
         FIG. 22  is a side view of the illustrative embodiment of the nut engaged with the alternative screw of  FIG. 21 ; and 
         FIG. 23  is a cross-sectional view of the illustrative embodiment of the nut engaged with the alternative screw of  FIGS. 21 and 22  taken along cut line  23 - 23  of  FIG. 22 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Detailed embodiments of the present plate and screw apparatus, and methods thereof are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the plate and screw apparatus and methods that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the systems and methods are intended to be illustrative, and not restrictive. Further, the drawing figures are not necessarily to scale, and some features may be exaggerated to show details of particular components. In addition, any measurements, specifications and the like shown in the drawing figures, or described below, are intended to be illustrative, and not restrictive. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present apparatus or system, and methods thereof. 
     With reference to  FIGS. 1, 2, 3, and 4 , an embodiment of a plate and screw apparatus  100  is provided. The plate and screw apparatus  100  may include a plate  103  having at least two bores  105 A,  105 B. Each respective bore  105 A,  105 B may receive or otherwise be engaged with an annulus, or collar,  110 A,  110 B. Each respective annulus, or collar,  110 A,  110 B may receive or be engaged with a screw  115 A,  115 B. The bores  105 A,  105 B may independently have any horizontal-cross-sectional shape including, generally trapezoidal, circular, rectangular, triangular, and the like. In the embodiments of  FIGS. 1, 2, 3, and 4 , the bores  105 A and  105 B have generally trapezoidal and circular horizontal-cross-sectional shapes, respectively; however, in alterative embodiments, the bores  105 A and  105 B may have the same horizontal-cross-sectional shape (such as for example, both generally trapezoidal or both generally circular). In an embodiment, at least one bore  105 A may have a trapezoidal cross-sectional shape and the bore  105 A may receive or otherwise be engaged with an annulus retainer, or slide,  120 . In this embodiment, the annulus retainer, or slide,  120  may receive or otherwise be engaged with the annulus, or collar,  110 A, which may receive or be engaged with the screw  115 A. 
     In an embodiment and with reference to  FIGS. 5, 6, 7, and 8 , the plate  103  may be any size and shape suitable to bridge a bone or joint break, fracture, dislocation, or joint fusion. In an embodiment, the plate  103  may have a generally trapezoidal horizontal-cross-section  125  with a length  130  ranging from about 1 to about 6 inches; alternatively from about 1 to about 3 inches; alternatively from about 0.5 to about 1.5 inches; alternatively about 2 inches, a width  135  ranging from about 0.5 to about 1.5 inches; alternatively about 0.75 inch, and a depth, or height,  140  ranging from about 0.1 to about 0.5 inches; alternatively about 0.25 inches. The ends  145 ,  150  of the plate  100  may have a profile ranging from curved to rectangular, including generally arced and generally semi-circular. In an embodiment, the ends  145 ,  150  of the plate  103  may have a profile of a general outside arc ranging from about 0.1 inches to about 0.75 inches. The plate  103  may have a plurality of edges  155 ,  155 ′ each having a fillet radii independently ranging from about 0.01 to about 0.125. The bore  105 B, which may or may not be tapered along a vertical axis, may have a minimum bore diameter  160 , which may range from about 0.1 inches to about 0.75 inches and alternatively may be about 0.2 inches or about 0.25 inches. In other embodiments, the minimum bore diameter  160  may be less than or equal the maximum annulus diameter  165  (described herein with respect to  FIGS. 1, 9, 10, and 11 ) of the annulus  110 B. In an embodiment, the trapezoidal bore  105 A, which may or may not be tapered along a vertical axis, may have a maximum trapezoidal bore length  170  that is greater than or equal the length of the slide  120  (described herein with respect to  FIGS. 12, 13, and 14 ) and a maximum trapezoidal bore width  175  that is less than or equal to the width of the slide  120 . In various embodiments, the inner surface of the bores  105 A,  105 B and the outer surface of annulus  110 A,  110 B may each be machined to a heavy texture (for example texturing by grid blasting) to enhance or otherwise improve the friction fit between component elements/parts and prevent (or reduce) rotation of the component elements/parts about themselves. The surface roughness RMS of at least a portion of the bores  105 A and  105 B may range from about 25 microinches to about 300 microinches (as tested by ASTM D7127-05). 
     In an embodiment and with reference to  FIGS. 1, 9, 10, and 11 , the annulus  110 A,  110 B may have an interior surface  180  and an exterior surface  185 . The interior surface  180  of the annulus  110 A may have a taper, T 1 , across its vertical-cross-sectional face. In an alternative embodiment (shown), the interior surface  180  of the annulus  110 A may have two tapers, T 1  and T 2 , across its vertical-cross-sectional face, such that it may be inserted into the bore  105 A or slide  120  without regard to an “up” or “down” orientation. In other words, in an embodiment, the interior surface  180  may be symmetric about an “x” or horizontal axis, and it does not matter which “end” is inserted into the bore  105  or slide  120 . In an embodiment, the tapers, T 1  and T 2 , may be of the same, similar, or different angles, which may independently range from about 1 degree from vertical to about 20 degrees from vertical; alternatively from about 1 degree to about 10 degrees. Preferably, the annulus  110 A,  110 B has a height ranging from about 0.1 inches to about 0.5 inches, and alternatively about 0.3 inches, with each taper being separated by a vertical space, S, ranging from about 0.02 inches to about 0.4 inches. The exterior surface  185  of the annulus  110  may form a general semi-circle. In an embodiment, the radius of the semi-circular exterior surface  185  may range from about 0.1 inches to about 0.4 inches, and alternatively be about 0.2 inches. In an embodiment, a force placed along the interior surface  180  of the annulus  110 , may expand the annulus  110  radially. In an embodiment, the annulus  110  may have an annulus gap  190 , which may facilitate the expansion of the annulus  110  without breaking or fracturing the annulus  110 . In an embodiment, the annulus gap  190  may have a length ranging from about 0.02 inches to about 0.1 inches, and alternatively be about 0.06 inches. The surface roughness RMS of at least a portion of the annulus  110 A,  110 B may range from about 25 microinches to about 300 microinches (as tested by ASTM D7127-05). 
     In an embodiment and with reference to  FIGS. 1, 12, 13, and 14 , the slide  120  may be any size and shape suitable for engagement with a respective bore of the plate  103 . In various embodiments, the slide  120  may have a generally trapezoidal horizontal-cross-sectional shape that is suitable for engagement with the generally trapezoidal bore  105 B of the plate  103 . In an embodiment, suitable engagement of the slide  120  within the bore  105 B is engagement such that the slide  120  fits snugly within the bore  105 B and at the same time can be moved or slid in at least one direction within the bore  105 B. For example, the slide  120  may be suitably engaged within the bore  105 B when a maximum width of the slide  120  is approximately equal to a maximum width of the bore  105 B and the length of the slide  120  is less than the length of the bore  105 B. In an embodiment, the slide  120  may be slid in at least one direction (alternatively two or three) within the rectangular bore before it is fit into place. 
     In various embodiments herein, the slide  120  may have a maximum slide depth  195  ranging from about 0.1 to about 0.5 inches; alternatively about 0.25 inches; a maximum slide length  200  ranging from about 0.25 to about 1 inch and alternatively about 0.75 inches; and a maximum slide width  205  of ranging from about ⅛ inch to about 0.75 inches and alternatively about 0.5 inches. In various embodiments, the slide  120  may have a slide bore  210 , optionally through which the screw  115  may be receive. The radius of the slide bore  120  may range from about 0.1 inches to about 0.75 inches and alternatively may be about 0.2 inches or about 0.25 inches. The slide  120  may have a slide gap  210 , which may facilitate the expansion of the slide  120  without breaking or fracturing the slide  120 . The slide  120  (like the annulus  110 A,  110 B) may expand or move out radially when the screw  115  is engaged therewith (or otherwise driven down) to “lock” the screw  115  in place within the plate  103  by a (preferably snug or tight) friction fit. In an embodiment, the slide gap  210  may have a length ranging from about 0.02 inches to about 0.1 inches, and alternatively be about 0.06 inches. The surface roughness RMS of at least a portion of the slide  120  may range from about 25 microinches to about 300 microinches (as tested by ASTM D7127-05). 
     In an embodiment and with reference to  FIGS. 1, 2, 4, and 15 , the screw  115  may have a head portion  215 , a body portion  220 , and a tip portion  225 . The head portion  215  may include a tapered circumference, T 3 , (otherwise called a bugle portion, a bugle head, a flat head, or a countersunk head). In an embodiment, the tapered head circumference, T 3 , may range from about 1 degrees from vertical to about 20 degrees from vertical and alternatively from about 1 degree to about 10 degrees. The head portion  215  may have a truncated conical cross section. In an embodiment, T 1 , T 2 , and T 3  have approximately equal degrees of tapers. The head portion  215  may further include recesses  230  (shown in  FIGS. 1 and 3 ) which may be of any shape, including a torx, which is sufficient to receive a screw driver (not shown). In an embodiment, the head portion  215  may have a height ranging from about 0.1 inches to about 0.4 inches, and preferably 0.2 inches. In an embodiment, the head portion  215  may have a maximum head diameter, which may range from about 0.1 inches to about 0.5 inches, at the head portion&#39;s  215  upper most circumference and tapers along T 3  down to lesser diameters until it is about the same, or the same, diameter as the body portion  220 . 
     The body portion  220  of the screw  115  may be of any cross section, including generally cylindrical and generally tapered or truncated conical. In an embodiment, the body portion  220  of the screw  115  may have a length ranging from about 0.5 inches to about 3 inches, alternatively from 1 inch to about 2 inches. In an embodiment, the body portion  220  of the screw  115  may have a maximum diameter ranging from about 0.1 inches to about 0.5 inches, and preferably about 0.25 inches. In various embodiments where the body portion  220  of the screw  115  is a generally truncated cone, the taper angle (not shown) may range from about 1 degree to about 10 degrees. In various embodiments, at least a portion of the body portion  220  may be of a generally truncated cone may include threads (not shown, but generally equivalent to the threads ( 235  of the tip portion  225  described below). 
     In still a further embodiment (not shown) the body portion  220  may include a combination of a generally cylindrical portion blended into a generally truncated conical portion. In this embodiment, the generally cylindrical portion of the body portion  220  may be preferably blended into the head portion  215  and may have a length ranging from about 0.1 inches to about 0.5 inches. In the embodiment having a combination of a generally cylindrical portion blended into a generally truncated conical portion, the generally truncated conical portion may be preferably blended into the tip portion  225 . 
     In an embodiment, the tip portion  225  of the screw  115  may include a plurality of threads  235 , which may optionally be suitable for biting into or otherwise engaging the bone of a patient (not shown). In an embodiment, the tip portion  225  of the screw  115  may have a length ranging from about 0.2 inches to about 0.4 inches. In an embodiment, the tip portion  225  of the screw  115  may have a maximum diameter ranging from about 0.1 inches to about 0.5 inches, and preferably about 0.25 inches. In various embodiments, the tip portion  225  may taper down along a taper T 4  that may have an angle ranging from 15 degrees to about 45 degrees and alternatively about 30 degrees. In various embodiments, the terminal end of the tip portion  225  may have a diameter ranging from about a sharp point to about 0.2 inches. 
     In an embodiment, the screw  115  may be inserted into the annulus  110 , which has been placed inside either the bore  105  or the slide  120 . The screw  115  may be driven down (by a screw driver—not shown) such that at least its threaded tip portion  225  engages a material (such as a bone of a patient). In this manner, the screw head portion  215  may place a force along the interior surface  110 A of the annulus  110  and cause it to expand (or move) out radially and against the sides of the bore  105  or slide  120 , which may preferably “lock” the screw  215  in place within the plate  103  by a (preferably snug or tight) friction fit. 
     With reference to  FIGS. 16 to 23 , an alternative plate and screw apparatus  240  is provided. The alternative plate and screw apparatus  240  may include a plate  103  having bores  105 A and  105 B, annuluses  110 A,  110 B, at least one optional slide  120 , and an alternative screw  245  having a head portion  250  having a threaded head portion  255  and a tapered head portion  260 , a body portion  265 , a tip portion  270 , and a threaded nut  275 . In the interest of brevity and ease of readability, Applicant refers the reader to the description herein of the plate  103 , annulus  110 , and slide  120  provided with respect to the screw  115  and elects, without prejudice, not to repeat the description with respect to the alternative plate and screw apparatus  240 . Applicant respectfully asserts that one of ordinary skill will recognize modifications and adjustments (such as changes to the dimensions) of those component elements in view of the differences between the screw  115  and the alternative screw  245  as described herein. 
     The head portion  250  may include a threaded head portion  255  and a taper head portion  260  having a tapered circumference, T 5 . In an embodiment, the threaded head portion  255  may engage or otherwise be screwed into the threaded nut  275 , which may have threads that are reciprocal with the threads of the threaded head portion. The tapered head portion  260  having a tapered circumference, T 5 , may range from about 1 degrees from vertical to about 20 degrees from vertical and alternatively from about 1 degree to about 10 degrees. The threaded head portion  255  may have a cylindrical cross section, which may flare, taper, or otherwise blend into the tapered head portion  260 , which may have a truncated conical cross section. In an embodiment, T 1 , T 2 , and T 5  have approximately equal degrees of tapers. The threaded nut  275  may include internal threads and a bore such that it may engage, receive, and otherwise be screwed onto, the threaded head portion  255 . An illustrative embodiment of an engagement of the threaded nut  275  and threaded head portion  255  is provided in  FIG. 23 . In an embodiment, the head portion  250  may have a height ranging from about 0.1 inches to about 0.75 inches, and optionally 0.5 inches. The threaded head portion  255  may have a height ranging from about 0.1 inches to about 0.2 inches, and optionally about 0.25 inches. The tapered head portion  260  may have a height ranging from about 0.1 inches to about 0.4 inches. The tapered head portion  260  may blend or taper into the body portion  265 . 
     The body portion  265  of the screw  245  may be of any cross section, including generally cylindrical and generally tapered or truncated conical. In an embodiment, the body portion  265  of the screw  245  may have a length ranging from about 0.5 inches to about 3 inches, alternatively from 1 inch to about 2 inches. In an embodiment, the body portion  265  of the screw  245  may have a maximum diameter ranging from about 0.1 inches to about 0.5 inches, and preferably about 0.25 inches. In various embodiments where the body portion  265  of the screw  245  is a generally truncated cone, the taper angle (not shown) may range from about 1 degree to about 10 degrees. In various embodiments, at least a portion of the body portion  265  may be of a generally truncated cone may include threads (not shown, but generally equivalent to the threads ( 135  of the tip portion  225  described above). 
     In still a further embodiment (not shown) the body portion  265  may include a combination of a generally cylindrical portion blended into a generally truncated conical portion. In this embodiment, the generally cylindrical portion of the body portion  265  may be preferably blended into the tapered head portion  260  and may have a length ranging from about 0.1 inches to about 0.5 inches. In the embodiment having a combination of a generally cylindrical portion blended into a generally truncated conical portion, the generally truncated conical portion may be preferably blended into the tip portion  270 . 
     In an embodiment, the tip portion  270  of the screw  245  may include a plurality of threads  280 , which may optionally be suitable for biting into or otherwise engaging the bone of a patient (not shown). In an embodiment, the tip portion  270  of the screw  245  may have a length ranging from about 0.2 inches to about 0.4 inches. In an embodiment, the tip portion  270  of the screw  245  may have a maximum diameter ranging from about 0.1 inches to about 0.5 inches, and preferably about 0.25 inches. In various embodiments, the tip portion  270  may taper down along a taper T 6  that may have an angle ranging from 15 degrees to about 45 degrees and alternatively about 30 degrees. In various embodiments, the terminal end of the tip portion  270  may have a diameter ranging from about a sharp point to about 0.2 inches. 
     In an embodiment, the screw  245  may be inserted into the annulus  110 , which has been placed inside either the bore  105  or the slide  120 . The nut  275  may be aligned with the threaded head portion screw  255  and the nut may be driven down (by a wrench or other such tool—not shown) such that at least its threaded tip portion  270  engages a material (such as a bone of a patient). In this manner, at least a portion of the nut  275  (which may optionally be tapered or otherwise include tapered portions) and/or the tapered head portion  260  may place a force along the interior surface  110 A of the annulus  110  and cause it to expand (or move) out radially and against the sides of the bore  105  or slide  120 , which may preferably “lock” the screw  245  in place within the plate  103  by a (preferably snug or tight) friction fit. 
     Further embodiments may be readily understood with reference to the remainder of the drawing figures and schematics included herein. 
     In an embodiment, the plates and screws of the present disclosure may be fabricated from various orthopaedic biomaterials including stainless steels, cobalt chromium alloys, and titanium and its alloys. The plate may further be fabricated from various polymer materials such as polyethyletherketone (PEEK) and/or combinations of polymers and metals such as PPEK plates with titanium alloy spherical and slide inserts placed with titanium alloy screws. 
     In still further embodiments, the screws may be coated with a ceramic material such as hydroxyapatite which may have the benefit of a biologically more favorable surface, release of calcium and phosphate to the surrounding tissues due to slow dissolution. The release of these materials may aid in the biological fusion process. In addition, ceramic coatings may seal off the metal and reduce ion release and corrosion. Still other coatings such as titanium nitrides and chromium carbides may be used for better corrosion protection and reduction of metal ion release. 
     Without wishing to be bound by the theory, Applicant believes that the present apparatus allows for enhanced flexibility in the surgical placement of screws in various anatomical positions, and multiple orientations. For example, and without wishing to be bound by the theory, Applicant believes that the plate of the present disclosure may accept the screw of the present disclosure at various angles throughout a 360 degree circumference. Thus, in an embodiment, the plate of the disclosure may bridge a bone fracture or break or a joint fracture, break, or dislocation. A first screw may be inserted into the bone on one side of the bone fracture or break (or joint fracture, break, or dislocation) and a second screw may be inserted into bone on another side of the bone fracture or break (or joint fracture, break, or dislocation). The plate may then be screwed down and may keep the fractured or broken bone or joint in a general position/orientation to facilitate healing. In an embodiment, the plate and screw apparatus of the present disclosure may be placed across a sacroiliac joint that has been fractured, broken, or otherwise dislocated to facilitate healing or otherwise reduce risk of future/further injury.