Vertebral Implant Including Preformed Osteoconductive Insert and Methods of Forming

Abstract

A vertebral implant for insertion into a patient includes an insert formed from an osteoconductive material and further including a biocompatible polymer body that is formed into the insert. The insert may extend over part of or substantially the entire bone contact surface of the implant. The insert includes a bone contact surface and a substrate interface. The implant may include fibers that extend across the substrate interface from the insert to the body. The insert may be thin relative to the overall thickness of the implant. The insert may be preformed. The insert may be formed using a molding process. The body may be molded onto the insert.

1 . A vertebral implant device for insertion between vertebral bodies in a patient, the implant comprising:
 an insert comprising a first bone contact surface and an opposing second surface, the insert constructed from an osteoconductive material with fibers with some of the fibers including a first section positioned in the insert and a second section that extends outward from the second surface, the insert also including an anchor that extends outward from the second surface a greater distance than the second sections of the fibers; and   a non-osteoconductive body attached to the second surface of the insert and being formed from a different material than the insert;   the second sections of the fibers and the anchor being positioned in the body;   the insert and the anchor having a unitary construction formed from the osteoconductive material.   
     
     
         2 . The vertebral implant of  claim 1 , wherein the fibers include carbon fibers. 
     
     
         3 . The vertebral implant of  claim 1 , wherein the fibers include metallic filaments. 
     
     
         4 . The vertebral implant device of  claim 1 , wherein the fibers that extend outward from the second surface are aligned approximately perpendicular to an interface between the insert and the body. 
     
     
         5 . The vertebral implant device of  claim 1 , wherein the anchor includes a stem that extends outward from the second surface of the insert and an enlarged head spaced away from the second surface of the insert, the enlarged head including a greater width than the stem. 
     
     
         6 . The vertebral implant device of  claim 5 , wherein the head includes a major axis that is approximately perpendicular to the stem. 
     
     
         7 . The vertebral implant device of  claim 1 , wherein the insert includes a smaller thickness than the body. 
     
     
         8 . The vertebral implant device of  claim 1 , wherein an additional number of the fibers are completely embedded within the insert. 
     
     
         9 . A vertebral implant device for insertion between first and second vertebral bodies in a patient, the implant comprising:
 a body constructed from a first material and having a first side and an opposing second side;   an insert attached to the first side of the body and being constructed from a second material having a plurality of fibers;   an anchor that extends outward from the insert into the body, the anchor including a stem adjacent to the insert and a head spaced away from the insert and positioned at an end of the stem, the stem including a smaller width than the head; and   the anchor and a portion of the plurality of fibers extending outward from the insert and into the body to improve adhesion between the body and the insert.   
     
     
         10 . The vertebral implant device of  claim 9 , wherein the plurality of fibers are aligned approximately perpendicular to an interface between the body and the insert. 
     
     
         11 . The vertebral implant of  claim 9 , wherein the plurality of fibers includes one of carbon fibers and metallic filaments. 
     
     
         12 . The vertebral implant device of  claim 9 , wherein the insert extends completely across the first side of the body and includes a smaller thickness than the body. 
     
     
         13 . The vertebral implant device of  claim 9 , wherein a second portion of the plurality of fibers are completely embedded within the insert. 
     
     
         14 . A vertebral implant device for insertion between first and second vertebral bodies in a patient, the implant comprising:
 an intermediate portion constructed of a first material and including a first side and a second side;   a first insert attached to the first side of the intermediate portion and including a first contact surface configured to contact against the first vertebral body when the vertebral implant device is inserted in the patient;   a second insert attached to the second side of the intermediate portion including a second contact surface configured to contact against the second vertebral body when the vertebral implant device is inserted in the patient;   each of the inserts being constructed from a second material with a plurality of fibers, a portion of the plurality of fibers of each of the first and second inserts extending into the intermediate portion;   a plurality of anchors that extend outward from the first and second inserts and into the intermediate portion, each of the plurality of anchors including a stem adjacent to the insert and a head spaced away from the insert and positioned at an end of the stem.   
     
     
         15 . The vertebral implant device of  claim 14 , wherein the first insert and at least one of the plurality of anchors are integrally formed from the second material and have a one-piece construction. 
     
     
         16 . The vertebral implant device of  claim 15 , wherein the second insert and at least another one of the plurality of anchors are integrally formed from the second material and have a one-piece construction. 
     
     
         17 . The vertebral implant device of  claim 14 , wherein the portion of the plurality of fibers that extend outward from the first insert are aligned approximately perpendicular to an interface between the intermediate portion and the first insert. 
     
     
         18 . The vertebral implant device of  claim 17 , wherein the portion of the plurality of fibers that extend outward from the second insert are aligned approximately perpendicular to an interface between the intermediate portion and the second insert. 
     
     
         19 . The vertebral implant of  claim 16 , wherein the plurality of fibers include one of carbon fibers and metallic filaments. 
     
     
         20 . The vertebral implant device of  claim 15 , wherein each of the first and second inserts include a smaller thickness than the intermediate portion.