# US 11,298,163 B2 · Internal breakoff set screw and driver

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- Number: US 11,298,163 B2
- Document ID: US11298163B2
- Status: Granted
- Kind: B2
- Application number: 16/391,264
- Filed: 2019-04-22
- Published: 2020-10-22
- Granted: 2022-04-12
- Earliest claimed: 2019-04-22
- Assignees: Warsaw Orthopedic, Inc.
- Applicants: Warsaw Orthopedic, Inc.
- Inventors: William A. Rezach
- Web page: https://patentgrep.com/patent/US11298163B2

## CPC

- A61B 17/7082: {for driving, i.e. rotating, screws or screw parts specially adapted for spinal fixation, e.g. for driving polyaxial or tulip-headed screws}
- A61B 17/7091: {for applying, tightening or removing longitudinal element-to-bone anchor locking elements, e.g. caps, set screws, nuts or wedges}
- A61B 17/7032: {Screws or hooks with U-shaped head or back through which longitudinal rods pass}
- A61B 17/8888: {at its central region}
- A61F 2/4603: {for insertion or extraction of endoprosthetic joints or of accessories thereof}
- F16B 23/0069: {with holes to be engaged with corresponding pins on the tool or protruding pins to be engaged with corresponding holes on the tool}
- A61B 17/8615: {at the central region of the screw head}
- A61B 2090/037: {with a frangible part, e.g. by reduced diameter}
- A61B: DIAGNOSIS; SURGERY; IDENTIFICATION (usefulness limited to only animals A61D)
- A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C)
- F16B: DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING (couplings for transmitting rotation F16D)

## Abstract

An approach is provided for engaging a set screw to an implant. The approach includes a surgical instrument. The surgical instrument may include a shaft having an elongated rigid structure, and a driver head positioned on a distal end of the surgical instrument. The driver head may include at least one groove or at least one protrusion extending in a longitudinal direction of the surgical instrument and a pin positioned at least partially within the driver head. The pin may be configured to deploy and retract in a lateral direction from with the driver head portion.

## Claims

### Claim 1

A surgical instrument comprising:
a shaft having an elongated rigid structure extending in a longitudinal direction from a first end to a second end, and
a driver head positioned on a distal end of the surgical instrument,
wherein the driver head comprises:
a magazine retention portion extending in the longitudinal direction from the second end towards the distal end of the surgical instrument a distance sufficient for simultaneously storing a plurality of broken-off breakoff head portions of a corresponding plurality of set screws;
at least one groove or at least one protrusion extending in the longitudinal direction along the magazine retention portion,
a coil spring and pin positioned at least partially within the driver head, the coil spring and pin being positioned between the distal end of the surgical instrument and the magazine retention portion, and
wherein the coil spring applies a biasing force urging the pin outward from the driver head in a lateral direction perpendicular to the longitudinal direction such that in a deployed position a head portion of the pin extends laterally farther than a lateral edge of the driver head and in a retracted position the coil spring is compressed within the driver head portion.

### Claim 2 (depends on 1)

The surgical instrument of claim 1, further comprising a handle positioned adjacent the first end of the surgical instrument opposite the driver head.

### Claim 3 (depends on 1)

The surgical instrument of claim 1, wherein the magazine portion is configured to store a broken-off breakoff head portion of a first set screw while the at least one groove is configured to interlock with at least one groove positioned on an internal surface of an opening of a second set screw.

### Claim 4 (depends on 1)

The surgical instrument of claim 1, wherein the magazine portion is configured to store a broken-off breakoff head portion of a first set screw while the at least one protrusion is configured to interlock with at least one groove positioned on an internal surface of an opening of a second set screw.

### Claim 5 (depends on 1)

The surgical instrument of claim 1, wherein a distal end portion of the pin comprises a semispherical shape.

### Claim 6 (depends on 5)

The surgical instrument of claim 5, wherein the distal end portion of the pin, positioned in the deployed state, is configured to:
retain the plurality of broken-off breakoff head portions of the corresponding plurality of set screws on the magazine retention portion;
prevent the plurality of broken-off breakoff head portions of the corresponding plurality of set screws from sliding off the driver head, and
seat within a cavity of a breakoff area of a first set screw, the first set screw having a breakoff head portion connected to a threaded portion.

### Claim 7

A system for engaging a set screw to an implant, the system comprising:
a first set screw comprising a first breakoff head and a first threaded portion coupled together via a first breakoff region and a first interlocking portion,
a second set screw comprising a second breakoff head and a second threaded portion coupled together via a second breakoff region and a second interlocking portion; and
a surgical instrument comprising:
a shaft having an elongated rigid structure extending in a longitudinal direction from a first end to a second end, and
a driver head positioned on a distal end of the surgical instrument,
wherein the driver head comprises:
a magazine retention portion extending in the longitudinal direction from the second end towards the distal end of the surgical instrument;
at least one interlocking portion extending in the longitudinal direction along the magazine retention portion,
a coil spring and pin positioned within a recessed detent of the driver head between the distal end of the surgical instrument and the magazine retention portion,
wherein the at least one interlocking portion of the driver head is configured to interlock with the first interlocking portion of the first breakoff head and/or the second interlocking portion of the second breakoff head,
wherein the spring applies a biasing force urging the pin outward from the driver head in a lateral direction perpendicular to the longitudinal direction such that in a deployed position a head portion of the pin extends laterally farther than an outside surface of the driver head and in a retracted position the spring is compressed within the recessed detent of the driver head, and
wherein, in a stacked position, the first breakoff head of the first set screw is disposed on the magazine retention portion and the distal end of the surgical instrument is engaged with the second set screw.

### Claim 8 (depends on 7)

The system of claim 7, wherein the surgical instrument further comprises a handle positioned on an end of the surgical instrument opposite the driver head.

### Claim 9 (depends on 7)

The system of claim 7, wherein the first interlocking portion of the first breakoff head comprises a first groove, the second interlocking portion of the second breakoff head comprises a second groove, and wherein the at least one interlocking portion of the driver head comprises a protrusion.

### Claim 10 (depends on 7)

The system of claim 7, wherein the first interlocking portion of the first breakoff head comprises a first protrusion, the second interlocking portion of the second breakoff head comprises a second protrusion, and wherein the at least one interlocking portion of the driver head comprises a groove.

### Claim 11 (depends on 7)

The system of claim 7, wherein, in the stacked position, the at least one interlocking portion of the driver head is interlocked with the second interlocking portion of the second breakoff head, and the driver head is configured to break off the second breakoff head from the second threaded portion when rotated.

### Claim 12 (depends on 7)

The system of claim 7, wherein:
the first set screw further comprises a first recessed area positioned on an inner surface of the first set screw and opposite to the first breakoff region, and
the second set screw further comprises a second recessed area positioned on an inner surface of the second set screw and opposite to the second breakoff region.

### Claim 13 (depends on 12)

The system of claim 12, wherein the first recessed area and the second recessed area are each formed in a shape complimentary to a semispherical shape of a distal end portion of the pin.

### Claim 14 (depends on 12)

The system of claim 12, wherein a distal end portion of the pin is configured to be inserted into the second recessed area of the second set screw while the first breakoff portion is retained on the magazine retention portion.

### Claim 15 (depends on 14)

The system of claim 14, wherein the distal end portion of the pin, positioned in the deployed state, is configured to prevent the first breakoff head, broken off the first set screw, from sliding off the driver head.

### Claim 16 (depends on 12)

The system of claim 12, wherein a distal end portion of the pin, positioned in a deployed state, extends beyond an outer surface of the driver head, and wherein the distal end portion of the pin is configured to be inserted into the second recessed area of the second set screw while the first breakoff portion is retained on the magazine retention portion.

### Claim 17 (depends on 7)

The system of claim 7, wherein, in an additional stacked position, the driver head is configured to retain the first breakoff head and the second breakoff head on the magazine portion in a position that is proximal relative to the pin.

### Claim 18 (depends on 7)

The system of claim 7, wherein the driver head is configured to retain at least three broken off breakoff heads, including at least the first breakoff head and the second breakoff head.