Composite spinal interbody device and method

A method for forming composite interbody suitable for insertion between two adjacent vertebrae, the method comprising:

• forming a first end plate comprising a biocompatible metal and having a superior surface operable to contact a upper vertebral body, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, the first end plate further comprising a first array of apertures passing from the superior surface to the inferior surface, a second array of apertures passing from the interior side wall to the exterior side wall, and a third array of apertures passing from another interior side wall to another exterior side wall, wherein the first, second, and third arrays of apertures intersect each other inside the first end plate;
• forming a first intermediate plate comprising a biocompatible metal and having a superior surface, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, the first intermediate plate further comprising a fourth array of apertures passing from the superior surface to the inferior surface, a fifth array of apertures passing from the interior side wall to the exterior side wall, and a sixth array of apertures, passing from another interior side wall to another exterior side wall, wherein the fourth, fifth, and sixth arrays of apertures intersect each other inside the first intermediate plate;
• connecting the first end plate to the first intermediate plate so that the first array of apertures at the inferior surface of the first end plate do not overlap the third array of apertures at the superior surface of the first intermediate plate when the inferior surface of the first end plate;
• forming a second intermediate plate comprising a biocompatible metal and having a superior surface, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, the second intermediate plate further comprising a seventh array of apertures passing from the superior surface to the inferior surface, an eighth array of apertures passing from the interior side wall to the exterior side wall, a ninth array of apertures, passing from another interior side wall to another exterior side wall, wherein the seventh, eighth, and ninth arrays of apertures intersect each other inside the second intermediate plate;
• forming a second end plate comprising a biocompatible metal and having a superior surface, an inferior surface operable to contact a lower vertebral body, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, the second end plate further comprising a tenth array of apertures passing from the superior surface to the inferior surface, an eleventh sixth array of apertures, passing from an interior side wall to an exterior side wall, and a twelfth array of apertures, passing from another interior side wall to another exterior side wall;
• connecting the second end plate to the second intermediate plate so that the seventh array of apertures at the inferior surface of the second intermediate plate does not overlap the tenth array of apertures at the superior surface of the second end plate;
• forming a central body comprising a biocompatible polymer and having a superior surface, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface;
• connecting the superior surface of the central body to the inferior surface of the first intermediate plate;
• and
• connecting the inferior surface of the central body to the superior surface of the second intermediate plate.

A composite interbody device adapted for insertion between two adjacent vertebrae, the interbody device comprising:

• a first end plate comprising a biocompatible metal and having a superior surface adapted to contact an upper vertebral body, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, the first end plate further comprising an array of apertures passing from the superior surface to the inferior surface;
• a first intermediate plate comprising a biocompatible metal and having a superior surface adapted to contact the inferior surface of the first endplate, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, wherein the inferior surface of the first intermediate plate further comprises an array of linear recesses passing from an exterior sidewall to an opposing exterior side wall;
• a central body comprising a biocompatible polymer and having a superior surface adapted to contact the inferior surface of the first intermediate plate, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface;
• a second intermediate plate comprising a biocompatible metal and having a superior surface adapted to contact the inferior surface of the central body, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, the second intermediate plate further comprising an array of linear recesses passing from an exterior side wall to an opposing exterior sidewall;
• a second end plate comprising a biocompatible metal and having a superior surface adapted to contact the inferior surface of the second intermediate plate, an inferior surface adapted to contact a lower vertebral body, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, the second end plate further comprising an array of apertures passing from the superior surface to the inferior surface.

A method for forming composite interbody suitable for insertion between two adjacent vertebrae, the method comprising:

• forming a first end plate comprising a biocompatible metal and having a superior surface operable to contact a upper vertebral body, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, the first end plate further comprising a first array of apertures passing from the superior surface to the inferior surface, a second array of apertures passing from the interior side wall to the exterior side wall, and a third array of apertures passing from another interior side wall to another exterior side wall, wherein the first, second, and third array of apertures intersect each other inside the first end plate;
• forming a first intermediate plate comprising a biocompatible metal and having a superior surface, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, the inferior surface of the first intermediate plate further comprising an array of linear recesses passing from an exterior sidewall to an opposing exterior side wall of the first intermediate plate;
• connecting the first end plate to the first intermediate plate;
• forming a second intermediate plate comprising a biocompatible metal and having a superior surface, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, wherein the superior surface of the second intermediate plate further comprises an array of linear recesses passing from an exterior side wall to an opposing exterior side wall of the second intermediate plate;
• forming a second end plate comprising a biocompatible metal and having a superior surface, an inferior surface operable to contact a lower vertebral body, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface, the second end plate further comprising a fourth array of apertures passing from the superior surface to the inferior surface, a fifth array of apertures passing from the interior side wall to the exterior side wall of the second end plate, and a sixth array of apertures passing from another interior side wall to another exterior side wall;
• connecting the second end plate to the second intermediate plate;
• forming a central body comprising a biocompatible polymer and having a superior surface, an inferior surface, an exterior side wall connecting the superior surface to the inferior surface, and an interior side wall connecting the superior surface to the inferior surface;
• connecting the superior surface of the central body to the inferior surface of the first intermediate plate;
• and
• connecting the inferior surface of the central body to the superior surface of the second intermediate plate.