Bellows Spinal Implant With Radiolucent Titanium Shell
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Solution Overview
Problem
Existing spinal interbody fusion devices face challenges in mimicking the biomechanical properties of the spine, achieving radiolucency for radiographic observation, and providing enhanced osteointegration with vertebral bodies.
Innovation Solution
A bellows-shaped spinal implant manufactured using additive technology, featuring a titanium shell with inwardly angled walls that provide stiffness similar to PEEK implants, and porous contact regions with gyroid lattice structures for enhanced osteointegration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If titanium is used for spinal interbody fusion device, then osteointegration with bone is improved, but radiolucency is worsened causing imaging obscuration
Solution Approach 1:
The patent employs a composite material structure combining PEEK (polyetheretherketone) as the base material with a titanium coating layer. The PEEK provides inherent radiolucency for imaging transparency, while the titanium coating on the surfaces interfacing with vertebral body endplates provides osteointegration. This composite approach resolves the contradiction by integrating materials with complementary properties.
2Difficulty of detecting and measuring
If PEEK is used for spinal interbody fusion device, then radiolucency and biomechanical properties similar to bone are improved, but osteointegration with bone is worsened
Solution Approach 1:
The patent uses a composite material system where PEEK serves as the base material providing radiolucency and biomechanical properties similar to bone, while a titanium coating layer is applied to the surfaces that contact the vertebral body endplates. This coating provides the osteointegration capability that PEEK lacks, thereby resolving the contradiction between radiolucency and bone integration.
3Reliability
If titanium coating is applied to PEEK implant, then osteointegration is improved, but device complexity is worsened
Solution Approach 1:
The patent specifies that the titanium coating is applied in a porous configuration to the PEEK implant surfaces. This porous structure enhances osteointegration by providing a scaffold for bone ingrowth while maintaining a relatively simple overall device structure. The additive manufacturing process further simplifies production of this complex porous coating pattern.
4Manufacturing precision
If additive manufacturing is used for spinal implant, then manufacturing precision and complex geometry are improved, but manufacturing cost is worsened
Solution Approach 1:
The patent utilizes additive manufacturing technology to create the bellows-shaped implant with precise control over geometric parameters including wall thickness, bellows expansion characteristics, and porous coating distribution. This manufacturing method enables complex geometries and precise dimensional control that would be difficult or impossible to achieve with traditional manufacturing methods, despite higher material and processing costs.
Data Source
AI summary
A bellows shaped spinal implant, comprising an upper plate, a lower plate and a bellows shaped shell extending between and joining the upper and lower plates. The bellows shaped shell is formed of titanium or an alloy comprising titanium and includes a wall extending therearound that defines a hollow interior. The wall has a thickness in the range of 0.5 mm to 1.0 mm to provide for radiographic imaging through the wall. The wall is angled or curved inwardly or outwardly between the upper and lower plates to provide stiffness mimicking the stiffness properties of a similarly sized polyetheretherketone (PEEK) implant. The upper and lower plates each comprise porous contact regions including a three-dimensional gyroid lattice structure defined by a plurality of struts and pores in communication with the hollow interior. The outer surfaces of at least a portion of the struts may comprise a laser ablated textured surface.