Expandable Interbody Implant With Hinged Endplates for Adjustable Lordosis

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Solution Overview

Problem

Conventional mechanically operated interbody implants for spinal procedures, particularly in the cervical region, often have a large footprint and are cumbersome, limiting the ability to optimize lordosis or sagittal alignment due to fixed lordotic angles between endplates.

Innovation Solution

An expandable interbody implant with hingedly coupled superior and inferior endplates, featuring a locking screw and breakoff tangs or female recesses for insertion, allowing adjustable lordosis and kyphosis configurations, and a surgical tool for expanding and securing the implant at a desired angle and height.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional mechanically operated interbody implants are used with fixed lordotic angles, then the implant structure is simple and robust, but the ability to optimize lordosis or sagittal alignment is limited

Engineering Contradiction:

Improveadjustability of lordosis and sagittal alignmentVSAvoidcomplexity of expandable mechanism and locking system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The implant transitions from a static fixed-angle design to a dynamic adjustable structure. The superior endplate is hinged to allow rotation relative to the inferior endplate, enabling adjustment of lordosis and sagittal alignment after insertion. The expandable mechanism allows the implant to be compressed for insertion and then expanded to the desired configuration, providing adaptability without requiring multiple pre-formed implants.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The superior endplate is positioned within a recess of the inferior endplate in a compressed state, allowing the implant to be inserted in a compact form. After insertion, the superior endplate is rotated and expanded to the desired angle, creating a nested configuration that enables both compact insertion and post-insertion adjustment.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of operation

If conventional implants with large footprint are used, then mechanical stability is adequate, but the implant is cumbersome and unsuitable for ACDF surgeries

Engineering Contradiction:

Improveease of insertion in ACDF surgeryVSAvoidmechanical stability of implant

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The implant uses a dynamic expansion mechanism where the superior endplate rotates from a horizontal to an angled position after insertion. This allows the implant to be inserted in a compact, low-profile state suitable for ACDF surgery, then expanded in situ to achieve the desired mechanical stability and lordotic alignment without requiring a large initial footprint.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The implant is divided into two main segments: the inferior endplate with a recess and the superior endplate that rotates within it. This segmentation allows the superior endplate to be inserted through the disc space in a compressed state and then rotated to expand, providing both ease of insertion and mechanical stability.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If the superior endplate is rotated to expand the implant, then adjustable lordosis is achieved, but the risk of over-rotation or under-rotation affecting alignment increases

Engineering Contradiction:

Improveprecision of lordotic angle adjustmentVSAvoiddifficulty of controlling rotation during insertion

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The implant incorporates visual feedback through alignment marks or indicators that show the surgeon the current rotation angle of the superior endplate relative to the inferior endplate. This feedback mechanism allows the surgeon to monitor the rotation in real-time and stop at the precise desired lordotic angle, reducing the risk of over-rotation or under-rotation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The implant is pre-configured with a recess in the inferior endplate and a corresponding superior endplate designed to rotate within that recess. The geometry of the recess and endplate interface is pre-engineered to guide the rotation path and limit the range of motion, ensuring that the rotation stays within safe boundaries and achieves the intended alignment without requiring complex real-time control.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12414863B2Expandable interbody implant and corresponding surgical tool

Publication Date: 2025.09.16 WARSAW ORTHOPEDIC INC

AI summary

An interbody system including an implant and a tool for inserting and expanding the medical implant and locking the implant in place is disclosed. The medical implant may include an expandable body defined by a superior endplate and an inferior endplate that are hingedly coupled and may be expanded and lordosed. The superior and inferior endplate may include radially disposed and opposed surfaces that mate and/or directly contact each other when a locking screw is threaded through a screw aperture. The implant may include a threaded breakoff screw disposed in the threaded screw aperture and movable between a locked position and an unlocked position, for example. In the locked position, the threaded locking screw may urge the distal engagement surface of the first core into direct contact with the proximal engagement surface of the second core. When broken, the breakoff screw may comprise a recessed fracture surface.