Continuous Fiber Bone Screw Composite Design
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Solution Overview
Problem
Conventional bone screws and pedicle screws made of metallic materials are highly visible on X-rays, which can hinder the visibility of certain patient anatomy elements during medical procedures.
Innovation Solution
A bone screw design comprising a first portion made of thermoplastic material and a second portion formed by layering continuous fibers on top of the first portion, achieving desired mechanical strength in all modes of loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials are used for bone screws, then mechanical strength is improved, but radiolucency deteriorates (X-ray visibility increases)
Solution Approach 1:
The bone screw uses a composite structure combining a metallic core (providing mechanical strength) with a polymer coating layer (providing radiolucency). This composite material approach allows the screw to simultaneously achieve high mechanical strength from the metal core and improved X-ray visibility through the radiolucent polymer exterior, directly resolving the contradiction between strength and radiolucency.
2Strength
If continuous fibers are layered on thermoplastic substrate, then mechanical strength in all loading modes is improved, but device complexity increases
Solution Approach 1:
The continuous fibers are oriented in specific directions (longitudinal, diagonal, helical, radial) to provide targeted mechanical strength in different loading modes. This local quality approach allows each region of the screw to have fiber orientations optimized for the specific stress patterns encountered in that area, achieving comprehensive mechanical performance without requiring complex overall structural changes.
Solution Approach 2:
The patent transitions from conventional isotropic materials to anisotropic composite materials with fibers arranged in multiple dimensions and orientations. By adding the dimensional aspect of fiber orientation (0 degrees, 45 degrees, 90 degrees, helical angles), the screw achieves superior mechanical properties in all loading modes while maintaining a relatively simple layered construction process.
Data Source
AI summary
The present disclosure provides for a bone screw formed of continuous fibers, for example. The bone screw may include a first portion having a cylindrical shape and extending in a longitudinal direction from a first end to a second end, for example. In various embodiments, the first portion may include a thermoplastic material and/or be substantially formed of a thermoplastic material. In various embodiments, the bone screw may include a second portion coupled to the first portion and surrounding the first portion, at least partly, for example. In various embodiments, the second portion may include a plurality of layers, each layer comprising a continuous fiber material, for example. In various embodiments, the continuous fibers may be oriented longitudinally, diagonally, helically, radially, etc. In various embodiments, the second portion may define an exposed thread pattern and a leading tip.