Geared Cam Interbody Implant for Even Spinal Expansion

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Solution Overview

Problem

Existing expandable spinal implants apply excessive, irregular expansion forces to the disc space, lack fine adjustment capabilities, and often have inadequate configurations at the distal tip for engaging with vertebral bodies.

Innovation Solution

An expandable spinal implant with geared cams that include upper and lower rack portions with projecting teeth, a chassis, a yoke, and spur gears, allowing controlled expansion through rotational motion translated into linear motion, ensuring even force distribution and precise adjustment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If conventional 4-bar or crank slider expansion mechanisms are used, then the implant can be expanded from collapsed to expanded position, but excessive initial expansion force is applied to the disc space

Engineering Contradiction:
Improveexpansion forceVSAvoidexcessive initial expansion force
Core Design Contradiction:
ForceVSObject-affected harmful factors

Solution Approach 1:

The patent employs a cam mechanism where the cam profile is specifically designed to provide a controlled expansion sequence. The cam surface geometry transforms rotational motion into a progressive linear displacement, allowing the expansion force to be applied gradually rather than abruptly. This dynamic control mechanism ensures that the expansion force increases progressively, avoiding excessive initial force while maintaining the ability to achieve full expansion.

Inventive Principle:
Principle #15Dynamics

2Force

If conventional expansion mechanisms are used, then the implant can be expanded, but irregular expansion force is applied to the disc space

Engineering Contradiction:
Improveexpansion forceVSAvoidregularity of expansion force
Core Design Contradiction:
ForceVSStability of the object's composition

Solution Approach 1:

The cam mechanism with specifically designed cam profile provides dynamic control over the expansion process. The cam surface geometry is engineered to ensure uniform distribution of expansion force throughout the expansion sequence, transforming irregular force application into a stable, progressive force distribution that maintains consistency throughout the expansion process.

Inventive Principle:
Principle #15Dynamics

3Ease of operation

If conventional expansion mechanisms are used, then the implant can be expanded, but fine adjustment capability is lacking

Engineering Contradiction:
Improvefine adjustment capabilityVSAvoidadjustment precision
Core Design Contradiction:
Ease of operationVSMeasurement precision

Solution Approach 1:

The cam mechanism allows for controlled rotational movement that can be precisely adjusted during the expansion process. The cam profile design enables the operator to achieve fine adjustments in the expansion position by controlling the rotational input, providing precise control over the final expanded position and enabling fine adjustment capabilities that were lacking in conventional mechanisms.

Inventive Principle:
Principle #15Dynamics

4Device complexity

If the implant lacks different configurations at the distal tip, then the structure is simpler, but engagement with adjacent vertebral bodies is inadequate

Engineering Contradiction:
Improvestructural complexityVSAvoidengagement reliability
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent applies the local quality principle by providing different configurations specifically at the distal tip of the implant while keeping other portions of the structure relatively simple. The distal tip features specialized engagement structures such as protrusions or textured surfaces that enhance engagement with the vertebral bodies, while the main body maintains a simpler geometry. This localized complexity ensures reliable engagement without unnecessarily increasing overall device complexity.

Inventive Principle:
Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The implant provides controlled, even expansion with fine adjustment capabilities, enhancing engagement with vertebral bodies and reducing the risk of excessive force, thereby improving surgical outcomes.

Implementation Method 1

At least one first spur gear is rotatably mounted on a distal end of one of the first and second walls of the yoke. The at least one first spur gear has teeth configured to engage the downwardly-projecting teeth of the upper rack portion. At least one second spur gear is rotatably mounted on a distal end of one of the first and second walls of the yoke. The at least one second spur gear has teeth configured to engage the upwardly-projecting teeth of the lower rack portion.

Methodology Applied
Scientific EffectGear mechanism: Gear

Implementation Method 2

A portion of the inner surface includes an upper rack portion. The upper rack portion includes downwardly-projecting teeth intermediate the proximal end and the distal end of the upper endplate, and at least one distal-most downwardly-projecting tooth proximate the distal end of the upper endplate.

Methodology Applied
Scientific EffectRack and pinion mechanism: Rack and Pinion

Data Source

PatentUS20260102259A1Geared cam expandable interbody implant and method of implanting same
Publication Date: 2026.04.16 WARSAW ORTHOPEDIC INC
  • US20260102259A1 patent drawing
  • US20260102259A1 patent drawing
  • US20260102259A1 patent drawing

AI summary

A geared cam expandable spinal implant. Rotational motion of a rotating portion is translated into linear motion of a yoke, which moves geared cams at the distal end of the implant to mate with, and walk along, teeth of corresponding racks. The walking of the gear cam teeth along the rack teeth creates a regular rate of implant expansion, reduces initial excessive expansion force applied to the implant, and provides fine adjustment of the expansion rate and force.