PEEK Spinal Rod with Radiopaque Markers and Oblong Cross-Section
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing spinal rods made from polymers lack optimal design features for precise surgical alignment and secure fixation, particularly in terms of radiolucency, flexibility, and customizable curvature for different spinal regions.
Innovation Solution
A curved spinal rod with an oblong cross-section, integrally formed from medical-grade polymers like PEEK, featuring visual guidance markers and radiopaque end caps for enhanced visibility during surgery, along with customizable radii of curvature and cross-sectional variations to match specific spinal regions, ensuring secure fixation and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spinal rods are made from radiolucent polymers, then biocompatibility and flexibility are improved, but visibility during surgery deteriorates
Solution Approach 1:
The spinal rod combines radiolucent polymer material for the main body with radiopaque markers at specific locations. This local differentiation allows the rod to maintain biocompatibility and flexibility from the polymer while providing surgical visibility through strategically placed radiopaque elements that appear on fluoroscopic images.
Solution Approach 2:
The invention uses composite construction by integrating radiopaque markers (such as metal or radiopaque polymer) into the radiolucent polymer rod structure. This composite approach combines the beneficial properties of both materials: the biocompatibility and flexibility of medical-grade polymers with the radiopacity needed for surgical visualization.
2Ease of manufacture
If spinal rods have standardized designs, then manufacturing simplicity is improved, but adaptability to different spinal regions deteriorates
Solution Approach 1:
The spinal rod system employs parameter variations including different radii of curvature, cross-sectional dimensions, and rod lengths to accommodate different spinal regions (cervical, thoracic, lumbar). These parameter changes allow a single base design to be adapted for multiple applications without requiring completely different rod types.
Solution Approach 2:
The rod design incorporates dynamic characteristics through varying curvature radii and cross-sectional properties along its length, allowing the rod to adapt to the natural curves and mechanical requirements of different spinal segments while maintaining structural integrity.
3Measurement precision
If spinal rods have complex geometric features for surgical alignment, then surgical precision is improved, but device complexity deteriorates
Solution Approach 1:
The spinal rod incorporates visual markers that can be seen on fluoroscopic imaging, providing surgical guidance without requiring complex geometric features. These markers may include radiopaque elements, colored coatings, or surface patterns that facilitate alignment and positioning during surgery while maintaining relatively simple rod geometry.
Data Source
Figure 1~3
Figure 4~7
Figure 8~11
AI summary
A method of manufacturing a curved spinal rod is disclosed. The method includes heating PEEK; injecting the PEEK into an arcuate spinal rod mold; holding the injected PEEK in the mold until the PEEK substantially sets; and removing the injected PEEK from the mold. In another aspect, a spinal rod is disclosed. The spinal rod includes an arcuate main body having a first end portion, a second end portion, and a central portion. The central portion has a non-circular cross-section with a height greater than its width. The first and second end portions and the central portion of the arcuate main body are integrally formed of a polymer such as polyetheretherketone (PEEK). The spinal rod also includes a rounded end cap adapted to mate with at least one of the end portions. The end cap is radiopaque.