Surgical Construct Coupling With Interference-Fit Gripping
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Solution Overview
Problem
Conventional surgical and pedicle screw coupling systems are bulky, causing tissue damage and irritation, difficult to maneuver, require complex assembly, and lack flexibility in rod stiffness, making them unsuitable for minimally invasive procedures and revision surgeries.
Innovation Solution
A coupling assembly with adjustable interference fit and gripping interface, allowing for flexible rod positioning and secure attachment via male and female members with engagement features, enabling precise adjustments and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional rigid coupling assemblies are used to connect surgical screws, then structural stability is achieved, but tissue damage and irritation increase due to the bulky size
Solution Approach 1:
The coupling system is divided into multiple independent modular units (coupling devices with rod-receiving chambers) that can be selectively connected. Each module is compact and can be positioned precisely, reducing overall bulk while maintaining structural integrity through the interconnected modular architecture.
Solution Approach 2:
The rod-receiving chamber is nested within the coupling device housing, with the rod positioned inside the chamber. This nested configuration allows the system to achieve structural stability through the enclosed rod-coupling-screw arrangement while minimizing the external profile and reducing tissue irritation.
2Strength
If conventional coupling systems are designed for rigid connection, then structural strength is improved, but adaptability for varying rod stiffness requirements is lost
Solution Approach 1:
The coupling device incorporates adjustable locking mechanisms (set screws, locking plates) that allow the structural properties to be modified after implantation. The rod-receiving chamber can accommodate rods of varying stiffness, and the locking mechanism can be adjusted to provide appropriate fixation strength, enabling transition between rigid and flexible constructs based on surgical requirements.
Solution Approach 2:
The system allows changing of critical parameters such as rod stiffness, coupling rigidity, and fixation strength through selectable components and adjustable locking mechanisms. Different rod materials and diameters can be used within the same coupling device, and the locking mechanism can be configured to provide varying degrees of rigidity to match clinical needs.
3Reliability
If conventional coupling systems require complex assembly with multiple locking components, then secure fixation is achieved, but surgical procedure complexity increases
Solution Approach 1:
Multiple locking functions are merged into integrated locking mechanisms within the coupling device. The set screw or locking plate simultaneously performs multiple functions (securing the rod, locking the coupling, providing compression) in a single action, reducing the number of separate components and steps required while maintaining secure fixation.
Solution Approach 2:
The coupling device incorporates self-aligning features and self-retaining mechanisms that reduce the precision and number of manual adjustment steps required. The rod-receiving chamber is designed to guide proper rod insertion, and the locking mechanism automatically maintains secure fixation without requiring continuous manual intervention, simplifying the surgical procedure.
4Ease of manufacture
If conventional systems require delivery of rod-receiving device already attached to screw head, then assembly is simplified, but surgical maneuverability is reduced
Solution Approach 1:
The coupling device is designed as a separate modular unit with a rod-receiving chamber that can be independently manipulated. This segmentation allows the surgeon to position the coupling device and secure it to the screw head in a controlled manner, improving surgical maneuverability compared to pre-attached configurations while maintaining assembly simplicity through the modular design.
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
Reduces tissue damage, simplifies surgical maneuvers, and allows for customizable rod stiffness, facilitating minimally invasive procedures and easy extension or revision of fusion constructs.
Implementation Method 1
The first and second bodies can be coupleable to one another by an interference fit when the raised portion of the male member is positioned within the area of decreased diameter associated with the internal bore of the female member
Implementation Method 2
The engagement features can be operable to provide a gripping interface between the male member and the female member to couple the male member and the female member one to another
Data Source
AI summary
A coupling assembly for use in surgical constructs includes a first body and a second body. One of the first body and the second body includes a male member and an other of the first body and the second body includes a female member. The male member is sized and shaped to be received within the female member and the female member has an internal bore sized and shaped to receive the male member therein. One of the male member or the female member includes one or more engagement features formed therewith or attached thereto. The engagement features are operable to provide a gripping interface between the male member and the female member to couple the male member and the female member one to another.