Radiolucent Carbon Fiber Vertebral Cage with Removable Locking Gate

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Solution Overview

Problem

Existing spinal fusion devices are prefabricated and not anatomically shaped, requiring multiple steps and tools for accurate placement, which can lead to decreased accuracy and increased risk of deformation or breakage, and limit visualization of bone fusion due to their metal composition.

Innovation Solution

A fillable, radiolucent carbon fiber cage with a removable locking gate and anatomically shaped designs for different spinal levels, along with a set of geometrically matched and color-coded instruments to facilitate precise placement and maximize endplate surface area access.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If prefabricated metal cages are used for spinal fusion, then immediate stabilization is achieved, but the number of steps and tools required increases and placement accuracy decreases

Engineering Contradiction:

ImprovestabilizationVSAvoidnumber of steps and tools

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cage is pre-shaped to match the natural anatomy of the intervertebral space, eliminating the need for multiple intraoperative shaping steps. The instrument geometrically matches the pre-shaped cage, allowing direct insertion without additional manipulation tools or steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The instrument serves multiple functions: it acts as a distractor to create the intervertebral space, a sizer to determine the appropriate cage size, and an introducer to deliver the pre-shaped cage. This multi-functionality consolidates multiple tools into a single device.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If prefabricated metal cages are used, then structural support is provided, but visualization of bone fusion mass is limited

Engineering Contradiction:

Improvestructural supportVSAvoidvisualization of bone fusion

Core Design Contradiction:

StrengthVSDifficulty of detecting and measuring

Solution Approach 1:

The cage is made radiolucent (transparent to X-rays) so that the bone fusion mass can be clearly visualized through the cage structure during imaging. This allows continuous monitoring of fusion progress without the cage obscuring the view.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The cage combines radiolucent material for the main structure with radiopaque markers at strategic locations. This composite approach provides both visualization of the bone fusion and necessary imaging reference points for surgical guidance.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If intervertebral space is shaped to accommodate prefabricated cages, then device placement is possible, but deformation or breakage risk increases

Engineering Contradiction:

Improvedevice placementVSAvoidrisk of deformation or breakage

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Instead of forcing a standard-shaped cage into a prepared space, the space is designed to receive a pre-shaped cage that already matches its geometry. This reverses the traditional approach and eliminates the need for forceful insertion that could cause deformation or breakage.

Inventive Principle:

Principle #13The other way round (Inversion)

4Adaptability or versatility

If multiple sized cages are used for different spinal levels, then anatomical variation is accommodated, but the number of instruments and trays increases

Engineering Contradiction:

Improveanatomical variation accommodationVSAvoidnumber of instruments and trays

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cage design uses adjustable parameters such as length, width, and height to accommodate different spinal levels and anatomical variations. The instrument similarly uses adjustable parameters to match different cage sizes, reducing the need for multiple specialized tools.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS7674297B2Anatomic vertebral cage

Publication Date: 2010.03.09 CTL MEDICAL CORP

AI summary

A spinal fusion system includes a cage with a fillable volume and removable locking gate, thereby enabling the fillable volume to be packed with graft, biologic or other materials prior to the gate being closed and locked. In the preferred embodiment, the locking gate is positioned anteriorally, though lateral, posterior, and combinations thereof are also possible. The cage is preferably radiolucent, being composed of a carbon fiber, but with one or more radiopaque markers to provide a certain degree of visualization. Some or all of the walls of the cage may include superior and/or inferior surface features to enhance positioning and/or minimize back-out, and the posterior wall may be indented to prevent neurocompression. The sidewalls of the cage may further include a recessed face with nipple indents and locking fasteners. According to a system aspect of the invention, multiple cages are provided, each being shaped differently for use at different spinal levels. For example, the cage may be larger and more trapezoidally-pronounced for the L5-S1 levels, or smaller and less trapezoidally pronounced for the T and L2 levels. The system may further including an implant introducer instrument geometrically matched to the cage, and the matched implant introducer instruments and cages may be color-coded to expedite the procedure.