Laminated Composite Orthopedic Fixators with Variable Fiber Orientation
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Solution Overview
Problem
Current orthopedic fixation devices made from metals face issues such as stiffness mismatch with bone, allergic reactions, and long acquisition lead times, and existing alignment methods for placing these devices are cumbersome and inaccurate.
Innovation Solution
The development of an orthopedic fixation device with a laminated composite design using biocompatible plastic and reinforcing fibers like carbon fiber, where the orientation of fibers in multiple layers is strategically selected to achieve desired mechanical properties, and a system is used to design and manufacture these devices based on specific patient and application requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal implants are used for orthopedic fixation, then strength and reliability are improved, but stiffness mismatch with bone causes stress shielding and bone loss
Solution Approach 1:
The patent applies composite materials by combining carbon fiber reinforcement with polymer matrices to create implants that match bone stiffness while maintaining strength. The carbon fiber orientation and layering are specifically designed to achieve mechanical properties comparable to cortical bone, eliminating stress shielding effects while providing sufficient structural support for fracture fixation.
Solution Approach 2:
The patent implements local quality by varying fiber orientation, material composition, and layer thickness at different regions of the implant to match the specific mechanical requirements of different bone areas. This allows the implant to provide appropriate stiffness locally rather than uniform properties throughout, optimizing stress distribution and preventing bone loss.
2Reliability
If metal implants are used for orthopedic fixation, then reliability is improved, but allergic reactions occur in some patients
Solution Approach 1:
The patent changes the material parameters from traditional metals to carbon fiber-reinforced polymers, fundamentally altering the chemical composition to eliminate metallic allergens. This parameter change maintains mechanical reliability through the high strength-to-weight ratio of carbon fiber while removing the harmful allergic response associated with nickel, chromium, and other metal allergens.
3Ease of operation
If traditional alignment methods are used for implant placement, then procedure is simpler, but alignment accuracy is poor
Solution Approach 1:
The patent introduces a new dimension of precision by integrating multiple imaging modalities and three-dimensional reconstruction techniques. The system transitions from two-dimensional radiographic alignment to three-dimensional optical tracking and registration, enabling accurate spatial positioning of the implant while maintaining surgical efficiency through preoperative planning and intraoperative guidance.
Solution Approach 2:
The patent replaces traditional mechanical alignment tools and radiographic methods with optical tracking systems and computer vision technologies. This substitution eliminates the limitations of manual alignment and two-dimensional imaging, providing real-time, three-dimensional feedback for precise implant placement without adding significant operational complexity.
4Adaptability or versatility
If customized composite implants are manufactured for each patient, then adaptability is improved, but manufacturing time increases
Solution Approach 1:
The patent applies preliminary action by performing preoperative imaging, three-dimensional reconstruction, and implant design before surgery. This allows customization of the implant to match the patient's specific anatomy and fracture pattern in advance, enabling the actual surgical procedure to proceed efficiently with pre-planned positioning and configuration, thereby reducing overall treatment time despite the customization involved.
Data Source
AI summary
A multi-layer, fiber-reinforced composite orthopaedic fixation device having a design selected based on a desired characteristic of the orthopaedic fixation device. The design may be selected according to a model of the device, the model defining design constraints, and the design may comprise a pattern of the fiber angle for each layer. The selection of a design may be analyzed using finite element analysis to determine whether the design will comprise the desired characteristic.