Layered Flat Bone Implant for Imaging-Safe Tissue Ingrowth
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Solution Overview
Problem
Existing implants for replacing or filling flat bones often compromise mechanical stability and interfere with X-ray or MRI diagnostics due to the use of metal structures, and polymer-based implants may lack sufficient mechanical strength during intraoperative adaptation.
Innovation Solution
A bi-layered implant structure comprising a non-porous polyetheretherketone (PEEK) or polyethylene (PE) first layer for stability and a porous polymer second layer for tissue ingrowth, eliminating the need for a metal support and ensuring compatibility with diagnostic imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal support structure is used to provide mechanical strength, then the mechanical stability is improved, but the compatibility with X-ray or MRI diagnostics deteriorates
Solution Approach 1:
The patent removes the metal support structure from the implant design entirely. The implant consists only of polymer materials (porous and non-porous layers), completely eliminating the metal component that caused interference with X-ray and MRI diagnostics while maintaining mechanical stability through the polymer layer structure.
Solution Approach 2:
The patent uses a composite structure combining porous polymer material and non-porous polymer material in layers. This composite polymer structure provides the necessary mechanical strength to replace metal support structures while remaining compatible with diagnostic imaging methods.
2Adaptability or versatility
If the implant shape is adapted during surgery by bending, then the adaptability is improved, but the mechanical strength deteriorates
Solution Approach 1:
The implant is pre-shaped during manufacturing to match the desired final geometry. The non-porous polymer layer provides dimensional stability that prevents further deformation during surgery, eliminating the need for intraoperative bending while maintaining mechanical integrity.
Solution Approach 2:
The patent changes the material parameters by using a non-porous polymer layer with high dimensional stability. This material property prevents plastic deformation during surgery, ensuring that the implant maintains its mechanical strength while the shape is predetermined from manufacturing.
3Reliability
If a porous polymer layer is added for tissue ingrowth, then the biocompatibility is improved, but the mechanical strength deteriorates
Solution Approach 1:
The patent divides the implant into functional segments: a porous polymer layer for tissue ingrowth and a non-porous polymer layer for mechanical strength. This segmentation allows each layer to perform its specific function optimally without compromising the other.
Solution Approach 2:
The patent creates a composite structure where porous polymer material (for biocompatibility and tissue integration) is combined with non-porous polymer material (for mechanical strength). The non-porous layer provides dimensional stability and prevents damage to the porous layer during implantation, while the porous layer enables tissue ingrowth.
Data Source
AI summary
An implant (X) for replacing or filling a defect of a flat bone has a flat shape with a first side (X1) and an opposite second side (X2). The implant (X) includes a first layer (S1) formed of non-porous polyetheretherketone or polyethylene, which has such a layer thickness that the shape of the implant (X) is established by the shape of the first layer (S1). The implant (X) includes, in at least some portions on the first side (X1), a second layer (S2) formed of a porous polymer which is not polyaryletherketone or polyetheretherketone. A method for producing such an implant (X) is also provided.