Flexible Cranial Mesh Implant for Curved Bone Flap Fixation

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Solution Overview

Problem

Existing cranial bone flap fixation systems, such as the CranioFix®2 clamp system, can cause irritation of the dura mater, lead to hematoma, require additional tools for handling, and are unsuitable for regions with significant curvature or thickness gradients, resulting in inadequate cosmetic and medical outcomes.

Innovation Solution

A flexible mesh structure made of plastic material with webs and openings, designed for fastening to the bone flap and skull, offering adjustable sizing and geometry, and can be bonded or fastened using adhesives or fastening elements, providing a thin, translucent, and isotropic elastic solution that adapts to the skull geometry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid clamp system with disk elements is used to fix the bone flap, then the fixation stability is improved, but the cosmetic appearance deteriorates due to visibility and scalp irritation

Engineering Contradiction:

Improvefixation stabilityVSAvoidcosmetic appearance and scalp irritation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies a flexible mesh structure made of thin plastic material instead of rigid metal clamp systems. This flexible mesh can conform to the curved skull surface while maintaining fixation stability, and its thin, translucent nature improves cosmetic appearance by reducing visibility under the scalp.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible mesh structure is designed to adapt to the curved geometry of the skull surface. Unlike rigid flat disk elements, the flexible mesh can conform to spherical or curved surfaces, ensuring stable fixation while lying flat against the skull contour and improving cosmetic results.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If rigid disk elements are pressed flat against the skull and bone flap, then fixation stability is improved, but adaptability to curved skull geometries deteriorates

Engineering Contradiction:

Improvefixation stabilityVSAvoidadaptability to skull curvature

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The flexible mesh structure replaces rigid disk elements, enabling adaptation to curved skull surfaces while maintaining the flat-lying configuration necessary for stable fixation. The flexibility allows the mesh to conform to various skull geometries without compromising fixation reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The mesh structure transitions from a rigid static form to a flexible dynamic form that can adapt to different skull curvatures. This dynamic adaptability allows the same flexible mesh to conform to various geometric configurations while maintaining stable fixation.

Inventive Principle:

Principle #15Dynamics

3Reliability

If additional tools are used to hold the rod element during fixation, then control of clamping force is improved, but ease of operation deteriorates due to increased handling complexity

Engineering Contradiction:

Improveclamping force controlVSAvoidhandling simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent extracts and eliminates the rod element and its associated holding tools from the fixation system. The flexible mesh structure achieves force control through its material properties and bonding mechanism, removing the need for additional tools and simplifying the surgical procedure.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The flexible mesh structure provides self-controlling characteristics through its material properties, allowing it to adapt to the bone flap and skull surfaces while maintaining appropriate fixation force without requiring external tool intervention for force regulation.

Inventive Principle:

Principle #25Self-service

4Strength

If the implant has significant thickness to provide structural support, then mechanical strength is improved, but cosmetic appearance and visibility under scalp deteriorates

Engineering Contradiction:

Improvemechanical strengthVSAvoidvisibility and cosmetic appearance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The flexible mesh structure achieves adequate mechanical strength through its flexible material properties and structural configuration rather than thickness. This allows the implant to be very thin and translucent, improving cosmetic appearance by minimizing visibility under the patient's scalp.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent uses plastic material for the flexible mesh structure, which provides an favorable combination of mechanical strength, flexibility, and thinness. This composite approach allows the implant to maintain structural integrity while being thin enough to minimize cosmetic concerns.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250288420A1Implant for fixing a cranial bone flap in a cranial opening of an osseous skull

Publication Date: 2025.09.18 AESCULAP AG

AI summary

An implant for fixing a cranial bone flap in a cranial opening of an osseous skull includes a flexible mesh structure having webs and openings formed between the webs. The flexible mesh structure is made of a plastic material and is designed to be fastened to the bone flap and to the osseous skull.