Knee Replacement Implant Stackable Spacers for Anatomy Fit

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Solution Overview

Problem

Existing knee replacement implants face challenges in minimizing inventory and cost while accommodating the variability in anatomical characteristics of patients, necessitating a need for implant solutions that reduce component numbers while expanding adaptability.

Innovation Solution

The implementation of stackable spacers for both tibial and distal femoral implants, which can be securely stacked and adjusted to provide varying spacings, allowing for a smaller number of components to accommodate a wider range of patient anatomies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple different spacer components are used to accommodate various patient anatomies, then adaptability is improved, but inventory complexity and manufacturing costs increase

Engineering Contradiction:

Improveadaptability to patient anatomyVSAvoidinventory complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The spacer system is divided into multiple individual spacer components of different thicknesses (e.g., 2mm, 4mm, 6mm, 8mm, 10mm) that can be selected and combined. Each spacer is a discrete, standardized segment that can be independently chosen based on patient anatomy requirements, allowing precise adaptation without maintaining complex custom-designed components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spacers are designed with universal features including standardized attachment mechanisms (screws, posts, or clips) and consistent geometric profiles that allow the same spacer design to be used across different implant types and patient anatomies. This multi-functionality enables a single spacer component to serve multiple purposes and accommodate various spacing requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple different spacer components are used to accommodate various patient anatomies, then adaptability is improved, but manufacturing costs increase

Engineering Contradiction:

Improveadaptability to patient anatomyVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The overall spacing requirement is segmented into discrete, standardized thickness increments. This segmentation allows manufacturers to produce spacers in standardized size batches rather than custom orders, significantly reducing per-unit manufacturing costs while still providing the flexibility to accommodate various anatomical needs through combination.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spacer system varies primarily one parameter (thickness) while keeping other parameters (material composition, attachment mechanism, geometric profile) constant. This single-parameter variation simplifies the manufacturing process, as the same production line, tooling, and quality control procedures can be used for all spacer sizes, reducing overall manufacturing costs.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If multiple different spacer components are used to accommodate various patient anatomies, then adaptability is improved, but the number of components increases

Engineering Contradiction:

Improveadaptability to patient anatomyVSAvoidnumber of spacer components

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The spacing requirement is segmented into discrete, standardized thickness increments. This segmentation allows precise adaptation to patient anatomy using only the necessary number of spacers rather than requiring a complete set of all possible thickness variations. For example, a 12mm spacing can be achieved with six 2mm spacers or three 4mm spacers, reducing the total component count.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each spacer component is designed with universal attachment features and consistent geometry that allow any spacer to be used in any position and combined with any other spacer. This universality means that a smaller variety of spacer designs can fulfill a wider range of spacing requirements, reducing the total number of different component types that must be manufactured and inventoried.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12403010B2Knee replacement implant having stackable spacers

Publication Date: 2025.09.02 ENCORE MEDICAL L P (D B A DJO SURGICAL)

AI summary

A knee replacement prosthesis includes a distal femoral implant, including a femoral head portion, including an outer arcuate surface, and interior posterior surface, an interior distal surface disposed at a first angle with respect to the interior posterior surface, and a first interior intermediate surface joining the interior posterior surface and the interior distal surface and being disposed at a second angle with respect to the interior posterior surface and at a third angle with respect to the interior distal surface. The distal femoral implant includes stackable femoral spacers secured to at least one of the interior posterior surface and the interior distal surface, thereby adjusting an aggregate spacing between the interior posterior surface and/or the interior distal surface and a resected surface of a distal femur of the patient. A tibial implant is also provided. Related methods of use of either implant or both are also provided.