Modular Bone Plates With Snap-Fit Tabs For Complex Geometries
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Solution Overview
Problem
Conventional bone reinforcement systems are inadequate for reconstructing irregularly shaped bones or complex surfaces during orthopedic surgeries, particularly in revision procedures.
Innovation Solution
A modular bone reinforcement system comprising a plurality of bone plates with series of tabs for snap-fit attachments, allowing for customizable assembly and dynamic adjustment to fit complex bone geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional bone reinforcement systems are used, then the structure is simple and easy to manufacture, but the system is inadequate for reconstructing irregularly shaped bones or complex surfaces
Solution Approach 1:
The bone reinforcement system is divided into multiple separate bone plates that can be individually selected and assembled. Each bone plate can be attached to adjacent plates through interlocking features, allowing the system to be segmented into manageable components that can be customized for complex bone geometries while maintaining manufacturing simplicity for each individual component.
Solution Approach 2:
The bone plates are designed with universal interlocking features (tabs and recesses) that allow the same basic component design to serve multiple functions and be assembled in various configurations. This enables a single standardized plate design to adapt to different bone shapes and surgical requirements through modular assembly rather than requiring custom-designed plates for each application.
2Adaptability or versatility
If a modular system with multiple bone plates is used, then the system can fit complex bone shapes, but the assembly and attachment process becomes more complex
Solution Approach 1:
The modular bone plate system is segmented into individual plates with standardized interlocking features. Each plate can be independently positioned and attached to adjacent plates through tab-recess connections, allowing surgeons to assemble complex configurations from simple, standardized components rather than manipulating a single complex piece.
Solution Approach 2:
The bone plates incorporate dynamic adjustment capabilities through rotatable connections and adjustable tab positions. This allows the assembled structure to be dynamically configured during surgery to match the specific bone geometry, providing customizability without requiring completely custom-designed plates for each case.
3Adaptability or versatility
If bone plates with series of tabs for snap-fit attachment are used, then the assembly can be dynamically adjusted, but the manufacturing precision requirements increase
Solution Approach 1:
The connection system is segmented into discrete tabs and recesses that can be manufactured as standardized features on each bone plate. This segmentation allows for tolerance accumulation to be managed at each connection point rather than requiring high precision across the entire assembly, reducing overall manufacturing precision requirements while maintaining dynamic adjustment capability.
Solution Approach 2:
The tab and recess features are designed with specific geometric parameters (width, depth, spacing) that provide a range of acceptable tolerances for snap-fit attachment. By optimizing these parameters, the system achieves adequate connection precision without requiring extremely tight manufacturing tolerances, balancing adjustability with manufacturability.
Data Source
AI summary
Modular bone reinforcement systems, bone plates, assembled bone reinforcements, and methods of reinforcing a bone are described. A modular bone reinforcement system includes a plurality of bone plates, each of which has a series of tabs disposed along at least one edge of the bone plate for forming a snap-fit attachment to a mating series of tabs of another bone plate of the plurality of bone plates to form an assembled bone reinforcement. A first bone plate of the plurality of bone plates has a first shape and a second bone plate of the plurality of bone plates has a second shape that is different from the first shape. The modular bone reinforcement system can include additional components, such one or more fixation devices, reduction devices, navigation aids, or other components.