Modular Joint Prosthesis with Adjustable Head Coupler
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Solution Overview
Problem
Current joint prostheses lack modularity and universality, often requiring revision surgeries due to suboptimal fit and configuration, especially in cases where only one joint component is replaced, necessitating a system that can be easily configured and modified during surgery without complete removal.
Innovation Solution
A modular prosthesis assembly system featuring a stem, coupler, and insert with Morse taper couplings allowing for variable rotational and pitch angle adjustments, enabling precise alignment and secure coupling of the head component relative to the bone-engaging portion, facilitating a wide range of configurations and easy modification during surgery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a typical humeral prosthesis with pre-determined head geometries is used, then the device structure is simple and easy to manufacture, but the adaptability to different patients and glenoid components is limited
Solution Approach 1:
The prosthesis is divided into multiple separable components: a stem portion, a coupler portion, and a head portion. This segmentation allows each component to be optimized independently and assembled in various configurations to match different patient anatomies and glenoid components, thereby improving adaptability without requiring complete redesign of the entire device.
Solution Approach 2:
The prosthesis incorporates dynamic adjustment capabilities through the coupler mechanism, which allows the head portion to be positioned at multiple angles and orientations relative to the stem. This dynamic configurability enables the device to adapt to different patient requirements while maintaining a relatively simple overall structure through standardized modular components.
2Ease of repair
If a non-modular prosthesis design is used, then the device is simpler to manufacture and inventory, but revision surgery requires complete removal of the prosthesis
Solution Approach 1:
The prosthesis is designed as a modular assembly of stem, coupler, and head portions that can be independently removed and replaced. This segmentation enables selective revision of specific components during surgery without requiring complete removal of the entire prosthesis, significantly improving ease of repair and revision procedures.
Solution Approach 2:
The modular design allows surgeons to discard only the specific component that requires replacement (e.g., just the head portion) while recovering and retaining the functional stem and coupler components. This approach reduces surgical time, implant removal complexity, and the need for complete prosthesis replacement.
3Manufacturing precision
If fixed head geometry options are provided, then manufacturing and inventory management are simplified, but the precision of fit and alignment with natural glenoid surface is compromised
Solution Approach 1:
The coupler mechanism provides dynamic angular adjustment capabilities, allowing the head portion to be positioned at multiple precise orientations relative to the stem. This enables achievement of optimal head-to-glenoid alignment precision while maintaining standardized manufacturing processes for each modular component, balancing precision requirements with manufacturing simplicity.
4Loss of time
If a prosthesis requiring complete removal for revision is used, then the original design can be simpler, but surgical time and patient recovery are extended
Solution Approach 1:
The modular segmented design allows selective replacement of only the necessary components during revision surgery, eliminating the need for complete prosthesis removal. This significantly reduces surgical time and patient recovery time, while the coupling mechanisms between segments provide the necessary complexity to enable this selective replacement capability.
Data Source
AI summary
A prosthesis assembly in one embodiment includes a stem configured to be implanted in a bone and including a first coupling portion, a head having a bearing surface configured to mate with at least one of a natural opposing joint component and a prosthetic opposing joint component, the head further having a second coupling portion, a coupler including a third coupling portion and a fourth coupling portion, the third coupling portion configured to couple with the second coupling portion, and an insert including (i) a fifth coupling portion configured to couple with the fourth coupling portion in any of a plurality of rotational orientations in combination with any of a plurality of roll angles and any of a plurality of pitch angles, and (ii) a sixth coupling portion configured to couple with the first coupling portion only when the insert assumes a predetermined rotational orientation with respect to the stem.