Modular Knee Spacer Device for Anatomical Adaptation
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Solution Overview
Problem
Existing articular spacer devices for temporary replacement of prostheses are either time-consuming to manually form during surgery or poorly adaptable to individual patient dimensions, leading to reduced mobility and quality of life during rehabilitation.
Innovation Solution
A modular spacer device comprising pre-formed tibial and femoral elements made of biologically compatible materials, with optional shims for size adjustment, allowing for secure anchoring and optimal articulation alignment without requiring on-site shaping, ensuring compatibility with varying patient anatomies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If pre-formed articulation spacers are used, then surgical time is reduced and ease of operation is improved, but adaptability to patient dimensions deteriorates
Solution Approach 1:
The spacer device is divided into separate femoral and tibial elements that can be independently selected and combined. This segmentation allows the surgeon to choose the appropriate size for each element based on the patient's specific anatomy, providing adaptability while maintaining the benefit of pre-formed components that reduce surgical time.
Solution Approach 2:
The spacer device is designed with universal compatibility across multiple size variations. The femoral and tibial elements are created in different sizes but maintain consistent articulation surfaces and connection mechanisms, allowing a single design platform to serve multiple patient anatomies without requiring custom fabrication.
2Manufacturing precision
If pre-formed articulation spacers are used, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
Dividing the spacer into separate femoral and tibial elements simplifies the manufacturing process for each component while maintaining high precision through standardized production methods. Each element can be manufactured independently with optimized processes, then assembled using straightforward connection mechanisms.
Solution Approach 2:
The spacer elements are pre-formed with precise articulation surfaces and connection features during manufacturing, eliminating the need for intraoperative shaping or adjustment. This preliminary preparation ensures manufacturing precision is achieved during controlled production rather than during surgery, while the modular design keeps the overall device complexity manageable.
Data Source
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AI summary
Disposable modular spacer device (1) of the articulation of a knee comprising a tibial element (2, 2', 2' ' ), constrainable to an end of the tibial bone in proximity of the articulation of the knee and comprising a lower surface (7) and an upper surface (16, 16', 16'') provided with a radius of curvature R2, and a femoral element (4, 4', 4''), comprising an inner surface (14), constrainable to an end of the femoral bone at the articulation of the knee and an outer convex surface (15, 15', 15''), provided with a radius of curvature R1 and in contact with the upper surface (16, 16', 16'') of the tibial element (2, 2', 2''), the tibial element (2, 2', 2") and the femoral element (4, 4', 4'') having various dimensions or sizes, the tibial element (2, 2', 2'') being configured so as to be coupled with any size of the femoral element (4, 4', 4'') to adapt the dimensions of the modular spacer device (1) with the dimensions of the bone ends to which it should be connected.