Modular Orthopaedic Spacer Mould for Variable Patient Anatomy

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Solution Overview

Problem

Existing orthopaedic spacer moulds lack flexibility to accommodate patients with varying physiques, requiring multiple moulds or limiting treatment to specific patient types due to fixed dimensions and shapes.

Innovation Solution

A modular mould system with interchangeable components, including first and second moulding elements and forming inserts, allows for variable configuration to create spacers of different sizes and shapes, enabling precise adaptation to individual patient anatomy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If fixed-dimension moulds are used, then manufacturing simplicity is maintained, but adaptability to different patient physiques deteriorates

Engineering Contradiction:

Improveadaptability to different patient physiquesVSAvoidmould system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mould is divided into a first moulding element and a second moulding element that can be coupled together. Each element can be independently configured with different dimensions and shapes, allowing the system to adapt to various patient physiques while maintaining manageable complexity through modular assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mould dimensions and configurations are made variable rather than fixed. The first and second moulding elements can be adjusted to different positions and orientations, enabling the same mould system to produce spacers of varying sizes and shapes to match different patient anatomies

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple fixed moulds are used to treat different patients, then adaptability improves, but device complexity and inventory requirements worsen

Engineering Contradiction:

Improvetreatment coverage for different patientsVSAvoidnumber of moulds required

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single mould system with configurable first and second moulding elements can perform the function of multiple fixed-dimension moulds. By adjusting the configuration and coupling of these elements, the same mould system produces spacers tailored to different patient physiques, eliminating the need for maintaining multiple separate moulds in inventory

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If custom modelling is performed in the operation theatre, then adaptability to individual patients is maximized, but manufacturing precision and time consumption worsen

Engineering Contradiction:

Improvecustom fit for individual patientsVSAvoidspacer dimensional accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The mould system is prepared in advance with configurable first and second moulding elements that can be set to specific dimensions and shapes before the operation. This preliminary configuration ensures manufacturing precision is maintained while still allowing customization for individual patients, avoiding the need for imprecise custom modelling during the operation itself

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12128592B2Mould and a method for forming an orthopaedic spacer made of medical cement

Publication Date: 2024.10.29 G21 SRL

AI summary

The modular mould (1) for forming an orthopaedic spacer made of medical cement defines a moulding cavity delimited by a moulding surface (3, 3′, 3″) and configured for impressing a predetermined shape on said medical cement and realising said orthopaedic spacer. The mould (1, 1′) comprises a first sector (7a, 7a′, 7a″), defining a first portion of said surface, and a second sector (7b, 7b′) defining a second portion of the surface, the first and the second portion of the surface being variable, so as to obtain spacers having variable dimensions.