Mosaic Bone Implants with Composite Mesh and Ceramic Coating
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Solution Overview
Problem
Current bone defect correction methods using metal meshes and ceramic scaffolds face challenges such as low bone formation, infections, and mechanical weakness, particularly in large defects like those in the cranium or long bones, where existing solutions fail to provide adequate structural support and promote effective tissue regeneration.
Innovation Solution
The development of mosaic implants comprising biocompatible mosaic plates interconnected by wires, which can be customized to fit specific bone defects through deformation and cutting, providing a flexible and supportive structure that can be fabricated using various materials like titanium and polymers, and molded with hydraulic cement compositions to enhance bone growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal meshes are used to fill large bone defects, then structural support is provided, but bone formation is low and infections occur
Solution Approach 1:
The patent uses composite materials combining metal mesh with ceramic coatings (hydroxylapatite and/or bioactive glass). The metal mesh provides structural support while the ceramic coating promotes bone formation and reduces infection risk, resolving the contradiction between mechanical strength and biological performance.
2Reliability
If ceramic scaffolds are used to fill bone defects, then bone formation is promoted, but mechanical strength is weak and scaffold failure risk is high
Solution Approach 1:
The patent creates a composite structure where ceramic materials (hydroxylapatite and/or bioactive glass) are coated onto metal mesh. The ceramic layer promotes osteointegration and bone formation while the underlying metal mesh provides mechanical strength, preventing scaffold failure.
Solution Approach 2:
The patent applies different materials to different regions: metal mesh provides structural support in load-bearing areas while ceramic coating is applied to surfaces contacting bone tissue to promote bone formation. This local differentiation resolves the contradiction between mechanical strength and bone formation promotion.
3Shape
If ceramic scaffolds are custom made in advance, then precise fitting to defect shape is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent uses a modular approach where a metal mesh base structure can be configured in segments that are then coated with ceramic materials. This segmentation allows for easier manufacturing and assembly while still achieving precise fitting to the defect shape through the flexible metal mesh substrate.
Data Source
AI summary
A mosaic implant (2010) comprises a mesh support frame comprising a plurality of polygonal support rings (2040 A, B, C) connected by a plurality of struts (2014), and a plurality of mosaic plates (2012). The support rings are positioned within the mosaic plates; the struts extend between adjacent plates. An implant (1510) for filling a bore hole comprises a plate (1512) and a support frame (1520) having a central portion (1522) located at least partially within the plate, a polygonal outer rim (1524) having a plurality of fastening points for attaching the implant to bone surrounding a bore hole, and a plurality of arms (1530) extending between the central portion and the outer rim. The plurality of arms extend inwardly and downwardly away from the outer rim such that the central portion is located below the plane of the outer rim and the upper surface of the plate is flush with or slightly above the upper surface of the outer rim.