Mosaic Implants for Bone Defect Correction

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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, mechanical weakness, and scaffold failure, particularly in large defects like those in the cranium or long bones, due to inadequate structural support and infection risks.

Innovation Solution

The development of mosaic implants comprising biocompatible mosaic plates interconnected by wires, which can be customized in size and shape to fit specific bone defects, providing structural support through deformable designs and retention features like eyelets for secure fixation, and made from materials like titanium or polymers to enhance mechanical strength and bone integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal meshes are used to fill large bone defects, then structural support is provided, but bone formation is low and infection risk increases

Engineering Contradiction:

Improvestructural supportVSAvoidbone formation

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention uses composite materials combining metal mesh with ceramic coatings (hydroxylapatite and/or tricalcium phosphate). 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 compatibility.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The ceramic coating is applied selectively to the surface of the metal mesh, creating different functional zones: the metal interior provides structural support while the ceramic exterior promotes osteointegration. This local differentiation allows simultaneous achievement of mechanical strength and bone formation.

Inventive Principle:

Principle #3Local quality

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

Engineering Contradiction:

Improvebone formationVSAvoidmechanical strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The composite structure combines weak but osteoconductive ceramic material with strong metal mesh. The ceramic provides bone formation promotion while the metal substrate provides mechanical strength, preventing scaffold failure.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The ceramic coating is applied as a porous layer on the metal mesh, allowing bone ingrowth while maintaining structural integrity. The porous structure promotes bone formation without compromising the overall mechanical strength provided by the metal substrate.

Inventive Principle:

Principle #31Porous materials

3Shape

If ceramic scaffolds are custom made in advance to fit defects, then shape conformity is achieved, but manufacturing complexity and time increase

Engineering Contradiction:

Improveshape conformityVSAvoidmanufacturing complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The implant consists of a modular metal mesh structure that can be configured in different shapes and sizes. This segmentation allows standard components to be assembled into custom configurations, reducing manufacturing complexity while maintaining shape conformity to the defect.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal mesh structure is designed to be deformable and adaptable, allowing it to be shaped and configured intraoperatively to match the specific defect geometry. This dynamic adaptability eliminates the need for complex pre-manufacturing customization.

Inventive Principle:

Principle #15Dynamics

4Reliability

If metal meshes are coated with hydroxylapatite powder, then bone in-growth is improved, but mechanical strength and structural integrity are reduced

Engineering Contradiction:

Improvebone in-growthVSAvoidmechanical strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The hydroxylapatite coating is applied as a porous layer rather than a dense coating, allowing bone ingrowth while maintaining the mechanical strength of the underlying metal mesh. The porous structure provides bone in-growth pathways without significantly compromising structural integrity.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The ceramic coating is applied as a thin surface layer, providing bone-promoting properties locally at the implant-bone interface while leaving the bulk metal structure intact to provide mechanical strength. This localized functional differentiation resolves the strength-bone formation contradiction.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9220597B2Mosaic implants, kits and methods for correcting bone defects

Publication Date: 2015.12.29 OSSDSIGN

AI summary

A mosaic implant conformable to a curved surface, comprising first and second implant sections coupled along a beam portion extending across a length of the implant, each of the implant sections havinga plurality of biocompatible mosaic plates, anda plurality of wires which interconnect the plates with one another.The mosaic implant is configured to be deformable such that at least a portion of the mosaic implant is conformable to a curved surface, with the beam portion providing structural support which resists inward deformation of the curved portion of the implant. A kit for forming a mosaic implant is also provided, along with a method for correcting a bone defect in a patient.