Implantable Prosthetic Scaffold for Form Stability and Wrinkle Reduction

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Solution Overview

Problem

Conventional breast implants face issues such as the 'ashtray effect,' rippling, wrinkling, and scalloping, which affect their aesthetic appearance and structural integrity, while also increasing weight and discomfort due to excess gel or shell tension, and lack effective methods to maintain form stability without altering feel or manufacturing complexity.

Innovation Solution

Incorporating a scaffold made of biocompatible polymeric material within the implant shell, which provides internal reinforcement to maintain shape and stability without increasing gel volume or shell thickness, thereby reducing weight and minimizing undesirable surface distortions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If additional gel is added to eliminate the ashtray effect, then the ashtray effect is reduced, but the weight of the implant increases

Engineering Contradiction:

Improveashtray effectVSAvoidimplant weight

Core Design Contradiction:

ShapeVSWeight of moving object

Solution Approach 1:

The patent applies this principle by using a thin film scaffold (microneedle array) that provides structural support to prevent the ashtray effect without requiring additional gel. The scaffold is integrated into the shell structure, creating a flexible yet supportive framework that maintains implant shape while minimizing weight addition compared to adding more gel material.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent utilizes porous materials through the microneedle scaffold structure, which creates a three-dimensional network that provides structural support and prevents collapse at the apex. The porous nature of the microneedle array allows it to maintain shape stability with minimal material, thereby reducing weight compared to solid gel additions.

Inventive Principle:

Principle #31Porous materials

2Shape

If shell tension is increased to reduce rippling, then rippling is reduced, but the implant feels less natural and comfort decreases

Engineering Contradiction:

ImproveripplingVSAvoidnatural feel

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The patent applies this principle by using a flexible thin film scaffold that provides internal support to reduce rippling while maintaining the soft, natural feel of the implant. The scaffold is thin and compliant, allowing it to integrate with the shell structure without creating excessive tension or hardness, thus resolving the contradiction between ripple reduction and natural feel.

Inventive Principle:

Principle #30Flexible shells and thin films

3Stability of the object's composition

If more cohesive gel is used to improve form stability, then form stability is improved, but the implant feels firmer and less natural

Engineering Contradiction:

Improveform stabilityVSAvoidnatural feel

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The patent uses a thin film scaffold that provides structural support for form stability without requiring more cohesive gel. The scaffold acts as an internal framework that maintains implant shape and prevents collapse, while the gel can remain less cohesive and more natural-feeling, as the structural support function is transferred to the scaffold.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent applies composite materials by combining the scaffold structure with the gel filler. The composite system integrates the structural support function of the scaffold with the soft, natural feel of the gel, allowing form stability to be achieved through the composite structure rather than relying solely on gel cohesiveness.

Inventive Principle:

Principle #40Composite materials

4Shape

If gel volume is increased to improve projection, then projection is improved, but the weight of the implant increases

Engineering Contradiction:

ImproveprojectionVSAvoidimplant weight

Core Design Contradiction:

ShapeVSWeight of moving object

Solution Approach 1:

The patent applies this principle by using a thin film scaffold that provides structural support to maintain projection without requiring additional gel volume. The scaffold creates an internal framework that supports the implant shape and projection, allowing the same projection to be achieved with less gel and therefore less weight.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS20230233307A1Implantable prosthetic devices having outer shells with integrated scaffolding for improving form stability, reducing wrinkling and reducing the weight of the implantable prosthetic devices

Publication Date: 2023.07.27 MENTOR WORLDWIDE LLC

AI summary

An implantable prosthetic device, such as a breast implant, includes a shell made of a biocompatible elastomeric material. The shell has a front portion and a base that surround an interior volume of the shell. A scaffold is disposed within the interior volume of the shell. The scaffold has an inner surface facing the base and an outer surface facing the front portion of the shell. A silicone gel is disposed within the interior volume of the shell. The scaffold has a shape that mirrors the shape of the front portion of the shell. The scaffold reinforces the shell to provide form stability for maintaining the shape of the shell and minimizing folding, dimpling and/or wrinkling of the shell. A second scaffold may be nested within the first scaffold. The second scaffold has a smaller outer dimension than an inner dimension of the first scaffold.