Segmented Bone Plate with Truss Structure for Jaw Reconstruction
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Solution Overview
Problem
Current bone plates for treating lower jaw fractures and defects are difficult to mold to individual anatomy, prone to microcracks and work hardening, and often require a large range of preformed plates, which is costly and inefficient.
Innovation Solution
A bone plate design with a main section and wings that can be bent out of plane to adapt to the lower jaw's unique anatomy, featuring a truss structure and variable-angle screw fixation to distribute loads and reduce deformation, allowing for easier shaping and increased stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard material like grade 4 titanium is used to increase rigidity, then the bone plate can withstand loads without noticeable bending, but the material becomes relatively brittle and prone to microcracks
Solution Approach 1:
The bone plate is divided into distinct functional zones: rigid load-bearing areas (head and tail sections) and flexible deformation areas (middle section with bending lines). This segmentation allows different parts of the same plate to have different mechanical properties, combining rigidity where needed with flexibility to prevent brittle failure.
Solution Approach 2:
Different regions of the bone plate are designed with different mechanical properties. The head and tail sections maintain high rigidity for load bearing, while the middle section is designed with bending lines that allow controlled deformation. This local differentiation of mechanical properties resolves the contradiction between overall rigidity and localized brittleness.
2Adaptability or versatility
If pre-formed anatomically specific bone plates are manufactured for every anatomy, then perfect anatomical fit is achieved, but it is impossible to keep suitable plates in stock for every individual variation
Solution Approach 1:
The bone plate transitions from a static, pre-formed component to a dynamic, adaptable structure. The middle section with bending lines can be deformed during surgery to match various anatomical configurations. This dynamic adaptability allows a single plate design to serve multiple anatomical variations, eliminating the need for extensive plate variety.
Solution Approach 2:
The bone plate is designed as a universal component that can be adapted to different anatomical situations through controlled deformation. The standardized head and tail sections provide consistent load-bearing functionality, while the flexible middle section allows the same plate to accommodate various anatomical shapes, making one plate type suitable for multiple applications.
3Strength
If reconstruction plates with material thickness of 2.0 to 3.5 mm are used to absorb high forces, then plate stability is improved, but the plates become difficult to adapt to specific bone shape and require very high forces for bending
Solution Approach 1:
The plate structure is segmented into rigid sections (head and tail) and flexible sections (middle with bending lines). The bending lines are strategically placed in the middle section where deformation is needed, allowing the thick plate to be shaped without requiring excessive force across the entire plate. The rigid sections maintain strength while the flexible sections enable adaptability.
Solution Approach 2:
The bending lines are pre-formed in the plate during manufacturing, creating predetermined deformation paths. This preliminary preparation reduces the force required during surgery, as the plate is guided to deform along pre-established lines rather than requiring high forces to create new deformation paths in the thick material.
4Ease of operation
If miniplates with relatively thin material thickness are used for easy shaping, then ease of bending is improved, but the plates are prone to plate fractures and dislocations under higher loads
Solution Approach 1:
The plate is segmented into thin flexible middle section and thicker rigid end sections. The middle section with bending lines provides ease of shaping like miniplates, while the thicker head and tail sections provide the load-bearing capacity of reconstruction plates. This segmentation combines the advantages of both plate types.
Solution Approach 2:
Different thicknesses are applied to different parts of the plate based on functional requirements. The middle section is thinner to facilitate bending and adaptation, while the head and tail sections are thicker to withstand high loads from bone screws and physiological forces. This local variation in thickness resolves the contradiction between ease of shaping and load bearing.
Data Source
Figure 1
Figure 2~3a
Figure 3b
AI summary
A bone screw (340; 350) is disclosed, comprising a first end (351) containing an engagement contour (342), and a second end (344) opposite the first end (351), which contains a locking element (324). A bone plate (101; 101'; 101") for the reconstruction or trauma treatment of a bone (113) is also disclosed, comprising a main section (109) having a truss structure.Also disclosed is a surgical set comprising at least one bone plate (101; 101'; 101") and at least one bone screw (340; 350), wherein the bone plate (101; 101'; 101") has at least one opening (102, 102', 146) for receiving at least one of the bone screws (340; 350), the opening (102, 102', 146) penetrating the bone plate (101; 101'; 101") along a longitudinal axis (L) from a top surface (202) to an opposite bottom surface (203), and the opening (102, 102', 146) opening at the top surface (202) into a first receiving area (204) which is for receiving and, in particular, angularly variable fixation of a locking element (345; 355) of a bone screw (340; 350) is formed in a first direction.