Porous Sternal Fusion Implant for Compression and Bone Regrowth
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Solution Overview
Problem
Conventional sternotomy procedures often result in non-union of sternal halves due to inadequate compression and realignment, leading to patient pain, increased infection risk, and formation of fibrous scar tissue instead of new bone, complicating further surgeries.
Innovation Solution
A bone implant system comprising an inner and outer layer, with the outer layer being porous and fibrous to receive cellular growth factors, is placed between sternal sections to promote fusion by applying compressive loads and secure the sections with tacks or fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sternotomy closure methods are used, then the procedure is simple and quick, but proper compression and realignment of sternal surfaces is rarely achieved resulting in non-union and fibrous scar tissue formation
Solution Approach 1:
The implant is divided into multiple functional layers: an outer porous layer for cellular growth factor delivery and an inner structural layer for mechanical support and compression. This segmentation allows each layer to optimize its specific function while working together to achieve reliable bone fusion.
Solution Approach 2:
The implant combines different materials with complementary properties: porous material for biological activity and growth factor delivery, dense structural material for mechanical strength and compression, and potentially resorbable materials for temporary support. This composite structure resolves the contradiction by integrating multiple functions into a single device.
2Productivity
If the implant includes porous outer layer to receive cellular growth factors, then bone fusion is accelerated, but manufacturing complexity increases
Solution Approach 1:
The outer layer is designed with controlled porosity to enable cellular infiltration and growth factor delivery. The porous structure can be created through established manufacturing techniques such as foam formation, sintering, or additive manufacturing, balancing biological performance with manufacturability.
Solution Approach 2:
The implant design allows adjustment of porosity parameters, pore size, and material composition to optimize both bone fusion performance and manufacturing processes. By controlling these parameters, the device achieves accelerated bone healing while remaining compatible with standard manufacturing methods.
3Reliability
If compression is applied to achieve proper realignment, then bone fusion is promoted, but risk of tissue damage increases
Solution Approach 1:
The implant is inserted into the sternal gap before compression is applied, serving as a protective cushion that distributes mechanical loads evenly across the sternal surfaces. This prevents concentrated stress points and reduces the risk of tissue damage while maintaining the necessary compression for bone fusion.
Solution Approach 2:
The implant acts as an intermediary element between the two sternal halves, mediating the compression force and protecting the bone surfaces from direct high-stress contact. This intermediary structure enables effective compression while minimizing harmful effects on the biological tissue.
Data Source
AI summary
An implant is provided that is operable to be disposed between and fuse two sections of a bone. The implant includes a material that is operable to abut against the two sections of the bone. The material is porous and/or fibrous and is operable to receive at least one cellular growth factor.