Metal alloy mono and poly-filament wire reinforced carbon fiber plating system

Abstract

The invention entails metal alloy mono and poly-filament wire reinforced carbon fiber plating system for the fixation of skeletal fractures and osteotomies. Current fracture fixation plating systems are metal alloy designs that block the field of vision of the fracture during radiographic evaluation. Carbon fiber and mono and poly-filament wire plating systems reduce the weight and thickness as compared to the current plating designs while permitting direct visualization of the fracture site during the healing process. The benefits of the plating design contribute to the satisfaction of the patient and reduce disruption to the surrounding soft tissue structures. An embodiment of the plating system entails layered sheets of carbon fiber with an infrastructural framework of metal alloy mono and poly-filament wire for added strength and durability of the plate. This system can be utilized for all types of skeletal fracture and osteotomy fixation as well as fields of mechanical, aerospace, and structural engineering where durable lightweight, high strength materials are required.

1 . A device for use in skeletal fixation, comprising: an orthopedic plate comprising a metal alloy mono and poly-filament wire inserted between layered carbon fiber in a non-continuous fashion. 
     
     
         2 . The device of  claim 1 , wherein said plate comprises at least one threaded shaft. 
     
     
         3 . The device of  claim 2 , further comprising a screw sized to mate with said threaded shaft. 
     
     
         4 . The device of  claim 3 , wherein said threaded shaft and screw are configured to allow a plurality of angular orientations of screw axis. 
     
     
         5 . The device of  claim 3 , wherein said screw has a threaded shaft and a head and wherein the threaded shaft and the screw head have a mating interface such that the screw engages the threaded shaft so as to cause a locked angular orientation of the screw axis in the threaded shaft. 
     
     
         6 . The device of  claim 1 , comprising a screw portal comprising a metal or metal-allow ring placed circumferentially about the surface of the screw portal parallel to the axis of the plate. 
     
     
         7 . The device of  claim 6 , wherein said ring comprises threads configured for mating with a screw. 
     
     
         8 . The device of  claim 6 , wherein said ring is configured to permit angulation of a screw to be fixated to an osseous structure under said plate in thirty degrees from perpendicular to the plane of the plate. 
     
     
         9 . The device of  claim 1 , wherein said plate has a longitudinal axis and wherein said plate comprises a curve transverse to the longitudinal axis and wherein said plate has a constant radius along the longitudinal axis. 
     
     
         10 . (canceled) 
     
     
         11 . The device of  claim 1 , wherein said plate system comprises a central trunk which includes a neck; the central trunk and the neck having a complex contour 1/3 tubular design that forms a spoon shape toward a bone facing surface. 
     
     
         12 . (canceled) 
     
     
         13 . A method for reinforcing carbon fiber sandwich paneling comprising:
 a) compressing mono and/or poly-filament metal alloy wires between layers of carbon fiber sheets, wherein a plurality of different wires are oriented in said sheets in different orientations, to form a carbon fiber sandwich; and   b) curing said carbon fiber sandwich.   
     
     
         14 . The method of  claim 13 , wherein said wires comprise a plurality of different gauge wires. 
     
     
         15 . The method of  claim 13 , wherein said wires comprise a plurality of different non-linear orientations. 
     
     
         16 . The method of  claim 13 , wherein a plurality of different wires are oriented in said sheets such that wires in a first layer are oriented in a first direction and wires in a second layer are oriented in a different direction. 
     
     
         17 . The method of  claim 13 , wherein said carbon fiber is prepared by vacuum resin infusion. 
     
     
         18 . The method of  claim 13 , wherein a heating element is applied during the curing process. 
     
     
         19 . The method of  claim 13 , wherein a heating element is not applied during the curing process. 
     
     
         20 . (canceled) 
     
     
         21 . A system comprising a metal alloy mono and poly-filament wire incorporated a carbon fiber sandwich panel forming a cylindrical tube or rod intramedullary nail configured for the fixation of long bone fractures, osteotomies, or arthrodesis inserted within a medullary canal cancellous bone in an anti-grade or retrograde orientation, said system further comprising screw portals. 
     
     
         22 . The system of  claim 21 , wherein said screw portals are configured such that locking screws or non-locking screws, when inserted into said screw portals, extend in a divergent manner from said nail and permit each end of screws to fixate cortical bone on each side of the intramedullary rod to be gripped by first and second locking screw or non-locking screws so as to stabilize said fractures, osteotomies, or arthrodesis. 
     
     
         23 . The system of  claim 21 , wherein said screw portals are positioned such that screws inserted therein pass through a non-articular portion of a cortical bone and fusion sites for joint arthrodesis, while gripping a cortical bone mass.