Surgical impactor

Abstract

An impactor, the impactor being electrically powered and adapted for use in surgery, the impactor comprising: a housing; a brushless DC motor including a stator having a plurality of coils and a rotor having a plurality of magnets; a motor controller including a motor driver that delivers a current to the coil of the stator to rotate the rotor about the stator; the planetary gear train comprises an input part, a sun gear, a planetary gear, a gear ring and an output part; a shaft body including a shaft body section provided with a non-circular cross-sectional shape; and the impact assembly comprises a driving part and a driven part.

Description

Technical Field

[0001] This patent application relates to an electric surgical impactor for joint replacement surgery. Background Technology

[0002] Patients with osteoarthritis or joint damage often undergo joint replacement surgery to relieve pain and restore normal joint function. As part of the surgical procedure, the diseased joint is surgically removed to prepare the patient's joint for prosthesis implantation, and then the artificial prosthesis component is fixed within the patient's anatomy. To prepare the patient's joint for receiving the artificial component, the surgeon must use a bone hammer to impact the patient's anatomy with specialized instruments such as bone reamers or bone compactors. Additionally, to achieve a press-fit between the patient's anatomy and the artificial joint component, the surgeon must typically impact the artificial joint component.

[0003] As mentioned above, surgical impact typically requires the use of a bone hammer. However, the use of a bone hammer has drawbacks. Because surgical impact is a necessary component of joint replacement surgery, surgeons report that prolonged and repetitive use of a bone hammer leads to surgeon fatigue and injury. Many surgeons themselves also have to undergo surgery or have their careers shortened. Therefore, there is a strong need for an electric device to replace the use of a bone hammer, thereby reducing surgeon fatigue and injury.

[0004] Furthermore, it is difficult to precisely control the speed of the hammer during impact, making it challenging to control the depth to which the instrument and prosthesis are impacted into the patient's anatomy. Patients with osteoarthritis often exhibit poor bone density and cannot withstand excessive hammering force; however, excessive hammer speed can exert excessive impact force on the patient's anatomy, leading to fractures. Prostheses must be precisely implanted, but excessive hammering can cause them to be implanted too deeply, while insufficient impact can result in inadequate fixation. Therefore, a powered instrument is needed that provides a limited stroke but sufficient force to cut through the patient's anatomy and secure the implant.

[0005] The foregoing is not intended to be an exhaustive explanation of all the disadvantages associated with bone reamers in the prior art; however, the present invention aims to overcome these (and other) disadvantages inherent in prior art systems. The advantages of the invention will be readily apparent to those skilled in the art upon reading the disclosure provided herein. Attached Figure Description

[0006] Figure 1 A three-dimensional diagram of the surgical impactor is depicted.

[0007] Figure 2 A three-dimensional view is depicted, viewed from one side of the surgical impactor.

[0008] Figure 3 A three-dimensional diagram depicts the motor, gear system, output section, and impact mechanism of the surgical impactor.

[0009] Figure 4 Cross-sectional views of the motor, gear system, output section, and impact mechanism of the surgical impactor are depicted.

[0010] Figure 5 A three-dimensional view depicts the motor, gear system (gear ring omitted), output section, and impact mechanism of the surgical impactor.

[0011] Figure 6 A three-dimensional diagram of the gear system of the surgical impactor is depicted.

[0012] Figure 7 A three-dimensional diagram of the motor rotor is depicted.

[0013] Figure 8 A three-dimensional diagram of the stator of the electric motor is depicted.

[0014] Figure 9 A three-dimensional diagram of the gear ring of the gear system is depicted.

[0015] Figure 10 A three-dimensional diagram of the gear ring of the gear system is depicted.

[0016] Figure 11 A cross-sectional view of the impactor (gear ring omitted) is depicted.

[0017] Figure 12 A three-dimensional diagram of the sun gear of the gear system is depicted.

[0018] Figure 13 A side view of the sun gear of the gear train is depicted.

[0019] Figure 14 A front view of the sun gear of the gear train is depicted.

[0020] Figure 15 A side view of the sun gear of the gear train is depicted.

[0021] Figure 16 Depicting along Figure 15 The diagram shows a cross-sectional view of the sun gear along line AA.

[0022] Figure 17 A side view of the planetary gears in the gear train is depicted.

[0023] Figure 18 A front view of the planetary gears in the gear train is depicted.

[0024] Figure 19 A rear view of the planetary gears in the gear train is depicted.

[0025] Figure 20 A front view of the surgical impactor (without housing and gear ring) is depicted.

[0026] Figure 21 Depicting along Figure 20 The diagram shows a cross-sectional view of line AA of the surgical impactor.

[0027] Figure 22 A side view of the input plate of the gear train is depicted.

[0028] Figure 23 A diagram depicting the rotor side of the input board is shown.

[0029] Figure 24 A three-dimensional view of the input panel is depicted.

[0030] Figure 25 A diagram depicting the gear side of the input board is shown.

[0031] Figure 26 A diagram depicting the load-bearing structure of the sun gear.

[0032] Figure 27 Depicting Figure 26 A cross-sectional view of the sun gear in the diagram.

[0033] Figure 28 A three-dimensional drawing of a surgical impactor (without housing and gear ring) is depicted.

[0034] Figure 29 A three-dimensional view of the output section of the gear train is depicted.

[0035] Figure 30 A front view of the output section of the gear train is depicted.

[0036] Figure 31 A side view of the output section of the gear train is depicted.

[0037] Figure 32 Depicting along Figure 31 A cross-sectional view of line AA of the output section.

[0038] Figure 33 A side view depicts the output section, tubular component, driving component, driven component, and shaft section.

[0039] Figure 34 Depicting along Figure 33 A cross-sectional view of line AA.

[0040] Figure 35 A three-dimensional drawing of the tubular component is depicted.

[0041] Figure 36 A front view of the tubular component is depicted.

[0042] Figure 37 Depicting Figure 36 A detailed view of region "A" of the tubular member shown.

[0043] Figure 38 A three-dimensional view of the drive components is depicted.

[0044] Figure 39 A three-dimensional view of the drive components is depicted.

[0045] Figure 40 A three-dimensional view of the drive components is depicted.

[0046] Figure 41 A three-dimensional view of the driving and driven components is depicted.

[0047] Figure 42 A three-dimensional view of a non-circular rotating component is depicted.

[0048] Figure 43 A diagram depicting the first end surface of a non-circular rotating component.

[0049] Figure 44 A three-dimensional view of a non-circular rotating component is depicted.

[0050] Figure 45 A front view of the surgical impactor (shell omitted) is depicted.

[0051] Figure 46 Depict a 3D view of the scrolling sub-component.

[0052] Figure 47 A bottom view of the scrolling sub-component is depicted.

[0053] Figure 48 A 3D view of the scrolling sub-component is depicted.

[0054] Figure 49 The side view of the scroll child component is depicted.

[0055] Figure 50 A side view of the stepped portion of the driven component is depicted.

[0056] Figure 51 A side view of the stepped portion of the driven component is depicted.

[0057] Figure 52 A top view of the stepped portion of the driven component is depicted.

[0058] Figure 53 Depicting along Figure 50 The cross-sectional view of line AA of the stepped portion of the driven component is shown.

[0059] Figure 54 Depicting along Figure 51The cross-sectional view of line BB of the stepped portion of the driven component is shown.

[0060] Figure 55 The side view depicts the driving component, shaft section, and driven component.

[0061] Figure 56 Depicting along Figure 55 The diagram shows a cross-sectional view of line AA of the driving component, shaft section, and driven component.

[0062] Figure 57-a A side view depicting the shaft section and driven component is shown.

[0063] Figure 57-b Depicting along Figure 57-a The cross-sectional view of the shaft section and the driven component along line AA is shown.

[0064] Figure 58 A three-dimensional view of the shaft section is depicted.

[0065] Figure 59 A side view of the shaft section is depicted.

[0066] Figure 60 A three-dimensional view of the shaft section is depicted.

[0067] Figure 61 A three-dimensional diagram of the impactor was depicted.

[0068] Figure 62 A cross-sectional view of the housing in which the gear ring is pressed is depicted.

[0069] Figure 63 A cross-sectional view of the impactor is depicted.

[0070] Figure 64 A three-dimensional view of the motor mounting section is depicted.

[0071] Figure 65 A three-dimensional view of the motor mounting section is depicted.

[0072] Figure 66 A perspective view of the motor mounting section, including the housing, is depicted.

[0073] Figure 67 A top view depicts the housing that extends into the motor mounting section.

[0074] Figure 68 A top view of the motor mounting section is depicted.

[0075] Figure 69 A cross-sectional view of the motor mounting section, including the battery housing, is depicted.

[0076] Figure 70A side view of the impactor, including the motor mounting section, is depicted, with the stepper motor located within the housing and the lead screw located within the gun drill shaft.

[0077] Figure 71 Depicting along Figure 70 A cross-sectional view of line AA.

[0078] Figure 72 The diagram depicts a linear encoder. Figure 73 Detailed view.

[0079] Figure 73 Depicting along Figure 72 A cross-sectional view of line BB.

[0080] Figure 74 A perspective view of an impactor is depicted, which includes a rail attached to the motor mounting section, a drill shaft, and a lead screw located within the drill shaft.

[0081] Figure 75 A three-dimensional diagram of the track was depicted.

[0082] Figure 76 A three-dimensional diagram of the track was depicted.

[0083] Figure 77 A three-dimensional diagram of the track was depicted.

[0084] Figure 78 A three-dimensional view of the anti-rotation component is depicted.

[0085] Figure 79 A three-dimensional view of the anti-rotation component is depicted.

[0086] Figure 80 A three-dimensional view of the anti-rotation component is depicted.

[0087] Figure 81 A three-dimensional view of the anti-rotation component is depicted.

[0088] Figure 82 A top view of the handle is depicted.

[0089] Figure 83 A cross-sectional view of the handle along line AA is depicted.

[0090] Figure 84 A side view depicting a partially disassembled handle is shown.

[0091] Figure 85 A side view depicting a partially disassembled handle is shown.

[0092] Figure 86 A side view depicting a partially disassembled handle is shown.

[0093] Figure 87A side view depicting a partially disassembled handle is shown.

[0094] Figure 88 A top view depicting a partially disassembled handle is shown.

[0095] Figure 89 A top view of the handle body is depicted.

[0096] Figure 90 A top view depicting the second opening of the impactor is shown.

[0097] Figure 91 A three-dimensional drawing of the handle is depicted.

[0098] Figure 92 A three-dimensional drawing of the handle is depicted.

[0099] Figure 93 A perspective view of the integrated track and motor mounting section is depicted.

[0100] Figure 94 A top view depicting the integrated track and motor mounting section is shown.

[0101] Figure 95 A bottom view depicting the integrated track and motor mounting section is shown.

[0102] Figure 96 A perspective view of the integrated track and motor mounting section is depicted.

[0103] Figure 97 A side view depicting the integrated track and motor mounting section is shown.

[0104] Figure 98 Depicting Figure 97 Cross-sectional view.

[0105] Figure 99 A side view depicting the integrated track and motor mounting section is shown.

[0106] Figure 100 Depicting Figure 99 Cross-sectional view.

[0107] Figure 101 A perspective view depicts a sealing cap with hexagonal protrusions, which is used to screw onto the threads of a track extending from the second opening of the impactor.

[0108] Figure 102 Depicting Figure 101 A perspective view of the sealing cap, showing the thread that mates with the threaded track.

[0109] Figure 103 A perspective view of a sealing cap with hexagonal protrusions is depicted, which is used to screw onto the threads of the housing located at the first end of the impactor.

[0110] Figure 104 Depicting Figure 103 A perspective view of the sealing cap, showing the threads that engage with the threaded part at the first end of the housing. Summary of the Invention

[0111] This invention is defined by the claims set forth herein; however, in brief, the invention relates to an impactor that is electrically powered and suitable for use in surgery, the impactor comprising: a housing; a brushless DC motor including a stator having a plurality of coils and a rotor having a plurality of magnets; a motor controller including a motor driver that supplies current to the coils of the stator to cause the rotor to rotate about the stator; a planetary gear train including an input section, a sun gear, planetary gears, a ring gear, and an output section; a shaft including a shaft section having a non-circular cross-sectional shape; an impact assembly including a drive member and a driven member, wherein: (i) a channel is defined in the drive member to provide clearance to a non-circular rotating member and a rolling sub-assembly; (1) the non-circular rotating member is attached to the rolling sub-assembly; (2) the non-circular rotating member and the rolling sub-assembly rotate through the output section of the gear train; (3) the rolling sub-assembly is provided with a plurality of shafts, a plurality of rollers, and a plurality of forks, wherein each roller is press-fitted onto each shaft. (ii) The driven member includes an impact portion and a stepped portion, wherein a non-circular hole is defined in the stepped portion: (1) the shaft section having the non-circular cross-sectional shape extends through the non-circular hole; (2) the stepped portion further includes a first roller support surface, a second roller support surface, a crown surface, a first ramp and a second ramp, each of the first roller support surface, the second roller support surface, the crown surface, the first ramp and the second ramp extending radially from the non-circular hole; (3) the first ramp extends axially from the first roller support surface to the crown surface, and the second ramp extends axially from the second roller support surface to the crown surface; (4) the crown surface is located between the first roller support surface and the second roller support surface; and (iii) the roller of the rolling sub-assembly rotates on the first roller support surface to the first ramp, and rotates upward to the crown surface, and then rotates downward along the second ramp to the second roller support surface. Detailed Implementation

[0112] Figure 1 and 2 A perspective view depicts an impactor 1000 constituting a preferred embodiment of the present invention. (See attached image.) Figure 1 and Figure 2As shown, the impactor 1000 is provided with a housing 1100 and a handle 1200. The components within the housing 1100 and the handle 1200 are made of a polyetherketone polymer known as "PEEK".

[0113] Figure 3 and Figure 4 Other illustrations of the impactor 1000 are provided. Figure 4 Provided Figure 2 The outlines of the housing 1100 and handle 1200 are shown. Figure 3 and Figure 5 middle, Figure 1 The housing 1100 and handle 1200 shown are completely removed, thus providing a perspective view of the motor 1300 (preferably a brushless DC motor including a stator 1310 and a rotor 1320), gear train 2000, output section 1500, and impact assembly 3000. As described more fully herein, the gear train 2000 is a planetary gear train in which each gear is made of PEEK and includes a sun gear 2100 with a plurality of teeth 2111, a planetary gear 2200 with a plurality of teeth 2211, and a ring gear 2300 with a plurality of teeth 2311.

[0114] Now go to Figure 20 and Figure 21 , Figure 20 and Figure 21 A perspective view and a cross-sectional view along AA are provided, showing the gear train 2000 with the ring gear 2300 omitted. The gear train 2000 provides gear reduction for the impactor 1000 to increase torque. In the preferred embodiment of the planetary gear train 2000, the ring gear 2300 remains fixed, while the sun gears 2100-a and 2100-b rotate about the impactor shaft 2500, which, like the ring gear 2300, remains fixed in place and does not rotate.

[0115] The impactor shaft 2500 is a stainless steel or titanium rod that is gun-drilled to form a hollow shaft including a cylindrical inner surface 2550, the cylindrical inner surface 2550 being sized to accommodate a lead screw, or, in an alternative embodiment, a ball screw. After gun drilling, the rod is flipped and precisely ground to provide a cylindrical outer surface 2510 with a precisely diametrically suited diameter for rotation of the sun gears 2100-a, 2100-b. The cylindrical outer surface 2510 radially surrounds the shaft axis 2501 and extends axially between a pair of opposing shaft ends 2502, 2503 (referred to as "first shaft end 2502" and "second shaft end 2503" to distinguish one end from the other).

[0116] A shaft flange 2511 extends radially from the outer surface 2510 of the cylindrical shaft at the first shaft end 2502 to position the stator 1310 of the motor 1300 (hereinafter referred to as the "first motor," "DC motor," or "BLDC motor"). In a preferred embodiment, both the shaft flange 2511 and the stator 1310 are bolted to a motor mounting portion 2520 (made of PEEK). Advantageously, the outer surface 2510 of the cylindrical shaft is provided with an axial stop or cylindrical sleeve that provides an axial gap between the stator 1310 and the rotor 1320; the axial gap is sized such that the magnets within the rotor 1320 are axially aligned with the coils in the stator.

[0117] As described above, the rotor 1320 is provided with a rotor shaft 1321 and multiple permanent magnets 1322, 1323, 1324, 1325, 1326, 1327, 1328, 1329 (e.g., ...). Figure 7 (As shown); similarly, the stator 1310 is provided with a stator axis 1311 and multiple coils 1312, 1313, 1314, 1315, 1316, 1317 (as shown). Figure 8 (As shown). Coils 1312 to 1317 are formed by winding copper wire around multiple electrical steel laminations, which are stacked together to form a single unit. The electrical steel laminations are radially spaced at equal intervals, so that coils 1312 to 1317 are also radially spaced at equal intervals around the stator axis 1311.

[0118] Permanent magnets 1322 to 1329 within rotor 1320 are arranged radially around rotor axis 1321 and alternate in polarity. For example... Figure 7 As shown, the magnet labeled "1322" is adjacent to the magnet labeled "1323", and the magnet labeled "1323" is adjacent to the magnet labeled "1324". Therefore, the polarity of each of magnets 1322 to 1329 is set to be opposite to the polarity of the adjacent magnet on either side of it.

[0119] As described above, the shaft flange 2511 positions the stator 1310 and thus ensures alignment of the shaft axis 2501 and the stator axis 1311 when the shaft flange 2511 and the stator 1310 are bolted to the motor mounting portion 2520. An axial stop or cylindrical sleeve disposed on the outer surface 2510 of the cylindrical shaft positions the permanent magnets 1322 to 1329 within the stator 1320, such that the magnets 1322 to 1329 are arranged radially around the coils 1312 to 1317 in the stator 1310. As previously stated, in the preferred embodiment, the rotor 1320 is an outer rotor extending radially around the coils 1312 to 1317 of the stator 1310.

[0120] In addition to coils 1312 to 1317 mentioned above, stator 1310 is also equipped with a Hall effect sensor; such as Figure 8 As shown, the stator 1310 is equipped with multiple Hall effect sensors (labeled 1318-a, 1318-b, and 1318-c). Hall effect sensors 1318-a, 1318-b, and 1318-c provide the position of magnets 1322 to 1329 in the rotor 1320 relative to coils 1312 to 1317 in the stator 1310. A signal is provided to the motor controller 1350 when each of the magnets 1322 to 1329 passes each of the Hall effect sensors 1318-a, 1318-b, and 1318-c.

[0121] When each of magnets 1322 to 1329 passes each of Hall effect sensors 1318-a, 1318-b, and 1318-c, a signal is provided to motor controller 1350. In a preferred embodiment, motor controller 1350 is a microcontroller 1351 or microprocessor 1352 communicatively connected to motor driver 1353 and wireless transceiver 1355; however, in an alternative embodiment, motor controller 1350 is simply motor driver 1353. In yet another alternative embodiment, motor controller 1350 is microcontroller 1351 or processor 1352. In a preferred embodiment, wireless transceiver 1355 is a near-field communication (NFC) transceiver with an operating center frequency of 13.56 MHz, a data rate range of 106 kbps to 424 kbps, and a typical operating range of less than or equal to 10 cm.

[0122] In a preferred embodiment, the motor controller 1350 is provided with a memory 1354 including a data lookup table 1356; such data includes gear parameters, gear reduction ratios, number of planetary gear stages, rotational parameters (including the rated torque of the motor 1300), output diameter, spacing between rollers 3134 and 3135, and geometric dimensions (such as length, width, and height) of ramps 3216, 3217, 3226, and 3227. Furthermore, the lookup table 1356 provides cutting data, including tool geometry, diameter of the cutting tool, number of cutting teeth, ideal chip load per tooth, and ideal material removal rate of the cutting tool (such as a broach, drill, reamer, and saw).

[0123] Based on signals from at least one of Hall effect sensors 1318-a, 1318-b, and 1318-c, motor controller 1350 causes current to flow through at least one of coils 1312 to 1317, thereby inducing a magnetic field within stator 1310. The induced magnetic field attracts or repels at least one of permanent magnets 1322 to 1329 in the rotor; thus, the induced magnetic field causes rotor 1320 to rotate about stator 1310. Additionally, signals from at least one of Hall effect sensors 1318-a, 1318-b, and 1318-c provide motor controller 1350 with the angular velocity of rotor 1320.

[0124] Because the rotor 1320 is connected to at least one sun gear 2100, when the induced magnetic field within the stator 1310 causes the rotor 1320 to rotate, the teeth 2111 of the at least one sun gear 2100 also rotate. The rotating teeth 2111 of the sun gear 2100 mesh with the teeth 2211 of at least one planet gear 2200, and the teeth 2211 of the at least one planet gear 2200 mesh with the teeth 2311 of the ring gear 2300. Because the ring gear 2300 is stationary, the planet gears 2200 rotate about the outer diameter 2102 of the sun gear 2100 and the inner diameter 2302 of the ring gear 2300. Therefore, the aforementioned sun gear-planet gear set can be considered a "gear set".

[0125] Figure 9 and Figure 10 A perspective view of a gear ring 2300 included in a gear train 2000 is provided. As described above, the gear ring 2300 is provided with a gear ring axis 2301, a cylindrical annular outer surface 2303, and a plurality of teeth 2311 (referred to as "internal teeth" or "gear ring teeth"). The gear ring teeth 2311 are arranged around the inner diameter 2302 of the gear ring 2300 and extend radially inward toward the gear ring axis 2301. Figure 6 and Figure 11 As shown, the gear ring tooth 2311 is configured to mesh with the planetary gear 2200 and the sun gear 2100. Each tooth of the gear ring 2300 is provided with a gear ring node for meshing with a corresponding node on each tooth of the planetary gear 2200, and the corresponding node on each tooth of the planetary gear 2200 meshes with a corresponding node on each tooth of the sun gear 2100.

[0126] In a preferred embodiment, a gear blank for the gear ring 2300 is manufactured by injecting PEEK into a mold; after injection molding, the blank is machined to an inner diameter suitable for the desired tooth profile, and then multiple teeth 2311 are cut out on a gear forming machine. For manufacturing efficiency, the gear ring 2300 is provided with an extended length such that a single gear ring 2300 meshes with multiple sets of sun gear-planetary gear sets; however, in an alternative embodiment, multiple gear rings are used, with one gear ring for one set of sun gear-planetary gear sets.

[0127] Now refer to Figure 12 , Figure 13 and Figure 14 The perspective view of the sun gear 2100 shows that the sun gear is a single-piece component, provided with an axis 2101 and a pair of ends 2103, 2104 (referred to as the "first sun gear end" and the "second sun gear end," and labeled "2103" and "2104"). The sun gear 2100 also provides a tooth structure 2110 and a load-bearing structure 2120. The tooth structure 2110 extends axially from the first sun gear end 2103 and includes, as described above, a plurality of teeth 2111 (referred to as "sun teeth" to distinguish the teeth of the sun gear from the teeth of the other gears mentioned herein). Figure 14 As shown, the sun tooth 2111 extends radially from the tooth structure 2110 and is provided with a node (referred to as the "sun gear node").

[0128] The load-bearing structure 2120 is configured to support motor-gear components, such as the planetary gear 2200 mentioned above, or the input plate (such as...). Figure 22 , Figure 23 , Figure 24 and Figure 25 The input panel shown is labeled "2400". Figure 14 and Figure 16 As shown, the load-bearing structure 2120 extends axially and radially from the gear tooth structure 2110 to form a flange 2121 (referred to as a "gear flange" to distinguish flange 2121 from other flanges disclosed herein). Figure 16 ( Figure 16 (This is a cross-sectional view of the Sun Gear 2100) and Figure 14 ( Figure 14 As shown in the perspective view of the sun gear 2100, at least one opening (and preferably multiple openings) is formed within the bearing structure 2120. Each of the openings 2122, 2123, 2124, and 2125 is provided with an axis (in... Figure 12 These are labeled "2126", "2127", "2128", and "2129" respectively. Additionally, the dimensions of each of the openings 2122 to 2125 are set to at least partially accommodate a planetary gear (such as...). Figure 17 , Figure 18 and Figure 19 The planetary gear 2200 shown.

[0129] like Figure 17As shown, the planetary gear 2200 is provided with an axis 2201 (referred to as the "planetary axis" to distinguish it from other axes disclosed herein), a pair of ends (referred to as the "first planetary gear end 2203" and the "second planetary gear end 2204"), and a shaft 2202 (referred to as the "planetary gear shaft" to distinguish it from other shafts disclosed herein). The planetary gear shaft 2202 is provided with a cylindrical outer surface 2209, the dimensions of which are set to be axially press-fitted by the inner diameter of a bearing (preferably a deep groove ball bearing) to form a planetary gear bearing assembly. The cylindrical outer surface 2209 of the planetary gear 2200 extends axially from the first planetary gear end 2203 and terminates at a stop 2207 for the bearing.

[0130] As described above and as Figure 18 and 19 As shown, the planetary gear 2200 is provided with a plurality of external teeth 2211 (referred to as "planetary teeth" to distinguish the planetary teeth 2211 from other gear teeth disclosed herein) extending radially and axially from the stop 2207. The planetary teeth 2211 are provided with nodes (referred to as "planetary gear nodes") and are shaped to contact the nodes of the sun teeth 2111.

[0131] The planetary gear shaft 2202 is sized to fit within each of the openings 2122, 2123, 2124, and 2125 formed within the bearing structure 2120 of the sun gear 2100. Each of the openings 2122 to 2125 is located radially along the sun gear axis 2101, such that the planetary gear node contacts both the sun gear node and the ring gear node (e.g., ...). Figure 6 (As shown). In a preferred embodiment, each of the openings 2122 to 2125 is provided with an inner diameter (referred to as the "bearing inner diameter (bearing ID)"). Figure 12 and 14 (These are labeled "2132", "2133", "2134" and "2135"). Each of the openings 2122 to 2125 has a cylindrical bearing ID, and its dimensions are set such that the outer diameter of the aforementioned deep groove ball bearing can be press-fitted therein.

[0132] Figure 21 A plurality of deep groove ball bearings (labeled 2141, 2142, 2143 and 2144) are shown, at least one of the plurality of deep groove ball bearings being press-fitted into one of the bearings ID defined within each opening. Figure 21It is also shown that each of bearings 2141 to 2144 is press-fitted onto each of planetary gear shafts 2202-a, 2202-b, 2202-c, 2202-d. In order to retain each of bearings 2141 to 2144 within each of bearings IDs 2132 to 2135, retaining plate 2145 is fastened to the bearing structure through through holes 2146, 2147, 2148, 2149 defined in the bearing structure.

[0133] Now refer to Figure 16 The sun gear 2100 is provided with a sun gear cavity 2160. For example... Figure 16 As shown, the sun gear cavity 2160 is defined within the sun gear 2100 and is provided with a cylindrical wall surrounding the sun gear axis 2101. This wall (hereinafter referred to as the "first cylindrical wall")... Figure 16 The dimension marked "2161" is set to receive the impactor shaft 2500. In a preferred embodiment, the cavity 2160 is provided with a plurality of cylindrical walls (in... Figure 16 The two walls are labeled "2162" and "2163" and are referred to as "the second cylindrical wall" and "the third cylindrical wall" respectively, in order to distinguish one wall from the other.

[0134] To allow the sun gears 2100-a and 2100-b to rotate around the shaft 2500 while the shaft 2500 remains stationary, the dimensions of the second cylindrical wall 2162 and the third cylindrical wall 2163 are set such that the bearings can be inserted into the cavity 2160. In a preferred embodiment, deep groove ball bearings are press-fitted onto the impactor shaft 2500, and then each sun gear is press-fitted onto a deep groove ball bearing; thus, after bearings 2171 and 2172 are press-fitted onto the impactor shaft 2500, the sun gear labeled "2100-a" is subsequently press-fitted onto bearings 2171 and 2172. Similarly, after bearings 2173 and 2174 are press-fitted onto the impactor shaft 2500, the sun gear labeled "2100-b" is subsequently press-fitted onto bearings 2173 and 2174. Therefore, the sun gears 2100-a and 2100-b are press-fitted onto the impactor shaft 2500, such that the axis 2501 of the impactor shaft and the axis 2101 of each of the sun gears 2100-a and 2100-b are coaxial (or at least substantially coaxial).

[0135] As described above, the shape of the support structure 2120 is configured to support the motor-gear component; furthermore, as described above, the motor-gear component may take the form of including Figure 17 , Figure 18 and Figure 19 The planetary gear 2200 shown and Figure 22 , Figure 23 , Figure 24 and Figure 25 The input plate 2400 is shown in various forms. The input plate 2400 is provided with multiple through holes for securing the rotor 1320 and one of the sun gears 2100-a and 2100-b. As described above regarding the securing connection, the input plate 2400 is located near the stator 1310 and is therefore made of aluminum to provide heat dissipation for the coils 1312 to 1317 in the stator 1310; however, in alternative embodiments, the input plate 2400 is made of PEEK, titanium, or stainless steel.

[0136] In addition, the input board 2400 is provided with an input axis 2401 (such as...). Figure 22 and 24 As shown), rotor side 2410 (as shown) Figure 22 and 23 (as shown) and gear side 2420 (as shown) Figure 22 , 24 (As shown in Figure 25). A first positioning portion 2411 is provided on the rotor side 2410 of the input plate 2400. The shape and size of the first positioning portion 2411 are configured such that the rotor 1320 is centered and axially aligned when fastened to the input plate 2400. In a preferred embodiment, the first positioning portion 2411 includes a lifting surface 2412 that extends axially from the rotor side 2410 of the input plate 2400 to provide a rotor surface 2413. The shape of the rotor surface 2413 is configured to match the positioning surface on the rotor 1320, so in a preferred embodiment, the rotor surface 2413 is cylindrical around the axis 2401 of the input plate 2400.

[0137] As described above, the gear side 2420 of the input plate 2400 is provided with a second positioning portion 2422. The shape and size of the second positioning portion 2422 are set such that the gear (such as one of the sun gears 2100-a and 2100-b) and the rotor 1320 are axially aligned when fastened together; therefore, the second positioning portion 2422 includes an alignment surface. Figure 24 and 25 As shown, the second positioning part 2422 is provided with a plurality of alignment surfaces 2423, 2424 (referred to as "first alignment surface 2423" and "second alignment surface 2424" to distinguish them from each other). Preferably, the alignment surfaces 2423, 2424 are truncated conical; however, in an alternative embodiment, the alignment surfaces 2423, 2424 are curved or spherical. In yet another alternative embodiment, the alignment surfaces 2423, 2424 are cylindrical.

[0138] Alignment surfaces 2423 and 2424 extend axially from the gear side 2420 of the input plate 2400 and terminate at an annular alignment surface 2422. The first alignment surface 2423, which is truncated conical, extends radially inward toward the input plate axis 2401, while the second alignment surface 2424 extends radially outward away from the input plate axis 2401; thus, the first alignment surface 2423 and the second alignment surface 2424 provide an alignment structure 2425 for the input plate 2400, which tapers as it extends axially from the gear side 2420 of the input plate 2400.

[0139] The gear side 2420 of the input plate 2400 and the support structure 2120 of the sun gear 2100 are complementary to each other. Therefore, the annular groove 2130 is defined within the support structure 2120 of the sun gear 2100. The annular groove 2130 surrounds the sun gear axis 2101 and includes a plurality of truncated conical surfaces (referred to as the "first truncated conical gear surface" and the "second truncated conical gear surface"), and... Figure 26 and Figure 27 (These are labeled "2133" and "2134" respectively). In a preferred embodiment, the first truncated bevel gear surface 2133 and the second truncated bevel gear surface 2134 terminate at the gear ring surface 2132.

[0140] The first truncated conical gear surface 2133 and the second truncated conical gear surface 2134 have the following characteristics: Figure 27 The cross-sectional profile shown. Figure 27 As shown, the first truncated bevel gear surface 2133 extends axially toward the tooth structure 2110 of the sun gear 2100 and radially inward toward the sun gear axis 2101. Similar to the first truncated bevel gear surface 2133, the second truncated bevel gear surface 2134 also extends axially toward the tooth structure 2110, but unlike the first truncated bevel gear surface 2133, the second truncated bevel gear surface 2134 extends radially away from the sun gear axis 2101. Therefore, when the truncated bevel gear surfaces 2133 and 2134 extend axially from the load-bearing structure 2120 of the sun gear 2100 toward the tooth structure 2110, the truncated bevel gear surfaces 2133 and 2134 provide a taper to the annular groove 2130 within the load-bearing structure 2120.

[0141] Will Figure 22 and Figure 25 and Figure 26 and Figure 27 For comparison, the alignment structure 2425 of the input board 2400 (in) Figure 22 and Figure 25 (shown in) and the annular groove 2130 of the bearing structure 2120 of the sun gear 2100 (in) Figure 26 and Figure 27 The shapes (shown in the diagram) are designed to be complementary to each other. Therefore, the alignment structure 2425 of the input plate 2400 is fitted within the annular groove 2130 of the sun gear 2100, ensuring axial alignment of the input plate 2400 and the sun gear 2100 when fastened together. As described above, just as the first truncated bevel gear surface 2133 extends axially toward the tooth structure 2110 away from the bearing structure 2120 and radially inward toward the sun gear axis 2201, the first alignment surface 2423 of the alignment structure 2425 of the input plate extends axially from the gear side 2420 of the input plate 2400 and radially inward toward the input plate axis 2401.

[0142] Similarly, just as the second truncated bevel gear surface 2134 extends axially toward the gear tooth structure 2110 away from the bearing structure 2120 and radially away from the sun gear axis 2201, the second alignment surface 2424 of the alignment structure 2425 of the input plate extends axially from the gear side 2420 of the input plate 2400 and radially away from the input plate axis 2401; therefore, the alignment structure 2425 of the input plate 2400 is provided with a taper. Thus, as... Figure 21 As shown, when the input plate 2400 is fastened to the sun gear 2100, the taper of the alignment structure 2425 pulls the alignment structure 2425 of the input plate 2400 into the annular groove 2130 defined in the bearing structure 2120 of the sun gear 2100, and positions the input plate 2400 and the sun gear 2100 in a more precise axial alignment.

[0143] As mentioned above Figure 3 , Figure 4 , Figure 5 and Figure 28 The impactor 1000 is provided with an output section 1500. The output section 1500 is made of PEEK and includes an output shaft 1501 and an output structure 1510 (e.g., ...). Figure 29 (As shown). The output flange 1521, which extends axially and radially from the output structure 1510, provides a function very similar to that of the load-bearing structure 2120 on the sun gear 2100.

[0144] Similar to the sun gear's support structure 2120, the output flange 1521 of the output section 1500 is configured to support the motor-gear assembly 2100, such as... Figure 17 , Figure 18 and Figure 19 The planetary gear 2200 shown or Figure 22 , Figure 23 , Figure 24 and Figure 25 The input board 2400 is shown. (Example) Figure 29 and Figure 30 ( Figure 29 and Figure 30 (This is a 3D view of the output unit 1500) and Figure 32 ( Figure 32 As shown in the cross-sectional view of the output section 1500, at least one opening (and preferably multiple openings) is formed within the output flange 1521. Figure 29 , Figure 30 and Figure 32 As shown, the preferred embodiment is provided with a plurality of openings 1522, 1523, 1524, 1525, and 1561, and each of the plurality of openings 1522, 1523, 1524, 1525, and 1561 is provided with an axis (the axis corresponding to opening 1522, 1523, 1524, and 1525 is referred to as the "opening axis"), and Figure 30 The numbers are labeled as "1526", "1527", "1528" and "1529" respectively.

[0145] The dimensions of each of openings 1522, 1523, 1524, and 1525 are set to at least partially accommodate the planetary gear, and more specifically, accommodate... Figure 17 , Figure 18 and Figure 19 The planetary gear shaft 2202 of the planetary gear 2210 is shown. Therefore, each of the openings 1522 to 1525 is relative to the output axis 1501 (in...). Figure 6 The radial positioning (shown as "X" inside the circle) ensures that the planetary gear node contacts both the sun gear node and the ring gear node (e.g., Figure 6 (As shown).

[0146] Just as each of the planetary openings 2122 to 2125 of the sun gear 2100 is provided with an inner diameter, each of the openings 1522, 1523, 1524, and 1525 of the output section 1500 is also provided with an inner diameter (each inner diameter is referred to as "bearing ID" and...). Figure 32 The bearing IDs are labeled "1532", "1533", "1534", and "1535". Each bearing ID is cylindrical, and its dimensions are set to allow the bearing to press-fit within it. Figure 21 As shown, the output section 1500 is equipped with multiple deep groove ball bearings (in Figure 21 The text is marked as "2143" and "2144".

[0147] like Figure 32As shown, the output section 1500 is provided with an output cavity 1560, the shape of which is configured to accommodate the impactor shaft 2500. The output cavity 1560 includes a plurality of cylindrical surfaces (referred to as "first cylindrical surface", "second cylindrical surface" and "third cylindrical surface", and labeled "1561", "1562" and "1563" respectively to distinguish them from each other). The dimensions of the first cylindrical surface 1561 and the second cylindrical surface 1562 are configured such that bearings can be press-fitted into the cavity 1560; in a preferred embodiment, deep groove ball bearings 1575 and 1579 are press-fitted onto the impactor shaft 2500 and enter the cylindrical cavity 1560 formed by the cylindrical surfaces 1561 and 1562.

[0148] As described above, the output flange 1521 carries the input board (such as...) Figure 22 , Figure 23 , Figure 24 and Figure 25 The input plate 2400 shown is within the scope of this invention. Therefore, in an alternative embodiment, the shape of the output flange 1521 is set to be complementary to the positioning portion 2422 of the gear side 2420 of the input plate 2400. Therefore, in an alternative embodiment, the output flange 1521 is provided with a shape that is complementary to the positioning portion 2422 of the gear side 2420 of the input plate 2400. Figure 26 and Figure 27 The annular groove is the same as the one shown in the annular groove 2130. The annular groove of the alternative output section 1500 surrounds the output axis 1501 and includes the same... Figure 26 and 27 The truncated conical gear surfaces 2133 and 2134 shown are identical to a plurality of truncated conical surfaces. Therefore, the truncated conical surface of the output flange 1521 provides the alternative output section 1500 with a taper that pulls the alternative output section 1500 and the input plate 2400 into a more precise axial alignment.

[0149] Now refer to Figure 29 and Figure 30 In the preferred embodiment, the output section 1500 is provided with an output structure 1510 configured to transmit torque; therefore, the output structure 1510 is provided with a non-circular radial profile 1580 including a convex angle. However, it is worth noting that the non-circular radial profile 1580 may also take the form of a gear, spline, shaft with keyways, or radial screw, which is also within the scope of this invention. Figure 29 and Figure 30 As shown, the convex angle of the non-circular radial profile 1580 is an outward convex angle; preferably, the non-circular radial profile 1580 includes multiple convex angles (referred to as "first outward convex angle", "second outward convex angle", "third outward convex angle" and "fourth outward convex angle"), and... Figure 30 The numbers are labeled as "1581", "1582", "1583" and "1584" respectively.

[0150] Advantageously, in addition to the convex angles 1581 to 1584, the non-circular radial profile 1580 is also provided with a plurality of transition surfaces 1585, 1586, 1587, and 1588. Each of the transition surfaces 1585 to 1588 extends from at least one of the convex angles 1581 to 1584 in a direction substantially perpendicular to the axis of the output portion 1501. The transition surfaces 1585 to 1588 are provided with a generally flat shape, but curved shapes are also within the scope of the invention. The output portion 1500 is also provided with a plurality of holes (two of the holes are located in...). Figure 32 As shown in the diagram, and labeled "1589" and "1590"). Each of the aforementioned holes extending radially inward from each of the transition surfaces 1585 to 1588 (including...) Figure 30 Each hole (marked as "1589" and "1590") is defined within a non-circular radial profile 1580 and is shaped to accommodate fasteners (preferably hex socket screws). Thus, each hole is threaded; however, in an alternative embodiment, the holes defined within transition surfaces 1581 to 1584 are shaped to accommodate pins and are therefore unthreaded.

[0151] Now refer to Figure 33 and Figure 34 The output section 1500 is provided with a tubular member 1595 and fasteners—ideally, multiple fasteners (in Figure 33 (Referring to “1597-a” and “1597-b”). In a preferred embodiment, the tubular member 1595 is made of PEEK and has four holes, each of which accommodates an internal hexagonal screw (although in...). Figure 33 (Only two of the four hexagon socket screws are visible in the perspective view). As previously described, the dimensions of each of the four holes defined within the tubular member 1595 are set to accommodate one of the aforementioned hexagon socket screws. The non-circular radial profile 1580 of the output portion 1500 is provided with threaded holes for external threaded fasteners; in a preferred embodiment, the non-circular radial profile 1580 is provided with four threaded holes, each threaded hole for securing the tubular member 1595 to one of the hexagon socket screws of the non-circular radial profile 1580 of the output portion 1500. In an alternative embodiment, the tubular member 1595 and the non-circular radial profile 1580 of the output portion 1500 form an integral part (therefore, in such an alternative embodiment, there are neither holes nor fasteners).

[0152] The tubular member 1595 has an outer surface 1598, which is generally cylindrical around the axis 1596, such as... Figure 35 As shown. Therefore, the outer surface 1598 surrounds the axis 1596 and the non-circular inner surface 1599. As the name suggests, the non-circular inner surface 1599 is provided with a large inner diameter 1576 and a small inner diameter 1577 (e.g., Figure 36(As shown).

[0153] like Figure 36 It is also shown that the non-circular inner surface 1599 is configured to transmit torque; therefore, the non-circular inner surface 1599 is within the scope of the invention in the form of an internal gear, a spline sleeve, or a cylindrical surface with keyways. Advantageously, the shape of the non-circular inner surface 1599 is set according to the non-circular profile 1580 of the output portion 1500. As a result, the shape of the non-circular inner surface 1599 is set to accommodate at least one convex corner, and preferably accommodates multiple outward convex corners.

[0154] Although the tubular member 1595 transmits torque using a single convex angle, preferably, the tubular member 1595 includes multiple convex angles (in... Figure 35 The numbers "1591", "1592", "1593", and "1594" are used to transmit torque. Figure 35 Specifically, each of the inner convex angles 1591 to 1594 is provided with a curved inner surface, such that the preferred embodiment provides a plurality of curved surfaces (in Figure 36 The curved surfaces 1571 to 1574 are labeled "1571", "1572", "1573", and "1574". Each of these curved surfaces is provided with a diameter (referred to as the "convex angle diameter"), and... Figure 36 (Note: 1578 is marked as such). In a preferred embodiment, the diameter of the convex corner 1578 is smaller than the small inner diameter 1577 of the non-circular inner surface 1599.

[0155] During rotation, the non-circular inner surface 1599 is configured to allow axial movement within the tubular member 1595. For example... Figure 35 and Figure 36 As shown, each of the curved surfaces 1571 to 1574 is integrally straight and extends axially parallel to the axis 1596 of the tubular member 1595, thereby facilitating axial movement. Simultaneously, the curved surfaces 1571 to 1574 extend radially into a non-circular shape to engage the transmission during rotation. Additionally, it is advantageous to provide a shallow slope to the curved surfaces 1571 to 1574 to prevent jamming; thus, the non-circular inner surface 1599 provides axial movement, while the curved surfaces 1571, 1572, 1573, and 1574 maintain torsional engagement.

[0156] To facilitate axial movement, the tubular member 1595 is provided with clearance surfaces. In a preferred embodiment, the non-circular inner surface 1599 is provided with multiple clearance surfaces 1561, 1562, 1563, and 1564. Figure 36 As shown, each of the clearance surfaces 1561 to 1564 is located between two of the two inwardly convex angles 1591 and 1594. Now refer to Figure 36 Detailed illustration (in) Figure 37As shown in the figure, the clearance surfaces 1561 to 1564 are rounded and therefore extend radially from the axis of the tubular member 1580.

[0157] Refer again Figure 33 and Figure 34 The impactor 1000 is equipped with an impact assembly 3000. For example... Figure 33 and Figure 34 As shown in both, the impact assembly 3000 is provided with multiple components and sub-assemblies including a drive component 3100, a driven component 3200, and a shaft section 3300. The drive component 3100 includes a rolling sub-assembly 3110 and a non-circular rotating component 3150, while the driven component 3200 includes a stepped portion 3210 and an impact portion 3250.

[0158] Now refer to Figure 38 , Figure 39 , Figure 40 and Figure 41 Various perspective views of the non-circular rotating component 3150 and the rolling sub-assembly 3110 are provided, and as shown... Figure 38 , Figure 39 , Figure 40 and Figure 41 As shown, the non-circular rotating component 3150 and the rolling sub-assembly 3110 are shown attached to each other. Therefore, the torque applied to the non-circular rotating component 3150 is transmitted to the rolling sub-assembly 3110. As described above, the shape of the non-circular rotating component 3150 is set according to the non-circular inner surface 1599 of the tubular member 1595. Therefore, the shape of the non-circular rotating component 3150 is set such that the torque from the output portion 1500 is transmitted to the rolling sub-assembly 3110. In a preferred embodiment, the torque from the output portion 1500 is transmitted to the rolling sub-assembly 3110 via the tubular member 1595 and the non-circular rotating component 3150.

[0159] Non-circular rotating part 3150 Figure 42 , Figure 43 and Figure 44 As shown in the image. Figure 42 , Figure 43 and Figure 44 As shown, the non-circular rotating component 3150 is made of PEEK and is provided with an axis 3151, a first end surface 3161, a second end surface 3162, and a non-circular radial surface 3570. The non-circular radial surface 3570 extends axially from the first end 3161 to the second end surface 3162. The non-circular radial surface 3570 also extends radially from the axis 3151 to provide a convex angle for the non-circular rotating component 3150. Although Figure 42 , Figure 43 and Figure 44A non-circular radial surface 3170 with a convex angle is depicted, but the non-circular radial surface 3170 in the form of a gear, spline, or shaft with keyways is also within the scope of the invention.

[0160] In a preferred embodiment, the shape of the non-circular radial surface 3170 is configured to provide a plurality of convex angles 3171, 3172, 3173, and 3174 to the non-circular rotating component 3150. As previously described, the dimensions of the non-circular radial surface 3170 of the rotating component 3150 are configured to mate with the non-circular inner surface 1599 of the tubular member 1595. Therefore, the dimensions of the non-circular radial surface 3170 are configured such that while a torque is applied to each of the convex angles 1591, 1592, 1593, and 1594 of the tubular member 1595 to each of the convex angles 3171, 3172, 3173, and 3174 of the rotating component 3150, the non-circular rotating component 3150 moves axially within the non-circular inner surface 1595. To allow axial movement of the non-circular rotating component 3150, both the non-circular inner surface 1599 of the tubular member 1595 and the non-circular radial surface 3170 of the non-circular rotating component 3150 are provided with a low coefficient of friction. In a preferred embodiment, the non-circular inner surface 1599 and the non-circular radial surface 3170 are low-energy surfaces (i.e., they are provided with a surface energy of less than 38 dynes per centimeter).

[0161] As described above, the non-circular inner surface 1599 of the tubular member 1595 transmits torque; advantageously, the inner convex angles 1591, 1592, 1593, 1594 defined within the non-circular inner surface 1599 transmit torque to the outer convex angles 3171, 3172, 3173, 3174 formed on the non-circular radial surface 3170 of the rotating member 3150. Figure 45 As shown, the shapes of the inner convex angles 1591, 1592, 1593, 1594 of the tubular member 1595 and the outer convex angles 3171, 3172, 3173, 3174 of the rotating member 3150 are set to ensure that the rotating member 3150 and the tubular member 1595 remain axially aligned (or at least substantially axially aligned) when the tubular member 1595 transmits torque to the rotating member 3150.

[0162] As shown in the cross-sectional view of the output section 1500 and the impact assembly 3000 (see example...), Figure 34The rolling element assembly 3110 is attached to the non-circular rotating component 3150 by two hex socket head cap screws (referred to as "fasteners" and labeled "3148" and "3149"). Therefore, the non-circular rotating component 3150 is provided with two threaded holes 3146 and 3147 extending from the second end surface 3162 toward the first end surface 3161. The threaded holes 3146 and 3147 are positioned such that the rolling element assembly 3110 is secured to the non-circular rotating component 3150 in an axially aligned (or at least substantially axially aligned) manner.

[0163] A cylindrical recess 3145 extends from the first end surface 3161 of the non-circular rotating component 3150. The shape of the cylindrical recess 3145 is configured to accommodate a bearing, preferably a thrust bearing. Figure 34 (Shown and labeled "3144"). Bearing 3144 axially holds the position of drive component 3100 within impactor 1000 while transmitting torque at output 1500.

[0164] Figure 39 and Figure 40 The rolling sub-assembly 3110 is shown to be axially aligned with the non-circular rotating component 3150. As described above and as... Figure 39 As shown, the rolling sub-assembly 3110 is connected by multiple bolts (with in... Figure 40 The bolt heads shown and labeled "3148-a" and "3149-a" are fixed to the non-circular rotating component 3150. As a necessary condition for the aforementioned bolted connection between the rolling sub-assembly 3110 and the non-circular rotating component 3150, a plurality of holes (hereinafter referred to as "fastening holes") are defined within the rolling sub-assembly 3110. Figure 47 and Figure 48 (These are labeled "3142" and "3143"). The fastening holes 3142 and 3143 are sized to allow threaded shanks 3148-b and 3149-b to extend through and engage with the threads of threaded holes 3146 and 3147 defined within the non-circular rotating component 3150 (e.g., ...). Figure 34 As shown). Figure 48 As shown, the non-circular rotating component 3150 is provided with a positioning surface 3138, which preferably includes a positioning portion (not shown) to ensure that the rolling sub-assembly 3110 and the non-circular rotating component 3150 remain axially aligned when fastened together.

[0165] like Figure 46 , 47As shown in Figures 48 and 49, the rolling sub-assembly 3110 is provided with a shaft structure 3130 including rollers and shafts, wherein the rollers are cylindrical and press-fitted onto the shafts. The shaft structure 3130 also includes fork-like portions that hold a plurality of shafts 3132, 3133 in place. In a preferred embodiment, the shaft structure 3130 is provided with a plurality of rollers (referred to as "first roller" and "second roller," and labeled "3134" and "3135"). Each of the rollers 3134, 3135 is press-fitted onto each of the shafts 3132, 3133. Figure 47 As shown, the shaft structure 3130 is in the form of multiple fork-shaped portions, each fork-shaped portion holding one of the shafts 3132 and 3133, on which one of the rollers 3134 and 3135 is pressed, in place.

[0166] like Figure 47 As further shown, the groove 3136 effectively provides two "forks" for the rolling sub-assembly 3110 for the shafts 3132, 3133 and the rollers 3134, 3135. The rolling sub-assembly 3110 is provided with walls (such as...) by milling or turning the groove 3136 into a solid metal part (ideally titanium or an alloy such as stainless steel). Figure 48 As shown), a radial hole 3137 can be drilled or reamed in the wall. The groove 3136 is provided with a generally rectangular cross-sectional shape that extends axially and radially into the rolling sub-assembly 3110 to accommodate the cylindrical roller therein.

[0167] like Figure 47 As shown, the rolling sub-assembly 3110 is cylindrical (and therefore has a diameter). Therefore, preferably, the groove 3136 has a radius (in... Figure 47 The circular shape marked "R" in the middle, and includes a circle around axis 3131 (in Figure 46 (As shown in the figure) multiple curved surfaces extending from it. As described above, the groove 3136 includes a generally rectangular cross-sectional shape to provide multiple opposing walls 3121, 3122 and 3123, 3124 (as shown in the figure) for the shaft structure 3130. Figure 39 and Figure 40 (As shown). The opposing walls 3121, 3122 and 3123, 3124 are sufficiently spaced so that the roller can be fitted between them and rotate freely. It should be noted that although the groove 3136 is preferably circular, the groove 3136 can extend in a straight line or be square or rectangular, and can provide a pair of opposing walls 3121, 3122 and 3123, 3124 to the rolling sub-assembly 3110.

[0168] As described above, the positioning surface 3138 of the rolling sub-assembly 3110 is fixed to the second end surface 3162 of the non-circular rotating component 3150 (which rotates itself via the tubular member 1595). To ensure axial alignment of the non-circular rotating component 3150 and the rolling sub-assembly 3110 when fixed together, the second end surface 3162 is provided with a positioning portion (not shown), which is in the form of a cylindrical blind hole defined within the non-circular rotating component 3150. The diameter of the positioning portion is set such that a diameter bolt of the rolling sub-assembly 3110 can be connected therein.

[0169] As described above, the rolling sub-assembly 3110 is fixed to the non-circular rotating component 3150; because the non-circular rotating component 3150 rotates via the tubular member 1595, the rolling sub-assembly 3110 also rotates, while at least one of the rollers 3134, 3135 abuts against the stepped portion 3210 of the driven component 3200. In a preferred embodiment, all rollers 3134, 3135 are positioned around the axis 3201 (in... Figure 52 The dot (shown as a circle) abuts against the stepped portion 3210 of the driven member 3200 when it rotates. Therefore, the driven member 3200 is provided with a roller support surface, and preferably with a plurality of roller support surfaces 3228, 3229.

[0170] As its name suggests, the stepped portion 3210 of the driven member 3200 is provided with a step; in the preferred embodiment, such as Figure 52 As shown, the stepped portion 3210 is provided with multiple steps 3211, 3212, 3214, and 3215. Advantageously, steps 3211, 3212, 3214, and 3215 are rounded to form smooth contoured slopes 3216 and 3217 (e.g., ...). Figure 50 (As shown). Each of the ramps 3216, 3217 extends from one of the roller support surfaces 3228, 3229 at an angle 3230 and abuts the crown surface 3213. In a preferred embodiment, the angle 3230 is 135°; however, in an alternative embodiment, the angle 3230 is 90° to 160° (and includes both 90° and 160°).

[0171] like Figure 52 As shown, each of the inclined surfaces 3216 and 3217 extends radially from axis 3201 (as described above) and axially from each of the roller support surfaces 3228 and 3229. In the preferred embodiment, the inclined surfaces 3216 and 3217, when extending axially and radially, form part of a thread around axis 3201, which is very similar to the thread of an externally threaded component. Figure 50As shown, each of the inclined surfaces 3216 and 3217 slopes upward from each of the roller support surfaces 3228 and 3229 and terminates at the coronal surface 3213, thereby forming a set of inclined surfaces 3216 and 3217.

[0172] The pitch dimensions of the ramps 3216 and 3217 are determined based on the outer diameter of the driven member 3200, the diameter and width of the rollers 3134 and 3135, the desired axial stroke length of each impact generated by the impactor 1000, and the number of impacts transmitted by the impactor 1000 per revolution of the rotor 1320. In a preferred embodiment, it is desirable that the impactor 1000 transmits an impact with a stroke length of 0.0625 inches, and that the impactor 1000 transmits two impacts with a stroke length of 0.0625 inches per revolution of the motor 1300. Therefore, it is preferable that the stepped portion 3210 of the driven member 3200 is provided with a plurality of roller support surfaces, a plurality of crown surfaces, and a plurality of ramps connecting the roller support surfaces and the crown surfaces.

[0173] Figure 52 The stepped portion 3210 of the driven member 3200 is shown to have two sets of inclined surfaces (hereinafter referred to as "first set of inclined surfaces" and "second set of inclined surfaces", and labeled "3216, 3217" and "3226, 3227"), which provide two impacts per revolution of the rotor 1320. The two sets of inclined surfaces 3216, 3217 and 3226, 3227 connect two roller support surfaces and two crown surfaces (hereinafter referred to as "first crown surface" and "second crown surface", and labeled "3213" and "3223" to distinguish them from each other).

[0174] The second set of ramps 3226 and 3227 includes multiple steps 3221, 3222, 3224, and 3225, which are rounded to form the smooth profile of ramps 3226 and 3227, which is very similar to Figure 50 The first set of ramps 3216 and 3217 are shown. Similar to the first set of ramps 3216 and 3217 that extend upwards to and downwards from the first coronal surface 3213, the second set of ramps 3226 and 3227 also extend upwards to and downwards from the second coronal surface 3223. Each of the ramps 3226 and 3227 in the second set extends axially and radially from one of the roller support surfaces 3228 and 3229 to form an angle 3230, and each ramp in the second set is adjacent to the second coronal surface 3223.

[0175] The angle 3230 formed between each of the inclined surfaces 3226, 3227 and each of the roller support surfaces 3228, 3229 is 135° (but in alternative embodiments, the angle 3230 is 90° to 160°, and includes 90° and 160°). As described above, each of the inclined surfaces 3226, 3227 extends radially from axis 3201 and axially from each of the roller support surfaces 3228, 3229 to form a portion of a thread around axis 3201. It should be noted that although it is preferred that the inclined surfaces 3226, 3227 extend from the roller support surfaces 3228, 3229 to the crown surfaces 3213, 3223 in a threaded manner, other stepped profiles (such as straight inclined surface profiles) are also within the scope of the invention.

[0176] Refer again Figure 52 Steps 3211, 3212 and 3221, 3222 (and thus the resulting ramps 3216, 3226 and coronal surfaces 3213, 3223) are positioned 180° to each other. Similarly, steps 3214, 3215 and 3224, 3225 (and thus the resulting ramps 3217, 3227) are also positioned 180° to each other. Thus, when the rolling sub-assembly 3110 rotates counterclockwise on the step portion 3210 of the driven member 3200, the first roller 3134 rolls on steps 3211, 3212 (and thus on the first ramp 3216) to reach the first coronal surface 3213, while simultaneously (or at least substantially simultaneously), the second roller 3135 rolls on steps 3221, 3222 (and thus on the second ramp 3226) to reach the second coronal surface 3223. Therefore, the rollers 3134 and 3135 of the rolling sub-assembly 3110 axially transmit the impact, which is then transmitted to the impact portion 3250 of the driven member 3200.

[0177] As described above, it is desirable for the impactor 1000 to deliver an impact with a stroke of 0.0625 inches. As described above, the two sets of ramps 3216, 3217 and 3226, 3227 extend axially from the roller support surfaces 3228, 3229 to reach upwards to the coronal surfaces 3213, 3223 and downwards from the coronal surfaces 3213, 3223. As further noted above, when the rollers 3134, 3135 roll over the two sets of ramps 3216, 3217 and 3226, 3227 and cross the two coronal surfaces 3213, 3223, the motor 1300 rotates once, thus the impactor 1000 of this preferred embodiment delivers two impacts. Therefore, in order to transmit an impact with a stroke of 0.0625 inches, the ramps 3216, 3217 and 3226, 3227 extend axially for 0.0626 inches from the roller support surfaces 3228, 3229 to the crown surfaces 3213, 3223.

[0178] Now refer to Figure 53 , Figure 54 and Figure 56 Ideally, the step portion 3210 and the impact portion 3250 of the driven member 3200 should remain axially aligned (or at least substantially axially aligned); therefore, both the step portion 3210 and the impact portion 3250 are provided with mating surfaces (referred to as "step mating surface 3218" (the step mating surface 3218 is provided on the step portion 3210 of the driven member 3200) and "impact mating surface 3219" (the impact mating surface 3219 is provided on the impact portion 3250 of the driven member 3200). In a preferred embodiment, as shown in FIG57, the impact mating surface 3219 also serves as an inner surface 3252.

[0179] The dimensions of mating surfaces 3218 and 3219 are set relative to each other to provide a press fit (e.g., Figure 56 (As shown). In a preferred embodiment, mating surfaces 3218, 3219 are cylindrical, wherein each of mating surfaces 3218, 3219 is provided with a diameter; the diameter of the stepped mating surface 3218 is 0.001 inches to 0.005 inches smaller than the diameter of the impact mating surface 3219 (and includes 0.001 inches and 0.005 inches).

[0180] Refer again Figure 52 The stepped portion 3210 of the driven member 3200 is provided with a non-circular hole 3202, the shape of which is configured to accommodate the shaft section 3300 and prevent the stepped portion 3210 from rotating. In a preferred embodiment, the non-circular shape is a square (with rounded corners); however, in an alternative embodiment, the non-circular shape is a keyway, an ellipse, or a polygon (such as a hexagon or rectangle). Therefore, even when the rolling sub-assembly 3110 rotates and the rollers 3134, 3135 roll on the steps 3211, 3212, 3214, 3215, 3221, 3222, 3224, 3225 and the crown surfaces 3213, 3223, the stepped portion 3210 of the driven member 3200 is prevented from rotating.

[0181] like Figure 34 As shown, the stepped portion 3210 is fastened to the impact portion 3250 by pins, preferably by a plurality of pins 3261, 3262 extending from the outer surface 3251 to the inner surface 3252 of the impact portion of the driven member 3200 (as shown in FIG. 57). Figure 54 As shown in the cross-sectional view of the stepped portion 3210, pins 3261 and 3262 further extend through fastening holes 3263 and 3264 defined within the stepped portion 3210. The fastening holes 3263 and 3264 of the stepped portion 3210 extend radially from the non-circular hole 3202 to the stepped mating surface 3218.

[0182] Pins 3261 and 3262 extend through fastening holes 3263 and 3264 defined within the stepped portion 3210 and enter holes 3265 and 3266 defined within the impact portion 3250 of the driven member 3200. To accommodate the pins 3261 and 3262 extending from the holes 3263 and 3264 in the stepped portion 3210, the shapes of the holes 3265 and 3266 defined within the impact portion 3250 are configured to extend radially from the inner surface 3252 of the impact portion 3250 (e.g., ...). Figure 57-a and Figure 57-b (As shown). The inner surface 3252 of the impact portion 3250 is sized to accommodate the spring 3240, and in a preferred embodiment, the inner surface 3252 of the impact portion 3250 is generally cylindrical.

[0183] The outer surface 3251 of the impact portion 3250 is cylindrical (and therefore has a circular cross-sectional shape); however, in alternative embodiments, the cross-sectional shape of the outer surface 3251 is not circular, but rather octagonal or hexagonal. In a preferred embodiment, the outer surface 3251 is sized to provide an impact support surface 3255 to the impact portion 3250, the impact support surface 3255 being an annular surface located at one of the two ends 3256, 3257 (referred to as the "stepped end" and the "instrument end," respectively). The impact support surface 3255 is located at the stepped end 3256 of the impact portion 3250 (this designation is used to distinguish the stepped end 3256 facing the stepped portion 3210 from the instrument end 3257, which has a threaded hole 3258 for attaching surgical instruments, such as bone files, bone compactors, or other instruments).

[0184] like Figure 57-b As shown, the impact support surface 3255 is adjacent to the outer surface 3251 and the inner surface 3252 of the impact portion 3250. As described above, the second support surface 3238 of the stepped portion 3210 abuts against the impact support surface 3255 of the impact portion 3250 of the driven member 3200.

[0185] Refer again Figure 57-a and 57-b The non-circular hole 3202 extends axially through the stepped portion 3210, and the shape of the non-circular hole 3202 is set to accommodate a shaft section 3300 having a non-circular cross-sectional shape. Shaft section 3300 (in...) Figure 57-b The radial shape of the non-circular hole 3202 (shown as a cross-section) mates with the stepped portion 3210 to prevent torsional movement of the stepped portion 3210 (and thus prevent torsional movement of the impact portion 3250 pinned to the stepped portion 3210). Therefore, as described above, the shape of the shaft section 3300 is set such that the stepped portion 3210 moves along the length axial direction of the shaft section 3300, while the non-circular cross-sectional shape of the shaft section 3300 prevents the stepped portion 3210 from rotating.

[0186] Now refer to Figure 58 The shaft section 3300 is provided with an axis 3301, a support surface 3302, a flange 3303, a slot 3305, and an end 3304 (referred to as the "spring end" to distinguish the end having the spring 3240 from the other ends disclosed herein). The slot 3305 extends through the shaft section 3300 to receive a pin 3267 (e.g., ...). Figure 57-b and Figure 56 (As shown). As previously described, pin 3267 extends through slot 3305 and through hole 3268 defined in step portion 3210 of driven member 3200. Thus, slot 3305 extends radially such that pin 3267 moves axially within slot 3305 during operation of impactor 1000 while preventing torsional movement.

[0187] As in Figure 55 and Figure 56 As can be seen, the shaft section 3300 extends through the channel 3102 defined within the drive member 3100. The channel 3102 is sized to provide clearance to the drive member 3100, and thus to the non-circular rotating member 3150 and the rolling sub-assembly 3110 that rotate around the shaft section 3300. Therefore, when the impactor 1000 is in operation, the shaft section 3300 is screwed onto the lead screw 2600 and does not rotate, while the tubular member 1595 attached to the output section 1500 causes the drive member 3100 to rotate (and thus causes the non-circular rotating member 3150 and the rolling sub-assembly 3110 to rotate). When the rollers 3134 and 3135 of the rolling subassembly 3110 roll up the inclined plane and roll on the crown surfaces 3213 and 3223 of the stepped portion 3210 of the driven member 3200, the stepped portion 3210 is forced to move axially along the shaft section 3300 (the same applies to the first support surface 3238 and the second support surface 3239 located on the outer surface of the stepped portion 3210). Because the first support surface 3238 of the stepped portion 3210 abuts against the impact support surface 3255 of the impact portion 3250 of the driven member 3200, the impact portion 3250 is forced to move axially.

[0188] Because the second support surface 3239 abuts against the spring 3240, the axial movement of the step portion 3210 compresses the spring 3240. When the rollers 3134 and 3135 roll off the inclined surfaces of the roller support surfaces 3228 and 3229 from the crown surfaces 3213 and 3223, the spring 3240 applies a force on the second support surface 3239 of the step portion 3210, thereby forcing the step portion 3210 to move axially toward the flange 3303 of the shaft section 3300. Therefore, the spring 3240 axially positions the step portion 3210 on the shaft section 3300, such that when the non-circular rotating component 3150 rotates about the shaft section 3300, the rollers 3134 and 3135 abut against the roller support surfaces 3228 and 3229 and impact the step (and thus the inclined surface).

[0189] like Figure 34 and Figure 56 A cross-sectional view of the shaft section 3300, drive member 3100, and driven member 3200 clearly shows that the spring 3240 abuts against the second support surface 3239 of the step portion 3210 and the flange 3307 (referred to herein as the "spring flange" to distinguish it from other flanges disclosed herein). The spring flange 3307 is attached to the shaft section 3300 by bolts 3306 and threaded holes 3308 tapped within the shaft section 3300. Although the preferred embodiment is shown with threaded attachment, alternative embodiments utilize welding or adhesive attachment between the shaft section 3300 and the spring flange 3307.

[0190] The housing 1100 is provided with a housing axis 1101, a first housing end 1110 terminating at a first housing opening 1111, and a second housing end 1120 terminating at a second housing opening 1122. An inner housing surface 1105 extends axially within the housing 1100 from the first housing opening 1111 and the second housing opening 1122. The shape and dimensions of the inner housing surface 1105 are configured to provide suitable fit between the housing 1100 and the various parts and components described herein.

[0191] like Figure 62 and 63 As shown, the inner surface 1113 of the first housing extends axially from the opening 1111 of the first housing, and the size of the inner surface 1113 of the first housing is set to provide a sliding fit with the outer surface 3251 of the impact portion 3250 (i.e., allowing the impact portion 3250 to slide axially back and forth); therefore, in a preferred embodiment, the diameter of the inner surface 1113 of the first housing is set to be 0.001 inches to 0.005 inches (inclusive) larger than the diameter of the outer surface 3251 of the impact portion 3250.

[0192] Figure 62Also shown is a second housing inner surface 1123 extending axially from the second housing opening 1122; the dimensions of the second housing inner surface 1123 are set to provide a press fit with the cylindrical outer surface 2528 located on the motor mounting portion 2520 (e.g., Figure 63 (As shown). The third housing inner surface 1133 is located within the inner surface 1105 of the housing 1100, which is located between the first housing inner surface 1113 and the second housing inner surface 1123. The third housing inner surface 1133 extends axially within the housing 1100 and provides a press fit to the impactor 1000 with the annular outer surface 2303 of the gear ring 2300.

[0193] Now refer to Figures 61 to 63 The image shows the impactor 1000 located within the housing 1100, with the stator 1310 positioned and engaged with the motor mounting portion 2520. In a preferred embodiment, the motor mounting portion 2520 positions multiple motors, thus providing multiple positioning portions. The preferred motor mounting portion 2520 is in the form of a plate, with the positioning portions located on opposite sides of the plate (in...). Figure 69 The text refers to it as “First Side 2518” and “Second Side 2519”.

[0194] Figure 64 and Figure 65 The first side 2518 of the motor mounting portion 2520 is shown. As depicted herein, the first side 2518 of the motor mounting portion 2520 (also referred to as the "DC motor side") and Figures 64 to 65 and Figure 68 The housing 1300 (marked as "2522") has a positioning part 2524 for the stator 1310 of the BLDC motor 1300 and a plurality of through holes 2525 and 2526 for mounting the stator 1310 and the shaft 2500. The positioning part 2524 is in the form of a shallow cylindrical recess, which aligns the axis 1301 of the BLDC motor 1300 with the axis 1101 of the housing 1100.

[0195] The motor mounting portion 2520 is provided with a second side 2519 opposite to the DC motor side 2522. Similar to the DC motor side 2522 of the motor mounting portion, the second side 2519 positions a second motor 1330, such as a servo motor (the first motor is a DC motor 1300 or a BLDC motor 1300 positioned on the first side 2518). However, in a preferred embodiment, the motor positioned on the second side 2519 of the motor mounting portion 2520 is not a servo motor, but a stepper motor 1330 (therefore, the second side 2519 is also referred to here as the "stepper side" and...). Figure 66 and 67 (marked as "2523" in the text). The stepper side 2523 of the motor mounting part 2520 is... Figure 66 and Figure 67As shown in the figure, it is provided with multiple threaded holes 2517, a positioning part 2516 for mounting the stepper motor 1330 onto the motor mounting part 2520, and a receiving part 2515 sized to accommodate the motor 1330.

[0196] Stepper motor 1330 is provided with a hybrid rotor that can rotate clockwise or counterclockwise with a resolution of 0.9°. Stepper motor 1330 drives a lead screw nut (or, alternatively, a ball screw nut). The lead screw nut is provided with threads corresponding to the lead screw 2600. In the figures, lead screw 2600 is shown as having a threaded section 2650; in a preferred embodiment, threaded section 2650 is a lead screw thread, such as a trapezoidal thread or an ACME thread. By way of example and not limitation, threaded section 2650 of lead screw 2600 is provided with 14-20 ACME threads. Therefore, the lead screw nut within stepper motor 1330 is provided with 14-20 ACME threads.

[0197] As described above, the stepper motor 1330 rotates the lead screw nut clockwise or counterclockwise, and the lead screw nut causes the lead screw 2600 to advance or retract depending on the direction of rotation. Furthermore, utilizing a 14-20 ACME thread profile, when the stepper motor 1330 rotates the lead screw nut clockwise or counterclockwise twenty times, the lead screw 2600 advances or retracts by 1 inch (0.05 inches per revolution). Because the stepper motor 1330 rotates the lead screw nut in 0.9° rotational increments, and because the lead screw 2600 is provided with a 14-20 ACME thread, the stepper motor 1330 causes the lead screw 2600 to advance or retract in 0.000125-inch increments (0.9° / 360° (resolution) × 1 / 20 (inches per revolution) = 0.000125 inches).

[0198] Through the NFC transceiver 1355, the motor controller 1350 can receive instructions, load programs, or provide feedback on the speed of the rotor 1320 and the feed rate of the lead screw 2600. The aforementioned data can be transmitted between different NFC transceivers, either peer-to-peer with NFC-enabled devices such as smartphones, digital cameras, laptops, or tablets, or as a reader / writer. According to one aspect of the invention, the NFC transceiver receives data from an NFC card or tag (or from an NFC device simulating a card or tag), a location within memory 1354 for a program or subroutine, or instructions.

[0199] Using an NFC transceiver, the surgeon can program the impactor 1000 so that the impact assembly 3000 advances with each rotation of the output unit 1500; by example, and not limitation, the impact assembly 3000 can advance 0.0125 inches for each 0.0625-inch impact. As described above, the impactor 1000 delivers two impacts for each rotation of the output unit 1500, each impact having a stroke of 0.0625 inches. Also as described above, Hall effect sensors 1318-a, 1318-b, and 1318-c provide data on each rotation of the rotor and the revolutions per minute within the motor controller 1350 to the microcontroller 1351. As further stated above, the stepper motor 1330 drives the lead screw nut, thus advancing or retracting the lead screw 2500 in increments of 0.000125 inches.

[0200] Now refer to Figures 70 to 77 The motor mounting section 2520 is also provided with a slot 2527 for extending electrical leads from the stator 1310 to the motor controller 1350, which is positioned within the track 2530 (e.g., ...). Figures 70 to 77 As shown). Figure 75 and Figure 76 As shown, the track 2530 is also provided with grooves (preferably multiple grooves 2521, 2529) for electrical wiring; advantageously, after the wiring is inserted into the grooves 2521, 2529, the grooves 2521, 2529 are filled with silicone rubber or RTV rubber to prevent water from entering.

[0201] like Figures 70 to 77 As shown, the impactor 1000 includes a linear encoder 2531 (including a reader 2533 and a magnetic strip 2534) and an anti-rotation component 2532 (such as...). Figures 78 to 81 The track 2530 (as shown). In a preferred embodiment, the track 2530 is attached to the motor mounting portion 2520, as shown. Figures 70 to 71 As shown. The anti-rotation component 2532 prevents the lead screw 2600 from rotating, while the linear encoder provides the position of the impact assembly 3000 to the motor controller 1350. In an alternative embodiment, a rotary encoder is attached to the lead screw nut and provides the axial position of the lead screw to the motor controller 1350.

[0202] although Figure 70 and Figure 71 While the track 2530 and the motor mounting portion 2520 are depicted as separate components, integrating the track 2530 and the motor mounting portion 2520 to form a single component is also within the scope of this invention (e.g., Figures 91 to 98(As shown). In this alternative embodiment, the track 2530 is provided with a sealing structure 2535, which is in the form of an elastic O-ring or rubber O-ring or a thread (preferably a multi-turn coarse thread, such as UNC4-4). Extending from the first opening 1111, the housing 1100 is provided with a housing sealing structure 1115, which is also in the form of an elastic or rubber O-ring and a thread (preferably a multi-turn coarse thread, such as 2-4 1 / 2 UNC). The track 2530 extends axially from the sealing structure 2535 toward the DC motor side 2522 and terminates adjacent to the motor mounting portion 2520.

[0203] Because the preferred embodiment employs multiple coarse threads as sealing structures 1115 and 2535 (referred to as "first sealing structure 1115" and "second sealing structure 2535" to distinguish them from each other), the impactor 1000 is provided with a threaded cap (e.g. Figures 101 to 104 (as shown) and elastic O-rings or rubber O-rings, threaded caps (such as...) Figures 101 to 104 (As shown) and the inner surface 1105 of the housing is sealed with an elastic O-ring or rubber O-ring to prevent water ingress, thereby allowing the impactor 1000 to be immersed in water for cleaning and subsequent sterilization. Advantageously, the impactor 1000 includes a threaded sleeve to prevent debris from getting stuck between the threads when using the impactor 1000 and to protect the threads of the sealing structures 1115, 2535.

[0204] To assemble the impactor 1000 within the housing 1100, the shaft 2500 is attached to the motor mounting portion 2520 by a plurality of bolts extending through holes 2526 in the motor mounting portion 2520. Then, the stator 1310 is attached and positioned to the motor mounting portion 2520 by a plurality of bolts extending through holes 2525 in the motor mounting portion 2520. Next, the sun gears 2100-a and 2100-b with input plates and the rotor 1320 are positioned on the shaft 2500 such that the rotor 1320 extends radially around the stator 1310. Then, the output portion 1500 and the tubular member 1595 are assembled onto the shaft 2500, and the shaft section 3300, on which the drive member 3100 and the driven member 3200 are mounted, is screwed onto the threaded end of the lead screw 2600. After the BLDC motor 1300, motor mounting section 2520, shaft 2500, gear train 2000, output section 1500, and shaft section 3300 with impact assembly 3000 have been assembled, the assembly is placed into housing 1100. As described above, the dimensions of the cylindrical outer surface 2528 of motor mounting section 2520 are set to provide a press fit with the second inner surface 1123 of housing 1100.

[0205] Now go to Figures 82 to 93The impactor 1000 is provided with a handle 1200. The handle includes two plates (a trigger plate and a support plate), a handle body, a triggering component, a support component, a switch, a bracket, and a cover. The trigger plate 1220 has two ends (referred to as the first trigger end 1221 and the second trigger end 1222); similarly, the support plate 1230 has two ends (referred to as the first support end 1231 and the second support end 1232). Similar to plates 1220 and 1230, the handle body 1240 also has two ends (referred to as the first body end 1241 and the second body end 1242).

[0206] Plates 1220 and 1230 are made of stainless steel (or optionally titanium) and are rounded to provide a handle 1200 with a cylindrical shape having a diameter of 1.20 inches to 2.1 inches (preferably 1.5 inches). To accommodate hand width, plates 1220 and 1230 are provided with a length of not less than 3.5 inches; in a preferred embodiment, the trigger plate 1220 is 4.5 inches long, while the support plate 1230 is 6.025 inches long.

[0207] like Figure 86 As shown, the first support member 1261 and the second support member 1262 are attached to the first body end 1241 and the second body end 1242 by a plurality of fasteners 1243 and 1244. Figure 81 As shown, the first triggering component 1251 and the second triggering component 1252 are attached to the triggering ends 1221 and 1222 by a plurality of fasteners 1293 and 1294 and a rectangular rod 1253. Each of the triggering components 1251 and 1252 is provided with a pair of grooves 1254 and 1255 for slidably fixing each of the triggering components 1251 and 1252 to each of the handle body ends 1241 and 1242.

[0208] like Figures 85 to 87 and Figure 92 As shown, the handle 1200 is equipped with switches (preferably, multiple single-pole, single-throw, normally open, and momentary tactile switches). Figures 85 to 87A switch 1270 is shown, which is insulated on a circuit board 1272 using a conformal coating and is housed and supported within at least one of support members 1261, 1262. Switch 1270 has an intrusion protection rating of 67 (i.e., IP rating 67) and an operating and storage temperature up to 125°C. To open the impactor 1000, switch 1270 must be actuated by pinching the trigger plate 1220 and the support plate 1230 (hence referred to herein as a "hand trigger"). Because each of the trigger members 1251, 1252 is slidably fixed to each of the body ends 1241, 1242, the trigger member 1250 slides toward one of the support members 1261, 1262 and slides into at least one switch 1270 housed in one of the support members 1261, 1262. Figure 83 As shown, switch 1270 is provided with a sufficient stroke extending beyond the support member, such that when the pinch plates 1220, 1230 are pinched, at least one of the members 1251, 1252 is triggered to press the actuator 1271 of switch 1270.

[0209] A pair of compression springs apply a force to the rectangular rod 1253 to guide the triggering element away from the actuator 1271 on the switch 1270, thereby returning the actuator 1271 to the open position to close the impactor 1000. Therefore, the surgeon must overcome the force of the springs to close the switch 1270 and open the impactor 1000, and can simply release the trigger plate 1220 to close the impactor 1000. To maintain the orientation of the springs, the rectangular rod 1253 is provided with a plurality of pins 1256, 1257 axially aligned with a pair of countersunk holes 1246, 1247 defined within the handle body 1240. The springs are positioned around the pins 1256, 1257 while fitting within the countersunk holes 1246, 1247. Therefore, the axial orientation of the springs is maintained when the trigger plate 1220 is pressed toward the support plate 1230 and then released.

[0210] The handle 1200 is fixed to the second end 1120 of the housing 1100 by a pair of brackets 1281 and 1282. Figure 63 and Figure 88 As shown, each of the supports 1281, 1282 is attached to the housing 1100 such that the handle 1200 extends radially from the axis 1101 of the housing 1100; thus, by holding the handle 1200, the surgeon's arm can be aligned with the axis 1101, allowing the impactor 1000 to be positioned more precisely, and the force generated by the impactor 1000 can be borne by the surgeon's upper arm and chest muscles, rather than by the surgeon's wrist as in the case of a pistol-handled power tool.

[0211] As described above, the handle 1200 includes a touch switch 1270, which is located within at least one of the support members 1261 and 1262. To connect to at least one of the switches located within the handle 1200, a wire is led out from the housing 1100, passes through at least one of the brackets 1281 and 1282, and enters at least one of the support members 1261 and 1262. To prevent water and debris from entering the brackets 1281 and 1282, the handle 1200 includes a cover, preferably a pair of covers 1291 and 1292 (one cover 1291 and 1292 corresponding to one bracket 1281 and 1282). To further prevent water and debris from entering, the plates 1220 and 1230 may be overmolded using silicone rubber or neoprene rubber.

[0212] Now refer to Figure 92 In addition to the aforementioned "hand trigger," the handle 1200 is also equipped with thumb triggers and finger triggers. Preferably, the handle 1200 is equipped with multiple thumb triggers (usually labeled "1211" and "1212," and respectively referred to as the "first thumb trigger" and "second thumb trigger") and multiple finger triggers (usually labeled "1201" and "1202," and respectively referred to as the "first finger trigger" and "second finger trigger"). Figure 92 As shown, the first finger trigger 1201 and the second finger trigger 1202 are located on opposite sides of the handle 1200; similarly, the first thumb trigger 1211 and the second thumb trigger 1212 are also located on opposite sides of the handle 1200. By positioning the finger triggers 1201, 1202 and the thumb triggers 1211, 1212 on opposite sides of the handle 1200, the surgeon is given the option to use either the left thumb and fingers or the right thumb and fingers.

[0213] Similar to the hand trigger, the thumb triggers 1211 and 1212 are equipped with a switch (in... Figure 92 The switches 1213 and 1214 are respectively labeled "1213" and "1214". Switches 1213 and 1214 are located on printed circuit boards 1215 and 1216, respectively. Each switch has an intrusion protection rating of 67 (i.e., IP rating of 67) and an operating and storage temperature of up to 125°C. Compression springs labeled "1217-a" and "1218-a" prevent the actuators (labeled "1217-b" and "1218-b" respectively) from being pressed; therefore, in order to actuate switches 1213 and 1214, the thumb levers (labeled "1217-c" and "1218-c" respectively) must be pressed.

[0214] Similarly, finger triggers 1201 and 1202 are equipped with switches (in... Figure 92The switches 1203 and 1204 are also located on printed circuit boards 1215 and 1216, respectively. They utilize conformal coating insulation, and each switch has an intrusion protection rating of 67 (i.e., IP rating 67) and can operate and store at temperatures up to 125°C. Compression springs, labeled "1207-a" and "1208-a", prevent the actuators (labeled "1207-b" and "1208-b" respectively) from being pressed; therefore, to actuate switches 1203 and 1204, the finger levers (labeled "1207-c" and "1208-c" respectively) must be pulled.

[0215] Finger triggers 1201, 1202 and thumb triggers 1212, 1212 actuate a second motor 1330 to advance and retract the lead screw 2600, while the hand trigger actuates a first motor 1300. Therefore, the surgeon can initiate the impact by pinching the hand trigger, and the surgeon can feed the surgical instrument by pulling at least one of the finger levers 1207-c, 1208-c. The surgeon can retract the surgical instrument by releasing the finger lever and depressing at least one of the thumb levers 1217-c, 1218-c.

[0216] Although the invention has been specifically shown and described with reference to preferred embodiments thereof, those skilled in the art will understand that various changes in form and detail may be made without departing from the spirit and scope of the invention as defined by the appended claims.

Claims

1. An impactor that is electrically powered and adapted for use in surgery, the impactor comprising: a) Shell; b) A brushless DC motor, comprising a stator with multiple coils and a rotor with multiple magnets; c) A motor controller, including a motor driver that supplies current to the coils of the stator to cause the rotor to rotate about the stator; d) Planetary gear system, including input section, sun gear, planetary gears, ring gear and output section; e) Shaft body, including shaft body sections with non-circular cross-sectional shapes; f) Impact assembly, comprising a driving component and a driven component, wherein: i) The drive component defines a channel to provide clearance to the non-circular rotating component and the rolling sub-assembly: (1) The non-circular rotating component is attached to the rolling sub-assembly; (2) The non-circular rotating component and the rolling sub-assembly rotate through the output part of the gear train; (3) The rolling sub-assembly is provided with multiple shafts, multiple rollers and multiple fork-shaped parts, wherein each roller is press-fitted onto each shaft and each shaft is press-fitted into each fork-shaped part; ii) The driven member includes an impact portion and a stepped portion, wherein a non-circular hole is defined in the stepped portion: (1) The shaft section having the non-circular cross-sectional shape extends through the non-circular hole; (2) The stepped portion further includes a first roller support surface, a second roller support surface, a crown surface, a first inclined surface and a second inclined surface, each of the first roller support surface, the second roller support surface, the crown surface, the first inclined surface and the second inclined surface extending radially from the non-circular hole; (3) The first inclined surface extends axially from the first roller support surface to the coronal surface, and the second inclined surface extends axially from the second roller support surface to the coronal surface; (4) The coronal surface is located between the first roller support surface and the second roller support surface; and iii) The roller of the rolling sub-assembly rotates on the first roller support surface to the first ramp, and then rotates upward to the crown surface, and then rotates downward along the second ramp to the second roller support surface.

2. The impactor according to claim 1, wherein, The sun gear, the planetary gear, and the ring gear are made of PEEK.

3. The impactor according to claim 1, wherein, The stepped section is made of PEEK.

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