Bone Broach Planar Member Stacking
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Solution Overview
Problem
The high cost of bone broaches produced by machining a single piece of metal limits their use to reusable instruments, requiring decontamination and sterilization, and existing stacked plate designs are prone to disconnection during use due to perpendicular forces.
Innovation Solution
A bone broach comprising a plurality of substantially planar members divided into groups with parallel planes within each group and angled planes between groups, forming interlocking stacks with minimal need for adhesives or joining, reducing the risk of disconnection and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bone broaches are produced by machining a single piece of metal, then the structural integrity and reliability are improved, but the manufacturing cost increases
Solution Approach 1:
The bone broach is divided into multiple planar members (first group with parallel planes, second group with angled planes) that are stacked and joined together. This segmentation allows each member to be manufactured separately at lower cost while maintaining overall structural integrity through the interlocking stack configuration.
Solution Approach 2:
The invention uses a composite structure composed of multiple planar members made from metal or metal alloy materials. These members are joined together to form a composite bone broach that combines the advantages of individual planar components with the overall strength needed for surgical application.
2Ease of manufacture
If bone broaches are made reusable to reduce cost, then the manufacturing cost per unit is reduced, but the need for decontamination and sterilization increases
Solution Approach 1:
The planar member construction enables production of lower-cost bone broaches that can be manufactured more economically. This cost reduction makes it economically viable to use single-disposable instruments, eliminating the time and resource costs associated with decontamination and sterilization of reusable instruments.
3Ease of manufacture
If broach plates are stacked perpendicular to the mandrel axis, then the profile definition is simplified, but the risk of disconnection during use increases
Solution Approach 1:
The invention introduces asymmetry in the stacking arrangement by dividing planar members into two groups: the first group has planes perpendicular to the longitudinal axis, while the second group has planes at an angle (e.g., 45 degrees) to the axis. This asymmetric configuration distributes mechanical stresses more evenly and prevents the uniform perpendicular forces that cause disconnection in conventional designs.
Solution Approach 2:
The invention adds angular orientation in a different dimensional configuration. Instead of all plates being perpendicular to the axis, the second group of plates is oriented at an angle, introducing a new dimensional aspect to the stacking arrangement that enhances connection stability while maintaining profile definition capability.
Data Source
AI summary
A bone broach is formed from a plurality of substantially planar members which are positioned adjacent to each other with each of the substantially planar members attached to at least one other substantially planar member. At least some of the substantially planar members defines at least one cutting profile at its perimeter. The plurality of substantially planar members include a first group of substantially planar members defining planes which are substantially parallel to each other, and at least one additional substantially planar member defining a plane which is angled relative to the planes defined by the first group of substantially planar members.