Breakoff Set Screw Driver With Stackable Internal Head Retention
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Solution Overview
Problem
Existing breakoff set screws with internal drive features cannot be stacked on a magazine of a breakoff driver due to geometry interference, and switching drivers or bits is cumbersome when multiple screw styles are used.
Innovation Solution
A breakoff driver system with a magazine retention portion and a pin mechanism that allows for stacking and secure retention of separated breakoff heads, featuring a pin that deploys and retracts to accommodate various screw sizes and types, and an adapter for multi-bit drivers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If breakoff set screws with internal drive features are used to avoid geometry interference, then geometry interference issues are resolved, but the separated breakoff heads cannot be stacked on a magazine due to the internal drive features creating geometry interference
Solution Approach 1:
The driver system is segmented into multiple components: a magazine retention portion that receives breakoff heads, a pin mechanism that interacts with the internal drive features, and a shaft. This segmentation allows the internal drive features to engage with the pin for driving functionality while the magazine retention portion provides a separate stacking surface, resolving the contradiction between maintaining internal drive features and enabling stackability.
2Adaptability or versatility
If multiple styles of screws are used within a single construct to meet various surgical requirements, then surgical versatility is improved, but the driver must be repeatedly switched out to accommodate various sized set screws and internal drive features
Solution Approach 1:
The magazine retention portion is designed with a universal interface that can accommodate multiple styles of breakoff heads with different internal drive features. The pin mechanism can engage with various drive feature geometries, allowing a single driver system to handle multiple screw styles without requiring driver changes, thus reducing time loss while maintaining surgical versatility.
Solution Approach 2:
The pin mechanism is designed to be dynamically adjustable, allowing it to engage with different internal drive feature geometries. This dynamic adaptability enables the single driver system to accommodate various sized set screws and drive features by adjusting the pin engagement rather than requiring physical driver changes.
3Device complexity
If external hex breakoff set screws are used, then simplicity of design is maintained, but they cannot be used in cases with geometry interference issues
Solution Approach 1:
The breakoff heads are designed with asymmetric internal drive features (such as hexalobe or hex shaped recesses) that provide directional engagement with the pin mechanism. This asymmetric design allows the heads to engage properly with the driver while avoiding geometry interference with surrounding implant structures, maintaining relative design simplicity while improving adaptability.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
An approach is provided for engaging a set screw to an implant. The approach includes a surgical instrument. The surgical instrument may include a shaft having an elongated rigid structure, and a driver head positioned on a distal end of the surgical instrument. The driver head may include at least one groove or at least one protrusion extending in a longitudinal direction of the surgical instrument and a pin positioned at least partially within the driver head. The pin may be configured to deploy and retract in a lateral direction from with the driver head portion.