Disposable Flex Reamer Induction Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current orthopedic reamers are costly, prone to dullness and contamination, and require time-consuming resharpening and sterilization, leading to potential patient trauma and infection due to their reuse and inadequate cleaning, especially when used for procedures other than their intended purpose.
Innovation Solution
A disposable flexible intramedullary reamer with a novel blade and assembly head design featuring a cylindrical body with slots for insert reamer blades, bonded via induction heating, which eliminates the need for expensive grinding processes and ensures sharpness and cleanliness by being used once.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional reamers are reused multiple times, then cost is reduced, but the cutting blades become dull and contaminated leading to patient trauma and infection
Solution Approach 1:
The patent applies the disposable principle by making the reamer head assembly a single-use component that is discarded after one use. This eliminates the need for resharpening and sterilization processes, ensuring that the cutting blades remain sharp and sterile throughout the procedure without the risks associated with reuse. The disposable nature directly resolves the contradiction by prioritizing reliability over ease of repair.
2Manufacturing precision
If multiple interchangeable reamers are used for incremental enlarging, then precise fit is achieved, but procedural time increases due to frequent extraction and replacement
Solution Approach 1:
The patent applies the dynamics principle by making the reamer head assembly adjustable rather than fixed. The ability to change blade configuration and diameter on-demand transforms a static tool into a dynamic one, allowing the surgeon to adapt the reamer size during the procedure without extraction and replacement, thus maintaining precision while reducing procedural time.
Solution Approach 2:
The patent applies the universality principle by designing a single reamer head assembly that can perform multiple functions across different reaming stages. The adjustable blade mechanism allows one tool to replace multiple specialized reamers, enabling the same device to handle incremental enlarging, final sizing, and even revision procedures, thereby reducing the need for frequent tool changes.
3Adaptability or versatility
If reamers are used for procedures other than intended, then tool versatility is increased, but blade degradation accelerates due to excessive wear
Solution Approach 1:
The patent applies the disposable principle to resolve the contradiction between versatility and blade durability. Since the reamer head is designed for single use, it can be employed in various procedures including revision surgeries without concern for blade degradation. The low cost of the disposable unit allows flexible adaptation to different procedural needs while eliminating the risk of using degraded blades.
4Manufacturing precision
If traditional precision machining is used to manufacture reamer cutting heads, then manufacturing accuracy is achieved, but production cost and time increase
Solution Approach 1:
The patent applies the mechanics substitution principle by replacing traditional mechanical precision machining with induction heating technology. The induction heating system uses electromagnetic fields to precisely heat and form the cutting blades, achieving the required manufacturing accuracy while significantly reducing production time and cost compared to conventional machining methods.
Solution Approach 2:
The patent applies the parameter changes principle by transitioning from mechanical machining parameters (cutting speed, feed rate, tool geometry) to thermal processing parameters (heating power, temperature distribution, heating time). This parameter transformation enables more efficient manufacturing while maintaining or improving the precision of the reamer cutting head through controlled thermal expansion and phase changes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides cost-effective, efficient, and sterile reaming with reduced procedural time and minimized patient trauma by ensuring the reamer remains sharp and clean throughout the procedure, enhancing surgical outcomes.
Implementation Method 1
bonded via induction heating
Data Source
Figure 1
Figure 2~4
Figure 5~5A
AI summary
The invention relates to a disposable intramedullary reamer (300) comprising: at least one continuous reamer blade (34) having a blade thickness and a blade length, comprising a reamer blade attachment portion and a reamer blade cutting portion, partitioned therebetween by a reamer blade transition line parallel to the blade length; a cylindrical body (10) comprising an outer surface, a proximal end portion and a distal end portion, the proximal end portion connectable to a reamer shaft (200); wherein each reamer blade is positioned about the cylindrical body, spaced apart from adjacent reamer blades by a blade separation distance, such that the reamer blade attachment portion is attached to the outer surface of the distal end portion of the cylindrical body, the forward blade cutting surface is positioned toward the cylindrical body distal end portion and the rearward relief blade surface is positioned toward the cylindrical body proximal end portion. The invention also relates to a disposable intramedullary reamer head assembly for cutting through an intramedullary space of a long bone and to a method of manufacturing such a disposable reamer head assembly.