Flexible Reamer with Helical Segments for Torque Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing reamer tools have limited capacity to bend and transfer torsional forces simultaneously, which hinders their effectiveness in navigating tight spaces during surgical procedures.
Innovation Solution
A flexible reamer tool with a cannulated shaft that can deform to vary its curvature, allowing for torque transfer at oblique angles while being additively manufactured as a single monolithic structure with helical segments and protrusions/recesses for enhanced flexibility and torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional subtractive manufacturing techniques are used to form reamers with limited material removal, then the reamer structure remains generally solid, but the capacity to bend and transfer torsional forces simultaneously is limited
Solution Approach 1:
The shaft is divided into multiple helical segments that can articulate relative to each other, allowing the shaft to bend while maintaining structural integrity. Each segment contains protrusions and recesses that enable controlled movement between segments, providing both flexibility and torque transfer capability simultaneously.
Solution Approach 2:
The shaft transitions from a static rigid structure to a dynamic articulated structure where helical segments can move relative to each other. This dynamic configuration allows the shaft to adapt its shape during use while maintaining the ability to transmit torsional forces through the articulated joints.
2Ease of operation
If the reamer shaft is made flexible to navigate tight spaces, then the ability to reach complex surgical sites is improved, but the torque transfer capability may be compromised
Solution Approach 1:
The shaft employs helical curvature in its segments, allowing it to bend and navigate curved anatomical pathways. The helical shape provides inherent flexibility while the interlocking protrusions and recesses ensure that torque can be transmitted through the curved configuration without significant loss.
Solution Approach 2:
The shaft combines flexible helical segments with rigid protrusion-recess joints, creating a composite structure that exhibits both flexibility for navigation and rigidity for torque transfer. This composite design allows the shaft to function as both a flexible catheter and a rigid drive shaft depending on the operational requirement.
3Reliability
If the shaft is designed with helical segments and protrusions/recesses for flexibility and torque transfer, then the structural complexity increases, but the manufacturing difficulty may increase
Solution Approach 1:
Multiple functional features (helical segments, protrusions, recesses, cannulation) are merged into a single monolithic structure manufactured by additive manufacturing. This integration eliminates the need for separate components and assembly steps, reducing manufacturing complexity despite the intricate geometry.
Solution Approach 2:
Additive manufacturing enables the production of complex geometries that would be difficult or impossible to create with conventional manufacturing methods. The manufacturing process parameters (layer thickness, infill density, material deposition) are optimized to produce the articulated helical structure with precise protrusion and recess features.
4Weight of moving object
If the shaft is made cannulated with profiled geometry, then the flexibility and weight are improved, but the structural integrity may be reduced
Solution Approach 1:
The shaft employs a cannulated (hollow) structure with profiled geometry that reduces weight while maintaining structural integrity. The strategic placement and shaping of the cannulation create a lightweight yet strong structure that can flex and transmit torque effectively.
Solution Approach 2:
The profiled cannulation geometry follows curved pathways that optimize structural strength-to-weight ratio. The curved walls of the cannulation provide rigidity while the hollow interior reduces mass, and the profiled shape distributes stresses evenly during bending and torque transmission.
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 tool enables effective torque transfer and flexibility, allowing it to reach complex surgical sites while maintaining structural integrity and ease of cleaning.
Implementation Method 1
The first helical segment may include a first plurality of contact surfaces and the second helical segment may include a second plurality of contact surfaces such that when a torque is applied to the shaft, the first plurality of contact surfaces or the second plurality of contact surfaces bears against the other of the first plurality of contact surfaces or the second plurality of contact surfaces.
Data Source
AI summary
A flexible instrument includes a first end portion, a second end portion opposite the first end portion, and a shaft extending from the first end portion to the second end portion along a central longitudinal axis. The shaft includes a first helical segment extending from the first end portion to the second end portion along a first helical path about the central longitudinal axis. The second helical segment extends from the first end portion to the second end portion along a second helical path about the central longitudinal axis. The first helical segment includes a first plurality of contact surfaces and the second helical segment includes a second plurality of contact surfaces such that when a torque is applied to the shaft, the first plurality of contact surfaces or the second plurality of contact surfaces bears against the other.