Orthopaedic Knee Impaction Instrument With Interchangeable Polymer Insert
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Solution Overview
Problem
Existing orthopaedic surgical instruments lack efficient and ergonomic designs for implanting orthopaedic knee prostheses, particularly in terms of material compatibility and tactile feedback during impact, which can affect the precision and efficiency of the implantation process.
Innovation Solution
A two-piece surgical instrument comprising a metallic impaction handle and a polymer impaction insert, where the insert is removably secured to the handle, allowing for different materials to be used for impact durability and component compatibility, with features like an elongated spine for tactile feedback and a pneumatic seal for enhanced impact control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-material impaction instrument is used, then the structure is simple, but the impact load transfer efficiency and component compatibility are limited
Solution Approach 1:
The impaction instrument is divided into two separate components: a metallic impaction handle and a polymer impaction insert. The handle is made of metal for durability and impact resistance, while the insert is made of polymer for compatibility with knee prosthesis components. This segmentation allows each part to be optimized for its specific function, resolving the contradiction between structural simplicity and impact load transfer efficiency.
Solution Approach 2:
The instrument combines two different materials (metal and polymer) to create a composite structure. The metallic handle provides strength and impact resistance, while the polymer insert provides compatibility with prosthesis components and controlled impact characteristics. This composite approach resolves the contradiction by achieving both durability and component compatibility that neither material could achieve alone.
2Ease of manufacture
If a fixed-material impaction instrument is used, then the manufacturing process is simple, but the adaptability to different knee prosthesis components is limited
Solution Approach 1:
By separating the handle and insert into independent components, the instrument allows for interchangeable inserts that can be selected and secured to match different knee prosthesis components. This segmentation enables adaptability to various components while keeping the handle manufacturing process simple and standardized.
Solution Approach 2:
The instrument transitions from a fixed-material design to a dynamic, interchangeable system where the polymer insert can be removed and replaced with different inserts suited for different prosthesis components. This dynamic capability enhances adaptability without significantly complicating the base handle manufacturing process.
3Device complexity
If traditional impaction instruments are used, then the design is simple, but the tactile feedback during impact is insufficient
Solution Approach 1:
The polymer insert is designed to provide tactile feedback during the impaction process. The polymer material's properties allow the surgeon to feel the progress of implant installation through the insert, providing real-time feedback on impact application and component positioning. This feedback mechanism enhances ease of operation while adding only minimal complexity to the overall design.
4Device complexity
If a non-removable impaction insert is used, then the instrument structure is simple, but the ease of replacing different inserts is poor
Solution Approach 1:
The instrument is segmented into a handle and an insert that can be easily separated and reconnected. This segmentation enables straightforward replacement of the polymer insert with different inserts suited for different prosthesis components, while maintaining a relatively simple overall instrument structure through the use of a straightforward attachment mechanism.
Data Source
AI summary
An orthopaedic surgical instrument for use during a surgical procedure to implant a tibial tray into a surgically-prepared proximal end of a tibia and a femoral component into a surgically-prepared distal end of a femur is disclosed. The surgical instrument includes a metallic impaction handle and a removable polymeric impaction insert.