Magnetic Torque-Limiting Knob for Secure Surgical Coupling

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Solution Overview

Problem

Traditional reference frame assemblies used in arthroplasty procedures can become loose or decoupled due to improper torque application, leading to inaccurate tracking of patient anatomy and interrupting surgical procedures.

Innovation Solution

A knob is designed to control torque by threading onto a medical instrument with a predetermined torque, featuring a repulsive magnetic force between magnets to prevent over-torquing and ensure secure coupling, accompanied by an audible signal when the predetermined torque is reached.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the knob is screwed down with high torque to prevent loosening, then the coupling reliability is improved, but the threads can become stripped and it becomes difficult to decouple components for reuse

Engineering Contradiction:
Improvecoupling reliabilityVSAvoidease of decoupling
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The patent applies parameter changes by introducing a magnetic repulsion force that dynamically adjusts the effective torque during the tightening process. The magnetic force increases as the knobs approach each other, automatically limiting the maximum torque to prevent thread stripping while ensuring secure coupling. This resolves the contradiction by changing the physical parameter of force application from purely mechanical to a combination of magnetic and mechanical forces.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The magnetic field acts as an intermediary between the two knobs, mediating the interaction force. Instead of direct mechanical contact alone, the magnetic repulsion serves as an intermediate force that prevents excessive torque application. This intermediary mechanism allows the system to achieve reliable coupling without the harmful effects of over-torquing, while still permitting easy decoupling when needed.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Ease of operation

If the knob is screwed down with low torque to allow easy decoupling, then the ease of operation is improved, but the components can become loose or decoupled during the procedure

Engineering Contradiction:
Improveease of decouplingVSAvoidcoupling reliability
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The magnetic repulsion force changes the torque characteristic during the tightening process. Initially, when knobs are far apart, minimal force is required to begin engagement. As they approach, the magnetic repulsion automatically increases to provide optimal tightening force, ensuring reliable coupling without requiring the operator to apply excessive manual torque. This resolves the contradiction by making the system self-regulating.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The system performs self-service by using the magnetic repulsion between knobs to automatically regulate the tightening force. The knobs themselves generate the force needed to achieve proper coupling through their mutual magnetic interaction, eliminating the need for external torque control mechanisms or complex adjustment procedures. This ensures reliable coupling while maintaining ease of operation and decoupling.

Inventive Principle:
Principle #25Self-service

3Device complexity

If traditional mechanical coupling is used without torque control, then the device complexity is reduced, but tracking accuracy deteriorates due to loosening or decoupling

Engineering Contradiction:
Improvedevice complexityVSAvoidtracking accuracy
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The magnetic field serves as an intermediary that provides torque control without adding complex mechanical components. Instead of incorporating sophisticated torque limiting mechanisms, the patent uses the simple magnetic repulsion between oppositely polarized magnets to automatically control the coupling force. This maintains device simplicity while ensuring tracking accuracy by preventing loosening during the procedure.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces complex mechanical torque control systems with a magnetic field-based solution. Instead of using mechanical springs, cam mechanisms, or electronic torque sensors to control coupling force, the invention uses the inherent magnetic repulsion between knobs. This substitution maintains low device complexity while achieving the desired torque control for accurate tracking throughout the procedure.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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 knob reduces inaccuracy and surgical complexity by maintaining secure coupling, minimizing the need for re-registration and reducing surgical time.

Implementation Method 1

a first magnet positioned within the outer housing; a second magnet positioned within the outer housing, wherein the second magnet and the first magnet are configured to exert a repulsive force with respect to one another

Methodology Applied
Scientific EffectMagnetic repulsion: Magnetism

Data Source

PatentUS12535845B2Knob configured for torque control
Publication Date: 2026.01.27 ORTHOSOFT ULC
  • US12535845B2 patent drawing
  • US12535845B2 patent drawing
  • US12535845B2 patent drawing

AI summary

A knob including an outer housing, a first magnet, a second magnet, a first crown and a second crown. The second magnet and the first magnet are configured to exert a repulsive force with respect to one another. The first crown positioned within the outer housing and restrained from translation relative to the outer housing. The second crown is coupled to the second magnet. The second crown is rotatable with the outer housing. The second crown has a second plurality of teeth on a second side thereof that interface with and selectively engage the first plurality of teeth on the first side of the first crown. The second crown overcomes the repulsive force between the first magnet and the second magnet and translates relative to the outer housing and the first crown when the first crown is threaded onto the first medical instrument to a predetermined torque.