Monolithic Ultrasonic Bone-Cutting Blade for Easier Manufacture
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Solution Overview
Problem
Existing ultrasonic surgical instruments for cutting bone tissue often have joints that can lead to manufacturing complexities and increased costs, and they are not easily manufactured with consistent specifications.
Innovation Solution
The development of an ultrasonic surgical instrument with a unitary blade and shaft design, where the blade is continuous with the shaft without an intervening joint, facilitated by machining a distal end of a tool blank to form a cylindrical shaft with a radially enlarged proximal end for attachment to an electromechanical transducer, and featuring a flat or planar blade body with a groove and channel system for fluid distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a jointed design is used for the ultrasonic surgical instrument, then the blade can be manufactured separately and attached to the shaft, but this increases manufacturing complexity and costs
Solution Approach 1:
The patent merges the blade and shaft into a single unitary structure, eliminating the joint between these two components. The blade is formed as an integral extension of the shaft, creating a simplified monolithic structure that reduces manufacturing steps and eliminates assembly requirements while maintaining functional performance
2Ease of manufacture
If a jointed design is used for the ultrasonic surgical instrument, then the blade can be manufactured separately, but this increases manufacturing expenses
Solution Approach 1:
The patent merges the blade and shaft into a single unitary structure, eliminating the joint between these two components. The blade is formed as an integral extension of the shaft, creating a simplified monolithic structure that reduces manufacturing steps and eliminates assembly requirements while maintaining functional performance
3Manufacturing precision
If a jointed design is used for the ultrasonic surgical instrument, then the blade can be manufactured separately and attached to the shaft, but this makes quality control more difficult
Solution Approach 1:
The patent merges the blade and shaft into a single unitary structure, eliminating the joint between these two components. The blade is formed as an integral extension of the shaft, creating a simplified monolithic structure that reduces manufacturing steps and eliminates assembly requirements while maintaining functional performance
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
This design reduces manufacturing expenses, simplifies the manufacturing process, and allows for tighter specifications and easier quality control, resulting in a more efficient and consistent ultrasonic bone-cutting instrument.
Implementation Method 1
The shaft is provided with an axially extending bore for the conveyance of cooling fluid to the cutting edge
Implementation Method 2
the blade body is provided in the major lateral surface with a groove continuous with the channel or bore at the outlet thereof
Implementation Method 3
an ultrasonic surgical blade, particularly for cutting bone tissue
Data Source
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AI summary
An ultrasonic surgical instrument comprises a cylindrical shaft and a blade at a distal or free end of the shaft, the blade being unitary and continuous with the shaft, without an intervening joint. The shaft has a longitudinal axis and the blade includes a flat or planar blade body with a proximal end eccentrically disposed relative to the shaft axis. Thus, the blade body or at least a proximal end portion thereof is disposed eccentrically relative to the shaft. The blade in its entirely may be inclined relative to the shaft axis or extend parallel thereto.