Orthopaedic Cutting Tool With Chemically Etched Metal Insert
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Solution Overview
Problem
Existing orthopaedic surgical instruments face challenges in efficiently removing bone portions during joint arthroplasty procedures due to limitations in tool design and material properties, particularly in distributing forces effectively and maintaining sterility.
Innovation Solution
The development of an orthopaedic cutting tool featuring a metallic cutting insert with chemically etched holes and a molded polymer body, where the body fills at least half the volume of the etched holes, providing enhanced adhesion and force distribution, and a method involving chemical etching and injection molding to create the tool's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional machining processes are used to fabricate metal surgical instruments, then manufacturing precision and strength are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines metal cutting inserts with polymer body components to create a composite surgical instrument. The metal insert provides necessary strength and cutting capability, while the polymer body reduces overall complexity and manufacturing cost compared to fully metal construction.
Solution Approach 2:
The instrument is divided into separate functional components: metal cutting inserts for strength and cutting, and polymer body sections for structural support and sterilization. This segmentation allows each material to be optimized for its specific function while simplifying overall manufacturing.
2Productivity
If metal instruments are used for bone cutting, then cutting efficiency is improved, but sterilization difficulty and cost increase
Solution Approach 1:
By using a polymer body with metal inserts, the instrument combines the bone-cutting efficiency of metal with the sterilization advantages of polymer materials, which can be more easily sterilized and are less prone to corrosion and contamination.
3Strength
If chemically etched holes are created in metal inserts, then adhesion strength is improved, but manufacturing time increases
Solution Approach 1:
The patent replaces traditional mechanical fastening methods with chemical etching to create adhesion between the polymer body and metal insert. The chemical etching process creates surface irregularities that enhance bonding strength without requiring additional mechanical assembly steps.
4Ease of manufacture
If polymer body is used instead of metal, then manufacturing cost is reduced, but force distribution capability worsens
Solution Approach 1:
The polymer body is strategically designed and positioned to work in conjunction with metal cutting inserts, allowing the polymer to handle non-critical forces while the metal components manage cutting and high-stress applications, optimizing both cost and force distribution.
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 enables efficient bone removal with improved force distribution and reduced material costs, while maintaining a sterile environment by using a polymer body that is less expensive and easier to fabricate into complex shapes, thus enhancing surgical precision and efficiency.
Implementation Method 1
chemically etched holes
Implementation Method 2
body molded to the cutting insert
Data Source
AI summary
An orthopedic surgical instrument comprising an orthopedic cutting tool includes a metallic cutting insert configured to remove portions of a patient's bone and a body molded to the cutting insert. The cutting insert includes a plurality of chemically etched holes, and the body is molded to the cutting insert such that each of the plurality of chemically etched holes is at least partially filled by a portion of the body. The cutting insert may include a plurality of cutting teeth configured to remove portions of the patient's bone. A method of manufacturing an orthopedic surgical instrument is also disclosed.