Orthopaedic Stapler with Breakable Lever Arms
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Solution Overview
Problem
Current orthopaedic staple implantation techniques are complex, requiring multiple instruments and steps, making them difficult to use and costly, especially during the insertion and release of staples into bone fragments, which complicates the stabilization of fractures and osteotomies.
Innovation Solution
An integrated orthopaedic stapler with lever arms and a breakable connection allows for one-handed adjustment and tensioning of staples, featuring a U-shaped design with sawtooth profiles for easy insertion and release, and a single-piece construction that includes centring holes and a lever support system for intuitive operation and reduced instrument complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard insertion techniques with multiple instruments are used, then reliable staple implantation is achieved, but device complexity and operational difficulty increase
Solution Approach 1:
The patent combines the staple and insertion instrument into a single integrated device. The staple is formed integrally at the distal ends of the pliers, eliminating the need for separate insertion instruments. This merging reduces device complexity while maintaining reliable implantation through the integrated lever arm mechanism that provides mechanical advantage during insertion.
Solution Approach 2:
The pliers serve multiple functions: they hold the staple, provide insertion force through lever arms, enable tensioning adjustment, and facilitate release through the breakable connection. This multi-functionality reduces the number of separate instruments needed while maintaining reliable staple implantation and removal.
2Reliability
If multiple instruments and steps are used for staple insertion and release, then secure fixation is achieved, but ease of operation deteriorates
Solution Approach 1:
By integrating the staple with the pliers, the surgeon can perform insertion, tensioning, and release operations with a single instrument. The lever arms provide mechanical advantage for secure insertion, while the breakable connection enables easy release, all without switching instruments.
Solution Approach 2:
The lever arms can be moved between different positions to provide mechanical advantage during insertion and to enable tensioning adjustment. The dynamic movement of lever arms simplifies operations while ensuring secure fixation through controlled force application.
3Manufacturing precision
If specialized insertion instruments are used, then precise staple placement is achieved, but productivity decreases
Solution Approach 1:
The integrated design eliminates the need for separate positioning and insertion instruments. The pliers themselves provide the positioning function through their geometry and the insertion function through the lever arm mechanism, streamlining the workflow and improving surgical efficiency while maintaining precise placement.
Solution Approach 2:
The staple is pre-formed and attached to the pliers in the correct configuration before surgery. The lever arms are pre-positioned to provide mechanical advantage, eliminating the need for complex intraoperative setup and improving procedural efficiency.
4Reliability
If complex insertion techniques are used, then staple security is improved, but loss of time increases
Solution Approach 1:
The lever arms provide dynamic mechanical advantage during insertion, enabling secure staple placement with a single instrument. The breakable connection provides a predetermined failure point that enables rapid release when needed, reducing time loss during both insertion and removal operations.
Solution Approach 2:
The connection between the staple and pliers is segmented into a breakable portion with a predetermined failure point. This segmentation allows the staple to remain securely attached during insertion while enabling easy separation and removal, reducing overall procedural time.
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 simplifies the insertion and release of staples, allowing for precise control and compressive pre-loading of bone fragments, reducing the need for additional instruments and improving ease of use, while materials with high elastic properties ensure recovery of tension after removal.
Implementation Method 1
The connection portion is breakable along a breakage section, so that the pliers can be detached from the staple
Implementation Method 2
allowing for one-handed adjustment and tensioning of staples, featuring a U-shaped design with sawtooth profiles for easy insertion and release
Implementation Method 3
materials with high elastic properties ensure recovery of tension after removal
Data Source
AI summary
An orthopaedic stapler (1) comprising orthopaedic pliers (3) and an orthopaedic staple (2) integrally formed at the distal ends of the pliers (3). The orthopaedic staple (2) comprises a beam portion (4) and two insertion brackets (5) at the two opposite ends (6) of the beam portion (4) and substantially transverse with respect to the beam portion (4). The orthopaedic pliers (3) comprise two lever arms (12) integrally connected to the orthopaedic staple (2) by means of connection portions (15) at the two opposite ends (6) of the beam portion (4). The connection portions (15) are breakable along breakage sections (24). The lever arms (12) comprise at least one first projecting element (19), at least one second projecting element (20), the first projecting element (19) on one lever arm (12) being directed towards the second projecting element (20) on the other lever arm (12). The first projecting element (19) and the second projecting element (20) are provided with a reciprocal engaging mechanism (21).