Orthopedic Impaction Force Sensing for Controlled Broach Installation

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Solution Overview

Problem

Surgeons face challenges in controlling the broaching and implant installation process during orthopedic surgeries, leading to complications such as bone fractures due to unpredictable impact forces from manual mallets and inefficiencies in existing impactor systems.

Innovation Solution

The use of force transducers and accelerometers to measure and analyze resistive and acceleration forces during the broaching process, generating real-time feedback to ensure controlled and safe implant installation, with optional displays and wireless communication for data recording and analysis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual mallets are used for broaching and implant installation, then surgical flexibility is maintained, but impact forces become unpredictable leading to bone fractures

Engineering Contradiction:

Improvesurgical flexibilityVSAvoidimpact force control

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system incorporates force transducers and accelerometers that provide real-time feedback on impact forces during broaching and implant installation. This feedback loop allows surgeons to monitor and adjust their technique to maintain safe force levels, combining manual flexibility with quantitative control data to prevent bone fractures.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces purely manual mechanical impact delivery with an instrumented system that uses sensors (force transducers and accelerometers) to measure and quantify impact forces. This substitution transforms uncontrolled manual striking into a monitored process where mechanical actions are augmented by electronic measurement and data feedback.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If existing impactor systems are used, then implant installation is achieved, but lack of force measurement leads to peri-prosthetic fractures

Engineering Contradiction:

Improveimplant installation efficiencyVSAvoidbone fracture risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

Real-time force measurement feedback from transducers and accelerometers provides surgeons with quantitative data on impact forces during implant installation. This enables continuous monitoring to ensure forces remain within safe thresholds, preventing peri-prosthetic fractures while maintaining installation efficiency.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Force transducers and accelerometers act as intermediary devices between the manual mallet and the bone-implant system. These sensors mediate the interaction by measuring forces before they reach the bone, providing a buffer of information that allows surgeons to adjust their technique and prevent harmful force transmission.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If force transducers and accelerometers are integrated into the impaction system, then impact force control is improved, but device complexity increases

Engineering Contradiction:

Improveimpact force controlVSAvoidsensor integration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The force transducer and accelerometer system serves multiple functions: measuring impact forces, providing real-time feedback, recording data for later analysis, and alerting surgeons to dangerous force levels. This multi-functionality justifies the added complexity by delivering comprehensive control and monitoring capabilities in a single integrated system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 approach reduces the risk of bone fractures by providing precise control over impact forces, improving surgical outcomes and reducing the need for costly revision surgeries.

Implementation Method 1

a force transducer configured to measure a resistive force of at least one of: a broach, an implant, or a broach/implant handle

Methodology Applied

Scientific EffectForce transduction: Force

Implementation Method 2

an accelerometer configured to measure acceleration of a portion of a manual impaction device and at least one of: a broach, an implant, or a broach/implant handle

Methodology Applied

Scientific EffectAcceleration measurement: Accelerometer

Implementation Method 3

a force transducer configured to measure an impact force between the manual impaction device and at least one of: the broach, the implant, or the broach/implant handle

Methodology Applied

Scientific EffectImpact force measurement: Impact Force

Data Source

PatentUS20250387239A1Force sensing devices and methods for orthopedic surgery

Publication Date: 2025.12.25 ORTHOIQ INC

AI summary

An impaction device that may include a force transducer and optional accelerometer to measure an impact force between an impactor device and broach/implant or broach/implant handle. The impaction device may include a microcontroller electrically coupled to memory and the force transducer and optional accelerometer, wherein the microcontroller is configured to execute operations stored in the memory, the operations comprising: receiving resistive force data and acceleration data to calculate resistance for each impaction and generate a resistance curve for output to a display.