Straight and Curved Femoral Broach Impactor Adapters for Controlled Impaction

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Solution Overview

Problem

Manual impaction of surgical instruments during joint arthroplasty procedures is unpredictable and imprecise, requiring surgeons to hold instruments with one hand and strike them with a mallet, leading to inefficiencies and potential inaccuracies.

Innovation Solution

An orthopaedic surgical instrument with an elongated body, levers, a leaf spring, and a pushbutton catch, which allows for secure attachment to an automated surgical impactor, enabling controlled impaction and easy release of surgical broaches using a compliant mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual impaction is performed by striking the instrument with a mallet, then the surgeon can impact the surgical instrument into the patient's bone, but the impaction becomes unpredictable and imprecise

Engineering Contradiction:

Improveimpaction precisionVSAvoidmanual operation

Core Design Contradiction:

Measurement precisionVSExtent of automation

Solution Approach 1:

The patent replaces the manual mallet-striking mechanical system with an automated surgical impactor that delivers controlled percussive impacts. The automated impactor uses a motorized mechanism to generate precise impact forces, eliminating the unpredictability of manual striking while maintaining the mechanical impaction function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the control parameters of impaction from manual force application to automated controlled parameters. The automated impactor allows precise control of impact frequency, amplitude, and duration, transforming the impaction process from qualitative manual control to quantitative automated control with measurable precision.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the surgeon holds the instrument with one hand and strikes with a mallet in the other hand, then impaction can be performed, but the operation becomes complex and inefficient

Engineering Contradiction:

Improvesurgical efficiencyVSAvoidoperation complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges the functions of holding and striking into a single automated device. The surgical impactor integrates the impact generation mechanism with the instrument positioning system, allowing the surgeon to control both functions simultaneously through one interface, thereby simplifying the operational complexity while maintaining surgical efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The automated impactor performs the striking function automatically once positioned, eliminating the need for the surgeon to continuously coordinate two-handed operations. The device self-generates the impact forces through its integrated mechanism, reducing the cognitive and physical load on the surgeon.

Inventive Principle:

Principle #25Self-service

3Strength

If a rigid drive train is used to connect the impactor to the surgical instrument, then mechanical connection is strong, but wear occurs during frequent impacts

Engineering Contradiction:

Improvemechanical connection strengthVSAvoidtool integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs a flexible coupling mechanism between the automated impactor and the surgical instrument rather than a completely rigid drive train. This flexible connection absorbs some of the mechanical stress and impact loads, reducing wear on the mechanical components while maintaining sufficient connection strength for effective impaction.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The coupling mechanism incorporates cushioning elements that absorb impact forces before they reach the mechanical connection points. This pre-cushioning protects the drive train components from excessive wear and potential failure during frequent impact operations, thereby improving reliability while maintaining connection strength.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

Facilitates precise and controlled impaction of surgical instruments, reducing manual effort and improving procedural accuracy by allowing one-handed operation with an automated impactor, minimizing wear and maintaining tool integrity during frequent impacts.

Implementation Method 1

a leaf spring having a first end pivotally coupled to the first lever and a second end pivotally coupled to the second lever such that movement of the first lever causes movement of the second lever

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12383324B2Straight and curved femoral broach impactor adapters

Publication Date: 2025.08.12 DEPUY SYNTHES PROD INC

AI summary

An orthopaedic surgical instrument may include an elongated body with a broach end and an impactor end. The body may be straight or curved. A latch lever may be pivotally coupled to the elongated body. The latch lever may be moveable between an open position and a latched position in which the latch lever is retained within the body. A surgical broach may be rigidly attached to the broach end of the elongated body. An automated surgical impactor may be attached to the impactor end.