Surgical Coupling System Press Fit Assembly
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Solution Overview
Problem
Conventional surgical coupling systems for bone stabilization are bulky, causing tissue damage and post-operative irritation, and are difficult to install and extend, especially in minimally invasive procedures, due to their large size and complex assembly requirements.
Innovation Solution
A surgical coupling system with a handle, a rod, and a trigger mechanism that allows for easy assembly and disassembly, enabling secure coupling and uncoupling of pedicle screws through a press fit mechanism, facilitating easier installation and extension during surgical procedures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional surgical coupling systems are used, then bone stabilization is achieved, but tissue damage and post-operative irritation increase due to bulky size
Solution Approach 1:
The coupling system is divided into separate components: a coupling device with a body and a separate rod. The rod can be inserted through the body and locked in place, allowing the system to provide stable fixation while having a smaller profile than traditional pre-assembled coupling systems. This segmentation enables the rod to pass through a smaller opening in the coupling device, reducing tissue disruption during implantation.
2Reliability
If conventional coupling systems are used, then bone stabilization is achieved, but surgical procedure complexity increases due to difficult assembly and extension
Solution Approach 1:
The rod is inserted through the coupling device body before final locking occurs. This preliminary insertion allows the components to be positioned and aligned prior to engagement, simplifying the assembly process. The rod passes through the body in an unlocked state, allowing for easy adjustment and extension if needed, before being secured with set screws or locking mechanisms.
Solution Approach 2:
The coupling device incorporates movable components such as set screws that can be adjusted after initial assembly. This dynamic locking mechanism allows the rod to be securely fixed once positioned, but also permits easy adjustment or removal if extension or modification is needed during surgery, reducing overall procedural complexity.
3Reliability
If conventional coupling systems are used, then bone stabilization is achieved, but inventory cost increases due to pre-assembled rod-receiving devices
Solution Approach 1:
The system separates the coupling device body from the rod, allowing each component to be manufactured and sterilized independently. This segmentation enables more efficient inventory management where rods can be produced in standard lengths and the coupling devices can be stocked separately, reducing the need to pre-assemble and store multiple complete coupling systems with different rod configurations.
4Reliability
If conventional coupling systems are used, then bone stabilization is achieved, but surgical time increases due to multiple locking components assembly
Solution Approach 1:
The rod is inserted through the coupling device body before final locking occurs. This preliminary insertion allows the components to be positioned and aligned prior to engagement, simplifying the assembly process. The rod passes through the body in an unlocked state, allowing for easy adjustment and extension if needed, before being secured with set screws or locking mechanisms.
Data Source
AI summary
A method of assembling a surgical construct includes installing a fastener within a bone of a patient. A connector rod is positioned on the fastener and an interference or press fit is created between the fastener and the rod, with very little effort required on the surgeon's part. No additional steps are necessary or desirable; the surgeon can simply position the rod over the fastener, and very quickly and accurately couple the two one to another. A securing device can be used to couple the fastener and the rod, and a different device can be used to uncouple the fastener from the rod. The securing device engages the fastener and the rod, and pushes the rod over the fastener as the surgeon activates the gripping mechanism.