The devices and methods disclosed pertain to patient stabilization, and in particular head and neck stabilization using stabilization devices known as head stabilization devices, which are also referred to as head fixation devices (hereinafter referred to as “HFDs” or “HFD” in singular). HFDs are sometimes used during a variety of surgical and other medical procedures, for example during head or neck surgery or testing, where it would be desirable to securely hold a patient's head in a certain position. Also, various methods have been used to manufacture HFDs and/or components of HFDs. While a variety of stabilization devices and methods of making stabilization devices have been made and used, it is believed that no one prior to the inventor(s) has made or used an invention as described herein.
While the specification concludes with claims which particularly point out and distinctly claim the invention, it is believed the present invention will be better understood from the following description of certain examples taken in conjunction with the accompanying drawings, in which like reference numerals identify the same elements.
The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.
The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.
Preforming (100) comprises determining a desired fiber orientation (102). When determining the desired fiber orientation (102), the end use of the component being made is considered to understand how the component is subjected to various forces in use. Based on this assessment and understanding, the orientation or arrangement of the fibers can be determined or planned. By way of example only, a component may provide support for an object, or be subject to forces from the object. Thus the object supplies a force or load on the component and this force or load has both a direction and magnitude. The force or load in this respect can also be described as a flux of force, with flux describing the magnitude and direction of the force imparted on the component, or this can be described and/or understood as a force vector where the force vector describes the magnitude and direction of the force.
Factors including, but not necessarily limited to, (1) the geometry of the object, (2) the geometry of the component, (3) the spatial relationship between the object and the component, and (4) how the component and object interact with each other will influence the magnitude and direction of force that is ultimately applied by the object on the component. In some cases, other factors can also influence fiber orientation decisions, such as the thermal expansion and/or stiffness of the materials used in making the component. In view of the teachings herein, various other ways to determine the how forces will impact or influence a given component in use will be apparent to those of ordinary skill in the art.
By way of example, with an understanding and appreciation for the flux of force an object applies on a component in use, the orientation of the fiber in that component can be planned such that the component will provide maximum stiffness and/or strength in a direction parallel to the flux of force that the object applies on the component. More specifically, to achieve these stiffness and/or strength properties in the component, the fibers during preforming (100) are oriented in a direction parallel to the direction of force being applied to the component in use by the object. By orienting the fibers in this manner, a component can be designed and fabricated with efficient strength and/or stiffness properties, meaning that the component provides more strength and/or stiffness with a lower mass of material to provide the necessary or desired strength and/or stiffness in use. This can also mean that the component is designed for the use without the need for costly overengineering the component, which can also have undesirable affects like heavier and/or larger components that make imaging more difficult, etc.
Preforming (100) further comprises determining the desired fiber type (104). By way of example only, and not limitation, some exemplary types of fiber that can be used comprise carbon fiber, glass fiber, aramid fiber, among others. When fabricating a given component one type of fiber can be used for that component, or in other instances more than one type of fiber may be used for that component. By way of example only, fiber type may be selected or determined based at least in part upon the magnitude of the forces expected on a given component in use. For example, in the context of an HFD, one component of the HFD may be subject to greater forces in use than another component of the HFD. Accordingly, in some examples, the component subject to greater forces may use fibers for reinforcement that have stronger and/or stiffer properties to provide for greater strength or stiffness in the component. It should also be understood in this regard that fiber type may refer to the kind of fiber as well as to the size of fiber or length of fiber. In view of the teachings herein, other various fiber types beyond those specifically mentioned that can be used with HFD components made using process (10) will be apparent to those of ordinary skill in the art.
Now that determining the desired fiber orientation (102) and determining the desired fiber type (104) have been explained, other acts in preforming (100), including how the fibers are handled to provide for the desired orientation, will be described. Referring to
By controlling the fiber placement in terms of patterns, shapes, and layers, a given finished component can be configured with various fiber types and/or with various fiber orientations. Therefore, while a given component may have a uniform fiber type and/or fiber orientation throughout, this is not required and in other instances a given component can have non-uniform fiber-types and/or fiber orientations throughout.
As mentioned above, where different types of fibers are used within the same component, this may be achieved by using different fiber types for different fiber layers (120). In some instances, fiber being placed can be done such that different fiber types can be used within the same fiber layer (120). This can happen by splicing fiber types together or placing different fibers sequentially within the same fiber layer (120). In view of the teaching herein, various ways to incorporate multiple fiber types into fiber layers (120) and ultimately formed components will be apparent to those of ordinary skill in the art.
As alluded to above, each fiber layer (120) represents a part, section, or slice of the final formed component. Accordingly, with an adequate number of fiber layers (120) for a given component fabricated, preforming (100) further comprises combining fiber layers (108). For instance, a given component may require multiple fiber layers (120) stacked together—and later molded as will be described—to form the desired component. Each fiber layer (120) may be placed and combined considering the orientation of the fiber (122) so that the ultimate formed component is made with the desired fiber orientation and thus strength and/or stiffness properties as discussed above.
With some components, but not required with all components, preforming (100) comprises draping fiber layers over a core (110) as depicted in
Core (128) can take a variety of forms. In some examples, core (128) comprises a foam core. Some such foam cores provide for occupying large volumes with little added weight. Other foam cores may be denser in nature however. In some examples, core (128) comprises a honeycomb core. A honeycomb core can provide for a rigid core structure without adding excessive mass to the component. In some examples, core (128) comprises a wool core, while in other examples core (128) comprises a solid core. In view of the teachings herein, various types of materials suitable for use as core (128) will be apparent to those of ordinary skill in the art.
Referring again to preforming (100) and
In some examples preforming (100) can include removal of substrate (124) or excess substrate (124) from fiber layer (120) prior to preform (126) being molded in molding subprocess (200). However, in other examples, such removal of substrate (124) during preforming (100) prior to molding (200) is not required. Where substrate (124) is removed, this removal may be done by cutting, dissolving, burning, or any other suitable way that keeps fiber (122) intact.
Referring now to
Referring now to
In the present example, one or more components of frame (405), e.g., first arm (406) and/or second arm (408), comprise a fiber-reinforced composite comprising layers of fiber combined with a molding material. Furthermore, such one or more components are configured with the fiber of the fiber-reinforced composite being oriented parallel to a flux of force experienced by the one or more components in use. For example,
The following examples relate to various non-exhaustive ways in which the teachings herein may be combined or applied. It should be understood that the following examples are not intended to restrict the coverage of any claims that may be presented at any time in this application or in subsequent filings of this application. No disclaimer is intended. The following examples are being provided for nothing more than merely illustrative purposes. It is contemplated that the various teachings herein may be arranged and applied in numerous other ways. It is also contemplated that some variations may omit certain features referred to in the below examples. Therefore, none of the aspects or features referred to below should be deemed critical unless otherwise explicitly indicated as such at a later date by the inventors or by a successor in interest to the inventors. If any claims are presented in this application or in subsequent filings related to this application that include additional features beyond those referred to below, those additional features shall not be presumed to have been added for any reason relating to patentability.
A method of manufacturing a fiber-reinforced component of a head fixation device used in stabilizing a head of a patient during a medical procedure comprises (a) preforming and (b) molding. Preforming comprises (i) placing fiber onto a substrate to form a fiber layer, and (ii) combining multiple fiber layers to form a preform. Molding comprises combining the preform with a molding material to form a molded preform.
The method of manufacturing of Example 1, wherein the act of preforming further comprises determining a desired orientation for the fiber when placing the fiber onto the substrate.
The method of manufacturing of any one or more of Examples 1 through 2, wherein the desired orientation for the fiber is determined by accounting for the stress that is expected to be experienced by the component in use.
The method of manufacturing of any one or more of Examples 1 through 3, wherein the desired orientation for the fiber aligns the fiber parallel to the flux of force that is expected to be experienced by the fiber-reinforced component in use.
The method of manufacturing of any one or more of Examples 1 through 4, wherein the act of preforming further comprises determining a fiber type to be used when placing the fiber onto the substrate to form the fiber layer.
The method of manufacturing of any one or more of Examples 1 through 5, wherein the act of preforming further comprises combining a first fiber layer having a first fiber type with a second fiber layer having a second fiber type, wherein the first and second fiber types are different.
The method of manufacturing of any one or more of Examples 1 through 6, wherein the act of preforming further comprises placing fiber of multiple fiber types onto the substrate to form the fiber layer.
The method of manufacturing of any one or more of Examples 1 through 7, wherein the act of preforming further comprises draping the fiber layers over a core.
The method of manufacturing of Example 8, wherein the core comprises a select one of a foam core, a honeycomb core, a wool core, and a solid core.
The method of manufacturing of any one or more of Examples 8 through 9, wherein the core directs the fibers of the fiber layers so the fibers are placed in a border area of the resulting fiber-reinforced component.
The method of manufacturing of any one or more of Examples 1 through 10 wherein the act of preforming further comprises adding an insert to the preform.
The method of manufacturing of Example 11, wherein the insert is configured to strengthen the resulting fiber-reinforced component.
The method of manufacturing of any one or more of Examples 11 through 12, wherein the insert comprises a select one of threads, serrations, and bushings.
The method of manufacturing of any one or more of Examples 11 through 13, wherein the insert is added at an interface area where multiple fiber-reinforced components are connectable.
The method of manufacturing of any one or more of Examples 1 through 14, wherein the substrate is removed before molding.
The method of manufacturing of any one or more of Examples 1 through 15, wherein the act of molding further comprises placing the preform in a mold cavity and injecting the mold cavity with the molding material.
The method of manufacturing of any one or more of Examples 1 through 16, wherein the act of molding further comprises curing the injected molding material under thermal energy, pressure, and time.
The method of manufacturing of any one or more of Examples 1 through 17, wherein the act of finishing further comprises milling the fiber-reinforced component.
The method of manufacturing of any one or more of Examples 1 through 18, wherein the act of finishing further comprises connecting a first fiber-reinforced component with a second fiber-reinforced component to form an assembly of fiber-reinforced components.
The method of manufacturing of any one or more of Examples 1 through 19, further comprising finishing, wherein the act of finishing comprises smoothing the molded preform to form the fiber-reinforced component.
A head fixation device for use to stabilize a head of a patient in a medical procedure comprises a frame, wherein at least a portion of the frame comprises a fiber-reinforced composite comprising fiber layers combined with a molding material, wherein the fiber of the fiber layers is configured to be oriented parallel to a flux of force experienced by the fiber-reinforced component in use.
The head fixation device of Example 21, wherein the frame comprises (a) a first arm; (b) a second arm selectively and adjustably connectable with the first arm; and (c) a pair of stabilizing assemblies, wherein one of the pair of stabilizing assemblies is selectively and adjustably connectable with the first arm, and wherein the other of the pair of stabilizing assemblies is selectively and adjustably connectable with the second arm.
The head fixation device of any one or more of Example 21 through Example 22, wherein the fiber layers surround a core.
It should be understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. that are described herein. The following-described teachings, expressions, embodiments, examples, etc. should therefore not be viewed in isolation relative to each other. Various suitable ways in which the teachings herein may be combined will be readily apparent to those of ordinary skill in the art in view of the teachings herein. Such modifications and variations are intended to be included within the scope of the claims.
Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometrics, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.
This application claims priority to U.S. Provisional Patent Application Ser. No. 62/818,960, filed Mar. 15, 2019, entitled “Method of Manufacturing Head Fixation Device Components,” the disclosure of which is incorporated by reference herein.
Number | Date | Country | |
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62818960 | Mar 2019 | US |