Reaming device with carbon fiber shaft and molded interface element

Abstract

A reaming device comprising a shaft with a mounting portion, the mounting portion having an outer surface; a carbon fiber layer located on the mounting portion outer surface; an injection molded interface element for mechanical coupling of an external device molded on the carbon fiber layer, the interface element having a mounting portion; wherein the carbon fiber layer extends over the outer surface of the shaft mounting portion and having an outer surface, wherein the carbon fiber layer outer surface has a non-smooth surface structure; wherein the injection molded interface element mounting portion is injection molded over the carbon fiber layer surface structure The method according to claim 12, further comprising preparing of shaft mounting portion before wrapping a carbon fiber layer for establishing a reliable connection between the shaft and the carbon fiber layer.

1 . A reaming device comprising
 a shaft with a mounting portion, the mounting portion having an outer surface;   a carbon fiber layer located on the mounting portion outer surface;   an injection molded interface element for mechanical coupling of an external device molded on the carbon fiber layer, the interface element having a mounting portion;   wherein the carbon fiber layer extends over the outer surface of the shaft mounting portion and having an outer surface,   wherein the carbon fiber layer outer surface has a non-smooth surface structure;   wherein the injection molded interface element mounting portion is injection molded over the carbon fiber layer surface structure.   
     
     
         2 . The reaming device according to  claim 1 , wherein the shaft is made of a carbon fiber reinforced material. 
     
     
         3 . The reaming device according to  claim 1 , wherein the carbon fiber layer comprises a wrapped carbon fiber with a resin impregnation. 
     
     
         4 . The reaming device according to  claim 1 , wherein the carbon fiber layer surface structure comprises a pressed tooth structure. 
     
     
         5 . The reaming device according to  claim 4 , wherein the pressed tooth structure comprises an elongated rippled structure. 
     
     
         6 . The reaming device according to  claim 1 , wherein the interface element comprises a coupling portion for coupling a power tool reamer drive as an external device. 
     
     
         7 . The reaming device according to  claim 6 , wherein the coupling portion comprises an end portion being capable of transmitting a torque. 
     
     
         8 . The reaming device according to  claim 6 , wherein the injection molded interface element comprises a rated break section between its mounting portion and its coupling portion. 
     
     
         9 . The reaming device according to  claim 1 , wherein the injection molded interface element comprises a mold material having shape stability at common sterilization temperatures. 
     
     
         10 . The reaming device according to  claim 1 , wherein the injection molded interface element comprises a deformation indicating pattern indicating a pre-breaking deformation. 
     
     
         11 . The reaming device according to  claim 1 , wherein both, the shaft and the interface element each have an elongated through bore, the both through bores aligning to each other. 
     
     
         12 . A method for manufacturing a reaming device, comprising:
 wrapping a carbon fiber layer over an outer surface of a mounting portion of a shaft; and   pressing a surface structure on an outer surface of the carbon fiber layer;   injection molding an interface element over the surface structure.   
     
     
         13 . The method according to  claim 12 , wherein wrapping comprises impregnating the carbon fiber layer with an impregnation agent being compatible with a material of the shaft. 
     
     
         14 . The method according to  claim 12 , further comprising preparing of shaft mounting portion before wrapping a carbon fiber layer for establishing a reliable connection between the shaft and the carbon fiber layer. 
     
     
         15 . The method according to  claim 12 , wherein pressing includes heat setting of the carbon fiber layer in a closed mold.