Bidirectional Torque-Limiting Driver with Flex Ramps

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Solution Overview

Problem

Reusable torque-limiting drivers in the medical industry require frequent recalibration to maintain precise torque application, which is cumbersome, while disposable drivers provide reliability but are single-use and not cost-effective for repeated applications.

Innovation Solution

A bidirectional torque-limiting driver with movable torque limiting flex ramps (TLFR) that disengages at a predefined torque limit, allowing for a predetermined number of uses without the need for recalibration, featuring a hollow body with internal flex ramps and a mechanism that biases the device to a predetermined torque per ramp movement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If reusable torque-limiting drivers are used, then cost-effectiveness for repeated applications is improved, but maintenance complexity increases due to frequent recalibration requirements

Engineering Contradiction:

Improvecost-effectiveness for repeated applicationsVSAvoidmaintenance complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent employs disposable torque-limiting drivers that are discarded after a predetermined number of uses or when torque limit is reached. Each driver is pre-calibrated at factory with specific torque limits and cannot be recalibrated, eliminating maintenance complexity while providing cost-effective repeated applications through bulk deployment of multiple single-use units

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the torque limiting parameter from adjustable/reconfigurable to fixed/pre-determined. The torque limit is set during manufacturing based on the specific implant requirements, and the driver is designed to operate only within this fixed parameter range, simplifying maintenance by eliminating recalibration needs

Inventive Principle:

Principle #35Parameter changes

2Reliability

If disposable torque-limiting drivers are used, then reliability of torque application is improved, but cost-effectiveness deteriorates due to single-use limitation

Engineering Contradiction:

Improvereliability of torque applicationVSAvoidcost-effectiveness

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent makes disposable drivers cost-effective by designing them to be used multiple times (up to a predetermined number of cycles or until torque limit is reached) rather than strictly single-use. The drivers maintain factory calibration throughout their service life, providing reliable torque application while reducing per-use cost through extended functionality

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If reusable drivers are used, then cost-effectiveness is improved, but time consumption increases due to routine recalibration tasks

Engineering Contradiction:

Improvecost-effectivenessVSAvoidtime consumption for recalibration

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent eliminates recalibration time by using disposable drivers that are pre-calibrated and designed for limited use. Each driver maintains its factory calibration throughout its service life without requiring intervention, eliminating the time-consuming recalibration tasks associated with reusable drivers while remaining cost-effective through extended usable cycles

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Measurement precision

If torque limiting mechanism with flex ramps is used, then torque precision is improved, but device complexity increases due to additional mechanical components

Engineering Contradiction:

Improvetorque precisionVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses flexible ramps (thin film structures) as the torque limiting mechanism. These flex ramps are integrated into the driver body and deform elastically under torque load to engage or disengage the torque limiting function. The flexible film design achieves precise torque control through material selection and geometric design while minimizing added complexity compared to rigid mechanical components

Inventive Principle:

Principle #30Flexible shells and thin films

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

The solution ensures precise and reliable torque application in both clockwise and counterclockwise directions, reducing the need for recalibration and extending the driver's usability beyond single applications, while maintaining accuracy and reliability.

Implementation Method 1

movable torque limiting flex ramps (TLFR) are formed on a wall bisecting said handle... TLFRs can flex in response to the passing of the force head(s) thereover... said ramp moving downward and allowing passage

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9668797B2Bidirectional ramped disposable torque limiting device

Publication Date: 2017.06.06 ECA MEDICAL INSTR

AI summary

A bidirectional torque limiting driver with a handle, internal wall, movable head and a tool mounted thereon, with flexible torque limiting flex ramp(s) formed on said internal wall, whereby said ramps move under sufficient force to impart a predetermined torque to a tip is disclosed.