Ultrasonic Clamp Pad Snap-Fit Attachment for Wear Reduction
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Solution Overview
Problem
Current ultrasonic surgical instruments face challenges in efficiently cutting and coagulating tissue due to limitations in precision control and durability of the clamp pads, which wear out quickly under heat and vibration, necessitating frequent replacements.
Innovation Solution
The design incorporates detachable clamp arms and pads with innovative attachment mechanisms, such as rotatable coupling members, split clamp arms, and resilient tabs, allowing for easy replacement and maintenance without disassembling the instrument, enhancing accessibility and reducing wear on components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clamp pads are made durable to withstand heat and vibration, then reliability improves, but device complexity increases due to specialized materials and attachment mechanisms
Solution Approach 1:
The clamp pad is designed as a separate replaceable component that can be independently replaced from the clamp arm. The attachment mechanism includes distinct elements (channel, key, snap-fit features) that allow the pad to be segmented and replaced without replacing the entire clamp assembly, thus improving reliability while managing complexity through modular design.
Solution Approach 2:
The clamp pad is designed as a consumable component that wears out under heat and vibration and can be discarded and replaced. The attachment mechanism allows for easy removal and replacement of the pad without requiring special tools or complex procedures, enabling quick recovery of the instrument's functionality while maintaining reliability through continuous availability of replacement pads.
2Productivity
If clamp pads are made replaceable to extend instrument lifespan, then productivity improves, but device complexity increases due to additional attachment and removal mechanisms
Solution Approach 1:
The clamp assembly is segmented into the clamp arm and the separate clamp pad component. This segmentation allows the pad to be replaced independently, maintaining instrument productivity without requiring replacement of the entire clamp assembly. The simplified attachment mechanism uses basic geometric features rather than complex fastening systems.
Solution Approach 2:
The clamp pad is designed as a relatively simple, low-cost component that can be replaced frequently without significant expense or complexity. The pad absorbs the wear from heat and vibration, allowing the more complex and expensive clamp arm to be preserved and reused many times, thus improving overall productivity while managing complexity through the disposable nature of the pad.
3Ease of operation
If easy replacement mechanisms are implemented, then ease of operation improves, but reliability may worsen due to potential loosening or detachment issues
Solution Approach 1:
The attachment mechanism is designed to be self-securing through snap-fit features and interference fits that automatically lock the clamp pad to the clamp arm when properly assembled. The design allows easy replacement by the operator without special tools while incorporating self-locking features that prevent accidental loosening or detachment during use, thus achieving both ease of operation and reliability.
Solution Approach 2:
The attachment mechanism includes built-in features such as resilient tabs, channels with retaining features, and geometric interlocking elements that prevent detachment before it can cause problems. These design elements provide a margin of security that accommodates normal operational stresses while maintaining easy replaceability, thus resolving the contradiction between ease of operation and attachment security.
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
This design improves the durability and maintainability of ultrasonic surgical instruments by allowing for quick and easy replacement of clamp pads and arms, reducing downtime and extending the instrument's lifespan while maintaining precision in tissue cutting and coagulation.
Implementation Method 1
These instruments include one or more piezoelectric elements that convert electrical power into ultrasonic vibrations
Implementation Method 2
an end effector having a blade element that vibrates at ultrasonic frequencies to cut and/or seal tissue
Data Source
AI summary
An apparatus for operating on tissue includes a body, a shaft assembly, and an end effector. The shaft assembly extends distally from the body and includes an acoustic waveguide. The waveguide is configured to acoustically couple with an ultrasonic transducer. The end effector includes an ultrasonic blade, a clamp arm, and a clamp pad. The blade is in acoustic communication with the waveguide. The clamp arm is configured to pivot about a first pivot point toward and away from the ultrasonic blade and includes a coupling feature. The clamp pad is selectively attachable to the blade to acoustically isolate the clamp arm from the ultrasonic blade. The coupling feature of the clamp arm is configured to provide a snap fit between the clamp pad and the clamp arm and thereby permit manipulation of the clamp pad for removal of the clamp pad from the clamp arm.