Surgical Clip Applier Modular Assembly via Bell Crank
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Solution Overview
Problem
The assembly of surgical clip appliers of varying sizes is complex and error-prone due to different component configurations, leading to inefficiencies in production and increased risk of mistakes during assembly procedures.
Innovation Solution
A unified surgical clip applier design featuring a housing, pivotable handles, a channel assembly with a clip carrier and wedge plate, a pusher bar, and a motion multiplier system, allowing for the same assembly method across different sizes, including a bell crank gear and accelerator rack mechanism, to facilitate the sequential deployment of clips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different sized surgical clip appliers include different components, then each size can be optimized for its specific function, but the assembly procedure becomes complex and error-prone
Solution Approach 1:
The patent applies universality by designing a family of surgical clip appliers where all sizes share the same fundamental components and assembly procedure. The core mechanism includes a handle assembly, jaw assembly, clip carrier, wedge plate, and pusher bar that remain consistent across different sizes, allowing technicians to use a single standardized assembly process for all variants while still achieving size-specific optimization through dimensional scaling.
2Manufacturing precision
If technicians are taught different assembly routines for various sized instruments, then each size can be assembled correctly, but the risk of mistakes increases
Solution Approach 1:
The patent applies homogeneity by ensuring that all surgical clip appliers in the family share identical component names, assembly sequences, and operational mechanisms. This uniformity across different sizes reduces cognitive load on technicians and eliminates confusion between varying assembly procedures, thereby maintaining high assembly accuracy while minimizing error rates through standardized practices.
3Manufacturing precision
If multiple assembly procedures are required for different sizes, then each instrument can be properly assembled, but production efficiency decreases
Solution Approach 1:
The patent resolves this contradiction by implementing a universal assembly procedure that works for all sizes of surgical clip appliers. The standardized process involves assembling the same core components (handle assembly, jaw assembly, clip carrier, wedge plate, pusher bar) in the same sequence regardless of instrument size, thereby maintaining assembly correctness while significantly improving production efficiency through reduced training requirements and minimized procedural variations.
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 enables efficient assembly of various sized surgical clip appliers using the same method, reducing errors and improving production efficiency by maintaining the same operational mechanism across different sizes, ensuring consistent performance and ease of use.
Implementation Method 1
a motion multiplier system including a bell crank gear and accelerator rack, allowing for the same assembly sequence to be used across different sizes
Implementation Method 2
a pivot arm having a first end connected to the drive channel and a second end connected to the wedge plate and the pusher bar
Data Source
AI summary
Surgical clip appliers are provided including a clip carrier disposed within a channel assembly and defining a channel and a plurality of windows therein; a plurality of clips slidably disposed within the channel of the clip carrier; a wedge plate reciprocally disposed within the channel assembly, the wedge plate including a plurality of apertures formed along a length thereof; and a clip follower slidably disposed within the channel of the clip carrier and disposed proximally of the plurality of clips, the clip follower being configured and adapted for selective engagement with the windows of the clip carrier and the apertures of the wedge plate. The clip follower is configured and adapted to urge the plurality of clips, in a distal direction relative to the clip carrier, upon reciprocal movement of the wedge plate. The clip applier may be adapted to different size clips by the method of replacing modular components.