Composite Handle Apparatus for Surgical Instruments
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Solution Overview
Problem
Existing surgical tool handles are often rigid and tubular, making them difficult to manufacture and unsuitable for use with instruments having moving parts, while also lacking the necessary flexibility and ergonomics for efficient surgical procedures.
Innovation Solution
A composite handle apparatus formed from a foldable strip of composite material, featuring a flexible portion and grips with varying flexibility and thickness, allowing for adjustable rigidity and ease of manufacturing, and incorporating a fastening mechanism and tool adaptor for secure attachment to surgical instruments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid tubular composite handles are used, then strength and structural integrity are improved, but flexibility and ease of manufacture deteriorate
Solution Approach 1:
The handle is divided into multiple discrete components including a proximal grip section, a flexible intermediate section, and a distal grip section. Each section can be manufactured separately using different processes optimized for its specific requirements, then assembled together. This segmentation allows the rigid grip sections to be manufactured with high precision while the flexible section can be manufactured separately and attached, resolving the contradiction between structural integrity and manufacturing ease.
Solution Approach 2:
The handle employs composite material construction with different material properties in different sections. The grip sections use rigid composite materials for strength and structural integrity, while the intermediate section uses flexible composite materials for ease of manufacture and adaptability. This multi-material composite approach allows each section to be optimized independently, resolving the contradiction between requiring strength and ease of manufacture.
2Stability of the object's composition
If rigid tubular handles are used, then structural stability is improved, but adaptability to instruments with moving parts deteriorates
Solution Approach 1:
The handle is segmented into rigid grip sections for structural stability and a flexible intermediate section for adaptability. This segmentation allows the handle to maintain structural integrity at the grip points while the flexible section can accommodate the movement and articulation of surgical instruments, resolving the contradiction between structural stability and adaptability to moving parts.
Solution Approach 2:
The handle transitions from a completely rigid structure to a dynamic structure with flexible intermediate sections that can bend and adapt. This dynamic flexibility in the intermediate section allows the handle to accommodate instruments with moving parts and articulation, while the rigid grip sections maintain structural stability, resolving the contradiction between stability and adaptability.
3Ease of manufacture
If uniform thickness composite handles are used, then manufacturing simplicity is improved, but ergonomic comfort and precision deteriorate
Solution Approach 1:
The handle employs varying thickness and material properties in different sections to optimize both manufacturing and ergonomics. The grip sections have greater thickness and rigid material composition for precision and comfort, while the intermediate section has reduced thickness and flexible material for ease of assembly and adaptability. This local variation in quality allows each section to be optimized for its specific function while maintaining overall manufacturing feasibility.
Solution Approach 2:
The handle is segmented into sections with different thickness specifications, allowing each section to be manufactured with optimal dimensions for its function. The thicker grip sections provide ergonomic comfort and precision, while the thinner intermediate section facilitates assembly and provides flexibility. This segmented approach with localized thickness variations resolves the contradiction between manufacturing simplicity and ergonomic comfort.
4Weight of moving object
If holes are disposed throughout composite handles to save weight, then weight reduction is improved, but structural strength and manufacturing complexity worsen
Solution Approach 1:
The handle is segmented into sections where weight reduction is prioritized in the intermediate flexible section and strength is prioritized in the grip sections. This segmentation allows strategic placement of weight-reducing features only where structural strength is less critical, resolving the contradiction between weight reduction and maintaining structural strength.
Solution Approach 2:
The handle employs local quality variations with different thickness and material density in different sections. The grip sections maintain higher density and thickness for strength, while the intermediate section uses lower density materials and reduced thickness for weight reduction. This localized optimization resolves the contradiction between reducing handle weight and maintaining necessary structural strength.
Data Source
Figure 1
Figure 2A~2D
Figure 3A~3B
AI summary
Systems and methods for forming a handle apparatus may include shaping a strip of composite material with a flexible central portion, two grips, and two end portions. The strip may be bent onto itself such that the end portions are fastened together by a fastening device. The handle apparatus may also include a hole disposed in the flexible central portion through which a tool actuator may be passed.