Disposable Multi-Axis Joint Structure for Surgical Instrument Flexion
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Solution Overview
Problem
Existing multi-axis joint structures for medical instruments are expensive, complex, and challenging to assemble, with metal components requiring costly post-operative processing, limiting flexibility and access to surgical sites.
Innovation Solution
A multi-axis joint structure using low-cost molded plastic components with a coupling member and engagement protrusions/recesses, allowing for a range of motion and easy assembly, suitable for single-use disposable instruments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal components are used in multi-axis joint structures, then strength and reliability are improved, but cost and manufacturing complexity increase
Solution Approach 1:
The patent applies the disposable principle by designing the multi-axis joint structure as a single-use component that is discarded after one procedure. This eliminates the need for expensive metal components and complex post-operative processing, while maintaining sufficient strength for the intended application duration. The joint structure is engineered to withstand surgical loads for a single use without requiring reuse.
Solution Approach 2:
The patent changes the material parameter from metal to molded plastic, fundamentally altering the cost, manufacturing complexity, and processing requirements. This material substitution maintains adequate strength for single-use applications while dramatically reducing manufacturing complexity and eliminating expensive post-operative processing steps.
2Reliability
If metal components are used in multi-axis joint structures, then reliability is improved, but post-operative processing cost and complexity increase
Solution Approach 1:
By designing the joint structure as a disposable single-use component, the patent eliminates the need for complex post-operative processing such as cleaning, sterilization, and refurbishment that would be required for reusable metal components. The molded plastic construction is inherently suitable for sterile single-use applications without requiring additional processing steps.
3Stability of the object's composition
If rigid shafts are used in medical instruments, then structural stability is improved, but flexibility and access to surgical sites deteriorate
Solution Approach 1:
The patent applies segmentation by dividing the shaft into multiple articulated segments connected by the multi-axis joint structure. This allows each segment to maintain structural stability while the collective arrangement provides flexibility and adaptability to reach various surgical sites. The joint structure enables relative motion between segments while maintaining overall structural integrity.
Solution Approach 2:
The patent transforms the rigid static shaft into a dynamic articulated structure with multiple degrees of freedom. The multi-axis joint structure enables the shaft to adapt its configuration dynamically during surgical procedures, providing both structural stability when needed and flexibility for accessing difficult surgical sites.
4Adaptability or versatility
If complex multi-axis joint structures are used, then range of motion is improved, but assembly difficulty and cost increase
Solution Approach 1:
The patent merges multiple joint axes and functional elements into a single integrated molded plastic component. This consolidation provides the full range of motion for multi-axis articulation while eliminating the need for separate metal components and complex assembly procedures. The integrated design is manufactured as a single piece through molding, dramatically simplifying assembly.
Data Source
AI summary
A medical instrument is provided for use with surgical system. The medical instrument includes an instrument shaft, a proximal disk coupled to a distal end of the instrument shaft, and a distal disk coupled to an end effector. At least one joint disk is positioned between and in axial alignment with the proximal disk and the distal disk. A distal face of the joint disk includes an engagement protrusion, while a proximal face of the joint disk includes an engagement recess that is orthogonal to the engagement recess. The medical instrument also includes a coupling member positioned within the central passage extending between the proximal disk and the distal disk the coupling member is fixedly coupled to the proximal disk and the distal disk but has an absence of coupling with the joint disk.