End-Formed Surgical Shaft Assembly for Sensor-Protected Navigation
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Solution Overview
Problem
Current surgical instruments lack efficient manufacturing methods that integrate sensors for use with image-guided surgery (IGS) systems, particularly for suction and cutting instruments used in ENT procedures, which require precise navigation within anatomical passageways.
Innovation Solution
The development of surgical instruments with end-formed shaft assemblies that incorporate position sensors, allowing for precise localization within IGS systems, and a manufacturing process that reduces component attachments to enhance robustness and minimize damage to sensors during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional manufacturing methods with multiple component attachments are used, then assembly flexibility is improved, but sensor damage risk increases
Solution Approach 1:
The patent merges multiple separate components (outer tube, inner tube, sensor, sealing elements) into a single integrated shaft assembly formed by end forming. This consolidation eliminates multiple attachment points where sensors could be damaged, while the integrated design maintains all necessary functional capabilities including suction, sensing, and sealing operations.
Solution Approach 2:
The patent employs a nested structure where the inner tube with sensor is positioned within the outer tube, and both are formed into a unified assembly. The inner tube containing the sensor is nested within the outer tube's lumen, creating a protected configuration that reduces sensor exposure to damage during assembly and operation while maintaining functional independence of each component.
2Productivity
If end forming process is used, then manufacturing efficiency is improved, but shape complexity is limited
Solution Approach 1:
The patent segments the shaft assembly into distinct functional zones (outer tube region, inner tube region, distal end region) that are formed sequentially through the end forming process. Each zone can have different geometric characteristics suited to its function, allowing complex overall shapes to be achieved by combining multiple simpler forming operations rather than requiring a single complex die.
Solution Approach 2:
The patent performs preliminary forming operations to create basic tube structures and geometries before final end forming. Pre-forming the outer and inner tubes with appropriate diameters and lengths allows the subsequent end forming process to focus on creating the final precise geometries and features, thereby overcoming limitations of single-step end forming while maintaining high manufacturing efficiency.
Data Source
AI summary
A method is used to manufacture a surgical instrument including a first tube, and a second tube. The first tube extends from a proximal first end portion to a distal first end portion. The second tube extends from a proximal second end portion to a distal second end portion. The second tube is positioned coaxially within the first tube with the distal second end portion positioned adjacent to the distal first end portion. The second tube defines a lumen. The sensor is secured proximal to the distal second end portion of the second tube. A die is engaged against a distal first end portion of the first tube while first tube rotates about its own longitudinal axis; and the die is simultaneously moved relative to the distal first end portion of the first tube along a predetermined path to form a predetermined shape.