Flexible Surgical Neck Assembly for Precise End Effector Articulation
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Solution Overview
Problem
Current surgical instruments face challenges in articulating end effectors within minimally invasive procedures due to complex assembly requirements and difficulties in achieving sufficient flexibility while maintaining rigidity and control.
Innovation Solution
A surgical device with a flexible neck assembly featuring a monolithic outer shell and separate dividers that allow for axial translation of articulation members, enabling the end effector to bend and articulate while maintaining structural integrity and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate parts are used to create the flexible portion, then assembly flexibility is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate articulation components into a single integrated flexible portion that includes an outer shell, inner shaft, and articulation mechanism as one unified structure. This merging reduces the number of separate parts that need to be assembled while maintaining the articulation flexibility needed for the end effector to articulate relative to the shaft.
2Adaptability or versatility
If a flexible portion is made more flexible, then articulation capability is improved, but structural rigidity and control deteriorate
Solution Approach 1:
The patent implements local quality by creating a flexible portion with non-uniform structural properties - the outer shell and inner shaft have different thicknesses and material properties at different locations. This allows certain regions to be more flexible for articulation while other regions maintain sufficient rigidity for control and structural support.
Solution Approach 2:
The flexible portion uses composite construction with an outer shell and inner shaft that can be made from different materials or have different structural characteristics. This composite structure enables the simultaneous achievement of flexibility for articulation and rigidity for control by optimizing the properties of each layer.
3Adaptability or versatility
If multiple separate parts are assembled, then articulation functionality is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent merges multiple articulation components into a single integrated flexible portion that can be manufactured as one piece or pre-assembled unit. This reduces the number of assembly steps required during final device assembly, thereby improving manufacturing efficiency and reducing production time while maintaining full articulation functionality.
Data Source
AI summary
Methods of manufacturing a medical device are provided, which include injection molding a substantially cylindrical monolithic outer shell having an inner lumen and a plurality of ribs spaced longitudinally and extending partially circumferentially around the substantially cylindrical monolithic outer shell with elongate slots separating each rib. At least one flexible divider can be injection molded and advanced into the inner lumen to separate the inner lumen into first and second elongate channels and can be freely slidable relative to the substantially cylindrical monolithic outer shell. Proximal and distal ends of the substantially cylindrical monolithic outer shell can be respectively mated to a distal end of the elongate shaft and a proximal end of an end effector. First and second articulation bands can be advanced through the elongate shaft and channels and mated to opposed sides of the end effector.