Forceps Guide Plug for Over-Travel Protection and Compact Packaging
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Solution Overview
Problem
Conventional medical devices, such as forceps, face challenges in reducing packaging space, simplifying design and manufacturing, enhancing user experience, increasing stability, and preventing damage during use.
Innovation Solution
The development of a medical device with a handpiece that includes an actuation system allowing for the control of end effectors to be rotatable, openable, closeable, extendable, and capable of supplying electromagnetic energy, featuring a drive shaft motion transfer assembly with a force-limiting spring and clip mechanism to prevent damage and improve user interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional forceps design is used, then manufacturing and packaging are straightforward, but packaging space is excessive and design complexity cannot be reduced
Solution Approach 1:
The guide plug is inserted into the hollow interior of the outer shaft, utilizing the empty space within the existing structure. This nesting approach allows the guide plug to be stored within the forceps assembly without increasing external dimensions, thereby reducing packaging space while maintaining design simplicity
Solution Approach 2:
The guide plug serves multiple functions: it guides the inner shaft during insertion, prevents over-travel of the blade, and can be removed for sterilization or replacement. This multi-functionality reduces the need for separate components, simplifying the overall design while achieving space efficiency
2Reliability
If no over-travel protection is provided, then the design is simpler, but damage to the forceps can occur during use
Solution Approach 1:
The guide plug is pre-positioned within the outer shaft at a location that corresponds to the maximum safe travel distance of the inner shaft. Before over-travel can occur, the guide plug physically blocks further movement, preventing damage to the forceps mechanism. This preliminary positioning of the protective element simplifies the actuation system by eliminating the need for complex sensors or control mechanisms
Solution Approach 2:
The guide plug acts as an intermediary mechanical element between the inner shaft and the outer environment. It mediates the interaction by providing a physical stop that prevents direct contact between the over-traveling inner shaft and potential damage points, thereby protecting the forceps while maintaining a simple actuation system
3Ease of operation
If precise control of end effectors is implemented, then user experience is improved, but stability and protection mechanisms become more complex
Solution Approach 1:
The guide plug provides self-service protection by automatically engaging when the inner shaft reaches its maximum travel position. No additional control systems, sensors, or feedback mechanisms are required - the mechanical geometry of the guide plug and outer shaft inherently provides the protection and control, maintaining simplicity while improving ease of operation
Data Source
AI summary
A surgical tool can include an outer tube, an end effector, an inner tube, and a distal plug. The outer tube can extend along a longitudinal axis and the outer tube can include a pair of outer arms. The end effector can be connected to the outer arms. The inner tube can be located within the outer tube and can extend along the longitudinal axis. The inner tube can be connected to the end effector and the inner tube can be translatable along the outer tube to operate the end effector. The distal plug can be securable to the outer tube between the outer arms proximal of the end effector. The distal plug can include a wire routing bore extending therethrough.