Forceps Handpiece Sleeve Coupling for Stable Motion Transfer
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Solution Overview
Problem
Existing medical device assemblies, including forceps, face challenges in manufacturing due to inadequate attachment methods, which can lead to reduced stability, increased risk of damage, and compromised user experience.
Innovation Solution
The implementation of a handpiece with a motion transfer assembly that includes a lumen, a sleeve affixed to the handpiece, and a shaft extending into the sleeve, where the sleeve is affixed using methods such as overmolding, adhesive, or welding, to enhance the attachment and stability of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional attachment methods are used for assembling handpiece components, then assembly is simpler, but stability and reliability are reduced
Solution Approach 1:
The sleeve is integrated with the handpiece housing through overmolding, merging two previously separate components into a single integrated structure. This eliminates the need for separate attachment operations while maintaining strong mechanical bonding, thereby improving reliability without significantly increasing assembly complexity
Solution Approach 2:
The handpiece utilizes composite construction with a housing made of one material and a sleeve made of another material (e.g., metal or different polymer). This allows each component to be optimized for its specific function while the overmolding process creates a strong bond between dissimilar materials, enhancing attachment stability
2Strength
If robust attachment methods like welding are used, then component stability increases, but risk of damage during assembly increases
Solution Approach 1:
The mechanical welding process is replaced with an overmolding process that uses material flow and cooling to create bonds. This substitution eliminates the high heat and force associated with welding that could damage sensitive components, while still achieving strong attachment through the molecular bonding of the overmolding material to the sleeve surface
Solution Approach 2:
The attachment process transitions from high-energy welding parameters (high temperature, high force) to low-energy overmolding parameters (controlled temperature, gradual pressure). This parameter change reduces the risk of thermal damage and mechanical stress to the components while maintaining attachment strength
3Reliability
If multiple attachment methods are used for different components, then attachment reliability improves, but manufacturing complexity increases
Solution Approach 1:
The overmolding process serves multiple functions simultaneously: it attaches the sleeve to the housing, provides structural support, enables motion transfer between components, and creates sealing surfaces. This multi-functionality consolidates what would otherwise require multiple separate manufacturing steps into a single operation, improving reliability while maintaining manufacturing simplicity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution improves the manufacturing process by simplifying design and assembly, reducing packaging space, enhancing user experience, increasing stability, and preventing damage to the forceps.
Implementation Method 1
the sleeve is affixed to the handpiece by overmolding
Implementation Method 2
the sleeve is affixed the handpiece by adhesive
Implementation Method 3
the sleeve is affixed to the shaft by a weld
Data Source
AI summary
Forceps including a handpiece configured to transfer motion from an actuator to an end effector of the forceps. The handpiece including: a lumen extending through a portion of the handpiece; a sleeve affixed to the handpiece, the sleeve extending through at least a portion of the lumen; and a shaft extending into the sleeve and affixed to the sleeve.