Hybrid Phacoemulsification Needle Polymer Overmold
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Solution Overview
Problem
Traditional phacoemulsification cutting needles made of titanium or stainless steel can damage eye structures and have sharp edges that are not necessary for cataract removal, posing risks during surgery.
Innovation Solution
A phacoemulsification needle with a hollow shaft and a polymer over mold covering the distal end, providing a smooth, rounded edge that reduces damage to delicate eye structures and withstands ultrasonic vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional metal cutting needle is used, then the needle can effectively emulsify and remove cataracts, but it may damage delicate eye structures due to sharp edges
Solution Approach 1:
The cutting needle combines a metal shaft (for structural integrity and ultrasonic vibration transmission) with an overmolded distal end made of softer material (for safety and reduced tissue damage). This composite structure allows the needle to maintain cutting effectiveness while protecting delicate eye structures from sharp edges.
Solution Approach 2:
The needle shaft maintains metal properties for rigidity and vibration transmission, while the distal end is locally modified with an overmold to provide a smooth, rounded edge. This local quality change ensures the cutting function is preserved in the shaft while the distal end becomes safer for ocular tissue contact.
2Object-affected harmful factors
If the distal end is made smoother to reduce damage, then eye structure safety improves, but the needle may lose rigidity needed for ultrasonic vibration
Solution Approach 1:
The overmolded distal end is constructed from materials that balance softness for tissue safety with sufficient rigidity to transmit ultrasonic vibrations effectively. This composite approach resolves the contradiction by providing both protective smoothness and functional stiffness.
Solution Approach 2:
The overmold acts as a flexible yet structurally sound shell covering the metal shaft's sharp edges. This shell provides the smooth surface needed for safety while the underlying metal shaft maintains the rigidity required for ultrasonic operation.
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
The polymer over mold protects eye structures from damage and ensures the needle can effectively emulsify and remove cataracts without causing unnecessary harm, while maintaining the necessary rigidity for surgical procedures.
Implementation Method 1
The crystals supply the required ultrasonic vibration needed to drive both the horn and the attached cutting needle during phacoemulsification
Implementation Method 2
The cutting needle is ultrasonically vibrated along its longitudinal axis within the irrigating sleeve by the crystal-driven ultrasonic horn, thereby emulsifying the selected tissue in situ
Implementation Method 3
The vibrating cutting needle liquefies or emulsifies the lens so that the lens may be aspirated out of the eye
Data Source
AI summary
A phacoemulsification needle comprises a hollow shaft with an interior surface, an exterior surface, and a distal end terminating in a distal edge. The shaft has a central bore extending there through. The central bore is defined by the interior surface of the hollow shaft. A first over mold is located on the exterior surface and distal edge of the hollow shaft. The first over mold covers at least a portion of a periphery of the exterior surface of the hollow shaft, the distal edge, and terminates at the central bore.