Locking Shipping Wedge for Surgical Instrument Drive Assembly
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Solution Overview
Problem
Surgical instruments with disposable or replaceable loading units often fail to properly engage due to unretained movable parts, leading to misalignment and improper function, and existing locking mechanisms are not effective in preventing manual removal of shipping wedges until attachment to a surgical instrument.
Innovation Solution
A locking shipping wedge assembly that includes a transverse member to engage the drive assembly, a lock plate with a keyhole mechanism to prevent initial separation, and flexible clips for stabilization, ensuring the drive assembly remains retracted until attached to a surgical instrument and allowing controlled release after proper engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a shipping wedge is used to retain the drive assembly in the retracted position, then the drive assembly remains stable during shipping, but the shipping wedge can be manually removed before attachment to the surgical instrument, causing misalignment
Solution Approach 1:
The locking mechanism is pre-configured in a locked state that prevents removal of the shipping wedge before attachment. The lock plate with keyhole geometry is positioned to block the transverse member, and the tab is in a first position that engages with the locking lip, creating a preliminary locked condition that maintains stability during shipping and handling.
Solution Approach 2:
The locking mechanism transitions from a static locked state to a dynamic unlocked state through the attachment process. When the loading unit is attached to the surgical instrument, the relative movement causes the tab to shift to a second position and the lock plate to move, dynamically changing the locking state to permit shipping wedge removal.
2Ease of manufacture
If the movable parts of the loading unit are not retained in position prior to attachment, then the loading unit can be easily assembled, but the components become misaligned with the surgical instrument, leading to improper function
Solution Approach 1:
The shipping wedge with transverse member is installed in advance to preliminarily secure the drive assembly in the correct position and orientation. This preliminary action ensures that the movable parts are retained in their proper positions before the loading unit is attached to the surgical instrument, preventing misalignment while allowing easy assembly of the loading unit itself.
3Stability of the object's composition
If a locking mechanism is added to prevent removal of the shipping wedge, then the shipping wedge remains securely attached during shipping, but the device complexity increases
Solution Approach 1:
The locking mechanism is designed to be self-actuating through the attachment process itself. The relative movement between the loading unit and surgical instrument during attachment automatically causes the tab to shift positions and the lock plate to move, which self-service unlocks the locking mechanism without requiring additional actuators, motors, or complex control systems.
Solution Approach 2:
The locking mechanism components are integrated with the existing loading unit structure. The tab is formed as part of the loading unit or drive assembly, the lock plate is positioned within the existing housing, and the keyhole geometry is incorporated into the transverse member or locking lip structure, merging the locking function with the existing components rather than adding separate independent systems.
Data Source
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Figure 2A
Figure 3
AI summary
A locking shipping wedge is provided and generally includes a body portion having an elongate transverse member projecting from the body portion which is engageable with a drive assembly of a loading unit. A locking mechanism is provided on the body portion of the shipping wedge which is engageable with locking structure movably mounted within the loading unit.