Modular Clutch Assembly for High-Torque Medical Drivers
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Solution Overview
Problem
Current disposable torque-limiting drivers in the medical industry are limited in their ability to impart higher torques required for larger applications, as they typically range from 4 to 20 inch-ounces, and existing piecemeal drivetrain systems are cumbersome with multiple part-to-part torque transitions.
Innovation Solution
A modular clutch assembly with swappable fortified gear rings made of 440c stainless steel, featuring a latch and catch system that allows for relative rotation and disengagement at a predetermined torque limit, reducing the number of torque transitions and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If piecemeal drivetrain systems are used to gear-up torque in disposable devices, then greater torque can be achieved, but the system becomes more complex with multiple part-to-part torque transitions
Solution Approach 1:
The patent combines multiple gear functions into a single integrated clutch assembly with a unified drivetrain. The clutch assembly integrates the clutch mechanism, gear rings, and torque transmission elements into one consolidated unit, eliminating the need for multiple separate gear stages and reducing part-to-part torque transitions while maintaining the ability to deliver high torque.
2Measurement precision
If reusable drivers are used to ensure precise torque, then accurate torque application is achieved, but constant recalibration and sterilization are required
Solution Approach 1:
The patent implements a disposable clutch assembly designed for single-use in torque-critical applications. The clutch assembly is pre-calibrated during manufacturing to deliver precise torque without requiring field recalibration. After use, the entire assembly is discarded, eliminating sterilization requirements and ensuring consistent torque precision without maintenance overhead.
3Device complexity
If traditional disposable drivers are used for low torque applications, then they are simple and inexpensive, but they cannot impart higher torques required for larger applications
Solution Approach 1:
The patent employs a dynamic clutch mechanism with spring-loaded engagement elements that allow the disposable driver to adapt to varying torque demands. The clutch assembly features movable components including springs and latches that engage and disengage based on applied load, enabling the device to deliver higher torques when needed while maintaining simplicity for low-torque operations.
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 solution enables a disposable torque-limiting driver to provide a consistent torque of at least 12 Newton-meters over multiple actuations, addressing the limitations of existing disposable drivers by reducing part transitions and improving torque consistency and durability.
Implementation Method 1
a coil spring between the upper cylindrical shank and the nut, wherein the spring is configured to apply a force across the upper cylindrical shank and the lower cylindrical shank and force provided by the spring securely maintains the drive connection of the shaft engaged within the drive socket
Implementation Method 2
the gear ring of the upper cylindrical shank and the gear ring of the lower cylindrical shank engage for relative rotation, and wherein the gear rings disengage when a predetermined torque limit is exceeded
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A clutch within a torque-limiting device which may include a shaft extending axially through a clutch assembly and a spring to connect to a nut. The clutch having swappable gear rings. The upper and lower shanks may be under a force from the spring and further configured to selectively engage within a predetermined torque limit and disengage at above the predetermined torque limit. Accordingly, the shaft may receive torque up to the predetermined limit as provided by a user operating a handle of the torque-limiting device. The torque-limiting device may be disposable, reusable, economical, and have high torque capabilities.