Modular Distal Assemblies for Medical Devices
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Solution Overview
Problem
Existing medical devices for endoscopic procedures often require complex assemblies and multiple instruments, leading to increased costs and procedural complexity due to the need for various manufacturing methods and dedicated assembly lines.
Innovation Solution
A modular tip assembly for medical devices that integrates mechanisms for illuminating, imaging, sensing, and accessing procedure sites, featuring a handle, shaft, and distal assembly with a flexible circuit board and customizable components for enhanced functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple instruments and complex assemblies are used with the endoscope to access and treat procedure sites, then the functionality and capabilities of the medical device are improved, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines multiple previously separate instruments and functions into a single integrated endoscope device. The distal assembly integrates imaging mechanisms, lighting mechanisms, working channels, and articulation capabilities into one unified structure, eliminating the need for separate instruments and reducing overall system complexity while maintaining full functionality
Solution Approach 2:
The endoscope device is designed with multi-functional capabilities where a single device performs multiple tasks: imaging (distal and lateral viewing), lighting, instrument delivery through working channels, articulation for accessing difficult angles, and sensor integration. This universal design allows one device to replace multiple specialized instruments
2Adaptability or versatility
If multiple instruments and dedicated assembly lines are used to manufacture the endoscope with additional features, then the device capabilities are improved, but the manufacturing costs and production complexity increase
Solution Approach 1:
The endoscope is designed with modular segmentation where the distal assembly, articulation section, working channels, and circuit boards are separate interchangeable components. This allows standardized mass production of individual modules followed by simple assembly, reducing the need for complex dedicated assembly lines while maintaining advanced capabilities
Solution Approach 2:
The articulation section incorporates dynamic joints that allow the distal assembly to articulate relative to the shaft, enabling access to difficult anatomical angles. This dynamic capability is achieved through mechanical joints that can be manufactured using standard techniques and assembled into the modular structure, avoiding the need for complex custom manufacturing
3Stability of the object's composition
If a rigid circuit board is used to mount the imaging and lighting mechanisms, then the structural stability and alignment are improved, but the ability to accommodate flexible positioning and articulation is reduced
Solution Approach 1:
The circuit board system is segmented into multiple sections that can flex relative to each other. The circuit board includes first, second, and third segments that can bend independently, allowing the rigid mounting surfaces to maintain alignment stability while the overall structure accommodates articulation and flexible positioning requirements
Solution Approach 2:
The circuit board incorporates flexible sections with varying rigidity to accommodate articulation. These flexible circuit board segments can bend and flex to match the articulation of the distal assembly while maintaining electrical connections and component alignment, bridging the gap between rigid mounting requirements and flexible positioning needs
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 modular tip assembly simplifies the manufacturing process, reduces costs, and enhances the capabilities of medical devices by providing customizable configurations for specific medical procedures, improving access and treatment of procedure sites.
Implementation Method 1
The lighting mechanism includes a light-emitting diode that is configured to emit blue light, and the material includes a phosphor formulation that is configured to modify the blue light to white light
Implementation Method 2
the second circuit assembly is flexibly deformable to selectively position the first circuit assembly in alignment with the end cap
Data Source
AI summary
A medical device that includes a handle, a shaft extending from the handle, and an assembly coupled to a distal end of the shaft. The assembly includes an end cap including first and second channels, an imaging mechanism coupled to the end cap and received within the first channel, and a lighting mechanism coupled to the end cap and received within the second channel. The assembly includes a first circuit assembly coupled to the end cap and a second circuit assembly coupled to the first circuit assembly. The imaging and lighting mechanisms are mounted onto the first circuit assembly. The first circuit assembly includes a rigid circuit board communicatively coupled to the imaging and lighting mechanisms. The second circuit assembly includes a flexible circuit board interposed between and communicatively coupled to the first circuit assembly and a control system of the medical device.