Modular Driver Tip with Containment Shield for Torque Limiting
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Solution Overview
Problem
Existing torque-limiting drivers in medical procedures face issues with driver tip failures, leading to inconsistent torque application, increased risk of infections, and complications such as driver tip implantation in the body, due to manufacturing inconsistencies and the need for frequent manual retrieval and replacement.
Innovation Solution
A surgical tool system featuring modular driver tips that deform at a threshold torque value, with a containment shield to retain the deformed tip and facilitate easy removal, allowing for sequential replacement and reducing the risk of complications by ensuring consistent torque application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If driver tips are made breakable to limit torque, then torque consistency is improved, but reliability deteriorates due to tip failures and implantation risks
Solution Approach 1:
The driver tip is designed as a disposable component that fractures after applying the desired torque. The proximal portion is made of a material that breaks at a predetermined torque level, while the distal portion engages with the driven member. After use, the entire tip assembly is discarded to eliminate implantation risks and ensure consistent torque application without reuse complications.
Solution Approach 2:
The driver tip is divided into distinct segments: a proximal portion that fractures first to limit torque, and a distal portion that remains engaged with the driven member. This segmentation allows the proximal portion to act as a torque-limiting element while the distal portion maintains the mechanical engagement, resolving the contradiction between torque consistency and reliability.
2Reliability
If driver tips are manually retrieved and replaced, then torque application can continue, but productivity deteriorates due to frequent manual handling and increased infection risk
Solution Approach 1:
The driver tip is designed as a single-use disposable component. After applying torque and fracturing, the entire tip assembly is discarded without manual retrieval. This eliminates the time-consuming manual retrieval and replacement process, reducing surgical time and infection risk while maintaining continuous torque application capability through immediate replacement of the fractured tip.
Solution Approach 2:
The fractured proximal portion of the driver tip is extracted from the surgical site through the containment shield, separating the useless fractured portion from the intact distal portion that remains engaged with the driven member. This extraction eliminates the need for manual retrieval operations and maintains surgical productivity.
3Ease of manufacture
If driver tips are reused after cleaning, then cost effectiveness improves, but reliability deteriorates due to manufacturing inconsistencies and contamination risk
Solution Approach 1:
The driver tip is designed as a disposable single-use component rather than a reusable one. This eliminates cleaning and reprocessing steps that introduce contamination risks and manufacturing inconsistencies. The low cost of disposable tips makes this economically viable while ensuring consistent torque limitation performance without the variability introduced by reuse.
4Manufacturing precision
If driver tips fracture to limit torque, then torque consistency is improved, but object-generated harmful factors worsen due to rough fracture surfaces causing tissue damage
Solution Approach 1:
The driver tip is designed to fracture in a controlled manner, with the proximal portion breaking at a predetermined torque level. The disposable nature allows the fractured proximal portion to be discarded without concern for tissue damage, as it is removed through the containment shield. This resolves the contradiction by making the harmful fracture surfaces irrelevant through immediate disposal.
Solution Approach 2:
The containment shield acts as an intermediary component that captures and contains the fractured proximal portion of the driver tip. This intermediary structure prevents the rough fracture surfaces from contacting and damaging surrounding tissue while allowing the torque-limiting function to be achieved through controlled fracturing.
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 system ensures reliable and consistent torque application, reduces the risk of infections by minimizing manual handling and reuse of driver tips, and improves the safety of surgical sites by preventing rough surfaces from causing tissue damage.
Implementation Method 1
The tip can be configured to deform at a threshold torque value applied by the driver. In some embodiments the deformation of the tip can result in the tip breaking into two or more pieces.
Implementation Method 2
The containment shield can receive at least a portion of the modular driver tip after tip deformation occurs.
Implementation Method 3
The distal end that is configured to apply torque from the driver to a driven member.
Data Source
AI summary
Devices, systems, and methods are provided for applying a controlled amount of torque during a surgical procedure. In one exemplary embodiment, after the amount of torque applied reaches a threshold amount, a modular driver tip can be deformed, for instance by breaking into pieces. A containment shield disposed around at least a portion of the tip is configured to receive at least a portion of the tip after it is deformed. In one aspect, multiple modular driver tips can be disposed in a cartridge, with a distal-most tip being held by a driver tip holder that has a holding force that is greater than a threshold torque value of the tip. Exemplary methods for operating surgical drivers and systems that include tips that deform at a threshold torque value, and a multitude of embodiments of tools and systems, are also provided.