Modular Surgical Instrument Coupling for Stable Tool Exchange
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Solution Overview
Problem
Conventional rotary cutting tools for surgical procedures have cumbersome and complex connections between the driving and cutting components, making them difficult to assemble and use effectively.
Innovation Solution
A medical instrument with a shaft and a cutting component that utilizes a simple, stable, and modular connection system, where the shaft is subtractively manufactured for economy and the cutting component is additively manufactured for intricate features, allowing for easy coupling and decoupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional standardized instrumentation connections are used, then the connection can be made with standardized components, but the assembly becomes complex and cumbersome requiring multiple individual components
Solution Approach 1:
The patent combines multiple individual components (main housing body, ball bearings, springs, pull buttons) into a single integrated connection structure. The additive manufacturing process enables these elements to be merged into one monolithic component that maintains all necessary functions while eliminating the complexity of assembling multiple separate parts.
Solution Approach 2:
The connection structure is designed to perform multiple functions within a single component: it provides mechanical coupling, rotational freedom, axial retention, and controlled release mechanisms. This multi-functional design eliminates the need for separate components for each function, reducing overall assembly complexity.
2Reliability
If conventional complex assemblies are used, then the connection can be made with standardized parts, but the instrument becomes cumbersome to assemble and use
Solution Approach 1:
The connection structure incorporates self-aligning and self-retaining features. The conical surface automatically guides the extension piece into proper alignment during insertion, while the spring-loaded pull buttons automatically engage and lock the connection without requiring precise manual positioning or additional fastening steps.
Solution Approach 2:
The additive manufacturing process pre-forms the complex three-dimensional geometry of the connection structure, including the conical alignment surface and the spring-loaded retention mechanism, as an integrated component. This preliminary formation of the complete connection architecture eliminates the need for complex assembly operations during instrument setup.
3Device complexity
If a singular cutting component is used, then the structure is simple, but it cannot accommodate different sizes or cutting edges
Solution Approach 1:
The cutting component is segmented from the shaft, allowing it to be independently manufactured and interchangeably attached. The extension piece with cutting element can be removed and replaced with different cutting components while maintaining a secure connection through the standardized interface, enabling versatility without complicating the overall structure.
Solution Approach 2:
The connection interface is designed with universal compatibility, allowing the same shaft to accommodate multiple different cutting components with varying sizes and cutting edge configurations. The standardized attachment mechanism ensures that any cutting component can be reliably mounted, providing adaptability while maintaining structural simplicity.
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 instrument provides improved stability and convenience during surgical procedures, enabling efficient cutting operations with interchangeable cutting components and a secure, easy-to-use connection mechanism.
Implementation Method 1
The pair of arms may be elastically deformable such that when the shaft is inserted into the opening of the extension piece and the radial protrusion passes the projections of the pair of arms, the pair of arms are pushed apart from a neutral position
Data Source
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AI summary
A flexible modular instrument (100) includes a shaft (110) and an extension piece (130). The shaft (110) includes an interior segment (112) having a first outer cross-sectional dimension and an end segment (120) extending from the interior segment (112) having a second outer cross-sectional dimension less than the first outer cross-sectional dimension. The interior segment (112) includes a radial protrusion (118a, 118b) adjacent to the end segment (120) such that the radial protrusion (118a, 118b) extends further from a central longitudinal axis (X) of the shaft (110) than an outer surface of the interior segment (112), wherein the first and second outer cross-sectional dimensions are measured orthogonally relative to the central longitudinal axis (X). The extension piece (130) includes an attachment portion (132) removably engageable with the end segment (120) of the shaft (110). The attachment portion (132) includes an opening (134) to receive the end segment (120), the opening (134) being defined in part by a pair of arms (136a, 136b), each arm of the pair of arms (136a, 136b) including a projection (138a, 138b) into the opening (134).