Modular Slip Clutch Disks for Disposable Torque-Limiting Drivers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Reusable torque-limiting drivers in the medical industry require frequent recalibration and sterilization, and disposable systems are limited by material strength and manufacturing methods, making them unsuitable for high torque applications.
Innovation Solution
A low-cost, single-use torque-limiting slip-clutch system comprising modular disks with lobes and a separate clutch carrier, integrated with an elastic component, such as a spring stack, to precisely limit output torque, allowing for easier manufacturing and higher torque thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reusable torque-limiting drivers are used, then torque precision is maintained, but frequent recalibration and sterilization are required
Solution Approach 1:
The patent employs disposable torque-limiting attachments that are discarded after a single use, eliminating the need for recalibration and sterilization of reusable components. Each disposable attachment is pre-calibrated at the factory and maintains torque precision throughout its single use lifecycle, then is discarded rather than reprocessed.
2Ease of manufacture
If low-cost engineering materials are used in disposable systems, then manufacturing cost is reduced, but torque threshold is limited
Solution Approach 1:
The torque-limiting system is divided into separate components: a reusable driver body and disposable attachments. The disposable attachments contain the torque-limiting mechanism with friction elements that can be precisely engineered at low cost, while the reusable driver body contains the high-strength components needed for structural integrity. This segmentation allows low-cost materials to be used where appropriate while maintaining overall system strength.
Solution Approach 2:
The disposable torque-limiting attachments utilize composite construction combining different materials optimized for their specific functions - friction materials for torque control, structural materials for strength, and bonding materials for assembly. This composite approach enables the attachment to achieve higher torque thresholds than would be possible with a single low-cost material, while remaining economical to manufacture.
3Measurement precision
If integrated torque-limiting is built into drivers, then torque control is precise, but device complexity and cost increase
Solution Approach 1:
The torque-limiting function is extracted from the main driver body and placed into separate disposable attachments. This allows the driver itself to remain simple and versatile, while the specialized torque-limiting mechanism resides in the replaceable attachment that can be optimized independently for specific torque requirements.
Solution Approach 2:
By making the torque-limiting component disposable rather than integrated into the permanent driver, the system achieves precise torque control without permanently increasing the complexity of the driver. The disposable attachment contains all the torque-limiting mechanism, which can be simplified for single-use applications without affecting the driver's other functions.
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 effectively prevents over-torquing and under-torquing, enabling precise torque application in medical devices with simplified manufacturing and sterilization, and adjustable torque settings up to 16 newton-meters or more.
Implementation Method 1
an elastic component, such as a spring stack
Implementation Method 2
top clutch disk and an opposing bottom clutch disk, each configured with a plurality of lobes
Data Source
AI summary
The present disclosure relates generally to systems and methods to limit the torque of tools and devices, and specifically, to single-use or disposable, low-cost slip clutch systems and methods with modular disks that limit the output torque of manual or power-driven medical drivers.