Modular Surgical Instrument Shaft and End Effector Coupling
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Solution Overview
Problem
Current surgical instruments lack a modular design that allows for easy interchangeability of shaft lengths and end effectors, limiting their versatility and efficiency in various surgical procedures.
Innovation Solution
The development of a surgical instrument with a modular shaft and end effector system, featuring coupling mechanisms such as resilient tabs, flexible handle assembly portions, and slide-locking mechanisms, enabling quick and secure attachment and detachment of different shafts and end effectors to a common handle assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If surgical instruments use a fixed non-modular design, then the structure is simple and reliable, but the versatility and adaptability are limited
Solution Approach 1:
The surgical instrument is divided into separate modular components including a handle assembly, shaft assembly, and end effector assembly that can be independently manufactured and then coupled together through coupling mechanisms such as bayonet-style connectors or screw-threaded interfaces
Solution Approach 2:
A universal handle assembly is designed with standardized coupling mechanisms that can accommodate multiple different shaft assemblies and end effector assemblies, allowing a single handle to perform multiple surgical functions by simply changing the attached module
2Ease of manufacture
If surgical instruments are designed as single integrated units, then manufacturing and quality control are easier, but interchangeability and procedural flexibility are reduced
Solution Approach 1:
The instrument is segmented into standardized modules that can be manufactured separately using optimized processes for each component type, then assembled through standardized coupling interfaces that ensure consistent quality and reliable connection
Solution Approach 2:
Standardized coupling parameters such as interface dimensions, tolerance ranges, and connection forces are established to ensure that separately manufactured modules can be reliably assembled and disconnected while maintaining consistent performance across different configurations
3Adaptability or versatility
If modular components are added to enable interchangeability, then versatility improves, but device complexity and assembly difficulty increase
Solution Approach 1:
Coupling mechanisms are designed with preliminary alignment features such as guide pins, tapered surfaces, or keyed interfaces that automatically orient and position modules correctly during assembly, reducing the skill and time required for proper connection
Solution Approach 2:
The coupling mechanisms incorporate dynamic elements such as spring-loaded locking features, cam-actuated clamps, or bayonet-style quarter-turn connectors that enable quick attachment and detachment through simple user actions rather than complex multi-step assembly procedures
4Adaptability or versatility
If multiple shaft lengths and end effectors are made interchangeable, then procedural flexibility improves, but time and costs for manufacturing and inventory increase
Solution Approach 1:
A universal handle assembly serves as a common platform for multiple different shaft and end effector configurations, allowing surgical teams to share a single handle across various procedures by simply changing the attached modules, thereby reducing the number of complete instruments that need to be manufactured and inventoried
Solution Approach 2:
The modular design enables individual components such as end effectors or shafts to be separately sterilized, repaired, or replaced without affecting the handle assembly, allowing selective maintenance and recovery of expensive components while reusing durable handle and shaft portions across multiple procedures
Data Source
AI summary
A surgical instrument operable to sever tissue includes a body assembly and a selectively coupleable end effector assembly. The end effector assembly may include a transmission assembly, an end effector, and a rotational knob operable to rotate the transmission assembly and the end effector. The body assembly includes a trigger and a casing having a distal aperture configured to receive a portion of the end effector assembly. First and second coupling mechanism portions cooperatively couple the end effector assembly to the body assembly for use. The coupling may mechanically and/or electrically couple the end effector assembly to the body assembly via various coupling mechanisms. For instance, a threaded slip nut may couple to threads within the body assembly. In one configuration, the end effector assembly may have locking tabs that rotate into rotational recesses in the body assembly. The locking tabs may include electrical contacts and/or optically perceivable indicators.