Modular Ultrasonic Surgical Instrument with Interchangeable End Effector
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Solution Overview
Problem
Existing endoscopic surgical instruments lack a modular design that allows for easy detachment and replacement of transmission assemblies with different end effectors, limiting their versatility and reusability.
Innovation Solution
A modular ultrasonic surgical instrument design featuring a multi-piece handle assembly that can be coupled with various transmission assemblies, enabling the reuse of the handle assembly with multiple transmission assemblies having different end effectors, such as blades of varying sizes and functions, by allowing for detachable and interchangeable components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional non-modular endoscopic surgical instrument design is used, then the instrument structure is simple and easy to manufacture, but the instrument lacks versatility and cannot easily accommodate different end effectors
Solution Approach 1:
The surgical instrument is divided into distinct modular segments: a handle assembly, a transmission assembly, and an end effector. These segments can be independently manufactured, sterilized, and reconfigured. The transmission assembly includes a waveguide that can be detached and replaced with different end effectors, enabling versatility while maintaining manageable structural complexity through standardized interfaces.
Solution Approach 2:
The handle assembly and transmission assembly are designed as universal components that can work with multiple types of end effectors. The standardized coupling mechanism allows a single handle assembly to support various surgical functions (cutting, coagulation, grasping) by simply changing the end effector, thereby achieving multi-functionality without requiring separate instruments for each function.
2Ease of manufacture
If a modular design with detachable transmission assemblies is implemented, then the instrument can be reused with multiple end effectors improving reusability, but the coupling and decoupling mechanisms increase manufacturing complexity
Solution Approach 1:
The instrument is segmented into reusable components (handle assembly, transmission assembly) and replaceable components (end effectors). The transmission assembly includes a waveguide with a standardized coupling interface that allows for easy attachment and detachment of different end effectors. This segmentation enables the expensive handle and transmission components to be reused multiple times while only the consumable end effectors are replaced.
Solution Approach 2:
The end effectors are designed as disposable components that are replaced after a single use or limited number of uses, while the handle assembly and transmission assembly are designed for multiple reuses. This approach reduces the overall cost of ownership by concentrating the disposable nature in the least expensive components (end effectors) while maximizing the value of reusable components.
3Adaptability or versatility
If different end effectors with varying sizes and functions are used, then operational versatility is improved, but the number of components that need to be managed and sterilized increases
Solution Approach 1:
The handle assembly and transmission assembly serve as universal platforms that can accommodate multiple types of end effectors (cutting, coagulation, grasping, etc.). This universality means that the time-consuming sterilization and setup processes are performed once on the handle and transmission components, which are then ready for rapid exchange of different end effectors during or between procedures, reducing overall component management time.
Solution Approach 2:
The handle assembly and transmission assembly are pre-sterilized and prepared in advance, allowing for rapid exchange of end effectors without requiring re-sterilization of the entire instrument. The standardized interfaces are pre-configured to ensure proper alignment and connection, reducing the time needed for component exchange and setup between different surgical tasks.
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
This design enhances the versatility and reusability of the surgical instrument, allowing for different operations to be performed with a single handle assembly by easily swapping transmission assemblies, which can be cleaned and reused, thereby improving operational efficiency and reducing waste.
Implementation Method 1
an ultrasonic blade...configured to vibrate in response to application of ultrasonic energy
Implementation Method 2
engage tissue in a number of ways to achieve a diagnostic or therapeutic effect (e.g., endocutter, grasper, cutter, stapler, clip applier, access device, drug/gene therapy delivery device, and energy delivery device using ultrasound, RF, laser, etc.)
Data Source
AI summary
A surgical instrument having a transmission assembly, a transducer, and a handle assembly is configured for coupling the transmission assembly to the handle assembly using a locking mechanism. The locking mechanism is operable to restrict the rotational movement of an actuator coupling member and the transducer relative to the handle assembly. The locking mechanism may also be operable to lock a trigger of the handle assembly in a first position. An inner tubular actuating member of the transmission assembly may be threadably attachable to the actuator coupling member or the actuator coupling member may include a latching mechanism to couple to a flared portion of the inner tubular actuating member. A waveguide of the transmission assembly may also be threadably attachable to the transducer. In one alternative, the trigger may be configured to operate the locking mechanism, either in the first position or when pivoted distally to a third position.