Monolithic Flexible Neck for Controlled Surgical Articulation
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Solution Overview
Problem
Current surgical instruments face challenges in articulating end effectors within minimally invasive procedures due to complex manufacturing processes and the need for multiple parts, which increases labor and costs while compromising flexibility and control.
Innovation Solution
A surgical device with a flexible neck assembly featuring a monolithic outer shell and a separate divider that separates the shell into elongate channels, allowing for axial translation of articulation members to bend the end effector, providing controlled articulation while reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate parts are used to manufacture the flexible portion, then assembly flexibility is improved, but device complexity and manufacturing labor increase
Solution Approach 1:
The patent combines multiple separate components (outer shell, inner core, articulation members) into a monolithic integrated structure that is formed as a single piece. This merging eliminates the need for separate assembly steps while maintaining the functional benefits of having distinct structural elements, thereby reducing device complexity and manufacturing labor without sacrificing assembly flexibility.
Solution Approach 2:
The monolithic structure is designed with internal segmentation featuring distinct layers and channels (outer shell, inner core, articulation members) that are integrated but functionally separate. This allows the single component to perform multiple functions independently, achieving the benefits of separate parts without the complexity of assembling multiple components.
2Adaptability or versatility
If multiple parts are assembled to create the flexible portion, then functional versatility is improved, but manufacturing costs and labor increase
Solution Approach 1:
The patent merges multiple functional components into a single monolithic structure that can be manufactured in one process. The integrated design maintains distinct functional zones (articulation members, flexible core, outer shell) without requiring separate assembly operations, thereby reducing manufacturing labor while preserving functional versatility.
Solution Approach 2:
The monolithic structure is designed to perform multiple functions within a single component, including providing flexibility, housing articulation members, maintaining structural integrity, and enabling controlled bending. This multi-functionality eliminates the need for separate specialized parts, reducing both manufacturing complexity and labor.
3Adaptability or versatility
If a flexible portion is designed with high flexibility, then articulation capability is improved, but structural rigidity deteriorates
Solution Approach 1:
The patent implements local quality by creating distinct zones within the monolithic structure with different mechanical properties. The inner core provides rigidity in the longitudinal direction to maintain structural integrity, while the articulation members and outer shell allow controlled bending in the transverse direction. This local differentiation enables the structure to exhibit both flexibility and rigidity where needed.
Solution Approach 2:
The monolithic structure functions as a composite system with multiple materials or phases having different mechanical properties. The combination of rigid inner core material and more flexible outer shell material creates a composite structure that simultaneously provides structural rigidity and articulation flexibility, resolving the contradiction between these two properties.
4Ease of operation
If a flexible portion is designed with high rigidity, then control over articulation is improved, but flexibility deteriorates
Solution Approach 1:
The patent applies local quality by creating specific regions within the monolithic structure that provide controlled resistance to bending. The rigid inner core and strategically positioned articulation members create zones that guide and control the articulation motion, ensuring predictable and controllable bending while maintaining overall flexibility of the flexible portion.
Data Source
AI summary
Methods and devices for allowing articulation of an end effector on a surgical instrument are provided. In one embodiment, a surgical device can include a flexible neck portion having an end effector coupled to a distal end thereof. The flexible neck portion is configured to bend to as to allow the end effector to articulate. The flexible neck portion can include a monolithic flexible outer shell defining an inner lumen extending therethrough. At least one flexible divider can be disposed within the inner lumen such that it separates the outer shell into elongate pathways configured to receive articulation members extending through the shaft assembly and the flexible neck and coupled to the end effector to cause articulating movement thereof.