Phacoemulsification Needle Splitting Metal Connector and Plastic Tip
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Solution Overview
Problem
Existing phacoemulsification needles made from metal materials are costly to manufacture, have a sharp rigid tip that increases the risk of capsular bag puncture during surgery, and are difficult to produce, limiting their accessibility and safety, especially in developing countries.
Innovation Solution
A two-body design phacoemulsification needle comprising a metal connector and a medical-grade plastic needle, where the plastic needle is connected to the metal connector, which is attached to the phacoemulsification hand piece, reducing manufacturing complexity and costs while eliminating the sharp rigid tip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If phacoemulsification needles are made from metal materials with integrated connecting mechanisms, then the needle structure is complete and functional, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The needle system is divided into two separate components: a reusable metal connector body and a disposable plastic needle. The connector body contains the connecting mechanism and attaches to the hand piece, while the needle is a separate element that inserts into the connector. This segmentation simplifies the manufacturing of each individual component while maintaining the complete functional structure.
2Reliability
If phacoemulsification needles are made from metal materials, then the needle is strong and durable, but the tip becomes sharp and rigid increasing surgical risk
Solution Approach 1:
The needle system combines metal and plastic materials, each serving different functions. The metal connector body provides structural strength, durability, and precise attachment to the hand piece. The plastic needle provides a softer, less rigid tip that reduces surgical risk while maintaining sufficient strength for the procedure. This composite approach allows each material to optimize its properties for its specific role.
3Reliability
If phacoemulsification needles are designed as single-use disposable items, then patient safety between uses is improved, but the cost per procedure increases
Solution Approach 1:
The needle system separates the expensive reusable metal connector body from the disposable plastic needle. The connector body can be sterilized and reused across multiple procedures, while only the plastic needle is discarded after each use. This segmentation allows the system to maintain disposable safety benefits while reducing overall cost by reusing the most expensive component.
4Ease of manufacture
If the needle connecting mechanism is integrated into the needle body, then the design is simplified, but the aspiration hole dimensions become difficult to manufacture
Solution Approach 1:
The connecting mechanism is relocated from the needle body to a separate metal connector body. This allows the needle to be manufactured with optimal aspiration hole dimensions using appropriate techniques for plastic materials, while the connecting mechanism with its threads and attachment features is manufactured separately in metal where such features are easier to produce with precision.
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 design improves safety and manufacturability, reduces surgical risks, and lowers overall costs, making the technology more accessible and safer for patients by using medical-grade plastic materials for the needle.
Implementation Method 1
a power ultrasonic transducer in the hand piece converts the electrical energy into mechanical energy of the high-speed small amplitude vibration
Implementation Method 2
the ultrasonic vibration amplitude is amplified by a mechanical transformer in the distal end of the hand piece, then through the connected phacoemulsification needle such ultrasonic vibration is applied to the human tissue to cause crushing, cutting, emulsification
Data Source
AI summary
An ultrasonic phacoemulsification needle with improved safety and manufacturability, comprising: a metal connection body and a plastic needle in a splitting structure. The plastic needle is connected at the distal end of the metal connection body, and the metal connection body is connected to the distal end of an ultrasonic hand piece. The ultrasonic phacoemulsification needle employing a design of splitting the connection body and the needle alleviates the difficulties for manufacturing otherwise caused by the conventional phaco tip designs. It reduces the surgical costs from patients. In addition, the ultrasonic phacoemulsification needle using a plastic body reduces the likeliness of punctuating the capsule bag, which otherwise easily occurs in the metal needle case due to the extremely sharp rigid tip at the end of the needle, thus the risks of surgery are reduced and safety is improved.