Plunger Tip Coupling for IOL Injector Alignment
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Solution Overview
Problem
Current manual and syringe-type injectors for intraocular lenses (IOLs) are cumbersome, require two hands, and produce inconsistent injection force and displacement, making them inefficient for delivering IOLs into the eye during cataract surgery.
Innovation Solution
A plunger tip wrench system that includes a body with alignment features and a detent mechanism to securely attach to an IOL injection device, ensuring proper alignment and orientation of the plunger tip, and utilizing a motor with back electromotive force (EMF) monitoring for fault detection and consistent plunger movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If threaded-type manual injectors are used, then the device can be operated with simple mechanical structure, but it requires two hands to operate which is cumbersome and tedious
Solution Approach 1:
The patent replaces manual threading operations with a motor-driven plunger mechanism. The motor automatically advances the plunger tip through the IOL, eliminating the need for manual threading and two-handed operation while maintaining precise mechanical control through automated actuation.
Solution Approach 2:
The device incorporates self-aligning features including alignment pins and guide structures that automatically position the plunger tip relative to the IOL without requiring manual adjustment. The system performs self-positioning and self-alignment during the injection process, reducing operational complexity.
2Reliability
If syringe-type injectors are used, then the device can deliver IOL with automated operation, but it produces inconsistent injection force and displacement
Solution Approach 1:
The patent incorporates force sensors and position sensors that provide real-time feedback to the control system. The control system monitors plunger displacement and injection force, automatically adjusting motor parameters to maintain consistent force application throughout the IOL delivery process, ensuring reliable and repeatable results.
Solution Approach 2:
The system dynamically adjusts motor speed, torque, and plunger advancement rate based on real-time sensor data. By changing operational parameters adaptively during the injection process, the device maintains consistent injection force despite variations in IOL properties or tissue resistance.
3Manufacturing precision
If alignment features are added to ensure proper orientation, then the injection precision is improved, but the device complexity increases
Solution Approach 1:
The patent employs asymmetric alignment features such as keyway slots, offset pins, and non-circular cross-sections on the plunger tip and housing. These asymmetric geometries provide unique orientation references that automatically guide the plunger into the correct angular position, ensuring precise alignment without complex adjustment mechanisms.
Solution Approach 2:
The alignment features are pre-configured during device assembly, with alignment pins and guide structures positioned in advance to automatically orient the plunger tip correctly before the injection begins. This preliminary positioning eliminates the need for real-time alignment adjustments during operation.
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 enables efficient, one-handed operation with consistent injection force and displacement, reducing the risk of errors and improving the precision of IOL delivery into the eye by ensuring proper alignment and monitoring for potential faults during the injection process.
Implementation Method 1
utilizing a motor with back electromotive force (EMF) monitoring for fault detection and consistent plunger movement
Data Source
AI summary
The present disclosure is directed to devices, systems, and methods directed to mounting a plunger tip to a plunger of an IOL injection device. A plunger tip wrench that is operable to releasably retain a plunger tip may be coupled to a holder extending from an end of the IOL injection device to align the plunger tip with the plunger of the IOL injection device. In some instances, the IOL injection device may include a motor and use a back electromotive force (EMF) of the motor to detect a position of the plunger as it is extended to engage the plunger tip. The plunger tip may be positioned relative to the plunger such that the plunger will engage the plunger tip within the entire range of a negative error position and a positive error position.