Rod-and-Collet Tool Adaptor for Worn Surgical Chuck Interfaces
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Solution Overview
Problem
Conventional powered surgical handpieces face challenges in robustly coupling with surgical cutting tools due to mismatched coupling features, leading to inefficient transfer of rotational motion, especially when tools have wear or non-standard shapes.
Innovation Solution
The introduction of an adaptor assembly comprising a rod and collet with complementary engagement features allows for the transfer of driven rotation between the handpiece and surgical cutting tool, even when their coupling features are incompatible, by providing adaptable male and female coupling portions that match the handpiece and tool respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional drive chuck with a single central axis is used to couple surgical cutting tools, then the coupling structure is simple and easy to manufacture, but the coupling robustness deteriorates when there is wear or shape mismatch between the drive chuck and tool tang
Solution Approach 1:
The coupling interface is segmented into multiple independent contact points arranged circumferentially around the central axis. Instead of a single axial contact, the drive chuck and tool tang engage through multiple distributed contact points, which distributes the mechanical load and maintains coupling robustness even when individual contact points experience wear.
Solution Approach 2:
The coupling mechanism transitions from a one-dimensional axial contact to a two-dimensional circumferential contact arrangement. Multiple contact points are positioned around the central axis in a radial pattern, adding a radial dimension to the coupling interface and enabling more robust engagement that resists wear and misalignment.
2Adaptability or versatility
If the drive chuck and tool tang have mismatched coupling features, then the adaptability to different tool types is improved, but the coupling robustness and rotational transfer efficiency deteriorates
Solution Approach 1:
The drive chuck is designed with a universal coupling interface that can accommodate multiple tool tang configurations. The circumferential contact point arrangement allows the same drive chuck to effectively couple with various tool types (drills, reamers, saws, etc.) while maintaining robust rotational transfer, as the distributed contact points adapt to different tang geometries.
Solution Approach 2:
The multiple circumferential contact points act as intermediaries between the drive chuck and tool tang, mediating the rotational force transfer. These contact points provide a buffer that accommodates geometric mismatches between different tool interfaces while ensuring efficient torque transmission through collective engagement.
3Device complexity
If point contacts are created solely about a single central axis, then the device complexity is reduced, but the rotational motion transfer efficiency deteriorates under wear conditions
Solution Approach 1:
The single central axis contact is segmented into multiple circumferential contact points. This segmentation distributes the rotational load across multiple points, maintaining high torque transfer efficiency even when individual contact points wear, without requiring complex additional mechanisms beyond the contact point arrangement.
Data Source
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AI summary
An adaptor assembly for coupling a cutting tool to a drill drive chuck such that driven rotation of the drive chuck is transferred to the cutting tool by the adaptor assembly. The adaptor assembly includes a rod, a collet and an enclosure. A proximal region of the rod provides an adaptor male coupling portion configured to engage a drill drive chuck. A leading of the collet provides an adaptor female coupling portion configured to engage a surgical cutting tool tang. Further, the rod and the collet form complementary engagement features for coupling to one another. The enclosure rotatably maintains the collet. Upon final assembly of the rod to the collet, rotation of the rod is transferred to the collet. During use, the adaptor assembly can facilitate coupling of a cutting tool to a powered handpiece under circumstances where the cutting tool is otherwise incompatible with the powered handpiece.