Elastomeric Acoustic Coupling for Surgical Flow Sensors
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Solution Overview
Problem
Conventional ophthalmic surgical systems face inaccuracies in fluid flow measurement due to variations in the force applied between the surgical cassette and the ultrasonic flow sensor transducer, caused by manufacturing variations and the need for precise control of aspiration and irrigation flows during surgery.
Innovation Solution
A surgical system with a console that includes a rigid fluid channel housing with an elastomeric acoustic coupling and an elastically mounted transducer, ensuring a constant force and eliminating the need for adhesives by over-molding the acoustic coupling onto the cassette.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manufacturing variations are present in the surgical cassette assembly, then production efficiency is improved, but the force between the transducer and acoustic coupling varies causing measurement inaccuracies
Solution Approach 1:
The transducer is mounted on a spring mechanism that allows dynamic adjustment of the contact force between the transducer and acoustic coupling. This dynamic mounting compensates for manufacturing variations in the surgical cassette assembly, ensuring consistent acoustic coupling and accurate flow measurements while maintaining production efficiency through a self-adjusting mechanism rather than tight tolerances
Solution Approach 2:
The spring-mounted transducer changes the contact force parameter dynamically to maintain optimal acoustic coupling. By allowing the force parameter to adjust automatically based on manufacturing variations, the system maintains measurement precision without requiring precise manufacturing control
2Manufacturing precision
If adhesives are used to attach the acoustic coupling to the cassette, then manufacturing precision is improved, but device complexity and potential fluid leakage paths increase
Solution Approach 1:
The acoustic coupling is made from elastomeric material that can be over-molded directly onto the rigid fluid channel housing. This flexible elastomeric coupling maintains acoustic contact without requiring adhesives or complex assembly steps, reducing device complexity while ensuring precise acoustic coupling through the compliant material
Solution Approach 2:
The system uses a composite construction with a rigid fluid channel housing and an elastomeric acoustic coupling over-molded onto it. This composite material approach eliminates the need for adhesives by creating an integrated assembly through over-molding, reducing complexity while maintaining manufacturing 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
This solution provides accurate and reliable fluid flow measurement by maintaining a consistent force between the cassette and transducer, reducing measurement inaccuracies and enhancing the precision of fluid flow control in ophthalmic surgeries.
Implementation Method 1
an ultrasonic flow sensor disclosed in U.S. Pat. No. 6,098,466 (Shkarlet) discloses a flow sensor capable of accurately measuring fluid flow in vessels or tubes
Implementation Method 2
the transducer must be acoustically coupled to the tubing in which the fluid is flowing so that any air located between the transducer and the tubing is removed
Implementation Method 3
The acoustic transducer is elastically mounted within the console, such as on a spring, so as to provide a relatively constant force between the transducer and the acoustic coupling
Data Source
AI summary
A surgical system having a console that receives a cassette with a rigid fluid channel formed into a rigid plastic component or housing. The housing serves as a substrate for an elastomeric acoustic coupling that can be formed on the housing outside of the fluid channel. The acoustic transducer is elastically mounted within the console, such as on a spring, so as to provide a relatively constant force between the transducer and the acoustic coupling when the cassette is installed in the console.