Segmented Chassis for Surgical Power Head Alignment
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Solution Overview
Problem
Surgical devices with battery compartments face challenges in reducing contaminated medical waste due to contamination issues during disposal and reprocessing, and existing chassis designs lack the necessary strength and precision for accurate alignment and reuse of complex internal components.
Innovation Solution
A structural chassis for a surgical instrument power head is introduced, formed from metal with a polymer housing, enabling proper alignment and replacement of operating components while preventing contamination, and featuring a sealed battery pack compartment for safe ejection and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a housing is used to enclose internal components, then protection from contamination is improved, but access for removal and reprocessing becomes difficult
Solution Approach 1:
The housing is divided into a first housing portion and a second housing portion that can be separated from each other. The internal components are mounted on a chassis that can be accessed by separating these housing portions, allowing contamination protection during storage/transport while enabling easy access for removal and reprocessing when needed.
2Manufacturing precision
If conventional chassis materials and designs are used, then manufacturing simplicity is maintained, but alignment precision and structural strength are insufficient
Solution Approach 1:
The chassis is constructed from composite materials that provide both the necessary structural strength and precision alignment capabilities. This composite structure enables accurate positioning of internal components while maintaining manufacturability, resolving the contradiction between alignment precision and structural complexity.
3Reliability
If internal components are made more complex with tighter tolerances, then device performance is improved, but reusability and reprocessing become more difficult
Solution Approach 1:
The housing is segmented into separable portions that provide controlled access to the internal components. This segmentation allows high-precision components to be protected and maintained with tight tolerances while enabling easy removal and reprocessing when needed, resolving the contradiction between performance reliability and reprocessing ease.
4Loss of substance
If a sealed housing is used to prevent contamination, then waste reduction is improved, but component replacement and maintenance become difficult
Solution Approach 1:
The housing is divided into separable portions that maintain a sealed configuration during normal operation to prevent contamination and reduce medical waste. When component replacement or maintenance is needed, these segmented portions can be separated to provide access to internal components, thus resolving the contradiction between waste reduction and component replacement ease.
Data Source
AI summary
A method of assembling a power head of a hand-held surgical instrument comprising: providing a power head having a housing enabling access to an interior volume of the power head encompassed by the housing; mounting a set of operating components of the power head on a chassis such that the set of operating components have a proper configuration for alignment in at least two orthogonal planes when the chassis and the set of components mounted thereon are deployed within the interior volume encompassed by the housing; and deploying the set of operating components mounted on the chassis within the interior volume encompassed by the housing; wherein mounting the set of operating components on the chassis occurs outside of the housing and prior to deploying the set of operating components mounted on the chassis within the interior volume, and wherein deploying the set of operating components mounted on the chassis within the interior volume provides the proper configuration for alignment in the at least two orthogonal planes of the set of operating components.