Surgical Ultrasonic Instrument Usage Indicator for Coupling Integrity
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Solution Overview
Problem
Conventional ultrasonic surgical instruments face issues with the threaded coupling between the ultrasonic blade and transducer, where applying too much torque can cause failure, and too little torque can lead to ineffective energy transmission, rendering the instrument inoperable.
Innovation Solution
An integrated usage indicator, such as a wheel ratchet usage indicator, is incorporated into the handle assembly to track and prevent excessive use cycles, ensuring appropriate torque application and preventing further use after a predetermined number of cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If torque is applied to the threaded coupling between ultrasonic blade and transducer, then effective transmission of ultrasonic energy is achieved, but excessive torque can cause the threaded coupling to fracture and fail
Solution Approach 1:
The patent applies preliminary action by incorporating a usage indicator mechanism that tracks the number of uses and warns before the maximum reuse limit is reached. This allows users to take preventive action (stop using the instrument) before the threaded coupling fails from excessive torque applications, thus resolving the contradiction between maintaining coupling integrity and applying necessary torque for energy transmission.
2Reliability
If torque is applied to the threaded coupling between ultrasonic blade and transducer, then effective transmission of ultrasonic energy is achieved, but insufficient torque can cause the threaded coupling to loosen and inhibit effective transmission
Solution Approach 1:
The patent implements feedback through the usage indicator mechanism that provides visual or tactile feedback to the user about the number of reuse cycles. This feedback loop allows users to adjust their torque application technique to maintain optimal coupling stability while ensuring effective ultrasonic energy transmission, preventing both loosening and over-tightening issues.
3Productivity
If the ultrasonic surgical instrument is reused beyond a predetermined number of cycles, then productivity is improved, but the risk of threaded coupling failure increases
Solution Approach 1:
The usage indicator mechanism performs preliminary action by warning users before the maximum reuse limit is reached, allowing them to stop using the instrument proactively. This prevents threaded coupling failure while maximizing productive reuse cycles, resolving the contradiction between productivity and reliability.
Solution Approach 2:
The patent applies the disposable principle by establishing a predetermined reuse limit for the ultrasonic surgical instrument based on threaded coupling durability. After reaching this limit, the instrument is disposed of rather than reused, ensuring reliability while allowing multiple productive uses. The usage indicator tracks and enforces this limited lifecycle.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
An ultrasonic instrument includes a housing, an ultrasonic transducer support by the housing, and an integrated usage indicator. The housing is configured to removably connect to a shaft assembly. The ultrasonic transducer is configured to be acoustically connected to a waveguide and operated a predetermined number of use cycles. The integrated usage indicator is operatively connected to the housing and includes a used state indicator. The used state indicator is configured to indicate to a clinician in a used state when the ultrasonic transducer has been operated at least the predetermined number of use cycles for limiting usage of the ultrasonic transducer to the predetermined number of use cycles.