Tracheostomy Tube Flange Assembly via Deformable Collar
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Solution Overview
Problem
The existing manufacturing process for tracheostomy tubes with a mounting flange is time-consuming and costly due to the assembly and bonding of separately formed flange components onto the shaft.
Innovation Solution
A tracheostomy tube design where the shaft includes a first retaining formation at the flange location, and a separately formed flange with a deformable retaining collar and second retaining formation, allowing for secure engagement and bonding of the flange to the shaft without requiring manual assembly during the bonding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the flange is separately formed from the shaft and bonded during assembly, then the flange can be securely attached to the shaft, but the manufacturing process becomes time-consuming and costly
Solution Approach 1:
The shaft is pre-formed with a retaining formation (protrusion) during shaft manufacturing, and the flange is pre-formed with a corresponding recess during flange manufacturing. These preliminary actions eliminate the need for complex assembly operations, allowing the components to be quickly connected by simply inserting the shaft into the flange, thus improving manufacturing efficiency while maintaining secure attachment
Solution Approach 2:
The retaining formation on the shaft and the corresponding recess on the flange are designed to work together as an integrated retention system. When assembled, these features automatically provide mechanical retention without requiring additional bonding materials or complex fastening mechanisms, thereby reducing manufacturing steps and costs while ensuring secure attachment
2Ease of manufacture
If the flange is separately formed from the shaft, then the components can be manufactured independently, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The retaining formation (protrusion) is incorporated into the shaft during shaft manufacturing, and the matching recess is formed in the flange during flange manufacturing. This preliminary preparation of complementary retention features simplifies the final assembly to a single insertion motion, eliminating complex alignment and fastening procedures
Solution Approach 2:
Instead of using a recess in the shaft and requiring a protrusion on the flange to be inserted, the design inverts this arrangement by placing the protrusion on the shaft and the recess in the flange. This inversion simplifies the assembly process as the shaft can be directly inserted into the flange without requiring additional manipulation or alignment steps
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 design simplifies the assembly process, reduces manufacturing time and costs, while ensuring secure retention of the flange on the shaft, thus improving the efficiency and cost-effectiveness of tracheostomy tube production.
Implementation Method 1
the collar is deformable to allow it to be stretched outwardly to enable the first and second retaining formations to be engaged with one another
Implementation Method 2
the shaft is secured with the flange by a bond between the outside of the shaft and the inside of the collar
Data Source
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AI summary
A tracheostomy tube has a shaft (10) with a patient end and a connector (14) at its machine end. The shaft is integrally moulded with a boss (15) located between its ends, the boss having two outwardly projecting retaining lugs (20) and two longitudinal alignment ribs (19). A mounting flange (30) is separately moulded of a deformable silicone and has a central collar (31) with two recesses (38) shaped to receive the lugs (20) on the shaft (10), and two alignment slots (36) to receive the ribs (19) on the shaft. The shaft (10) is threaded through the collar of the flange, which is deformed outwardly to enable the lugs (20) enter the collar and locate in the recesses (38). A bonding substance is applied to the shaft or collar to bond the flange on the shaft.