Bipolar Coagulator Interference Fit Connector
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Solution Overview
Problem
Existing coaxial bipolar coagulators face issues with unreliable electrical connections, mechanical fastening complexities, and thermal stress, leading to device failure and reduced coagulation performance, especially in smaller tip diameters, which can cause delays and safety concerns during surgical procedures.
Innovation Solution
A disposable coaxial bipolar coagulator design featuring a molded handle with interlocking profiles, spring-loaded compressive force for secure electrical connections, and an auxiliary resistive circuit to enhance power delivery, along with a visible power indicator light to ensure proper function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical fastening methods (welding, soldering, crimp connection) are used to connect conductive elements, then electrical connection is achieved, but connection reliability deteriorates due to stress and fatigue leading to breakage
Solution Approach 1:
The patent replaces mechanical fastening methods (welding, soldering, crimping) with an interference fit mechanical connection system. The connector features a proximal interference fit portion that mechanically engages with the distal interference fit portion of the coaxial assembly, creating a stress-free, fatigue-resistant connection that eliminates the reliability issues associated with traditional mechanical fastening methods.
2Ease of manufacture
If over-molding process is used to create device handle, then handle is formed around electrical assembly, but connection strength deteriorates due to polymer injection and plastic shrinkage stress
Solution Approach 1:
The patent segments the device into distinct modular components: the coaxial assembly with its interference fit portion, the connector with its corresponding interference fit features, and the molded handle. This segmentation allows each component to be manufactured independently using optimal processes, avoiding the stress-inducing over-molding of the entire assembly while still achieving a secure integrated structure through the interference fit connection.
3Manufacturing precision
If smaller tip diameter is used in coaxial bipolar coagulator, then coagulation precision is improved, but power delivery deteriorates leading to insufficient coagulation performance
Solution Approach 1:
The patent optimizes the electrical and geometric parameters of the coaxial assembly to achieve enhanced power delivery despite the small tip diameter. By carefully controlling the impedance, conductor dimensions, and interference fit geometry, the device maintains sufficient power delivery capability while preserving the precision advantages of a smaller tip diameter for accurate coagulation application.
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
The design improves reliability, safety, and coagulation performance by reducing the risk of connection failures, maintaining secure connections under thermal stress, and providing consistent power delivery, thus enhancing surgical efficiency and safety.
Implementation Method 1
spring-loaded compressive force for secure electrical connections
Implementation Method 2
maintaining secure connections under thermal stress
Implementation Method 3
auxiliary resistive circuit to enhance power delivery
Implementation Method 4
providing consistent power delivery
Implementation Method 5
visible power indicator light to ensure proper function
Implementation Method 6
conduction of high frequency current between the tip poles and through the surrounding tissues and fluids for localized coagulation
Implementation Method 7
application of high frequency electrical energy for coagulation
Data Source
AI summary
A bipolar electrosurgical coagulator utilizes a handle having distal and proximal ends with a conductor carried by the handle and having coaxial inner and outer electrically conductive elements. The conductor extends from the distal end of the handle to a coagulating tip, with the proximal end of the conductor secured within the handle for electrical interconnection with a power source entering the handle at its proximal end.