Composite Surgical Console Frame With Molded Joint Assembly
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Solution Overview
Problem
Existing support structures for surgical consoles lack specific design and protection for ancillary equipment and consumables, often providing inadequate protection and customization for the surgical console they serve.
Innovation Solution
A frame system comprising rod structures with interface joints and cross-face structural members, which are molded or attached to secure various components, including a surgical console, with features like dimples for attachment points and plugs to prevent molding material flow, allowing for secure and customizable assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sheet metal or plastic structures with multiple components are used, then structural strength can be achieved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple discrete components (frame members, fasteners, shelves, and cosmetic covers) into an integrated molded structure. The frame structure is molded as a single piece or pre-assembled unit with built-in attachment features, eliminating the need for separate fasteners and simplifying the overall assembly while maintaining structural strength.
Solution Approach 2:
The patent uses composite materials, specifically a molded frame structure that combines structural support elements with cosmetic covering in a single molded component. This composite approach provides both structural integrity and aesthetic finish without requiring separate metal and cosmetic components.
2Ease of manufacture
If simple open support structures are used, then ease of manufacture is improved, but protection for ancillary equipment and consumables deteriorates
Solution Approach 1:
The patent segments the support structure into distinct functional zones: open areas for air circulation, enclosed spaces for protecting ancillary equipment and consumables, and designated shelves for organized storage. This segmentation provides protection where needed while maintaining ease of manufacture through modular design.
Solution Approach 2:
The patent applies local quality by providing different levels of enclosure and protection in different areas of the support structure. Critical components receive enclosed protection, while areas requiring ventilation remain open, optimizing both protection and manufacturability.
3Adaptability or versatility
If multiple discrete components are assembled together, then adaptability and customization are improved, but ease of operation and assembly are worsened
Solution Approach 1:
The patent incorporates preliminary action by pre-molding attachment features, receiving holes, and alignment structures into the frame structure before final assembly. This preliminary preparation of connection points simplifies the assembly process while maintaining adaptability for different configurations.
Data Source
AI summary
In various embodiments a frame system for a surgical system may include a plurality of rod structures cross connected through one or more structural members. In some embodiments, the rod structures may each include at least one rod with an interface joint molded over the at least one rod. One or more of the interface joints may include a receiving hole for receiving a structural member to couple at least two of the plurality of rod structures together. One or more surgical components (such as a surgical console) may be received into the frame system. Other components may also be received into the frame system (e.g., an aesthetic skin). The rod structures may also include cross face structural members that are secured to portions of the rod structures through being molded to the rod structures through the interface joints.