Cutting Electrode Break-Edge Manufacturing for Precise Tissue Cutting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing surgical instruments face challenges in manufacturing cutting electrodes with precise geometry and insulation, which are crucial for achieving precise and energy-efficient cuts during tissue fusion and dissection.
Innovation Solution
A method for manufacturing a cutting electrode involves creating a rated break location in a metal sheet blank, which separates into a handling section and an electrode section. The electrode section is then embedded in a plastic body using injection molding, resulting in a cutting edge that is uncovered and forms the electrical cutting edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cutting electrode is embedded in insulation material with different depths, then the current distribution is optimized for precise cutting, but the manufacturing complexity increases
Solution Approach 1:
The electrode is divided into multiple sections with different embedding depths in the insulation material. The narrow side of the electrode remains uncovered while the broad sides are embedded to different depths, creating distinct current flow paths. This segmentation allows optimization of cutting precision through controlled current distribution without requiring complex multi-step manufacturing processes.
Solution Approach 2:
Different portions of the electrode are given different embedding depths in the insulation material. The narrow side remains exposed for current flow, while the broad sides are embedded to varying depths to control current distribution. This local differentiation of electrode properties enables precise cutting while simplifying the overall manufacturing approach.
2Manufacturing precision
If a narrow cutting edge is created for precise cuts, then the current concentration is improved, but the manufacturing difficulty increases
Solution Approach 1:
A rated break location is created in the electrode material before final assembly, which serves as a predetermined fracture point. This preliminary action allows the narrow cutting edge to be formed by simple breaking rather than complex precision machining, significantly easing manufacturing while maintaining the precise narrow geometry needed for current concentration and accurate cutting.
Solution Approach 2:
The formation of the narrow cutting edge is achieved through mechanical breaking at the rated break location rather than through precision mechanical machining or other complex manufacturing methods. This substitution of the edge-forming process simplifies manufacturing while producing the precise narrow geometry required for effective current concentration.
3Use of energy by moving object
If the electrode geometry is optimized for energy-efficient cutting, then the current usage is minimized, but the manufacturing complexity increases
Solution Approach 1:
The electrode is segmented into sections with different embedding depths, creating distinct current flow paths that concentrate current at the narrow cutting edge while distributing it along the broad sides. This segmentation optimizes energy efficiency by directing current where needed for cutting while minimizing overall current consumption, achieved through a relatively simple manufacturing approach.
Solution Approach 2:
Different regions of the electrode are given different embedding depths to create localized current flow characteristics. The narrow side remains exposed for concentrated current flow enabling efficient cutting, while the broad sides are embedded to control current distribution. This local optimization of electrode properties achieves energy-efficient cutting without requiring complex manufacturing processes.
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 method allows for the precise manufacturing of cutting electrodes with a narrow breaking edge, enabling efficient energy distribution and achieving high-quality cuts with minimal current usage and mechanical stress on tissues.
Implementation Method 1
a radio frequency current originating from the instrument shall predominantly flow through the edges of the instrument
Implementation Method 2
The dissection electrode can be embedded in an insulation material with different depths depending on the embodiment, such that only the narrow side of the dissection electrode and parts of its flat sides are accessible
Data Source
AI summary
A method for manufacturing a cutting electrode for a surgical instrument. The method involves starting with a material blank that is provided with a rated break location. The material blank is dimensioned to allow for separation with forces sufficiently low that they can also be transmitted by the plastic body. The rated break location separates the material blank in a first section serving exclusively for handling and positioning of the material blank in a mold as well as in a second section that self-supportingly projects in a mold hollow space and is overmolded by plastic. After removal, the first section can be easily broken off the cutting electrode. The created breaking edge forms a cutting edge.