Disposable Endoscope Air/Water Valve With Over-Molded Seals
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Solution Overview
Problem
Reusable air/water valves for endoscopes incur significant costs due to the need for repeated cleaning, disinfection, and sterilization, and there is a risk of contamination and infection, with existing designs being complex and prone to clogging.
Innovation Solution
Development of disposable air/water valves with a monolithic main stem and simplified components, featuring seals, a button/cap, and a resilient member, manufactured using over-molding and terminal sterilization to ensure sterility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a reusable air/water valve is used, then cost is reduced, but cross-contamination between patients occurs and sterilization is difficult
Solution Approach 1:
The patent implements a disposable air/water valve that is discarded after a single use, eliminating cross-contamination risks between patients while maintaining acceptable cost levels through efficient molding processes. The valve assembly includes all necessary components (main stem, seals, retaining ring, button cap, boot) integrated into a single disposable unit.
2Ease of manufacture
If multiple separate components are used for the air/water valve, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple valve components into a single integrated disposable unit. The main stem, seals, retaining ring, button cap, and boot are all part of one assembled valve assembly that functions as a complete unit, reducing the complexity of managing separate replaceable parts while maintaining manufacturing efficiency through modular molding of sub-components.
Solution Approach 2:
The valve is manufactured by molding separate sub-components (main stem with seals, retaining ring, button cap, boot) that are then assembled together. This segmentation allows each component to be optimized for its specific function and manufactured efficiently, then combined into a complete valve assembly.
3Manufacturing precision
If precision molding is used for the main stem, then manufacturing precision is improved, but manufacturing time increases
Solution Approach 1:
The air passage and other critical features are pre-formed during the molding of the main stem, eliminating the need for subsequent precision machining or drilling operations. The seals are pre-attached to the main stem through over-molding, ensuring precise positioning without additional assembly steps that would consume time.
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
Reduces the need for cleaning and sterilization, minimizes contamination risk, and lowers manufacturing costs while maintaining effective air and water flow control.
Implementation Method 1
resilient member (e.g., spring)
Implementation Method 2
resilient member (e.g., spring)
Data Source
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AI summary
A disposable air/water valve may include a main stem providing an air passage through the center bore of the main stem. A method for manufacturing a disposable air/water valve may include several steps. The main stem is molded, and placed in a mold for over-molding seals onto the main stem. Prior to the next steps, the retaining ring, button cap, and boot may be molded. The back end of the main step is placed through the center of the retaining ring and resilient member (e.g.. spring). The button cap is then placed on and secured to the main stem.