Electrosurgical Return Electrode Plug Assembly for Simpler Manufacturing
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Solution Overview
Problem
The construction of existing electrosurgical return electrodes with overmolded plugs is complex and costly due to a multi-step manufacturing process, leading to high scrap material and complicated supply chains.
Innovation Solution
A simplified manufacturing process for electrosurgical return electrodes using a plug assembly that involves a base and cap secured together via laser or ultrasonic welding, or adhesive, with bosses and recesses for alignment and bonding, allowing for a single-step assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-step overmolding process is used to construct the plug, then the plug provides secure electrical connection and structural integrity, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The plug is divided into two separate components: an inner plug component (molded from ABS plastic) and an outer plug component (molded from TPU material). These components are manufactured separately and then assembled together, eliminating the need for complex multi-step overmolding processes while maintaining the structural integrity and electrical connection security of the original design.
2Reliability
If a multi-step overmolding process is used to construct the plug, then the plug provides secure electrical connection, but the scrap material and waste production increase
Solution Approach 1:
By segmenting the plug into separately manufacturable inner and outer components, each component can be produced through simpler molding processes with higher material utilization. The assembly of these pre-formed components eliminates the material waste associated with multi-step overmolding, where intermediate steps generate significant scrap material that must be discarded.
3Reliability
If a multi-step overmolding process is used to construct the plug, then the plug provides secure electrical connection, but the supply chain and manufacturing logistics become complicated
Solution Approach 1:
The plug design is segmented into an inner component and an outer component that can be manufactured independently at different facilities. The inner plug component can be produced at one manufacturing facility while the outer plug component can be produced at another, allowing for distributed manufacturing and simplified supply chain logistics. These components are then easily assembled together, eliminating the need for complex multi-step overmolding processes that require specialized equipment and single-facility production.
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 approach reduces manufacturing complexity and costs by enabling a single facility production, minimizing waste, and ensuring secure electrical connections.
Implementation Method 1
The cap and the base are laser or ultrasonically welded together
Implementation Method 2
The cap and the base are laser or ultrasonically welded together
Data Source
AI summary
An electrosurgical return electrode includes a conductive layer and a plug connected thereto. The conductive layer is configured to conduct electrical current and has one or more apertures extending therethrough. The plug includes a base having one or more bosses configured to extend through the one or more apertures in the conductive layer. The plug also includes a cap disposed adjacent to the conductive layer and opposite to the base. The cap and the base are laser or ultrasonically welded together or the conductive layer, the base, and the cap are joined together via an adhesive.