Electrosurgical End Effector Seal Plate Welding

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Solution Overview

Problem

The manufacturing of conventional electrosurgical forceps end effector assemblies is time-consuming and costly due to the need for precise alignment of knife blade slots in structural support and seal plates, which requires tight machining tolerances.

Innovation Solution

The end effector assembly features seal plates with a thickness that allows the knife blade to translate independently of the structural support members, secured via welding, eliminating alignment issues and simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional over-molding and stamping processes are used to assemble structural support and seal plate, then manufacturing precision can be maintained, but manufacturing time and cost increase significantly

Engineering Contradiction:

Improvealignment precision of knife blade slotsVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The end effector assembly is divided into separate components (structural support member and seal plate) that are joined through apertures rather than over-molded together. This segmentation allows independent manufacturing of components with standard tolerances, eliminating the need for tight alignment tolerances during assembly and significantly reducing manufacturing time while maintaining functional precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Apertures serve as intermediary features that facilitate the joining of the structural support member and seal plate. These apertures enable straightforward alignment and secure connection without requiring complex over-molding processes, thereby simplifying the manufacturing workflow and reducing both time and cost while achieving adequate alignment.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If tight machining tolerances are enforced for slot alignment, then alignment precision improves, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveslot alignment toleranceVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

By segmenting the assembly into separately manufacturable components joined through apertures, the design decouples the manufacturing precision requirements from the final assembly alignment. Each component can be manufactured with standard tolerances, and the aperture-based joining mechanism ensures proper alignment without requiring tight machining tolerances, thereby reducing manufacturing process complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design accepts standard-tolerance components rather than investing in expensive tight-tolerance machining. The aperture-based joining system provides sufficient alignment functionality without the need for precision-critical slots, effectively using a simpler, more cost-effective manufacturing approach that avoids complex machining operations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If seal plate is secured via welding through apertures, then ease of manufacture improves, but manufacturing precision may be compromised

Engineering Contradiction:

Improveassembly simplicityVSAvoidalignment accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The aperture-based joining system segments the assembly process into simple, sequential steps: position the seal plate over the structural support member, align through the apertures, and weld. This segmentation provides inherent alignment guidance through the aperture geometry while maintaining manufacturing simplicity, achieving both ease of manufacture and adequate precision without requiring complex alignment procedures.

Inventive Principle:

Principle #1Segmentation

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 design reduces manufacturing complexity and costs by allowing for more forgiving alignment tolerances and secure welding of seal plates to structural support members, enhancing the efficiency and cost-effectiveness of the production process.

Implementation Method 1

The seal plates are secured to their respective structural support members via at least one of welding, soldering and brazing

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The seal plates are secured to their respective structural support members via at least one of welding, soldering and brazing

Methodology Applied

Scientific EffectSoldering: Soldering

Implementation Method 3

The seal plates are secured to their respective structural support members via at least one of welding, soldering and brazing

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentUS8764748B2End effector assembly for electrosurgical device and method for making the same

Publication Date: 2014.07.01 COVIDIEN LP

AI summary

An end effector assembly for use with a forceps is provided. The end effector assembly including a pair of opposing jaw members operatively connected to each other about a pivot. Each jaw member includes a structural support member having a seal plate secured thereto. Each of the seal plates defines a slot having a depth and configured to translate a knife blade therethrough. The combined depth of the slot is greater than the height of the knife blade.