End Effector Substrate Integration for Surgical Tissue Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing energy-based surgical forceps face challenges in achieving precise tissue sealing and cutting due to limitations in mechanical clamping pressure, energy control, and gap distance between jaw members, which can result in incomplete tissue sealing and inefficient cutting.
Innovation Solution
A method of manufacturing an end effector assembly with a substrate formed as a single integrated component, including energizable portions interconnected by a connector portion, which is removed to electrically insulate and align tissue-contacting and cutting members, facilitating precise energy distribution and cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate components are used for tissue sealing and cutting functions, then functional versatility is improved, but device complexity and alignment precision deteriorate
Solution Approach 1:
The patent combines multiple separate components (tissue sealing electrode, cutting electrode, insulating supports) into a single integrated substrate that serves both tissue sealing and cutting functions. This integration reduces the number of parts, simplifies assembly, and ensures precise alignment between functional elements while maintaining full functional versatility.
Solution Approach 2:
The single integrated substrate performs multiple functions: it provides tissue sealing through the first electrode, tissue cutting through the second electrode, and electrical insulation through its non-conductive material. This multi-functional design eliminates the need for separate components for each function, reducing device complexity.
2Stability of the object's composition
If multiple thin supports are used to hold the cut electrode in place, then structural stability is improved, but manufacturing complexity and time increase
Solution Approach 1:
The insulating supports are integrated directly into the substrate structure rather than being separate components that need to be attached. The substrate itself provides the structural framework that holds the electrodes in precise positions, eliminating the need for multiple separate support elements and simplifying manufacturing.
Solution Approach 2:
The electrodes and insulating supports are formed in their final positions during the single-step substrate formation process. This preliminary positioning eliminates subsequent assembly steps where supports would need to be attached separately, reducing manufacturing complexity and time.
3Manufacturing precision
If photochemical etching or stamping processes are used to form electrodes, then manufacturing precision is improved, but manufacturing time and complexity increase
Solution Approach 1:
The patent combines electrode formation, substrate creation, and insulating support integration into a single manufacturing step using additive manufacturing. This eliminates the need for separate photochemical etching or stamping processes, maintaining precision while dramatically reducing manufacturing time and complexity.
Solution Approach 2:
The patent replaces traditional mechanical manufacturing processes (photochemical etching, stamping) with additive manufacturing technology. This substitution enables complex three-dimensional structures to be formed in a single step with high precision, eliminating multiple sequential manufacturing operations.
4Reliability
If connector portion is removed to electrically insulate portions, then electrical insulation is improved, but structural integrity during manufacturing deteriorates
Solution Approach 1:
The connector portion is designed with pre-defined fracture lines that allow controlled removal after the substrate has been formed and attached to the insulating member. This preliminary positioning ensures the substrate maintains structural integrity during manufacturing, and the connector is removed only when electrical insulation is required for final operation.
Solution Approach 2:
The substrate is designed as a single integrated component that can be selectively separated into functionally independent portions (tissue sealing electrode and cutting electrode) through removal of the connector portion. This segmentation allows electrical insulation between functional elements while maintaining structural integrity as a unified manufacturing unit.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A method of manufacturing an end effector assembly including first and second energizable portions configured to supply energy to tissue is provided. The method includes forming a substrate including first and second portions interconnected by a connector portion. The substrate is formed as a single integrated component. The method further includes engaging the substrate with an insulative member, and removing the connector portion of the substrate to electrically insulate the first and second portions from one another.