Surgical Forceps Jaw Member Manufacturing via Co-Molding
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Solution Overview
Problem
Current methods for manufacturing jaw members of surgical forceps require specialty equipment and precise tolerances, leading to increased manufacturing costs and process variability, particularly in securing insulative stop members to maintain a specific gap distance between jaw members.
Innovation Solution
A method involving forming an electrically-conductive plate with an aperture, machining a stop member from heat-resistant ceramic, and overmolding an outer housing to secure the jaw frame, electrically-conductive plate, and stop member, ensuring a consistent gap distance of 0.001 to 0.006 inches between the jaw members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current techniques of forming and securing stop members are used, then manufacturing precision of gap distance is maintained, but device complexity and manufacturing cost increase due to specialty equipment and precise tolerances
Solution Approach 1:
The stop member is integrated directly into the jaw member structure through co-molding, merging two previously separate components (jaw member and stop member) into a single integrated part. This eliminates the need for separate formation and securing processes, reducing device complexity while maintaining manufacturing precision of the gap distance through molded-in features.
Solution Approach 2:
The jaw member is designed to perform multiple functions: it provides the structural framework, contains the electrosurgical electrode, and incorporates the stop member for gap distance control. This multi-functionality reduces the number of separate components and processes needed, simplifying the manufacturing process while maintaining precision.
2Manufacturing precision
If current techniques of forming and securing stop members are used, then manufacturing precision of gap distance is maintained, but manufacturing cost increases due to specialty equipment and process variability
Solution Approach 1:
The stop member is integrated directly into the jaw member structure through co-molding, merging two previously separate components (jaw member and stop member) into a single integrated part. This eliminates the need for separate formation and securing processes, reducing device complexity while maintaining manufacturing precision of the gap distance through molded-in features.
Solution Approach 2:
The co-molding process allows the stop member to be self-formed and self-secured within the jaw member during a single manufacturing operation. The molded-in features automatically provide the necessary positioning and securing functions without requiring additional specialized equipment or post-processing steps, reducing manufacturing cost and variability.
3Manufacturing precision
If stop members are secured via current techniques, then specific gap distance is maintained for tissue treatment, but process variability increases
Solution Approach 1:
The stop member is integrated directly into the jaw member structure through co-molding, merging two previously separate components (jaw member and stop member) into a single integrated part. This eliminates the need for separate formation and securing processes, reducing device complexity while maintaining manufacturing precision of the gap distance through molded-in features.
Solution Approach 2:
The co-molding process allows the stop member to be self-formed and self-secured within the jaw member during a single manufacturing operation. The molded-in features automatically provide the necessary positioning and securing functions without requiring additional specialized equipment or post-processing steps, reducing manufacturing cost and variability.
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 eliminating the need for precise equipment and process variability, ensuring consistent gap distances for effective tissue treatment in surgical forceps.
Implementation Method 1
overmolding an outer housing about at least a portion of the jaw frame, electrically-conductive plate, and stop member to secure the jaw frame, electrically-conductive plate, and stop member to one another
Data Source
AI summary
A method of manufacturing a jaw member of a surgical forceps includes forming a jaw frame having a distal jaw support. The method also includes forming an electrically-conductive defining an aperture having a first diameter, forming a stop member including a body having a second diameter smaller than the first diameter and a shoulder having a third diameter greater than the first diameter. The method also includes inserting the stop member into the aperture such that the body extends through the aperture and the shoulder abuts a portion of the electrically-conductive plate surrounding the aperture, and overmolding an outer housing about at least a portion of the jaw frame, electrically-conductive plate, and stop member to secure the jaw frame, electrically-conductive plate, and stop member to one another.