Forceps Jaw Gap Control via Overmold Teeth and Hard Stops

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Solution Overview

Problem

Existing electrosurgical instruments face challenges in cost-effectively controlling the gap distance between jaw members, as ceramic dots used for this purpose increase manufacturing costs.

Innovation Solution

The use of a hard stop and overmold teeth within at least one jaw member of the forceps, where the hard stop primarily controls the gap distance and the overmold teeth assist in maintaining the appropriate gap distance by bearing a smaller portion of the applied load.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If ceramic dots are used to control gap distance, then gap distance control precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvegap distance controlVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive ceramic dots with a cost-effective composite structure consisting of a hard stop and overmold teeth made from durable plastic materials. This substitution maintains gap control functionality while significantly reducing manufacturing costs by eliminating the need for costly ceramic materials and their associated deposition processes.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention employs a composite structure combining a hard stop (providing primary mechanical support and gap limitation) with overmold teeth (providing secondary positioning and tissue engagement). This composite approach distributes the gap control function across multiple elements, achieving precision comparable to ceramic dots while using more economical materials.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If hard stop and overmold teeth are used instead of ceramic dots, then manufacturing cost is reduced, but gap distance control reliability may be affected

Engineering Contradiction:

Improvemanufacturing costVSAvoidgap distance control

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The gap control function is segmented into two distinct components: a hard stop that provides the primary gap limitation through direct mechanical contact, and overmold teeth that provide secondary positioning and stabilization. This segmentation ensures reliable gap control by distributing the functional requirements across multiple elements, preventing single-point failure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The overmold teeth are designed to engage before the hard stop is fully compressed, providing a cushioning effect that guides the jaw members into proper alignment and prevents excessive force concentration. This preliminary engagement ensures reliable operation by preparing the system for the primary gap-limiting action of the hard stop.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS12336749B2Gap control via overmold teeth and hard stops

Publication Date: 2025.06.24 COVIDIEN LP

AI summary

A forceps includes an end effector assembly having a stop and a plurality of overmold teeth within at least one jaw member. One (or both) of the jaw members is moveable relative to the other between a spaced-apart position and an approximated position for grasping tissue therebetween. One (or both) of the jaw members includes a stop molded within an insulative housing, and an insulator plate with the overmold teeth formed from plastic. The overmold teeth extend through openings within a sealing plate and protrude past the tissue sealing surface of the sealing plate. The stop primarily controls the gap distance between opposing jaw members by bearing most of an applied load and the overmold teeth assist in controlling the gap distance by bearing the remaining applied load.