Injection-Molded Articulation Joint for Disposable Endoscopes
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Solution Overview
Problem
Conventional endoscopes are expensive, inflexible, and require complex assembly, making them costly and prone to damage, while existing disposable endoscopes lack affordable articulation joints for single-use applications.
Innovation Solution
The development of a low-cost, easily assembled articulation joint for endoscopes using injection-molded segments with hinge elements and cable guide loops, allowing for flexible bending via control cables, and a method involving snap-fitted annular rings for forming the joint body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional endoscopes are built with sturdy materials to withstand repeated disinfections and use, then reliability and durability are improved, but flexibility decreases and patient comfort is reduced
Solution Approach 1:
The endoscope is divided into multiple rigid segments connected by articulation joints, allowing each segment to maintain structural integrity while the overall system achieves flexibility through the articulated connection between segments
Solution Approach 2:
The articulation joint combines rigid components (molded body, cable guide elements) with flexible elements (control cables, hinge mechanisms) to create a composite structure that provides both durability and flexibility
2Strength
If conventional endoscopes use complex stamped and formed metal parts brazed together with adhesives to create articulation joints, then strength and durability are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The complex mechanical assembly process involving brazing and adhesive bonding is replaced with injection molding technology, which integrates the articulation joint components into a single molded piece, eliminating the need for complex joining operations
Solution Approach 2:
Multiple separate components (articulation joint body, cable guide elements, hinge structures) that were previously manufactured separately and assembled through brazing and adhesives are merged into a single integrated injection-molded component
3Reliability
If conventional endoscopes use metal articulation joint segments requiring special tooling and brazing operations, then reliability is improved, but production cost increases
Solution Approach 1:
The injection-molded articulation joint enables the endoscope to be manufactured as a disposable device at low cost, eliminating the need for expensive metal processing and brazing operations while maintaining sufficient reliability for single-use applications
Solution Approach 2:
The material selection shifts from metal to polymer, and the manufacturing process changes from brazing to injection molding, fundamentally altering the production parameters to reduce cost while maintaining functional performance
4Manufacturing precision
If conventional endoscopes are hand assembled with complex procedures, then precision and quality control are improved, but productivity decreases and assembly complexity increases
Solution Approach 1:
The articulation joint is pre-formed through injection molding with all structural features (hinges, cable guides, connection points) integrated into the molded part, eliminating the need for complex post-assembly operations and enabling rapid assembly or disposal
Data Source
AI summary
In one aspect, the present invention is an articulation joint for use in a low cost medical device such as an endoscope intended for a single use. In one embodiment, the articulation joint comprises a plurality of interconnected segments. In another embodiment, the articulation joint comprises an elongated tubular body. In another aspect, the present invention provides methods of manufacturing an articulation joint for use in a medical device.