3D Injection Molded Circuits for Miniaturized Surgical Instruments
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Solution Overview
Problem
Manufacturers face challenges in creating compact electrosurgical instruments that fit through smaller cannulas while maintaining reliability and low manufacturing costs, as devices become smaller and more complex, making it difficult to incorporate electrical circuits and mechanical components effectively.
Innovation Solution
The use of multi-shot 3D injection molded electrical circuits and connections, where insulative spacers with conductive strips are formed within the instrument, allowing for miniaturization and integration of electrical paths, enabling smaller, lighter, and more portable devices with reduced component count and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional separate component assembly is used for electrical circuits, then manufacturing flexibility is maintained, but device size increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple separate components (insulative spacer, electrical circuit traces, and connections) into a single integrated structure by co-molded injection molding. This merging of components reduces the overall device volume while the一体化 manufacturing process eliminates the need for separate assembly steps, thereby reducing manufacturing complexity despite the advanced molding technique required.
Solution Approach 2:
The insulative spacer structure serves multiple functions simultaneously: it provides electrical insulation, supports the electrical circuit traces, provides structural support, and acts as a housing component. This multi-functionality reduces the number of separate components needed, thereby reducing device volume and simplifying the overall manufacturing process.
2Volume of moving object
If device size is reduced to fit through smaller cannulas, then patient benefit increases, but manufacturing precision requirements increase
Solution Approach 1:
The electrical circuit traces and connections are pre-formed within the insulative spacer structure during the injection molding process itself, before final assembly. The co-molded technique allows circuits to be created directly in the spacer material, eliminating subsequent assembly steps and reducing the precision requirements for post-manufacturing alignment and connection.
Solution Approach 2:
The patent replaces traditional mechanical assembly methods (separate component fabrication, manual or automated assembly, connection welding or soldering) with a single co-molded injection molding process. This substitution of manufacturing methodology reduces the cumulative precision requirements that would arise from multiple separate manufacturing and assembly operations.
3Device complexity
If component count is reduced through integration, then assembly is simplified, but manufacturing process complexity increases
Solution Approach 1:
The insulative spacer structure is designed to self-integrate the electrical circuits and connections during the molding process. The co-molded technique allows the spacer to automatically form the circuit traces and connections as part of its own structure, eliminating the need for separate assembly operations. This self-service approach simplifies assembly while the single-step co-molding process manages the manufacturing complexity.
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 enables the creation of smaller, more reliable, and cost-effective surgical instruments by integrating electrical paths and components, addressing the challenge of miniaturization while maintaining performance and reducing manufacturing complexity.
Implementation Method 1
The conductive strip is configured to transmit a first electrical potential to the first electrically conductive plate
Implementation Method 2
multi-shot 3D injection molded electrical circuits and connections, where insulative spacers with conductive strips are formed within the instrument
Data Source
AI summary
An end effector assembly includes a first jaw member and a second jaw member. The first and second jaw members are operably movable relative to one another between an open position and a clamped position. The first and second jaw members each include an electrically conductive plate. The electrically conductive plates of the first and second jaw members oppose each other and are configured to conduct energy through tissue clamped therebetween. The first jaw member further includes an insulative spacer having a rib and a conductive strip. The rip extends from a surface of the insulative spacer towards the electrically conductive plate. The conductive strip is integrally formed on a surface of the rib to contact the electrically conductive plate. The conductive strip is configured to transmit an electrical potential to the electrically conductive plate.