High Flow Insufflation Needle Stylet Progressive Die Stamping
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Solution Overview
Problem
The high cost of manufacturing insufflation needle assemblies with machined metal obturators limits cost savings in laparoscopic procedures, while existing methods are inefficient in reducing insufflation time and ensuring organ protection.
Innovation Solution
A method using a thin sheet of metal in a progressive die to stamp and roll the obturator into a high-flow stylet configuration, reducing material costs and increasing insufflation efficiency by forming a stylet with a distal section, intermediate section, and proximal section, and trimming support tabs to enhance gas flow and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a metal obturator is machined to remove portions of the wall, then the transition speed and insufflation rate are improved, but the manufacturing cost increases
Solution Approach 1:
The patent changes the manufacturing parameters by switching from traditional machining processes to progressive stamping and forming operations. This allows the obturator to achieve the required wall removal and shaping through incremental forming steps rather than costly machining, thereby maintaining high transition speed while reducing manufacturing cost
Solution Approach 2:
The patent employs a disposable obturator design where the obturator is manufactured as a single-use component. By using progressive stamping to create the optimized geometry, the cost of each disposable unit is reduced while maintaining the performance benefits of removed wall portions for fast transition and high insufflation rate
2Productivity
If portions of the obturator wall are removed, then the insufflation rate increases, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the obturator manufacturing process into distinct progressive stages: initial stamping of the flat pattern, formation of the cylindrical shape, and creation of the removed wall portions through sequential forming operations. Each stage is accomplished through dedicated tooling in the progressive die, breaking down the complex geometry creation into manageable steps that increase insufflation rate while controlling manufacturing complexity
3Loss of time
If the obturator mass is reduced, then the transition time decreases, but the structural integrity may be compromised
Solution Approach 1:
The patent applies local quality by strategically removing portions of the obturator wall only in specific regions where mass reduction is needed for faster transition, while maintaining full wall thickness in areas requiring structural integrity. The progressive forming process allows precise control over which wall portions are removed and to what extent, optimizing the balance between transition time and structural strength
Data Source
AI summary
A method for forming a high flow insufflation needle stylet having distal, intermediate and proximal sections includes providing a flat sheet of metal and forming pilot holes in the sheet proximate opposed edges of the sheet. A profile of a flat pattern of the stylet is formed. The flat pattern has a proximal end, a distal end and a pair of substantially longitudinal edges. At least one support tab is positioned between the flat pattern and the sheet. The intermediate and the proximal sections of the stylet are progressively formed into a partial cylindrical shape with the proximal end being open and the longitudinal edges in the intermediate and proximal sections being positioned between about 90° and 180° apart. The distal section is progressively formed into a substantially cylindrical shape having a closed distal end. The stylet is trimmed from the sheet by cutting the at least one support tab.