Electrically-insulative hinge for electrosurgical jaw alignment
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Solution Overview
Problem
There is a need for a simple and effective electrically-insulative hinge that can be integrated into the manufacturing process of electrosurgical instruments to isolate movable components and ensure proper jaw alignment and gap distances, as traditional metal hinge configurations are complex and require tightly controlled processes.
Innovation Solution
An electrically-insulative hinge with pivot-hole locators is used to align and isolate jaw members in an electrosurgical forceps, allowing for easy integration and ensuring electrical isolation between components, with a manufacturing method involving attachment of the hinge to one jaw member and pinning with a pivot pin for pivotable mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional metal hinge configurations are used, then electrical isolation between jaw members is achieved, but device complexity increases and manufacturing precision requirements become tighter
Solution Approach 1:
The patent combines the hinge structure with the electrically insulative component into a single integrated assembly. The insulative material is molded directly onto the hinge pin, eliminating the need for separate insulative sub-assemblies and reducing overall device complexity while maintaining electrical isolation between the first and second jaw members.
Solution Approach 2:
The invention uses composite construction by overmolding electrically insulative material onto a metal hinge pin. This creates a hybrid component that simultaneously provides mechanical connectivity (metal core) and electrical isolation (insulative outer layer), resolving the contradiction between reliability of electrical isolation and device complexity.
2Reliability
If traditional metal hinge configurations with multiple sub-assemblies are used, then electrical isolation is achieved, but manufacturing time increases due to multiple overmolding and integration steps
Solution Approach 1:
The patent merges multiple manufacturing steps into a single overmolding operation. The insulative material is molded directly onto the hinge pin in one continuous process, eliminating the need for separate assembly steps where components are individually overmolded and then mechanically integrated, thereby reducing manufacturing time while maintaining electrical isolation.
Solution Approach 2:
The hinge pin is prepared with specific surface characteristics before overmolding to ensure proper bonding and alignment. This preliminary preparation enables the subsequent single-step overmolding process to proceed efficiently without requiring additional adjustment or rework steps, reducing overall manufacturing time.
3Reliability
If traditional metal hinge configurations are used, then electrical isolation is achieved, but manufacturing precision requirements increase for jaw alignment and gap distances
Solution Approach 1:
The composite structure of the insulative hinge provides inherent alignment features through the molded geometry. The insulative material can incorporate integrated alignment pins or guide features that automatically position the jaw members correctly during assembly, reducing the need for tightly controlled machining tolerances and complex alignment procedures.
Solution Approach 2:
The insulative material is strategically positioned and shaped at specific locations on the hinge pin to provide localized alignment and positioning functions. This local geometric control through molding allows for precise jaw alignment without requiring high precision across the entire hinge assembly, reducing overall manufacturing precision requirements.
Data Source
AI summary
An end effector assembly suitable for use with a forceps includes opposing first and second jaw members pivotably mounted with respect to one another. The first jaw member includes one or more pivot holes defined therein configured to receive a portion of a pivot pin therein. The end effector assembly also includes an electrically-insulative hinge configured to electrically isolate the first and second jaw members from one another including one or more pivot-hole locators having an aperture defined therein. The electrically-insulative hinge is attached to the first jaw member such that the one or more pivot-hole locators align with the one or more pivot holes of the second jaw member.