Jaw Member Alignment Spacer for Surgical End-Effector Tolerance
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Solution Overview
Problem
Existing surgical instruments face challenges in predicting mechanical factors such as pressure and gap distance between electrodes in bipolar electrosurgical forceps, affecting the effectiveness of electrosurgical energy on tissue, due to manufacturing tolerances not being consistently met.
Innovation Solution
A method of manufacturing end-effector assemblies that involves assembling and aligning jaw members using an alignment spacer to set precise jaw gaps and alignments, ensuring consistent mechanical factors for effective electrosurgical procedures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for end-effector assemblies, then manufacturing simplicity is maintained, but manufacturing precision and tolerance requirements for jaw gap and alignment are not met
Solution Approach 1:
The alignment spacer is designed with pre-configured engagement features that automatically position the jaw members and sealing plates in the correct alignment during assembly. The spacer includes protrusions that engage with recesses in the jaw members, and the jaw gap is pre-set to a specific dimension, eliminating the need for complex post-assembly adjustments and ensuring tolerance requirements are met
Solution Approach 2:
The alignment spacer acts as an intermediary component between the jaw members and sealing plates during assembly. It mediates the alignment process by providing a fixed reference structure that ensures proper positioning of all components, thereby achieving the required manufacturing precision without directly modifying the jaw members or sealing plates
2Manufacturing precision
If conventional manufacturing methods are used for end-effector assemblies, then manufacturing simplicity is maintained, but alignment precision of sealing plates and jaw members is insufficient
Solution Approach 1:
The alignment spacer is pre-configured with engagement features including protrusions and recesses that automatically align the sealing plates with the jaw members during assembly. This preliminary alignment configuration ensures that when components are assembled, they are automatically positioned with the required precision without needing complex alignment procedures
Solution Approach 2:
The alignment spacer serves as a mediating component that facilitates precise alignment between the sealing plates and jaw members. By providing a fixed geometric reference structure, it mediates the alignment process and ensures that all components are positioned correctly relative to one another, achieving high alignment precision while keeping the assembly process relatively simple
3Reliability
If jaw gap and alignment are not precisely controlled, then manufacturing complexity is reduced, but the effectiveness and predictability of electrosurgical energy application deteriorates
Solution Approach 1:
The alignment spacer is designed with a pre-determined jaw gap dimension built into its structure. During assembly, the spacer automatically maintains this specific gap distance between the jaw members, ensuring consistent mechanical factors for electrosurgical energy application. This preliminary configuration of the gap dimension ensures reliability and predictability of surgical outcomes
Solution Approach 2:
The alignment spacer acts as a mediating structure that ensures consistent jaw gap and alignment, which are critical for the predictability of electrosurgical energy application. By maintaining fixed geometric relationships between components, it mediates the mechanical factors that affect energy delivery, thereby ensuring reliable and predictable surgical results
Data Source
AI summary
A method of manufacturing a matched pair of opposing jaw members of an end-effector assembly includes assembling a first jaw member having a knife channel, assembling a second jaw member having a knife channel, setting a jaw gap and aligning a first sealing plate of the first jaw member and a second sealing plate of the second jaw member in relation to one another by bringing the first jaw member and the second jaw member into clamped engagement with an alignment spacer. The alignment spacer is configured to engage the knife channel of the first jaw member and the knife channel of the second jaw member. The method also includes coupling the first jaw member to the second jaw member.