Light Handle Cover Injection Molding with Segmented Core
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Solution Overview
Problem
Existing light handle covers for surgical lights often have misaligned teeth and sharp edges, which can cause damage to gloves and skin during installation, and lack a secure grip, compromising the sterile environment and ease of use.
Innovation Solution
A method of injection molding a light handle cover with a cylindrical grab portion and a circular base shield, featuring inwardly extending trapezoidally-shaped teeth spaced to prevent contact and misalignment, and a shoulder ring to cover sharp edges, ensuring secure attachment and minimizing contact risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional light handle covers are manufactured, then production is simpler, but the teeth become misaligned and sharp edges are exposed causing damage to gloves and skin
Solution Approach 1:
The mold tool is divided into multiple independent components including a first mold half with a core and a second mold half with a cavity. The core is segmented into a proximal portion and a distal portion that can be independently positioned and adjusted. This segmentation allows precise control over teeth formation and alignment during the molding process, resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The mold tool is pre-configured with a core that defines the teeth geometry before the molding process begins. The core is preliminarily positioned to ensure proper teeth alignment and spacing. This preliminary action ensures that teeth are formed correctly from the start, preventing misalignment and eliminating the need for post-manufacturing adjustments, thus improving manufacturing precision without proportionally increasing complexity.
2Object-affected harmful factors
If traditional manufacturing methods are used, then production is faster, but sharp edges are exposed creating safety hazards
Solution Approach 1:
The mold cavity is designed with rounded corners and edges that correspond to the final product geometry. This beforehand cushioning approach ensures that sharp edges are prevented from forming in the first place during the molding process. The rounded mold surfaces transfer to the molded handle cover, eliminating sharp edges that could damage gloves or skin, while maintaining a relatively simple manufacturing process.
3Shape
If simple mold tools are used, then manufacturing is easier, but the handle cover lacks secure grip and proper shape
Solution Approach 1:
The mold tool incorporates localized features such as a core with specific geometric configurations that define the cylindrical grab portion and teeth structures. The core includes a proximal portion and a distal portion with specific shapes that impart the desired local qualities to different parts of the handle cover. This local quality approach allows complex shapes to be achieved through targeted mold features rather than overall mold complexity.
4Stability of the object's composition
If traditional ejection methods are used, then the process is simpler, but the handle cover becomes deformed during ejection
Solution Approach 1:
The mold tool incorporates an air ejection system that uses compressed air to remove the handle cover from the mold cavity. This pneumatic ejection method applies uniform pressure to eject the handle cover without causing deformation, maintaining the stability of the object's composition. The air blast provides a simple yet effective ejection mechanism that preserves the handle cover's uniform shape without requiring complex mechanical ejection systems.
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
The solution provides a secure, sterile, and easy-to-install light handle cover with reduced risk of damage, maintaining a uniform shape and preventing misalignment, thus enhancing safety and usability during surgical procedures.
Implementation Method 1
The mold cavity is injected with a moldable material
Implementation Method 2
The light handle cover is ejected from the second mold tool with a burst of air
Data Source
AI summary
A method of making a light handle cover including providing a first mold tool and a second mold tool. The first mold tool engages with the second mold tool to form a mold cavity. The mold cavity is injected with a moldable material. The light handle cover is formed as a single integral piece with a substantially cylindrical grab portion that is circumscribed on one end by a substantially circular base shield. A plurality of teeth are formed in the light handle cover. Each of the plurality of teeth is separated by a space. The light handle cover is ejected from the second mold tool with a burst of air.