Medical Handle Lighting Device Encapsulation

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Solution Overview

Problem

The production of medical handles with integrated lighting devices is hindered by the need for separate holders for each lighting device, which increases production effort and costs, and the chemical curing process of synthetic resin leads to adherence issues and slow hardening, making sterilization and light transmission inconsistent.

Innovation Solution

Encapsulating optical semiconductor components with a transparent thermoplastic material that hardens through cooling, eliminating the need for separate holders and allowing for faster production, improved sterilization resistance, and consistent light transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If synthetic resin is used to encapsulate LEDs in a holder, then sterilization is enabled, but production effort and costs increase due to the need for separate holders

Engineering Contradiction:

Improvesterilization capabilityVSAvoidproduction effort

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the holder structure and encapsulation material into a single integrated component. The injection-molded housing serves both as the structural holder and as the encapsulation medium for the LED, eliminating the need for separate holders and reducing assembly steps while maintaining sterilization capability through the medical-grade plastic material

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The injection-molded housing performs multiple functions simultaneously: it provides structural support, encapsulates the LED for protection, enables sterilization through material selection, and facilitates electrical insulation. This multi-functional design eliminates the need for separate specialized components for each function

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If synthetic resin is used for encapsulation, then LEDs are sealed, but hardening is slow and adherence to holder is problematic

Engineering Contradiction:

Improvesealing effectivenessVSAvoidhardening time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the chemical curing process of synthetic resin with a mechanical injection-molding process. Molten plastic is injected directly into the mold cavity around the LED, where it solidifies through cooling rather than chemical reaction, dramatically reducing the time required for encapsulation while maintaining effective sealing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The encapsulation process utilizes the phase transition of thermoplastic material from molten state to solid state through controlled cooling in the injection mold. This phase change provides rapid encapsulation without the slow chemical curing required by synthetic resins, while the material properties ensure proper sealing and adhesion

Inventive Principle:

Principle #36Phase transitions

3Ease of manufacture

If holder is used during liquid phase, then LEDs are held in position, but removal is difficult due to adhesion

Engineering Contradiction:

Improvepositioning capabilityVSAvoidremoval difficulty

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

Instead of removing the encapsulation material from the holder after curing (which causes adhesion problems), the patent inverts the process: the LED and encapsulation material are placed in the mold together, and the entire assembly is formed in one piece. The housing is designed to be removable from the mold as a complete unit with the LED already positioned, eliminating the adhesion removal problem entirely

Inventive Principle:

Principle #13The other way round (Inversion)

4Reliability

If separate holder is provided for each lighting device, then LEDs are secured, but storage and production costs increase

Engineering Contradiction:

ImproveLED securingVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent combines multiple components (holder, encapsulation material, and LED mounting structure) into a single injection-molded housing. This consolidation reduces the total number of parts that need to be manufactured, stored, and assembled, directly reducing production costs and inventory requirements while maintaining secure LED positioning through the integrated design

Inventive Principle:

Principle #5Merging (Combining)

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 method simplifies and reduces the cost of producing medical handles with lighting devices, enabling efficient sterilization and maintaining consistent light yield, while preventing electrical hazards and ensuring reliable encapsulation of components.

Implementation Method 1

the hardening process of the thermoplastic material is many times faster than with synthetic resin, since the hardening process is not caused by a chemical reaction but by a cooling process

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentEP1870022B1Medical handle with a lighting device and method of manufacturing

Publication Date: 2016.05.11 W & H DENTALWERK BURMOOS GMBH

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AI summary

The present invention relates to a medical handle (30) with a lighting device (1, 1', 1") comprising at least one optical semiconductor device (2) and a method for manufacturing such a handle (30). To adapt the handle (30) to the specific requirements of medical use, such as consistent light output, high mechanical resistance, sterilizability, and electrical safety, the invention proposes encasing the at least one optical semiconductor device (2) with a transparent thermoplastic material.