Medical Handpiece Illumination Device with Hermetic Sealing
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Solution Overview
Problem
Medical handles with existing lighting devices face issues such as degraded light output due to yellowing of synthetic resins after sterilization, mechanical damage risk, and failure to meet electrical safety requirements, especially with encapsulated LEDs having metallic components.
Innovation Solution
A medical handle with a lighting device featuring a base body and blind holes for optical semiconductor components, using non-conductive and sterilization-resistant materials, and a transparent light emission window for improved mechanical durability and electrical safety, along with a covering device for hermetic sealing and reliable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If synthetic resin is used to encapsulate LEDs, then the lighting device can be sterilized in an autoclave, but the resin yellows after repeated sterilization causing degraded light transmission and light yield
Solution Approach 1:
The patent removes the synthetic resin encapsulation material from the lighting device structure. Instead of embedding LEDs in resin, the invention uses a holder with blind holes that receive and mechanically secure the LEDs without requiring resin encapsulation for structural integrity or sterilization resistance.
Solution Approach 2:
The patent employs a composite structure combining a holder made of one material (capable of withstanding sterilization) and LEDs mounted within blind holes. This composite approach eliminates the need for yellowing-prone synthetic resin while maintaining sterilization capability and light transmission properties.
2Reliability
If synthetic resin is used to encapsulate LEDs, then the lighting device can be sterilized, but the soft resin surface is prone to mechanical damage such as scratches and cracks
Solution Approach 1:
The patent extracts the synthetic resin encapsulation from the design, eliminating the soft, mechanically vulnerable surface layer. The holder structure provides mechanical support without relying on resin encapsulation, thereby preventing scratches and cracks that would compromise LED protection.
Solution Approach 2:
The patent designs the holder with a curved, dome-shaped surface that replaces the flat resin encapsulation. This curved geometry is inherently more resistant to mechanical damage and does not develop scratches or cracks that would allow water vapor or chemicals to reach the LEDs during sterilization.
3Strength
If conventional encapsulated LEDs with metallic components are used, then the LEDs are protected, but they cannot meet electrical safety requirements due to insufficient clearance and creepage distances in small-diameter handles
Solution Approach 1:
The patent introduces a non-conductive holder as an intermediary component between the metallic outer sleeve of the handle and the LED components. This holder with blind holes provides both mechanical protection for the LEDs and electrical insulation, eliminating the need for large clearance and creepage distances while ensuring electrical safety in small-diameter handles.
4Device complexity
If the front surface of the resin is made planar, then the structure is simple, but further processing of the emitted light is not possible
Solution Approach 1:
The patent incorporates optical elements directly into the holder structure during manufacturing, performing light processing preparation in advance. The holder can be designed with integrated lenses or optical features that shape and direct the emitted light, enabling further light processing without requiring additional separate components.
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 handle with consistent light output, enhanced mechanical resistance, and compliance with electrical safety standards, ensuring the LEDs remain protected during sterilization and maintain functionality.
Implementation Method 1
a lighting device with a light emitting diode (LED)
Implementation Method 2
a light emission window (9) which is formed by that part of the wall (7) which extends from the bottom (10) of the blind hole (8) to the first end (4) of the base body (3)
Data Source
Figure 1~2
Figure 3~4
AI summary
The handle has a covering device (11) e.g. ring shaped closing body, connected with a base plate (3) and forming a hermetically sealed inner space by a blind hole opening (8). An illumination device (1) is provided as a light source with an optical semiconductor component (2) arranged in the hermetically sealed inner space, and is connected with a current source by an electric supply device. The covering device and the base plate are made from an electrically non-conductive and repeatedly sterilized resistive material. An independent claim is also included for a method for manufacturing a medical handle with an illumination device.