Metallized Surgical Instrument Assembly Without Overmolding

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Solution Overview

Problem

In overmolding techniques, achieving an adequate bond between polymeric, ceramic, or ceramic-polymer composite components and underlying components is challenging, especially in small assemblies, due to limited or no adhesion between mating surfaces, which affects the strength of the assembly.

Innovation Solution

The use of a structural metal element with a metallic foam layer and a nonmetallic spacer, where the surfaces to be joined are metallized to create a 'tie' layer for alternative bonding methods such as soldering, brazing, or adhesive bonding, allowing for improved adhesion between metal and nonmetallic components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If overmolding is used to create structural attachment between polymeric/ceramic components and underlying components, then assembly strength is improved, but assembly volume increases and adhesion between mating surfaces remains limited

Engineering Contradiction:

Improveassembly strengthVSAvoidassembly volume

Core Design Contradiction:

StrengthVSVolume of stationary object

Solution Approach 1:

The patent changes the bonding interface from polymeric/ceramic to metallic by applying metallized layers to component surfaces. This parameter change enables alternative bonding methods (soldering, brazing, adhesive bonding) that achieve strong structural attachment without requiring overmolding, thereby maintaining assembly strength while reducing assembly volume.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The metallized layer acts as an intermediary between the polymeric/ceramic component and the underlying metal component. This intermediate metallic layer enables direct structural attachment through conventional metal bonding techniques, eliminating the need for overmolding and reducing overall assembly volume while maintaining bond strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If overmolding is used to achieve structural attachment, then bond strength is improved, but the complexity of the manufacturing process increases

Engineering Contradiction:

Improvebond strengthVSAvoidmanufacturing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the bonding interface material parameter from polymeric/ceramic to metallic through surface metallization. This enables the use of well-established metal bonding processes (soldering, brazing, adhesive bonding) that are generally easier to manufacture than overmolding, while achieving superior bond strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent substitutes the mechanical overmolding process with metallization followed by alternative bonding methods. This replacement eliminates the complexity of overmolding tooling and processing while achieving equivalent or superior structural attachment through simpler, more established metal bonding techniques.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Volume of stationary object

If direct bonding is attempted between polymeric/ceramic surfaces and metal surfaces, then assembly size is reduced, but adhesion is limited or non-existent

Engineering Contradiction:

Improveassembly volumeVSAvoidadhesion strength

Core Design Contradiction:

Volume of stationary objectVSStrength

Solution Approach 1:

The patent changes the surface material parameter of polymeric/ceramic components by applying metallized layers. This parameter change enables direct bonding to metal surfaces with strong adhesion, achieving both compact assembly size and high bond strength simultaneously.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure where a metallized layer is applied to the polymeric/ceramic component surface. This composite approach combines the advantages of the base material with the bonding capabilities of metal, enabling strong direct adhesion to underlying metal components without requiring overmolding.

Inventive Principle:

Principle #40Composite materials

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 approach enhances the adhesion between components, enabling the creation of smaller and more robust assemblies, particularly in medical instruments, by providing a strong mechanical attachment and electrical/thermal isolation, while eliminating the need for an overmold layer.

Implementation Method 1

the surfaces to be joined are metallized to create a 'tie' layer for alternative bonding methods

Methodology Applied

Scientific EffectMetallization:

Data Source

PatentUS10925663B2Metallized components and surgical instruments

Publication Date: 2021.02.23 MOUND LASER & PHOTONICS CENTER INC

AI summary

An apparatus and related methods are described. The apparatus is described that includes a structural metal element including a metallic foam layer. The apparatus also includes a second metal element and a nonmetallic spacer. The nonmetallic spacer arranged between the structural metal element and the second metal element, the metallic foam layer joined to the nonmetallic spacer.