Notch-locating fixture for electrochemical grinding of needle wire
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Solution Overview
Problem
The challenge lies in consistently and effectively forming notches in small diameter steel alloy needle wires for endoscopic suturing apparatuses without deforming the wire, altering its mechanical or metallurgical properties, while maintaining precise curvature and geometry for continuous loop functionality.
Innovation Solution
A notch-locating fixture with a base and cover member secured by bolts, featuring semi-circular recesses and aligned slots for precise alignment and electro-chemical grinding, ensuring notches are formed without mechanical deformation, using a conductive stainless steel sheet and neoprene foam pad for secure and conductive contact, and a CNC ECG machine for precise notch geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional notching methods are used on small diameter needle wire, then notches can be formed, but the wire is deformed and mechanical properties are altered
Solution Approach 1:
The patent replaces conventional mechanical notching methods with electrochemical machining (ECM). The ECM process uses electrochemical reactions to remove material without mechanical contact, thereby avoiding deformation and alteration of mechanical properties of the small diameter needle wire while still forming precise notches.
Solution Approach 2:
The patent changes the fundamental parameter of the notching process from mechanical force to electrochemical reaction. By controlling electrical current, electrolyte composition, and processing time, precise notches are formed without the mechanical stresses that cause wire deformation and property changes.
2Length of moving object
If the needle wire diameter is reduced for smaller endoscopic devices, then device profile is reduced, but notch formation becomes increasingly difficult
Solution Approach 1:
The electrochemical machining process eliminates the need for mechanical contact during notching, which is particularly beneficial for small diameter wires where mechanical forces would cause excessive deformation. The ECM process scales well to smaller dimensions because it relies on electrochemical reactions rather than mechanical forces.
Solution Approach 2:
The patent introduces an electrolyte solution as an intermediary medium between the electrode and the needle wire. This electrolyte enables material removal through electrochemical reactions without direct mechanical contact, making it possible to form notches in very small diameter wires that would be impossible with conventional mechanical methods.
3Manufacturing precision
If mechanical notching is used to ensure precise notch geometry, then notch shape can be controlled, but the needle wire curvature varies and functionality is compromised
Solution Approach 1:
By replacing mechanical notching with electrochemical machining, the patent achieves precise notch geometry through control of electrical parameters and electrode positioning without applying mechanical forces that would alter the wire's curvature. The ECM process allows the wire to maintain its pre-formed curvature while still achieving precise notch dimensions.
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
Enables the production of notches with precise geometry and minimal deformation, maintaining the needle wire's strength and smoothness, suitable for mass production with consistent results, achieving precise dimensional requirements and maintaining the needle wire's curvature for effective use in endoscopic suturing devices.
Implementation Method 1
electro-chemical grinding, ensuring notches are formed without mechanical deformation
Data Source
AI summary
A notch-locating fixture for forming notches at predetermined locations along a needle wire used in a surgical suturing apparatus includes a base having at least one semi-circular recess shaped and dimensioned for receiving the needle wire. The fixture also includes a cover member including at least one aligned slot formed therein in a manner providing a grinding wheel with access to needle wire held between the base and the cover member. The fixture further includes a securing structure selectively coupling the base to the cover member.