Overmolded Elastomeric Distal Pipe for Blade Clearance

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Solution Overview

Problem

Existing ultrasonic surgical instruments face challenges in cost-effective assembly and efficient prevention of interference between components during closure, which can affect the precision and reliability of tissue cutting and sealing.

Innovation Solution

The implementation of an overmolded distal pipe on the ultrasonic surgical instrument, formed by injecting an elastomer material over the ultrasonic blade assembly or sheath, provides a cost-effective solution that prevents interference and enhances assembly efficiency while maintaining clinical performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional assembly methods are used for ultrasonic surgical instruments, then manufacturing precision and component protection are maintained, but assembly costs increase and assembly time is extended

Engineering Contradiction:

Improveassembly costVSAvoidcomponent alignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The distal pipe is integrated directly into the sheath structure, eliminating the need for separate protective components. The elastomeric material is molded to form both the protective covering and the structural pipe in a single integrated component, reducing assembly steps and costs while maintaining precision through the molding process itself.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The distal pipe serves multiple functions: it protects the ultrasonic blade assembly, provides structural support, prevents interference between components, and acts as a guide for the clamp arm. This multi-functionality eliminates the need for multiple separate components, reducing assembly complexity and cost while maintaining manufacturing precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional distal pipe structures are used, then component protection is provided, but interference between ultrasonic blade and clamp arm occurs during closure

Engineering Contradiction:

Improvecomponent protectionVSAvoidclosure operation smoothness

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The distal pipe is constructed with varying wall thicknesses and elastomeric properties at different locations. The material composition and density are optimized locally to provide enhanced protection where needed while maintaining flexibility and smooth surfaces in areas that contact the clamp arm, preventing interference during closure operations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The distal pipe is made from elastomeric material that provides flexible protection rather than rigid shielding. This flexibility allows the pipe to accommodate minor movements and maintain smooth operation of the clamp arm during closure, while still providing adequate protection for the ultrasonic blade assembly.

Inventive Principle:

Principle #30Flexible shells and thin films

3Manufacturing precision

If multiple separate components are used for the distal pipe assembly, then manufacturing precision can be maintained, but assembly time and complexity increase

Engineering Contradiction:

Improveassembly precisionVSAvoidassembly efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The distal pipe is integrated directly into the sheath structure through molding processes, eliminating the need for separate protective components and fasteners. This integration maintains manufacturing precision through the molding process while significantly improving assembly efficiency by reducing the number of assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The protective distal pipe structure is pre-formed through molding processes before final assembly. This preliminary formation of the integrated structure ensures manufacturing precision is achieved during molding while eliminating subsequent assembly steps, thereby improving overall assembly efficiency.

Inventive Principle:

Principle #10Preliminary action

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 overmolded distal pipe reduces assembly costs and ensures smooth operation by preventing contact between the ultrasonic blade and clamp arm, thereby improving the precision and reliability of tissue cutting and sealing.

Implementation Method 1

an overmolded distal pipe extending distally from the sheath, the overmolded distal pipe formed by injecting an elastomer material over the ultrasonic blade assembly or sheath

Methodology Applied

Scientific EffectOvermolding:

Data Source

PatentUS20250228584A1Surgical instrument with elastomeric distal pipe and related methods

Publication Date: 2025.07.17 CILAG GMBH INTERNATIONAL

AI summary

A surgical instrument includes an ultrasonic blade assembly, a sheath, a first mating feature, and an overmolded distal pipe. The ultrasonic blade assembly extends distally along a longitudinal axis from a waveguide to an ultrasonic blade. Sheath is positioned over the ultrasonic blade assembly. The first mating feature is positioned on at least one of the sheath or the ultrasonic blade assembly. The overmolded distal pipe extends distally from the sheath with a second mating feature configured to be adhered to the first mating feature.