Plastic Electrosurgical Forceps Injection Molding Design
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Solution Overview
Problem
The high manufacturing cost and complexity of conventional electrosurgical forceps, particularly due to expensive material stamping and intricate assembly processes, as well as their single-use nature due to electrical components, make them impractical for repeated use and sterilization.
Innovation Solution
The development of an open electrosurgical forceps made from plastic via injection molding, featuring a pivotally coupled pair of shaft members with electrically conductive sealing plates and a cutting mechanism, where the seal plates are secured via press-fit or friction-fit, allowing for easy assembly and sterilization, and the cutting mechanism is removably coupled for enhanced usability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional material stamping and assembly processes are used, then manufacturing precision and reliability are improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent combines multiple components (shaft members, seal plates, stop members, cutter assembly) into a single molded unit, eliminating separate stamping and assembly operations. The injection molding process creates an integrated structure where all parts are formed simultaneously, reducing manufacturing steps and costs while maintaining precision through mold-based geometry control.
Solution Approach 2:
The molded shaft members incorporate multiple functions within single components: structural support, electrical insulation, mechanical stopping features, and cutter guide channels. This multi-functionality eliminates the need for separate components that would otherwise be required for each function, simplifying manufacturing while maintaining operational precision.
2Strength
If conventional material stamping and intricate assembly processes are used, then structural strength and reliability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates multiple structural components into unified molded parts. The shaft members combine structural support, insulation, and mechanical features into single pieces, eliminating the complexity of assembling multiple separate components while maintaining overall structural strength through the integrated design.
Solution Approach 2:
The patent utilizes plastic materials with appropriate mechanical properties to achieve structural strength without requiring complex metal assemblies. The molded plastic components provide sufficient strength for surgical applications while simplifying the overall device structure and reducing assembly complexity.
3Reliability
If electrosurgical forceps with electrical components are used, then tissue treatment capability is improved, but reusability and ease of sterilization deteriorate
Solution Approach 1:
The patent describes a disposable forceps design where the entire instrument is molded as a single-use unit. This eliminates sterilization requirements and allows the forceps to be discarded after one use, solving the reusability problem while maintaining full tissue treatment capability through integrated electrosurgical components.
Solution Approach 2:
The patent also describes a reusable variant where the electrosurgical components are segmented into separable parts that can be sterilized independently. The molded shaft members without electrical components can be sterilized and reused, while the electrosurgical elements are replaced or sterilized separately, enabling multiple uses while maintaining treatment capability.
4Manufacturing precision
If non-conductive stop members are positioned on seal surfaces, then jaw alignment precision is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent integrates the stop members directly into the molded shaft members, eliminating separate positioning and attachment steps. The stop features are formed as integral parts of the shaft during injection molding, achieving precise jaw alignment while reducing manufacturing time by eliminating sequential assembly operations.
5Adaptability or versatility
If cutter or knife blade assembly is operably coupled to shafts, then cutting functionality is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent integrates the cutter assembly guidance features directly into the molded shaft members. The knife channel and associated structural elements are formed as integral parts of the shaft, eliminating separate manufacturing and assembly steps for the cutting mechanism while maintaining full cutting functionality.
Solution Approach 2:
The molded shaft members serve multiple functions: structural support, electrical insulation, stop member integration, and cutter guide. This multi-functionality reduces the need for separate components and assembly operations, lowering manufacturing costs while maintaining cutting capability through the integrated design.
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 solution reduces manufacturing costs and enables the forceps to be reused or sterilized, providing a cost-effective and practical option for open surgical procedures while maintaining effective tissue treatment capabilities.
Implementation Method 1
Each of the jaw members includes an electrically conductive sealing plate for communicating electrosurgical energy through tissue held therebetween
Implementation Method 2
a pair of shaft members (4, 6) formed of plastic and formed via an injection molding process
Implementation Method 3
The seal plates are secured via press-fit or friction-fit
Data Source
AI summary
An open electrosurgical forceps is provided and includes a pair of first and second shaft members each having a jaw member at a distal end thereof. The jaw members are movable from a first position in spaced relation relative to one another to a subsequent position wherein the jaw members cooperate to grasp tissue therebetween. A cutting mechanism is adapted to selectively and removably couple to one of the first and second shaft members. The cutting mechanism includes a cutting trigger for selectively advancing a knife blade extending therefrom through a knife channel defined along one or both of the jaw members. The first shaft member includes a stop feature formed thereon and the second shaft feature includes a stop member formed thereon. The stop feature and stop member configured to selectively engage one another to limit rotation of the first and second shaft members with respect to one another.