Polymer Vessel Sealer Jaws for Lower-Complexity Electrosurgical Assembly
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Solution Overview
Problem
Existing scissor style vessel sealers in the market have high assembly complexity and costs due to the use of numerous metal components and complex manufacturing processes, which require insulation and bonding techniques.
Innovation Solution
An electrosurgical instrument with overmoulded jaws formed from structural polymer, reducing the need for metal components and incorporating polymer-based pivot holes, flanges, and a flexible lever arm for simplified assembly and enhanced functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal components are used to form jaw and lever arm assemblies, then structural strength and support are improved, but assembly complexity and manufacturing costs increase
Solution Approach 1:
The patent combines multiple separate metal components (jaw, lever arm, reinforcement elements, insulation components) into a single integrated polymer component. The overmoulded polymer structure integrates the jaw member, lever arm, and reinforcement into one piece, eliminating the need for assembly of multiple parts and reducing overall complexity.
Solution Approach 2:
The patent uses composite polymer materials with embedded reinforcement elements (such as fiber reinforcements) to achieve the structural strength previously requiring metal components. The composite structure provides both the mechanical strength needed for jaw support and the insulation properties required for electrosurgical applications.
2Strength
If multiple metal components are used in the assembly, then structural support is improved, but manufacturing and bonding requirements increase
Solution Approach 1:
The patent merges multiple manufacturing steps and components into a single overmoulding process. The polymer component is formed in one manufacturing operation with embedded reinforcement elements, eliminating the need for separate machining, assembly, and bonding operations required for metal components.
Solution Approach 2:
The patent replaces mechanical assembly processes (fastening, bonding, insulation installation) with a single polymer forming process. The overmoulded structure inherently provides both structural support and electrical insulation, eliminating the need for separate mechanical fastening and insulation steps.
3Strength
If metal reinforcement components are added to support the jaws, then jaw bending is reduced, but assembly complexity increases
Solution Approach 1:
The patent incorporates reinforcement elements directly into the polymer matrix during the overmoulding process, creating a composite material structure. The reinforcement (such as fibers or embedded structures) provides the necessary rigidity and strength to prevent jaw bending, while being integrated into the single polymer component rather than added as separate metal parts.
Data Source
AI summary
An improved electrosurgical instrument, specifically a scissor style vessel sealer, comprising two overmoulded jaws formed from a structural polymer held in place by a pivot pin. The moulded structural polymer replaces many metal components which would otherwise be required for such an assembly. Additionally, reinforcement members can be positioned within the jaws of the instrument to provide support. Not only does the use of the moulded structural polymer simplify the assembly of the instrument, it also enables the following additional functionality: moulded pivot holes, flanges providing lateral support, and a flexible lever arm which is designed to provide the force needed to clamp and seal vessels.