One-Piece Stopcock Plug Molding for Precise Surgical Sealing
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Solution Overview
Problem
Existing production methods for stopcock plugs are cumbersome and cost-intensive due to the need for multiple process steps and adhesive bonding of separate grip and cone parts, which complicates achieving the required precision and durability of sealing surfaces.
Innovation Solution
The plug is designed as a single integral part, produced through a combination of injection molding and embossing, allowing for precise and durable webs to be formed in a single process step, eliminating the need for separate assembly and additional machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the plug is produced using traditional multi-step processes (injection molding followed by turning), then the sealing precision and material hardness are improved, but the production complexity and cost increase
Solution Approach 1:
The patent combines the injection molding process and the embossing process into a single integrated production step. The embossing is performed directly on the injection-molded plug without requiring separate turning or machining operations. This merging of processes maintains the sealing precision and material hardness requirements while eliminating the complexity of multiple production steps and adhesive bonding operations.
2Ease of manufacture
If the plug is produced as a single integral part through injection molding and embossing, then the production simplicity and cost are improved, but the sealing precision must be maintained
Solution Approach 1:
The embossing process is performed as a preliminary action during the injection molding process itself, rather than as a subsequent separate operation. The mold cavities are designed to create the embossed sealing surfaces directly during plastic injection, ensuring the required precision is built-in from the start. This preliminary formation of sealing surfaces eliminates the need for post-processing while maintaining manufacturing precision.
3Reliability
If multiple process steps and adhesive bonding are used, then the plug can be produced with required properties, but the production time and cost increase
Solution Approach 1:
The patent merges the formation of the cone part, grip part, and sealing webs into a single injection molding process with integrated embossing. This eliminates the need for separate adhesive bonding steps and multiple machining operations, significantly reducing production time while maintaining the reliability and durability of the plug through the integral one-piece construction.
4Manufacturing precision
If the webs are formed with high precision and hardness, then the sealing performance is improved, but the manufacturing complexity increases
Solution Approach 1:
The embossing process enables the webs to form their own precise sealing surfaces through self-contained mold cavities during injection molding. The plastic material itself is shaped into the required web geometry with precise sealing surfaces, eliminating the need for complex external machining or finishing operations. The process serves itself by creating the precision features directly during the primary manufacturing step.
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 method simplifies and reduces the cost of production while ensuring exceptional stability and sealing performance by achieving the necessary precision and hardness of the webs in a single step, enhancing the plug's sealing capability.
Implementation Method 1
The plug, with the grip part and the cone part, is injection-moulded in one part
Implementation Method 2
a cone surface of the cone part has at least two horizontal webs which extend annularly around the cone part
Data Source
AI summary
In order to flush away local bleeding during surgery with a medical instrument, the instruments are commonly provided with a flushing device. In order to be able to control an inflow and outflow of a flushing liquid, the instruments have a stopcock. In order to achieve the sealing action of the stopcock, the plugs of the stopcock have to be formed with a very high degree of precision. The known production processes for such plugs are very cumbersome and cost-intensive. This provides a plug for a stopcock and a stopcock and a method for producing a plug, by way of which the stated problem is eliminated. This is achieved in that a plug, with a grip part and a cone part, is formed in one part and can be produced in a single process step.