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US 9,861,263 B2Granted
Polymeric material for use in and with sterilizable medical devices
AssigneeKARL STORZ Imaging, Inc.
InventorsKin Ming Kwan, Dejan Korkut, Thomas J. Anhalt, Paul McCarty, Diegas E. Zavala
Life of this patent
Estimating the term…
Abstract
The invention provides an endoscopic video camera having a polymeric knob assembly, wherein the polymeric material used for manufacturing the knob assembly includes polyphenylsulfone resin, titanium dioxide, tin oxide, and colored metallic additives, is capable of withstanding sterilization, and has a metallic cosmetic appearance. The invention also provides methods of manufacturing the knob assembly by plastic injection molding processes, wherein undesirable molding characteristics are concentrated on portions of the knob assembly that are removed by secondary machining or post machining.
Claims20
A method of manufacturing a knob assembly, the method comprising:
- forming a first plastic blank using a plastic injection molding process, the first plastic blank having a shell, an interior surface, an exterior surface, a first end, a second end, a sprue, a center web, at least one rib extending from the interior surface, a floor adjoining the interior surface at the second end, at least one boss extending from the floor, and a groove on the interior surface at the first end;
- forming a second plastic blank using a plastic injection molding process, the second plastic blank having a sprue, a center web, and a skirt, the center web of the second plastic blank having at least one recess;
- trimming the sprues of the first plastic blank and the second plastic blank;
- machining an o-ring pocket into the first plastic blank;
- inserting a ring into the first plastic blank, the ring having an inside diameter and at least one groove on the inside diameter, the ring positioned on the floor and aligned between the at least one rib and the at least one boss;
- welding the skirt of the second plastic blank to the groove of the first plastic blank to form the knob assembly, the knob assembly covering at least a portion of the ring;
- machining an o-ring pocket and a stop groove into the second plastic blank of the knob assembly;
- and
- machining the exterior surface of the knob assembly.
6 more elements
A method of manufacturing a camera having at least one knob assembly, the method comprising:
- forming a first plastic blank using a plastic injection molding process, the first plastic blank having a shell, an interior surface, an exterior surface, a first end, a second end, a sprue, a center web, at least one rib extending from the interior surface, a floor adjoining the interior surface at the second end, at least one boss extending from the floor, and a groove on the interior surface at the first end;
- forming a second plastic blank using a plastic injection molding process, the second plastic blank having a sprue, a center web, and a skirt, the center web of the second plastic blank having at least one recess;
- trimming the sprues of the first plastic blank and the second plastic blank;
- machining an o-ring pocket into the first plastic blank;
- inserting a ring into the first plastic blank, the ring having an inside diameter and at least one groove on the inside diameter, the ring positioned on the floor and aligned between the at least one rib and the at least one boss;
- welding the skirt of the second plastic blank to the groove of the first plastic blank to form the knob assembly, the knob assembly covering at least a portion of the ring;
- machining an o-ring pocket and a stop groove into the second plastic blank of the knob assembly;
- machining the exterior surface of the knob assembly;
- and
- assembling the knob assembly into the camera.
7 more elements
A method of manufacturing a knob assembly, the method comprising:
- forming a first metal blank using a metal injection molding process, the first metal blank comprising a ring having a first end, a second end, an outside diameter, an inside diameter, at least one groove on the inside diameter, a stop groove on the first end, and at least one boss extending from the outside diameter;
- forming a second metal blank using a metal injection process, the second metal blank comprising a ring having an outside diameter, an inside diameter, and a skirt extending from the inside diameter of the second metal blank;
- assembling the first and second metal blanks to form an inner ring;
- over-molding the inner ring with a plastic material using a plastic injection molding system to form a knob assembly;
- and
- post-machining the knob assembly.
3 more elements
A method of manufacturing a camera having at least one knob assembly, the method comprising:
- forming a first metal blank using a metal injection molding process, the first metal blank comprising a ring having a first end, a second end, an outside diameter, an inside diameter, at least one groove on the inside diameter, a stop groove on the first end, and at least one boss extending from the outside diameter;
- forming a second metal blank using a metal injection process, the second metal blank comprising a ring having an outside diameter, an inside diameter, and a skirt extending from the inside diameter of the second metal blank;
- assembling the first and second metal blanks to form an inner ring;
- over-molding the inner ring with a plastic material using a plastic injection molding system to form the at least one knob assembly;
- post-machining the knob assembly;
- laser marking the knob assembly;
- and
- assembling the knob assembly into the camera.
5 more elements
Dependencies are inferred from the claim text.