Classifications

• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
  • A61B50/00—Containers, covers, furniture or holders specially adapted for surgical or diagnostic appliances or instruments, e.g. sterile covers
  • A61B50/10—Furniture specially adapted for surgical or diagnostic appliances or instruments
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
  • F16B39/00—Locking of screws, bolts or nuts
  • F16B39/22—Locking of screws, bolts or nuts in which the locking takes place during screwing down or tightening
  • F16B39/28—Locking of screws, bolts or nuts in which the locking takes place during screwing down or tightening by special members on, or shape of, the nut or bolt
  • F16B39/282—Locking by means of special shape of work-engaging surfaces, e.g. notched or toothed nuts
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
  • A61B50/00—Containers, covers, furniture or holders specially adapted for surgical or diagnostic appliances or instruments, e.g. sterile covers
  • A61B50/10—Furniture specially adapted for surgical or diagnostic appliances or instruments
  • A61B50/13—Trolleys, e.g. carts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
  • B29C45/14598—Coating tubular articles
  • B29C45/14614—Joining tubular articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
  • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
  • B29C66/52—Joining tubular articles, bars or profiled elements
  • B29C66/524—Joining profiled elements
  • B29C66/5244—Joining profiled elements for forming fork-shaped connections, e.g. for making window frames or Y-shaped pieces
  • B29C66/52441—Joining profiled elements for forming fork-shaped connections, e.g. for making window frames or Y-shaped pieces with two right angles, e.g. for making T-shaped pieces
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L13/00—Non-disconnectible pipe-joints, e.g. soldered, adhesive or caulked joints
  • F16L13/14—Non-disconnectible pipe-joints, e.g. soldered, adhesive or caulked joints made by plastically deforming the material of the pipe, e.g. by flanging, rolling
  • F16L13/16—Non-disconnectible pipe-joints, e.g. soldered, adhesive or caulked joints made by plastically deforming the material of the pipe, e.g. by flanging, rolling the pipe joint consisting of overlapping extremities having mutually co-operating collars
  • F16L13/161—Non-disconnectible pipe-joints, e.g. soldered, adhesive or caulked joints made by plastically deforming the material of the pipe, e.g. by flanging, rolling the pipe joint consisting of overlapping extremities having mutually co-operating collars the pipe or collar being deformed by crimping or rolling
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
  • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
  • A61B2017/00017—Electrical control of surgical instruments
  • A61B2017/00199—Electrical control of surgical instruments with a console, e.g. a control panel with a display
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
  • A61B50/00—Containers, covers, furniture or holders specially adapted for surgical or diagnostic appliances or instruments, e.g. sterile covers
  • A61B50/10—Furniture specially adapted for surgical or diagnostic appliances or instruments
  • A61B2050/105—Cabinets
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49826—Assembling or joining

Definitions

• the present invention generally pertains to support structures. More particularly, but not by way of limitation, the present invention pertains to support structures for surgical consoles.
• support structures for the storage and transportation of surgical consoles have been used in the past. Simple, open support structures with several, stacked shelves are sometimes used.
• the support structures may be made from metal or plastic, and may employ solid shelves or shelves formed from spaced, parallel members. Such support structures may not be specifically designed for the surgical console they serve, and may provide little, if any, protection for the ancillary equipment and consumables that are used with the surgical console.
• support structures have been designed for medical applications. These support structures may have an external surface for supporting a surgical console, an internal frame made from metal with shelves and/or drawers to store the ancillary equipment and consumables used with the surgical console, and an outer housing disposed over the internal frame.
• the outer housing may be constructed of multiple sheets of sheet metal or multiple plastic components (e.g., made from such methods as structural foam molding, injection molding, gas-assist injection molding and thermoforming) fastened together with screws, rivets, or other conventional fastening apparatus.
• the sheet metal or plastic components may be painted to provide a chemically resistant and aesthetically pleasing external surface.
• a frame system for a surgical system may include a plurality of rod structures cross connected through one or more structural members.
• the rod structures may each include at least one rod with an interface joint molded over the at least one rod.
• One or more of the interface joints may include a receiving hole for receiving a structural member to couple at least two of the plurality of rod structures together.
• One or more surgical components (such as a surgical console) may be received into the frame system. Other components may also be received into the frame system (e.g., an aesthetic skin).
• the rod structures may include an attachment point (e.g., a dimple) at the portion of the rod structure receiving an interface joint to better secure the interface joint to the rod structure.
• the rod structures may also include cross face structural members that are secured to portions of the rod structures through being molded to the rod structures through the interface joints. In some embodiments, these cross face structural members may be plugged on an end that engages the interface joint to avoid molding material flowing into the interior of the cross-face structural member during the molding process.
• portions of the rod structures, cross-face structural members, and/or other structural members may be inserted into the interface joints after formation of the interface joints (and secured thereto through, for example, adhesive, snap fit, or a friction fit).
• FIGs. l a-b illustrate a rod structure of a structural frame system, according to two embodiments;
• FIG. 2 illustrates a surgical system with an incorporated structural frame system, according to an embodiment;
• FIG. 3 illustrates a surgical system with an incorporated structural frame system, according to another embodiment
• FIGs. 4a-b illustrate different views of a rod structure with incorporated interface joints, according to an embodiment
• FIG. 5 illustrates two rod structures prior to attachment, according to an embodiment
• FIG. 6 illustrates two rod structures coupled together through cross-structural members, according to an embodiment
• FIG. 7 illustrates various components attached to the frame system, according to an embodiment
• FIGs. 8a-d illustrate embodiments of various interface joints
• FIGs. 9a-b illustrate a cross-sectional view of an embodiment of an interface joint and molding tool
• FIG. lOa-b illustrate cross-sectional views of two embodiments of an interface joint and a structural member with a plug
• FIG. 1 1 illustrates another cross-sectional view of an interface joint and a structural member with a plug, according to an embodiment
• FIGs. 12a-b illustrate two views of a plug for a structural member, according to an embodiment
• FIGs. 13a-16h illustrate inserts, according to various embodiments
• FIG. 17 illustrates a flowchart of a method for assembling a frame system, according to an embodiment
• FIG. 18 illustrates various cross sectional shapes for various structural members of the frame system, according to various embodiments.
• FIGs. 19a-g illustrate embodiments of a self centering plug
• FIGs. 20a-c illustrate additional embodiments of the interface joints. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to provide a further explanation of the present invention as claimed. DETAILED DESCRIPTION OF THE EMBODIMENTS
• FIGs. l a-b illustrate embodiments of a structural frame system 101 a-b (generally referred to herein as "frame system 101 ") that includes various interface joints 105 and structure members to support various loads throughout the frame system 101.
• a surgical system e.g., an ophthalmic surgical system 201 (FIG. 2) or ophthalmic surgical system 301 (FIG. 3)
• interface joints 105 may be coupled to and/or molded over portions of a rod structure 103 to provide mounting points for structure members and other components.
• rod structure 103 may include structural members 401a-i that are attached together through corresponding interface joints 105.
• structural members 401a-i may be part of a continuous rod (e.g., a rod bent to a predetermined shape) and the interface joints 105 may be molded (e.g., insert molded, injection molded, gas-assist injection molded, metal injection molded, Thixomolded, compression molded, hand layup, cast molded, etc.) over the continuous rod to provide mounting points for structure members and other components.
• molded e.g., insert molded, injection molded, gas-assist injection molded, metal injection molded, Thixomolded, compression molded, hand layup, cast molded, etc.
• Other techniques for forming the rod structure 103, structural members, etc. are also contemplated.
• the various components may be machined, welded, pultruded, extruded, hand layup, or hydroformed.
• cross-face structural members 405a-e may be attached to various respective interface joints 105a-h (generally referred to herein as "interface joint 105") by overmolding the interface joint on the rod structure 103 and the cross-face structural members 405a-e.
• the cross-face structural members 405a-e may be attached by sliding the cross-face structural members 405a-e into receiving holes in previously formed interface joints 105.
• cross-face structural members 405a and 405b may form a continuous cross-face structural member (both part of a single member that is similar to cross-face structural member 405e) that includes an interface joint 105i formed on the cross structural member.
• cross-face structural members 405c and 405d may form a continuous cross-face structural member that includes an interface joint 105j formed (e.g., molded) on the cross structural member.
• material fillers such as carbon or glass fibers utilized for the interface joints 105 may be added during an initial compounding of a resin into a pellet for molding the interface joints 105.
• a twin screw extruder may be used to create the pellets and appropriately blend in the material fillers. The pellets may then feed into a hopper of an injection molding machine and drawn into the molded machine's heated barrel and screw where the pellets may be melted and then shot into a tool to create a desired interface joint (e.g., around a section of the rod structure 103).
• a portion of the frame's system (e.g., a portion of the rod structure, structural members, etc.) may be placed into an injection molding machine's tool (e.g., see mold halves 903a,b shown in FIG. 9b).
• the tool may be closed and shut off around the portion in specific regions to shut off where the plastic is to flow to form the interface joint geometry around the inserted portion.
• Other molding processes are also contemplated.
• the interface joints 105 may include receiving holes 403a- h for cross-structural members to connect rod structure 103 with another rod structure.
• FIG. 5 shows two rod structures 103 prior to connecting and FIG.
• FIG. 6 shows the two rod structures connected through cross-structural members 601a-h that interface with the rod structures 103 through the interface joints 105.
• additional structures and components can be attached to the interface joints 105, rod structures 103, and/or cross-structural members 601 a-h.
• aesthetic skins 107 also seen in FIG. 2 may be attached (e.g., snapped, glued, ultrasonically welded, swaged, or fastened) to the composite rod structure 103.
• tray mounting point 703 may be attached to the composite rod structure 103 (e.g., through attachments to cross-structural members 601c-d).
• a printed circuit board 705 may be attached and may include interface connectors 707 for interfacing with a surgical module (e.g., module 203 which may be slid into the frame system 101 ).
• FIGs. 8a-d illustrate various embodiments of an interface joint 105.
• the interface joint 105 shown in FIG. 8a may be overmolded on rod sections 401c-d (which may form a continuous rod through the overmolded interface joint 105) and rod section 405a to attach rod sections 401c-d to rod section 405a and provide an attachment point (such as a receiving hole 403e to receive structural member 601c).
• an adhesive may be applied to the interior of receiving hole 403e and/or structural member 601 c prior to insertion of structural member 601c into receiving hole 403e.
• the adhesive e.g., glue or epoxy
• the adhesive may include 3M ADH 2216 B/A Epoxy, JD Lincoln 2-part high peel paste-PART (oxirane, 2,2- ⁇ methylenebis (phenleneoxymethylene)) bis-reaction product of epichlorohydrin and bisphenol A 40-60%, polymer/solids ⁇ 8%, benezenediol ⁇ 2%, silica-amorphous-fumed ⁇ 7% and fibrous glass ⁇ 2%) and PART B (Poly(oxy(methyl-l,2-ethanediyl)), alpha-2-amino- methyleneyl)omega-2-aminomethylethoxy) 25-45%, benzyl alcohol >10%, triethylenetetramine ⁇ 2%, nonyphenol ⁇ 5%, silica-amorphous, fumed
• interface joint 105 may include structural features such as braces 801 a-b, braces 803a-b, and brace 805 to increase the strength of the interface joint 105.
• the various braces may be formed through the molding process or may be attached after the molding process.
• a mold seam line 807 may form where an upper mold and a lower mold meet (e.g., in a cast or injection molding process) to form the interface joint (e.g., the molds may meet with the rod sections 401c-d and 405a in between the molds prior to injecting, for example, a plastic in a space defined by the upper and lower molds).
• the rod structure may include one or more mounting points 81 la-b (which may include, for example, protrusions with holes extending into the interior of the rod structure).
• interface joints may have one or more holes 809a-d for receiving and/or attaching components in the frame system 101.
• FIGs. 9a-b illustrates a cross section of an embodiment of an interface joint 105c that includes an attachment point 901.
• one or more attachment points 901 e.g., an indentation or cut-out
• the attachment points 901 may allow molding material from the interface joint 105 to collect into the attachment points 901 to hold the interface joint 105 in place (i.e., to prevent the interface joint 105 from slipping and/or impede creepage along the rod structure 103).
• the attachment point 901 may include an indentation made in the rod structure 103 (e.g., by pressing a feature into the surface of the rod structure 103 to form a dimple in the rod structure 103) that allows molding material to collect in a depression of the indentation.
• the attachment points 901 may include cutouts (e.g., stamped through the rod structure) that allow molding material to enter an interior of the rod structure 103.
• attachment points 901 may not be used (e.g., adhesive may be used to secure the interface joints 105 to the rod structure 103).
• FIGs. l Oa-1 1 illustrate cut-away views of various interface joints 105.
• the structure members coupled to interface joints 105 may include a plug (e.g., plug l OOl a/b).
• the plug 1001a may be formed on an end of the structure member (e.g., structural members 401a-i, structural members 405a-e, cross-structural members 601a-h, etc.) to inhibit flow of molding material from the interface joint 105 into an interior of the structure member.
• FIG. 10a illustrates a cut-away section of a plug 1001 a for a round structural member
• FIG. 10b illustrates a cut-away section of a plug 1001 b for a square structural member.
• the structure member may include a crimped section (e.g., crimp 1003a/b) with a reduced diameter to secure the plug 1001 in place.
• the plug 1001 may be formed separately from the structure member and inserted into the structure member (after which the structure member may be crimped to hold the plug) or the plug 1001 may be formed directly on the end of the structure member (e.g., molded onto the end of the structure member by inserting the end of the structure member into a plastic mold).
• the plug l OOl a/b may be made of a material with an equal or higher melting temperature (e.g., aluminum) than the material used to form the interface joint 105 (e.g., plastic) to prevent melting of the plug l OO l a/b during the molding of the interface joint 105 over the plug 1001.
• FIGs. 12a-b illustrate views of the plugged structure member outside of an interface joint 105.
• a plug l OOl a/b may not be used (e.g., the end of the structure member may be left open and may receive some molding material during the molding of the interface joints 105 on the rod structure 103).
• the plug l OO la/b may prevent molded material from entering cross-face structural member 405a and may provide a small undercut to inhibit pull out of structural member 405a once structural member 405a is overmolded.
• a flat corresponding geometrical shape may be welded to the end of member 405a in order to cap the end.
• plug 1001a may be made to contact member 103 to provide an electrical connection between members 405a and 103.
• an embodiment of the plug may include plug 1901 that may be configured to automatically center itself between members 103 on each side due to a molded in spring feature 1903 which may improve the reproducibility and repeatability of the assembly.
• the spring feature 1903 may include an angle and be flexible such that the spring feature 1903 may bend to allow movement of the plug 1901.
• the spring feature 1903 may further include a curve to abut against the outer curve of the structural member 40 Id (as seen in FIG. 19c).
• FIG. 19d illustrates the plug 1901 in a corner joint.
• FIG. 19e illustrates two plugs 1901 on either side of a structural member 60 I d.
• the curve in the spring feature of each plug may allow the structural member 60 Id to center itself (via interaction between the curve and the outer profile of the outer structural member) between the outer structural members (e.g., 401d) prior to molding the interface joints 105.
• the spring on each side may act to center the rod since each spring should be displaced by approximately the same length (if each spring has approximately the same spring rate).
• a hole or alignment feature may be used to center the tube structure in an injection molding tool to repeatably place the structure. This may result in a more repeatable pattern for fastening points on the cross member.
• FIGs. 19f-g illustrate another example of a spring connector. As seen in FIGs.
• connector 1905 may be coupled to a spring 1907 (e.g., a flexible wire structure) that may deflect (as seen in FIG. 19g) as the connector 1905 is pressed against a structural member.
• Connectors 1905 on each side of structural member 601 may center the structural member 601 as the structural member 601 is placed between outer structural members 401 (as an example) in a molding tool 191 1.
• the structural members 601 may be crimped 1909 around the connector 1905 (other coupling such as adhesive, snap fit, etc.) is also contemplated.
• a plug may not be used (e.g., as seen in FIG. 9a, the structure member may be, for example, attached to the interface joint 105c through an adhesive, friction fit, etc).
• FIGs. 13a-16h illustrate inserts, according to various embodiments.
• Floating inserts 1301, 1401 , and 1601 may provide tolerance between a screw (or other fastener) and the insert (such as a brass insert) in an assembly (such as frame system 101) for attaching a skin (such as a sheetmetal skin).
• the insert may be positioned in a polymeric portion (such as in hole 2071 a in the joint shown in FIGs. 20a-b) of the frame system 101 or in a metal portion (such as in hole 2071b in the structural member shown in FIGs. 20a-b).
• the insert may include an inner shaped plug (e.g., plug 1319 and 1419) with a squared end (e.g., end 1303 or 1403) and a rounded end (e.g., end 1305 or 1405). In some embodiments, both ends may be rounded (e.g., end 1603 and 1605 as seen in FIG. 16a). In some embodiments, a flange 1407 may be formed between the two ends with a threaded section 1409 formed through the center.
• an inner shaped plug e.g., plug 1319 and 1419
• a squared end e.g., end 1303 or 1403
• a rounded end e.g., end 1305 or 1405
• both ends may be rounded (e.g., end 1603 and 1605 as seen in FIG. 16a).
• a flange 1407 may be formed between the two ends with a threaded section 1409 formed through the center.
• the exterior may include a pattern with flutes or grooves to allow a melted polymer to flow freely into the crevices when the insert is ultrasonically welded into a polymeric boss (which may be formed and/or include hole 2071 a, b). Once the melted polymer in the boss re-solidifies it may form undercuts that may hold the insert in the boss and prevent the insert from being pulled out.
• a clearance e.g., clearance 1413
• an interface between insert portion 1415 (as seen in FIG. 14e) and inset portion 1417 (as seen in FIG. 15) may inhibit rotation of plug 1319/1419 when screwing a screw (or attaching a different fastener) into the plug 1319/1419 through an interference fit between the edge portion 1415 and inset portion 1417.
• the plug 1319 may be inserted into a bottom of the body 131 1 and a spring 1323 may be inserted into the body 131 1 from a top of the body 131 1 prior to a top 1325 of the plug 1319 being swaged (FIG. 13a shows un-swagged and FIG. 13b shows a swagged top) into a cone shape in order to trap the plug 1319 and spring 1323 inside the body 131 1.
• the plug 1619 may be placed into body 1621 and a portion 1623 of the body may be swaged into, for example, a dome shape to encapsulate the plug 1619.
• brass inserts ultrasonically welded into a plastic boss and then fastened to the structure using a screw may be used to fasten plastic skins to a mechanical assembly. This may allow for float by means of having the screw being able to move to align to the fixed boss/insert combination.
• Another method may include a floating female mounting point attached directly to the sheetmetal frame.
• the frame system 101 may be in the shape of a circle, biloba, ellipse, rectangle, square, octagon, and other geometrical combinations and variations of the aforementioned. As seen in FIG. 18, various cross sectional shapes may be used for the various structural members (e.g., structural members 405a-e) of the frame system 101. Various components for the structure may be formed using die forming, hydroforming, mechanical bending, hand layup, etc.
• the frame system 101 may further provide cable management for internal cables (e.g., through hooks and other cable retaining features that can be coupled to various parts of the frame system), provide mounting locations for fans, improve thermal management by directing air flow of internal machine components, as well as provide other benefits such as lighter weight mounting points and higher tolerances/repeatability over a pure sheet metal structure.
• structure members may have different configurations (e.g., made of different materials, have different cross section geometries, etc). For example, structure member 401 includes circular cross section while structure member 403 includes a rectangular cross section.
• the rod structure 103 may include round tubes which may be easier to bend while the cross-structural members 601a-h may include rectangular cross sections that may be easier for mounting sheet metal (e.g., aesthetic sheet metal skins may be welded along their perimeter to portions of the rectangular cross sections). Hollow cross sections may be used for the rod structure 103 and/or structural members to reduce the overall weight of the frame system 101.
• solid cross sections may be used (e.g., solid cross sections of light-weight high strength materials such as a high strength plastic, carbon fiber, or aluminum-titanium allow).
• molding the interface joint 105 may include molding plastic around a performed part (such as a tubular structure member 401 or rectangular structure member 601 a-h).
• the preformed part may include a material and/or geometry designed to hold its shape and support characteristics throughout the molding process (e.g., able to withstand pressures and temperatures associated with molding).
• some embodiments of the frame system 101 may be made with thermal welding, some embodiments may not include thermal welds (e.g., the frame system 101 may use insert molded joints as the primary attachment mechanism). Frame systems 101 without thermal welds may not have thermal dimensional issues that may be inherent with thermal welding.
• the rod structure 103 may be made from steel or aluminum and overmolded with plastic or aluminum utilizing an insert molded investment casting technique. Overmolded aluminum may be used to increase the structural integrity of the structure. (In some embodiments, this form may also be glued together instead of or in addition to the overmolding).
• the rod structure and/or structure members may be made of metal, aluminum, steel, carbon fiber, ceramic, polymers and/or composite materials. Other materials may also be used.
• Polymers that may be used to create the interface joints may include polyamide, polyphenylene sulfide, polycarbonate, polyvinylchloride, polyarylate, polysurfone, acetal, cellulosics, polyester, melamine, phenolic, urea molding compound, vinyl ester, unsaturated polyester, PC/ABS (polycarbonate/acrylonitrile butadiene styrene), polyetheretherkeytone, liquid crystal polymer, polypropylene, high density polyethylene, bulk molding compound, sheet molding compound, epoxy, and polyurethane. Other materials may also be used.
• the interface joints 105 may be made of electrically conductive materials to assist in grounding the frame.
• an epoxy/glue used in addition to the interface joints 105 may also be electrically conductive. While unmodified plastics may be good electrical insulators (e.g., 10 12 to 10 16 ohm-cm) and metals may be good electrical conductors (e.g., 10 "6 to 10 "1 ohm- cm), the electrical conductivity measured as electrical resistivity with the addition of conductive fillers in polymers may be approximately in the range 0.1 to 10,000 ohm- cm. To become electrically conductive, various fillers may be added in various quantities to a polymer used in the interface joints 105.
• a glue/epoxy used to bond the rod structure 103/interface joints 105/structural members together may be made electrically conductive using fillers such as metal fibers, carbon fibers, carbon nanotubes, metal coated inorganic non-particles, carbon powder, and nano-fibers.
• Additional electrically conductive materials for the interface joints may be selected from polymer grades including (E-Series): E2- conductive LCP (liquid crystal polymer), E3603 and E3605- conductive PA46, E4501 and E4507 Conductive Polycarbonate, E 1201 Conductive Polypropylene, E5101, E5107, E5109- Conductive Polyphenylene Sulfide.
• Typical flexural modulus of unfilled polymers may be in the range of 300-1000 ksi (thousands of pounds per square inch) and up to 1000 to 7500 ksi for composite polymer types. Other materials with different flexural modulus are also contemplated.
• an electrically conductive coating may be applied to one or more components.
• FIG. 17 illustrates a flowchart of an assembly method for the frame system 101 , according to an embodiment.
• the elements provided in the flowchart are illustrative only. Various provided elements may be omitted, additional elements may be added, and/or various elements may be performed in a different order than provided below.
• a rod structure 103 may be shaped.
• the rod structure 103 may include a continuous bar that is bent into a predetermined shape.
• various rod structure members may be shaped and prepared for joining into a larger rod structure 103.
• interface joints 105 may be formed and/or attached to the rod structure 103. In some embodiments, the interface joints 105 may be molded directly onto the rod structure 103.
• the rod structure 103 may include structural members (e.g., cross-face structural members 405a and 405b) that are attached to each other and/or to the rod structure 103 through the interface joints 105.
• the interface joints 105 may be formed over a portion of the rod structure 103 and an adjacent structural member to couple the structural member to the rod structure 103.
• an end of the structural member may be plugged prior to molding the interface joint 105 over the structural member.
• an attachment point e.g., attachment point 901 in the form of a dimple
• attachment point 901 may be formed in rod structure 103 through a moveable indention feature (e.g., a movable cylinder) located inside the injection molding tooling (e.g., see cylinders 905a,b in mold halves 903a,b shown in FIG. 9b).
• a moveable indention feature e.g., a movable cylinder located inside the injection molding tooling (e.g., see cylinders 905a,b in mold halves 903a,b shown in FIG. 9b).
• the cylinders 905a,b may pushed forward (e.g., by hydraulics) to create a dimple (or hole) in rod structure 103 and then may be retracted (see movement arrows in FIG. 9b).
• the cylinders 905a,b may be activated as soon as the mold was clamped onto the rod structure 103.
• Activation of the cylinders 905a,b may cause the dimpling of structure 103 inside the mold halves 903a,b to create a dimple or hole for mold material to flow into and form attachment point 901.
• several of the interface joints 105 for a rod structure may be molded at once (e.g., simultaneously).
• one or more joints may be angled (e.g., by angle 0 which may be, for example, approximately between 0.5 to 10 degrees) to avoid scraping of a mold along a side of a square member during the opening and closing of the mold halves.
• the side portions of the mold may scrape corresponding sides of a square member (which would be positioned perpendicular to the page) as the molds are clamped to the square member and the brace member 2003 the square member will be attached to.
• the mold sides may come together slightly offset of the square member and the molding material for the joint 2001 may be injected between the mold halves and around the square member and brace member 2003. If the angle ⁇ is 0, then slides or another moving mechanism may be needed in the tooling, which may make the tooling more complicated, more expensive, and possibly require more maintenance.
• valve gates may be used during injection molding tooling (opening and closing the valve gates to allow through injection molding material may be done in an ordered sequence (e.g., of material flow) across the rod structure).
• one or more combinations of barrels and screws may be used to allow for greater flexibility in applying the injection molding material to the rod structure (e.g., through an injection molding tooling) and allow for the use of more than one type of resin to be shot into the tool.
• the rod structure may include both a more expensive structural grade resin (e.g., with a less expensive panel) and a skin mounting grade resin used in the same structure.
• two or more rod structures 103 may be coupled together through cross-structural members (e.g., cross-structural members 601a-h).
• adhesive may be used in receiving holes (e.g., receiving holes 403a-h) of the interface joints 105 and the cross-structural members 601a-h may be attached to corresponding receiving holes in two or more rod structures 103 to couple the rod structures 103 to each other.
• an adhesive may not be used (e.g., the cross-structural members 601a-h may fit in the receiving holes through a friction fit).
• the interface joints 105 may be molded over the cross-structural members 601 a-h and rod structure 103. FIGs.
• various surgical modules and/or components may be attached to various sections of the frame system 101 that includes the rod structure 103 and structural members coupled together through interface joints 105.
• sheet metal aesthetic skins may be welded onto square cross section structural members or attached to the structure through one or more fasteners and inserts (e.g., inserts 1301, 1401 , or 1601).
• a molding and/or assembly system for the frame system 101 may include one or more processors.
• the processor may include single processing devices or a plurality of processing devices.
• Such a processing device may be a microprocessor, controller (which may be a micro-controller), digital signal processor, microcomputer, central processing unit, field programmable gate array, programmable logic device, state machine, logic circuitry, control circuitry, analog circuitry, digital circuitry, and/or any device that manipulates signals (analog and/or digital) based on operational instructions.
• the memory coupled to and/or embedded in the processors may be a single memory device or a plurality of memory devices.
• Such a memory device may be a read-only memory, random access memory, volatile memory, non-volatile memory, static memory, dynamic memory, flash memory, cache memory, and/or any device that stores digital information.
• the processors implement one or more of its functions via a state machine, analog circuitry, digital circuitry, and/or logic circuitry
• the memory storing the corresponding operational instructions may be embedded within, or external to, the circuitry comprising the state machine, analog circuitry, digital circuitry, and/or logic circuitry.
• the memory may store, and the processor may execute, operational instructions corresponding to at least some of the elements illustrated and described in association with FIG. 17.

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• 2009
  • 2009-12-10 US US12/635,070 patent/US8851308B2/en active Active
• 2010
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