Medical felting system and power unit

Abstract

The present disclosure relates to a medical felting system (1). The medical felting system comprises a felting device (200) and a power unit (100). The felting device comprises at least one felting needle (203) configured to move back and forth between two end positions. The power unit comprises a battery (155) storing electrical energy, an electric motor (165) and a controller (164). The electric motor is configured to actuate the at least one felting needle. The electric motor is electrically connected to the battery. The controller is configured to control the electric motor and to actuate the motor to drive the felting needle. The felting device and the power unit are separable from each other. The felting system comprises a mechanical coupler (300) operably and releasably connecting the power unit to the felting device. The mechanical coupler transfers rotational motion from the motor to the at least one felting needle.

Description

[0001] This invention relates to a medical felting system and its power unit.

[0002] Recently, the applicant has developed a novel fixation technique for soft tissues such as skin, muscles, and tendons. In this technique, a nonwoven material is felted into the soft tissue. The nonwoven material comprises a large number of fibers in the form of mat-like or felt-like patches. Some fibers of the felt-like patch are pushed or pulled through the implant into the soft tissue, thereby creating a connection between the felt material and the soft tissue. A felting system is provided to push and pull the fibers of the felt-like patch through the implant into the soft tissue. An exemplary felting system is disclosed in WO 2020 / 227838 A1.

[0003] Any tools and devices used in a clinical setting, especially during procedures, must be sterile. Felt systems, such as those shown in WO2020 / 227838 A1, can be used invasively or non-invasively during procedures. Therefore, these devices must be sterile before use. Typically, a new sterile felting system can be used each time. While this approach may be convenient, it can result in excessive waste, and replacing the entire tool after a single use can be costly. Alternatively, the felting system can be sterilized after the procedure. However, sterilization ties up hospital resources. Furthermore, sterilization typically involves heating the individual parts of the device to, for example, 121 to 134°C and applying steam to the device. This process is aggressive and can damage components of the felting system. Another problem is that complex structures are difficult to sterilize, leading to long sterilization times.

[0004] Furthermore, the recently introduced felting technique is particularly useful in arthroscopic applications such as rotator cuff tendon repair. In arthroscopic applications, the operator's freedom of movement is especially important. However, previously disclosed felting systems require wiring connections for power supply, making the device less flexible.

[0005] This disclosure aims to address one or more of the aforementioned problems. In particular, the purpose of this disclosure is to provide a safe and reusable felting system.

[0006] A first aspect of this disclosure relates to a medical felting system. The medical felting system includes a felting device and a power unit. The felting device includes at least one felting needle configured to reciprocate between two end positions. The power unit includes a battery for storing electrical energy, an electric motor, and a controller. The electric motor is configured to actuate at least one felting needle. The electric motor is electrically connected to the battery. The controller is configured to control the electric motor and actuate the motor to drive the felting needle. Driving the felting needle can be understood as moving the felting needle back and forth between two end positions. The felting device and the power unit are separable from each other. The felting system includes a mechanical coupling that operatively and releasably connects the power unit to the felting device. The mechanical coupling transmits rotational motion from the motor to at least one felting needle.

[0007] The felting device described herein can be understood as part of a device comprising at least one felting needle. The felting device may additionally include one or more of the following: an outer housing, an inner frame, a guide hole, a biasing element, a spring, a yoke, a sliding pin, and a buckling element. The outer housing may enclose the felting device.

[0008] Preferably, the felting device is intended for single use and is discarded after use. The felting device is susceptible to contamination during use and may include components that are difficult to sterilize. For example, removing the needle separately poses a health hazard to the operator because the needle may have come into contact with bodily fluids, such as blood that may contain pathogens of infectious diseases. Disposing of the needle may also require a specialized needle container, such as a cannula disposal container. Furthermore, inserting a new needle introduces a risk of injury, especially with a sharp tip. Providing a detachable felting device avoids these risks. An exemplary felting device is disclosed in CH000247 / 12023.

[0009] The battery can be rechargeable and / or replaceable, and can comprise one or more electrochemical cells. While lithium-ion batteries are preferred, batteries of any chemical system can be used. During operation, the battery can store sufficient energy to actuate the needle for, for example, at least 1 minute, 2 minutes, 5 minutes, 10 minutes, 15 minutes, 30 minutes, or 60 minutes. The battery can comprise a battery pack comprising multiple identical cells or units. The battery allows the system to be moved freely without the need for cables for power. Therefore, a more portable and easier-to-use felting system is provided. Furthermore, the same power unit can be reused after operation and can be flexibly interchanged.

[0010] The electric motor can be configured to operate at 1,000 to 5,000 RPM, preferably 2,000 to 3,000 RPM. The electric motor can produce a torque of at least 10 mNm, 20 mNm, 25 mNm, or 28 mNm. The electric motor can be a DC or AC motor. DC motors are preferred because they do not require power electronics to provide a high rotational frequency when powered by a battery. In a specific example, the motor is a DCX22L GB KL 36V Maxon motor.

[0011] The controller may include control electronics, which may include a microcontroller.

[0012] Preferably, the felting device includes only one felting needle. When referring to a felting needle below, this may mean only one felting needle or at least one felting needle, i.e., one, two, three or more felting needles.

[0013] The two end positions can be a distal position and a proximal position. The felting needle can be fully retracted into the housing of the felting device in the proximal position. In the retracted position, the needle tip is protected, for example, by the outer housing, and damage to the needle tip can be prevented. Preferably, the felting device also includes a spring configured to bias the felting needle to the proximal position, i.e., the retracted position.

[0014] Preferably, the mechanical connector includes a slit for receiving an input shaft of the felting device. Accordingly, the input shaft may include a plate-like end that engages the slit. The slit allows for easy attachment.

[0015] Preferably, the electric motor includes a motor output shaft, and the mechanical connector includes a coupling member. The coupling member can receive the motor output shaft and includes a slit. The coupling member can receive the motor output shaft directly or indirectly; for example, a motor adapter can be present between the coupling member and the motor output shaft. The coupling member allows a releasable connection between the power unit and the felt device.

[0016] Preferably, the mechanical connector includes a first beveled edge for rotating the mechanical connector. The mechanical connector engages the input shaft of the felting device. The beveled edge may be disposed on one or more side surfaces defining the slit. The beveled edge may define angled surfaces, particularly circular surfaces, which may form the side surfaces of the slit. These side surfaces may be configured to rotate the coupling connector to align with the current position of the felting needle. Therefore, when the power unit is attached to the felting device, the felting needle can remain in the retracted position. Attachment does not cause movement of the felting needle. Furthermore, the user can directly connect the power unit to the felting device without having to check the current position of the input shaft, coupling connector, motor, or power unit.

[0017] Preferably, the mechanical connector includes a second inclined edge for rotating the mechanical connector when it engages the motor shaft. The second inclined edge may be attached to or replace the first inclined edge and may have the same or different shape.

[0018] Preferably, the mechanical coupling rotates freely when the electric motor is not actuated. For example, the motor can rotate freely.

[0019] Preferably, the device includes a manual trigger. The manual trigger can be configured to move from a first position to a second position. Movement of the manual trigger to the second position causes the controller to actuate the electric motor. The manual trigger can be part of a felting device or a power unit. However, preferably, the manual trigger is part of the power unit. Thus, all electrical components can be retained within the power unit.

[0020] Preferably, the manual trigger is biased toward the first position. An exemplary biasing element is a spring, but any elastically deformable material may also be suitable.

[0021] Preferably, the manual trigger includes a locking mechanism. The locking mechanism can be a mechanical lock or an electronic lock. When activated, the locking mechanism prevents the actuation of the manual trigger. For example, the locking mechanism can prevent movement of the manual trigger. In other embodiments, the electrical connection of the manual trigger is deactivated, disabled, or blocked. The locking mechanism prevents unintentional actuation of the felting needle.

[0022] Preferably, the controller is configured to store or store the zero position of the motor when the mechanical coupler engages with the felting device. The mechanical controller may include a memory, preferably non-volatile memory, to store the zero position. The zero position may be the zero position of the motor. In some embodiments, the zero position may be the zero position of both the motor and the coupler. The motor may include an encoder. The encoder may detect the current position of the motor, such as an angular position. At the zero position of the motor, the felting needle may be in a retracted position.

[0023] When the motor is powered, for example, when power is supplied to the motor's coils, it can apply a stopping torque. Therefore, when the felting device is disconnected from the power unit, or at least during the attachment of the felting device and the power unit, the controller can not supply power to the motor. Then, when the power unit is connected to the felting device, the motor can rotate freely. The zero position can be the position of the motor after the felting device and the power unit are attached to each other.

[0024] The felting device may include a biasing element, such as a spring, which biases the pin toward the retracted position. The same or different biasing elements can rotate the motor to a zero position upon engagement. Upon engagement, the motor shaft can be aligned with the retracted position. For example, the motor can rotate to a motor position corresponding to the retracted pin position.

[0025] Preferably, the controller is configured to store a zero position, for example, when power is supplied to the motor. The motor may alternatively or additionally store a zero position when the power unit is turned on and / or when attachment between the power unit and the felting device is detected.

[0026] Preferably, the controller is configured to return the motor to the zero position after it has been actuated. This ensures that the needle remains in the retracted position after the device has been used.

[0027] Preferably, the controller is configured to control the motor to actuate at least one needle at a constant speed during operation. The motor can maintain a constant speed. Constant speed can mean a constant rotational speed, for example, a constant number of revolutions per minute (rpm). For example, when the motor speed decreases, the controller can increase the motor torque, for example, by applying a higher voltage. In one example, the controller may include a PI or PID controller that controls the motor speed to a set motor speed.

[0028] During the procedure, the needle can move through soft tissue and nonwoven materials, and the resulting friction can slow down the needle's movement and / or cause irregular needle movement. For example, the needle's movement speed can depend on the felted implant and the felted soft tissue. Slower or even irregular needle movement can reduce attachment achieved during felting within a set time period. To avoid uneven attachment of the implant, a controller is used to maintain a constant movement speed, even in adverse felting environments.

[0029] Preferably, the felting device includes a felting device housing. The power unit includes a power unit housing. The power unit housing surrounds the battery, electric motor, and controller. The power unit housing protects the electrical components.

[0030] Preferably, the motor and / or battery can be removed from the power unit housing. In one example, the power unit housing includes a first end attached to the felting device and an opposing second end. The second opposing end may be a bottom end. Preferably, the motor and / or battery can be removed from the bottom end.

[0031] Preferably, the power unit housing includes an inner housing surrounding the motor and / or battery. This allows the motor and / or battery to be easily removed from the power unit housing. This simplifies the charging, cleaning, and sterilization of the power unit.

[0032] Preferably, the inner housing or outer motor housing includes a spring-loaded electrical connector that electrically connects the motor and / or battery to the controller. This ensures a reliable electrical connection between the components (e.g., the motor and / or battery) held in the inner housing and the rest of the power unit.

[0033] Preferably, the inner housing includes a first inner housing portion that houses the battery and a second inner housing portion that houses the motor. The first and second inner housing portions can be releasably connected to each other.

[0034] Preferably, the electric motor is configured to drive the movement of the felting needle between two end positions.

[0035] Preferably, the power unit of the felting system includes a magnetic coupling for transmitting torque from an electric motor to a mechanical coupling that operatively and releasably connects the power unit to the felting device. The magnetic coupling may include a top coupling containing one or more magnets and / or a bottom coupling containing one or more magnets. The top and bottom couplings may be spaced apart. The magnetic coupling allows setting a maximum transmittable force for transmitting torque to components of the system, particularly the felting needles. If the maximum transmittable torque is exceeded, the magnetic coupling may begin to slide, preventing torque exceeding the set maximum value from being transmitted to other components of the system.

[0036] Preferably, the magnetic connector has a maximum transmission torque of 100 mNm, more preferably 80 mNm, more preferably 70 mNm, most preferably 65 mNm or less.

[0037] The power unit may include a separator. The separator may be a physical separator. The separator may have a sheet-like shape. The separator may extend within a magnetic connector. In one embodiment, the separator extends between a top connector and a bottom connector. The separator may be sealed between the top connector and the bottom connector. The separator may allow for an airtight separation between the chambers or cavities of electrical components such as motors and batteries and the felting device.

[0038] As described above, a magnetic coupler, namely one or more magnets in a top coupler and a bottom coupler, can define one or more zero positions. Therefore, the control mechanism described above regarding the zero position can also be used with a magnetic coupler.

[0039] Another aspect of the invention relates to a power unit as described above. The power unit may be sterilizable. Sterilization may involve applying steam at a temperature of 121 to 134°C for an extended period, for example, 30 to 60 minutes. A sterilizable power unit means that the power unit can withstand this procedure. Furthermore, as described above, certain components of the power unit, such as the battery and / or motor, may be removable, such that only components (e.g., only the power unit housing) may require sterilization. In one example, all electrical components are removable, and only the remaining components are sterilized, particularly only mechanical components (e.g., the power unit housing, triggers, etc.) may be sterilizable.

[0040] Other features and advantages of the invention will be described in detail with reference to the accompanying drawings. The drawings illustrate exemplary embodiments that do not limit the scope of this disclosure.

[0041] Figure 1 A side view of the felting system is shown.

[0042] Figure 2 A side view of the exploded diagram of the felting system is shown, with the outer housing of the power unit removed.

[0043] Figure 3 It shows the assembled form Figure 1 The cross-section of the felting system is shown.

[0044] Figure 4 The side view and perspective view of the connecting connector are shown.

[0045] Figure 5 A three-dimensional view of the power unit is shown.

[0046] Figure 5 Different embodiments of the trigger are shown.

[0047] Figure 7 Another example trigger and its cross-section are shown.

[0048] Figure 8 It shows Figure 4 Exploded view of the power unit and sterile transfer shield.

[0049] Figure 9 It shows the closed position. Figure 4 The latch of the power unit.

[0050] Figure 10 It is shown in the open position. Figure 4 The latch of the power unit.

[0051] Figure 11 A side view is shown with the battery unit and motor unit separated from each other.

[0052] Figure 12 The connection between the battery unit and the motor unit is shown.

[0053] Figure 13A The battery and motor units are shown in a 3D diagram when they are connected to each other.

[0054] Figure 13B It shows Figure 12 A top view of the battery and motor unit of A.

[0055] Figure 14 The control logic of the power unit's controller is shown.

[0056] Figure 15A and Figure 15B An alternative felting system is shown.

[0057] Figure 16 A side view and a perspective view of a second embodiment of the connecting member are shown.

[0058] Figure 17 An exploded side view of the felting system according to the present invention is shown.

[0059] Figure 18A It shows Figure 17 The cross-section of the power unit of the felting system shown.

[0060] Figure 18B Shown in magnified view Figure 18A Part of it.

[0061] Figure 19A and Figure 19B It shows Figures 17 to 18B Example configuration of the power unit.

[0062] Figure 20A and Figure 20B It shows Figures 17 to 19B The top and bottom connectors of the power unit are shown.

[0063] Appendix Figures 1 to 3 A felting system 1, including a power unit 100 and a felting device 200, is shown. The felting device 200 includes an outer housing 201 and a tubular member 202 extending distally from the outer housing. As used herein, the proximal and distal directions are defined from the perspective of the operator of the felting system. The proximal direction can generally be defined towards the operator, and the distal direction can generally be defined away from the operator in the gripping assembly form of the felting system. The tubular member 202 holds the felting needle 203 (see...). Figure 3 During operation, the felting needle 203 moves along the longitudinal direction of the tubular member and is discharged and retracted from the distal end 204 of the tubular member 202. The outer housing 201 may include a proximal portion 205 and a distal portion 206. The outer housing may be made of a rigid plastic material. A drive mechanism for the felting needle 203 is arranged within the outer housing 201. Figure 3As can be seen, the drive mechanism may include a guide rod 208 that holds the felting needle at its distal end. The guide rod 208 is connected to a buckling element 209, which in turn is connected to a piston rod 210 terminating at an anti-rotation yoke 211. The guide rod 208, buckling element 209, piston rod 210, and anti-rotation yoke 211 are arranged along the longitudinal direction of the felting needle 203, connected to each other, and move together along the longitudinal direction of the felting needle 203. A sliding pin 212 extends parallel to the handle axis H and is arranged within the anti-rotation yoke 211. The pin 212 is connected to the top end of the felting device input shaft 213. During actuation, the felting device input shaft rotates about its axis, which also causes the pin 212 to rotate about the axis of the input shaft 213. This activates the anti-rotation yoke 211 and causes a reciprocating motion between the two end positions of the felting needle 203. Furthermore, the felting device 200 includes a biasing element, such as a spring 214. Spring 214 pushes piston rod 210 and thus the felting needle 203 to its nearest-side position. The nearest-side position can be the retracted position. Further details of the felting device are described in application CH000247 / 12023.

[0064] Figures 2 to 4 A connecting member 300 is also shown. The connecting member 300 includes a first side pointing towards the felting device 200 and a second side pointing towards the power unit 100. The first side of the connecting member 300 includes a slit 301 (see...). Figure 4 The slit 301 has a straight shape and is limited by side surfaces 302 and 303. The slit 301 can resemble the slit of a flat-head screwdriver. The slit 301 can be formed by two extensions from the body of the connecting member 300. The extensions can be forked. The slit can be formed between the two forked prongs. The first side is adapted to receive the felting device input shaft 213. The end of the felting device input shaft 213 has the shape of a flat-head screwdriver. The end may include a flat side surface that can extend along direction H. The flat side surface can be fitted into the slit 301 of the connecting member 300.

[0065] In addition, from Figure 4 As can be seen, the first side includes a first inclined edge 304. The inclined edge 304 may cut off a portion of the side surfaces 302 and / or 303 and may provide a guide surface angled relative to the longitudinal axis H or rotation axis of the coupling connector 300. The angled guide surface may also be angled relative to a plane perpendicular to the longitudinal axis H. Furthermore, the angled guide surface may be flat. However, in a preferred embodiment, the angled guide surface has a circular shape to guide the rotation of the felting device input shaft 213. The angled guide surface may be convex or concave. Each side of the slit 301 (e.g., each fork-shaped fork) may include the inclined edge 304, but in some embodiments, only one side of the slit 301 may include the inclined edge 304.

[0066] from Figure 2 and Figure 16 As can be seen, the second side of the connecting member includes a flat-head shape 350, similar to the end of the felting device input shaft 213. The second side may include two flat outer surfaces 351 for rotational engagement. In this embodiment, the second side may have the shape of a flat-head screwdriver, and / or may have the shape of the end of the felting device input shaft 213. The second side may include a flat outer wall extending parallel to the longitudinal axis of the connecting member. In this embodiment, the motor output shaft 101 may include the shape described and shown with respect to the first side of the connecting member 300.

[0067] In the second embodiment, the second side of the coupling connector 300 may include a standard connection interface, such as a hexagonal key (or any other number of edges) or any other known screw drive mechanism. Figure 4 In the illustrated embodiment, the second side may have a constant cross-section and may be assembled in multiple rotational positions for ease of assembly. Figure 4 The second side shown has a shape similar to an external multi-drive, but provides more than six flat teeth. The illustrated embodiment includes eight cam-shaped teeth, which allow for the transmission of high torque. The cam-shaped teeth are arranged directly adjacent to each other and extend parallel to each other.

[0068] The coupling connector may include a motor adapter 310. The motor adapter 310 includes a first side facing the coupling connector and a second side for attachment to a motor. Some motors may have a D-shaped motor shaft (sometimes described as type D). The second side may include a corresponding inverted D-shape for fitting onto the motor output shaft 101. The first side may mate into the second side of the coupling connector and may be shaped accordingly.

[0069] Figure 3 A felting system is shown, comprising a power unit 100 in an assembled state and a felting device 200. A motor 165 actuates a motor output shaft 101. The motor output shaft 101 rotates an adapter 310 and a connecting member 300. These, in turn, actuate the felting device input shaft 213 and thus the felting needle 203.

[0070] Figure 5 An embodiment of the power unit 100 is shown separately. Typically, the power unit 100 includes a power unit housing 102, which may be made of a rigid plastic material. The power unit housing 102 may or may not use the same material as the housing 201 of the felting device. Typically, the power unit housing 102 has a cylindrical shape. The front side of the power unit housing 102 includes a concave notch 103 for clamping the power unit 100. The power unit includes... Figure 6 and Figure 7The manual trigger 110 is shown in more detail below. The manual trigger 110 is arranged on the forward side and may include a button 111. Pressing the button actuates a motor, as will be described in more detail below. The manual trigger 110 includes a trigger housing 112. The trigger housing 112 may include a trigger base 113 attached to the top side of the power unit housing 102. The power unit housing 102 may include two pins 114, and the trigger base 113 may include corresponding recesses for securing the trigger housing 112 to the power unit housing 102. Two levers 115 extend from the trigger base 113 and together hold the button 111. The levers 115 may include wires connecting the button 111 to a controller held in the power unit 100. Figure 7 A cross-section of the trigger housing 112 is shown. It can be seen that button 111 is outwardly biased by spring 116, which ensures that button 111 is deactivated as the default position. When button 111 is pressed against the force of spring 116 exceeding a threshold, electrical switch 117 is activated.

[0071] Figure 6 , Figure 15A and Figure 15B An alternative manual trigger 110 is shown. Figure 6 The image shows different sizes of button 111 and multiple orientations of lever 115. Figure 15A In the middle, the manual trigger is directly installed on the front side, i.e., the proximal side, of the power unit housing 102. Figure 15B In this configuration, a manual trigger 110 is positioned below the recess 214 of the felting device. The trigger is actuated by compressing the housing of the felting device. Furthermore, the power unit 100 may include an on / off switch 104.

[0072] Figure 8 An exploded view of the components held within a power unit housing 102 is shown. The power unit housing 102 includes a bottom latch 120. Opening the bottom latch 120 allows for the release of a motor and battery unit 130. The motor and battery unit 130 can slide into and out of the outer housing through an opening at the bottom of the power unit housing 102. Additionally, in some embodiments, a sterile transfer shield 140 may be provided. The sterile transfer shield 140 allows for the insertion of the motor and battery unit 130 without contact with the power unit 100. The latch 120 can be opened, the sterile transfer shield 140 can be positioned on the bottom end of the housing 102, and the motor and battery unit 130 can then be removed or inserted without contacting the inner surface of the latch 120. Therefore, the risk of contamination of external components of the power unit 100 or the risk of contamination for persons handling the power unit 100 can be reduced.

[0073] In one example, the power unit housing 102 may be sterile on the outside. A fully charged motor and battery unit 130 may be non-sterile. An operator (e.g., a nurse) can insert the motor and battery unit 130 into the sterile power unit housing 102 through a sterile transfer shield 140. The additional use of the sterile transfer shield 140 prevents any contact between the non-sterile motor and battery unit 130 and the sterile outer surface of the power unit housing 102. Therefore, even after replacing the motor and battery unit 130, the power unit housing 102 of the power unit 100 may not require re-sterilization. The sterile transfer shield 140 may be provided with the power unit and / or with the felting system described herein.

[0074] Removing the motor and battery unit 130 from the bottom of the power unit 100 is preferable because it allows for battery / motor replacement without having to remove the power unit from the device.

[0075] Figure 9 and 10 The latch 120 is shown in more detail. Figure 9 and Figure 10 Each is shown as a bottom view of the latch 120 on the left and a top view of the latch 120 on the right (i.e., from inside the body 102). The latch 120 may have a circular shape. In the example shown, the latch 120 has an elliptical shape, but other shapes such as an egg shape may also be suitable. The latch 120 includes a circular (i.e., circular) handle 121, which may include a straight rod 122 extending from edge to edge through the center of the circular handle 121. The circular handle 121 can be rotated to lock and unlock the latch 120. Rotation of the circular handle 121 causes the locking end 124 to rotate as well. Figure 9 and Figure 10 The comparison shows that clockwise rotation (see...) Figure 9 (Left side) causes the locking end 124 to move behind the inner base plate 125 of the latch 120 (see left side) Figure 10 (Right side). The locking end 124 can interlock with the nose 126 (see right side). Figure 3 The nose 126 can be disposed on the inner wall of the power unit housing 102, particularly at the bottom of the cylindrical portion of the power unit housing 102. The locking end 124 can be disposed at the end of the flat rod. Furthermore, a connecting device (i.e., a screw) can connect the flat rod to the locking end and the handle 121, allowing them to rotate together. The rotation of the handle can be limited, for example, by using a stop.

[0076] In addition, the latch includes a connector 122, through which the latch 120 is rotatably attached to the power unit housing 102. After the handle 121 is rotated to the open position, the latch 120 can rotate about the connector 122, and the motor and battery unit 130 can be removed.

[0077] Figures 11 to 13B A battery and motor unit 130 is shown. The battery and motor unit 130 includes an outer casing 131 that can be divided into a motor unit 150 and a battery unit 160 (see [reference]). Figure 13A Each of these units includes corresponding housings 151 and 161 that house the respective motor 165 and battery 155 (see...). Figure 3 The housing 151 of the motor unit 150 typically extends along a longitudinal axis that extends in the same direction as the output motor shaft to which the coupling connector 300 is attached. The same applies to the housing 161 of the battery unit 160. The motor housing 151 includes a longitudinally extending recess 152, and the battery housing includes a correspondingly shaped track 162. Figure 12 As shown, track 162 can slide into recess 152 to attach and release motor unit 150 and battery unit 160 to each other. This allows battery unit 160 to be charged separately from motor unit 150. Furthermore, battery unit 160 can be charged while connected to motor unit 150. Battery unit 160 may include charging connector 166. Alternatively, battery unit 160 may include wireless charging circuitry. Figure 11 As can be seen, the track 162 and the corresponding groove 152 extend from the top surface 131 along the longitudinal axis without reaching the bottom ends of the motor unit housing 151 and the battery unit housing 161. The end of the groove 152, preferably the bottom end, may include one or more spring-loaded electrical connectors (not shown). Alternatively, the end of the track 162, preferably the bottom end, may include one or more spring-loaded electrical connectors. This provides a reliable electrical connection between the battery unit 160 and the motor unit 150.

[0078] Typically, the battery and motor unit 130 has a cylindrical shape with an elliptical cross-section, similar to that of housing 102. A portion of the motor unit 150 may extend from this cylindrical shape. The elliptical shape prevents the battery and motor unit 130 from being inserted in an undesirable orientation. The battery and motor unit 130 may include a top surface 133 on which upward-facing, spring-loaded connectors 132 are disposed. These connectors connect to corresponding electrical connectors within the outer housing, such as those connected to the aforementioned manual trigger. While spring-loaded connectors are preferred, conductors without spring loading may also be used.

[0079] Control electronics 164 in motor housing 160 (see Figure 3 It can detect the connection between the upward-facing electric spring-loaded connector 132 and the manual trigger 110.

[0080] Assembly of the felting system 1 may include the following steps. First, the battery and motor unit 130 may be inserted into the power unit housing 102 of the power unit 100. Then, the latch 120 is closed. The closure of the latch 120 pushes the battery and motor unit against the spring-loaded connector 132 upward along the longitudinal axis of the power unit housing 102. In this position, the latch 120 is locked. The coupling connector 300 and adapter 310 may be fixedly attached to the motor output shaft 101, or may be manually slid onto the motor output shaft 101 after the battery and motor unit 130 are inserted. After assembling the power unit 100, the power unit 100 and the felting device 200 are connected to each other. When the power unit 100 and the felting device 200 are connected, the felting device input shaft 213 moves into the coupling connector 300. During this assembly, power from the battery 155 may not be supplied to the motor 165. In one example, the control electronics 164 may be turned off. In another example, the control electronics 164 may be powered off during assembly. This allows motor 165 to rotate freely. Spring 214 biases the rotational position of the felting device input shaft toward the retracted position of needle 203. During attachment, the inclined edge of the connector element rotates the motor to the position of the felting device input shaft 213.

[0081] The battery and motor unit 130 also includes control electronics 164, such as a microcontroller. The control electronics can check whether the trigger and battery are accurately connected, for example, using a spring-loaded connector 132.

[0082] Figure 14 The control logic of the control electronics is shown. The control logic can also use, for example, an additional electrical connector to verify that the felting device 200 and the power unit 100 are accurately connected. The motor is not powered as long as the control electronics 164 is off. When the control electronics 164 is turned on (e.g., using a switch or trigger), the current position of the motor is read by the control electronics 164. The motor 165 may include an encoder that can transmit the current position of the motor to the control electronics 164. If the power unit 100 and the felting device 200 are accurately connected, this current position corresponds to the retracted position of the felting needle 203. The current position is then stored in the control electronics 164 as the zero position.

[0083] Control electronics 164 monitors whether the trigger is pressed ("executes a while(1) loop"). When the trigger is not pressed, the control electronics hold the motor in the zero position and thus hold the felted needle 203 in the retracted position. In one example, control electronics 164 may include a PID controller for controlling the position of the motor. Whenever the encoder detects a deviation from the zero position, such as when an encoder interrupt is triggered, control electronics 164 signals the motor to return to the zero position. The motor can rotate in two directions, such as clockwise and counterclockwise. Preferably, the control electronics selects the minimum amount of rotation to return to the zero position. This avoids the needle 203 being pushed in the distal direction and reduces the risk of damage.

[0084] If the trigger is pressed, the motor is actuated at a predetermined rotational speed, for example, 2,500 RPM. The detected motor position increments whenever an encoder interrupt is triggered. A timer (“TIM2”) causes the microcontroller to calculate the current motor speed (angular velocity) at set time intervals. Figure 14 In the example shown, this occurs every 1ms ("1MHz, counter period 1,000"). The measured speed is filtered using an exponential moving average filter. The measured and filtered speed is then fed into a PID controller. The PID controller uses feedback from the encoder to keep the rotational speed constant. PWM (Pulse Width Modulation) is used to control the actuation of the motor. A timer ("TIM3") is initialized for the PWM. Pulse Width Modulation can generate an average voltage that determines the applied torque and / or rotational speed. If the motor is running too fast, PWM can be used to reduce the average voltage and thus reduce the applied torque and / or rotational speed. If the motor is running too slowly, the average voltage and therefore the applied torque and / or rotational speed may increase.

[0085] Figures 17 to 20B A second embodiment of the felting system 2 according to the present invention is shown. The felting system 2 is similar to the felting system 1 described above, wherein a magnetic connector is added between the power unit 400 (similar to the power unit 100) and the felting device 500 (similar to the felting device 200). Unless otherwise described below, the power unit 400 corresponds to the power unit 100, and unless otherwise described below, the felting device 500 corresponds to the felting device 200.

[0086] The power unit 400 includes a motor and a battery unit 430, as well as a power unit housing 402 with a bottom latch 402. Although Figure 17 An exploded view of the power unit 400 is shown. Figure 18A and 18B A cross-section of the power unit 400 in its assembled form is shown.

[0087] The felting system 2 includes a magnetic connector 401 between the power unit 400 and the felting device 500. In one embodiment, the magnetic connector 401 is entirely included in the power unit 400. The magnetic connector 401 may include a top connector 420 and a bottom connector 440. The top connector 420 is located in... Figure 20B The image is shown in two perspective views, and the bottom connector 440 is... Figure 20A The top connector 420 is shown in two perspective views. It may include one, two, or more magnets. In the illustrated embodiment, the top connector 420 includes four magnets 421 to 424, but it may also include more magnets, such as five, six, eight, ten, or more. Magnets 421 to 424 are preferably permanent magnets. In an alternative embodiment, the top connector 420 may include a magnetizable material, such as a ferromagnetic material like iron, instead of magnets 421 to 424. The top connector 420 may have a cylindrical shape and may be circular, such as... Figure 20B As shown. The top connector 420 includes a socket 425 for each magnet 421 to 424. Magnets 421 to 424 may be glued, press-fitted, or otherwise held in the socket 425. On the side of the top connector opposite to the magnets 421 to 424, the top connector 420 includes a connector interface 426. The connector interface 426 is intended to connect to the felting device 500 and may include two pins 427 and 428 forming a slit 429 between pins 427 and 428. The slit 429 may also be formed in other ways. The slit 429 is configured to receive (i.e., receive in an assembled form) the input shaft 213 of the felting device 500 and to transmit torque from the top connector 420 to the input shaft 213 as described above. In some embodiments, the connector interface 426 may include a side surface, such as an inclined side surface, as referenced. Figure 4 See reference numerals 302 and 303 in the accompanying drawings and the description herein.

[0088] The top connector 420 can be circular, such as... Figure 20B As shown. However, other shapes, such as squares, rectangles, hexagons, and ellipses, are also possible. The top connector 420 may have a diameter of 30 mm or less (e.g., 15 mm) and a height of 20 mm or less (e.g., 12 mm).

[0089] The top connector 420 can be attached, for example, by press fit, glue, or thread, to a pivot bearing 470, which is held within the housing 402 of the power unit 400 (similar to housing 102). The bearing 470 can securely and rotatably connect the top connector 420 to the housing 402 of the power unit 400. The bearing 470 can be attached to pins 427, 428. The unit including the bearing 470 and the top connector 420 can be securely attached to the housing as described above and can be retained without removal from the housing (e.g., by a user).

[0090] like Figure 18B As shown, the housing of the power unit includes a separator 460 located between a cavity 405 holding the motor and battery unit 430 within a housing 102 and a connection structure connected to the input shaft 213. The separator 460 may be formed as a sheet of housing material that closes the cavity 405 towards the felting device. In other embodiments, the separator may be fixedly and hermetically attached to the housing. The separator may have a thickness of 1 mm or less. In one embodiment, the separator may have a thickness of 1 mm, 0.6 mm, 0.4 mm, 0.3 mm, 0.2 mm, or less. The separator 460 hermetically separates the torque output from the motor and the torque input from the felting device. The separator 460 may extend between a top connector 420 and a bottom connector 440. The separator 460 may be made of an antimagnetic material. The separator may be stationary.

[0091] In contrast to known seals, the combination of a separator and a magnetic coupling eliminates the need for any seal between moving parts, which can (i) reduce the transmitted torque and (ii) still allow some non-sterile fluids to pass through under certain conditions (e.g., due to wear and tear). Typically, rotary seals are required to transmit torque. However, such rotary seals reduce torque and therefore require larger and / or more expensive batteries and motors.

[0092] Bottom connector 440 is connected to the motor output shaft 101. Bottom connector 440 is... Figure 20A The following two perspective views are shown. The bottom connector 440 may include one, two, or more magnets. In the illustrated embodiment, the bottom connector 440 includes four magnets 441 to 444, but the bottom connector 420 may also include more magnets, such as five, six, eight, ten, or more. Preferably, the bottom connector 440 and the top connector 420 include the same number of magnets. Magnets 441 to 444 are preferably permanent magnets. In an alternative embodiment, the bottom connector 440 may include a magnetizable material, such as a ferromagnetic material like iron, instead of magnets 441 to 444. The bottom connector 440 may have a cylindrical shape and may be circular, such as... Figure 20AAs shown. The bottom connector 440 includes a socket 445 for each magnet 441 to 444. The magnets can be glued, press-fitted, or otherwise held in the socket 445. The bottom connector 440 can be round, such as... Figure 20A As shown in Figure 18. However, other shapes, such as squares, rectangles, hexagons, and ellipses, are also possible. As shown in Figure 18, the bottom connector 440 is directly and securely attached to the battery and motor unit 130.

[0093] Although Figure 20A The bottom connector 440 shown includes a post 446 for connection to the motor, but other configurations are possible. Instead of the post, the bottom connector 440 can be directly attached to the motor output shaft 101 or an intermediate component therebetween. The bottom connector 440 can be attached to the motor or intermediate component by gluing, screws (e.g., retaining screws), press-fitting, or other means.

[0094] The bottom connector 440 may have a diameter of 35 mm or less (e.g., 24 mm) and a height of 30 mm or less (e.g., 21 mm) including the post 446. Without the post 446, the bottom connector 440 may have a height of 15 mm or less (e.g., 7 mm).

[0095] from Figure 18A and Figure 18BAs can be seen, a gap exists between the bottom connector 440 and the top connector 420. The size of this gap can be selected based on the desired distance between magnets 421 to 424 in the top connector 420 and magnets 441 to 444 in the bottom connector 440. The distance between magnets 421 to 424 and 441 to 444, the strength of the magnets, and the number of magnets used determine the maximum torque that can be transmitted between the top and bottom connectors. If the maximum torque is exceeded, the connector will slip. Setting the maximum torque in this case prevents damage to the needle of the felting device. For example, if the needle of the felting device strikes a hard surface (e.g., bone), the top and bottom connectors can slide to prevent further force from reaching the needle and to prevent damage to the needle and the hard surface. In one example, the connector can transmit a maximum torque of 50 mNm. In this example, the distance between the magnets of the top connector and the bottom connector can be 1.5 mm (or less). In another example, the distance between the top connecting magnets 421 to 424 and the bottom connecting magnets 441 to 444 can be 0.6 mm, and the connection can transmit a maximum torque of 65 mNm. Typically, in one example, the transmitted torque may not exceed 100 mNm. In another example, the magnets of the top and / or bottom connectors are neodymium magnets (NdFeB) with a grade of N52 or less (e.g., N45 or less). The magnets of the top and / or bottom connectors can be cylindrical (as shown) with a diameter of 5 mm and a height of 5 mm, but other shapes are also possible. More generally, the magnets can have a diameter of 10 mm or less and / or a height of 10 mm or less. Therefore, the magnetic connector provides a safety mechanism to protect components in the system (such as needles) from excessive torque. The magnets can be coated with a corrosion-resistant coating, such as PTFE. The magnetic connector allows for contactless torque transmission and seamless removal of all components (e.g., battery and motor unit) without the need for sterilization.

[0096] Although Figures 17 to 2 0 can show a top connector 420 held within housing 402, but the top connector 420 can also be directly attached to input shaft 213.

[0097] Magnets 441 to 444 and 421 to 424 may have a magnetic orientation along the longitudinal axis of the power unit 400; that is, a portion of magnets 421 to 424 oriented toward the motor and battery unit 430 may have a first magnetic pole, and a portion of magnets 421 to 424 oriented away from the motor and battery unit 430 may have a second magnetic pole for each magnet. Typically, magnets 421 to 424 and 441 to 444 may have opposing magnetic poles facing each other. In one configuration (see...) Figure 19A The magnet of the bottom connector 440 may have alternating magnetic poles along the circumference of the bottom connector. For example... Figure 19A As shown, magnets 441 to 444 may have a north pole (magnet 441), a south pole (magnet 442), a north pole (magnet 443), and a south pole (magnet 444) facing the top connector 420. Conversely, magnets 421 to 424 may have a south pole (magnet 421), a north pole (magnet 422), a south pole (magnet 443), and a north pole (magnet 44) facing the bottom connector 440. This configuration may have two zero positions.

[0098] In another configuration ( Figure 19B In this configuration, three of magnets 441 to 444 may have a north pole (or south pole) facing the top connector 420, and three of magnets 421 to 424 may have a south pole (or north pole) facing the bottom connector 440. Only one of magnets 441 to 444 may have a south pole (or north pole) facing the top connector 420, and only one of magnets 421 to 424 may have a north pole (or south pole) facing the top connector 440. In this configuration, the connector has only a single zero position.

[0099] Other aspects of this disclosure are described below: 1. A medical felting system, comprising: a. A felting device, comprising at least one felting needle configured to move back and forth between two end positions; and b. Power unit, including: i. Batteries that store electrical energy ii. An electric motor for actuating the felting device, the electric motor being electrically connected to a battery. iii. A controller for controlling an electric motor, the controller being configured to actuate the electric motor to drive the felting device, and c. wherein the felting device and the power unit are separable from each other, and wherein the felting system includes a mechanical coupler that operatively and releasably connects the power unit to the felting device, wherein the mechanical coupler is configured to transmit rotational motion from a motor to at least one felting needle.

[0100] 2. The medical felting system according to aspect 1, wherein the felting device includes an input shaft, and wherein the mechanical connector includes a slit for receiving the input shaft of the felting device.

[0101] 3. The medical felting system according to aspect 2, wherein the electric motor includes a motor output shaft, and wherein the mechanical connector includes a connecting member, wherein the connecting member receives the motor output shaft and includes a slit.

[0102] 4. A medical felting system according to one of the foregoing aspects, wherein the mechanical connector includes a first inclined edge to rotate the mechanical connector when the mechanical connector engages the input shaft of the felting device.

[0103] 5. A medical felting system according to one of the foregoing aspects, wherein the mechanical connector includes a second inclined edge to rotate the mechanical connector when the mechanical connector engages the motor shaft.

[0104] 6. A medical felting system according to one of the foregoing aspects, wherein the mechanical connector rotates freely when the electric motor is not actuated.

[0105] 7. A medical felting system according to any of the foregoing aspects includes a manual trigger configured to move from a first position to a second position, wherein the movement of the manual trigger to the second position causes a controller to actuate an electric motor.

[0106] 8. The medical felting system according to aspect 7, wherein the manual trigger is biased toward the first position.

[0107] 9. The medical felting system according to aspect 7 or 8, wherein the manual trigger includes a locking mechanism, particularly a mechanical or electronic lock, which prevents the actuation of the manual trigger when the lock is activated.

[0108] 10. A medical felting system according to one of the foregoing aspects, wherein the controller is configured to preferably store a zero position when the mechanical connector is engaged with the felting device.

[0109] 11. A medical felting system according to one of the foregoing aspects, wherein the controller is configured to store a zero position when power is supplied to the motor.

[0110] 12. The medical felting system according to aspect 10 or 11, wherein the controller is configured to return the motor to the zero position after the motor is actuated.

[0111] 13. A medical felting system according to one of the foregoing aspects, wherein the controller is configured to control the motor to actuate at least one needle at a constant speed during operation.

[0112] 14. A medical felting system according to any of the foregoing aspects, comprising an outer housing, wherein the outer housing surrounds a battery, an electric motor, and a controller.

[0113] 15. The medical felting system according to aspect 14, wherein the motor and / or battery can be removed from the outer housing, preferably at the bottom end opposite the mechanical connector.

[0114] 16. The medical felting system according to aspect 14 or 15, wherein the motor and / or battery includes an inner housing housing the motor and / or battery, and wherein the inner housing is removable from the outer housing.

[0115] 17. The medical felting system according to aspect 16, wherein the inner housing includes a spring-loaded electrical connector.

[0116] 18. A medical felting system according to aspect 16 or 17, wherein the inner housing includes a first inner housing portion for housing a battery and a second inner housing portion for housing a motor, and wherein the first inner housing portion and the second inner housing portion are releasably connected to each other.

[0117] 19. A medical felting system according to one of the foregoing aspects, wherein an electric motor is configured to drive the movement of the felting needle between two end positions.

[0118] 20. A medical felting system according to one of the foregoing aspects, wherein the felting device further includes a spring configured to bias the felting needle to a retracted position.

[0119] 21. A medical felting system according to any of the foregoing aspects, wherein the power unit includes a magnetic coupling for transmitting torque from an electric motor to a mechanical coupling that operatively and releasably connects the power unit to the felting device.

[0120] 22. The medical felting system according to the foregoing aspect, wherein the magnetic connector includes a top connector of one or more magnets and / or a bottom connector of one or more magnets, wherein the top connector and the bottom connector are separated by a certain distance.

[0121] 23. A medical felting system according to one of the aforementioned two aspects, wherein the power unit includes a separator, which preferably extends between the top connector and the bottom connector and seals between the top connector and the bottom connector.

[0122] 24. A medical felting system according to one of the aforementioned three aspects, wherein the magnetic connector has a maximum transmission torque of 100 mNm, preferably 80 mNm, more preferably 70 mNm, most preferably 65 mNm or less.

[0123] 25. A medical felting system according to one of the aforementioned four aspects, wherein the magnetic connector defines one, two or more zero positions.

[0124] 26. A power unit based on one of the aforementioned aspects.

[0125] 27. The power unit according to the foregoing aspects, wherein the power unit is sterilizable.

[0126] 28. A power unit according to any of the foregoing aspects, wherein the power unit includes a magnetic connector for transmitting torque from an electric motor to a felting device.

[0127] 29. The power unit according to the foregoing aspect, wherein the power unit includes a partition that seals and separates the electric motor from the mechanical coupling, the mechanical coupling being configured to operatively and releasably connect the power unit to the felting device, wherein the partition preferably extends across the magnetic coupling.

Claims

1. A medical felting system (1, 2), comprising: a. A felting device (200, 500) comprising at least one felting needle (203) configured to move back and forth between two end positions; as well as b. Power unit (100, 400), including: i. A battery for storing electrical energy (155), ii. An electric motor (165) for actuating the felting device (200), the electric motor (165) being electrically connected to the battery (155), iii. A controller (164) for controlling the electric motor (165), the controller (164) being configured to actuate the motor (165) to drive the felting device (200), and c. wherein the felting device (200, 500) and the power unit (100, 400) are separable from each other, and wherein the felting system includes a mechanical coupling that operatively and releasably connects the power unit (100, 400) to the felting device (200, 500), wherein the mechanical coupling is configured to transmit rotational motion from the electric motor (165) to the at least one felting needle (203).

2. The medical felting system according to claim 1, wherein the felting device includes an input shaft (213), and wherein the mechanical connector includes a slit (301) for receiving the input shaft (213) of the felting device (200).

3. The medical felting system according to claim 2, wherein the electric motor (165) includes a motor output shaft (101), and wherein the mechanical connector includes a coupling connector (300), wherein the coupling connector (300) receives the motor output shaft (101) and includes the slit (301).

4. The medical felting system according to claim 1 or 2, wherein the power unit includes a magnetic coupling for transmitting torque from the electric motor to the mechanical coupling, the mechanical coupling operatively and releasably connecting the power unit to the felting device.

5. The medical felting system of claim 4, wherein the power unit includes a separator that extends within the magnetic connector and seals between the mechanical connector and the electric motor.

6. The medical felting system according to any one of the preceding claims, wherein the mechanical connector includes a first inclined edge to rotate the mechanical connector when the mechanical connector engages the input shaft (213) of the felting device (200).

7. The medical felting system according to any one of the preceding claims, comprising a manual trigger (110) configured to move from a first position to a second position, wherein the movement of the manual trigger (110) to the second position causes the controller (164) to actuate the electric motor (165).

8. The medical felting system according to claim 7, wherein the manual trigger (110) includes a locking mechanism, particularly a mechanical lock or an electronic lock, the locking mechanism preventing the actuation of the manual trigger (110) when the lock is activated.

9. The medical felting system according to any one of the preceding claims, wherein the controller (164) is configured to preferably store a zero position when the mechanical connector is engaged with the felting device (200).

10. The medical felting system according to any one of the preceding claims, wherein the controller (164) is configured to store the zero position when power is supplied to the motor (165).

11. The medical felting system of claim 10, wherein the controller (164) is configured to return the motor (165) to the zero position after the motor (165) is actuated.

12. The medical felting system according to any one of the preceding claims, wherein the power unit includes an outer housing, and wherein the motor (165) and / or the battery (155) are removable from the outer housing (201) of the power unit, preferably at the bottom end opposite the mechanical connector.

13. The medical felting system according to any one of the preceding claims, wherein the power unit includes an outer housing, and wherein the motor (165) and / or the battery (155) includes an inner housing housing the motor (165) and / or the battery (155), and wherein the inner housing is removable from the outer housing (201).

14. The medical felting system according to claim 12, wherein the inner housing includes a first inner housing portion for housing the battery (155) and a second inner housing portion for housing the motor (165), and wherein the first inner housing portion and the second inner housing portion are releasably connected to each other.

15. The medical felting system according to any one of the preceding claims, wherein the power unit (100) is sterilizable.

Images