Aseptic Battery Jacket for Surgical Instrument Sterility
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Solution Overview
Problem
Rechargeable battery assemblies used in surgical instruments are difficult to sterilize and transfer aseptically between charging areas and surgical environments, risking contamination and infection due to their incompatibility with standard sterilization techniques.
Innovation Solution
A battery jacket system that releasably engages with both the battery assembly and the surgical instrument, allowing for snap-fit insertion and sealing, enabling aseptic transfer and sterilization without interrupting the electrical coupling to the charging device, and can be made from sterilizable materials like metal or thermoplastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard sterilization techniques (autoclaving) are used on battery assemblies, then complete sterilization is achieved, but the battery assembly is damaged due to incompatibility with these techniques
Solution Approach 1:
The system divides the battery assembly into two separable components: a sterilizable battery jacket and a non-sterilizable battery pack. The battery jacket can withstand autoclaving and sterilization processes, while the battery pack remains protected from these harsh conditions. This segmentation allows the sterilizable portion to be completely sterilized without damaging the sensitive battery cells.
Solution Approach 2:
The battery jacket serves as an intermediary barrier between the sterile surgical environment and the non-sterile battery pack. It creates a sterile interface that allows electrical coupling while maintaining sterility, enabling the battery pack to remain unsterilized while still functioning in a sterile environment through the mediating jacket.
2Productivity
If battery assemblies are transferred directly between charging areas and surgical environments, then transfer speed is maximized, but contamination risk increases due to multiple transitions and exposure points
Solution Approach 1:
The battery pack is pre-assembled with the battery jacket in a controlled manufacturing environment before entering the surgical workflow. This preliminary assembly ensures proper alignment and connection of electrical contacts, eliminating the need for complex assembly steps during urgent surgical situations while maintaining contamination barriers throughout the transfer process.
Solution Approach 2:
The battery jacket acts as a protective intermediary that shields the battery pack from contamination during transfer. It provides a sterile barrier that allows the battery assembly to move between non-sterile charging areas and sterile surgical environments without exposing the battery pack to contaminants, thus reducing contamination risk while enabling efficient transfer.
3Object-affected harmful factors
If the battery assembly is designed with complex sealing mechanisms to maintain sterility, then contamination prevention is improved, but device complexity and difficulty of manufacture increase
Solution Approach 1:
The sealing function is segmented and assigned specifically to the battery jacket, which is designed as a standalone sterilizable component. This separates the sealing responsibility from the battery pack, allowing the jacket to incorporate simple yet effective sealing features like friction fits or snap connections that maintain sterility without requiring complex mechanisms. The sealed interface between jacket and battery pack is straightforward, facilitating easy manufacturing.
4Ease of operation
If the battery assembly allows easy removal for charging, then ease of operation is improved, but sterility maintenance becomes more difficult due to frequent openings
Solution Approach 1:
The system segments the battery into a removable battery pack and a retained battery jacket. The battery pack can be easily removed and reinserted without compromising sterility because the battery jacket remains in place as a permanent sterile barrier. This segmentation allows frequent charging cycles while maintaining the sterile interface, as only the sealed battery pack needs to be removed, not the entire assembly.
Solution Approach 2:
The battery jacket serves as a permanent intermediary that remains attached to the surgical instrument throughout use, maintaining the sterile barrier even when the battery pack is removed for charging. This mediating structure allows the battery pack to be freely removed and reinserted without breaching sterility, as the jacket continuously protects the sterile interface.
Data Source
AI summary
A method of transferring a battery assembly to a battery-powered surgical instrument includes releasably engaging a battery jacket with the battery assembly, transferring the battery jacket, having the battery assembly engaged thereto, to a battery-powered surgical instrument, and releasably engaging the battery jacket with a handle of the battery-powered surgical instrument such that the battery assembly is electrically coupled to the battery-powered surgical instrument and such that the battery jacket and the handle cooperate to enclose the battery assembly therein. Aseptic battery jackets for such use are also provided.