Electrosurgical Instrument Segmentation for Sterility
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrosurgical instruments face challenges in ensuring sterility due to contamination from blood and tissue debris, particularly in reusable parts with complex designs that are difficult to clean and sterilize, posing a risk of cross-contamination between patients.
Innovation Solution
The design separates the electrosurgical instrument into two assemblies: a disposable end effector unit with moving parts and a reusable electronics unit with radio frequency signal generator circuitry and battery, where the electronics unit is hermetically sealed with inductive charging, reducing the number of connections and potential ingress points for debris, allowing for simplified sterilization and reusability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the electrosurgical instrument is designed with reusable parts containing electronic circuitry and mechanical components, then the device can be reused to reduce waste and cost, but the complex design with multiple connections and apertures increases the risk of contamination from blood and tissue debris
Solution Approach 1:
The electrosurgical instrument is divided into two separable assemblies: a disposable end effector unit containing the end effector and mechanical drive components, and a reusable electronics unit containing the RF signal generator and battery. This segmentation allows the disposable unit to be discarded after single use, eliminating contamination risks, while the sealed reusable unit can be sterilized and reused, reducing waste.
Solution Approach 2:
The end effector unit with its mechanical components is designed as a disposable single-use component that is discarded after one surgical procedure. This eliminates the need to sterilize complex mechanical parts and prevents cross-contamination, while the expensive electronics are protected in a reusable sealed unit.
2Ease of operation
If the reusable electronics unit has multiple connections and apertures for mechanical drive and electrical contacts, then the device can transfer power and motion effectively, but the increased number of interfaces creates more potential ingress points for surgical debris
Solution Approach 1:
The mechanical drive components and electrical contacts are extracted from the reusable electronics unit and placed in the disposable end effector unit. This extraction eliminates the need for mechanical connections and apertures in the reusable unit, allowing it to be hermetically sealed with only essential electrical contacts, thereby reducing ingress points for contamination.
Solution Approach 2:
The patent replaces mechanical drive connections between the reusable unit and end effector with a magnetic coupling system. The magnetic drive mechanism uses magnetic fields to transmit rotational motion without physical contact, eliminating mechanical apertures and connections in the reusable electronics unit that could allow contamination.
3Reliability
If the electrosurgical instrument uses traditional sterilization methods for reusable parts with complex mechanisms, then sterility can be maintained, but the complex internal structures make thorough cleaning and sterilization difficult and time-consuming
Solution Approach 1:
By separating the instrument into disposable and reusable assemblies, the patent eliminates the need to sterilize complex mechanical components. The disposable unit is discarded after single use, while the reusable electronics unit has a simplified sealed design that can be sterilized more efficiently using standard autoclaving or chemical sterilization methods.
Solution Approach 2:
The end effector unit with its complex mechanical drive components is designed as a disposable item that is discarded after one use, eliminating the need for sterilization entirely. This transfers the sterility requirement to the reusable electronics unit, which has a simpler sealed design that is easier and faster to sterilize.
4Ease of manufacture
If the electrosurgical instrument is designed as a single integrated unit, then manufacturing and assembly are simpler, but the entire device must be disposed of after single use or undergo complex sterilization procedures
Solution Approach 1:
The instrument is segmented into two assemblies that can be manufactured separately and then connected via a bayonet-style interface. The disposable end effector unit contains the end effector and mechanical drive, while the reusable electronics unit contains the RF generator and battery. This segmentation allows the expensive electronics to be reused while only the disposable components are discarded.
Solution Approach 2:
The reusable electronics unit is designed with a universal interface that can accommodate different disposable end effector units. This allows a single reusable electronics unit to be used with multiple types of end effectors, increasing versatility and reducing waste by maximizing the reuse of the electronics portion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances sterility by minimizing the risk of cross-contamination, reduces waste, and simplifies the sterilization process, making the instrument safer and more environmentally friendly while ensuring the electronics unit can be reused multiple times.
Implementation Method 1
The power pack may be removable from the instrument and connectable to a remote charger base
Implementation Method 2
the reusable electronics unit is sealed, the reusable electronics unit further comprising a user-releasable electrical interface
Data Source
AI summary
A surgical instrument is configured to consist of two separable parts. The first part includes a disposable end effector unit, including an electrosurgical end effector and mechanical drive componentry. The second part includes a reusable electronics unit, containing the RF electronic circuitry of the instrument. A user-releasable complementary interface is provided on each part, allowing the parts to be connected in use. Providing a division of components in this manner improves the sterility of the device, providing easier cleaning of the reusable part of the instrument.