Encapsulated Plug Assembly for Autoclave-Resistant Surgical Adapters
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Solution Overview
Problem
Existing surgical devices with linearly driven end effectors are not compatible with powered surgical devices that use rotary motion, and there is a need for adapters that can withstand multiple sterilization cycles, particularly in high pH environments and high temperature autoclave conditions.
Innovation Solution
A plug assembly for electromechanical surgical systems featuring a transparent housing with encapsulated electrical contacts and a ribbon cable, using materials like polyphenylsulfone and UV-curable resin, which forms a fluid-tight seal and is resistant to disinfecting chemicals and autoclave pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If adapters include electronic components to enable compatibility between linear driven end effectors and rotary driven surgical devices, then adaptability is improved, but reliability deteriorates due to sensitivity to high pH environments and autoclave conditions
Solution Approach 1:
The patent introduces an adapter assembly as an intermediary component between the rotary driven surgical device and linear driven end effector. This adapter includes a rotary-to-linear converter mechanism that translates rotary motion into linear motion, enabling compatibility while isolating the electronic components from direct exposure to harsh sterilization environments. The adapter serves as a mediator that bridges two incompatible systems without requiring the end effector itself to withstand autoclave conditions.
Solution Approach 2:
The patent changes the operational parameters of the adapter assembly by designing it to be sterilizable through multiple methods including autoclaving, ethylene oxide sterilization, and gamma irradiation. The electronic components are sealed in hermetic enclosures that maintain their functional parameters (electrical connectivity, signal transmission) while withstanding the extreme temperature, pressure, and chemical conditions of sterilization cycles. This parameter change approach allows the adapter to maintain reliability across repeated sterilization treatments.
2Reliability
If adapters are designed to withstand multiple autoclave cycles with high temperature and pressure, then reliability is improved, but device complexity increases due to need for specialized materials and sealing mechanisms
Solution Approach 1:
The patent employs composite material construction for the adapter housing, combining autoclave-resistant polymers (such as polyetheretherketone or polyphenylsulfone) with metal reinforcement elements. The housing may also include ceramic-coated components for enhanced thermal stability. This composite approach provides the necessary resistance to high temperature and pressure while managing the complexity through standardized material selections that are proven to withstand sterilization conditions.
Solution Approach 2:
The patent implements a nested sealing structure where multiple sealing mechanisms are concentrically arranged within the adapter assembly. Hermetic seals enclose electronic components, while additional seals protect mechanical interfaces. This nested arrangement allows each sealing layer to address specific vulnerability points without requiring a completely redesigned complex sealing system, as each nested seal operates independently to protect its enclosed components.
3Reliability
If electronic components are sealed in hermetic enclosures for sterilization resistance, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes flexible hermetic seal films and elastomeric gaskets that can be molded or extruded to precise specifications and then assembled through standardized interfaces. These flexible sealing elements conform to mating surfaces, providing hermetic protection without requiring extremely tight tolerances on the rigid housing components. The flexible nature of these seals allows for compensation of minor manufacturing variations while maintaining chemical resistance and sterility.
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
Enables compatibility between linearly driven end effectors and rotary-driven surgical devices, ensuring reliable operation through multiple sterilization cycles while maintaining electrical integrity and resistance to harsh environmental conditions.
Implementation Method 1
UV-curable resin
Data Source
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AI summary
A plug assembly for an electromechanical surgical system includes: a housing defining a proximal facing bore; a pair of electrical contacts disposed within the housing, each electrical contact including a distal end portion projecting distally from a distal end of the housing; and a proximal end portion disposed within the proximal facing bore of the housing; a ribbon cable having a distal end portion electrically connected to the proximal end portion of each of the pair of electrical contacts, and being disposed with the proximal facing bore of the housing; and an encapsulating material filling the proximal facing bore of the housing.