Hermetic Load Sensing Assembly for Surgical Devices

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Solution Overview

Problem

Existing surgical devices face challenges with load sensing systems that are not compatible with rotary motion, leading to signal degradation and failure due to exposure to disinfecting and sterilization cycles, and lack adjustability for zero balance variations.

Innovation Solution

A hermetically sealed load sensing assembly with integrated signal processing circuit and thermal management material to protect components from harsh environments and allow for programmable adjustments, ensuring accurate and reliable load measurements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If load sensing devices are disposed on mechanical components to gather mechanical force information, then measurement capability is improved, but the devices are exposed to harsh sterilization environments causing signal degradation

Engineering Contradiction:

Improveload sensing accuracyVSAvoidsignal stability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent combines the load sensing device and signal processing circuit into a single integrated assembly that is hermetically sealed together. This merging eliminates the need for separate wiring and protects both components from the harsh sterilization environment while maintaining measurement capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a hermetic seal around the load sensing device and signal processing circuit, effectively isolating them from the external harsh environment including autoclave cycles, saline irrigation, and disinfecting solutions. This inert environment prevents degradation of electronic components and sensor leads.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Ease of manufacture

If signal processing circuits are placed away from load sensing devices due to size constraints, then component layout flexibility is improved, but signal loss increases and measurement fidelity decreases

Engineering Contradiction:

ImprovePCB layout flexibilityVSAvoidsignal fidelity

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent integrates the signal processing circuit directly with the load sensing device within the same hermetically sealed assembly. This eliminates long signal transmission leads and associated signal loss, while the modular design allows for easy manufacturing and assembly.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If adapters are made more sophisticated with electronic components to enable rotary motion compatibility, then functional versatility is improved, but susceptibility to sterilization damage increases

Engineering Contradiction:

Improverotary motion compatibilityVSAvoidsterilization resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent integrates the load sensing functionality directly into the adapter assembly, combining mechanical adaptation with electronic sensing in a single hermetically sealed unit. This eliminates the need for separate electronic components that would be vulnerable to sterilization.

Inventive Principle:

Principle #5Merging (Combining)

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

The solution enhances the reliability and accuracy of load sensing in surgical devices by protecting components from sterilization cycles and allowing for adjustments, reducing signal loss and maintaining measurement fidelity.

Implementation Method 1

a hermetic seal between the load sensing assembly and the adapter assembly

Methodology Applied

Scientific EffectHermetic sealing:

Implementation Method 2

a thermal management material in thermal communication with the signal processing circuit and the load sensing device

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

load sensing devices, such as load cells, are disposed on one or more mechanical components of the powered surgical device

Methodology Applied

Scientific EffectPiezoresistive effect: Piezoresistive Effect

Data Source

PatentUS11534164B2Strain gauge stabilization in a surgical device

Publication Date: 2022.12.27 COVIDIEN LP

AI summary

A surgical device includes an adapter assembly including a tubular housing having a proximal end portion configured to couple to a handle assembly, and a load sensing assembly disposed with the tubular housing. The load sensing assembly is configured to measure a load exerted on the tubular housing and includes: a sensor body including a pocket defined therein; a load sensor circuit disposed within the pocket and coupled to the sensor body; a signal processing circuit disposed within the pocket and electrically coupled to the load sensor circuit; a cover defining a cavity and disposed over the pocket and enclosing the load sensor circuit and the signal processing circuit therein, the cover being coupled to the sensor body thereby forming a first hermetic seal therebetween; and a thermal management material disposed within the cavity and in contact with the load sensor circuit and the signal processing circuit.