Hermetic Seal Assembly for Surgical Load Sensors

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Solution Overview

Problem

Existing surgical devices with electronic sensors face challenges in withstanding multiple cleaning and autoclave cycles, requiring load sensing devices that can maintain functionality in harsh sterile environments.

Innovation Solution

A load sensing assembly with a hermetic seal assembly, comprising a metal base portion and a plastic cover, encloses load sensor and signal processing circuits, providing a durable and reliable solution for monitoring mechanical forces during surgical procedures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If electronic sensors are used in surgical devices to provide feedback during operation, then measurement precision is improved, but reliability deteriorates due to inability to withstand multiple cleaning and autoclave cycles

Engineering Contradiction:

Improveforce measurement accuracyVSAvoidwithstand sterilization cycles

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The device is divided into sterile and non-sterile sections. The load sensor circuit is isolated in a hermetic seal that acts as a barrier, allowing the sensor to remain protected while the rest of the device undergoes sterilization. This segmentation enables electronic sensing capability while maintaining sterilization compatibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A hermetic seal assembly acts as an intermediary barrier between the electronic load sensor circuit and the sterile environment. This intermediary protects the sensitive electronics from moisture and sterilization processes while still allowing the device to function in the sterile surgical environment.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If load sensing devices are disposed of after single use, then reliability is improved by avoiding sterilization damage, but loss of substance worsens due to single-use disposal

Engineering Contradiction:

Improvefunctional integrityVSAvoiddevice disposal

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The surgical device is segmented into disposable and reusable components. The hermetic seal with the load sensor can be designed as a disposable component that is replaced after use, while the main surgical device housing can be sterilized and reused. This allows the sensitive electronic component to be protected from sterilization while enabling device reuse.

Inventive Principle:

Principle #1Segmentation

3Reliability

If hermetic seal assembly is used to protect electronic components, then reliability is improved by withstanding sterilization, but device complexity increases

Engineering Contradiction:

Improvesterilization resistanceVSAvoidseal assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The hermetic seal assembly uses a thin-film or flexible membrane structure that provides effective hermetic protection while maintaining a compact and relatively simple form factor. This approach achieves reliable sealing without requiring complex multi-layer or rigid structures.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentEP3756586B1Load sensing assemblies and methods of manufacturing load sensing assemblies

Publication Date: 2023.09.27 COVIDIEN LP

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AI summary

An adapter assembly of a circular stapling instrument includes a load sensing assembly configured to measure a load exerted on a tubular housing of the adapter assembly. The load sensor assembly has a sensor body, electrical components supported by the sensor body, and a hermetic seal assembly enclosing the electrical components. The hermetic seal assembly includes a stamped base portion and an overmolded upper portion.