Isolated Surgical Actuation Members for Electrical Energy Control

Solution Overview

Problem

Surgical instruments with conductive actuation members face challenges in maintaining electrical isolation while ensuring durability and reliability, as conductive materials like metals are prone to misdirect electrical energy due to their conductivity.

Innovation Solution

The actuation member is designed with an electrically conductive distal flexible portion and a conductive proximal rod portion, surrounded by electrically insulating materials, ensuring electrical isolation between these components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conductive materials (metals or metal alloys) are used for actuation members to withstand high forces and provide durability, then strength and reliability are improved, but electrical energy may be misdirected from the intended application site due to electrical conductivity

Engineering Contradiction:

ImprovestrengthVSAvoidelectrical energy misdirection

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The actuation member is divided into multiple segments: a conductive proximal portion, an electrically insulating intermediate portion, and a conductive distal portion. This segmentation allows each segment to perform its specific function - the conductive portions transmit mechanical force while the insulating portion prevents electrical energy misdirection, thereby resolving the contradiction between strength and electrical safety.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The actuation member employs a composite structure combining different materials with distinct properties: metal or metal alloy for the conductive portions (providing strength and conductivity where needed), and electrically insulating material for the intermediate portion (preventing harmful electrical energy transmission). This composite approach allows the actuation member to simultaneously achieve strength, durability, and electrical isolation.

Inventive Principle:

Principle #40Composite materials

2Object-generated harmful factors

If electrically insulating materials (polymers or ceramics) are used for actuation members to prevent electrical energy misdirection, then electrical isolation is improved, but yield strength, toughness, hardness, and wear resistance are insufficient

Engineering Contradiction:

Improveelectrical energy misdirectionVSAvoidyield strength

Core Design Contradiction:

Object-generated harmful factorsVSStrength

Solution Approach 1:

The actuation member is divided into multiple segments: a conductive proximal portion, an electrically insulating intermediate portion, and a conductive distal portion. This segmentation allows each segment to perform its specific function - the conductive portions transmit mechanical force while the insulating portion prevents electrical energy misdirection, thereby resolving the contradiction between strength and electrical safety.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The actuation member employs a composite structure combining different materials with distinct properties: metal or metal alloy for the conductive portions (providing strength and conductivity where needed), and electrically insulating material for the intermediate portion (preventing harmful electrical energy transmission). This composite approach allows the actuation member to simultaneously achieve strength, durability, and electrical isolation.

Inventive Principle:

Principle #40Composite materials

3Object-generated harmful factors

If electrically insulating material surrounds the actuation member to prevent electrical energy misdirection, then electrical isolation is improved, but device complexity increases

Engineering Contradiction:

Improveelectrical energy misdirectionVSAvoiddevice complexity

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The electrically insulating intermediate portion is integrated directly into the actuation member structure, merging the insulation function with the mechanical transmission function. This integration eliminates the need for separate insulation components or assemblies, thereby reducing overall device complexity while maintaining electrical isolation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The actuation member employs a composite structure combining different materials with distinct properties: metal or metal alloy for the conductive portions (providing strength and conductivity where needed), and electrically insulating material for the intermediate portion (preventing harmful electrical energy transmission). This composite approach allows the actuation member to simultaneously achieve strength, durability, and electrical isolation.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12564416B2Surgical instruments with electrically isolated actuation members, related devices, and related methods

Publication Date: 2026.03.03 INTUITIVE SURGICAL OPERATIONS INC

AI summary

An actuation member for transmitting force from a drive mechanism to an end effector of a surgical instrument includes an electrically conductive distal flexible portion configured to be operably coupled with an end effector of a surgical instrument and an electrically conductive proximal rod portion connected to the flexible distal portion. The proximal rod portion is configured to be operably coupled to a drive mechanism. An electrically insulating material surrounds at least a portion of a length of the distal flexible portion and at least a portion of a length of the proximal rod portion. The electrically insulating material extends at least over a location where the distal flexible portion and the proximal rod portion connect. Surgical instruments include such actuation members. Methods relate to configuring actuation members.