Modular Surgical Instrument Reclamation for Sterile Remanufacturing

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Solution Overview

Problem

Existing surgical instruments face challenges in efficient disassembly and sterilization processes, particularly when transitioning between sterile and non-sterile environments, which complicates disposal, reuse, and remanufacturing due to potential contamination from patient contact.

Innovation Solution

A modular and interactive surgical system with integrated hubs and modules that facilitate seamless disassembly and reassembly of surgical instruments, utilizing magnetic, mechanical, and electrical connectors, along with a unified management of power, data, and fluid lines, ensuring sterility and ease of handling during surgical procedures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If surgical instruments are designed as integrated units for durability, then reliability is improved, but ease of disassembly and sterilization deteriorates

Engineering Contradiction:

Improveinstrument durabilityVSAvoiddisassembly ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The surgical instrument is divided into multiple modular components including a reusable main body, disposable end effectors, and interchangeable modules. This segmentation allows the main body to maintain durability while individual components can be easily separated for sterilization or replacement, resolving the contradiction between integrated durability and disassembly ease.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If surgical instruments are designed as single-use disposable units, then ease of sterilization is improved, but loss of substance deteriorates due to disposal of functional components

Engineering Contradiction:

Improvesterilization easeVSAvoidfunctional component waste

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The critical functional components that require sterilization are extracted as separable modules or end effectors that can be independently processed. These extracted components can be sterilized and reused, while only the non-critical portions are disposed of, thereby reducing substance loss while maintaining sterilization ease.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The instrument design enables selective discarding of non-critical components while recovering and reusing critical functional modules after sterilization. This approach minimizes waste of valuable functional components while still addressing sterilization requirements for parts that contact patient tissue.

Inventive Principle:

Principle #34Discarding and recovering

3Reliability

If surgical instruments are designed with complex connectors for secure assembly, then reliability is improved, but device complexity deteriorates

Engineering Contradiction:

Improveassembly securityVSAvoidconnector complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Complex mechanical connectors are replaced with magnetic coupling mechanisms or snap-fit designs that provide secure assembly through non-mechanical means. These substitutions maintain reliable connections while significantly reducing the complexity of the connector structures, making assembly and disassembly more straightforward.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 efficient disassembly and sterilization of surgical instruments, reducing contamination risks and simplifying the processing of instruments for reuse or remanufacturing, thereby enhancing sustainability and operational efficiency in surgical environments.

Implementation Method 1

a magnetic lock assembly including a first magnetic member and a second magnetic member, the first magnetic member and the second magnetic member configured to retain the first shroud and the second shroud in the connected state

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

an end effector having a blade element that vibrates at ultrasonic frequencies to cut and/or seal tissue

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 3

one or more piezoelectric elements that convert electrical power into ultrasonic vibrations

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 4

seal tissue by applying radiofrequency (RF) electrosurgical energy to the tissue

Methodology Applied

Scientific EffectRadiofrequency heating: Electromagnetic Induction

Data Source

PatentUS20260031213A1Method of reclaiming portions of surgical instruments for remanufacturing and sustainability

Publication Date: 2026.01.29 CILAG GMBH INTERNATIONAL

AI summary

A method of reclaiming portions of a surgical kit having a surgical instrument includes disassembling the surgical instrument and determining a disposal methodology of the surgical kit. Furthermore, reclaiming further includes verifying reuse capacity of a portion of the surgical instrument and determining a waste stream for the portion of the surgical instrument. The method also includes disassembling the portion of the surgical instrument from a remainder of the surgical instrument at a predetermined region of the surgical instrument to thereby reclaim the portion of the surgical instrument according to the waste stream.