Modular Surgical Instrument Segmentation for Sterilization

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Reusable surgical instruments face challenges due to contamination and degradation of tissue-contacting components, requiring labor-intensive cleaning and extensive training for disassembly, which can lead to contamination and discourage use.

Innovation Solution

A modular surgical system with a reusable handle assembly, steerable cannula assembly, and interchangeable surgical instruments, featuring a joystick controller, self-contained battery pack, and electronic circuitry, allowing for easy assembly and disassembly for cleaning and reuse, with mechanical mating mechanisms for secure coupling and precise control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If surgical instruments are made reusable to reduce costs, then instrumentation costs per procedure are reduced, but cleaning complexity and contamination risk increase

Engineering Contradiction:

Improveinstrumentation costVSAvoidcleaning complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The surgical instrument is divided into multiple separable components including a handle assembly, a shaft assembly, and a functional component (electrode or knife). Each component can be independently removed, cleaned, and sterilized, simplifying the cleaning process while maintaining reusability and reducing overall contamination risk.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The functional component (electrode or knife) is extracted as a separate replaceable element that can be removed from the shaft assembly. This allows the critical tissue-contacting surface to be easily replaced or sterilized independently, reducing cleaning complexity while maintaining instrument reusability.

Inventive Principle:

Principle #2Taking out (Extraction)

2Loss of substance

If surgical instruments are made reusable to reduce costs, then instrumentation costs per procedure are reduced, but contamination risk increases

Engineering Contradiction:

Improveinstrumentation costVSAvoidcontamination risk

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The instrument is segmented into separable components that can be independently sterilized and reassembled in a controlled manner, reducing contamination risk while maintaining cost-effectiveness through reuse.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Components are designed to be pre-sterilized and stored in sterile packaging, allowing assembly in a controlled environment before use. This preliminary sterilization action reduces contamination risk while maintaining instrument reusability.

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If removable components are added to provide clean surfaces for each use, then contamination risk is reduced, but disassembly complexity and training requirements increase

Engineering Contradiction:

Improvecontamination riskVSAvoiddisassembly ease

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The instrument is divided into clearly defined modular components with standardized connection interfaces, making disassembly and reassembly intuitive and reducing training requirements while providing clean surfaces for each use.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The functional component (electrode or knife) is designed as a disposable element that is replaced rather than cleaned, eliminating contamination risk at the tissue-contacting surface while keeping the overall system reusable and cost-effective.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Object-affected harmful factors

If complex disassembly procedures are implemented for reusable instruments, then clean surfaces are achieved, but extensive training is required and use is discouraged

Engineering Contradiction:

ImprovecontaminationVSAvoidassembly ease

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The instrument uses clearly segmented modular components with intuitive connection interfaces that simplify assembly and disassembly procedures, reducing training requirements while maintaining contamination control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Critical tissue-contacting components are designed as disposable elements that are simply replaced rather than disassembled and cleaned, dramatically simplifying the process while ensuring contamination-free surfaces for each use.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS10307038B2System and method for performing surgical procedures with a modular surgical system

Publication Date: 2019.06.04 COVIDIEN LP

AI summary

A surgical system is provided including a reusable handle assembly having a controller and a reusable cannula assembly configured to be operatively connected to and steerable by the reusable handle assembly. Additionally, the surgical system includes a plurality of surgical instruments configured to be inserted through the reusable handle assembly and configured to advance a length of the reusable cannula assembly, such that the plurality of surgical instruments are engaged with at least one trigger mechanism of the reusable handle assembly. The handle assembly, the cannula assembly, and the plurality of surgical instruments are modular components configured to be releasably or removably coupled or interconnected to each other.