Modular Surgical Instrument Power and Shaft Switching

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Solution Overview

Problem

Existing surgical instruments lack versatility and efficiency in performing multiple surgical tasks such as grasping, dissecting, clipping, and suturing, with a need for improved mechanical and electrical integration for enhanced maneuverability and power management.

Innovation Solution

A surgical instrument system comprising a handle assembly with interchangeable shaft assemblies and end effectors, powered by a motor-driven drive unit, featuring a modular power supply and advanced control systems for precise motor operation and articulation, allowing for multiple surgical functions and customizable grip options.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a surgical instrument system is designed with multiple interchangeable shaft assemblies and end effectors to perform various surgical tasks, then the versatility and adaptability of the system is improved, but the device complexity increases

Engineering Contradiction:

ImproveversatilityVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The surgical instrument system is divided into separate modular components including a handle assembly, multiple interchangeable shaft assemblies, and various end effectors. Each shaft assembly can be detached and replaced to perform different surgical functions, allowing the system to maintain versatility while managing complexity through standardized modular interfaces

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The handle assembly is designed with a universal interface that can accommodate multiple types of shaft assemblies and end effectors through standardized connecting features. This multi-functionality allows a single handle to perform various surgical tasks by simply changing the attached shaft and end effector components

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If a modular power supply system is implemented to enable interchangeable components, then the adaptability and ease of operation are improved, but the device complexity and manufacturing difficulty increase

Engineering Contradiction:

ImproveadaptabilityVSAvoidease of manufacture

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The power supply system is segmented into modular units with standardized electrical connections. Each shaft assembly and end effector includes standardized electrical connectors that mate with corresponding receptacles in the handle assembly, enabling interchangeable components while simplifying manufacturing through standardized connection interfaces

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Standardized electrical connectors and receptacles serve as intermediaries between the handle assembly and interchangeable components. These standardized interfaces facilitate easy manufacturing by providing predetermined connection protocols and mechanical/electrical mating features that simplify assembly processes

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If advanced control systems with sensors are integrated to enable precise motor operation and articulation, then the measurement precision and manufacturing precision are improved, but the device complexity and cost increase

Engineering Contradiction:

ImproveprecisionVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Sensors are integrated into the shaft assembly and end effector to provide feedback signals to the control system. This feedback enables precise control of motor operation and articulation by continuously monitoring position, orientation, and operational status, allowing real-time adjustments to achieve surgical precision

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Traditional mechanical linkages and switches are replaced with electronic sensors and digital control systems. This substitution enables more precise measurement and control of surgical instrument movement, replacing mechanical precision requirements with electronic sensing and control algorithms

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Duration of action of moving object

If battery arrangements are added to provide power to the motor and control systems, then the duration of action and power availability are improved, but the weight and volume of the system increase

Engineering Contradiction:

ImprovedurationVSAvoidweight

Core Design Contradiction:

Duration of action of moving objectVSWeight of moving object

Solution Approach 1:

The battery arrangement is nested within the handle assembly or shaft assembly structure. By integrating the power source into the existing component architecture rather than adding it as a separate external unit, the system achieves extended operational duration while minimizing additional weight and volume

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentEP4311508B1Surgical instrument systems comprising battery arrangements

Publication Date: 2025.12.03 ETHICON INC

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AI summary

A surgical instrument system comprising a handle, a shaft, and a disposable power module is disclosed. The handle comprises a motor, a control switch, and a motor-control processor which is in communication with the control switch. In various instances, the disposable power module comprises a disposable battery and a display unit configured to indicate at least one function of the surgical instrument system.