Potting Sealed Powered Surgical Stapler
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Solution Overview
Problem
Current powered surgical staplers require significant manual force to operate, leading to surgeon fatigue, and internal components are vulnerable to moisture, chemicals, and biological contaminants, necessitating improved protection and efficiency.
Innovation Solution
A powered surgical instrument with a housing containing internal components encapsulated in a potting material within the housing, including a drive motor and control circuit, which is sealed to prevent contamination and damage, and a method for manufacturing this instrument by injecting and solidifying a liquid potting material to protect these components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual force is used to clamp tissue and deploy surgical fasteners, then the surgical procedure can be performed, but surgeon hand fatigue occurs due to repeated use requiring 10-60 pounds of force
Solution Approach 1:
The patent replaces the manual mechanical clamping system with a motor-powered system. The motor assembly (200) provides automated actuation of the anvil assembly (162) and cartridge assembly (164), eliminating the need for surgeons to manually apply 10-60 pounds of force repeatedly. The motor converts electrical energy to mechanical motion, substituting human physical effort with automated mechanical actuation.
2Reliability
If internal components are exposed within the housing, then the device structure remains simple, but components are vulnerable to moisture, chemical cleaners, vapors, gases, and biological contaminants
Solution Approach 1:
The patent employs a potting material (404) that encapsulates the motor assembly (200) and control circuit (400) within the housing (110). This potting material acts as a protective barrier, sealing the internal components from moisture, chemical cleaners, vapors, gases, and biological contaminants. The potting process creates a hermetic seal without requiring complex separate sealing mechanisms for each component.
Solution Approach 2:
The patent uses a composite structure where the potting material (404) combines with the housing (110) to create a protected environment. The potting material is specifically selected to resist degradation from exposure to chemical cleaners and sterilization processes, creating a composite protective system that shields sensitive electronic and mechanical components from harsh surgical environments.
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
The solution reduces manual force requirements and protects internal components from contamination and environmental stress, enhancing the instrument's durability and usability in surgical procedures.
Implementation Method 1
injecting a liquid potting material injected into a housing defining an inner cavity therein, the housing including at least one internal component disposed within the housing; and solidifying the potting material to encapsulate at least a portion of the at least one internal component
Data Source
AI summary
The present disclosure provides a powered surgical instrument including a housing defining an inner cavity therein; at least one internal component disposed within the housing; and potting material injected into the inner cavity encapsulating at least a portion of the at least one internal component.