Surgical Stapler Adapter Cable Assembly for Rotating Electrical Contacts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing surgical device adapter assemblies face challenges in withstanding mechanical stresses and require reliable electrical connectors that can maintain connectivity under rotation, while also simplifying manufacturing and assembly processes.
Innovation Solution
The adapter assembly incorporates a flexible cable with conductive layers between dielectric substrates, featuring flexible fingers soldered to contact clips, which are attached to a rotatable lock member, reducing mechanical stress and eliminating the need for additional wires and labor-intensive cutting/stripping processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rigid cable assemblies with separate wires are used, then electrical connectivity is established, but mechanical stress resistance deteriorates and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple separate wires into a single flexible cable assembly with integrated conductive layers between dielectric substrates. This merging reduces the number of individual components and simplifies the overall structure while maintaining electrical connectivity and improving mechanical stress resistance through the unified flexible construction.
Solution Approach 2:
The patent employs flexible dielectric substrates and thin film conductive layers to create a cable assembly that can bend and flex without damage. This flexible construction allows the cable to withstand mechanical stresses during surgical procedures while maintaining reliable electrical connections, eliminating the need for rigid wire assemblies.
2Reliability
If additional wires and cutting/stripping processes are used, then electrical connections are established, but manufacturing time and labor increase
Solution Approach 1:
The flexible cable assembly is pre-manufactured with conductive layers already positioned between dielectric substrates, eliminating the need for on-site wire cutting, stripping, and termination. This preliminary preparation significantly reduces manufacturing time and labor requirements while ensuring consistent, reliable electrical connections.
Solution Approach 2:
The flexible cable assembly is designed to be self-contained and self-terminating, with the conductive layers and dielectric substrates forming complete electrical connections without requiring additional wires or manual termination processes. This self-service design simplifies the manufacturing process and improves productivity.
3Reliability
If rigid electrical connectors are used, then electrical connectivity is maintained, but adaptability to rotation and movement deteriorates
Solution Approach 1:
The patent transitions from rigid electrical connectors to a dynamic flexible cable assembly that can adapt to rotation and movement. The flexible dielectric substrates and conductive layers allow the cable to bend and flex while maintaining electrical connectivity, enabling the connector to accommodate various positions and movements during surgical procedures.
Solution Approach 2:
The patent changes the physical parameters of the electrical connector from rigid to flexible by using flexible dielectric substrates and thin film conductive layers. This parameter change allows the connector to adapt to rotation and movement while maintaining reliable electrical connections, providing both flexibility and durability.
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
This solution enhances the reliability of electrical connections, simplifies manufacturing, and reduces the number of parts required, ensuring consistent performance and ease of assembly while maintaining sterility in a surgical environment.
Implementation Method 1
a wire harness disposed within the tubular housing and interconnecting the electrical connector and the electrical contact assembly. The wiring harness is a flexible cable having a first flexible dielectric substrate, one or more conductive layers disposed on the first flexible dielectric substrate and a second flexible dielectric substrate, wherein the one or more conductive layers are enclosed between the first flexible dielectric substrate and the second flexible dielectric substrate
Implementation Method 2
featuring flexible fingers soldered to contact clips
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A surgical device includes a handle assembly including a controller and a first electrical connector. The surgical device also includes an adapter assembly having: a tubular housing having a proximal end portion configured to couple to the handle assembly, and a distal end portion; a second electrical connector disposed at the proximal end portion and configured to couple to the first electrical connector; an electrical contact assembly disposed at the distal end portion; and a wire harness disposed within the tubular housing and interconnecting the second electrical connector and the electrical contact assembly. The surgical device also includes a surgical end effector configured to couple to the distal end portion of the adapter assembly, the surgical end effector includes an electrical contact configured to couple to the electrical contact assembly.