Sterile Adapter Couplers for Robotic Surgical Tool Torque Transfer

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Solution Overview

Problem

Conventional robotic surgical systems face challenges in maintaining a sterile environment during minimally-invasive surgery, as components like motors and encoders cannot be sterilized using conventional methods, and existing sterile barriers complicate the actuation of surgical tools.

Innovation Solution

A sterile adapter system is introduced, featuring a frame, plate assembly, and rotatable couplers that facilitate torque transmission between a tool driver and surgical tool while maintaining sterility, with features like engagement mechanisms, mounts, and a sterile drape to create a barrier.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a sterile barrier is introduced between the tool driver and surgical tool, then sterility is maintained, but torque transmission and tool actuation are interfered with

Engineering Contradiction:

Improvesterility maintenanceVSAvoidtool actuation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

A sterile adapter assembly acts as an intermediary component between the non-sterile tool driver and sterile surgical tool. The adapter includes a non-sterile adapter portion that interfaces with the tool driver and a sterile adapter portion that interfaces with the surgical tool, with a sterile barrier between them. This intermediary structure allows torque and actuation forces to be transmitted while maintaining sterility through magnetic coupling and flexible membrane mechanisms.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces direct mechanical contact across the sterile barrier with magnetic field coupling. Magnets are positioned on both sides of the sterile barrier to transmit rotational torque without physical penetration. This substitution allows torque transmission while maintaining the integrity of the sterile barrier.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If a sterile barrier is introduced, then sterility is maintained, but tool exchange becomes complicated

Engineering Contradiction:

Improvesterility maintenanceVSAvoidtool exchange time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system is segmented into three distinct modules: the non-sterile tool driver, the sterile adapter assembly (which remains in place), and the sterile surgical tool. The sterile adapter assembly includes engagement features that can quickly interface with different surgical tools. During tool exchange, only the surgical tool needs to be detached and reattached to the sterile adapter, while the sterile barrier and adapter assembly remain stationary, enabling rapid tool exchange without compromising sterility.

Inventive Principle:

Principle #1Segmentation

3Reliability

If conventional sterilization methods are used, then components are sterilized, but motors and encoders cannot be sterilized

Engineering Contradiction:

ImprovesterilizationVSAvoidcomponent compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The electronic components (motors and encoders) are extracted from the sterile field and placed in the non-sterile tool driver portion. The sterile adapter assembly and surgical tool form a separate sterile module that can be sterilized independently using conventional methods. This extraction allows the electronic components to remain outside the sterile barrier where they cannot be sterilized, while the sterile components are kept separate and can be properly sterilized.

Inventive Principle:

Principle #2Taking out (Extraction)

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 system allows for efficient tool exchange without compromising sterility and ensures seamless actuation of surgical tools, maintaining a sterile surgical field.

Implementation Method 1

at least one rotatable coupler supported by the plate assembly and configured to communicate torque from an output drive of the tool driver to an input drive of the surgical tool

Methodology Applied

Scientific EffectTorque transmission: Torque

Data Source

PatentUS12551307B2Sterile adapter drive disks for use in a robotic surgical system

Publication Date: 2026.02.17 AURIS HEALTH INC

AI summary

Generally, a sterile adapter for use in robotic surgery may include a frame configured to be interposed between a tool driver and a surgical tool, a plate assembly coupled to the frame, and at least one rotatable coupler supported by the plate assembly and configured to communicate torque from an output drive of the tool driver to an input drive of the surgical tool.