Sterile Coupler Assembly for Rapid Teleoperated Instrument Exchange

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Solution Overview

Problem

Teleoperated surgical systems face challenges in maintaining a sterile environment and efficiently attaching and detaching surgical instruments due to the need for complex connections that cannot be sterilized using conventional methods, and the limited number of instrument holders required for multiple instruments during procedures.

Innovation Solution

A sterile adapter with a bottom component and coupling component, featuring a locking mechanism and retention tabs, allows for easy engagement and disengagement of surgical instruments with teleoperated actuators while preventing contamination and enabling quick attachment of successive instruments, ensuring a sterile area is maintained.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional sterilization methods (steam, heat, pressure, chemicals) are used on teleoperated actuators, then complete sterilization is achieved, but the motors, sensors, encoders and electrical connections are damaged or destroyed

Engineering Contradiction:

Improvesterilization completenessVSAvoidcomponent integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The system is divided into two distinct segments: a sterile surgical instrument that can withstand sterilization and a non-sterile teleoperated actuator that remains protected. The sterile adapter acts as an interface barrier between these segments, allowing the instrument to be sterilized without exposing the actuator to damaging sterilization agents.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A sterile adapter serves as an intermediary component between the surgical instrument and the teleoperated actuator. This adapter creates a sterile barrier that allows mechanical force and electrical signal transmission while preventing contamination transfer, enabling the actuator to remain non-sterile while the instrument maintains sterility.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If multiple surgical instruments are used through the same trocar sleeve, then the number of incisions is minimized, but the frequency of instrument attachment and detachment increases

Engineering Contradiction:

Improvenumber of incisionsVSAvoidinstrument exchange time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The sterile adapter is pre-assembled with the surgical instrument before the instrument needs to be attached to the actuator. The coupling component is designed with pre-positioned engagement features and retention tabs that facilitate rapid connection, eliminating the need for complex assembly during instrument exchange.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The coupling mechanism incorporates dynamic elements including a rotatable coupling component with retention tabs that can be quickly engaged and disengaged. The spring-loaded locking mechanism provides automatic locking upon engagement, enabling rapid instrument exchange without manual adjustment or complex procedures.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If multiple connections are provided for transmitting actuator forces, electrical signals, and data, then control functionality is complete, but the attachment complexity increases

Engineering Contradiction:

Improvecontrol functionalityVSAvoidattachment complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple connection functions are merged into an integrated sterile adapter assembly. The adapter simultaneously provides mechanical force transmission through the coupling component, electrical signal transmission through integrated contacts, and data transmission pathways, all within a single attachable unit that simplifies the overall connection process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sterile adapter serves multiple functions simultaneously: it acts as a mechanical coupling element for force transmission, an electrical connector for signal and power transmission, a data interface for communication, and a sterile barrier for contamination prevention. This multi-functionality reduces the number of separate components needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3610821B1Coupler to transfer motion to surgical instrument from teleoperated actuator

Publication Date: 2021.12.08 INTUITIVE SURGICAL OPERATIONS INC

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AI summary

A sterile adapter for coupling a surgical instrument and a surgical instrument manipulator includes a bottom component and a coupling component. The bottom component includes a bottom component opening with a bottom lip having a locking mechanism. The coupling component is rotatably coupled to the bottom component. The coupling component includes an engagement feature that engages the surgical instrument manipulator. The coupling component further includes a locking mechanism opening that engages the locking mechanism when the engagement feature has not engaged the surgical instrument manipulator. The coupling component may include a retention tab that is aligned with the keyway to insert the coupling component into the bottom component opening and then misaligned with the keyway to retain the coupling component in the bottom component opening. A ramp may be provided on a leading edge of a pocket to facilitate engaging the coupling component with the surgical instrument manipulator.