Sterile Coupler Locking Design for Teleoperated Surgical Instruments

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Solution Overview

Problem

In teleoperated surgical systems, there is a challenge in maintaining a sterile environment and efficiently attaching and detaching surgical instruments from teleoperated actuators, as conventional sterilization methods damage the necessary motors, sensors, and electrical connections, and the complex connections required for force, signal, and data transmission complicate the process.

Innovation Solution

A sterile adapter system with a bottom component and a 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, reliable attachment of successive instruments, maintaining a sterile area.

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 barrier physically separates 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 barrier (sterile adapter/sterile drape) is introduced as an intermediary between the surgical instrument and the teleoperated actuator. This barrier allows force transmission and signal communication while preventing contamination and protecting the actuator from sterilization processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If multiple connections are provided for force transmission, electrical signals, and data between surgical instrument and teleoperated actuator, then functional completeness is improved, but attachment complexity increases

Engineering Contradiction:

Improvefunctional completenessVSAvoidattachment complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple separate connection functions (force transmission, electrical signals, data communication) are merged into a single integrated sterile adapter assembly. The adapter simultaneously establishes all necessary connections when the surgical instrument is attached to the teleoperated actuator, eliminating the need for separate connection steps for each function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sterile adapter serves multiple functions simultaneously: it acts as a sterile barrier, a mechanical coupling element for force transmission, an electrical connection interface, and a data communication pathway. This multi-functionality reduces the number of separate components and simplifies the overall attachment process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If surgical instruments are frequently attached and detached from the same instrument holder, then instrument versatility is improved, but attachment time and contamination risk increase

Engineering Contradiction:

Improveinstrument interchangeabilityVSAvoidattachment time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The sterile adapter is pre-attached to the teleoperated actuator before the surgical procedure begins and remains in place throughout. This preliminary action eliminates the need to repeatedly attach and detach the adapter when changing surgical instruments, allowing instruments to be quickly exchanged while maintaining the sterile barrier.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sterile barrier maintains continuous protection between the non-sterile actuator and the sterile surgical field throughout the entire procedure, even as multiple instruments are exchanged. This continuous sterile environment eliminates the need to re-establish sterility with each instrument change, reducing both time and contamination risk.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS12114956B2Coupler to transfer motion to surgical instrument from teleoperated actuator

Publication Date: 2024.10.15 INTUITIVE SURGICAL OPERATIONS INC

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.