Sterile Coupling Mechanism for Teleoperated Surgical Instrument Attachment

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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 while preventing contamination, due to the complexity of connections required for force, electrical signals, and data transmission, and the limitations of conventional sterilization methods on motors and sensors.

Innovation Solution

A sterile adapter system 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, ensuring a sterile interface and quick, reliable attachment of instruments, while preventing contamination and accommodating the limitations of sterilization processes.

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 connections for force transmission, electrical signals, and data are merged into a single integrated sterile adapter assembly. The adapter simultaneously establishes all necessary connections when attached to the actuator, eliminating the need for separate attachment steps for each connection type.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sterile adapter serves multiple functions simultaneously: it acts as a mechanical coupling for force transmission, provides electrical connections for signals and power, enables data communication, and maintains the sterile barrier. 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 versatilityVSAvoidattachment time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The sterile adapter is pre-assembled with the surgical instrument in a controlled environment before surgery. This preliminary assembly includes pre-sterilizing the adapter and instrument together, so that during surgery only a simple attachment to the actuator is needed, minimizing attachment time and contamination risk.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system is designed for dynamic reconfiguration during surgery, allowing quick exchange of instrument-adapter assemblies while maintaining sterility. The standardized interface enables rapid attachment and detachment without compromising the sterile field or requiring complex reconnection procedures.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10912616B2Coupler to transfer motion to surgical instrument from teleoperated actuator

Publication Date: 2021.02.09 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.