Abstract:
A method for sealing surgical instruments, particularly reusable electric surgical instruments sterilized using an autoclave process, is disclosed. The method having the steps of providing at least two body shells having a runner system on the mating surfaces, aligning the body shells, securing the body shells in position relative to each other, inserting an injection device into the runner system, injecting an elastomer material from the injection device into the runner system, removing the injection device from the runner system, and curing the elastomer material. The elastomer material seals the housing chamber of the instrument. The elastomer material may bond the body shells together.

Description:
BACKGROUND 
       [0001]    1. Technical Field 
         [0002]    The present disclosure relates generally to reusable surgical instruments, and more particularly, to reusable electrical surgical instruments that are sterilized. 
         [0003]    2. Description of Related Art 
         [0004]    Electrical surgical instruments generally comprise of a handle portion having multiple body shells, which houses the electrical components, and a working portion extending from the handle portion, which comes in contact with a patient. After each use, an electrical surgical instrument is disposed of, reused, or partially disposed of and partially reused. Any part of an electrical surgical instrument that is reused must be sterilized to neutralize potentially infectious agents before being reused. 
         [0005]    The autoclave process has been used for many years to sterilized reusable surgical instruments. However, the steam and the high-pressure used in the autoclave process can damage electrical components within the housing. Even where the components are disposed in a shell, the components can be damaged if the steam is allowed to infiltrate the joints between the body shells of an electrical surgical instrument. Different sealing methods have been used to seal the joints between body shells. 
         [0006]    One such sealing method is to bond the body shells of the handle portion together with adhesives. Another known method employs an o-ring that is compressed between the body shells using screws or other joining means. 
         [0007]    The existing sealing methods are known to fail after a varying number of autoclave processes. One cause of the failure is that the sealing materials and the material of the body shells expand and contract at different rates and to differing extents during the autoclave process. 
         [0008]    Based on the above, a continuing need exists for a sealing method that will extend the life of reusable electrical surgical instruments capable of maintaining a sealed chamber during the contracting and expansion that takes occurs during the autoclave process. 
       SUMMARY 
       [0009]    Disclosed herein is a method for sealing body shells that injects an elastomer material into a runner system. The method includes the steps of providing body shells of an instrument having a runner system, aligning the body shells, securing the body shells together, inserting an injection device into the runner system, injecting an elastomer material, removing the injection device, and curing the elastomer material forming a seal between the body shells. 
         [0010]    In an embodiment of the method, the runner system forms a half-cylindrical groove on the joining surface. 
         [0011]    In a certain embodiment of the method, the runner system is on both joining surfaces of a pair of mutual joining surfaces. 
         [0012]    In another embodiment of the method, the elastomer material forms a bond between the body shells along the pair of mutual joining surfaces. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0013]    The above and other aspects, features, and advantages of the present disclosure will become more apparent in light of the following detailed description when taken in conjunction with the accompanying drawings in which: 
           [0014]      FIG. 1  is a top plan view of a body shell having a runner system on the joining surface; 
           [0015]      FIG. 2  is an enlarged view of the area of detail  2  of  FIG. 1 ; 
           [0016]      FIG. 3  is a front cross-sectional view of two body shells mated together taken along section line  3 - 3  of  FIG. 1 ; 
           [0017]      FIG. 4  is a top view of an alternative configuration of a runner system; 
           [0018]      FIG. 5  is a top view of a body shell showing an injection device inserted in the runner system; and 
           [0019]      FIG. 6  is an enlarged view of the area of detail  6  of  FIG. 5 . 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0020]    Particular embodiments of the present disclosure will be described herein with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail. 
         [0021]    Referring now to the drawings, in which like reference numerals identify identical or substantially similar parts throughout the several views,  FIG. 1  illustrates first body shell  10  having runner system  30  in accordance with the principles of the present disclosure. 
         [0022]    As shown in  FIG. 1 , first body shell  10  defines side wall  20  about the perimeter of first body shell  10 . Side wall  20  has interior surface  22  and exterior surface  24 . The side wall surface between interior surface  22  and exterior surface  24  defines joining surface  26 . In any of the embodiments disclosed herein, the runner system can be a recess, channel, or space defined by part of the shell, and is generally narrow and extending the periphery of the chamber of the joined shell parts. 
         [0023]    Continuing to refer to  FIG. 1 , runner system  30  is disposed on joining surface  26 . Runner system  30  remains between interior surface  22  and exterior surface  24 . Runner system  30  diverts around connecting holes  15 . Runner system  30  has inlet port  32  and outlet port  34  connected by bridge section  36  as shown in  FIG. 2 . The corners of runner system  30  may be generally rounded. 
         [0024]    In the embodiment illustrated in  FIG. 2 , inlet port  32  and outlet port  34  each penetrate exterior surface  24  of side wall  20 . In another embodiment, illustrated in  FIG. 4 , inlet port  32 ′ and bridge  36 ′ penetrate an exterior surface  24 ′ of side wall  20 ′ while outlet port  34 ′ remains between interior surface  22 ′ and exterior surface  24 ′. 
         [0025]    Now referring to  FIGS. 1 and 3 , a particular embodiment of the method is disclosed, the first step is to provide first body shell  10  and second body shell  110 . First body shell  10  and second body shell  110  each having joining surfaces  26 ,  126 . Joining surface  26  configured to mate with joining surface  126 . The pair of joining surfaces  26 ,  126  defines a pair of mutual joining surfaces. 
         [0026]    Runner system  30  is partially disposed within at least one of joining surfaces  26 ,  126 . Runner system  30  may be partially disposed within each joining surface  26 ,  126 . In this configuration, runner system  30  defines a substantially semi-circular groove on each joining surface  26 ,  126 . 
         [0027]    Next, the pair of mutual joining surfaces are aligned such that runner system  30  is in contact with each joining surface  26 ,  126  as shown in  FIG. 3 . 
         [0028]    Once aligned, body shells  10 ,  110  are secured in position relative to one another. Any known method of securing the body shells together is envisioned. One known method is to clamp the body shells in position. Another known method is to screw the body shells together using connecting holes  15 . Another known method is by sonic welding the body shells together. Adhesives and other methods can be used. 
         [0029]    Once body shells  10 ,  110  are secured in position, injection device  200  is inserted into inlet port  32  such that tip  211  of injection device  200  is past bridge section  36  as shown in  FIGS. 5 and 6 . Injection device  200  includes distal portion  210  insertable into inlet port  32 . Distal portion  210  includes a lumen in fluid communication with an opening in the tip  211  for delivering material. Distal portion  210  is fluidly coupled to a source of material (e.g., the elastomer material). The source can be a reservoir of elastomer material or a cartridge. Injection devices are well known to a person skilled in the art and include needles and other suitable devices. 
         [0030]    After injection device  200  is inserted, an elastomer material (not shown) is injected from injection device  200  through tip  211  into inlet port  32 . The Elastomer material may be a natural rubber, a synthetic rubber, a silicone that is room temperature vulcanizing (RTV), or any suitable material with the viscosity to flow through the runner system filling all voids before flowing from the outlet port. 
         [0031]    When the elastomer material is injected through runner system  30 , the elastomer material flows from inlet port  32  through runner system  30  towards outlet port  34 . When the elastomer material flows from outlet port  34 , injection device  200  is removed from inlet port  32  while continuing to inject the elastomer material. Injection device  200  is removed slowly to allow the elastomer material to fill outlet port  34  and bridge section  36 . This is done to ensure that there are no voids in runner system  30 . Thus, the elastomer material completely fills runner system  30 . 
         [0032]    When runner system  30  is filled with the elastomer material, the elastomer material is cured or allowed to cure. After the elastomer material is cured, the elastomer material forms a seal or barrier between exterior surfaces  24 ,  124  and interior surfaces  22 ,  122  forming housing chamber  80  within body shells  10 ,  110  illustrated in  FIG. 3 . The material may cure on its own, or using heat, UV light, etc. 
         [0033]    In an embodiment of the method, the elastomer material also forms a bond between body shells  10 ,  110 , further attaching the first and second body shells. 
         [0034]    In any of the embodiments disclosed herein, the elastomer material has similar expansion and contracting properties to the materials of body shells  10 ,  110  such that during an autoclave process, the elastomer material and the body shell material expand and contract at substantially the same rate maintaining a barrier between housing chamber  80  and exterior surfaces  24 ,  124 . 
         [0035]    In any of the embodiments, runner system  30  is comprised of a half cylindrical groove in each joining surface  26 ,  126  such that when joining surfaces  26 ,  126  are aligned runner system  30  is substantially cylindrical, illustrated in  FIG. 3 . 
         [0036]    It is envisioned that this method may be used for instruments with a plurality of body shells having a plurality of pairs of mutual joining surfaces having a plurality of runner systems. It is envisioned that each runner system may be injected either sequentially with respect to other runner systems or simultaneously with respect to other runner systems or a combination of sequential and simultaneous injection. In any of the embodiments disclosed herein, one or more chambers  80  can be formed so that components in the chambers are separately sealed from the exterior of the instrument, as well as each other. 
         [0037]    While several embodiments of the disclosure have been shown in the drawings and/or discussed herein, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Different embodiments of the disclosure may be combined with one another based on the particular needs of the patients to achieve optimal results of the surgical procedures. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.