TRANSPONDER DEVICE TO MARK IMPLEMENTS, SUCH AS SURGICAL IMPLEMENTS, AND METHOD OF MANUFACTURING AND USING SAME

• US 20100033309A1
• Filed: 08/05/2009
• Published: 02/11/2010
• Est. Priority Date: 08/06/2008
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: RF Surgical Systems, Incorporated (Medtronic Plc)
• Inventors: Blair, William A.
• Granted Patent: US 8,354,931 B2
• Time in Patent Office: Days
• US Class Current: 340/10.100
• CPC Class Codes: A61B 90/90 Identification means for patients or instruments, e.g. tags
• CPC Class Codes: A61B 90/98 using electromagnetic means, e.g. transponders
• CPC Class Codes: H04Q 2213/13003 Constructional details of switching devices

Abstract

A transponder device to mark a surgical implement, such as a metallic surgical instrument, is provided that comprises a transponder housing attachable to a portion of the surgical implement. The housing may include a transponder receiving cavity spaced at least 1 millimeter, and preferably at least 2 millimeters, from any portion of the surgical implement when the housing is attached to the surgical implement, and preferably includes a saddle-shaped finger support surface or a stabilizing surface sized and configured to receive a finger of a user for providing additional leverage and/or stabilizing structure when operating the implement. The housing may be removably attached to the surgical implement or permanently attached. In use, a transponder is retained in the device. Methods of manufacturing transponder devices and methods of detecting a transponder indicating the possible presence of a surgical implement are also provided.

Claims

1. A device to mark surgical implements, the device comprising:

a flexible strap; and

a housing attachable to a portion of a surgical implement, the housing including a transponder receiving cavity sized to receive a transponder, an implement receiving cavity sized to receive a portion of the surgical implement, a strap receiving cavity sized to receive at least a portion of the strap, and a saddle-shaped finger support surface sized and configured to receive a finger of a user and provide additional leverage for operating the surgical implement when the housing is attached to the portion of the surgical implement via the strap and the implement receiving cavity.

2. The device of claim 1 wherein the housing includes a base substrate and a first overmold portion that forms the implement receiving cavity.

3. The device of claim 2 wherein the first overmold portion includes an indentation proximate a base of the strap where the strap is fixed to the housing such that a bend radius of the strap is reduced relative to an identically sized strap without an indentation.

4. The device of claim 2 wherein the first overmold portion includes a raised surface proximate a base of the strap that substantially conforms with a contour of a handle of the surgical implement when the housing is attached thereto.

5. The device of claim 2 wherein a projection of the first overmold portion extends beyond an interior profile of a handle of the surgical instrument to provide a gradual transition from the interior profile of the handle to a surface of the strap when the housing is attached to the handle.

6. The device of claim 2, further comprising:

the transponder, wherein the transponder is retained in the transponder receiving cavity.

7. The device of claim 6 wherein the housing includes a second overmold portion, the second overmold portion retaining the transponder within the transponder receiving cavity.

8. The device of claim 7 wherein the first overmold portion and the second overmold portion comprise a material that is different from a material of the base substrate.

9. The device of claim 7 wherein the first overmold portion and the second overmold portion are each composed of an elastomeric material.

10. The device of claim 1 wherein the strap receiving cavity provides a void proximate a lower surface of the housing such that an end of the strap does not protrude beyond the lower surface when the strap is received in the strap receiving cavity and trimmed to a final length.

11. The device of claim 1 wherein the transponder receiving cavity is spaced at least about 1 millimeter from any portion of the surgical implement when the housing is attached to the surgical implement via the strap.

12. The device of claim 1 wherein the strap and the housing form a unitary structure.

13. A transponder device comprising:

a housing having a base substrate and an overmold portion, the base substrate containing a transponder receiving cavity;

attachment means for attaching the housing to a portion of a surgical implement; and

a wireless transponder received in the transponder receiving cavity.

14. The transponder device of claim 13 wherein the housing positions the wireless transponder at least 1 millimeter from the surgical implement when attached to the portion of the surgical implement.

15. The transponder device of claim 13 wherein the overmold portion retains the transponder in the base substrate.

16. The transponder device of claim 13 wherein the overmold portion includes an implement receiving cavity.

17. The transponder device of claim 16 wherein the housing further includes a saddle-shaped finger support surface sized and configured to receive a finger of a user and provide additional leverage for operating the surgical implement when the housing is attached to the portion of the surgical implement via the implement receiving cavity.

18. The transponder device of claim 13 wherein the overmold portion includes a first overmold location and a second overmold location, the first overmold location including an implement receiving cavity and the second overmold location retaining the transponder in the base substrate.

19. The transponder device of claim 13 wherein the overmold portion comprises a material different from a material of the base substrate.

20. The transponder device of claim 13 wherein the overmold portion is composed of an elastomeric material.

21. The transponder device of claim 13 wherein the attachment means includes a strap and a detent mechanism that is integral to the housing.

22. The transponder device of claim 21 wherein the overmold portion includes an indentation proximate a base of the strap where the strap is fixed to the housing such that a bend radius of the strap is reduced relative to an identically sized strap without an indentation.

23. The transponder device of claim 21 wherein the overmold portion includes a raised surface proximate a base of the strap that substantially conforms with an interior contour of a handle of the surgical implement when the housing is attached thereto.

24. The transponder device of claim 23 wherein the overmold portion includes an indentation in the raised surface such that a bend radius of the strap is reduced relative to an identically sized strap without an indentation.

25. The transponder device of claim 21 wherein the overmold portion includes at least one projection extending beyond an interior profile of a handle of the surgical instrument to provide a gradual transition from the interior profile of the handle to a surface of the strap when the housing is attached to the handle.

26. The transponder device of claim 21 wherein the housing further includes a strap receiving cavity sized to receive at least a portion of the strap, the strap receiving cavity providing a void proximate a lower surface of the housing such that an end of the strap does not protrude beyond the lower surface when the strap is received in the strap receiving cavity and trimmed to a final length.

27. A method for manufacturing a device to mark implements comprising:

molding a base substrate, the base substrate including a transponder receiving cavity sized to receive a transponder, a flexible strap, a strap receiving cavity sized to receive at least a portion of the strap, and a saddle-shaped finger support surface sized and configured to receive a finger of a user and provide additional leverage for operating an implement when the base substrate is attached to a portion of the implement;

inserting the transponder in the transponder receiving cavity; and

retaining the transponder within the transponder receiving cavity.

28. The method according to claim 27 wherein retaining the transponder within the transponder receiving cavity includes retaining the transponder within the transponder receiving cavity by covering a portion of the transponder with a first overmold portion.

29. The method according to claim 27 wherein retaining the transponder within the transponder receiving cavity includes retaining the transponder within the transponder receiving cavity by covering the transponder with a cap.

30. The method according to claim 27, further comprising:

forming an overmold portion with an implement receiving cavity such that a surface of the implement receiving cavity and the finger support surface converge proximate a tip of the device.

31. A method comprising:

aligning a housing having a saddle-shaped finger support surface and a implement receiving cavity with a handle of each of one or more rigid surgical implements such that, when the handle is received in the implement receiving cavity, a wireless transponder enclosed within the housing is at least 1 millimeter from the handle, a central plane of the housing is substantially co-planar with a central plane of the handle, and the finger support surface is oriented to receive a finger of a user when the user is utilizing the surgical implement; and

securing the housing onto the handle via a flexible strap.

32. The method of claim 31, further comprising:

transmitting a signal in a first frequency band during a first time proximate to a confined area;

transmitting a signal in a second frequency band during a second time proximate to the confined area;

receiving a response, if any, to the transmission of the signal in the first frequency band; and

receiving a response, if any, to the transmission of the signal in the second frequency band.

33. The method according to claim 31 wherein securing the housing onto the handle via a flexible strap includes securing the housing onto the handle via a flexible strap using a tool.

34. The method according to claim 31, further comprising:

trimming the flexible strap with a tool.

35. A device to mark surgical implements, the device comprising:

a housing attachable to a portion of a surgical implement, the housing having a perimeter configured to accommodate at least an upper portion of a finger ring of the surgical implement and position a stabilizing surface to receive a finger of a user when operating the surgical implement; and

a transponder retained in the housing and positioned such that the transponder is fixedly spaced at least about 1 millimeter from any portion of the surgical implement when the housing is attached to the surgical implement.

36. The device of claim 35 wherein the housing includes a first surface and a second opposing surface, the second opposing surface being offset from the first surface such that a thickness of the housing is about equal to a thickness of the portion of the surgical implement.

37. The device of claim 35 wherein the stabilizing surface includes a concave portion sized and shaped to receive the finger of the user.

38. The device of claim 35 wherein the housing is a rigid casing fabricated with the transponder enclosed therein.

39. The device of claim 35 wherein the housing is a rigid shell structure having at least two parts that cooperate form a closed cavity sized to receive the transponder therein.

40. The device of claim 35 wherein the housing is a rigid body having a pre-existing cavity sized to receive the transponder.

41. The device of claim 35, further comprising:

a strap for coupling the housing to the surgical implement.

42. The device of claim 35, further comprising:

an adhesive layer, the adhesive layer positioned on a portion of the perimeter of the housing to securely adhere the housing to the surgical implement when attached thereto.

43. A device to mark surgical implements, the device comprising:

a transponder; and

a unitary rigid housing attachable to a portion of a surgical implement, the housing having an implement receiving portion configured to engage an elongated handle portion of the surgical implement and a transponder receiving portion having the transponder received therein, the transponder receiving portion being configured with respect to the implement receiving portion to position the transponder substantially parallel to the elongated handle portion and fixedly space the transponder at least about 1 millimeter from any portion of the surgical implement when the housing is attached to the elongated handle portion of the surgical implement.

44. The device of claim 43, further comprising:

an elastomeric band, wherein the band is configured to encircle the elongated handle portion of the surgical implement and attach the housing to the surgical implement.

45. The device of claim 43, further comprising:

an adhesive layer, wherein the housing is attached to the elongated handle portion of the surgical implement via the adhesive layer.

46. The device of claim 43 wherein the transponder is retained in the housing during fabrication of the housing.

47. The device of claim 43 wherein the transponder is retained in the housing only after fabrication of the housing.

48. A transponder device selectively attachable to surgical implements, the transponder device comprising:

a transponder circuit;

a non-metallic framework that substantially encloses the transponder circuit, the framework having a number of outward extending projections; and

a non-metallic body which at least partially surrounds the framework and which completely surrounds the transponder circuit, wherein the outward extending projections of the framework position the transponder circuit inwardly from an exterior surface of a mold used to form the body during a fabrication of the transponder device.

49. The transponder device of claim 48 wherein the framework is elongated having a first end and a second end, and the framework includes at least two pairs of opposed outward extending projections, one pair at each of the first and the second ends.

50. The transponder device of claim 48 wherein the framework is completely received in the body.

51. The transponder device of claim 48, further comprising:

an encapsulant that encapsulates the transponder circuit and which is surrounded by the framework.

52. The transponder device of claim 48, further comprising:

a compliant overmold that interfaces with at least a first portion of the body.

53. The transponder device of claim 52 wherein the compliant overmold includes an implement receiving cavity formed therein, the implement receiving cavity sized to at least partially receive a portion of a surgical implement.

54. The transponder device of claim 48 wherein the framework is a first shot of an injection molded material.

55. The transponder device of claim 54 wherein the body is a second shot of an injection molded material.

56. The transponder device of claim 55, further comprising:

a third shot of an injection molded material that forms a compliant overmold that interfaces with at least a first portion of the body.

57. The transponder device of claim 56 wherein the third shot of injection molded material is a different type of material from the second shot of injection molded material.

58. The transponder device of claim 57 wherein the third shot of injection molded material is an elastomeric material.

59. The transponder device of claim 48 wherein the body includes a saddle-shaped finger support surface, the finger support surface sized and configured to receive a finger of a user and provide additional leverage to operate a surgical implement when the transponder device is attached to the surgical implement.

60. The transponder device of claim 48 wherein the body includes an elongated strap extending therefrom, the strap dimensioned to encircle a portion of a surgical implement to attach the transponder device to the surgical implement.

61. The transponder device of claim 60 wherein the body includes a strap receiving cavity formed therein, the strap receiving cavity sized to receive at least a portion of the strap therethrough.

62. A transponder device selectively attachable to surgical implements, the transponder device comprising:

a transponder circuit;

a framework having a number of outward extending projections that space the transponder circuit from a surface that forms a cavity of a mold in the shape of a body;

the body, which body at least partially surrounds the framework and which completely surrounds the transponder circuit; and

a compliant overmold interfacing with at least a first portion of the body.

63. The transponder device of claim 62 wherein the framework is a first shot of an injection molded material, the body is a second shot of an injection molded material, and the compliant overmold is a third shot of an injection molded material.

64. The transponder device of claim 62 wherein the body includes a saddle-shaped finger support surface, the finger support surface sized and configured to receive a finger of a user and provide additional leverage to operate a surgical implement when the transponder device is attached to a surgical implement.

65. The transponder device of claim 62 wherein the body includes an elongated strap extending therefrom and a strap receiving cavity formed therein, the strap dimensioned to encircle a portion of a surgical implement and the strap receiving cavity sized to receive at least a portion of the strap therethrough, to attach the transponder device to the surgical implement.

66. The transponder device of claim 62 wherein the compliant overmold includes an implement receiving cavity formed therein, the implement receiving cavity sized to at least partially receive a portion of a surgical implement.

67. A method for manufacturing a transponder device attachable to surgical implements, the method comprising:

forming a non-metallic framework around a transponder circuit, the framework including a number of outward extending projections;

retaining the framework in a mold cavity, wherein the outward extending projections of the framework position the transponder circuit inwardly from an exterior surface of the mold cavity;

forming via the mold cavity a non-metallic body which at least partially surrounds the framework and which completely surrounds the transponder circuit; and

forming a compliant overmold that interfaces with at least a first portion of the body, the compliant overmold including an implement receiving cavity sized to at least partially receive a portion of a surgical implement.

68. The method according to claim 67 wherein the framework is formed with a first shot of an injection molded material, the body is formed with a second shot of an injection molded material;

and the compliant overmold is formed with a third shot of an injection molded material.