White Paper: Power
Designing Battery Packs for Surgical Power Tools that Withstand Autoclaving Sterilization
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Battery-powered surgical tools are increasingly sought after for orthopedic and other medical procedures, offering advantages such as portability, efficiency, and enhanced ergonomics compared to corded alternatives. The adoption of advanced battery chemistries, particularly Lithium Ferro Phosphate (LFP), has enabled longer use, rapid charging, and improved performance. However, these tools (and their battery packs) must meet stringent requirements for ergonomic design, sterilization resilience, reliability, and compliance with FDA Class II medical device standards.
Leveraging 65 years of experience in custom battery pack development, Inventus Power has helped surgical tool manufacturers address these design challenges by engineering and manufacturing autoclavable lithium battery packs tailored to specific OEM requirements, while ensuring resilience to repeated sterilization and meeting long life and performance expectations. Inventus Power’s innovation-driven approach and ongoing investment in battery technology research and development position it as a trusted partner for medical device OEMs seeking reliable, high-performance, custom battery and power solutions.
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Overview
The document discusses the evolution and advancements in battery technology for surgical tools, particularly focusing on the transition from early rechargeable batteries to modern Lithium Ferro Phosphate (LFP) batteries. It highlights the growing trend of battery-powered surgical instruments, which offer significant advantages over traditional corded tools, including increased portability, efficiency, and the ability to support various orthopedic procedures such as bone cutting and tissue coagulation.
Historically, surgical tools began utilizing motorized systems in the 1890s, and the market for powered surgical tools is projected to grow at a compound annual growth rate of 6.07% from 2025 to 2034, driven by an aging population and advancements in surgical techniques. The document emphasizes the importance of battery performance, reliability, and the ability to withstand sterilization processes, particularly autoclaving, which subjects battery packs to high heat and pressure to ensure sterility.
Modern surgical tools predominantly use Lithium-ion (Li-ion) batteries due to their high energy density and fast charging capabilities. Innovations in battery management systems (BMS) allow for real-time monitoring of battery performance, reducing the risk of failure during procedures. However, the design of battery packs must accommodate the harsh conditions of autoclaving, which can significantly impact battery longevity.
Inventus Power is highlighted as a leader in designing autoclavable battery packs for surgical tools, utilizing advanced materials and design techniques to enhance the durability and performance of these batteries. The document also discusses alternative methods for sterilization, such as aseptic packs, which allow for the separation of the battery from the sterilization process, potentially extending battery life to 300-400 cycles.
Looking ahead, the document notes that the market for LFP battery packs remains strong due to the availability of raw materials and the effectiveness of this technology. As the demand for battery-operated surgical tools and robotics increases, ongoing advancements in battery chemistry and technology are anticipated.
In conclusion, the document underscores the critical role of battery technology in the future of surgical tools, emphasizing the need for continuous innovation to meet the evolving demands of the medical field.