Composite Stamped Anvil for Medical Stapler Rigidity
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Solution Overview
Problem
Existing medical stapler anvils are expensive and labor-intensive to manufacture due to their need for high rigidity, which is typically achieved through machining, resulting in increased manufacturing complexity and waste.
Innovation Solution
A stamped sheet metal anvil design is proposed, featuring an anvil pocket beam and an anvil back beam with equal moments of inertia, which are attached via welding, to provide the necessary rigidity while reducing manufacturing costs and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If machined medical stapler anvils are used to achieve sufficient rigidity, then the rigidity requirement is met, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent applies composite materials by combining sheet metal components with foam core material. The foam-filled sheet metal construction provides the necessary rigidity and strength while being more cost-effective and less waste-intensive than traditional machined metal anvils. This composite approach resolves the contradiction by achieving structural performance through material composition rather than expensive machining processes.
2Strength
If machined medical stapler anvils are used to achieve sufficient rigidity, then the rigidity requirement is met, but manufacturing waste increases
Solution Approach 1:
The patent changes the manufacturing parameters from traditional machining to stamping and foam-filling processes. The stamped sheet metal components with foam core provide equivalent rigidity through geometric and material parameter optimization rather than removing material through machining. This parameter change reduces manufacturing waste significantly while maintaining the required rigidity.
3Strength
If machined medical stapler anvils are used to achieve sufficient rigidity, then the rigidity requirement is met, but device complexity increases
Solution Approach 1:
The patent segments the anvil into multiple components: sheet metal outer structure, foam core material, and staple forming pockets. These segmented components are manufactured separately through stamping and assembly processes rather than through complex monolithic machining. This segmentation reduces manufacturing complexity while achieving the required rigidity through the composite structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The stamped sheet metal anvil achieves the required rigidity for medical stapling while significantly reducing manufacturing costs and complexity, and minimizing waste, thus offering an economically viable solution for medical stapler production.
Implementation Method 1
The anvil back beam can be fixedly attached to the anvil pocket beam
Data Source
AI summary
A medical stapler anvil including an anvil pocket beam and an anvil back beam. The anvil pocket beam can include a plurality of staple forming pockets and an anvil pocket beam moment of inertia. The anvil back beam can be fixedly attached to the anvil pocket beam and can include a crown disposed opposite the plurality of staple forming pockets and an anvil back beam moment of inertia approximately equal to the anvil pocket beam moment of inertia. The anvil pocket beam and the anvil back beam can be stamped from sheet metal.