Continuous Staple-Forming Pockets for High-Density Surgical Stapling
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Solution Overview
Problem
Existing surgical staplers face challenges in achieving high staple density while minimizing misalignments between unformed staples and staple forming pockets, which can affect sealing and mechanical securing of stapled tissue, and also require costly and time-consuming manufacturing and inspection processes.
Innovation Solution
The design of modified staple cartridges and anvils with increased staple density, featuring continuous staple forming pockets that align with multiple rows of staples, allowing for simultaneous or sequential deformation of staple legs during a single firing stroke, and optimized staple orientations to enhance sealing and reduce manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If staple density is increased to improve tissue sealing, then sealing effectiveness is improved, but misalignment between staples and forming pockets increases
Solution Approach 1:
Multiple rows of staples are merged into a single continuous forming pocket structure. The anvil features a continuous pocket that receives and forms multiple rows of staples simultaneously, eliminating the need for separate pockets for each row and reducing alignment complexity while maintaining high staple density
Solution Approach 2:
The continuous forming pocket serves multiple functions: it forms multiple rows of staples, provides alignment guidance for all staples, and maintains consistent forming pressure across all rows. This multi-functional design simplifies the overall structure while achieving high-density stapling with improved alignment
2Manufacturing precision
If traditional separate pocket designs are used for each staple row, then alignment is easier, but manufacturing complexity and inspection time increase
Solution Approach 1:
Multiple individual pocket structures are merged into a single continuous forming pocket. This consolidation reduces the total number of discrete components that need to be manufactured and inspected, while the continuous nature of the pocket maintains precise alignment for all staple rows
Solution Approach 2:
The continuous forming pocket is designed with segmented internal features that correspond to each staple row, allowing each row to be formed independently within the unified structure. This segmentation enables precise alignment control without requiring separate external pockets
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
This approach increases staple density, improving tissue sealing and mechanical securing while reducing manufacturing time and costs, and allows for easier access to anatomical structures, applicable to various surgical staplers including linear, endocutter, circular, right angle, and curved types.
Implementation Method 1
a first staple forming pocket that is configured to transition the first legs of the first and second staples from a non-deformed state to a deformed state with the same firing stroke
Data Source
AI summary
An apparatus includes a stapling assembly and an anvil. The stapling assembly includes first and second staples. Each of the first and second staples include first legs. The anvil together with the stapling assembly is configured to clamp tissue of a patient. The anvil includes a first staple forming pocket that is configured to transition the first legs of the first and second staples from a non-deformed state to a deformed state with the same firing stroke.