D-Shaped Staples and Foam Adjunct for Tissue Stapling
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Solution Overview
Problem
Existing surgical staplers face difficulties in securely grasping and stapling tissue due to variations in tissue size, shape, thickness, and toughness, and the refilling process can be time-consuming and prone to misfires.
Innovation Solution
A surgical fastening device with a cartridge jaw and anvil, featuring D-shaped staples that rotate into tissue and an adjunct foam material on the jaw surface to securely fasten the staples to the tissue, which can be partially biologically derived and compressible, preventing misfires and improving tissue engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional staples are used to grasp and staple tissue, then the stapling function is provided, but it is difficult to grasp and staple tissue with varying size, shape, thickness, and toughness
Solution Approach 1:
The patent employs D-shaped staples with asymmetric geometry where the curved portion provides enhanced engagement with tissue of varying thickness and toughness. The specific shape configuration allows the staple to adapt locally to different tissue properties while maintaining reliable fastening across diverse tissue types
2Ease of manufacture
If cartridges are made small to fit in the stapler jaw, then the stapler can be refilled, but the cartridges are difficult to manipulate and properly secure within the jaw
Solution Approach 1:
The cartridge incorporates asymmetric alignment features including a cam surface on the cartridge that engages with a corresponding cam surface on the jaw, along with asymmetric lugs and grooves. This asymmetric design provides tactile feedback and mechanical guidance during insertion, making it easy to properly secure the small cartridge within the jaw without complex manipulation
Solution Approach 2:
The patent introduces a carrier component as an intermediary between the staples and the cartridge housing. The carrier holds multiple staples in an organized array and facilitates their controlled deployment, simplifying the refilling process and ensuring proper positioning within the compact cartridge structure
3Productivity
If refilling is performed manually, then the stapler can be reused, but the process is time-consuming and can result in improperly loaded cartridges
Solution Approach 1:
The cartridge is pre-loaded with staples in a precise array configuration during manufacturing, with alignment features pre-formed on the cartridge and carrier. This preliminary preparation eliminates the need for time-consuming manual loading and ensures proper staple positioning before the cartridge is inserted into the stapler jaw
Solution Approach 2:
The cartridge design incorporates self-aligning features including cam surfaces and asymmetric lugs that automatically guide the cartridge into the correct position within the jaw during insertion. The system performs its own alignment and securing functions without requiring precise manual manipulation, reducing refilling time and preventing improper loading
Data Source
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AI summary
Devices and methods are provided for securing fasteners and adjunct materials to tissue. In general, a surgical device can include at least one adjunct material to help improve surgical procedures performed using the surgical device. In one embodiment, an end effector of a surgical device can be configured to deliver an adjunct materials to a surgical site during a surgical procedure to help improve the surgical procedure. When the fasteners are deployed at a treatment site, the adjunct material(s) can remain at the treatment site with the fasteners. The fasteners can be "D" shaped and configured to rotate through the adjunct material when the fastener rotates from the end effector into tissue.