Disposable Surgical Stapling System with Segmented Drive Mechanism
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Solution Overview
Problem
Existing electromechanical surgical devices are costly to manufacture and operate, and their complex power transmission mechanisms can lead to unintended operation, potentially causing damage or injury due to inadvertent actuation.
Innovation Solution
A surgical stapling system with a hand-held instrument featuring a modular design, including a reusable handle with a removable and replaceable adapter assembly, and interchangeable linear surgical stapling reloads with a drive mechanism that includes a flexible bar supported by guides and blowout plates, allowing for safe and controlled articulation and stapling operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex electromechanical linkages are used to transmit power from handle assemblies to disposable loading units, then the surgical device can achieve multiple functions (rotation, pivoting, clamping, fastener ejection), but the complexity of the power transmission mechanisms increases the risk of inadvertent actuation and unintended operation
Solution Approach 1:
The surgical system is divided into separate reusable handle assemblies and disposable loading units. The complex electromechanical linkages are contained within the disposable loading units, which are replaced after each use. This segmentation prevents the accumulation of wear and reduces the risk of inadvertent actuation in the reusable handle assemblies, while maintaining full functional capability in each disposable unit.
Solution Approach 2:
The patent employs disposable loading units that contain the complex power transmission mechanisms. These units are designed for single-use, eliminating the risk of inadvertent actuation from wear or malfunction in reusable components. The disposable nature ensures that each unit starts with full reliability, while the low cost allows for replacement rather than repair.
2Manufacturing precision
If expensive electromechanical surgical devices with complex power transmission mechanisms are manufactured, then high functionality and precision are achieved, but the manufacturing and operational costs increase significantly
Solution Approach 1:
The system separates expensive, precision electromechanical components into disposable loading units, while the reusable handle assemblies contain less complex, lower-cost components. This allows manufacturers to optimize each segment independently - high precision in disposable units that are replaced anyway, and cost-effective design in reusable units that perform multiple procedures.
Solution Approach 2:
By placing the complex, precision electromechanical mechanisms in disposable loading units, the patent enables use of higher-precision components without permanently increasing system cost. Each disposable unit can be optimized for precision, while the reusable handle assemblies use more cost-effective components that don't require the same level of precision durability.
3Adaptability or versatility
If reusable handle assemblies with complex electromechanical linkages are used, then operational versatility is maintained, but the risk of damage to the surgical device and injury to the patient from unintended operation increases
Solution Approach 1:
The surgical system is segmented into reusable handle assemblies and disposable loading units. The disposable units contain the complex electromechanical linkages that could potentially actuate inadvertently. By containing these mechanisms in single-use components, the system maintains operational versatility in the reusable handles while eliminating the risk of injury from wear-related malfunction in reusable components.
Solution Approach 2:
The patent uses disposable loading units to contain the complex power transmission mechanisms. These units are designed for single-use, ensuring that any potential inadvertent actuation cannot affect subsequent patients. The disposable nature eliminates the accumulation of wear and fatigue in components that could lead to unintended operation, while maintaining full operational versatility in each use.
Data Source
AI summary
A surgical device includes a jaw assembly, an articulating assembly and a drive shaft. The jaw assembly includes first and second jaws. The articulating assembly is removably coupled to a proximal end of the jaw assembly and includes a distal joint member, a proximal joint member, and a pivot pin. The pivot pin is fixedly coupled to the distal joint member and is rotatably coupled to the proximal joint member. The jaw assembly and the distal joint member together define a first longitudinal axis. The proximal joint member defines a second longitudinal axis. The drive shaft includes a gear element that is meshingly engaged with a pivoting gear element that is fixedly coupled to the pivot pin. Longitudinal movement of the first drive shaft pivots the jaw assembly relative to the proximal joint member about a pivot axis defined by the pivot pin.