Disposable Loading Unit Locking Mechanism for Surgical Instruments
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Solution Overview
Problem
Surgical devices with replaceable fastener cartridges often require multiple devices during a single procedure due to exhausted fasteners, leading to increased costs, as the drive assembly is not retained in a prefired position, necessitating frequent replacements.
Innovation Solution
A disposable loading unit (DLU) with a locking mechanism that retains the drive assembly in a prefired position until attached to a surgical instrument, utilizing a cam-based locking system and biasing member to ensure the drive assembly remains locked until proper attachment, preventing accidental actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the drive assembly is left movable in the DLU, then the DLU is easy to operate and assemble, but the drive assembly may be accidentally actuated or lost its prefired position before attachment to the surgical instrument
Solution Approach 1:
The locking member is pre-configured in a locking position that automatically engages with the drive assembly during DLU assembly, preventing accidental actuation before surgical instrument attachment. This preliminary locking action ensures the drive assembly maintains its prefired position without requiring additional operational steps.
2Reliability
If a locking mechanism is added to retain the drive assembly, then the position retention is improved, but the device complexity increases
Solution Approach 1:
The locking mechanism is integrated into the DLU structure by combining the locking member with the actuator assembly. The locking member is positioned to engage the drive assembly during normal assembly operations, merging the locking function with the existing structural components rather than adding a separate independent locking system.
Solution Approach 2:
The locking mechanism operates automatically through the natural assembly motion of the DLU. As the DLU is assembled, the locking member self-engages with the drive assembly in the locking position without requiring external intervention or complex control systems, allowing the structure to lock itself through its own assembly dynamics.
3Reliability
If the locking member is always engaged, then the position retention is improved, but the ease of operation deteriorates when attachment to surgical instrument is required
Solution Approach 1:
The locking mechanism transitions from a static locked state to a dynamic unlocked state through the actuator. During normal operation, the locking member remains engaged to retain the drive assembly. When the surgical instrument is attached and actuation is required, the actuator moves the locking member to disengage from the drive assembly, allowing controlled movement while maintaining security during transport and assembly.
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 solution reduces the need for multiple device replacements by ensuring the drive assembly is only activated when the DLU is securely attached, minimizing wastage and operational costs by maintaining the drive assembly in a locked state until insertion into the surgical instrument.
Implementation Method 1
A biasing member, e.g., a spring, is provided to urge the locking member actuator to its retracted position
Implementation Method 2
The locking member includes a cam member which is slidably positioned within a cam slot formed in the locking member actuator
Data Source
AI summary
A disposable loading unit is provided which includes a tool assembly and a body portion. A drive assembly is movably positioned at least partly within the body portion and is operably associated with the tool assembly to operate the tool assembly. A locking mechanism is provided for maintaining the drive assembly in a prefired position prior to and during attachment of a DLU to a surgical instrument. The locking mechanism includes a locking member and a locking member actuator. The locking member actuator is movable to move the locking member to an unlocked position in response to linear insertion of an insertion tip of the DLU into a surgical instrument.