Electrosurgical Stapler End Effector for Consistent Staple Formation
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Solution Overview
Problem
Existing electrosurgical stapling devices for minimally invasive procedures face challenges in forming consistent B-shaped staples due to mechanical limitations, such as deflection and alignment issues, leading to multiple cartridge reloads and increased surgical time, especially for larger organs like the stomach.
Innovation Solution
A surgical instrument with an end effector featuring a first and second jaw, a cartridge, and electrodes, allowing for a single cartridge and single firing to staple, resect, and seal anatomical structures, while using bipolar or monopolar energy to effect hemostasis, with a low profile design to fit through a trocar and maintain alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional electrosurgical stapling device is used, then stapling function is provided, but mechanical deflection and alignment issues occur leading to inconsistent B-shaped staple formation
Solution Approach 1:
The end effector is divided into multiple independent components: a first jaw with anvil, a second jaw with cartridge, and a blade assembly. This segmentation allows each component to be optimized independently for its specific function while maintaining overall alignment through the coupling mechanism, resolving the contradiction between staple formation consistency and alignment reliability.
Solution Approach 2:
A coupling mechanism serves as an intermediary between the first and second jaws, providing a stable connection that maintains alignment during the stapling process. This intermediary structure eliminates mechanical deflection issues while ensuring consistent B-shaped staple formation through reliable alignment of all components.
2Manufacturing precision
If multiple cartridge reloads are performed, then staple formation can be maintained, but surgical time increases
Solution Approach 1:
The first jaw with anvil and the second jaw with cartridge are merged into a single integrated end effector assembly that can perform multiple functions in one operation. This merging eliminates the need for separate cartridge reloads while maintaining high-quality staple formation, thereby reducing surgical time without compromising staple quality.
Solution Approach 2:
The end effector is designed as a universal assembly that combines stapling, cutting, and electrosurgical functions in a single device. The cartridge can be repositioned relative to the anvil, allowing the same assembly to perform multiple operations without requiring separate devices or repeated cartridge reloads, thus reducing surgical time while maintaining staple formation quality.
3Ease of operation
If a low profile design is used, then the device can fit through a trocar, but mechanical alignment may be compromised
Solution Approach 1:
The blade assembly is nested within the channel of the first jaw, and the second jaw is positioned adjacent to the first jaw with the cartridge facing the anvil. This nested arrangement allows the entire end effector to have a compact, low-profile profile that fits through a trocar while maintaining precise alignment between all components through the integrated coupling mechanism.
Solution Approach 2:
The cartridge is positioned in a plane adjacent to the anvil rather than directly behind it, allowing the components to be arranged in a compact three-dimensional configuration. This dimensional arrangement enables the low-profile design to fit through a trocar while maintaining alignment precision through the coupling mechanism that connects all components in multiple dimensions.
4Productivity
If electrodes are positioned on one side of the blade, then hemostasis can be effected, but the other side of the anatomical structure remains untreated
Solution Approach 1:
The end effector allows dynamic repositioning of the cartridge relative to the anvil, enabling the surgeon to adjust the orientation and position of the electrodes and blade assembly. This dynamic capability allows the electrodes to be positioned to treat different sides of the anatomical structure as needed, providing both efficient hemostasis and adaptable treatment coverage for various surgical scenarios.
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 solution enables high-quality, consistent staple formation with reduced surgical time and lower costs by minimizing cartridge reloads, improving clinical outcomes and staple line integrity.
Implementation Method 1
a plurality of electrodes coupled to one side of the blade, such that the plurality of electrodes contact the anatomical structure during resection to effect hemostasis by heating the tissue and blood vessels to cauterize, coagulate/desiccate, and/or seal tissue
Implementation Method 2
The first and second electrodes are in electrical communication with an electrosurgical power generating source, such as a bipolar energy source
Data Source
AI summary
Embodiments include an end effector including an anvil that includes a first end, a second end, and an anvil face positionable on the first side of an anatomical structure, a cartridge operably configured to house a plurality of staples, the cartridge comprising a first end, a second end, and a cartridge face positionable on the second side of the anatomical structure. The end effector includes a blade assembly comprising a blade, a beam, and a nut, the blade comprising a first side and a second side joined at a cutting edge. The end effector includes first and second electrodes coupled to the first side of the blade and an electrosurgical power generating source in electrical communication with the first and second electrodes.