Laser Machining Surgical Stapler Anvil Pockets
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Solution Overview
Problem
Conventional methods for forming staple pockets on surgical stapler anvils are imprecise, cause material accumulation and structural damage, limit complex shapes, and lack consistency and ease of modification.
Innovation Solution
A laser-machining system that uses a CO2-type laser-emitting device controlled by a programmable module to precisely form staple pockets by removing material, allowing for precise alignment, smooth surfaces, and varied shapes without structural damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coining methods are used to form staple pockets, then the process is simple and cost-effective, but the manufacturing precision and alignment accuracy are insufficient
Solution Approach 1:
The patent replaces the mechanical coining system with a laser-machining system. The laser beam removes material through ablation rather than mechanical displacement, achieving precise staple pocket formation with controlled depth, alignment, and surface smoothness while eliminating the need for complex mechanical coining tools and their associated wear and fracture problems
Solution Approach 2:
The patent changes the physical state and parameters of the machining process by using laser energy instead of mechanical force. The laser parameters (power, pulse duration, scanning speed) are precisely controlled to achieve the desired staple pocket geometry, surface finish, and alignment accuracy that cannot be obtained through conventional mechanical coining
2Manufacturing precision
If conventional coining methods are used to form staple pockets, then the process is straightforward, but material accumulation occurs causing uneven surfaces
Solution Approach 1:
The laser-machining system replaces mechanical coining by using optical energy to ablate material rather than mechanically displacing it. This eliminates material accumulation and produces smooth, even staple pocket surfaces without the complexity of additional material removal or finishing operations
Solution Approach 2:
The laser beam extracts material from the anvil surface through controlled ablation, removing excess material rather than displacing it. This creates clean, smooth staple pocket surfaces without the material accumulation and unevenness that characterize conventional coining methods
3Reliability
If conventional coining methods are used to form staple pockets, then the process is simple, but structural fractures occur damaging the anvil
Solution Approach 1:
The patent replaces the high-force mechanical coining process with a non-contact laser-machining process. The laser beam delivers energy to the anvil surface to vaporize and remove material without applying mechanical stress, thereby preventing structural fractures and maintaining anvil integrity while achieving precise staple pocket formation
Solution Approach 2:
The laser beam acts as an intermediary between the machining system and the anvil material. Instead of direct mechanical contact that causes stress concentration and fracture, the laser energy mediates the material removal process through controlled ablation, preserving the structural integrity of the anvil
4Manufacturing precision
If conventional coining tools are used over time, then initial production is efficient, but tool wear results in inconsistent staple pocket shapes
Solution Approach 1:
The laser-machining system replaces mechanical coining tools that are subject to wear. The laser beam parameters can be precisely controlled and maintained over time, ensuring consistent staple pocket formation without the degradation that occurs with mechanical tool wear, thereby eliminating the need for frequent tool replacement and recalibration
Solution Approach 2:
The laser-machining system maintains its own precision through software control and parameter adjustment rather than relying on mechanical tools that degrade. The system can self-correct and maintain consistent staple pocket formation over extended periods without the wear-related inconsistencies that plague conventional coining tools
5Adaptability or versatility
If conventional coining methods are used, then the process is simple, but modifying staple pocket shapes requires new tools and fabrication
Solution Approach 1:
The laser-machining system introduces dynamics and flexibility to the staple pocket formation process. The laser parameters (power, speed, pattern) can be dynamically adjusted through software to create different staple pocket shapes and configurations without physical tool changes, enabling rapid adaptation to different surgical requirements
Solution Approach 2:
The laser-machining system serves multiple functions: it can form various staple pocket shapes, sizes, and configurations using the same basic apparatus by changing software parameters. This universal capability eliminates the need for multiple specialized coining tools and complex fabrication processes required by conventional methods
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 laser-machining system achieves precise, consistent, and damage-free formation of staple pockets with complex shapes, improving surgical stapler performance and reducing manufacturing costs by preventing material accumulation and structural fractures.
Implementation Method 1
a laser-emitting device that is configured to emit laser beams for forming staple pockets on the anvil of a surgical stapler
Data Source
Figure 1(a)
Figure 1(b)
Figure 2(a)~3(b)
AI summary
A system and method for forming a staple pocket on the anvil portion of a surgical stapler device. A laser-machining system may include a laser-emitting device that is configured to emit a laser beam or beams for forming staple pockets on the anvil of a surgical stapler. The staple pockets of an anvil may be formed successively or simultaneously. The anvil of the surgical stapler is mounted in a mounting mechanism so as to control its movement, and the laser-emitting device is controlled by a control module, which may control any aspect of the laser-machining operation, e.g., the intensity of the laser beam, the movement of the laser-emitting device relative to the anvil, etc. The control module may be a processor that includes software that provides instructions for the operation of the control module, and may be programmable by a user for inputting parameters.