Modular Surgical Stapler Coupling for Variable Loading Units
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Solution Overview
Problem
Current laparoscopic surgical stapling devices are limited by the need for multiple instruments due to fixed disposable loading unit sizes, increasing procedure time, complexity, and costs, and often struggle with maintaining tissue clamping during stapling and incision.
Innovation Solution
A surgical stapling apparatus with a modular design allowing multiple disposable loading units of varying sizes to be used, featuring a secure attachment mechanism to prevent detachment, an actuator for clamping tissue before stapling, and an anvil that can be moved between open, closed, and collapsed positions for easier insertion through small incisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple fixed-size disposable loading units are used to accommodate different surgical procedures, then adaptability is improved, but device complexity and procedure time increase
Solution Approach 1:
The surgical instrument is designed with a universal coupling mechanism that can accommodate disposable loading units of various sizes (e.g., 30mm, 45mm, 60mm) through a single standardized interface. The connector portion includes a cavity with engagement features that work with corresponding protrusions on different loading unit sizes, allowing one instrument to perform multiple surgical functions without requiring multiple specialized instruments.
Solution Approach 2:
The disposable loading unit is designed as a separable module that can be independently attached and detached from the surgical instrument. The coupling mechanism divides the system into a reusable instrument portion and a disposable loading unit portion, allowing the loading unit to be segmented and replaced based on specific surgical needs without affecting the main instrument.
2Adaptability or versatility
If multiple fixed-size disposable loading units are used for different procedures, then versatility is improved, but procedure time increases
Solution Approach 1:
The disposable loading unit is pre-assembled with staples, anvil, and driving mechanism in a ready-to-use configuration before insertion. The coupling mechanism is designed so that the entire loading unit can be pre-loaded and then quickly attached to the instrument in a single motion, eliminating the need for time-consuming assembly steps during the surgical procedure.
Solution Approach 2:
The coupling mechanism incorporates a detent system with spring-loaded balls that automatically engage with recesses in the loading unit during insertion. This dynamic engagement provides immediate mechanical locking upon attachment, ensuring the loading unit is securely fixed without requiring additional adjustment time during the procedure.
3Reliability
If a secure attachment mechanism is used to prevent loading unit detachment, then reliability is improved, but device complexity increases
Solution Approach 1:
The detent retention mechanism is extracted as a separate functional component within the coupling system. Spring-loaded balls are positioned in recesses that engage with corresponding features on the disposable loading unit, providing independent retention functionality that can be designed and manufactured separately from the main instrument structure.
Solution Approach 2:
The detent mechanism is nested within the coupling structure, with spring-loaded balls housed in recesses that are integrated into the connector portion. The retention feature is contained within the overall coupling assembly, allowing the secure attachment function to be incorporated without significantly increasing the external dimensions or overall complexity of the instrument.
4Ease of operation
If the anvil is moved between open, closed, and collapsed positions for easier insertion, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The anvil is designed with movable capability relative to the staple cartridge, allowing it to be positioned in open, closed, and collapsed configurations. The anvil can be moved between these positions through mechanical actuation during the insertion and operation sequence, enabling the instrument to adapt to different surgical requirements while maintaining a relatively simple overall structure.
Data Source
AI summary
In various embodiments, a surgical stapling instrument can include a handle, a shaft extending from the handle, wherein the shaft defines an axis, and a disposable loading unit which is assembled to the shaft in a direction which is transverse to the shaft axis. Such a connection between the disposable loading unit and the shaft can prevent, or at least inhibit, the disposable loading unit from being unintentionally displaced proximally and/or distally relative to the shaft of the surgical instrument. The surgical stapling instrument and/or disposable loading unit can further include a threaded collar and/or detent assembly configured to hold the disposable loading unit in place. In various embodiments, a disposable loading unit can include a lockout feature which can prevent, or at least inhibit, an expended disposable loading unit from being reassembled to the elongated body of the surgical instrument.