Overlapping Staple Pattern for Surgical Stapler Seal Strength
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Solution Overview
Problem
Existing surgical staplers face challenges in achieving high staple density and seal strength while maintaining efficient manufacturing and reduced dimensions for accessing complex anatomies, leading to potential luminal leakage and increased costs.
Innovation Solution
The use of overlapping staple patterns and modified anvils with increased staple density, where staple legs overlap to form a robust staple line, combined with reduced anvil dimensions, enhances seal strength and reduces manufacturing and inspection costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional staple patterns are used, then manufacturing is simpler, but staple density and seal strength are insufficient leading to luminal leakage
Solution Approach 1:
The staple pattern is segmented into multiple rows with specific spacing and orientation arrangements. The staples are divided into different functional zones (overlapping regions vs. non-overlapping regions) that perform different sealing functions, allowing high staple density without requiring every staple to be identical in configuration
Solution Approach 2:
The invention transitions from traditional single-plane staple arrangements to a multi-dimensional overlapping pattern where staples in adjacent rows are offset and interlock. This creates a three-dimensional seal structure that significantly enhances seal strength and prevents luminal leakage while maintaining manufacturability
2Reliability
If high staple density is achieved through traditional means, then seal strength improves, but manufacturing and inspection costs increase
Solution Approach 1:
The invention extracts and standardizes specific geometric parameters of the overlapping staple pattern (row spacing, offset distances, staple orientations) that can be manufactured using existing surgical staple manufacturing processes. This allows high-density sealing to be achieved without requiring entirely new manufacturing equipment or processes
Solution Approach 2:
The invention optimizes specific parameters of the staple pattern including the spacing between staple rows, the offset distance between overlapping staples, and the orientation angles. These parameter changes enable high staple density and seal strength while remaining compatible with current manufacturing capabilities and inspection methodologies
3Volume of moving object
If reduced anvil dimensions are used, then access to complex anatomies is improved, but manufacturing precision requirements increase
Solution Approach 1:
The anvil is segmented into distinct functional zones including staple forming pockets, tissue contact surfaces, and structural support regions. Each zone is optimized for its specific function, allowing the overall anvil to be miniaturized while maintaining the precision required for staple formation and sealing in reduced anatomical spaces
Data Source
AI summary
A surgical stapling instrument includes an anvil and a stapling assembly. The stapling assembly includes first and second staples. The anvil is configured to deform the first and second staples to thereby transition the first and second staples from a non-deformed state to a deformed state. The first staple includes a first crown. The second staple includes a second crown and a first leg disposed at a first angle relative to the second crown in the non-deformed state. The first leg of the second staple is configured to extend over the first crown to form an overlapping staple pattern between the first and second staples when the first and second staples are in the deformed state.