Overlapping Staple Patterns for Dense Surgical Stapler Seals
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Solution Overview
Problem
Existing surgical staplers face challenges in achieving high staple density for enhanced seal strength and reduced manufacturing and inspection costs, while maintaining ease of access to anatomical sites.
Innovation Solution
The use of overlapping staple patterns and modified anvils with increased staple density, allowing for interleaved staple configurations and reduced anvil dimensions, which enhance seal strength and reduce manufacturing and inspection costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional non-overlapping staple patterns are used, then manufacturing and inspection are simpler, but staple density is reduced and seal strength is compromised
Solution Approach 1:
The patent transitions from traditional non-overlapping staple arrangements to a three-dimensional overlapping configuration where staples extend across multiple planes. The interleaved pattern creates vertical and diagonal overlaps that add dimensional complexity to achieve higher staple density within the same tissue area, thereby improving seal strength without simply increasing staple count in a single plane.
Solution Approach 2:
The overlapping staple pattern creates a nested configuration where staples are positioned to overlap and interleave with adjacent staples, forming a hierarchical structure. This nesting approach allows multiple staples to occupy overlapping spatial regions, effectively increasing the functional staple density within the sealed area while maintaining a manageable overall structure.
2Reliability
If high staple density is achieved through traditional methods, then seal strength improves, but manufacturing and inspection costs increase
Solution Approach 1:
The staple pattern is segmented into distinct overlapping rows and columns, with staples systematically arranged in an interleaved configuration. This segmentation allows for modular manufacturing approaches where staple arrays can be pre-formed and assembled, facilitating more efficient production and inspection processes compared to traditional high-density non-overlapping patterns.
3Ease of operation
If conventional anvil dimensions are used, then manufacturing is simpler, but access to anatomical sites is more difficult
Solution Approach 1:
The anvil incorporates localized high-density staple forming regions with overlapping patterns concentrated at specific anatomical access points. This local quality approach allows the anvil to provide enhanced staple density where needed for difficult-to-reach sites while maintaining simpler designs in other areas, optimizing both accessibility and sealing performance without requiring complete redesign of the entire anvil structure.
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.