Partial-Pocket Surgical Stapler for Smaller Cannulas
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Solution Overview
Problem
Conventional surgical staplers face challenges in fitting through smaller cannulas due to the size and alignment requirements of their components, leading to jamming and increased manufacturing complexity, especially in minimally invasive procedures.
Innovation Solution
The surgical stapler design features a handle assembly connected to a cartridge assembly with a jaw assembly that includes a smooth anvil surface and staple pockets, allowing for staples to be ejected without staple-forming pockets, and a caming surface that translates within a slot to deploy staples, accommodating smaller cannulas and reducing alignment issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional surgical staplers use anvil pockets and pushers, then staple formation is reliable, but device diameter and manufacturing complexity increase
Solution Approach 1:
The patent removes the anvil pocket structure and pusher components from the stapler design. The smooth anvil surface eliminates the need for recessed pockets, and the angled staple configuration allows direct ejection by the slider without requiring separate pusher mechanisms. This extraction of unnecessary components reduces device complexity while maintaining staple formation functionality.
Solution Approach 2:
Instead of using a traditional design where the anvil has recessed pockets to guide staple formation, the patent inverts the approach by using a smooth, convex anvil surface. The staples are angled relative to the anvil surface, and formation occurs through direct contact with the smooth surface during ejection, eliminating the need for complex pocket structures.
2Reliability
If conventional surgical staplers use anvil pockets and pushers, then staple formation is reliable, but manufacturing cost increases
Solution Approach 1:
By removing the anvil pockets and pusher components, the patent significantly reduces the number of parts that need to be manufactured and assembled. The smooth anvil surface can be created through simpler manufacturing processes, and the elimination of pushers reduces component count and assembly steps, thereby lowering overall manufacturing cost.
3Force
If conventional surgical staplers are designed with standard components, then firing force is sufficient, but device diameter increases
Solution Approach 1:
The patent changes the geometric parameters of the staples by angling them relative to the anvil surface. This angular configuration allows the staples to be ejected and formed with adequate force while reducing the radial space required, thereby decreasing the overall device diameter without compromising firing force.
4Reliability
If conventional surgical staplers use standard components, then staple ejection is effective, but misalignment issues occur
Solution Approach 1:
By eliminating the pusher components and anvil pockets, the patent removes the interfaces where misalignment can occur. The direct contact between the slider and angled staples, combined with the smooth anvil surface, creates a simpler system with fewer alignment requirements, reducing manufacturing precision demands while maintaining ejection effectiveness.
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 redesigned stapler effectively deploys staples through smaller cannulas, enhancing reliability and reducing manufacturing complexity while maintaining staple formation quality.
Implementation Method 1
Staples are driven out of the cartridge by a caming surface or slider that moves longitudinally against a plurality of laterally positioned pushers that push each staple out of the cartridge individually. The caming surface of the slider is angled to complement the angular surface of the pushers.
Implementation Method 2
The caming surface of the slider is angled to complement the angular surface of the pushers. The cooperation between the angular surfaces of the pushers and the slider is a key step of the surgical stapling process.
Implementation Method 3
Some staplers include a blade that follows the caming surface so as to cut the tissue between the two or more rows of delivered staples.
Data Source
AI summary
A surgical stapler includes a jaw assembly at a distal end connected to a handle assembly that is configured to control the stapler and actuate the deployment of staples. The surgical stapler successfully eliminates intermediate caming portions commonly known as pushers that are located between the staples and a translating slider. The staples are located in pockets at an angle such that the base of the staple is parallel to an angled caming surface of the slider. The translating slider comes into direct contact with staples during deployment as the slider moves through each staple pocket where staples are partially supported by recesses along the slider pathway. The staples are deployed at an angle against the anvil surface. Because there are no pushers, a great deal of space is saved resulting in a much smaller diameter surgical stapler that is particularly suitable for laparoscopic stapling applications.