Partially Reusable Surgical Stapler with Removable Actuator Module
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Surgical staplers are complex to sterilize and reuse, leading to high costs and waste due to the repeated replacement of firing and cutting components during procedures, with a need for a design that allows for disassembly and reconditioning of reusable parts while incorporating a disposable firing module.
Innovation Solution
A partially reusable surgical stapler with a removable actuator module and a latching mechanism that enables easy assembly and disassembly, allowing for the reuse of firing and cutting components with multiple staple cartridges within a single patient procedure, and subsequent sterilization and reconditioning of reusable parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surgical staplers are designed to be reusable, then costs are reduced and waste is decreased, but the devices become difficult to sterilize after use
Solution Approach 1:
The surgical stapler is divided into separate modules: a reusable body portion and a disposable firing module. This segmentation allows the reusable portions to be sterilized independently while the disposable module is discarded after single use, resolving the contradiction between reusability and sterilization difficulty.
Solution Approach 2:
The firing module is designed as a disposable component that is discarded after a single use. This eliminates the need to sterilize complex firing mechanisms repeatedly, while the reusable body portion can be sterilized and reused, reducing overall costs and waste.
2Reliability
If disposable surgical staplers with reloadable staple cartridges are used, then sterility is assured, but costs increase due to repeated replacement of firing and cutting components
Solution Approach 1:
The stapler is segmented into a reusable body and a disposable firing module containing the knife. This allows the knife to be reused with multiple staple cartridges within the same procedure, reducing material consumption while maintaining sterility through proper module replacement.
Solution Approach 2:
The reusable body portion can accommodate multiple different staple cartridges while retaining the same firing module (within the same procedure). This multi-functionality reduces the need to replace the entire stapler or firing assembly with each cartridge change, decreasing waste and cost.
3Reliability
If the knife and firing assembly are replaced with every staple cartridge, then sterility is maintained, but costs increase and material waste increases
Solution Approach 1:
The firing assembly is separated into a disposable module that can be replaced as needed, rather than requiring replacement of the entire stapler. This segmentation allows selective replacement of only the necessary components, reducing the quantity of materials used while maintaining sterility requirements.
4Loss of substance
If a partially reusable design is implemented, then costs are reduced and waste is decreased, but the device requires disassembly and reconditioning procedures
Solution Approach 1:
The stapler is designed with clearly defined separation points between reusable and disposable portions, making disassembly straightforward. The modular design with standardized interfaces simplifies the reconditioning process while maximizing waste reduction.
Solution Approach 2:
The disposable firing module is extracted as a separate removable component from the reusable body. This extraction simplifies the disassembly process, allowing quick removal of the disposable portion for replacement while leaving the reusable body intact for reconditioning and reuse.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A partially reusable surgical stapler for deploying staples into tissue. The stapler has a body with a distal end, a proximal end and a longitudinal axis therebetween. The proximal end includes a handle while the distal end includes a staple cartridge holder and an opposing anvil. The stapler also has an actuator module for deploying staples. The actuator module includes at least one longitudinally movable member for sequentially ejecting staples towards the anvil. The actuator module is readily removable and replaceable to and from the body. The components of the stapler body can be disassembled, reconditioned and reassembled for reuse in a different surgical procedure.