Powered Surgical Tack Applier Actuation and Articulation

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Solution Overview

Problem

Existing surgical tack appliers face challenges in meeting performance requirements and preventing premature ejection of tacks, as well as timing issues during tack ejection.

Innovation Solution

A surgical tack applier with a handle assembly featuring an actuation assembly and an articulation lever assembly, which includes a motor, an actuation rod, and an articulation lever. The actuation assembly also incorporates a processor, optical motor encoder, and encoder wheel to ensure precise tack ejection and articulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a reusable power module is used in the surgical tack applier, then the device can meet performance requirements and reduce costs, but premature ejection of tacks may occur

Engineering Contradiction:

Improvereusability of power moduleVSAvoidpremature ejection of tacks

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The device is divided into a reusable power module and a disposable shaft assembly. The power module contains the motor and control electronics, while the shaft assembly contains the loading unit with tacks. This segmentation allows the power module to be reused without compromising reliability, as the disposable shaft assembly is replaced after each use to prevent any potential issues with tack ejection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The encoder wheel is positioned and indexed before tack ejection to establish a reference point. The processor then controls the motor to rotate the actuation rod for the precise number of degrees needed to eject each tack. This preliminary positioning and controlled execution prevents premature ejection by ensuring the rod rotates only the exact amount required.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If precise control of tack ejection is implemented using encoders and processors, then timing issues are reduced, but device complexity increases

Engineering Contradiction:

Improveprecision of tack ejectionVSAvoidcomplexity of actuation assembly

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The manual mechanical actuation system is replaced with a powered motor system controlled by electronic encoders and a processor. The optical encoder measures the rotational position and degree of rotation of the actuation rod, while the encoder wheel provides reference positioning. This electronic control system eliminates timing issues and ensures precise tack ejection, despite the increased device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the actuation rod is made rotatable to eject tacks, then productivity increases, but the risk of premature ejection increases

Engineering Contradiction:

Improverate of tack ejectionVSAvoidpremature ejection of tacks

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The optical encoder provides continuous feedback to the processor on the rotational position and degree of rotation of the actuation rod. The processor uses this feedback to control the motor precisely, stopping rotation at the exact moment the tack should be ejected. This closed-loop feedback system prevents premature ejection while maintaining high productivity through controlled rapid rotation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The motor is controlled to rotate the actuation rod at a specific, precise degree rather than a fixed speed. The processor adjusts the rotation parameter dynamically based on the encoder feedback, ensuring the rod rotates only the exact amount needed to eject the tack. This parameter control prevents premature ejection while maintaining high ejection speed.

Inventive Principle:

Principle #35Parameter changes

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 solution effectively addresses the challenges of tack ejection and articulation, ensuring reliable and precise application of surgical tacks into tissue, while preventing premature ejection and timing issues.

Implementation Method 1

The actuation assembly may further include an optical motor encoder configured to count turns of the motor output shaft to ensure a proper number of turns are made to insert a surgical tack into tissue.

Methodology Applied

Scientific EffectOptical encoder:

Implementation Method 2

The actuation assembly includes a motor, an actuation rod, and an actuation switch configured to actuate the motor.

Methodology Applied

Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Data Source

PatentUS12295571B2Powered surgical tack applier

Publication Date: 2025.05.13 COVIDIEN LP

AI summary

A powered surgical tack applier is configured to deploy a surgical tack through tissue or a surgical mesh. The surgical tack applier is articulatable to facilitate placement of the surgical tack to a desired surgical location. The powered surgical tack applier includes a power module that includes a battery, a motor, and a gear box. The power module provides a high-speed/low-toque output and a low-speed/high-torque output.