Raised-Deck Surgical Stapler Cartridge for Buttress Adhesion
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Solution Overview
Problem
The height of raised gripping features on surgical stapler cartridges inhibits optimal adhesion of adjunct materials, such as buttresses, to the stapling assembly, preventing effective deployment and reinforcement of staples.
Innovation Solution
The incorporation of enlarged or modified pocket extenders and contact surfaces on the stapler cartridge deck to enhance the adhesion of buttress assemblies, ensuring secure attachment of adjunct materials despite the presence of raised features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If raised gripping features are added to enhance tissue gripping and staple guidance, then tissue gripping capability is improved, but adhesion of adjunct material to the stapling assembly deteriorates
Solution Approach 1:
The patent introduces a second deck surface located above the first deck surface, creating a vertical dimension for adjunct material adhesion. This upper surface provides an additional adhesion plane that is not blocked by the raised gripping features, allowing buttress material to be properly attached while maintaining the raised features for their tissue gripping function.
Solution Approach 2:
The patent introduces adhesive material as an intermediary substance between the raised gripping features and the adjunct material. This adhesive fills the gaps and spaces created by the raised features, enabling effective bonding of the buttress material to the cartridge structure despite the irregular surface topology.
2Strength
If raised pocket extenders are positioned at cartridge ends to enhance gripping, then tissue clamping is improved, but adhesive material cannot reach the deck for proper adhesion
Solution Approach 1:
By creating an upper surface of the deck that is positioned above the level of the raised pocket extenders, the patent provides an accessible plane for adhesive application. This vertical displacement allows the adhesive to be applied without being blocked by the raised features, solving the manufacturing accessibility problem while preserving the clamping function.
Solution Approach 2:
The deck is segmented into multiple surfaces at different vertical levels: a lower first deck surface and an upper second deck surface. This segmentation allows different regions to serve different functions - the lower surface maintains structural integrity while the upper surface provides an accessible adhesion zone for adjunct materials.
Data Source
AI summary
A stapling assembly for a surgical instrument includes a body extending along a longitudinal axis and having an upper deck, a plurality of pockets extending through the upper deck for receiving respective staples and arranged in at least two longitudinal rows, a plurality of staple drivers, and a staple driver actuator. The stapling assembly also includes a plurality of pocket extenders extending upwardly from the upper deck. Each pocket extender has a respective top surface. The stapling assembly further includes at least one upwardly-facing surface configured to contact an adhesive of an adjunct for securing the adjunct to the stapling assembly. The at least one upwardly-facing surface is disposed at least partially between at least a portion of the upper deck and the top surfaces of the plurality of pocket extenders, and spans laterally at least partially across at least two longitudinal rows of the plurality of pockets.