Removable Surgical Stapler Power Pack for Sterile Reuse
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Solution Overview
Problem
Current surgical staplers face challenges with contamination risks, high costs, and damage to electronic components due to sterilization processes, especially in reusable power-driven models, leading to inefficiencies and increased disposal costs.
Innovation Solution
A fully enclosed and removable power pack for surgical staplers that is sealed within the stapler handle assembly, allowing multiple uses without sterilization, and includes a motor and engagement member to facilitate staple firing and articulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reusable powered staplers are used, then force requirements are reduced and productivity is improved, but the electronic components are damaged during sterilization processes
Solution Approach 1:
The stapler is divided into two distinct segments: a reusable powered handle containing electronic components and a disposable sterile shaft. The handle is sealed within a sterile barrier that allows it to be reused without sterilization, while the shaft is discarded after a single use. This segmentation isolates the electronic components from the sterile field requirements.
Solution Approach 2:
The shaft and cartridge assembly is designed as a disposable component that is discarded after a single use, eliminating the need to sterilize electronic components. The handle is retained and reused, with the sterile barrier ensuring that the disposable shaft does not contaminate the reusable handle.
2Reliability
If disposable staplers with electronic components are used, then contamination risks are eliminated, but costs increase due to discarding electronic components
Solution Approach 1:
The stapler system is segmented into a reusable powered handle and a disposable shaft. The handle containing expensive electronic components is retained and reused across multiple procedures, while only the sterile shaft is discarded. This segmentation prevents waste of electronic components while maintaining sterile integrity.
Solution Approach 2:
A sterile barrier or seal acts as an intermediary between the reusable handle and the disposable shaft. This barrier allows the handle to remain non-sterile and reusable while ensuring that the shaft maintains sterility during its single use, preventing contamination without requiring handle sterilization.
3Reliability
If sterilization processes are applied to powered staplers, then contamination is prevented, but the sterilization process damages electronic components and increases time and cost
Solution Approach 1:
The stapler is segmented such that only the disposable shaft requires sterility, while the reusable handle does not undergo sterilization. This eliminates the time-consuming and damaging sterilization process for electronic components while maintaining sterility where needed through the disposable nature of the shaft.
Solution Approach 2:
The shaft is designed as a disposable component that is pre-sterilized and sealed in a sterile barrier. Since it is discarded after a single use, there is no need to sterilize the reusable handle, eliminating the time and resource consumption associated with sterilization processing.
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
Reduces the need for sterilization, lowers costs, and maintains functionality by keeping the power pack isolated from patient fluids, enabling cost-effective and efficient reuse of the stapler.
Implementation Method 1
the power pack comprising a housing containing a battery, a motor having a motor shaft
Implementation Method 2
a motor having a motor shaft, a rotatable member operably connected to the motor shaft
Data Source
Figure 1~2C
Figure 3A~3C
Figure 3D
AI summary
A surgical fastener applier for receiving a power pack and a loadable power pack. The surgical fastener applier includes a housing containing a compartment, an elongated member extending distally from the housing, first and second jaws and a firing mechanism positioned within the housing. The firing mechanism is movable between a first position and a second position to effect firing of fasteners into the tissue clamped between the first and second jaws. A cover on the housing is openable to access the compartment. A power pack is removably loadable into the compartment, the power pack having a motor and an engagement member removably engageable with the firing mechanism within the compartment when the power pack is loaded into the compartment to effect movement of the firing mechanism from the first position to the second position.