Retainer-Coupled Surgical Stapler Lockout for Cartridge Detection

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Solution Overview

Problem

Existing surgical staplers do not prevent firing when the end effector is loaded with a spent staple cartridge or lacks a cartridge, potentially leading to unintended tissue severing without stapling.

Innovation Solution

Incorporation of a lockout assembly that includes a sensor and lockout mechanism to inhibit firing when a spent or absent staple cartridge is detected, ensuring the end effector is properly loaded before firing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a surgical stapler is designed without a lockout mechanism, then the device structure remains simple and easy to manufacture, but the device may fire when the end effector is loaded with a spent staple cartridge or lacks a cartridge, leading to unintended tissue severing without stapling

Engineering Contradiction:

Improvefiring control reliabilityVSAvoidlockout assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The lockout assembly is configured to detect the presence and state of the staple cartridge before the firing action occurs. The sensor detects whether the cartridge is properly loaded with staples, and the lockout mechanism prevents firing initiation until proper loading is confirmed, thereby ensuring reliable firing control without unintended tissue severing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The lockout assembly acts as an intermediary between the trigger mechanism and the firing mechanism. It includes a sensor that detects cartridge status and a lockout component that mediates the transmission of firing forces, blocking the firing sequence when improper loading is detected while allowing normal operation when properly loaded.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If a lockout assembly with sensor and lockout mechanism is incorporated, then firing is prevented when spent or absent cartridge is detected, enhancing safety, but the device complexity increases

Engineering Contradiction:

Improveunintended tissue severingVSAvoidlockout assembly structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The lockout assembly replaces purely mechanical firing control with a sensor-based detection system. The sensor electronically detects the presence and state of the staple cartridge, and this detection signal controls the mechanical lockout component, thereby eliminating unintended tissue severing through intelligent control rather than complex mechanical interlocking.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250331851A1Surgical stapler with firing lockout feature coupled to end effector retainer

Publication Date: 2025.10.30 CILAG GMBH INTERNATIONAL

AI summary

An apparatus includes a body (700), a shaft (600A), an end effector (200), and a lockout assembly (1100). The end effector includes a cartridge jaw (202), an anvil jaw (204), a knife (206) and a distal retainer (1110). The lockout assembly includes a sensor (1120) and a lockout (1140). The lockout is vertically constrained. The sensor is associated with a first pivot (1124) and a second pivot. The first pivot is grounded with respect to a channel (1114). The second pivot is a moving pivot. The lockout assembly includes an unlocked and locked position. The second pivot is positioned above the first pivot when the lockout assembly is in the unlocked position with the lockout providing no interference with respect to actuation of the knife. The first pivot and the second pivot are positioned at substantially the same height when the lockout assembly is in the locked position.