Segmented Surgical Stapler Shaft for Thoracic Articulation

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Solution Overview

Problem

Existing surgical instruments face limitations in range of movement and positioning ability, particularly when inserted through a thoracotomy, as they may damage patient ribs or soft tissue during angulation or movement.

Innovation Solution

A surgical instrument with a multi-diameter shaft featuring a closure tube with varying diameters, allowing for increased range of movement and positioning by reducing patient trauma and preventing tissue damage, along with an articulation joint for remote deflection of the end effector.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a surgical instrument shaft is designed with uniform diameter for insertion through trocar, then the instrument can be inserted and manipulated, but the range of movement and positioning ability is limited when reaching thoracic organs

Engineering Contradiction:

Improverange of movement and positioning abilityVSAvoidinsertion and manipulation difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The shaft is divided into multiple segments with different diameters along its length. The proximal portion has a larger diameter for manipulation, while the distal portion has a smaller diameter for insertion through trocar and navigation through rib spaces. This segmentation allows the instrument to be inserted through small openings while maintaining adequate size for control and articulation capabilities at the distal end.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the shaft are given different diameters suited to their specific functions. The proximal shaft portion is designed with larger diameter to facilitate manipulation and articulation, while the distal shaft portion is designed with smaller diameter to pass through narrow anatomical spaces between ribs. This local differentiation of properties optimizes both insertion ease and positioning capability.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If the shaft diameter is increased to improve positioning ability, then the instrument can reach and position at various angles, but it may damage patient ribs or soft tissue during movement

Engineering Contradiction:

Improvepositioning ability at various anglesVSAvoidtissue damage and patient trauma

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The shaft is segmented into proximal and distal portions with different diameters. The distal portion has a smaller diameter that can navigate through narrow intercostal spaces without damaging ribs or soft tissue, while the proximal portion maintains larger diameter for adequate manipulation and articulation range, thus preventing tissue damage while achieving positioning capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The shaft design incorporates a flexible, thin-walled tubular structure that can bend and articulate at various angles without rigid contact with surrounding tissues. This flexibility allows the distal end to reach target positions through natural tissue planes without causing trauma, while the articulated joints enable positioning at various angles.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If an articulation joint is added to enable remote deflection of end effector, then precise placement and surgical accessibility are improved, but the device complexity increases

Engineering Contradiction:

Improvesurgical accessibility and precise placementVSAvoidstructure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The shaft is divided into multiple articulation segments connected by joints that allow controlled deflection. Each segment can articulate relative to adjacent segments, enabling the distal end effector to reach positions and angles that would be impossible with a straight shaft, thus improving surgical accessibility without requiring an excessively long or complex mechanism.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The articulation joints provide dynamic positioning capability, allowing the shaft to be deflected and repositioned during the surgical procedure. The joints enable controlled movement and articulation of the end effector relative to the shaft axis, providing precise placement capability while maintaining a relatively simple mechanical structure through standardized joint designs.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP3673829B1Surgical stapler shaft formed of segments of different materials

Publication Date: 2024.08.07 ETHICON INC

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AI summary

A surgical instrument includes an end effector and a shaft. The end effector includes a first jaw movable relative to the second jaw. The shaft extends proximally from the end effector. The shaft includes a proximal coupler, a tube, and a distal coupler. The proximal coupler includes a distal coupling feature adjacent a distal end. The tube includes proximal and distal coupling features that are adjacent the respective proximal and distal ends of the tube. The proximal coupling feature is configured to engage the distal coupling feature of the proximal coupler to securably lock the tube and the proximal coupler together. The distal coupler includes a proximal coupling feature adjacent the proximal end of the distal coupler. The proximal coupling feature of the distal coupler is configured to engage the distal coupling feature of the tube to securably lock the distal coupler and the tube together.