Segmented Electromechanical Surgical Device With Disposable End Effector
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Solution Overview
Problem
Existing electromechanical surgical devices are expensive to manufacture, purchase, and operate, necessitating a need for more economical solutions that maintain high operability throughout their lifecycle, from development to disposal.
Innovation Solution
The design of a hand-held electromechanical surgical device with a rotatable drive screw and flexible drive cable system, featuring a shaft assembly with a lock actuator and articulation bar, allowing for secure connection and disconnection of disposable or single-use end effectors, which includes a cartridge assembly for stapling and cutting, and an adapter shaft assembly for interconnecting with an electromechanical power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If proprietary drive systems with reusable handle assemblies and disposable loading units are used, then operability and functionality are maintained, but manufacturing and operational costs increase
Solution Approach 1:
The surgical device is divided into separate functional modules: a reusable handle assembly containing the motor and control electronics, and disposable loading units containing the end effector and drive components. This segmentation allows the expensive motor assembly to be reused while discarding the less expensive disposable components after each use, reducing overall manufacturing and operational costs while maintaining high operability.
Solution Approach 2:
The patent employs disposable loading units that are inexpensive to manufacture and discard after single use. These disposable units include the end effector, drive screw, and associated components, which are replaced rather than sterilized and reused. This approach eliminates the need for expensive sterilization infrastructure and reduces operational complexity while maintaining reliable functionality.
2Ease of manufacture
If disposable loading units are used instead of reusable components, then operational costs and complexity are reduced, but reliability and reusability deteriorate
Solution Approach 1:
By segmenting the device into reusable handle assemblies and disposable loading units, the patent achieves both cost reduction and reliability. The reusable handle assembly with its motor and control systems maintains high reliability through proper sterilization and maintenance, while the disposable loading units provide consistent reliability through factory-sterilized, single-use components that are replaced rather than reused.
Solution Approach 2:
The disposable loading units are manufactured under controlled conditions with built-in reliability features, then discarded after single use. This eliminates the wear and contamination issues associated with reusing disposable components, maintaining high reliability while reducing operational costs. The handle assembly's reusability is maintained through standardized sterilization protocols.
3Ease of operation
If complex drive systems with multiple components are used, then functionality and operability are enhanced, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The drive system is segmented into modular components: the handle assembly contains the motor, gear train, and control electronics, while the loading unit contains the end effector and drive screw. This modular architecture simplifies manufacturing by allowing independent production and assembly of standardized interfaces, reducing overall system complexity while maintaining enhanced functionality through the coordinated operation of modules.
Solution Approach 2:
The handle assembly is designed as a universal platform that can interface with multiple types of loading units through standardized coupling mechanisms. This multi-functionality allows a single reusable handle to perform various surgical functions by simply changing the disposable loading unit, reducing manufacturing complexity compared to creating specialized drive systems for each function while maintaining high functionality.
4Reliability
If secure connection mechanisms are implemented for end effector attachment, then reliability is improved, but ease of operation and detachment speed deteriorate
Solution Approach 1:
The coupling mechanism incorporates preliminary alignment features such as guide pins, alignment keys, and pre-positioned locking elements that automatically engage when the loading unit is inserted into the handle assembly. This preliminary action ensures reliable connection without requiring complex manual adjustment or multiple steps, maintaining both connection security and rapid attachment speed.
Solution Approach 2:
The connection mechanism is designed to be self-aligning and self-locking, where the geometry of the coupling surfaces and the sequence of engagement features automatically ensure proper alignment and secure locking upon insertion. The operator simply needs to insert the loading unit, and the mechanism self-performs the alignment and locking actions, maintaining both reliability and ease of operation without requiring complex manual procedures.
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
This configuration reduces manufacturing and operational costs while maintaining high operability, enabling efficient and secure attachment/detachment of end effectors, thus addressing the economic and functional challenges of existing devices.
Implementation Method 1
a flexible drive cable rotatably supported therein and extending therefrom, wherein the flexible drive cable receives rotational forces and transmits said rotational forces to the drive screw to actuate the end effector
Implementation Method 2
an end effector configured to perform at least one function. The end effector includes a rotatable drive screw
Implementation Method 3
a lock actuator having at least a first position and a second position. In use, when the lock actuator is in the second position the coupling lug of the shaft assembly may be prevented from insertion into the central opening of the end effector
Implementation Method 4
an articulation bar at least partially slidably supported in the distal neck housing
Data Source
AI summary
An electromechanical surgical device is provided and includes an end effector configured to perform at least one function; and a shaft assembly. The end effector includes a rotatable drive screw having a coupling member at a proximal end thereof; and a flexible drive cable rotatably supported therein and extending therefrom, wherein the flexible drive cable receives rotational forces and transmits said rotational forces to the drive screw to actuate the end effector. The shaft assembly includes a proximal neck housing supported at a distal end of the outer tube; and a distal neck housing pivotally connected to the proximal neck housing, wherein a distal end of the distal neck housing is configured and adapted for operative connection with the end effector. In use, when the end effector is connected to the shaft assembly, the flexible drive cable extends through the proximal neck housing and the distal neck housing.