Spring-Loaded Surgical Stapler for Consistent Staple Height

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Solution Overview

Problem

Existing surgical staplers require user input for adjusting staple height, lack tissue measurement mechanisms, and do not account for varying tissue thickness, leading to improper staple formation and potential tissue damage.

Innovation Solution

A self-adjusting height reload stapler that automatically adjusts to tissue thickness, using pressure-force feedback to set the proper staple height and compensate for jaw gap variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a fixed jaw gap height is used for stapling, then the device structure is simple and easy to operate, but the staple height cannot adapt to varying tissue thicknesses, leading to improper staple formation and potential tissue damage

Engineering Contradiction:

Improveease of operationVSAvoidadaptability to tissue thickness

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The patent implements a dynamic jaw gap adjustment mechanism that automatically adapts the jaw gap height to match the thickness of the tissue being stapled. The system uses a lift mechanism with a biasing member that allows the jaw gap to dynamically change based on tissue characteristics, resolving the contradiction between operational simplicity and adaptability to varying tissue thicknesses

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The stapler incorporates a self-adjusting mechanism where the lift and biasing member automatically set the appropriate jaw gap height without requiring manual user adjustment. The system self-regulates based on the tissue thickness, eliminating the need for users to manually estimate or measure tissue dimensions while maintaining adaptability across different tissue types

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If manual adjustment mechanisms are added to adapt staple height to tissue thickness, then adaptability to tissue thickness is improved, but the device complexity increases and requires user input that may not be accurate

Engineering Contradiction:

Improveadaptability to tissue thicknessVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs a self-adjusting lift mechanism with a biasing member that automatically determines and sets the appropriate jaw gap height based on tissue thickness. This eliminates the need for complex manual adjustment interfaces, dial settings, or user input, while maintaining high adaptability to varying tissue characteristics. The system performs the adjustment function autonomously, reducing device complexity compared to manually-controlled adjustment systems

Inventive Principle:

Principle #25Self-service

3Reliability

If excessive compression force is applied to ensure staple formation, then staple formation reliability is improved, but tissue damage and ischemia risk increase

Engineering Contradiction:

Improvestaple formation reliabilityVSAvoidtissue damage and ischemia

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent implements a feedback mechanism through the lift and biasing member system that automatically regulates compression force. As the jaw closes on the tissue, the lift mechanism senses the tissue thickness and adjusts the jaw gap accordingly, ensuring optimal compression force is applied without excessive pressure. This feedback-controlled approach maintains reliable staple formation while preventing tissue damage and ischemia by avoiding over-compression

Inventive Principle:

Principle #23Feedback

4Adaptability or versatility

If multiple staple size options are provided for different tissue thicknesses, then adaptability to tissue thickness is improved, but the difficulty of selecting the correct staple size increases

Engineering Contradiction:

Improveadaptability to tissue thicknessVSAvoidease of staple selection

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent eliminates the need for users to select from multiple staple sizes by implementing a self-adjusting mechanism. The lift and biasing member system automatically configures the appropriate jaw gap height and compression force based on the actual tissue thickness encountered during stapling. This removes the burden of staple selection from the user while maintaining full adaptability to different tissue types and thicknesses, significantly improving ease of operation

Inventive Principle:

Principle #25Self-service

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

Ensures consistent staple formation and tissue sealing without excessive compression, reducing the risk of ischemia and tissue damage by adapting to the actual tissue thickness.

Implementation Method 1

A spring or other biasing member is positioned between the cartridge and the retainer. The spring applies a force to move the cartridge vertically

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12465360B2Surgical stapler with self-adjusting staple height

Publication Date: 2025.11.11 APPL MEDICAL RESOURCES CORP

AI summary

A surgical stapler is provided that includes a spring loaded lift that automatically adjusts a staple cartridge and/or staple formation between a range of sizes. The lift is automatically released as the staple firing mechanism begins its forward translation of the firing sequence. The automatic one-way adjustment also adjusts the staple cartridge while maintaining the cartridge parallel to the anvil to provide consistent staple formations.