Low Profile Surgical Staple Bridge Design for Fatigue Resistance

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Solution Overview

Problem

Existing low-profile surgical staples face challenges in achieving high sustained compression while minimizing localized strain concentrations, which can lead to fatigue failure.

Innovation Solution

The development of a low-profile surgical staple with a bridge having a continuous cross-section, legs with teeth cut into their inner surfaces, and a design that distributes strain evenly throughout the bridge, enhancing fatigue performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a low-profile staple design is used, then the profile height is reduced, but the stored strain and compression capacity are limited

Engineering Contradiction:

Improveprofile heightVSAvoidcompression capacity

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The bridge cross-section thickness is changed from a uniform design to a variable thickness design, where the thickness varies along the length of the bridge. This parameter change allows the bridge to maintain a low overall profile while having sufficient material thickness in critical regions to store and sustain high compression forces.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Different portions of the bridge are given different cross-sectional thicknesses based on their functional requirements. The central portion and portions near the shoulders have greater thickness for strength and strain storage, while other portions have reduced thickness to maintain low profile. This local differentiation resolves the contradiction between low profile and high compression capacity.

Inventive Principle:

Principle #3Local quality

2Shape

If a low-profile staple design is used, then the profile height is reduced, but localized strain concentrations increase

Engineering Contradiction:

Improveprofile heightVSAvoidfatigue performance

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The bridge cross-section thickness is varied along its length to create a more uniform strain distribution. By strategically placing thicker sections at critical locations (central portion and near shoulders), the design reduces stress concentrations that would otherwise occur at geometric discontinuities, thereby improving fatigue performance while maintaining low profile.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The bridge incorporates curved transitions and rounded features instead of sharp corners or abrupt geometric changes. This curvature eliminates localized strain concentrations at corners and transitions, reducing the risk of fatigue failure while preserving the low-profile geometry.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Strength

If high compression is achieved, then the compression force is increased, but the staple may fail due to localized strain concentrations

Engineering Contradiction:

Improvecompression forceVSAvoidfatigue performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The bridge is designed with locally varied thickness to concentrate material where highest stresses occur (central portion and shoulder regions). This local reinforcement allows the staple to sustain high compression forces without failing at critical locations, as the thicker sections absorb and distribute the strain more effectively.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Curved transitions and rounded geometric features are incorporated throughout the bridge structure to eliminate sharp corners and abrupt changes in cross-section. These curved features distribute strain more uniformly and prevent localized stress concentrations that would lead to fatigue failure under high compression loads.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

The staple achieves high sustained compression and improved fatigue performance by evenly distributing strain and minimizing stress concentrations, leading to increased durability and reduced risk of failure.

Implementation Method 1

deforming a nitinol staple from a first position to a second position for inserting the nitinol staple into tissue of a patient

Methodology Applied

Scientific EffectSuperelasticity: Pseudoelasticity

Implementation Method 2

the central bridge portion comprising: a substantially continuous cross-section... strain is distributed substantially evenly throughout the bridge

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS12207815B1Low profile staple and methods for using the same

Publication Date: 2025.01.28 MEDSHAPE

AI summary

According to particular embodiments, the present staple includes a low-profile bridge and has the capacity for high sustained compression. In some embodiments, the staple includes a bridge with a continuous cross-section, and one or more pairs of legs with teeth cut therein, the inner legs and outer legs each including an angle of about 16 degrees.