Surgical Stapler Actuation Layout for Taller Staples
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Solution Overview
Problem
Conventional surgical instruments are limited by the need for an actuator coil that occupies space in the central portion of the staple cartridge, restricting the height of staples and requiring a larger cross-sectional area, which complicates maneuverability and efficiency in minimally invasive procedures.
Innovation Solution
The actuation mechanism is redesigned to pass through the jaw instead of the staple cartridge, allowing for taller staples and a more compact instrument design by eliminating the internal channel for the actuation mechanism, using a coil that traverses through a metal anvil, which is structurally stronger than plastic pathways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the actuator coil is positioned in the central portion of the staple cartridge, then the instrument structure is simplified, but the staple height is restricted and the cross-sectional area must be larger
Solution Approach 1:
The actuator coil is repositioned from the central portion (one dimension) to the lateral portion of the staple cartridge, utilizing the lateral space that was previously underutilized. This dimensional relocation allows the coil to traverse through the metal anvil laterally, freeing the central channel for staple accommodation and enabling taller staples without increasing the overall cross-sectional area.
Solution Approach 2:
The actuator coil is nested within the lateral wall structure of the staple cartridge, passing through the metal anvil which is itself nested within the jaw assembly. This nested arrangement allows multiple components (coil, anvil, cartridge) to occupy overlapping spatial volumes, maximizing space utilization and enabling taller staples while maintaining a compact instrument profile.
2Device complexity
If the actuator coil occupies the central portion of the staple cartridge, then the actuation mechanism is straightforward, but the instrument cross-sectional area must be larger complicating maneuverability
Solution Approach 1:
The actuator coil traverses the metal anvil in a lateral dimension rather than through the central longitudinal channel. This dimensional change allows the coil to utilize the lateral thickness of the anvil wall, reducing the required cross-sectional area of the staple cartridge while maintaining the actuation function.
Solution Approach 2:
The metal anvil's lateral wall is designed with specific local properties (thickness, material strength, structural integrity) to accommodate the actuator coil traversal. This localized structural optimization allows the coil to pass through the anvil laterally without compromising the overall structural strength, enabling a more compact instrument design.
3Reliability
If taller staples are used, then tissue sealing capability is improved, but the instrument cross-sectional area must be larger
Solution Approach 1:
By relocating the actuator coil to the lateral portion and having it traverse the metal anvil laterally, the central channel is freed to accommodate taller staples. This dimensional reorganization allows taller staples (improving tissue sealing) without increasing the cross-sectional area, as the coil occupies lateral space rather than central space.
Solution Approach 2:
The staple cartridge is segmented into distinct functional zones: the central portion dedicated to staple storage and delivery (allowing taller staples), and the lateral portions dedicated to housing the actuator coil mechanism. This segmentation allows each zone to be optimized independently, enabling taller staples without increasing overall cross-sectional area.
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 design enables the use of taller staples and a more compact surgical instrument, enhancing maneuverability and efficiency in minimally invasive surgeries.
Implementation Method 1
The actuation mechanism includes a coil that applies a distal force to the first portion of the drive member. The coil is configured to pass through at least a portion of the channel in the first jaw to translate the drive member distally through the end effector.
Data Source
Figure 1
Figure 1A
Figure 1B~1C
AI summary
The present disclosure provides a surgical instrument, such as a tissue sealing instrument, with an elongate shaft and an end effector. The end effector includes a first jaw and a second jaw that includes a staple cartridge with a plurality of staples for engaging tissue. The instrument further includes a drive member for closing the jaws and engaging the staples, and an actuation mechanism, such as a coil, in contact with the drive member. The actuation mechanism is configured to translate the drive member distally through the first jaw (instead of through the staple cartridge as in conventional surgical stapling instruments). Eliminating the internal channel for the actuation coil from the staple cartridge provides more space in the cartridge for the staples, allowing for the use of taller staples and/or a more compact and maneuverable instrument.