Surgical Stapler Anvil Pocket Forming With Dual-Punch Coining
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Solution Overview
Problem
Current surgical staplers face challenges in efficiently forming staple pockets on anvil plates with existing coining methods, which often require high tonnage and result in short tool life and imprecise staple formation.
Innovation Solution
A coining assembly using a pocket-forming top punch and embossing bottom punch cooperates to form staple pockets with minimal tonnage and enhanced precision, extending tool life and achieving accurate staple formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing coining methods are used to form staple pockets on anvil plates, then staple pockets can be formed, but high tonnage is required resulting in short tool life
Solution Approach 1:
The coining process is segmented into two independent stages: first forming shallow recesses, then forming final pockets. This segmentation reduces the tonnage required at each stage, extending tool life while maintaining manufacturing precision for staple pocket formation.
Solution Approach 2:
Shallow recesses are formed as a preliminary action before forming the final staple pockets. This preliminary action prepares the anvil plate surface to receive subsequent pocket formation with reduced tonnage requirements, preventing tool failure while achieving precise staple pocket geometry.
2Productivity
If existing coining methods are used to form staple pockets, then pockets can be formed, but imprecise staple formation results
Solution Approach 1:
The coining process is divided into two sequential operations: first forming shallow recesses, then forming final pockets with precise geometry. This segmentation allows each stage to be optimized for its specific function, achieving both productivity and precise staple formation.
Solution Approach 2:
The shallow recesses act as an intermediary structure between the initial anvil plate surface and the final staple pockets. This intermediary preparation enables subsequent precise pocket formation with reduced tonnage and improved staple formation accuracy.
3Manufacturing precision
If high tonnage is applied in coining to form staple pockets, then pockets can be formed, but tool stress increases reducing tool life
Solution Approach 1:
The high tonnage requirement is segmented across two separate coining operations. The first operation forms shallow recesses with moderate tonnage, and the second operation forms final pockets with reduced tonnage, preventing excessive tool stress while achieving precise pocket formation.
Solution Approach 2:
The preliminary formation of shallow recesses prepares the material structure to accept final pocket formation with lower tonnage. This preliminary action reduces the stress required in the subsequent pocket formation step, extending tool life while maintaining formation precision.
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 method allows for precise formation of staple pockets with reduced tool stress and extended tooling life, ensuring accurate staple deformation and improved surgical stapler performance.
Implementation Method 1
contacting a first side of the workpiece with the first punch and thereby plastically deforming the first side with the first plurality of protrusions to displace at least some material of the first side in a direction toward a second side of the workpiece
Implementation Method 2
contacting the second side of the workpiece with the second punch and thereby plastically deforming the second side with the second plurality of protrusions to displace at least some material of the second side in a direction toward the first side
Data Source
AI summary
A method is provided for forming a surgical stapler anvil with a first punch having a first plurality of protrusions and an opposing second punch having a second plurality of protrusions. A workpiece having first and second sides is positioned between the first and second punches. The first side is contacted by the first punch, thereby plastically deforming the first side with the first plurality of protrusions to displace material of the first side toward the second side. The second side is contacted by the second punch, thereby plastically deforming the second side to displace material of the second side toward the first side. A plurality of pockets is formed in the first side via the contact of the first punch with the first side and the contact of the second punch with the second side. Each of the pockets is configured to deform a leg of a surgical staple.