Circular Stapler Deck with Asymmetric Recessed Features
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Solution Overview
Problem
Current circular staplers for end-to-end anastomosis in surgical procedures face challenges in minimizing tissue damage and ensuring secure staple deployment during insertion and actuation, particularly in complex anatomical structures like the colon, where tissue folding and pinching can lead to damage.
Innovation Solution
The design incorporates a stapling head assembly with a deck member featuring a first zone with a flat, curved outer edge and a second zone with recessed stand-off features and an annular wall, which reduces the risk of tissue snagging and over-compression during insertion and enhances tissue engagement and staple deployment during actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a circular stapler is inserted into complex anatomical structures like the colon, then the stapler can perform end-to-end anastomosis, but tissue folding and pinching can occur leading to tissue damage
Solution Approach 1:
The deck member features a differentiated surface design with a first zone having a flat outer edge and a second zone having recessed stand-off features. This local variation in surface geometry allows different regions to perform different functions: the flat zone minimizes snagging during insertion while the recessed zone provides controlled tissue engagement during stapling, thereby reducing overall tissue damage while maintaining adaptability to complex anatomy.
Solution Approach 2:
The deck member surface is segmented into distinct functional zones: a first zone with a flat outer edge for safe insertion and a second zone with recessed stand-off features for controlled tissue engagement. This segmentation allows the stapler to navigate complex anatomical structures without causing tissue folding and pinching, while still achieving effective stapling in the targeted area.
2Reliability
If the stapler applies sufficient pressure to secure staple deployment, then reliable anastomosis is achieved, but tissue over-compression and fracture risk increase
Solution Approach 1:
The recessed stand-off features in the second zone create localized pressure points that concentrate force precisely where needed for secure staple deployment, while the surrounding recessed areas distribute excess pressure away from critical tissue regions. This local quality differentiation ensures reliable anastomosis without causing widespread tissue over-compression or fracture.
3Manufacturing precision
If the deck member has features to enhance tissue engagement during stapling, then staple deployment is improved, but the risk of tissue snagging during insertion increases
Solution Approach 1:
The deck member is segmented into a first zone with a flat outer edge that minimizes tissue snagging during insertion, and a second zone with recessed stand-off features that enhance tissue engagement during stapling. This spatial segmentation resolves the contradiction by providing different surface characteristics at different locations and times during the surgical procedure.
Solution Approach 2:
The flat outer edge in the first zone is designed to facilitate smooth insertion of the stapler into the anatomical structure before the stapling action occurs. This preliminary design feature prepares the path for insertion without compromising the subsequent stapling function provided by the recessed features in the second zone.
Data Source
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AI summary
An apparatus includes a body, a shaft assembly, a stapling head assembly, and an anvil. The stapling head assembly includes a deck member, a plurality of staples, and a driver. The deck member includes a first deck surface, a second deck surface, an outer annular array of staple openings formed through the deck surfaces, an inner annular array of staple openings formed through the deck surfaces, and a plurality of stand-off features extending distally from the second deck surface. The second deck surface is recessed relative to the first deck surface. The driver is operable to drive the staples through the staple openings. The anvil is operable to compress tissue against the deck surface.