Replaceable Stapler End Effector With Reusable Drive Beam Coupling
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Solution Overview
Problem
Existing medical staplers face challenges in balancing performance, ease of use, and affordability, particularly in single-use devices where replaceable staple cartridges and end effectors either compromise robustness or require frequent replacement.
Innovation Solution
A medical stapler design featuring a reusable handle with a replaceable end effector that includes a robust drive beam and a fresh cutting edge, utilizing a tongue-and-groove coupling mechanism for ease of replacement and cost-effective multi-use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If entirely replaceable single use end effectors are used, then ease of swap between uses is improved, but robustness and clamping force capability deteriorate
Solution Approach 1:
The end effector is segmented into two functional parts: a reusable shaft assembly containing the robust drive beam and articulation mechanism, and a replaceable end effector component containing the cutting edge and staple cartridge. This segmentation allows the robust mechanical components to be reused while the consumable parts are replaced, resolving the contradiction between ease of swap and robustness.
2Strength
If replaceable staple cartridges are used, then other components can be made more robust, but the reusable knife becomes progressively duller with successive uses
Solution Approach 1:
The cutting edge is segmented as a separate replaceable component within the end effector, distinct from the reusable shaft and drive beam. This allows the robust mechanical components to be reused indefinitely while the cutting edge is replaced when dull, maintaining both robustness and cutting reliability.
Solution Approach 2:
The cutting edge is designed to be discarded after a certain number of uses or when it becomes dull, while the robust shaft and drive beam components are recovered and reused. This principle resolves the contradiction by selectively discarding only the consumable cutting edge while preserving the valuable robust components.
3Reliability
If a robust end effector is made, then stapling performance is improved, but manufacturing cost increases
Solution Approach 1:
The end effector system is segmented into expensive reusable components (shaft, drive beam) and cheaper replaceable components (end effector with cutting edge). This allows the system to achieve robust stapling performance where needed while using cost-effective materials for consumable parts, optimizing the overall manufacturing cost-performance ratio.
Data Source
AI summary
A medical stapler including a replaceable end effector and a closure and firing assembly. The end effector can include an anvil jaw, a cartridge jaw, and a releasable connector formed at the hinge of the end effector. The cartridge jaw can include a staple cartridge containing therein a plurality of staples, a sled configured to advance the staples from the staple cartridge, and a cutting edge. The closure and firing assembly can be configured to couple to the end effector via an engagement coupling and can include and a drive beam configured to: translate, from outside of the replaceable end effector therethrough thus advancing the sled from the proximal portion to the distal portion. Further, drive beam can retract from the slot to remain with the closure and firing assembly upon disengagement of the releasable connector and the engagement coupling.