Powered Surgical Stapler Handle With Ball-Screw Jaw Centering

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Solution Overview

Problem

Surgical staplers with complex mechanisms face manufacturing burdens, potential device failure, and user confusion, necessitating a simpler and more reliable stapling system.

Innovation Solution

A powered handle for surgical staplers featuring a drive system, manual articulation mechanism, and control system that includes a ball screw mechanism for continuous jaw assembly articulation, a motor-driven clamping and firing mechanism, and a redundant manual override system for safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If complex mechanisms with multiple triggers and handles are used to provide proper stapling, then stapling functionality is achieved, but manufacturing burden and device complexity increase

Engineering Contradiction:

Improvemanufacturing burdenVSAvoidcomplex mechanisms

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical mechanisms with a motorized drive system. The motorized actuator eliminates the need for multiple mechanical triggers and handles, reducing both manufacturing complexity and operational complexity while maintaining stapling functionality through automated control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The motorized drive system serves multiple functions that previously required separate mechanical mechanisms. A single motorized actuator handles clamping, staple deployment, and jaw articulation, consolidating multiple functions into one system and reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If complex mechanisms with multiple triggers and handles are used to provide proper stapling, then stapling functionality is achieved, but potential sources for device failure increase

Engineering Contradiction:

Improvedevice failureVSAvoidcomplex mechanisms

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces multiple mechanical triggers and handles with a single motorized drive system. This substitution reduces the number of potential failure points while maintaining reliable stapling functionality through controlled motor actuation and electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The motorized drive system with electronic control provides self-regulated operation, eliminating the need for multiple user-actuated mechanical components. The system automatically controls the stapling sequence, reducing opportunities for user error and mechanical failure.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If complex mechanisms with multiple triggers and handles are used to provide proper stapling, then stapling functionality is achieved, but user confusion increases

Engineering Contradiction:

Improveuser confusionVSAvoidcomplex mechanisms

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces multiple mechanical triggers and handles with a simplified motorized interface. The motorized actuator with electronic control provides intuitive operation through digital displays and automated sequencing, eliminating user confusion about complex mechanical controls.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The motorized drive system incorporates electronic feedback mechanisms that provide real-time information to the user through displays and tactile feedback. This feedback system guides users through the stapling process, reducing confusion and improving ease of operation.

Inventive Principle:

Principle #23Feedback

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 powered handle provides efficient, reliable, and user-friendly stapling with enhanced ergonomics, reduced manufacturing complexity, and improved safety through motor-driven clamping and firing, along with a manual override for system failures.

Implementation Method 1

The manual articulation system can include a ball screw mechanism. The ball screw mechanism can allow continuous articulation of a jaw assembly of the stapling system within a predetermined articulation range.

Methodology Applied

Scientific EffectBall screw mechanism: Screw

Implementation Method 2

The powered handle can comprise a drive system powered by a power supply to selectively actuate an actuation adapter

Methodology Applied

Scientific EffectElectric motor: Electromagnetic Induction

Data Source

PatentUS12471919B2Surgical stapler having a powered handle

Publication Date: 2025.11.18 APPL MEDICAL RESOURCES CORP

AI summary

A powered handle for a surgical stapler can have a drive system including an electric motor. The powered handle can include a manual articulation mechanism to articulate a jaw assembly coupled to a reload shaft connected to the handle. The manual articulation mechanism can include a ball screw mechanism that translates an articulation member responsive to rotation of an articulation knob when an instrument shaft is engaged with the handle. The articulation mechanism includes a release function that allows the jaw assembly to return to a longitudinally centered orientation. The powered handle includes a battery pack serving as a power supply for the drive system. A control system can control actuation of the motor based on user inputs and operating parameters of the stapler and can provide certain motor drive profiles for predetermined positions of the stapler. The powered handle can include a manual return mechanism.