Surgical Stapler Knife Closure Control for Force Spike Reduction

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Solution Overview

Problem

Endoscopic surgical staplers experience force spikes during surgical procedures, which can lead to damage and inefficiencies in the drivetrain.

Innovation Solution

The surgical instrument employs an adaptive knife-based closure method that modulates clamping speed and force using a controller with force and position sensors to smooth out force peaks, utilizing a motor and sensor feedback to adjust the clamping and firing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional open surgical devices are used, then the surgical instrument can effectively perform the procedure, but the surgical incision size and post-operative recovery time increase

Engineering Contradiction:

Improvesurgical procedure effectivenessVSAvoidsurgical incision size

Core Design Contradiction:

Ease of operationVSLength of moving object

Solution Approach 1:

The surgical system is divided into modular components including a reusable end effector assembly and a disposable cartridge, allowing the complex function to be achieved through coordinated action of separate elements that can be optimized independently for minimally invasive use

Inventive Principle:

Principle #1Segmentation

2Reliability

If the surgical stapler clamps down on tissue layers, then the tissue can be sealed together, but force spikes are generated that can damage the drivetrain

Engineering Contradiction:

Improvetissue sealing effectivenessVSAvoidforce spikes to drivetrain

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system transitions from static clamping to dynamic, controlled clamping through motor-driven advancement of the knife at regulated speeds, allowing the clamping force to be applied and released in a controlled manner that prevents force spikes while maintaining tissue sealing effectiveness

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The controller receives feedback from sensors monitoring the clamping process and adjusts the knife advancement speed and clamping force in real-time to maintain optimal tissue sealing while preventing excessive forces from damaging the drivetrain

Inventive Principle:

Principle #23Feedback

3Productivity

If the knife advances through the staple cartridge to fire staples, then the tissue can be stapled, but force spikes occur during the firing process

Engineering Contradiction:

Improvetissue stapling capabilityVSAvoidforce spikes during firing

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The knife advancement and stapling process is performed in controlled periodic cycles with regulated speeds and pauses, allowing the force to be applied in manageable increments rather than continuous high-force impact, thereby reducing force spikes while maintaining stapling productivity

Inventive Principle:

Principle #19Periodic action

Data Source

PatentUS20250387119A1Adaptive knife-based closure methods for surgical stapler

Publication Date: 2025.12.25 CILAG GMBH INTERNATIONAL

AI summary

An apparatus includes an end effector, a motor, a sensor, and a controller. The end effector includes first and second jaws and a knife. The controller obtains using the sensor a first force value exerted by the motor as the knife is contacting the ramp surface. The controller determines whether the first force value exerted by the motor exceeds a first predetermined force threshold as the knife is contacting the ramp surface. The controller is configured to alter travel of the knife. Altering the travel of the knife includes at least one of: pausing the knife for a predetermined amount of time, pausing the knife until a second force value exerted by the motor obtained from the sensor is below the first predetermined force threshold, or advancing the knife at a second speed that is less than the first speed.