Removable Surgical Stapler Power Pack for Sterilization-Free Reuse
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Surgical staplers face challenges with contamination and high costs due to the need for sterilization, and powered staplers risk damage from sterilization processes affecting their functionality and lifespan.
Innovation Solution
A fully enclosed and removable power pack for surgical staplers that prevents contact with patient fluids, allowing reuse without sterilization, and includes motors and encoders for precise control of stapling and articulation functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surgical staplers are made reusable to reduce cost, then cost effectiveness improves, but sterilization time and risk of infection increase
Solution Approach 1:
The stapler is divided into two segments: a reusable handle assembly and a disposable cartridge. The handle assembly containing electronic components can be sterilized and reused, while the cartridge is disposable and does not require sterilization. This segmentation allows the reusable portion to be properly sterilized while avoiding the need to sterilize the entire device, reducing sterilization time and cost.
Solution Approach 2:
The electronic components and drive mechanism are extracted into a separate reusable handle assembly that can be sterilized independently. The staple cartridge is separated as a disposable component. This extraction allows the handle to be reused after sterilization while the cartridge is discarded, eliminating the time-consuming sterilization process for the entire device.
2Ease of manufacture
If powered staplers are made reusable to reduce cost, then cost effectiveness improves, but sterilization process can damage electronic components and shorten lifespan
Solution Approach 1:
The stapler is segmented into a reusable handle assembly containing electronic components and a disposable cartridge. The handle assembly can be sterilized using appropriate methods that do not damage electronics, while the cartridge is disposable and does not require sterilization. This segmentation protects electronic components from damage while enabling cost-effective reuse of the handle.
Solution Approach 2:
Different parts of the device have different quality requirements. The handle assembly requiring electronic component protection uses sterilization methods suitable for electronics (lower temperature, no harsh chemicals), while the disposable cartridge uses standard sterilization. This local quality approach preserves electronic component lifespan while maintaining overall system effectiveness.
3Reliability
If single-use disposable staplers are used to eliminate sterilization risk, then infection risk is reduced, but cost increases due to discarding expensive electronic components
Solution Approach 1:
The stapler is segmented into a reusable handle assembly and a disposable cartridge. The disposable cartridge eliminates infection risk from the staple-firing portion, while the expensive handle assembly with electronic components is reused after appropriate sterilization. This segmentation reduces both infection risk and cost by avoiding disposal of the handle.
Solution Approach 2:
The expensive electronic components are extracted into a reusable handle assembly that can be sterilized and reused. The disposable cartridge contains only the staple mechanism and is discarded after single use. This extraction allows the expensive components to be reused while maintaining infection control through cartridge disposal.
4Strength
If high forces are required to fire staples through tissue, then stapling effectiveness improves, but user fatigue and operational difficulty increase
Solution Approach 1:
The manual mechanical firing mechanism is replaced with a powered drive mechanism using motors and lead screws. The motors provide the high forces needed to fire staples through tissue, eliminating the need for user to apply high manual forces. This substitution maintains stapling effectiveness while greatly improving ease of operation.
Solution Approach 2:
The system uses motor-driven lead screw mechanisms to convert rotational motion into linear force for staple firing. This mechanical amplification provides high firing forces with minimal user effort, improving ease of operation while maintaining adequate stapling strength.
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
Reduces sterilization time and costs, extends stapler lifespan, and ensures reliable operation by maintaining the power pack in a sealed environment, enabling efficient and safe multiple uses.
Implementation Method 1
an encoder is positioned within the power pack to detect movement of the rotatable screw to determine a firing position of the firing mechanism
Data Source
AI summary
A surgical fastener applier having a housing containing a compartment therein, an elongated member extending distally from the housing and first and second jaws. A firing mechanism is positioned within the housing movable to a second position to effect firing of fasteners. A power pack is removably loadable into the compartment, the power pack having one or both of a) a first motor and a first engagement member removably engageable with the firing mechanism when the power pack is loaded into the compartment to effect movement of the firing mechanism; and b) a second motor and a second engagement member removably engageable with an articulating mechanism in the housing of the surgical fastener applier to effect movement of an articulation mechanism to effect articulation. One or both of a firing position and an articulation position are tracked during the surgical procedure. Sensors are provided to detect select parameters and instrument functions.