Surgical Stapler Shipping Member for Reliable Loading Unit Engagement

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Solution Overview

Problem

Existing surgical stapling devices with replaceable loading units often fail to properly retain staples within the cartridge and maintain movable parts in position, leading to improper engagement with the actuation unit and subsequent malfunction.

Innovation Solution

A shipping member with a base portion, leg portion, and locking portion is integrated into the loading unit to securely maintain staples within the cartridge and prevent premature advancement of the staple pusher and knife assemblies, ensuring proper engagement with the actuation unit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a loading unit includes movable parts (staple pusher assembly and knife assembly) that can move freely, then the loading unit can be easily assembled and disassembled, but the movable parts may not be properly retained in position and may cause improper engagement with the actuation unit

Engineering Contradiction:

Improveease of assembly and disassemblyVSAvoidproper engagement with actuation unit

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The shipping member is pre-configured with a shipping position that maintains the staple pusher assembly and knife assembly in specific locations before attachment. This preliminary positioning ensures that when the loading unit is assembled, the movable parts are already in the correct positions to engage properly with the actuation unit, eliminating the need for complex alignment procedures during assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The shipping member acts as an intermediary component between the housing and the movable parts (staple pusher assembly and knife assembly). It provides a temporary support structure that maintains the movable parts in proper positions during shipping and assembly, and then allows them to be released for normal operation. This intermediary structure ensures reliable engagement without requiring the movable parts to be freely movable during assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the loading unit allows free movement of movable parts during attachment, then the assembly process is simplified, but the staples within the staple cartridge may not be properly retained

Engineering Contradiction:

Improvesimplicity of assembly processVSAvoidretention of staples within cartridge

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If automatic locking systems are used to block movement of components, then proper engagement with the actuation unit is ensured, but the system becomes more complex and may not retain staples within the staple cartridge

Engineering Contradiction:

Improveproper engagement with actuation unitVSAvoidcomplexity of locking system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The shipping member is divided into distinct functional segments: a base portion that interfaces with the housing, a leg portion that extends to engage the knife assembly, and a locking portion that provides the locking mechanism. This segmentation allows each portion to perform its specific function independently, simplifying the overall design while ensuring reliable engagement. The shipping member itself acts as the locking mechanism, eliminating the need for separate complex locking systems.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The shipping member performs multiple functions: it maintains the staple pusher assembly in position, maintains the knife assembly in position, and provides the locking mechanism for engagement with the actuation unit. By combining these functions into a single component, the design avoids the complexity of multiple separate locking systems while ensuring reliable engagement and staple retention.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If a shipping member is added to maintain movable parts and staples, then reliability is improved, but the device complexity increases

Engineering Contradiction:

Improveretention of staples and movable partsVSAvoidstructure of loading unit

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The shipping member merges multiple functions into a single component: it provides structural support, maintains the staple pusher assembly in position, maintains the knife assembly in position, and provides the locking mechanism. By combining these functions that would otherwise require separate components, the overall device complexity is minimized while achieving the desired reliability for staple and movable part retention.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11071541B2Loading unit including shipping member

Publication Date: 2021.07.27 COVIDIEN LP

AI summary

A loading unit including a shipping member is provided. The loading unit includes a housing, a staple pushing assembly, a knife assembly, and a staple cartridge. The shipping member is configured to be selectively secured to the housing of the loading unit and prevents advancement of the staple pushing assembly and the knife assembly. The shipping member also retains staples within the staple cartridge.