Surgical Stapler Sled with Cam Surface Alignment
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Solution Overview
Problem
Current surgical staplers lack a mechanism to effectively stabilize the staple cartridge and align staple drivers with staple forming pockets during the stapling process, leading to potential misalignment and suboptimal staple formation.
Innovation Solution
A wedge sled with a cartridge wall support feature and multiple surface finishes is introduced, providing rigidity to the staple cartridge and ensuring proper alignment of staple drivers with staple forming pockets through a combination of inclined cam surfaces and chamfers, which stabilize the cartridge body and anvil during the stapling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a wedge sled with cartridge wall support feature is introduced, then the rigidity and stability of the staple cartridge is improved, but the device complexity increases
Solution Approach 1:
The wedge sled acts as an intermediary component between the cartridge body and the anvil. It provides the necessary support and alignment functions that stabilize the cartridge during operation, while being a separate, replaceable component that doesn't permanently increase the complexity of the main cartridge structure.
Solution Approach 2:
The support feature is segmented into a separate wedge sled component rather than being integrated into the cartridge body itself. This allows the stability function to be added without permanently complicating the cartridge design, as the sled can be independently manufactured and installed.
2Manufacturing precision
If multiple surface finishes and chamfers are added to the wedge sled, then the alignment precision of staple drivers with staple forming pockets is improved, but the manufacturing complexity increases
Solution Approach 1:
Different surface finishes and geometric features (chamfers, cam surfaces) are applied only to specific localized areas of the wedge sled where they are needed for alignment and support functions. This provides precise alignment control at critical interfaces without requiring complex manufacturing throughout the entire component.
Solution Approach 2:
The alignment features are pre-formed during wedge sled manufacturing, establishing precise geometric relationships before assembly. This preliminary preparation of surfaces and chamfers ensures accurate alignment during operation without requiring complex adjustment mechanisms during surgery.
3Manufacturing precision
If the wedge sled provides rigidity to the staple cartridge, then the staple formation quality is improved, but the device complexity increases
Solution Approach 1:
The wedge sled serves as a mediator that transmits and distributes forces uniformly across the cartridge components during stapling. This intermediary role provides the rigidity needed for high-quality staple formation while keeping the force distribution mechanism simple and modular.
Data Source
AI summary
A staple driver actuator for a surgical stapler includes a base having at least one bottom surface. The bottom surface defines a plane and is configured to slide longitudinally relative to a jaw of the surgical stapler. The base also has at least one top surface parallel to the plane. The staple driver actuator further includes at least one rail extending upwardly from the base. The rail includes at least one first cam surface. The first cam surface is inclined relative to the plane, and the first cam surface is longitudinally aligned with at least a portion of the at least one top surface.