Surgical Stapler Sled Surface Finish Alignment
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Solution Overview
Problem
Current surgical stapling instruments face challenges in ensuring precise alignment and stability of staple drivers with staple forming pockets during the stapling process, leading to potential misalignment and suboptimal staple formation.
Innovation Solution
The design incorporates a wedge sled with a cartridge wall support feature and multiple surface finishes, along with a staple driver support feature and tapered distal end, to promote alignment and stability by providing rigidity to the staple cartridge and ensuring proper interaction between staple drivers and staple forming pockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional surgical stapler design is used, then the device structure is simple, but the alignment precision between staple drivers and staple forming pockets deteriorates
Solution Approach 1:
The end effector is divided into distinct functional components: a cartridge body housing, a wedge sled with multiple surface finishes, staple drivers, and an anvil. This segmentation allows each component to be optimized independently for its specific function while maintaining overall alignment precision.
Solution Approach 2:
Different surface finishes are applied to different regions of the wedge sled and cartridge body. Specifically, the wedge sled has a first surface finish on its top surface that interfaces with staple drivers, and a second surface finish on its bottom surface that interfaces with the cartridge body. This local differentiation of surface properties enhances alignment and reduces friction in critical interaction zones.
2Stability of the object's composition
If the staple cartridge rigidity is increased to improve alignment, then the alignment stability improves, but the device complexity increases
Solution Approach 1:
The cartridge body is constructed with a composite structure featuring a PTFE-coated interior surface. This composite material approach provides both the structural rigidity needed for alignment stability and the low-friction surface properties that facilitate smooth operation of the staple drivers and wedge sled.
Solution Approach 2:
The wedge sled is pre-configured with specific surface finishes and geometric features (including tapered distal end and cartilage support features) that establish proper alignment between staple drivers and staple forming pockets before the stapling action begins. This preliminary alignment configuration ensures consistent performance throughout the stapling process.
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 stapling assembly of the surgical stapler. The staple driver actuator also includes at least one rail extending upwardly from the base. The at least one rail includes at least one rail cam surface, and the rail cam surface is inclined relative to the plane. The staple driver actuator further includes a first surface texture on a first portion of the staple driver actuator, and a second surface texture on a second portion of the staple driver actuator. The second surface texture is smoother than the first surface texture.