Surgical Stapling Instrument Lockout Mechanism

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Solution Overview

Problem

Current surgical stapling instruments lack effective mechanisms to prevent accidental firing when a spent or unspun staple cartridge is present, leading to potential surgical errors and inefficiencies.

Innovation Solution

The implementation of a firing assembly lockout mechanism that ensures the stapling instrument can only be fired when an unfired staple cartridge is installed, utilizing a combination of mechanical interlocks and sensors to verify cartridge status before allowing a firing stroke.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a spent or unspun staple cartridge is present in the surgical instrument, then the instrument can be reused without replacement, but accidental firing may occur causing tissue damage and safety issues

Engineering Contradiction:

Improveinstrument reusabilityVSAvoidaccidental firing causing tissue damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

A lockout mechanism is introduced as an intermediary component between the firing assembly and the spent/unspun cartridge. This lockout mechanism includes a lockout bar that physically blocks the firing mechanism when a spent or unspun cartridge is detected, preventing accidental firing while allowing controlled operation when a proper cartridge is installed. The lockout mechanism acts as a mediator that translates cartridge status into mechanical blocking of the firing function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a lockout mechanism is added to prevent accidental firing, then safety is improved, but device complexity increases

Engineering Contradiction:

Improveprevention of accidental firingVSAvoidmechanical interlocks and sensors

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The lockout mechanism is merged with the existing firing assembly structure. The lockout bar is integrated into the firing mechanism, and the sensor system is combined with the cartridge detection system. By merging these functions into a unified assembly, the patent reduces the need for separate, independent components, thereby limiting the increase in device complexity while maintaining safety functionality.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If mechanical interlocks and sensors are used to verify cartridge status, then firing control precision is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecartridge status verificationVSAvoidassembly of lockout mechanism

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The lockout mechanism is segmented into distinct functional modules: a sensor system for detecting cartridge status, a mechanical link system for transmitting the detection signal, and a lockout bar for physical blocking. This segmentation allows each module to be manufactured and tested independently, simplifying the overall manufacturing process while ensuring precise cartridge status verification through the coordinated function of these modular components.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20220378428A1Surgical instrument system comprising an end effector lockout and a firing assembly lockout

Publication Date: 2022.12.01 CILAG GMBH INTERNATIONAL

AI summary

Surgical stapling instruments are disclosed comprising a staple cartridge, a firing member, and a cartridge lockout configured to prevent the firing member from being advanced through the staple cartridge if the staple cartridge has been already spent. The stapling instruments further comprise a lockout in the shaft that responds to the cartridge lockout blocking the firing member.