Surgical Stapling Loading Unit Stroke Counter Lockout
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Solution Overview
Problem
Surgical stapling systems often require multiple devices during a single procedure due to limited staple supply, leading to increased costs and inefficiency, as existing systems lack effective tracking of staple usage and prevention of firing after depletion.
Innovation Solution
A surgical loading unit with a rotatable counter and lockout mechanism that tracks firing strokes and visually indicates staple supply levels, preventing further firing when a predetermined number of strokes is reached, allowing for seamless replacement and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple surgical staplers are used for a single procedure due to limited staple supply, then the surgical procedure can be completed, but the cost increases significantly
Solution Approach 1:
The patent implements a stroke counter mechanism that provides real-time feedback on the number of firing strokes remaining in the loading unit. This feedback system includes a visual indicator that allows the clinician to monitor staple supply status without removing the loading unit, enabling proactive replacement planning and avoiding unexpected depletion during surgery.
Solution Approach 2:
The lockout mechanism is designed to prevent firing after a predetermined number of strokes have been completed. This preliminary action stops the device before complete staple depletion occurs, giving the clinician advance notice to replace the loading unit and ensuring continuous operation without interruption or additional cost.
2Reliability
If multiple surgical staplers are used for a single procedure, then the surgical procedure can be completed, but the efficiency decreases
Solution Approach 1:
The visual indicator provides continuous feedback on staple supply status, allowing the surgical team to plan loading unit replacement during natural pauses in the procedure. This eliminates unexpected interruptions and maintains surgical flow, thereby preserving efficiency while ensuring procedure completion.
Solution Approach 2:
By implementing a lockout that prevents firing after a predetermined number of strokes, the system provides advance warning before staple depletion. This allows the surgical team to prepare and replace the loading unit proactively, avoiding mid-procedure interruptions and maintaining productivity.
3Reliability
If a stroke counter and lockout mechanism are added to the loading unit, then staple supply tracking and prevention of firing after depletion is achieved, but the device complexity increases
Solution Approach 1:
The tracking and lockout functions are segmented into distinct mechanical components: a stroke counter mechanism that increments with each firing, a visual indicator system that displays remaining strokes, and a lockout mechanism that engages after a predetermined number of strokes. This modular segmentation makes the complex functions manageable and maintainable.
Solution Approach 2:
The stroke counter and lockout mechanism are designed as self-contained mechanical systems that automatically track and control firing without requiring external power sources, electronic controls, or complex programming. The mechanical self-service nature reduces overall device complexity while achieving reliable staple supply tracking.
Data Source
AI summary
A surgical loading unit includes a drive and a rotatable counter that is adapted for rotational movement. The rotatable counter has visual indicators for providing visual indicia corresponding to a number of firing strokes completed by the drive.