Surgical Loading Unit Low Profile Pusher Design
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Solution Overview
Problem
Conventional surgical instruments with loading units are limited by the size of their end effectors and pushers, restricting their ability to achieve smaller diameters necessary for procedures like pediatric surgeries or tight tissue locations.
Innovation Solution
A loading unit design featuring a proximal body portion, end effector with a cartridge and anvil assembly, actuation sled, single and double pushers, and retention cavities, allowing for a reduced diameter of approximately 12 mm, enabling insertion through smaller trocars and versatile use in various surgical procedures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional pusher designs are used in loading units, then the structural integrity and fastener engagement are maintained, but the diameter of the end effector and loading unit cannot be reduced below typical sizes
Solution Approach 1:
The pusher is divided into multiple functional segments: a body portion for engagement, lateral extensions for guiding surfaces, and camming surfaces for actuation. This segmentation allows each component to perform its specific function efficiently while reducing the overall diameter of the loading unit.
Solution Approach 2:
The pusher design utilizes lateral extensions that extend perpendicular to the longitudinal axis, creating guiding surfaces in a radial dimension. This dimensional approach allows the pusher to maintain structural integrity and engagement capability while reducing the longitudinal profile and overall diameter of the end effector.
2Length of moving object
If the diameter of the loading unit is reduced to enable insertion through smaller trocars, then access to tight tissue locations is improved, but the space available for pusher components and fasteners is reduced
Solution Approach 1:
The cartridge assembly is designed with localized features including retention cavities for fasteners of varying sizes and shapes, and camming surfaces positioned to engage with different fastener configurations. This local quality approach allows the compact loading unit to accommodate multiple fastener types while maintaining a reduced overall diameter.
Solution Approach 2:
The pusher design incorporates universal engagement features that can interact with different fastener types through the anvil assembly. The camming surfaces and guiding surfaces are configured to work with various fastener geometries, providing multi-functionality within the constrained space of the reduced-diameter loading unit.
3Ease of operation
If single pushers with multiple lateral extensions are used to engage individual fasteners, then precise fastener control is achieved, but the manufacturing complexity increases
Solution Approach 1:
The pusher is pre-configured with lateral extensions and camming surfaces during manufacturing that are designed to automatically engage and guide fasteners into the correct position. This preliminary configuration ensures precise fastener control during operation while streamlining the manufacturing process by integrating multiple functions into a single component design.
Data Source
AI summary
A loading unit for engagement with a surgical instrument, and including single and double retention slots, is discloses. At least one single retention cavity includes a first retention guiding surface configured to engage a first pusher guiding surface of a single pusher retained therein, a second retention guiding surface configured to engage a second pusher guiding surface of a single pusher retained therein, a third retention guiding surface configured to engage a third pusher guiding surface of a single pusher retained therein, and a fourth retention guiding surface configured to engage a fourth pusher guiding surface a the single pusher retained therein. At least one double retention cavity includes a first retention guiding surface configured to engage a first pusher guiding surface of a double pusher retained therein, and a second retention guiding surface configured to engage a second pusher guiding surface of a double pusher retained therein.