Overlapping Staple Patterns for Surgical Stapler Seal Strength
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Solution Overview
Problem
Existing surgical staplers face challenges in achieving high staple density and seal strength while reducing manufacturing and inspection costs, and accessing complex anatomical structures efficiently.
Innovation Solution
The use of overlapping staple patterns and alternative anvils with increased staple forming pockets allows for higher staple density and improved seal strength, while reducing the size and cost of the anvil, and facilitating easier access to anatomical sites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional staple patterns are used, then manufacturing and inspection costs are lower, but staple density and seal strength are reduced
Solution Approach 1:
The patent transitions from a traditional linear staple arrangement to a two-dimensional overlapping grid pattern. Staples are arranged in multiple rows and columns with intentional overlap, creating a planar distribution network that increases staple density across the sealing surface without requiring proportional increases in manufacturing complexity.
Solution Approach 2:
The patent combines multiple staple functions into a single integrated pattern. The overlapping staples serve dual purposes: individual staples provide localized sealing, while the collective overlapping arrangement creates a distributed reinforcement network that enhances overall seal strength and distributes mechanical stresses across the entire sealing area.
2Strength
If traditional staple patterns are used, then manufacturing and inspection are simpler, but seal strength is reduced
Solution Approach 1:
The patent transitions from a traditional linear staple arrangement to a two-dimensional overlapping grid pattern. Staples are arranged in multiple rows and columns with intentional overlap, creating a planar distribution network that increases staple density without requiring proportional increases in manufacturing complexity.
Solution Approach 2:
The overlapping staple pattern is pre-configured in the cartridge before surgery. The geometric arrangement of overlapping staples is designed in advance to optimize seal strength and stress distribution, eliminating the need for complex real-time adjustments during the surgical procedure.
3Adaptability or versatility
If standard anvil sizes are used, then manufacturing is easier, but access to complex anatomical structures is limited
Solution Approach 1:
The anvil is divided into multiple independent forming pockets arranged in the overlapping staple pattern. Each pocket is a discrete geometric feature that can be independently manufactured and positioned, allowing the overall anvil structure to be scaled or customized for different anatomical configurations without requiring complete redesign.
Solution Approach 2:
The anvil features localized forming pockets with specific geometric characteristics optimized for creating the overlapping staple pattern. Different regions of the anvil can have varied pocket configurations to accommodate different tissue thicknesses and anatomical structures, providing adaptability without uniform complexity throughout the entire device.
Data Source
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AI summary
A surgical stapling instrument includes an anvil and a stapling assembly. The stapling assembly includes first and second staples. The anvil is configured to deform the first and second staples to thereby transition the first and second staples from a non-deformed state to a deformed state. The first staple includes a first crown. The second staple includes a second crown and a first leg disposed at a first angle relative to the second crown in the non-deformed state. The first leg of the second staple is configured to extend over the first crown to form an overlapping staple pattern between the first and second staples when the first and second staples are in the deformed state.