Disposable Loading Unit Alignment for Surgical Staplers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current surgical stapling devices for endoscopic and laparoscopic procedures, such as the MULTIFIRE ENDO GIA, face challenges in reducing manufacturing complexity and cost while maintaining clinical benefits, particularly in providing a fresh knife blade for each firing and accommodating multiple size disposable loading units.
Innovation Solution
The surgical stapling device features a disposable loading unit with a mounting portion that secures the tool assembly to the body portion, including a cartridge assembly with staples and an anvil assembly, and a handle assembly with a movable trigger and rotatable member, allowing for articulation and easy attachment of multiple size loading units, ensuring a fresh knife blade for each firing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional surgical stapling devices are used, then clinical benefits are provided, but manufacturing complexity and cost are high
Solution Approach 1:
The surgical stapling device is divided into a reusable proximal body portion and a disposable loading unit with tool assembly. This segmentation allows the complex components to be manufactured once in the proximal body while the disposable unit uses simpler, standardized parts, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The proximal body portion is designed to accommodate multiple size disposable loading units (DLU's) through universal engagement features including lugs received in channels and bayonet-style coupling. This universality reduces the need for multiple specialized components, simplifying manufacturing while maintaining compatibility with various staple cartridge sizes.
2Ease of operation
If disposable loading units are designed for easy attachment, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The disposable loading unit includes pre-formed engagement features such as lugs with rounded distal ends and channels with angled distal ends that guide proper alignment during attachment. The bayonet-style coupling mechanism is pre-configured to automatically orient the loading unit correctly, making the attachment process intuitive and error-proof without requiring complex alignment procedures.
Solution Approach 2:
The lugs feature rounded distal ends that complement the curved engagement surfaces in the proximal body portion. This curved geometry facilitates smooth insertion and automatic self-alignment during the bayonet-style attachment, improving ease of operation while maintaining a relatively simple mounting assembly structure.
3Adaptability or versatility
If multiple size disposable loading units are accommodated, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The proximal body portion incorporates universal engagement features including standardized lugs received in channels and a bayonet-style coupling mechanism that can accommodate multiple size disposable loading units. This universal design allows a single proximal body to work with various staple cartridge sizes, improving adaptability while using the same manufacturing processes for the core components.
Solution Approach 2:
The disposable loading units are designed to nest within the proximal body portion during attachment and storage. The tool assembly with cartridge and anvil can be compactly positioned within the proximal body when not in use, allowing multiple size variants to be manufactured using the same overall dimensional envelope, thereby reducing manufacturing complexity.
Data Source
AI summary
A surgical stapling device is provided for sequentially applying a plurality of fasteners to body tissue and simultaneously incising tissue. The surgical stapling device includes an elongated body which is adapted to receive a single use loading unit (“SULU”) or a disposable loading unit (“DLU”) having staples in linear rows whose length can be between about 30 mm and 60 mm. Each DLU includes a proximal body portion, a mounting assembly and a tool assembly. The proximal body portion has a proximal end having one or more lugs which are dimensioned to be received within one or more channels formed in the distal end of the elongated body. The distal end of the walls defining the channels can be chamfered or angled such that if the DLU is not properly aligned with the elongated body when the proximal end of the DLU is inserted into the distal end of the elongated body, the chamfered or angled distal ends of the walls defining the channels will cam the lugs to properly align the DLU with the elongated body.