U.S. patent application number 11/820121 was filed with the patent office on 2008-12-18 for surgical stapling and cutting instruments.
Invention is credited to Glen A. Armstrong, Leslie M. Fugikawa, Christopher J. Schall, Charles J. Scheib, Frederick E. Shelton, Richard W. Timm, Eugene L. Timperman.
Application Number | 20080308602 11/820121 |
Document ID | / |
Family ID | 55969502 |
Filed Date | 2008-12-18 |
United States Patent
Application |
20080308602 |
Kind Code |
A1 |
Timm; Richard W. ; et
al. |
December 18, 2008 |
Surgical stapling and cutting instruments
Abstract
A multi-axis surgical stapling and cutting instrument. In
various embodiments, the instrument includes a tool assembly that
operably supports a cable powered knife assembly and further has an
anvil that is actuated by axial movement of a closure ring. The
instrument may further include a disposable reload unit that may be
attached to the reusable portion of the instrument without the use
of tools. Various embodiments may also employ an active
articulation control system for actively articulating the tool
assembly.
Inventors: |
Timm; Richard W.;
(Cincinnati, OH) ; Shelton; Frederick E.; (New
Vienna, OH) ; Scheib; Charles J.; (Kettering, OH)
; Schall; Christopher J.; (Cincinnati, OH) ;
Armstrong; Glen A.; (Liberty Township, OH) ;
Timperman; Eugene L.; (Cincinnati, OH) ; Fugikawa;
Leslie M.; (Cincinnati, OH) |
Correspondence
Address: |
K&L GATES LLP
535 SMITHFIELD STREET
PITTSBURGH
PA
15222
US
|
Family ID: |
55969502 |
Appl. No.: |
11/820121 |
Filed: |
June 18, 2007 |
Current U.S.
Class: |
227/175.1 ;
227/176.1; 227/180.1 |
Current CPC
Class: |
A61B 2017/0069 20130101;
A61B 2017/07214 20130101; A61B 2017/07278 20130101; A61B 2017/2916
20130101; A61B 2017/2936 20130101; A61B 2017/320052 20130101; A61B
17/07207 20130101; A61B 2017/294 20130101; A61B 2017/2934 20130101;
A61B 2017/2946 20130101; A61B 2017/2927 20130101; A61B 2017/2937
20130101; A61B 2017/292 20130101; A61B 2017/2933 20130101; A61B
2017/00473 20130101; A61B 2017/07285 20130101; A61B 2034/715
20160201; A61B 2017/2939 20130101 |
Class at
Publication: |
227/175.1 ;
227/176.1; 227/180.1 |
International
Class: |
A61B 17/04 20060101
A61B017/04; A61B 17/10 20060101 A61B017/10 |
Claims
1. A surgical instrument comprising: a tool assembly operably
supporting a cable driven knife assembly therein and having an
anvil assembly movably coupled thereto for selective movement
between open and closed positions; a closure ring operably
interfacing with said tool assembly for selectively applying at
least a closing motion to said anvil assembly; and a distal closure
tube segment for selectively applying an actuation motion to said
closure ring to cause said closure ring to apply said closing
motion to said anvil assembly, said distal closure tube segment
pivotally attached to a closure tube assembly by an articulation
joint that facilitates pivotal travel of said tool assembly
relative to said closure tube assembly.
2. The surgical instrument of claim 1 further comprising an
articulation joint locking assembly for selectively locking said
articulation joint in a desired position.
3. The surgical instrument of claim 1 further comprising an active
articulation system interfacing with said articulation joint to
apply articulation motions thereto.
4. The surgical instrument of claim 3 wherein said distal closure
tube segment is operably mounted to a distal spine segment that is
pivotally coupled to said closure tube assembly by said
articulation joint and wherein said articulation system comprises a
plurality of articulation actuation members coupled to said distal
spine segment and interfacing with an articulation control system
oriented relative to a proximal end of said closure tube
assembly.
5. The surgical instrument of claim 4 wherein said articulation
control system is operably supported by a handle assembly operably
coupled to the proximal end of said closure tube assembly and
wherein said articulation control system comprises a joy stick
assembly.
6. The surgical instrument of claim 1 wherein said articulation
joint comprises: an articulation member pivotally coupled to said
tool assembly for selective pivotal travel about a horizontal axis,
said articulation member pivotally coupled to a spine member for
selective pivotal travel relative thereto about a vertical axis;
means for selectively applying horizontal articulation motion to
said tool assembly to selectively cause said tool assembly to pivot
about said horizontal axis relative to said articulation member;
and means for selectively applying a vertical articulation motion
to said articulation member to selectively cause said articulation
member to pivot about said vertical axis relative to said spine
member.
7. The surgical instrument of claim 6 further comprising: means for
selectively locking said tool assembly in any one of a plurality of
first positions about said horizontal axis relative to said
articulation member; and means for selectively locking said
articulation member in any one of a plurality of second positions
about said vertical axis relative to said spine member.
8. The surgical instrument of claim 7 wherein said means for
selectively locking said tool assembly comprises: at least one set
of first horizontal locking teeth on a portion of said tool
assembly; and a set of second horizontal locking teeth
corresponding to each said set of first horizontal locking teeth
and being selectively movable into and out of engagement therewith
and wherein said means for selectively locking said articulation
member comprises: at least one set of first vertical locking teeth
on said articulation member; and a set of second vertical locking
teeth corresponding to each set of first vertical locking teeth and
being selectively movable into and out of engagement therewith.
9. The surgical instrument of claim 1 wherein said closure tube
assembly comprises: an intermediate closure tube segment pivotally
attached to said distal closure tube segment by said articulation
joint; and a proximal closure tube segment removably coupled to
said intermediate closure tube segment.
10. The surgical instrument of claim 9 wherein said proximal
closure tube segment is removably coupled to said intermediate
closure tube segment by a quick disconnect joint assembly.
11. A method for processing an instrument for surgery, the method
comprising: obtaining the surgical instrument of claim 1;
sterilizing the surgical instrument; and storing the instrument in
a sterile container.
12. A surgical instrument comprising: a handle assembly; a cable
drive system operably supported by said handle assembly; a proximal
closure tube operably coupled to closure tube actuation system
operably supported by said handle assembly; and a disposable reload
unit operably and removably coupled to said proximal closure tube
by a joint assembly, said disposable reload unit comprising: a tool
assembly operably supporting a knife assembly therein constructed
to be driven by said cable drive system in said handle assembly and
an anvil assembly movably coupled thereto for selective movement
between open and closed positions upon receipt of actuation motions
from said proximal closure tube.
13. The surgical instrument of claim 12 wherein said disposable
reload unit further comprises an articulation joint.
14. The surgical instrument of claim 13 wherein said articulation
joint is constructed to be actively articulated by an articulation
control system supported by said handle assembly when said
disposable reload unit is coupled to said proximal closure
tube.
15. The surgical instrument of claim 13 wherein said articulation
joint is constructed to facilitate selective pivotal travel of said
disposable reload unit about multiple axes relative to said
proximal closure tube.
16. The surgical instrument of claim 13 further comprising an
articulation joint locking assembly for selectively locking said
articulation joint in a desired position.
17. The surgical instrument of claim 12 wherein said cable drive
system comprises; a knife screw shaft driven by a drive system
selected from the group of drive systems consisting of manually
driven drive systems and motor driven drive systems; and a nut
threadably journaled on said driven knife screw and coupled to a
proximal end of at least one drive cable coupled to said knife
assembly.
18. The surgical instrument of claim 12 wherein said joint assembly
comprises a quick disconnect joint.
19. A method for processing an instrument for surgery, the method
comprising: obtaining the surgical instrument of claim 12;
sterilizing the surgical instrument; and storing the instrument in
a sterile container.
20. A surgical instrument comprising: a disposable reload assembly,
comprising: a tool assembly operably supporting a knife assembly
therein and having an anvil assembly selectively movable between
open and closed positions; a distal spine segment; a distal closure
tube segment coupled to said distal spine segment; a closure ring
operably coupled to said distal closure tube segment and said tool
assembly such that upon rotation of said distal closure tube
segment, said closure ring is caused to move axially relative
thereto to apply actuation motions to said anvil assembly; an
intermediate spine segment coupled to said distal spine segment by
an articulation joint assembly; an intermediate closure tube
segment coupled to said articulation joint to transmit a rotary
actuation motion through said articulation joint to said distal
closure tube segment; a knife screw shaft operably supported within
said intermediate closure tube segment and constructed to rotate in
response to a rotary drive motion; a knife nut on said knife screw
shaft; and a drive cable attached to said knife assembly and said
knife nut and wherein said surgical instrument further comprises; a
handle assembly; a proximal closure tube assembly operably coupled
to a closure tube actuation system operably supported by said
handle assembly; a rotary drive shaft operably coupled to a rotary
drive system supported by said handle assembly; and a quick
disconnect joint for operably interconnecting: said intermediate
closure tube segment with said proximal closure tube segment; said
intermediate spine segment to said proximal spine segment; and said
knife screw to said knife drive shaft without the use of tools.
Description
[0001] The present application is related to the following
commonly-owned U.S. patent applications filed on even date
herewith, the disclosures of which are hereby incorporated by
reference in their entirety:
[0002] (1) U.S. patent application entitled "Surgical Stapling and
Cutting Instrument With Improved Firing System" to Richard W. Timm,
Frederick E. Shelton, IV, Eugene L. Timperman, and Leslie M.
Fugikawa, (Docket No. END6094/KLG No. 070064);
[0003] (2) U.S. patent application entitled "Surgical Stapling and
Cutting Instrument With Improved Closure System" to Richard W. Timm
and Frederick E. Shelton, IV, Eugene L. Timperman, and Leslie M.
Fugikawa, (Docket No. END6095USNP/KLG. No. 070065);
[0004] (3) U.S. patent application entitled "Cable Driven Surgical
Stapling and Cutting Instrument With Apparatus For Preventing
Inadvertent Cable Disengagement" to Richard W. Timm and Frederick
E. Shelton, IV, (Docket No. END6096USNP/KLG. No. 070066);
[0005] (4) U.S. patent application entitled "Cable Driven Surgical
Stapling and Cutting Instrument With Improved Cable Attachment
Arrangements" to Frederick E. Shelton, IV and Richard W. Timm,
(Docket No. END6097USNP/KLG. No. 070067); and
[0006] (5) U.S. patent application entitled "Surgical Stapling and
Cutting Instrument With Improved Anvil Opening Features" to Richard
W. Timm, Frederick E. Shelton, IV, and Jeffrey S. Swayze, (Docket
No. END6098USNP/KLG. No. 070068).
FIELD OF THE INVENTION
[0007] The present invention relates in general to endoscopic
surgical instruments including, but not limited to, surgical
stapler instruments that are capable of applying lines of staples
to tissue while cutting the tissue between those staple lines and,
more particularly, to improvements relating to firing and drive
systems therefor.
BACKGROUND
[0008] Endoscopic surgical instruments are often preferred over
traditional open surgical devices since a smaller incision tends to
reduce the post-operative recovery time and complications.
Consequently, significant development has gone into a range of
endoscopic surgical instruments that are suitable for precise
placement of a distal end effector at a desired surgical site
through a cannula of a trocar. These distal end effectors engage
the tissue in a number of ways to achieve a diagnostic or
therapeutic effect (e.g., endocutter, grasper, cutter, staplers,
clip applier, access device, drug/gene therapy delivery device, and
energy device using ultrasound, RF, laser, etc.).
[0009] Known surgical staplers include an end effector that
simultaneously makes a longitudinal incision in tissue and applies
lines of staples on opposing sides of the incision. The end
effector includes a pair of cooperating jaw members that, if the
instrument is intended for endoscopic or laparoscopic applications,
are capable of passing through a cannula passageway. One of the jaw
members receives a staple cartridge having at least two laterally
spaced rows of staples. The other jaw member defines an anvil
having staple-forming pockets aligned with the rows of staples in
the cartridge. The instrument commonly includes a plurality of
wedges that, when driven distally, pass through openings in the
staple cartridge and engage drivers supporting the staples to
effect the firing of the staples toward the anvil.
[0010] An example of such surgical staplers is disclosed in U.S.
Patent Publication No. US 2006/0011699 A1 to Olson et al., the
disclosure of which is herein incorporated by reference. The
stapling devices disclosed therein employs a cable or cables that
are positioned around distally located pins or pulleys and are
fixed to the knife. The ends of the cables are pulled in a proximal
direction. Such system, however, suffers from a low mechanical
advantage and tends to require relatively high forces to pull the
knife through its stroke. Such systems often employ a cable or
cables to close and clamp the end effector that are threaded back
and around a surface in the anvil and terminated at a closure ring.
When the proximal or free end of the cable is pulled, the closure
ring is pulled distally and effects closure of the anvil. Such
systems, however, suffer from limited capacity to generate clamping
force.
SUMMARY
[0011] In one aspect of the invention, there is provided a surgical
instrument that comprises a tool assembly that operably supports a
cable driven knife assembly therein and has an anvil assembly
movably coupled thereto for selective movement between open and
closed positions. A closure ring may operably interface with the
tool assembly for selectively applying at least a closing motion to
the anvil assembly. The instrument may further include a distal
closure tube segment for selectively applying an actuation motion
to the closure ring to cause the closure ring to apply the closing
motion to the anvil assembly. The distal closure tube segment may
be pivotally attached to a closure tube assembly by an articulation
joint that facilitates pivotal travel of the tool assembly relative
to the closure tube assembly.
[0012] In another general aspect of various embodiments of the
present invention there is provided a surgical instrument that
comprises a handle assembly and a cable drive system that is
operably supported by the handle assembly. A proximal closure tube
may be operably coupled to closure tube actuation system that is
operably supported by the handle assembly. A disposable reload unit
may be operably and removably coupled to the proximal closure tube
by a joint assembly. In various embodiments, the disposable reload
unit may comprise a tool assembly that operably supports a knife
assembly therein that is constructed to be driven by the cable
drive system in the handle assembly. An anvil assembly may be
movably coupled to the tool assembly for selective movement between
open and closed positions upon receipt of actuation motions from
the proximal closure tube.
[0013] In still another general aspect of various embodiments of
the present invention there is provided a surgical instrument that
comprises a disposable reload assembly that may include a tool
assembly that operably supports a knife assembly therein and has an
anvil assembly that is selectively movable between open and closed
positions. The reload unit may further comprise a distal spine
segment and a distal closure tube segment that is coupled to the
distal spine segment. A closure ring may be operably coupled to the
distal closure tube segment and the tool assembly such that upon
rotation of the distal closure tube segment, the closure ring is
caused to move axially relative thereto to apply actuation motions
to the anvil assembly. An intermediate spine segment may be coupled
to the distal spine segment by an articulation joint assembly. An
intermediate closure tube segment may be coupled to the
articulation joint to transmit a rotary actuation motion through
the articulation joint to the distal closure tube segment. A knife
screw shaft may be operably supported within the intermediate
closure tube segment and be constructed to rotate in response to a
rotary drive motion applied thereto. A knife nut may be operably
supported on the knife screw shaft. A drive cable may be attached
to the knife assembly and the knife nut. The surgical instrument
may further comprise a handle assembly and a proximal closure tube
assembly that is operably coupled to a closure tube actuation
system that is operably supported by the handle assembly. A rotary
drive shaft may be operably coupled to a rotary drive system
supported by the handle assembly. A quick disconnect joint may be
used to operably interconnect the intermediate closure tube segment
with the proximal closure tube segment. The quick disconnect joint
may further connect the intermediate spine segment to the proximal
spine segment and also interconnect the knife screw to the knife
drive shaft without the use of tools.
[0014] These and other objects and advantages of the present
invention shall be made apparent from the accompanying drawings and
the description thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0015] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate embodiments of
the invention, and, together with the general description of the
invention given above, and the detailed description of the
embodiments given below, serve to explain various principles of the
present invention.
[0016] FIG. 1 is a perspective view of a surgical stapling and
severing instrument of various embodiments of the present
invention.
[0017] FIG. 2 is an exploded perspective view of a tool assembly
depicted in FIG. 1.
[0018] FIG. 3 is a right perspective view of the tool assembly of
FIG. 1 with some components thereof shown in cross-section.
[0019] FIG. 4 is a left side partial cross-sectional view of the
tool assembly depicted in FIGS. 2 and 3.
[0020] FIG. 5 is a bottom perspective view with some parts
separated therefrom of a cartridge assembly of various embodiments
of the present invention.
[0021] FIG. 6 is an exploded assembly view of a sled, staples and
staple pushers of various embodiments of the present invention.
[0022] FIG. 7 is a perspective view of an anvil assembly of various
embodiments of the present invention.
[0023] FIG. 8 is a perspective view of a dynamic clamping member of
various embodiments of the present invention.
[0024] FIG. 9 is a side cross-sectional view of the tool assembly
depicted in FIGS. 1-4 with tissue clamped therein.
[0025] FIG. 10 is a bottom perspective view of an elongate channel
assembly of various embodiments of the present invention.
[0026] FIG. 11 is a perspective view of a proximal portion of the
elongate channel assembly of FIG. 10.
[0027] FIG. 12 is a perspective view of distal portion of the
elongate channel assembly of FIGS. 10 and 11.
[0028] FIG. 13 is a cross-sectional elevational view of a distal
portion of the elongate channel assembly of FIGS. 10-12 with the
dynamic clamping member supported therein.
[0029] FIG. 14 is another bottom view of the elongate channel
assembly of FIGS. 10-13.
[0030] FIG. 15 is a diagrammatic side view of a firing system of
various embodiments of the present invention.
[0031] FIG. 15A is a diagrammatic view of another firing system of
various embodiments of the present invention.
[0032] FIG. 16 is a diagrammatic top view of the firing system of
FIG. 15.
[0033] FIG. 16A is a diagrammatic view of the firing system of FIG.
15A.
[0034] FIG. 17 is a front perspective view of a winch assembly of
various embodiments of the present invention.
[0035] FIG. 18 is a rear perspective view of the winch assembly
embodiment of FIG. 17.
[0036] FIG. 19 is a right side elevational view of the winch
assembly embodiment of FIGS. 17 and 18.
[0037] FIG. 20 is a cross-sectional view of the winch assembly
embodiment of FIGS. 17-19 in a neutral position.
[0038] FIG. 21 is a perspective view of a drive system embodiment
of the present invention.
[0039] FIG. 22 is a partial cross-sectional view of another
embodiment of the present invention that employs an articulation
joint.
[0040] FIG. 23 is an enlarged partial cross-sectional view of the
articulation joint depicted in FIG. 22.
[0041] FIG. 24 is an enlarged cross-sectional view of a portion of
the instrument depicted in FIG. 22.
[0042] FIG. 25 is a bottom view of another elongate channel
assembly embodiment of the present invention.
[0043] FIG. 26 is an enlarged view of a distal end portion of the
elongate channel assembly of FIG. 25.
[0044] FIG. 27 is a cross-sectional view of a portion of the distal
end of the elongate channel assembly of FIG. 26 taken along line
27-27 in FIG. 26.
[0045] FIG. 28 is a portion of a bottom view of a distal end of
another elongate channel assembly embodiment of the present
invention with some components shown in cross-section.
[0046] FIG. 29 is a cross-sectional view of the portion of the
elongate channel assembly depicted in FIG. 28 taken along line
29-29 in FIG. 28.
[0047] FIG. 30 is a diagrammatical top view of another cable
arrangement that employs a cable tensioning joint of various
embodiments of the present invention.
[0048] FIG. 31 is another diagrammatical top view of the cable
arrangement of FIG. 30 with the cable tensioning joint in a fully
expanded position.
[0049] FIG. 32 is another diagrammatical top view of the cable
arrangement of FIGS. 30 and 31 in an articulated position.
[0050] FIG. 33 is an enlarged partial view of the cable tensioning
joint depicted in FIGS. 30-32.
[0051] FIG. 34 is a perspective view of a cable embodiment of the
present invention.
[0052] FIG. 35 is an enlarged view of a cable attachment joint
embodiment of the present invention.
[0053] FIG. 36 is a cross-sectional view of a cable anchor joint
embodiment of the present invention attached to a dynamic clamping
assembly.
[0054] FIG. 37 is a perspective view of the cable anchor joint of
FIG. 36.
[0055] FIG. 38 is a cross-sectional view of another cable anchor
joint embodiment of the present invention attached to a dynamic
clamping assembly.
[0056] FIG. 39 is a partial view of another cable attachment
embodiment of the present invention.
[0057] FIG. 40 is a partial view of another cable attachment
embodiment of the present invention.
[0058] FIG. 41 is a partial perspective view of an articulation
joint arrangement.
[0059] FIG. 42 is a perspective view of a closure tube joint
assembly embodiment of the present invention.
[0060] FIG. 43 is a cross-sectional view of the closure tube joint
assembly embodiment of FIG. 42 taken along line 43-43.
[0061] FIG. 44 is a perspective view of the closure tube joint
assembly of FIGS. 42 and 43 installed over the articulation joint
depicted in FIG. 41.
[0062] FIG. 44A is a perspective view of another closure tube joint
assembly embodiment of the present invention installed over the
articulation joint of FIG. 41.
[0063] FIG. 45 is a perspective view of another anvil assembly
embodiment of the present invention.
[0064] FIG. 46 is an exploded perspective view of a handle assembly
and a closure tube actuation arrangement of an embodiment of the
present invention.
[0065] FIG. 47 is a partial cross-sectional view of a handle
assembly and tool assembly of an embodiment of the present
invention, with some components thereof shown in solid view and the
anvil assembly in a closed or clamped position.
[0066] FIG. 48 is a partial cross-sectional view of a closure tube
assembly and a tool assembly of an embodiment of the present
invention with the anvil assembly in a closed or clamped
position.
[0067] FIG. 49 is another partial cross-sectional view of the
handle assembly and tool assembly of FIG. 47 with the anvil
assembly thereof in an open position.
[0068] FIG. 50 is another partial cross-sectional view of the
closure tube assembly and tool assembly of FIG. 48 with the anvil
assembly thereof in an open position.
[0069] FIG. 51 is a partial cross-sectional view of a closure tube
and a closure ring of another embodiment of the present
invention.
[0070] FIG. 52 is a partial perspective cross-sectional view of a
universal articulation joint arrangement of another embodiment of
the present invention.
[0071] FIG. 53 is a cross-sectional view of a tool assembly and
articulation joint of FIG. 52.
[0072] FIG. 54 is a top view of the tool assembly and articulation
joint of FIG. 53.
[0073] FIG. 55 is a cross-sectional view of another universal
articulation joint of another embodiment of the present
invention.
[0074] FIG. 56 is a perspective view of a cable controlled lockable
articulation joint embodiment of the present invention.
[0075] FIG. 57 is an end view of the cable controlled lockable
articulation joint embodiment of FIG. 56.
[0076] FIG. 58 is a cross-sectional view of another cable
controlled lockable articulation joint of another embodiment of the
present invention.
[0077] FIG. 59 is a partial perspective end view of a proximal
spine segment of the cable-controlled lockable articulation joint
of FIG. 58.
[0078] FIG. 60 is an end view of the proximal spine segment of FIG.
59.
[0079] FIG. 61 is a partial side view of the proximal spine segment
of FIGS. 59 and 60.
[0080] FIG. 62 a cross-sectional view of another lockable
articulation joint of another embodiment of the present
invention.
[0081] FIG. 63 is a partial perspective end view of a proximal
spine segment of the lockable articulation joint of FIG. 62.
[0082] FIG. 64 is an end view of the proximal spine segment of FIG.
63.
[0083] FIG. 65 a cross-sectional view of another lockable
articulation joint of another embodiment of the present
invention.
[0084] FIG. 66 is a partial perspective end view of a proximal
spine segment of the lockable articulation joint of FIG. 65.
[0085] FIG. 67 is an end view of the proximal spine segment of FIG.
66.
[0086] FIG. 68 a cross-sectional view of another lockable
articulation joint of another embodiment of the present
invention.
[0087] FIG. 69 is a partial perspective end view of a proximal
spine segment of the lockable articulation joint of FIG. 68.
[0088] FIG. 70 is an end view of the proximal spine segment of FIG.
69.
[0089] FIG. 71 a cross-sectional view of another lockable
articulation joint of another embodiment of the present
invention.
[0090] FIG. 72 a cross-sectional view of another lockable
articulation joint of another embodiment of the present
invention.
[0091] FIG. 73A is a partial cross-sectional view of a tool
assembly and articulation joint of another surgical instrument
embodiment of the present invention.
[0092] FIG. 73B is a partial cross-sectional view of the closure
tube assembly of the surgical instrument of FIG. 73A.
[0093] FIG. 74A is another partial cross-sectional view of a tool
assembly and articulation joint of the surgical instrument of FIGS.
73A and 73B.
[0094] FIG. 74B is another partial cross-sectional view of the
closure tube assembly of the surgical instrument of FIGS. 73A and
73B.
[0095] FIG. 75 is a cross-sectional view through the closure tube
assembly depicted in FIG. 74A taken along line 75-75 in FIG.
74A.
[0096] FIG. 76 is another cross-sectional view of the closure tube
assembly depicted in FIG. 74B taken along line 76-76 in FIG.
74B.
[0097] FIG. 77 is another cross-sectional view of the closure tube
assembly depicted in FIG. 74B taken along line 77-77 in FIG.
74B.
[0098] FIG. 78 is a partial exploded assembly view of a quick
disconnect joint of an embodiment of the present invention with the
components thereof shown in cross-section.
[0099] FIG. 79 is another partial exploded assembly view of the
quick disconnect joint of FIG. 78.
[0100] FIG. 80 is another partial exploded assembly view of the
quick disconnect joint of FIGS. 78 and 79.
[0101] FIG. 81 is another partial exploded assembly view of the
quick disconnect joint of FIGS. 78-80.
[0102] FIG. 82 is a cross-sectional view of another handle assembly
embodiment of the present invention.
[0103] FIG. 83 is a diagrammatic end view of a drive system of
various embodiments of the present invention.
[0104] FIG. 84 is a partial perspective view of a brake release
mechanism of various embodiments of the present invention.
[0105] FIG. 85 is a partial perspective view of another
articulation joint embodiment of various embodiments of the present
invention.
[0106] FIG. 86 is an exploded assembly view of the articulation
joint of FIG. 85.
[0107] FIG. 87 is a partial side elevational view of the
articulation joint of FIGS. 85 and 86.
[0108] FIG. 88 is a top view of the articulation joint of FIG.
87.
[0109] FIG. 89 is another top view of the articulation joint of
FIGS. 87 and 88 in an articulated position.
[0110] FIG. 90 is a partial perspective view of another tool
assembly and closure tube arrangement of various embodiments of the
present invention with a portion of the closure tube shown in
cross-section.
[0111] FIG. 91 is a cross-sectional elevational view of the tool
assembly and closure tube arrangement of FIG. 90 with the trunnion
lock bar in a locked position retaining the trunnions in their
respective slots.
[0112] FIG. 92 is a partial top view of the tool assembly and
closure tube arrangement of FIG. 91 with portions thereof shown in
cross-section.
[0113] FIG. 93 is a cross-sectional elevational view of the tool
assembly and closure tube arrangement of FIGS. 90-92 with the
trunnion lock bar in an unlocked position.
[0114] FIG. 94 is a partial top view of the tool assembly and
closure tube arrangement of FIG. 93 with portions thereof shown in
cross-section.
[0115] FIG. 95 is a cross-sectional elevational view of the tool
assembly and closure tube arrangement of FIGS. 90-92 with the
trunnion lock bar in an unlocked position and the trunnions moved
out of the trunnion slots in the elongate channel assembly.
[0116] FIG. 96 is a side elevational view of a dynamic clamping
assembly of various embodiments of the present invention.
[0117] FIG. 97 is a side elevational view of another dynamic
clamping assembly of various embodiments of the present
invention.
[0118] FIG. 98 is a side elevational view of another dynamic
clamping assembly of various embodiments of the present
invention.
[0119] FIG. 99 is a side elevational view of another dynamic
clamping assembly of various embodiments of the present
invention.
[0120] FIG. 100 is another side elevational view of the dynamic
clamping assembly of FIG. 99 after the slot has been opened and the
pin removed.
[0121] FIG. 101 is a side elevational view of another dynamic
clamping assembly of various embodiments of the present
invention.
[0122] FIG. 102 is a side elevational view of another dynamic
clamping assembly of various embodiments of the present
invention.
[0123] FIG. 103 is a partial cross-sectional view of the dynamic
clamping assembly of FIG. 102 taken along line 1030-103 in FIG.
102.
[0124] FIG. 104 is a side elevational view of a portion of another
surgical instrument embodiment of the present invention with a
closure ring moved in its distal-most position and with some
components thereof shown in cross-section.
[0125] FIG. 105 is a side elevational view of the surgical
instrument embodiment of FIG. 104 with the closure ring moved in
its proximal-most position and with some components thereof shown
in cross-section.
DETAILED DESCRIPTION
[0126] Certain exemplary embodiments will now be described to
provide an overall understanding of the principles of the
structure, function, manufacture, and use of the devices and
methods disclosed herein. One or more examples of these embodiments
are illustrated in the accompanying drawings. Those of ordinary
skill in the art will understand that the devices and methods
specifically described herein and illustrated in the accompanying
drawings are non-limiting exemplary embodiments and that the scope
of the various embodiments of the present invention is defined
solely by the claims. The features illustrated or described in
connection with one exemplary embodiment may be combined with the
features of other embodiments. Such modifications and variations
are intended to be included within the scope of the present
invention.
[0127] Turning to the Drawings, wherein like numerals denote like
components throughout the several views, FIG. 1 depicts a surgical
instrument, which in the illustrative versions is more particularly
a surgical stapling and severing instrument 1, capable of
practicing certain unique benefits of the present invention.
Instrument 1 may essentially comprise a surgical stapler of the
form and construction disclosed in the previously cited U.S. Patent
Publication No. 2006/0011699 A1, which has been herein incorporated
by reference in its entirety, with one or more of the improvements
described below. As the present Detailed Description proceeds,
however, those of ordinary skill in the art will appreciate that
the various embodiments and improvements described herein may be
incorporated in connection with other surgical stapler
constructions without departing from the spirit and scope of the
present invention.
[0128] As shown in FIG. 1, the instrument 1 may include a housing 3
that has distal and proximal ends 4 and 6, respectively, an
elongated shaft 20 mounted to housing 3, preferably to its distal
end 4, and a handle assembly generally designated as 5. Shaft 20
may have a distal end 20a to which may be operatively attached by
attachment mechanism 20b to a disposable loading unit 10. As also
shown in FIG. 1, disposable loading unit (DLU) 10 may comprise a
tool assembly 100 and a shaft connector portion 20c which may be
pivotally and operatively attached to each other through connector
mechanism C.
[0129] It is within the scope of this disclosure that tool assembly
100 may be pivotally, operatively, or integrally attached, for
example, through a connection mechanism such as C permanently and
directly to distal end 20a of shaft 20 of a disposable surgical
stapler. As is known, a used or spent disposable loading unit 10
can be removed from shaft 20 of a reusable or disposable open,
endoscopic or laparoscopic surgical stapler, and replaced with an
unused disposable unit. In various embodiments, it is contemplated
that shaft 20 with or without an integral or removably attached
disposable loading unit can be selectively removable from the
housing 3.
[0130] Shaft connector portion 20c includes a proximal end 24 and a
distal end 22. As mentioned above, the proximal end 24 can be
permanently or removably associated with a handle or other
actuating assemblies of a manually (or other, e.g., robotic or
computer) operated open or endoscopic surgical stapler 1. Distal
end 22 of shaft connector portion 20c is operatively connected to
tool assembly 100. Tool assembly 100, in general, may include an
elongate channel assembly 120, an anvil assembly 110, and a staple
cartridge assembly 200. Tool assembly 100 may also preferably
include an actuator, preferably a dynamic clamping member 150, a
sled 160, as well as staple pushers 228 and staples 350 once an
unspent or unused cartridge 200 is mounted in elongate channel
assembly 120. See FIGS. 2, 5, and 6.
[0131] It will be appreciated that the terms "proximal" and
"distal" are used herein with reference to a clinician gripping a
handle of an instrument. Thus, the tool assembly 100 is distal with
respect to the more proximal handle assembly 5. It will be further
appreciated that, for convenience and clarity, spatial terms such
as "vertical" and "horizontal" are used herein with respect to the
drawings. However, surgical instruments are used in many
orientations and positions, and these terms are not intended to be
limiting and absolute.
[0132] Shaft connector portion 20c may be cylindrical in shape and
define an internal channel 25 which may be dimensioned to receive a
tube adapter 40. See FIG. 2. Shaft connector portion 20c may also
receive or house actuators for actuating tool assembly 100. Tool
assembly 100 may mount to distal end 22 of shaft connector 20c (or
the distal end 20a of shaft 20). In various embodiments, tool
assembly 100 may be mounted onto tube adapter 40 which includes an
outer cylindrical surface 47 that may be slidingly received in
friction-fit engagement with the internal channel 25 of shaft
connector 20c (or, again, to shaft 20). Herein, the description of
the proximal connection or attachment of tool assembly 100 to shaft
connector 20c may also apply to its connection to shaft 20. The
outer surface 47 of the tube adapter 40 may further include at
least one mechanical interface, e.g., a cutout or notch 45,
oriented to mate with a corresponding mechanical interface, e.g., a
radially inwardly extending protrusion or detent (not shown),
disposed on the inner periphery of internal channel 25 to lock the
tube adapter 40 to the shaft connector 20c.
[0133] In various embodiments, the distal end of tube adapter 40
may include a pair of opposing flanges 42a and 42b which define a
cavity 41 for pivotably receiving a pivot block 50 therein. Each
flange 42a and 42b may include an aperture 44a and 44b oriented to
receive a pivot pin 57 that extends through an aperture in pivot
block 50 to allow pivotable movement of pivot block 50 about a "Z"
axis defined as perpendicular to longitudinal axis "X" of tool
assembly 100. See FIG. 3. As will be explained in more detail
below, the channel assembly may be formed with two upwardly
extending flanges 121a, 121b that have an aperture 122a, 122b,
respectively, which are dimensioned to receive a pivot pin 59. In
turn, pivot pin 59 mounts through apertures 53a, 53b of pivot block
50 to permit rotation of the tool assembly 100 about the "Y" axis
as needed during a given surgical procedure. Rotation of pivot
block 50 about pin 57 along "Z" axis rotates tool assembly 100
about the "Z" axis. Other methods of fastening the channel 120 to
the pivot block and of fastening the anvil to the channel may be
effectively employed without departing from the spirit and scope of
the present invention.
[0134] In various embodiments, an actuator or a plurality of
actuators (not shown) preferably pass through shaft connector
portion 20c, tube adapter 40, and pivot block 50 and operably
connect to tool assembly 100 to permit the surgeon to articulate
tool assembly 100 about the "Y" and "Z" axes as needed during a
surgical procedure. In addition, shaft 20 of surgical stapler 1 may
be rotatable 360.degree. by the rotation of knob "K". As a result,
tool assembly 100 may be articulatable at least 90.degree. in all
directions. Various actuators, hand assemblies, and pivot blocks
are envisioned which can be utilized to accomplish this task some
of which are identified in U.S. Pat. Nos. 6,250,532 and 6,330,965,
the entire contents of which are each hereby incorporated by
reference herein.
[0135] As mentioned above, in various embodiments, tool assembly
100 may include anvil assembly 110 and elongate channel assembly
120. See FIG. 2. Elongate channel assembly 120 may support the
staple cartridge assembly 200, an actuator, e.g., a dynamic
clamping member 150, and a sled 160. As such, these various
assemblies and their respective internal components, when
assembled, cooperate to allow the tool assembly to manipulate,
grasp, clamp, fasten and, preferably, sever tissue during a given
surgical procedure as explained below. Elongate channel assembly
120 may include a bottom surface 128 having upwardly extending side
walls or flanges 121a and 121b which define elongated support
channel 125 which, in turn, is dimensioned to mountingly receive
staple cartridge assembly 200 therein. Elongate channel assembly
120 may also include a plurality of mechanical interfaces 127a,
127b, 127c, 127d oriented to receive a corresponding plurality of
mechanical interfaces 235a, 235b, 235c, and 235d disposed in the
outer-facing surfaces of staple cartridge assembly 200. See FIGS. 2
and 6.
[0136] Staple cartridge assembly 200 mounts within the elongate
channel assembly 120 and includes an upper tissue contacting or
facing surface 231 which, as will become further apparent as the
present Detailed Description proceeds, opposes a tissue contacting
or facing bottom anvil surface 114b of anvil assembly 110. Staple
cartridge assembly 200 can be assembled and mounted within elongate
channel assembly 120 during the manufacturing or assembly process
and sold as part of overall tool assembly 100, or staple cartridge
assembly 200 may be designed for selective mounting to channel
assembly 120 as needed and sold separately, e.g., as a single use
replacement, replaceable or disposable staple cartridge assembly
200. For example, staple cartridge assembly 200 may be manufactured
to include sled 160 and dynamic clamping member 150. Alternatively
dynamic clamping member 150 with a knife 155 may be sold as part of
the replaceable staple cartridge assembly 200 without a knife blade
155a (but preferably with a knife blade 155a) to enhance and/or
insure accurate cutting of tissue after staple formation. Tool
assembly 100 may also be sold as a kit that includes a variety of
staple cartridges 200 containing surgical fasteners 350 of
different sizes, and/or arranged to be ejected in different
patterns, any of which may be selectively-coupled to the elongate
channel assembly 120 as desired for use during a particular
operation.
[0137] As best seen in FIG. 6, sled 160 may include a pair of
upwardly-extending cam wedges 161a and 161b which, when actuated to
move by the user, cam a series of surgical fasteners 350 or staples
into and through the tissue and against staple forming pockets 111
(shown in FIG. 9) of anvil assembly 110 to form the fasteners 350
and fasten tissue therewith. Dynamic clamping member 150 is
associated with, e.g., mounted on and rides on, or with or is
connected to or integral with and/or rides behind sled 160. It is
envisioned that dynamic clamping member 150 can have cam wedges or
cam surfaces attached or integrally formed or be pushed by a
leading distal surface thereof.
[0138] In various embodiments, dynamic clamping member 150 may
include an upper portion 157 having a transverse aperture 154 with
a pin 159 mountable or mounted therein, a central support or upward
extension 151 and substantially T-shaped bottom flange 152 which
cooperate to slidingly retain dynamic clamping member 150 along an
ideal cutting path during longitudinal, distal movement of sled
160. See FIG. 8. The leading cutting edge 155, here, knife blade
155a, is dimensioned to ride within slot 282 of staple cartridge
assembly 200 and separate tissue 400 once stapled. It is envisioned
that leading edge 153a of the dynamic clamping member 150 may be
serrated, beveled or notched to facilitate tissue cutting. In some
embodiments, for example, the upper camming member need not be a
pin but can be any integral or removable suitable outwardly
protruding cam surface(s). The same applies to bottom flange 152
which can be any suitable camming surface, including a pin or a
removable pin, a button to facilitate mounting of the dynamic
clamping member into the sled 160 or elongate channel assembly 120.
As used herein, the term "knife assembly" 170 may include the
aforementioned dynamic clamping member 150, knife 155, and sled 160
or other knife/beam/sled drive arrangements. In addition, the
various embodiments of the present invention may be employed with
knife assembly arrangements that may be entirely supported in the
staple cartridge or partially supported in the staple cartridge and
elongate channel assembly or entirely supported within the elongate
channel assembly.
[0139] As best shown in FIG. 10, the elongate channel assembly 120
has a distal end 123 and proximal end 123'. The bottom surface 128
of the elongate channel assembly 120 also includes an elongated
longitudinal slot 126 which includes and communicates at its
proximal end with a cut out or notch 129. Notch 129 is dimensioned
to allow bottom flange 152 of dynamic clamping member 150 to pass
therethrough. The narrower portion of slot 126 is dimensioned to
slidingly receive and allow upward support or extension 151 to pass
therethrough. See FIG. 13. Other dynamic clamping members 150,
channel slots, and sled configurations may be employed.
[0140] When tool assembly 100 is assembled, sled 160 may be
slidingly positioned between the staple cartridge assembly 200 and
the elongate channel assembly 120 (See FIG. 3). Sled 160 and the
inner-working components of staple cartridge assembly 200 detailed
above operatively cooperate to deform staples 350. More
particularly, as indicated above, sled 160 may include upwardly
extending, bifurcated cam wedges 161a and 161b which engage and
cooperate with a series of staple pushers 228 to drive staples 350
through slots 225 from cartridge assembly 200 and deform against
staple forming pockets 11 of anvil assembly 100. Further details of
a sled 160, dynamic clamping member 150 and the staple cartridge
assembly 200 of various embodiments are further described in U.S.
Publication No. US 2006/0011699 A1.
[0141] As shown in FIGS. 2 and 7, anvil assembly 110 may be
elongated and include a proximal end 116, a distal end 118, and top
and bottom surfaces 114a and 114b, respectively. A pair of
trunnions 119a and 119b may be disposed near proximal end 116 and
are designed for pivotable engagement with corresponding pair of
notches 123a and 123b provided in the sidewalls 121a, 121b near the
proximal end of the elongate channel assembly 120. It is
contemplated that actuation by conventional means (e.g., activated
remotely, e.g., by a handle assembly 5 will cause clamping collar
140 to move in a distal direction and engage forward cam surface
115 of anvil assembly 110. This will cause the anvil assembly 110
to pivot from an open first position wherein the anvil assembly 110
and the elongate channel assembly 120 are disposed in spaced
relation relative to one another to a second closed position
wherein anvil assembly 110 and staple cartridge assembly 200
cooperate to grasp tissue therebetween, i.e., pre-clamp the tissue
between tissue engaging surface 114b of anvil assembly 110 and
opposing tissue engaging surface 231 of staple cartridge assembly
200. However, other anvil assembly arrangements may be successfully
employed.
[0142] In various embodiments, anvil assembly 110 may include an
elongated cross or T-shaped channel or slot generally designated
112 having a depending central portion or leg 112a and a transverse
upper portion 112b. See FIG. 7. Slot 112 preferably extends
longitudinally from proximal end 113 of upper portion 114a of the
anvil assembly 110 to the distal end 118 thereof. Leg 112a starts
from or enters proximal end 113 of anvil assembly 110 and extends
to distal end 118 and upper transverse portion 112b starts proximal
cam 115 and extends to distal end 118. See FIG. 7. Preferably,
upper portion 112b is dimensioned to slidingly receive transverse
pin 159 that extends within aperture 154 in upper portion 157 of
central support or extension 157 of dynamic clamping member 150
(see FIG. 9). Pin 159 is dimensioned to slidingly lock the upper
portion 157 of dynamic clamping member 150 within the T-shaped slot
112 such that the dynamic clamping member 150 is
longitudinally-reciprocatable within slot 112.
[0143] In various embodiments, pre-clamping collar 140 may be
designed to encompass and clamp or pre-clamp the channel assembly
120 and the anvil assembly 110 together in an approximated and
clamped position prior to tissue fastening. By moving pre-clamping
collar 140 distally, the user can actuate/move the anvil assembly
110 from an open, first position toward channel assembly 120 to
approximate the jaws, i.e., the anvil assembly 110 and staple
cartridge 200, to a second, closed position to grasp tissue
therebetween. The sled 160 can be actuated by the user to staple
and subsequently incise the tissue.
[0144] As best illustrated by FIGS. 4, 8, and 9, during distal
translation of the dynamic clamping member 150 through tissue 400,
the combination of the heavy gauge material of the anvil assembly
110 and the substantially vertical alignment of the flange 152,
knife edge 155, and camming pin 159 operate to further proximate
(i.e., further clamp) the opposing tissue engaging surfaces (i.e.,
anvil bottom surface 114b and upper facing surface 231 of staple
cartridge assembly 200) at a moving point which is distal to the
leading edge 155 of the knife 155a. The further clamping of the
tissue 400 distally relative to the translating dynamic clamping
member 150 acts to maintain a maximum acceptable gap between the
opposing surfaces 114b and 231 and forces fluid from the tissue 400
which may enhance stapling and reduce the likelihood of
hydraulically displacing the staples 350 during deformation. It is
contemplated that the combination of the enhanced closure force as
a result of the heavy gauge material of the anvil assembly 110,
together with the above described dynamic clamping member 150,
permits relatively accurate cutting of tissue 400 when leading edge
155 is advanced through tissue 400.
[0145] From the foregoing and with reference to the various
Figures, those skilled in the art will appreciate that certain
modifications can also be made to the present disclosure without
departing from the scope of the present disclosure. For example,
the above-described tool assembly 100 may be part of or
incorporated into a disposable loading unit (DLU) such as disclosed
in U.S. Pat. No. 6,330,965 or attached directly to the distal end
of any known surgical stapling device. A handle assembly for
actuating the approximation member(s) can be selected from a
variety of actuating mechanisms including toggles, rotatable and
slideable knobs, pivotable levers or triggers, and any combination
thereof. The use of the above-described tool assembly 100 as part
of a robotic system is also envisioned.
[0146] FIGS. 10-18 illustrate a single use tool assembly
arrangement. As can be seen in those Figures, a pair of cables,
ropes, threads, bands or belts 800, 820 may be supported by the
channel assembly 120. As can be seen in FIGS. 11 and 12, a first
cable 800 may include an anchor segment 802 that is fixed to a
first point of attachment 803 on the bottom 128 of the elongate
channel assembly 120 at the distal end 123 thereof, an activation
portion 804 that extends to the drive system (not shown) located in
the housing portion 5, and a moving portion 805. As can be most
particularly seen in FIG. 12, the first cable 800 is operably
supported on a first distal cable transition support 830 that may
comprise, for example, a pulley, rod, capstan, etc. mounted to the
bottom 128 at the distal end 123 of the elongate channel assembly
120. The first cable 800 may also be operably supported on a second
cable transition support 840, which may comprise, for example, a
double pulley 840 mounted to the knife assembly 170. In one
embodiment, for example, the second cable transition support is
mounted to the bottom flange portion 152 of the dynamic clamping
member 150. See FIGS. 12 and 13. The first cable 800 may pass
through a longitudinally extending first groove 806 provided in the
bottom 128 of the elongate channel assembly 120. The moving portion
805 may move freely back and forth axially adjacent the slot 126.
The activation portion 804 may pass through a first transition
passage 808 in the bottom 128 of the elongate channel assembly 120
as shown in FIG. 11.
[0147] Also in this embodiment, a second cable 820 may have an
anchor portion 822 that is fixed to the bottom 128 of the elongate
channel assembly 120 at the distal end 123 thereof at a second
point of attachment 803', an activation portion 824 that extends to
the drive system located in the handle housing 5, and a moving
portion 825. The second cable 820 may be operably supported on a
second distal cable transition support 850 which may, for example,
comprise a second pulley, rod, capstan, etc. that is attached to
the distal end 123 of the elongate channel assembly 120 and is also
operably supported on the second cable transition support 840. The
second cable 820 may pass through a longitudinally extending second
groove 826 provided in the bottom 128 of the elongate channel
assembly 120. The moving portion 825 may freely move back and forth
axially adjacent the slot 126. The activation portion 824 may pass
through a second transition passage 828 in the bottom 128 of the
elongate channel assembly 120. See FIG. 11. Those of ordinary skill
in the art will appreciate that such arrangement may provide
improved mechanical advantages over prior cable arrangements and
thereby reduce the amount of firing forces that must be generated
to advance the knife assembly 170 in the form of the dynamic
clamping member 150, knife 155, and sled 160 to fire the staples
350.
[0148] As indicated above, the advancement and retraction of the
knife assembly 170 (i.e., dynamic clamping assembly 150, knife 155,
and sled 160) is controlled by the cables 800, 820 that each have
proximal ends which may be attached, for example, to a cable drive
system which may include, for example, a rotatable take up drum or
drums (not shown) operably supported in the handle 5. The take up
drum or drums may be mechanically or manually rotated or powered by
a motor to rotate the cables 800, 820 thereon. As the cables 800,
820 are taken up on those drums, the knife assembly 170 (dynamic
clamping assembly 150/sled 160 are driven from the proximal end of
the elongate channel 120 to the distal end thereof to complete the
severing and stapling operations. In various embodiments no means
are provided to retract the knife assembly 170 back to the proximal
end of the channel 120, so the tool assembly may not be reused.
[0149] An alternative firing system 1300 embodiment is disclosed in
FIGS. 15-20. As can be seen in FIGS. 15-17, this embodiment employs
an advance cable 1302 that is bifurcated into a pair of advance
cable portions 1310, 1320 and a retract cable 1330 which are
illustrated in diagrammatic form. As can be most particularly seen
in FIG. 16, a first advance cable portion 1310 may be operably
supported on a first distal cable transition support 1340 which may
comprise, for example, a pulley, rod, capstan, etc. that is
attached to the distal end 123 of the elongate channel assembly 120
as was described above. A distal end 1312 of the first advance
cable portion 1310 may be affixed to the knife assembly 170
(dynamic clamping assembly 150). The second advance cable portion
1320 may be operably supported on a second distal cable transition
support 1360 which may, for example, comprise a pulley, rod,
capstan etc. that is mounted to the distal end 123 of the elongate
channel assembly 120. A distal end 1322 of the second advance cable
portion 1320 is attached to the knife assembly 170 (dynamic
clamping assembly 150). Also in these embodiments, a retract cable
1330 is employed. In one embodiment, the retract cable 1330 may be
formed in a loop such that the distal looped end 1332 is fixedly
attached (swaged, etc.) to the dynamic clamping assembly 150.
[0150] In various embodiments, the advance cable 1302 and the
retract cable 1330 may be driven by, for example, a cable drive
system 1000 which, for example, may comprise a manually actuatable
winch assembly 1001 mounted in or otherwise supported by the handle
assembly 5. See FIGS. 17-20. The winch assembly 1000 may include,
for example, an actuator 1002 in the form of a firing trigger 1004
that is pivotally supported by the handle assembly 5. While this
embodiment employs a grippable trigger 1004, those of ordinary
skill in the art will appreciate that the actuator 1002 may
comprise a push button, lever, slide, etc. without departing from
the spirit and scope of the present invention. In the embodiment
depicted in FIGS. 17-20, the winch assembly 1001 may include a
transmission 1010 and first and second rotatable spools 1250, 1260,
respectively, that are supported on a frame assembly 1012.
[0151] In various embodiments, a handle gear segment 1006 may be
formed or otherwise provided on the firing trigger 1004. The handle
gear segment 1006 is mounted in meshing engagement with a primary
drive gear 1040 that is mounted to a shaft 1042 attached to a first
ratchet clutch plate 1052 of a clutch assembly 1050. See FIG. 18. A
second ratchet clutch plate 1060 is supported on a clutch shaft
1062 that is rotatably supported within the handle assembly 5. The
clutch shaft 1062 may be provided with a shoulder portion 1064 and
have a clutch spring 1066 journaled thereon and in contact with a
portion of the housing 3 to bias the second ratchet clutch plate
1060 into meshing engagement with the first ratchet clutch plate
1052. As can also be seen in FIG. 18, a second drive gear 1070 is
journaled on the clutch shaft 1062 and is in meshing engagement
with a third drive gear 1080 that is attached to a first
transmission shaft 1090 that is rotatably supported by a first
transmission bearing or sleeve 1092 mounted in the frame assembly
1012. See FIG. 18. The first transmission shaft 1090 may have a
first pinion gear portion 1100 and a series of first gear teeth
1102 formed thereon for selective meshing engagement with a series
of primary gear teeth 1112 on an axially and rotatably movable
shaft spool 1110. As can be seen in FIG. 20, the shaft spool 1110
is received on a splined shaft 1120 that is rotatably received
within the first transmission shaft 1090 and a second pinion gear
1130. The second pinion gear 1130 has a second pinion gear portion
1132 and a series of second gear teeth 1134 for selective meshing
engagement with secondary gear teeth 1114 on the shaft spool 1110.
The second pinion gear 1130 may be rotatably supported by a second
bearing 1136 mounted 1136 in the frame assembly 1012 as shown. As
can be seen in FIGS. 18 and 20, a reversing bevel gear 1140 is
supported by the frame assembly 1012 in meshing engagement with the
first and second pinion gears 1100, 1130, respectively.
[0152] As can also be seen in FIGS. 18 and 20, the shaft spool 1110
may have a collar portion 1150 formed thereon for receiving two
opposing pins 1162 extending from a yoke 1160 formed on a bottom
portion of a switch bar 1166. The switch bar 1166 may have a shaft
portion 1168 that is pivotally pinned to a crossbar portion 1014 of
the frame assembly 1012. A portion of the shaft 1168 protrudes out
through an opening in the handle case (not shown) and a switch
button 1170 may be attached to the end of the shaft 1168 to enable
the user to shift the shaft 1168 axially back and forth to reverse
the transmission 1010 as will be further discussed below. Those of
ordinary skill in the art will appreciate that the yoke arrangement
1160 enables the shaft spool 1110 to freely rotate relative to the
yoke 1160 while enabling the yoke 1160 to shift the shaft spool
1110 axially on the splined shaft 1120.
[0153] As can be seen in FIG. 20, a shifter output gear 1180 is
keyed or otherwise attached to the splined shaft 1120 for rotation
therewith. The shifter output gear 1180 is arranged in meshing
engagement with a first spool gear 1190 that is attached to the
shaft 1200 of the first rotatable spool 1250. Attached to the other
end of the first rotatable spool shaft 1200 is a first spool
transfer gear 1220. The first spool transfer gear 1220 is in
meshing engagement with a reversing gear 1230 which is meshing
engagement with a second spool drive gear 1240 that is attached to
the shaft 1252 of the second rotatable spool 1260. See FIG. 17. In
various embodiments, the advance cable 1302 may be received on
second (bottom) rotatable spool 1260 and the retraction cable 1330
may be received on the first rotatable spool 1250.
[0154] A method of operating the winch 1000 will now be described
with reference to FIGS. 17-20. Turning to FIG. 20 first, in that
Figure, the shaft spool 1110 is in the neutral position. Thus,
actuation of the firing trigger 1004 will not result in any
movement of the dynamic clamping member 150, knife 155 or sled 160.
To fire the device (advance the dynamic clamping member 150, knife
155, and sled 160 from the proximal end of the elongate channel
assembly 120 to the distal end of the elongate channel assembly
120), the clinician shifts the shifter button 1170 to the position
shown in FIG. 18. In doing so, the primary gear teeth 1112 of the
shaft spool 1110 are brought into meshing engagement with the first
gear teeth 1102 of the first pinion gear 1100. After the shaft
spool 1110 has been moved to that position, the clinician may begin
to pull/pivot the firing trigger 1004 to cause the handle gear
segmental 006 to move in the direction represented by arrow "A" in
FIG. 18. As the firing trigger 1004 continues to pivot, the gear
segment 1006 rotates the primary drive gear 1040 as well as the
clutch assembly 1050 and the second drive gear 1070 in the "B"
direction. As the second drive gear 1070 rotates in that direction,
the third drive gear 1080 is rotated in the opposite "A" direction
which also causes the first pinion gear 1100 to rotate in that
direction. Because the first teeth 1102 of the first pinion gear
1100 are in meshing engagement with the primary teeth 1112 of the
shaft spool 1110, the shaft spool 1110 also rotates in the "A"
direction. As the shaft spool 1110 rotates in the "A" direction,
the splined shaft 1120 and the shifter output gear 1180 also rotate
in that direction. The shifter output gear 1180 is in meshing
engagement with the first spool gear 1190 that is attached to the
shaft 1200 of the first payout spool 1250. As the shifter output
gear is rotated in the "A" direction, the first spool gear 1190 is
rotated in the "B" direction. The first spool transfer gear 1220 is
attached to the shaft 1200 and also rotates in the "B" direction.
As the first spool 1250 rotates in the "B" direction, the retract
cable 1330 is paid off of the first spool 1250. As the first spool
rotates 1250, the first spool transfer gear 1220 rotates in the
same direction. The first spool transfer gear 1220, reversing gear
1230, and second spool drive gear 1240 cause the second spool 1260
to wind up the advance cable 1302 thereon.
[0155] After the firing trigger 1004 has been depressed as far as
it can go (to the end of its stroke), the clinician releases the
firing trigger 1004 and a spring (not shown) or other suitable
arrangement supported by the handle assembly 5 biases the firing
trigger back 1004 to the starting (unfired position). As the firing
trigger 1004 returns to the starting position, the first clutch
plate 1052 rotates backwards ("A" direction) relative to the second
clutch plate 1060 while the second clutch plate 1060 remains
stationary and does not move. The user can then depress the firing
trigger 1004 again until the dynamic clamping member 150, knife
155, and sled 160 have been completely advanced to the end distal
position within the channel assembly 120 by the advance cable
1302.
[0156] To retract (move the knife assembly 170 in the proximal
direction "PD" to a starting position) the dynamic clamping
assembly 150, the knife 155, and the sled 160 (knife assembly 170),
the clinician shifts the shifter button 1170 to bring the secondary
gear teeth 1114 of the shaft spool 1110 into meshing engagement
with the second gear teeth 1134 on the second pinion gear 1130.
After the shaft spool 1110 has been moved to that position, the
clinician may begin to pull/pivot the firing trigger 1004 in the
manner described above. As the firing trigger 1004 continues to
pivot, the gear segment 1006 rotates the primary drive gear 1040 as
well as the clutch assembly 1050 and the second drive gear 1070 in
the "B" direction. As the second drive gear 1070 rotates in that
direction, the third drive gear 1080 is rotated in the opposite "A"
direction which also causes the first pinion gear 1100 to rotate in
that direction. As the first pinion gear 1100 rotates, it causes
the reversing bevel gear 1140 to rotate and cause the second pinion
gear 1130 to rotate in the "B" direction. Because the secondary
teeth 1114 of the shaft spool 1110 are in meshing engagement with
the second teeth 1134 of the second pinion gear 1130, the shaft
spool 1110 and the splined shaft 1120 rotate in the "B" direction.
The shift output gear 1180 causes the first spool transfer gear
1220 to rotate in the "A" direction. As the first spool transfer
gear 1220 rotates in the "A" direction, the retract cable 1330 is
wound onto the first spool 1250. As the first spool rotates 1250,
the first spool transfer gear 1220 rotates in the same direction.
The first spool transfer gear 1220, reversing gear 1230 and second
spool drive gear 1240 cause the second spool 1260 to rotate to
payout the advance cable 1302 therefrom.
[0157] After the firing trigger 1004 has been depressed as far as
it can go (to the end of its stroke), the user releases the firing
trigger 1004 and a spring (not shown) supported by the handle
assembly 5 biases the firing trigger back 1004 to the staring
(unfired position). As the firing trigger 1004 returns to the
starting position, the first clutch plate 1052 rotates backwards
relative to the second clutch plate 1060 while the second clutch
plate 1060 remains stationary and does not move. The user can then
depress the firing trigger 1004 again until the dynamic clamping
member 150, knife 155, and sled 160 have been completely retracted
into a starting position within the elongate channel assembly 120
by the retract cable 1330.
[0158] In an embodiment depicted in FIGS. 18 and 20, the first
rotatable spool 1250 and the second rotatable spool 1260 are
tapered. That is, they have a decreasing diameter along their
respective axial directions. Thus, the winch assembly 1001 has the
ability to change the mechanical advantage as it takes up cable. In
this embodiment, the advance cable 1302 is attached to spool 1260
and the retract cable 1330 is attached to spool 1250 such that the
greatest take up force is generated at the beginning of the firing
process. If the winch assembly 1001 is turned at a constant torque,
cable is taken up on the spool and the change in the spool's
diameter would change the force transmitted to the cable. Such
arrangement is particularly advantageous when the largest
frictional or resistive forces that must be overcome during the
firing process occur at the beginning of the firing sequence. If,
however, the largest frictional and resistive forces are expected
to be encountered toward the end of the firing process, the cables
1302, 1330 could be attached to the other ends (the smaller ends)
of their respective spools 1260, 1250. In still other embodiments,
if the largest resistive and friction forces are encountered midway
during the firing process, each of the spools 1250, 1260 may have a
central portion that has a larger diameter than the diameters of
the end portions of the spools. Such unique and novel spool
configurations, along with the unique and novel pulley arrangements
describe above, enable the device to be designed to address
different frictional and resistive forces encountered during the
firing sequence and represent a vast improvement over prior cable
related drive systems employed in connection with surgical stapling
instruments.
[0159] While the cable drive system 1000 described above comprises
a manually actuatable drive system, other contemplated embodiments
of the present invention may employ a battery powered motor or
motors, alternating current powered motor or motors or
pneumatically powered motors to power the cable drive systems.
Thus, the protection afforded to the various embodiments of the
present invention should not solely be limited to surgical
instruments that are manually actuatable.
[0160] FIGS. 15A, 16A, and 21 illustrate another improved firing
system embodiment 1300' of the present invention. As can be seen in
FIGS. 15A and 16A, this embodiment employs a pair of advance cables
1310', 1320' and a retract cable 1330. FIGS. 15A and 16A,
illustrate the cables 1310', 1320', and 1330 in diagrammatic form.
As can be seen in those Figures, a first advance cable 1310' is
operably supported on a first distal cable transition support 1340
which may comprise, for example, a pulley, rod, capstan, etc. that
is attached to the distal end 123 of the elongate channel assembly
120 as was described above and a first proximal cable transition
support 1350 which may comprise, for example, a pulley, rod,
capstan, etc. 1350 that is operably supported by the elongate
channel assembly 120. A distal end 1312' of the first advance cable
1310' is affixed to the knife assembly 170 (dynamic clamping
assembly 150) and the proximal end 1314' of the first advance cable
1310' is attached to a connector 1380 attached to a reciprocatable
drive member 1390. As can be seen in FIGS. 15A and 16A, the first
distal cable transition support 1340 may be oriented such that its
axis of rotation is substantially perpendicular to the axis of
rotation of the first proximal cable transition support 1350. The
second advance cable 1320' is operably supported on a second distal
cable transition support 1360 which may, for example, comprise a
pulley, rod, capstan etc. that is mounted to the distal end 123 of
the elongate channel assembly 120 and a second proximal cable
transition support 1370 which may, for example, comprise a pulley,
rod, capstan, etc. mounted to the proximal end of the elongate
channel assembly 120. The proximal end 1322' of the second advance
cable 1320 may be attached to the knife assembly 170 (dynamic
clamping assembly 150) and the proximal end 1324' may be attached
to the connector 1380'. Also in these embodiments, a retract cable
1330 is employed. In one embodiment, the retract cable 1300 may be
formed in a loop such that the distal looped end 1332 is fixedly
attached (swaged, etc.) to the dynamic clamping assembly 150 and
the two proximal ends 1334, 1336 are each fixedly attached (swaged,
etc.) to the connector 1380.
[0161] Those of ordinary skill in the art will understand that the
dynamic clamping assembly 150, knife 155, and sled 160 may be
advanced in the distal direction ("DD") when the drive rod 1390 is
also advanced in the distal direction "DD". To retract the knife in
the proximal direction "PD", the drive rod 1390 is moved in the
proximal direction "PD". In various embodiments, the drive rod 1390
may be selectively advanced and retracted by a drive system 1400
that is somewhat similar in operation as to the operation of the
winch assembly 1001, except for the differences discussed below. In
particular, as can be seen in FIG. 21, a handle gear segment 1006
may be formed or otherwise provided on the firing trigger (not
shown). The handle gear segment 1006 may be mounted in meshing
engagement with a primary drive gear 1040 that is mounted to a
shaft (not shown) attached to a first ratchet clutch plate 1052 of
a clutch assembly 1050. A second ratchet clutch plate 1060 is
supported on a clutch shaft 1062 that is rotatably supported within
the handle assembly 5. The clutch shaft 1062 may be provided with a
shoulder portion (not shown) and have a clutch spring 1066
journaled thereon to bias the second ratchet clutch plate 1060 into
meshing engagement with the first ratchet clutch plate 1050.
[0162] A second drive gear 1070 may be journaled on the clutch
shaft 1062 and is in meshing engagement with a third drive gear
1080 that is attached to a first transmission shaft 1090 that is
rotatably supported by a first transmission bearing or sleeve (not
shown) mounted in the frame assembly 1012'. The first transmission
shaft 1090 has a first pinion gear portion 1100 and a series of
first gear teeth 1102 formed thereon for selective meshing
engagement with a series of primary gear teeth 1112 on a an axially
and rotatably movable shaft spool 1110. The shaft spool 1110 is
received on a splined shaft (not shown) 1120 that is rotatably
received within the first transmission shaft 1090 and a second
pinion gear 1130. The second pinion gear 1130 has a second pinion
gear portion 1132 and a series of second gear teeth 1134 for
selective meshing engagement with secondary gear teeth 1114 on the
shaft spool 1110. The second pinion gear 1130 may be rotatably
supported by a second bearing (not shown) mounted in the frame
assembly 1012' as shown.
[0163] A reversing bevel gear 1140 is supported by the frame
assembly 1012' in meshing engagement with the first and second
pinion gears 1100, 1130, respectively. The shaft spool 1110 has a
collar portion 1150 formed thereon for receiving two opposing pins
1162 extending from a yoke 1160 formed on a bottom portion of a
switch bar 1166. The switch bar 1166 has a shaft portion 1168 that
is pivotally pinned to a crossbar portion 1014' of the frame
assembly 1012'. A portion of the shaft 1168 protrudes out through
an opening in the handle case (not shown) and a switch button 1170
may be attached to the end of the shaft 1168 to enable the user to
shift the shaft 1168 axially back and forth to reverse the drive
1400 as will be further discussed below. Those of ordinary skill in
the art will appreciate that the yoke arrangement 1160 enables the
shaft spool 1110 to freely rotate relative to the yoke 1160 while
enabling the yoke 1160 to shift the shaft spool 1110 axially on the
splined shaft 1120.
[0164] A shifter output gear 1180 is keyed or otherwise attached to
the splined shaft 20 for rotation therewith. The shifter output
gear 1180 is arranged in meshing engagement with a drive gear 1190'
that is attached to a drive shaft 1200'. Attached to the drive
shaft 1200' is a drive gear 1410 that is in meshing engagement with
a rack 1420 that is constrained to move axially in the distal and
proximal directions between two lugs 1422, 1424 formed in the frame
1012'. To affix the proximal end of the drive rod 1390 to the rack
1420, a T-slot 1426 may be formed in the distal end 1425 of the
rack 1420. However, other methods of attachment may also be
employed.
[0165] A method of operating the drive system 1400 will now be
described. As can be seen in FIG. 21, the shaft spool 1110 is in
the neutral position. Thus, actuation of the firing trigger 1004
will not result in any movement of the dynamic clamping member 150,
knife 155 or sled 160. To fire the device (advance the dynamical
clamping member 150, knife 155, and sled 160 in the distal
direction DD), the clinician shifts the shifter button 1170 such
that the first gear teeth 1102 of the first pinion gear 1100 are
brought into meshing engagement with the primary gear teeth 1112 of
the shaft spool 1110. After the shaft spool 1110 has been moved to
that position, the clinician may begin to pull/pivot the firing
trigger 1004 to cause the handle gear segment 1006 to move. As the
firing trigger 1004 continues to pivot, the gear segment 1006
rotates the primary drive gear of the clutch assembly 1050 and the
second drive gear 1070. As the second drive gear 1070 rotates in
one direction, the third drive gear 1080 is rotated in the opposite
direction which also causes the first pinion gear 1100 to rotate in
that direction. Because the first teeth 1102 of the first pinion
gear 1100 are in meshing engagement with the primary teeth 1112 of
the shaft spool 1110, the shaft spool 1110 also rotates in that
direction. As the shaft spool 1110 rotates in that direction, the
splined shaft and the shifter output gear 1180 also rotate in that
direction. The shifter output gear 1180 causes the drive gear
1190', drive shaft 1200', and drive gear 1410 to rotate in the "B"
direction thereby driving the rack in the distal direction DD.
[0166] After the firing trigger 1004 has been depressed as far as
it can go (to the end of its stroke), the clinician releases the
firing trigger 1004 and a spring (not shown) or other suitable
arrangement supported by the handle assembly 5 biases the firing
trigger back 1004 to the staring (unfired position). As the firing
trigger 1004 returns to the starting position, the first clutch
plate 1052 rotates backwards (A direction) relative to the second
clutch plate 1060 while the second clutch plate 1060 remains
stationary and does not move. The clinician can then depress the
firing trigger 1004 again until the knife assembly 170 (dynamic
clamping member 150, knife 155, and sled 160) have been completely
advanced to the end distal position within the elongate channel
assembly 120 by the rack 1420 and the drive rod 1390.
[0167] To retract (move in the proximal direction "PD" to a
starting position) the dynamic clamping assembly 150, the knife
155, and the sled 160, the clinician shifts the shifter button 1170
to bring the secondary gear teeth 1114 of the shaft spool 1110 into
meshing engagement with the second gear teeth 1134 on the second
pinion gear 1130. After the shaft spool 1110 has been moved to that
position, the clinician may begin to pull/pivot the firing trigger
1004 in the manner described above. As the firing trigger 1004
continues to pivot, the gear segment 1006 rotates the primary drive
gear 1040 as well as the clutch assembly 1050 and the second drive
gear 1070 in the "B" direction. As the second drive gear 1070
rotates in that direction, the third drive gear 1080 is rotated in
the opposite "A" direction which also causes the first pinion gear
1100 to rotate in that direction. As the first pinion gear 1100
rotates, it causes the reversing bevel gear 1140 to rotate and
cause the second pinion gear 1130 to rotate in the "B" direction.
Because the secondary teeth 1114 of the shaft spool 1110 are in
meshing engagement with the second teeth 1134 of the second pinion
gear 1130, the shaft spool 1110 and the splined shaft 1120 rotate
in the "B" direction. The shift output gear 1180 causes the drive
gear 1190', drive shaft 1200', and drive gear 1410 to rotate in the
"A" direction which causes the rack 1424 to move in the proximal
direction "PD".
[0168] After the firing trigger 1004 has been depressed as far as
it can go (to the end of its stroke), the user releases the firing
trigger 1004 and a spring (not shown) supported by the handle
assembly 5 biases the firing trigger 1004 back to the starting
(unfired) position. As the firing trigger 1004 returns to the
starting position, the first clutch plate 1052 rotates backwards (A
direction) relative to the second clutch plate 1060 while the
second clutch plate 1060 remains stationary and does not move. The
user can then depress the firing trigger 1004 again until the
dynamic clamping member 150, knife 155, and sled 160 have been
completely retracted into a starting position within the elongate
channel assembly 120 by the drive rod 1390 and the rack 1424. Those
of ordinary skill in the art will understand that changes in the
gear ratios--either in the transmission or rack and pinion could be
used to attain improved mechanical advantages for driving the knife
assembly 170 (dynamic clamping assembly 150, knife 155, sled 160)
within the elongate channel assembly 120.
[0169] While the cable drive system 1400 described above comprises
a manually actuatable drive system, other contemplated embodiments
of the present invention may employ a battery powered motor or
motors, alternating current powered motor or motors or
pneumatically powered motors to power the cable drive system. Thus,
the protection afforded to the various embodiments of the present
invention should not solely be limited to surgical instruments that
are manually actuatable.
[0170] FIGS. 22-24 illustrate a portion of another surgical
stapling instrument 1500 that may employ certain features of the
present invention. This embodiment employs a hollow spine or tube
1510 that extends from the handle (not shown) to the channel
assembly (not shown). In the embodiment depicted in FIGS. 22-24,
the hollow spine 1510 is coupled to an articulation joint 1512 of
the type and construction disclosed in U.S. Patent Publication No.
US 2005/0006432 to Racenet et al., the disclosure of which is
herein incorporated by reference. Other articulation joint
arrangements could also be employed without departing from the
spirit and scope of the present invention. As can be seen in FIGS.
22-24, a drive rod 1520 extends through the hollow tube 1510 and
has a proximal end 1522 that may be coupled to the rack of a drive
arrangement of the type described above and supported by the
handle. A transition block 1530 may be attached to or otherwise
formed on the distal end 1524 of the drive rod 1520 for attachment
to a driven rod 1540. A proximal pulley, rod, capstan, etc. 1560 is
mounted within the hollow tube 1510 as shown in FIGS. 22 and
24.
[0171] A cable, thread, band, belt, etc. 1570 may be operably
supported on one or more pulleys, rods, capstans, etc. (not shown)
formed on the channel assembly (not shown) and extend through the
articulation joint 1512 and operably supported on the distal pulley
1560 as shown in FIGS. 22-24. The cable 1570 may have an advance
portion 1572 and a retract portion 1574. The end 1576 of the
retract portion 1574 may be fixedly attached to the distal end 1542
of the driven rod 1540 as shown in FIG. 22. Likewise, the other end
1578 of cable 1570 is attached to the distal end 1542 of the driven
rod 1540. FIG. 22 illustrates the position of the driven rod 1540
when the dynamic clamping assembly (not shown), knife (not shown),
and sled (not shown) are at the distal end of the elongate channel
assembly (not shown). The dynamic clamping assembly, knife, and
sled may be moved to a retracted position by operating the drive
system described above (FIG. 21) in the retract mode described
above which will cause the drive rod 1520 and the driven rod 1540
to move in the proximal direction "PD". The person of ordinary
skill in the art will understand that such arrangement represents a
vast improvement in mechanical advantage over prior cable
arrangements. It will be further appreciated that the cable 1570
may flex as the instrument is articulated. In other embodiments,
however, the ends of the cable may be coupled together with a
spring coupling arrangement of the type described in further detail
below.
[0172] As was mentioned above, one problem that may be encountered
when using a cable driven surgical cutting and severing instrument
is that the cable or cables may become disengaged from a cable
transition support or supports such as pulleys, rods, capstans,
etc. or the like which could disable the device. Such cable
disengagement may, for example, be caused by mechanical vibration
during use of the device or may result from shock to the device
experienced during use or shipping. FIGS. 25-27 illustrate other
embodiments of the present invention that employ cable stop members
1600 which may, for example, comprise cable retention blocks 1601
on the elongate channel assembly 120 that are in close proximity to
the cable transition supports 830, 850 to retain the cables 800,
820 thereon, respectively. In various embodiments, the cable
transition supports 830, 850 may comprise, for example, pulleys,
rods, capstans, etc. Although the cable retention blocks 1610 may
be provided in various shapes and configurations, in various
embodiments, each cable retention block 1601 may have an arcuate
surface 1602 that is complementary-shaped relative to the cable
800, 820, such that the cable 800, 820 cannot become disengaged
from the cable transition support 800, 820.
[0173] FIGS. 28 and 29 illustrate another cable stop member 1700
which may, for example, comprise a cable retention block 1701 of
other embodiments of the present invention. As can be seen in those
Figures, the block 1701 has a passage 1702 therethrough that forms
an arcuate bearing surface 1704 over which the cable 800, 820 may
pass. In this embodiment, the cable may be threaded into and
through the arcuate passage 1702 during installation. Such
arrangement avoids the problem of the cable becoming dislodged from
a pulley or pulleys, rods, capstans, etc.
[0174] FIGS. 30-33 illustrate another embodiment of the present
invention in diagrammatic form. This embodiment employs an elongate
channel assembly 120 that has a dynamic clamping assembly 150,
knife 155, and sled assembly 160 (collectively referred to herein
as "knife assembly 170") that is driven by a cable 1800. In
particular, the cable 1800 may be operably supported on a pair of
cable transition supports 1802, 1804, which may comprise, for
example, pulleys, posts, capstans, etc. mounted to the bottom 128
of the distal end 123 of the elongate channel assembly 120 and a
third cable transition support 1806 which may comprise, for
example, a pulley, post, capstan, etc. on the knife assembly 170.
In addition, the cable 1800 may be operably supported on a drive
pulley 1808 that is movably supported by the handle assembly 5. The
drive pulley 1808 may be selectively movable in the distal
direction "DD" and the proximal direction "PD" by a trigger (not
shown) or other actuator arrangement (not shown) in the handle
assembly 5.
[0175] Other embodiments of the present invention as illustrated in
FIGS. 30-33, employ a unique and novel cable tensioning joint 1801
for connecting the ends of the cable 1800 to maintain the tension
in the cable 1800 to prevent the cable 1800 from shifting off the
pulleys 1802, 1804, 1806, 1808. In particular, this arrangement
employs a tensioning member in the form of a spring 1810 that is
oriented in a substantially parallel path to the cable load path.
As can be seen in those Figures, a first stop member or block 1820
is fixedly attached (swaged, glued, welded, etc.) to a first end
1803 of the cable 1800. The second end 1805 of the cable 1800 is
also fixedly attached (swaged, welded, glued, etc.) to a second
stop member or block 1830. As can be seen in FIG. 33, the second
stop member 1830 has a passage 1832 therethrough through which a
portion of the cable 1800 may slidably pass as represented by the
arrow in that Figure. A third stop member or block 1840 is fixedly
attached to the cable 1800 and an end of the spring 1810 is
attached thereto. The other end of the spring 1810 is attached to
the second stop member 1830. Those of ordinary skill in the art
will understand that such arrangement permits the cable 1800, when
operably supported on cable transition supports in the form of, for
example, pulleys, capstans, retention blocks etc., to lengthen a
distance "L" (the distance between the first and second stop
members 1820, 1830) when the tension spring 1810 is unexpanded. It
will be further appreciated that such arrangement is particularly
advantageous when an articulated instrument is employed as
demonstrated in FIG. 32. In particular, use of the cable tensioning
joint 1801 enables the cable to extend or bend around the
articulation joint while remaining taught about the various cable
transition supports.
[0176] As indicated above, another challenge commonly encountered
when employing cable driven systems relates to connecting the ends
of the cable (drive member) in such a manner as to ensure that the
cable effectively transmits the desired force to the knife/dynamic
clamping member or other surgical instrument component. FIGS. 34
and 35 illustrate an endless cable 1900 of various embodiments of
the present invention. In this embodiment, for example, the endless
cable 1900 may comprise a woven metal wire or woven plastic member.
To form the endless cable, the fibers 1903 of the end 1902 may be
interwoven with the fibers 1905 of the end 1904 to form a cable
loop. Another embodiment is a Chinese finger cuff (FIG. 35)
approach wherein one end is inserted into the other end of a hollow
woven cable to form a connection that gets tighter with tension. In
various embodiments, some fastening agent/adhesive may be employed
during assembly to facilitate such pretentioning of the joint. Such
arrangement, for example, may permit the cable 1900 to somewhat
constrict about its longitudinal axis "L-L" when tension is applied
in the longitudinal direction. One example of such weave pattern is
disclosed in U.S. Pat. No. 4,817,643 to Olsen, the disclosure of
which is herein incorporated by reference. After the ends 1902,
1904 are braded together as shown, the cable 1900 forms a closed
loop 1906. The cable may be looped around a driven pulley or other
member and a portion of a movable member such as pins, pulleys,
capstans or other portions of the surgical instrument components
when the ends 1902, 1904 are braided or interwoven together.
[0177] FIGS. 36-38 illustrate another cable attachment arrangement
2000 of the present invention for attaching a cable to a surgical
instrument component. As can be seen in those Figures, the cable
2002 may have a substantially wedge-shaped or substantially
conically shaped slug 2010 that has a hole 2012 extending
therethrough for receiving an end 2004 of the cable 2002 as shown
in FIG. 36. The slug 2010 may be crimped, swaged, glued,
overmolded, ultrasonically welded, etc. onto the cable end 2012 as
shown. In various embodiments, for example, the slug 2010 may be
fabricated from a somewhat soft material such as lead, copper,
brass, stainless steel, titanium, etc. or, for example, a
thermoplastic material such as nylon or polycarbonate. The slug
2010 is sized to be received in a complementary shaped pocket 2020
in surgical instrument component to which it is to be attached such
as, for example, the dynamic clamping member 150. The pocket 2020
may be sized such that, as tension is applied to the cable 2002 in
the "T" direction, the connection gets tighter. That is, as the
cable tension increases, the slug 2020 is further compressed on the
end 2004 of the cable 2002. In various embodiments, the pocket 2020
may be open on at least one side thereof to permit the slug 2010 to
be installed therein.
[0178] FIG. 39 illustrates another cable attachment arrangement
2100 of various embodiments of the present invention. As can be
seen in that Figure, the end 2112 of the cable 2110 may be wrapped
around a pin 2120 and be attached to the other portion 2114 of the
cable 2110 by one or more clamps 2130 that may be crimped or
otherwise cinched thereon to form a loop 2140 for receiving at
least a portion of the surgical instrument component such as, for
example, a pulley, pin, capstan, etc.
[0179] FIG. 40 illustrates another cable attachment arrangement
2200 of various embodiments of the present invention. As can be
seen in that Figure, the end portion 2212 of the cable 2210 may be
wrapped around a pin 2220 and be melted or glued to another
adjacent portion 2214 of the cable 2210 to form a loop 2240 for
receiving at least a portion of the surgical instrument component
such as, for example, a pulley, pin, capstan, etc.
[0180] The endocutter disclosed in U.S. Patent Publication No.
US2006/0011699 A1 employs two cable systems: one for closing the
anvil; and one that pulls the dynamic clamping assembly, knife, and
sled to cut tissue and form staples. In one arrangement, a cable is
attached to the clamping collar for pulling the clamping collar
distally onto and over cam surface to close the anvil relative to
the staple cartridge assembly and compress the tissue. That closure
cable must be threaded back through the articulation joint to the
handle. When the proximal end of that cable is pulled, the distal
end of the cable, which is attached to the clamping collar, causes
the clamping collar to move distally and close the anvil. Such
arrangement, however, suffers from the limited ability to generate
clamping force.
[0181] FIG. 41 illustrates an articulation joint 1512 of the type
disclosed in the above-mentioned publication. FIGS. 42 and 43
illustrate the articulation joint assembly 2302 of a closure tube
assembly 2300 of various embodiments of the present invention that
may be used in connection with the articulation joint 1512 and
eliminate the use of a cable to close the anvil 110. FIG. 44
illustrates the closure tube assembly 2300 installed over the
articulation joint 1512. As will be discussed in further detail
below, in various embodiments, the closure tube assembly 2300 is
operably supported adjacent the elongate channel assembly 120 for
selectively applying a closing motion to the anvil assembly 110
upon closing contact with the closure tube assembly 2300.
[0182] As can be seen in FIG. 42, an embodiment of the closure tube
assembly 2300 may include a distal closure tube segment 2310 that
has proximal end 2312 and a distal end 2314, a central closure tube
segment 2320 that has a distal end 2322 and a proximal end 2324,
and a proximal closure tube segment 2330 that has a proximal end
2332 and a distal end 2334. The proximal end 2332 of the proximal
closure tube segment 2330 may be non-rotatably coupled to a distal
end 2342 of a closure tube segment 2340. As can be seen in FIG. 43,
the distal end 2342 of the hollow closure tube segment 2340 may be
provided with a notch 2344 therein for receiving a tab 2336
protruding proximally from the distal end 2334 of the proximal
closure tube segment 2330. As can also be seen in FIG. 43, the
proximal end 2332 may be received within the hollow distal end 2342
of the hollow closure tube segment 2340. The proximal closure tube
segment 2330 may be retained in coupling engagement with the
closure tube segment 2340 by adhesive, glue, etc. Those of ordinary
skill in the art will understand that such unique and novel
configuration helps to facilitate assembly of the device. However,
in other embodiments for example, the proximal closure tube segment
2330 may be integrally formed with the closure tube segment
2340.
[0183] In various embodiments, the closure tube assembly 2300 may
further comprise a first upper tab 2350 protruding from the distal
end 2334 of the proximal closure tube segment 2330 and a first
lower tab 2352 protruding from the distal end 2334 of the proximal
closure tube segment 2330 in spaced relation to the first upper tab
2350. The first upper tab 2350 has a first upper pivot hole 2354
therethrough and the first lower tab 2352 has a first lower pivot
hole 2356 therethrough that is coaxially aligned with the first
upper hole 2354 in various embodiments. The proximal end 2324 of
the central closure tube segment 2320 has a second upper tab 2326
protruding therefrom and a second lower tab 2328 protruding
therefrom in spaced relation to the second upper tab 2326. The
second upper tab 2326 has a second upper pivot hole 2327
therethrough and the second lower tab 2328 has a second lower pivot
hole 2329 therethrough that is substantially coaxially aligned with
the second upper pivot hole 2327.
[0184] As can be seen in FIG. 44, the distal end 2322 of the
central closure tube segment 2320 has a first lateral tab 2321 and
a second lateral tab 2323 protruding therefrom. The first lateral
tab has a first lateral hole (not shown) therethrough and the
second lateral tab 2323 has a second lateral hole 2325 therethrough
that is coaxially aligned with the first lateral hole 2325. In
addition, the proximal end 2312 of the distal closure tube segment
2310 has a third lateral tab 2316 protruding therefrom and a fourth
lateral tab 2318 protruding therefrom in spaced relation to the
third lateral tab 2316. The third lateral tab 2316 has a third
lateral pivot hole (not shown) therethrough and the fourth lateral
tab 2318 has a fourth lateral pivot hole 2319 therethrough that is
substantially coaxially aligned with the third lateral pivot
hole.
[0185] In various embodiments, the closure tube joint assembly 2302
further includes an upper double pivot link 2360 that has a first
upper pin 2362 and a second upper pin 2364 protruding therefrom.
The first upper pin 2362 is sized to be pivotally received in the
first upper pivot hole 2354 and the second upper pin 2364 is sized
to be pivotally received in the second upper pivot hole 2327. The
upper double pivot link 2360 may be retained in position between
the proximal end 2324 of the central closure tube segment 2320 and
the distal end 2334 of the proximal closure tube segment 2330 by
the articulation joint assembly 1512. The closure tube joint
assembly 2300 may further include a lower double pivot link 2370
that has a first lower pin 2372 and a second lower pin 2374
protruding therefrom. See FIG. 43. The first lower pin 2372 is
sized to be pivotally received within the first lower pivot hole
2356 and the second lower pin 2374 is sized to be pivotally
received in the second lower pivot hole 2329. The lower double
pivot link 2370 may be retained in position between the proximal
end 2324 of the central closure tube segment 2320 and the distal
end 2322 of the central closure tube segment 2320 by the
articulation joint assembly 1512.
[0186] When the upper double pivot link 2360 and the lower double
pivot link 2370 are attached to the proximal end 2324 of the
central closure tube segment 2320 and the distal end 2334 of the
proximal closure tube segment 2330, the first upper pin 2362 and
the first lower pin 2372 are coaxially aligned along a first pivot
axis D-D that, in various embodiments, may be substantially
transverse to an elongated shaft axis C-C that extends through the
elongated closure tube assembly 1000. See FIG. 43. Likewise, the
second upper pivot pin 2364 and the second lower pivot pin 2374 are
coaxially aligned along a second pivot axis E-E. In various
embodiments, the second pivot axis E-E is substantially transverse
to the elongated shaft axis C-C and substantially parallel to the
first pivot axis D-D. The reader will appreciate that such
arrangement permits the central closure tube segment 2320 to pivot
relative to the proximal closure tube segment 2330 about pivot axes
D-D and E-E.
[0187] In various embodiments, the closure tube joint assembly 2302
may further include a first lateral double pivot link 2380 that has
a first upper pin (not shown) and a second upper pin (not shown)
protruding therefrom. The first lateral pin is sized to be
pivotally received in the first lateral pivot hole (not shown) in
the first lateral tab 2321 and the second lateral pin is sized to
be pivotally received in the second lateral pivot hole (not shown)
in the third lateral tab 2316. The first lateral double pivot link
2380 may be retained in position between the proximal end 2312 of
the distal closure tube segment 2310 and the distal end 2322 of the
central closure tube segment 2320 by the articulation joint
assembly 1512. The closure tube joint assembly 2300 may further
include a second lateral double pivot link 2390 that has a third
lateral pin 2392 and a fourth lateral pin 2394 protruding
therefrom. The third lateral pin 2392 is sized to be pivotally
received within the second lateral hole 2325 in the second lateral
tab 2323 and the fourth lateral pin 2394 is sized to be pivotally
received in the fourth lateral pivot hole 2319 in the fourth
lateral tab 2318. The second lateral double pivot link 2390 may be
retained in position between the proximal end 2312 of the distal
closure tube segment 2310 and the distal end 2322 of the central
closure tube segment 2320 by the articulation joint assembly
1512.
[0188] When the first lateral double pivot link 2380 and the second
double pivot link 2390 are attached to the proximal end 2312 of the
distal closure tube segment 2310 and the distal end 2322 of the
central closure tube segment 2320, the first lateral pin and the
third lateral pin 2392 are coaxially aligned along a third pivot
axis F-F that, in various embodiments, may be substantially
transverse or orthogonal to the elongated shaft axis C-C. Likewise,
the second lateral pivot pin and the fourth lateral pivot pin 2394
are coaxially aligned along a fourth pivot axis G-G. In various
embodiments, the third pivot axis F-F is substantially transverse
or orthogonal to the elongated shaft axis C-C and the first axis
D-D and the second axis E-E and is substantially parallel to the
fourth pivot axis G-G. The reader will appreciate that such
arrangement permits the distal closure tube segment 2310 to pivot
relative to the central closure tube segment 2320 about pivot axes
F-F and G-G. Thus, such arrangement provides a closure tube
assembly that can move axially over the joint assembly 1512 and
still afford multi-articulation about four axes.
[0189] Those of ordinary skill in the art will understand that, as
the closure tube assembly 2300 is moved (pushed) in the distal
direction DD, the distal end 2314 of the distal closure tube
segment 2310 applies a closing motion to the anvil assembly 110 by
contacting the cam surface 115 of anvil assembly 110 (shown in
FIGS. 2, 4 and 7) to close anvil assembly 110 relative to the
staple cartridge assembly 200. In various embodiments, a return
mechanism, e.g., a spring, cable system or the like (not shown),
may be employed to return the closure tube assembly 2300 to a
preclamping orientation which causes the anvil assembly 110 to
re-open as the closure tube segment 2310 contacts a reverse cam
surface 117 on the proximal end of the anvil assembly 110. See
FIGS. 2 and 7. In other embodiments as illustrated in FIG. 45, the
anvil assembly 110' may be formed with an upstanding actuation tab
111' that is sized to extend into a horse-shoe shaped opening 2315
in the distal end 2314 of the distal closure tube segment 2310. See
FIG. 44A. Thus, as the closure tube assembly 2300 is moved in the
distal direction DD, the horse-shoe shaped opening 2315 contacts
the ramp 115 and forces the anvil assembly 110' to a closed
position. When the closure tube assembly 2300 is moved in the
proximal direction PD, the horse-shoe shaped opening 2315 pulls the
tab 111' and causes the anvil assembly 110' to pivot to an open
position.
[0190] One closure tube drive system of the present invention is
briefly depicted in FIG. 46. However, other systems could also be
effectively employed without departing from the spirit and scope of
the present invention. As can be seen in FIG. 46, one form of
closure tube drive system 2400 includes a yoke 2402 connected to a
closure trigger 18. A pivot pin 2404 is inserted through aligned
openings in both the closure trigger 18 and the yoke 2402. The
distal end of the yoke 2402 is connected, via a pin 2406, to a
first portion 2408 of a closure bracket 2410. The first closure
bracket portion 2408 connects to a second closure bracket portion
2412. Collectively, the closure bracket 2410 defines an opening in
which the proximal end 2346 of the closure tube segment 2340 is
seated and held such that longitudinal movement of the closure
bracket 2410 essentially pushes or drives the closure tube segment
2340 (and ultimately the elongated closure tube assembly 2300) in
the distal direction DD.
[0191] In operation, when the yoke 2402 rotates due to retraction
of the closure trigger 18, the closure bracket 2410 causes the
proximal closure tube segment 2340 to move in the proximal PD
direction, which causes the distal closure tube segment 2310 to
move proximately. If the anvil assembly 110' is employed, the tab
111' causes the anvil assembly 110' to open when the distal closure
tube segment 2310 moves proximately. When the closure trigger 18 is
unlocked from the locked position, the proximal closure tube
segment 2340 is pushed or otherwise driven in the distal direction
DD, which causes the distal closure tube segment 2310 to slide
distally. The distal closure tube segment 2310 forces the anvil
assembly 110' closed by driving it distally into ramp 115. Such
closure system 2400 is further described in commonly owned U.S.
patent application Ser. No. 11/343,547 entitled "Endoscopic
Surgical Instrument With a Handle That Can Articulate With Respect
to the Shaft" to Frederick E. Shelton, IV, et al., the disclosure
of which is hereby incorporated by reference in its entirety. Other
closure systems may be employed, however, to axially move the
closure tube assembly 2300 in the proximal and distal
directions.
[0192] FIGS. 47-50 illustrate another unique and novel closure
system 2500 of various embodiments of the present invention. In the
embodiments depicted in these Figures, a manually actuatable drive
system 2600 is employed. Such a drive system arrangement is
disclosed in commonly owned U.S. patent application Ser. No.
11/475,412, filed Jun. 27, 2006, entitled "Manually Driven Surgical
Cutting and Fastening Instrument" to Frederick E. Shelton, et al.,
the disclosure of which is hereby incorporated by reference in its
entirety. Thus, the operation of such drive system arrangement will
not be discussed in great detail herein. As the present Detailed
Description proceeds, the person of ordinary skill in the art will
appreciate, however, that the closure system 2500 of the present
invention may also be effectively employed in connection with
surgical stapling instruments that employ a cable or cables to
drive the dynamic clamping member, knife and sled. In addition, the
closure system 2500 may also be effectively employed in connection
with other surgical stapling instruments that employ a motor to
drive the dynamic clamping member, knife, sled, etc. Thus, the
protection afforded to the closure system 2500 as described herein
should not be limited to use only in connection with the manually
actuatable drive system depicted in the present FIGS. 47-50.
[0193] As shown in these Figures, a firing trigger 2610 is operably
supported by the handle assembly 5 and has a series of gear teeth
2612 thereon that meshingly interface with the drive gear
arrangement (not shown) that operably interfaces with a rotary
drive shaft 2614. The rotary drive shaft 2614 may be rotatably
supported within a spine 2616 that extends through an elongate
hollow closure tube 2510. The rotary drive shaft 2614 may interface
with other drive components operably supported by the spine 2616 to
convey a rotary driving motion to the tool assembly 100'. Also in
various embodiments, a shifter assembly 2620 interfaces with the
drive gear arrangement. The shifter assembly may include a selector
switch 2622 such that when the switch is in one position and the
firing trigger 2610 is pivoted in a ratcheting motion, the rotary
drive shaft 2614 rotates in a first direction to ultimately impart
a rotary motion to the tool assembly 100' to cause the dynamic
clamping member or knife assembly to move in a distal DD direction
and, when the selector switch 2622 is moved to a second position,
ratcheting of the firing trigger 2610 causes the rotary drive shaft
2614 to rotate in an opposite direction to thereby impart an
opposite rotary motion to the tool assembly 100' and cause the
dynamic clamping assembly or knife assembly to move in the proximal
PD direction.
[0194] As can also be seen in these Figures, the closure tube
assembly 2500 may further include a closure knob 2520 and a
rotation assembly 2550 for rotation of the tool assembly. As can be
most particularly seen in FIG. 48, the closure knob 2520 may be
supported on the proximal end 2512 of the closure tube 2510 and a
spine attachment tube 2618. For assembly purposes, the closure knob
2520 may be provided in half sections that are interconnected by
mechanical fasteners or adhesive. In one embodiment, the spine
attachment tube 2618 is hollow and has a flanged proximal end 2619.
The flanged end 2619 is rotatably supported in a radial slot 2522
provided in the closure knob 2520 such that the closure knob 2520
can freely rotate about the spine attachment tube 2618. As can also
be seen in FIG. 48, the spine 2616 may have a proximal end 2617
sized to extend into the spine attachment tube 2618. However, other
arrangements may be employed. As can also be seen in FIG. 48, the
proximal end 2512 of the closure tube 2510 may be flanged and
oriented to be non-rotatably retained within a second radial slot
2524 formed in the closure knob 2520 such that rotation of the
closure knob 2520 causes the rotation of the closure tube 2510.
[0195] Various embodiments may also include a rotation assembly
2550. As can be seen in FIGS. 47, 49, and 50, the rotation assembly
2550 may include a rotation knob 2552 that is rotatably received on
the handle assembly 5. As with the closure knob 2520 and housing
assembly 5, the rotation knob 2552 may be provided in two segments
that may be interconnected by mechanical fasteners--screws, snaps,
etc. or adhesive for assembly purposes. In various embodiments, the
distal end 2554 of the rotation knob 2552 has a hole 2556
therethrough that is adapted to receive therein a spline tube 2560
that has a splined section 2562 that is in axial engagement with
the distal end 2554 of the rotation knob 2552 such that the
rotation knob 2550 may be moved axially relative to the spline tube
2560, but always be engaged with the splined section 2562 thereof.
As can be seen in FIG. 48, the spline tube 2560 has a distal end
2564 that extends into the closure knob 2520 and is non-rotatably
attached to the spine attachment tube 2618. by adhesive or other
suitable fastener arrangement. A proximal end 2566 of the spline
tube 2560 is flanged and is adapted to be received in an annular
slot 2570 provided in the handle assembly 5 such that the flanged
end 2566 can rotate therein.
[0196] As can also be seen in FIGS. 47 and 49, the distal end 2580
of the housing assembly is flanged and has a first radial gear 2582
formed thereon. The flanged end 2580 of the housing assembly
extends into an annular cavity 2567 formed in the rotation knob
2552. The annular cavity 2567 is formed by an inwardly extending
annular flange 2568 that has a second radial gear 2569 formed
thereon for selective meshing engagement with the first radial gear
2582. The annular flange 2568 also extends into an annular spring
cavity 2584 formed in the housing assembly 5. A locking spring 2590
is provided in the spring cavity 2584 to bias the second radial
gear 2569 into meshing engagement with the first radial gear 2582.
As will be discussed in further detail below, the clinician can
unlock the spine 2616 thereby enabling the clinician to rotate the
spine 2616 and ultimately the tool assembly 100' to position the
tool assembly 100' in a desired orientation by pulling the rotation
knob 2552 proximally to disengage the second radial gear 2569 from
the first radial gear 2582 to enable the rotation knob 2550, spline
tube 2560 and spine 2616 to rotate.
[0197] As shown in FIGS. 47 and 48, the distal end 2514 of the
closure tube 2510 may be formed with a reduced diameter portion
2515 for slidably receiving a nonrotatable closure ring 2594
thereon. In various embodiments, a pair of slots 2516 are provided
therein that are oriented to receive corresponding pins 2596 that
protrude inward from the wall of the closure ring 2594. In various
embodiments, at least one pin and slot arrangement is employed. In
alternative embodiments, the pins 2596 may be in the closure tube
2510 and the slots 2516 may be provided in the closure ring. FIG.
50 illustrates the anvil 110' of the tool assembly 100' in an open
position. To close the anvil 110', the clinician simply rotates the
closure knob 2520 in a first direction which also rotates the
closure tube 2510 in that direction. The rotation of the closure
tube 2510, by virtue of the interaction between the pins 2596 and
slots 2516, causes the closure ring 2594 to move distally into
contact with a portion of the anvil 110' to pivot the anvil 110' to
the closed position depicted in FIGS. 47 and 48. As shown in FIG.
48, there is a distance 2599 between the proximal end 2598 of the
closure ring 2594 and the ledge 2517 of the reduced diameter
portion 2515 of the closure tube 2510. Such distance 2599
represents the amount of axial travel that is available to the
closure ring 2594. The person of ordinary skill in the art will
appreciate that by providing the slots 2516 at relatively low
angles, the pins 2596 will tend to remain in that position and
thereby also retain the anvil 110' in the closed position. However,
other locking arrangements may be employed.
[0198] To open the anvil 110', the clinician again moves the brake
knob 2552 in the proximal direction PD and then rotates the closure
knob 2520 (and closure tube 2510) in a second direction as shown in
FIGS. 49 and 50. In various embodiments, the tissue that was
clamped in the tool assembly 100' causes the anvil 110' to move to
the open position. In other embodiments, a spring or other biasing
member (not shown) may be employed to bias the anvil 110' to the
open position when the closure ring 2594 has been moved to the
position depicted in FIGS. 49 and 50. In other embodiments, the
closure ring 2594 may be provided with the horse-shoe shaped
opening described above and the anvil 110' may be configured with a
tab 111' as shown in FIG. 45. Thus, in that embodiment, when the
closure ring 2594 is drawn proximally, it pulls the anvil 110' to
the open position. Once in the open position, the clinician may
release the brake knob 2552 and the brake 2550 will lock the
closure tube 2510 (and anvil 110') in the open position. The person
of ordinary skill in the art will appreciate that the closure
system 2500 may also be effectively employed in connection with the
closure tube joint assembly 2302 described above. In such
arrangement, the slots 2516 may be provided in the distal closure
tube segment 2310. Such arrangement would be operated in the same
manner as described above, however, the instrument would also be
articulatable about multiple axes.
[0199] FIG. 51 illustrates another embodiment of the present
invention wherein the distal end 2515' of the closure tube 2510 has
threads 2513 thereon for threaded engagement with threads 2597 on
the closure ring 2594'. In this embodiment, the closure ring 2594'
may be configured to interact with the channel assembly 120 and or
spine 2616 such that the closure ring 2594' can move axially
relative thereto, but does not rotate. The threads 2597 are formed
in the proximal end 2595 of the closure ring 2594' such that as the
closure tube 2510 is rotated in one direction, the closure ring
2594' is axially moved in the distal direction DD to contact the
anvil 110' and pivot the anvil 110' to the clamped position.
Rotation of the closure ring 2594' in the opposite direction causes
the closure ring 2594' to move in the proximal direction PD to
enable the anvil 110' to be pivoted open by the tissue that was
clamped therein, or by springs or other biasing members. Such use
of multiple turn threads may provide more closure power than other
closure ring arrangements. In alternative embodiments, the closure
ring 2594' may be provided with the horse-shoe shaped opening to
interact with a closure tab on the anvil. See FIG. 45. The rotation
and locking of the closure tube 2510' may be controlled by the
closure system 2500 and closure tube brake assembly 2550 as was
described above. This embodiment may also be used in connection
with the various articulation joints described above without
departing from the spirit and scope of the present invention. It
will be further appreciated that such embodiment may be effectively
used with the manual drive system depicted in FIGS. 47 and 49 or
with other drive arrangements, such as cable drive arrangements,
etc.
[0200] FIGS. 52-54 illustrate another cable-actuated closure system
2700 embodiment of the present invention. As can be seen in those
Figures, various embodiments may include a proximal cover tube 2710
that axially supported a proximal spine segment 2720. The proximal
spine segment 2720 extends from the handle assembly (not shown) and
may be supported thereby in any one of a number of known
arrangements without departing from the spirit and scope of the
present invention.
[0201] In various embodiments, the proximal spine segment 2720 has
a distal end 2722 that has a neck portion 2724 protruding therefrom
that has a ball-shaped member 2730 attached thereto or otherwise
formed therewith. As can also be seen in these Figures, the
ball-shaped member 2730 is sized to be received in a socket 2750
formed in a proximal end 2742 of a channel-shaped distal spine
segment 2740. The ball-shaped member 2730 and socket 2750
collectively form a ball joint, generally designated as 2760, that
affords the distal spine segment 2740 the ability to articulate in
multiple directions relative to the proximal spine segment 2720. A
sufficient amount of clearance 2748 is provided between the
proximal end 2742 of the distal spine segment 2740 and the distal
end 2722 of the proximal spine segment 2720 to enable the distal
spine segment to articulate in a desired range of motion relative
to the proximal spine segment 2720. In various embodiments, the
distal spine segment 2740 is attached to the elongate channel
assembly 120'' to which the anvil 110'' is pivotally attached. As
can be further seen in FIGS. 52-54, a closure ring 2770 is
supported on the distal spine segment 2740 for selective axial
travel thereon.
[0202] In various embodiments, the opening and closing of the anvil
110' may be accomplished by a closure cable 2780 that extends from
the handle assembly (not shown) through a hollow passage 2726 in
the proximal spine segment 2720 and neck portion 2724. The proximal
end (not shown) of the closure cable 2780 may be attached to one of
the cable drive systems described herein or other cable control
systems for selectively applying tension to the cable 2780. Those
of ordinary skill in the art will further appreciate that a drive
cable system of the various types described above may also be
employed to drive the dynamic clamping member, knife, and sled.
[0203] As can be seen in FIGS. 52-54, the closure ring 2770 may
have a first cable transition support 2790 mounted thereon that
extends into the open upper end of the channel-shaped distal spine
segment 2740 such that the first cable transition support 2790 can
move distally and axially back and forth within the distal spine
segment 2740 as the closure ring 2770 moves thereon. In various
embodiments, the first cable transition support 2790 may comprise a
support selected from the group of supports consisting of pulleys,
rod, capstans, etc. In addition, a second cable transition support
2792 may be mounted within the distal spine segment 2740 in the
orientation shown such that the closure cable 2780 may be operably
supported on the first and second cable transition supports 2790,
2792. Similarly, the second cable transition support 2792 may
comprise a cable transition support selected from the group of
transition supports consisting of pulleys, rods, capstans, etc.
[0204] The distal end 2782 of the closure cable 2780 may be fixed
to the distal spine segment 2740 at a point of attachment 2744.
Thus, applying tension to the closure cable 2780 (pulling the
closure cable 2780 in the proximal direction PD) causes the closure
ring 2770 to move in the distal direction DD to contact the anvil
110' and pivot it to a closed position in the manner discussed
above. In various embodiments, the tissue that was clamped in the
tool assembly 100'' causes the anvil 110' to move to the open
position. In other embodiments, a spring or other biasing member
(not shown) may be employed to bias the anvil 110' to the open
position when the closure ring 2770 has been axially moved to its
proximal unclamped position. Such unique and novel cable actuated
closure system enjoys a significant mechanical advantage
improvement over prior cable powered closure systems while also
providing the ability to articulate the tool assembly 100''
relative to the other portion of the instrument. Other embodiments
are also contemplated wherein the ball-shaped member is formed in
the distal spine segment 2740 and the socket is formed in the
proximal spine segment 2720. In still other embodiments, no
articulation joint is employed. That is, the proximal spine segment
and distal spine segment comprise a single member.
[0205] FIGS. 55-57 illustrate a cable controlled lockable
articulation joint 2800 of various embodiments of the present
invention that interfaces between the elongate channel assembly
120'' and a proximal spine segment 2820. In various embodiments,
the proximal spine segment 2820 may extend from the handle assembly
(not shown) and may be supported thereby in any one of a number of
known arrangements without departing from the spirit and scope of
the present invention. The proximal spine segment 2780 may have a
distal end 2822 that has a neck portion 2824 protruding therefrom
that has a substantially ball-shaped member 2830 attached thereto
or otherwise formed therewith. As can also be seen in these
Figures, the ball-shaped member 2830 may be sized to be received in
a socket 2850 formed in a proximal end 2842 of a distal spine
segment 2840. The ball-shaped member 2830 and socket 2850
collectively form a ball joint, generally designated as 2800, that
affords the distal spine segment 2840 with the ability to
articulate in multiple directions relative to the proximal spine
segment 2820. A sufficient amount of clearance 2848 may be provided
between the proximal end 2842 of the distal spine segment 2840 and
the distal end 2822 of the proximal spine segment 2820 to enable
the distal spine segment 2840 to articulate in a desired range of
motion relative to the proximal spine segment 2820. In various
embodiments, the distal spine segment 2840 may be attached to the
channel assembly 120'' to which the anvil (not shown) is pivotally
attached.
[0206] In various embodiments, one or more radially extendable
portions 2880 may be provided in the ball-shaped member 2830. In
the embodiment depicted in FIGS. 55-57, three radially extendable
fingers 2880 are provided, for example. In various embodiments, the
radially extendable fingers 2880 may be equally spaced about the
ball-shaped member 2830 (e.g., spaced at 120.degree. intervals).
Other numbers of radially extendable fingers 2880 could also be
successfully employed. In various embodiments, the ball-shaped
member 2830 may be fabricated from, for example, plastic, metal,
etc. such that the radially extendable fingers may be pulled or
otherwise driven radially outward a distance to lock the
ball-shaped member 2830 in a desired orientation within the socket
2850.
[0207] In various embodiments, each of the radially extendable
fingers 2880 may have a cable 2882 attached thereto that extend
adjacent the neck portion 2824 of the proximal spine segment 2820
and through corresponding passages 2826 in the distal end 2822 of
the proximal spine segment 2820. The cables 2882 may extend through
the hollow proximal spine segment 2820 to a control system
supported by the handle (not shown) to selectively apply a tension
force to the cables 2882. For example, the cables 2882 may be
associated with a locking trigger or other mechanism supported in
the handle that can be moved to apply a tension to the cables and
be selectively retained in that position until it is desired to
release the joint whereby the mechanism may be unlocked to release
the tension in the cables 2882. As can be seen in FIG. 55, a hollow
cable ring 2890 may be employed as shown to retain the cables 2882
adjacent the neck portion 2824.
[0208] To use this embodiment, the clinician positions the tool
assembly 100 in the patient and then applies an articulation force
to the tool assembly with another surgical instrument or by
bringing the tool assembly 100 into contact with a portion of the
patient to articulate the tool assembly to a desired position
before applying tension to the locking cables 2882. After the tool
assembly 100 has been articulated to the desired position, the
clinician applies a tension force to the locking cables 2882 which
causes the radially extendable fingers 2880 to extend radially
outward and lock the ball-shaped member 2830 in that orientation
within the socket 2850 to thereby retain the distal spine segment
2840 (and the tool assembly 100 attached thereto) in that
articulated position. Such system employs a "passive" articulation
technique.
[0209] FIGS. 58-61 illustrate another cable controlled lockable
articulation joint 2900 of various embodiments of the present
invention. As can be seen in those Figures, various embodiments may
include a proximal spine segment 2920 that extends from the handle
assembly (not shown) and may be supported thereby in any one of a
number of known arrangements without departing from the spirit and
scope of the present invention. As can also be seen in FIG. 58, a
ball-shaped member 2936 may be formed on a proximal end 2932 of a
distal spine segment 2930. The ball-shaped member 2936 may be sized
to be received in a socket 2924 formed in the distal end 2922 of
the proximal spine segment 2920. The ball-shaped member 2936 and
socket 2924 collectively form a ball joint, generally designated as
2910, that affords the distal spine segment 2930 with the ability
to articulate in multiple directions relative to the proximal spine
segment 2920. A sufficient amount of clearance 2948 is provided
between the proximal end 2932 of the distal spine segment 2930 and
the distal end 2922 of the proximal spine segment 2920 to enable
the distal spine segment 2930 to articulate in a desired range of
motion relative to the proximal spine segment 2920. In various
embodiments, the distal spine segment 2930 may be attached to the
channel assembly (not shown) to which the anvil (not shown) is
pivotally attached.
[0210] In various embodiments, the distal end 2922 of the proximal
spine segment 2920 may have a flexible section 2950 and a cincture
section 2960. The proximal spine section may be fabricated from,
for example, plastic, metal, etc. The flexible section 2950 may be
defined by a series of equally spaced slots 2952 provided into the
distal end 2922 of the proximal spine segment 2920 to form a
plurality of radially contractable locking portions in the form of,
for example, flexible segments 2954 that serve to define the socket
2924 therebetween. In addition, a circumferentially extending
groove 2956 may be provided around the circumference of the distal
end 2922 of the proximal spine segment 2920. A locking cable 2970
may extend through the hollow proximal spine segment 2920 and be
looped around the cincture section 2960 in the circumferentially
extending groove 2956 as shown in FIGS. 59 and 61. As can be seen
in those Figures, the cable 2970 may pass through two passages
2957, 2958 such that the ends thereof may extend through the
proximal spine section 2920 to a cable control system (not shown)
supported in the handle assembly (not shown) that may be used to
selectively apply a tension force to the cable 2970.
[0211] To use this embodiment, the clinician positions the tool
assembly 100 in the patient and then applies an articulation force
to the tool assembly with another surgical instrument or by
bringing the tool assembly 100 into contact with a portion of the
patient to articulate the tool assembly to a desired position
before applying tension to the locking cable 2970. After the tool
assembly 100 has been articulated to the desired position, the
clinician applies tension to the locking cables 2970 which causes
the flexible segments 2954 to lock around the ball-shaped member
2936 and prevent it from moving relative to the proximal spine
segment 2920 to thereby retain the distal spine segment 2840 (and
the tool assembly 100 attached thereto) in that articulated
position. Such system employs a "passive" articulation technique.
To release the ball-shaped member to permit further articulation of
the tool assembly, the tension is released from the cable 2970.
[0212] FIGS. 62-64 illustrate another lockable articulation joint
3000 of various embodiments of the present invention. As can be
seen in those Figures, various embodiments may include a proximal
spine segment 3010 that extends from the handle assembly (not
shown) and may be supported thereby in any one of a number of known
arrangements without departing from the spirit and scope of the
present invention. The proximal spine segment 3010 has a distal end
3012 that has a neck portion 3014 protruding therefrom that has a
substantially ball-shaped member 3016 formed thereon. As can be
seen in FIGS. 63 and 64, the ball-shaped member 3016 has a series
of slots 3018 therein that serve to define a series of ball
segments 3020. As shown in FIG. 62, the ball-shaped member 3016 may
be sized to be received in a socket 3034 formed in a proximal end
3032 of a distal spine segment 3030. The ball-shaped member 3016
and socket 3034 collectively form a ball joint, generally
designated as 3040 that affords the distal spine segment 3030 with
the ability to articulate in multiple directions relative to the
proximal spine segment 3010. A sufficient amount of clearance 3042
may be provided between the proximal end 3032 of the distal spine
segment 3030 and the distal end 3012 of the proximal spine segment
3010 to enable the distal spine segment 3030 to articulate in a
desired range of motion relative to the proximal spine segment
3010. In various embodiments, the distal spine segment 3030 may be
attached to the channel assembly (not shown) to which the anvil
(not shown) is pivotally attached.
[0213] As can be seen in FIG. 62, an actuation member 3050 may be
used to selectively radially extend the ball segments 3020 to
expand and lock the ball-shaped member 3016 in the socket 3034. In
one embodiment (FIGS. 62-64), the actuation member has a hollow
shaft portion 3052 that extends through a passage 3015 in the neck
portion 3014 of the proximal spine segment 3010 and also through a
passage 3017 in the ball-shaped member 3016. The distal end 3054 of
the actuation member 3050 has a substantially cone-shaped portion
3056 that is received in a cone-shaped actuation pocket 3018 in the
ball-shaped member 3016 as shown. As the actuation member 3050 is
drawn in the proximal direction PD, the cone-shaped portion 3056
causes the ball segments 3020 to extend radially outward and lock
the ball-shaped member 3016 within the socket 3034. Various trigger
and locking arrangements (not shown) in the handle may be employed
to selectively axially move the actuation member in the proximal PD
and distal DD directions and lock the actuation member 3050 in
position to retain the ball-shaped member 3016 in an
expanded/locked condition.
[0214] To use this embodiment, the clinician positions the tool
assembly 100 in the patient and then applies an articulation force
to the tool assembly with another surgical instrument or by
bringing the tool assembly 100 into contact with a portion of the
patient to articulate the tool assembly to a desired position
before drawing the actuation member 3050 in the proximal direction
PD. After the tool assembly 100 has been articulated to the desired
position, the clinician draws the actuation member 3050 in the
proximal direction to cause the ball segments 3020 to expand
radially outwardly and lock the ball-shaped member 3016 in that
orientation within the socket 3034 to thereby retain the distal
spine segment 3030 (and the tool assembly 100 attached thereto) in
that articulated position. Such system employs a "passive"
articulation technique.
[0215] FIGS. 65-67 depict another lockable articulation joint 3100
of various embodiments of the present invention that is
substantially identical in operation as articulation joint 3000
described above, except for the actuation member 3150 and the
ball-shaped member 3116. As can be seen in those Figures, the
ball-shaped member 3116 has at least one and preferably three
radially extendable portions 3120 formed therein. The actuation
member 3150 has a hollow shaft portion 3152 that extends through a
passage 3015 in the neck portion 3014 of the proximal spine segment
3010 and also through a passage 3017 in the ball-shaped member
3116. The distal end 3154 of the actuation member 3150 has a
cone-shaped wedge portion 3156 that corresponds to each of the
radially extendable portions 3120 in the ball-shaped member 3116
that extends into a cone-shaped actuation pocket 3118 in the
ball-shaped member 3116 as shown. As the actuation member 3150 is
drawn in the proximal direction PD, the cone-shaped wedge portions
3156 causes the corresponding radially extendable portions 3120 to
expand radially outward and lock the ball-shaped member 3116 within
the socket 3034. Various trigger and locking arrangements (not
shown) in the handle may be employed to selectively move the
actuation member in the proximal PD and distal DD directions and
lock the member in position to retain the ball-shaped member 3116
in a expanded/locked condition.
[0216] To use this embodiment, the clinician positions the tool
assembly 100 in the patient and then applies an articulation force
to the tool assembly with another surgical instrument or by
bringing the tool assembly 100 into contact with a portion of the
patient to articulate the tool assembly to a desired position
before drawing the actuation member 3150 in the proximal direction
PD. After the tool assembly 100 has been articulated to the desired
position, the clinician draws the actuation member 3150 in the
proximal direction to cause the radially extendable portions 3120
to extend radially outwardly and lock the ball-shaped member 3116
in that orientation within the socket 3034 to thereby retain the
distal spine segment 3030 (and the tool assembly 100 attached
thereto) in that articulated position. Such system employs a
"passive" articulation technique.
[0217] FIGS. 68-70 illustrate another lockable articulation joint
3200 of various embodiments of the present invention. As can be
seen in those Figures, various embodiments may include a proximal
spine segment 3210 that extends from the handle assembly (not
shown) and may be supported thereby in any one of a number of known
arrangements without departing from the spirit and scope of the
present invention. The proximal spine segment 3210 may have a
distal end 3012 that has a plurality of radially contractable
portions in the form of, for example, flexible socket fingers 3214
that define a socket 3216 therein. As can also be seen in these
FIG. 68, a ball-shaped member 3310 may be formed on a proximal end
3312 of a distal spine segment 3300. The ball-shaped member 3310
may be formed on the end of a neck portion 3308 sized to be
received in a socket 3216 formed by the socket fingers 3214. The
ball-shaped member 3310 and socket 3216 collectively form a ball
joint, generally designated as 3320, that affords the distal spine
segment 3300 with the ability to articulate in multiple directions
relative to the proximal spine segment 3210. A sufficient amount of
clearance 3002 may be provided between the proximal end 3304 of the
distal spine segment 3300 and the distal end 3212 of the proximal
spine segment 3210 to enable the distal spine segment 3300 to
articulate in a desired range of motion relative to the proximal
spine segment 3210. In various embodiments, the distal spine
segment 3300 may be attached to the channel assembly (not shown) to
which the anvil (not shown) is pivotally attached. In addition, a
hollow passage 3306 may be provided through the ball-shaped member
3310 and a neck portion 3308 to facilitate passage of cables or
other actuation instruments/components therethrough.
[0218] As can also be seen in FIGS. 68-70, this embodiment may also
include a closure ring 3400 that is selectively slidably and
axially movable on the proximal spine segment 3210 in the proximal
and distal directions. The various systems and components described
above may be employed to selectively move the closure ring 3400 in
the distal and proximal directions. As can be most particularly
seen in FIG. 68, the socket fingers 3214 have a sloped or tapered
end surface 3215 to enable the distal end portion 3402 of the
closure ring 3400 to slide thereupon and cause the closure fingers
to 3214 to close upon the ball-shaped member 3310 and lock it in
position.
[0219] To use this embodiment, the clinician positions the tool
assembly 100 in the patient and then applies an articulation force
to the tool assembly with another surgical instrument or by
bringing the tool assembly 100 into contact with a portion of the
patient to articulate the tool assembly to a desired position
before advancing the closure ring 3400 distally. After the tool
assembly 100 has been articulated to the desired position, the
clinician advances the closure ring 3400 distally to cause the
closure fingers 3214 to closure upon the ball-shaped member 3310
and lock the ball-shaped member 3310 in that orientation within the
socket 3216 to thereby retain the distal spine segment 3300 (and
the tool assembly 100 attached thereto) in that articulated
position. Such system employs a "passive" articulation
technique.
[0220] FIG. 71 illustrates another passive articulation joint 3500
of various embodiments of the present invention. As can be seen in
those Figures, various embodiments may include a proximal spine
segment 3510 that extends from the handle assembly (not shown) and
may be supported thereby in any one of a number of known
arrangements without departing from the spirit and scope of the
present invention. The proximal spine segment 3510 may have a
distal end 3512 that has a socket 3514 therein. As can also be seen
in FIG. 71, a ball-shaped member 3530 is formed on a neck portion
3532 formed on the proximal end 3522 of a distal spine segment
3520. The ball-shaped member 3530 and socket 3514 collectively form
a ball joint, generally designated as 3540, that affords the distal
spine segment 3520 with the ability to articulate in multiple
directions relative to the proximal spine segment 3510. In
alternative embodiments, the socket may be formed in the distal
spine segment and the ball-shaped member may be formed in the
proximal spine segment. A sufficient amount of clearance 3542 may
be provided between the proximal end 3522 of the distal spine
segment 3520 and the distal end 3512 of the proximal spine segment
3510 to enable the distal spine segment 3520 to articulate in a
desired range of motion relative to the proximal spine segment
3510. In various embodiments, the distal spine segment 3520 is
attached to the channel assembly (not shown) to which the anvil
(not shown) is pivotally attached.
[0221] As can be further seen in FIG. 71, the proximal facing face
3532 of the ball-shaped member 3530 has a plurality of detents 3534
formed therein. A locking pin 3550 is operably supported within the
proximal spine segment 3510 and is oriented for engagement with the
detents 3534. The locking pin 3550 may be spring biased toward the
proximal facing face 3532 of the ball-shaped member 3530 such that
as the distal spine segment 3520 is articulated relative to the
proximal spine segment 3510, the locking pin snaps into a
corresponding one of the detents 3534 to retain the distal spine
segment 3520 in that position.
[0222] To use this embodiment, the clinician positions the tool
assembly 100 in the patient and then applies an articulation force
to the tool assembly with another surgical instrument or by
bringing the tool assembly 100 into contact with a portion of the
patient to articulate the tool assembly to a desired position or
another surgical tool may be used to apply an articulation force to
the tool assembly to cause the tool assembly 100 to move to a
desired direction. As the tool assembly is articulated, the distal
end 3552 of the locking pin will snap into and out of detents 3534
until the desired articulation position is achieved. Such system
employs a "passive" articulation technique.
[0223] FIG. 72 illustrates another passive articulation joint 3600
of various embodiments of the present invention that is somewhat
similar to the articulation joint 3500 described above except for
the differences discussed below. In this embodiment for example,
the ball-shaped member 3630 may be formed on a neck portion 3632
that protrudes distally from the proximal spine segment 3610. The
proximal spine segment 3610 may extend from the handle assembly
(not shown) and may be supported thereby in any one of a number of
known arrangements without departing from the spirit and scope of
the present invention. The distal spine segment 3620 has a socket
3624 therein. The ball-shaped member 3630 and socket 3622
collectively form a ball joint, generally designated as 3650 that
affords the distal spine segment 3620 the ability to articulate in
multiple directions relative to the proximal spine segment 3610. A
sufficient amount of clearance 3642 is provided between the
proximal end 3622 of the distal spine segment 3620 and the distal
end 3612 of the proximal spine segment 3610 to enable the distal
spine segment 3620 to articulate in a desired range of motion
relative to the proximal spine segment 3610. In various
embodiments, the distal spine segment 3620 is attached to the
channel assembly (not shown) to which the anvil (not shown) is
pivotally attached.
[0224] As can be further seen in FIG. 72, a portion 3638 of the
socket face 3636 may have a plurality of detents 3639 formed
therein. A locking pin 3660 is operably supported within the
proximal spine segment 3610 and is oriented for engagement with the
detents 3639. The locking pin 3660 may be spring biased toward the
face 3636 such that as the distal spine segment 3620 is articulated
relative to the proximal spine segment 3610, the locking pin 3660
snaps into a corresponding one of the detents 3639 to retain the
distal spine segment 3620 in that position.
[0225] To use this embodiment, the clinician positions the tool
assembly 100 in the patient and then applies an articulation force
to the tool assembly with another surgical instrument or by
bringing the tool assembly 100 into contact with a portion of the
patient to articulate the tool assembly to a desired position or
another surgical tool may be used to apply an articulation force to
the tool assembly to cause the tool assembly 100 to move to a
desired direction. As the tool assembly is articulated, the distal
end 3662 of the locking pin 3660 will snap into and out of detents
3639 until the desired articulation position is achieved. Such
system employs a "passive" articulation technique.
[0226] Various surgical stapling instrument embodiments of the
present invention may be designed to accommodate tool assemblies
that are designed to be discarded after a single use. After the
stapling operation is completed, the tool assembly is discarded and
the instrument may be re-sterilized in preparation for another
operation. In such applications, it is often desirable, therefore,
to employ a joint arrangement that facilitates quick attachment and
detachment of the tool assembly to the instrument. FIGS. 73-83
illustrate a surgical instrument 4000 that is constructed for use
in connection a surgical tool assembly 100'' that can perform a
surgical action. In various embodiments, the tool assembly 100'' is
constructed to cut and staple tissue my means of the cable-powered
dynamic clamping member/knife arrangement described above. In other
embodiments, different drive arrangements may be employed to drive
the dynamic clamping member/knife through the elongate channel
portion of the tool assembly 100''.
[0227] In some embodiments, the tool assembly 100'' comprises a
portion of a disposable reload unit 4002. In other embodiments, the
tool assembly 100'' may be permanently attached to the other
portions of the instrument 4000 and capable of reuse in connection
with staple cartridge assemblies. The disposable reload unit 4002
may further include a connector segment 4004 for coupling the
disposable reload unit 4002 to the instrument 4000. In various
embodiments, the tool assembly 100'' may be articulatable relative
to the connector portion 4004 by means of an articulation joint
4006.
[0228] As can be most particularly see in FIG. 73A, one tool
assembly 100'' embodiment may include an elongate channel assembly
4012 that has an anvil assembly 4020 pivotally coupled thereto. For
example, in one embodiment, the anvil assembly 4020 may have a pair
of trunnions 4022 that are adapted to be received in corresponding
slots 4014 in the walls of the elongate channel assembly 4012 as
shown. The anvil assembly 4020 may be formed with an anvil closure
tab 4026 on a proximal end 4024 thereof for selective contact by a
closure ring 4030. The non-rotating closure ring 4030 is keyed to
the elongate channel assembly 4012 and/or anvil assembly 4020 such
that the closure ring 4030 cannot rotate relative to the elongate
channel 4012. A tab clearance opening 4032 may be provided through
the closure ring 4030 to receive the anvil closure tab 4026 when
the anvil assembly 4020 is in the closed (clamped) position. A
series of internal threads 4036 may be provided in the proximal end
4034 of the non-rotating closure ring 4030 for threadably receiving
a threaded distal end 4042 of a distal closure tube segment 4040.
As will be discussed in further detail below, as the distal closure
tube segment 4040 is rotated, the closure ring 4030 is driven
axially in the distal direction DD. As the closure ring 4030 moves
in the distal direction DD, it rides up a ramp 4021 on the proximal
end of anvil assembly 4020 to cause the anvil assembly 4020 to
pivot to a closed position. Such arrangement represents a vast
improvement over prior arrangements wherein the closure ring is
pulled by a cable in the distal direction.
[0229] The surgical instrument 4000 may further include an elongate
closure tube assembly 5000 that houses a variety of components and
which is operably attached to a handle assembly as will be
discussed in further detail below. In various embodiments of the
present invention, the closure tube assembly 5000 may comprise an
intermediate closure tube segment 5001 and a proximal closure tube
segment 5020. In some embodiments, the tool assembly 100'' may be
coupled to the intermediate closure tube segment 5001 of closure
tube assembly 5000 by an articulation joint 4006 that facilitates
travel of the tool assembly 100'' relative to the closure tube
assembly 5000 about two axes UA-UA and OA-OA that are substantially
orthogonal to each other as will be discussed in further detail
below. Also, various embodiments may include a means for actively
controlling the pivotal travel of the tool assembly 100'' as well
as having the capability of passive articulation while also having
the ability to lock the tool assembly in the desired articulated
position. These unique and novel features and advantages will
become further apparent as the present Detailed Description
proceeds.
[0230] In various embodiments, for example, the distal closure tube
segment 4040 may be formed with a pair of opposed universal pivot
arms 4046 that protrude in the proximal direction therefrom. The
distal end 5002 of the intermediate closure tube segment 5001 may
be formed with two opposing fastener arms 5004, 5006 that protrude
distally therefrom. See FIGS. 73A and 74B. Fastener arm 5004 has a
pivot hole 5008 therethrough and fastener arm 5006 has a pivot hole
5010 that is substantially coaxially aligned with the pivot hole
5008 to define the universal pivot axis UA-UA. Positioned between
the fastener arms 5004 and 5006 is a universal ring 4070 that has
two pairs of pins 4072, 4074 protruding therefrom wherein each pin
may be spaced ninety degrees from each other about the
circumference of the universal ring 4070 (one pin 4074 is shown in
dashed lines in FIGS. 73A and 74A). As shown in FIG. 73A, one pin
4072 is pivotally received in upper pivot hole 5008 in the fastener
arm 5004 and the other pin 4072 is pivotally received in the lower
pivot hole 5010 in the fastener arm 5006. Such arrangement enables
the universal ring 4070 to pivot about the universal axis UA-UA
relative to the closure tube assembly 5000. Each of the opposed
universal pivot arms 4046 protruding from the distal closure tube
4040 has a hole 4047 therein to pivotally receive a corresponding
one of the pins 4074 therein to enable the distal closure tube 4040
to pivot relative to the universal ring 4070 and closure tube
assembly 5000 about an orthogonal axis OA-OA (shown in FIG. 75) in
a first pivotal direction represented by arrow FD in FIG. 73A and
second pivotal direction represented by arrow SD in FIG. 73A. Axis
UA-UA and OA-OA may be substantially orthogonal to each other.
[0231] Thus, the person of ordinary skill in the art will
appreciate that the above-described universal ring 4070 arrangement
facilitates the articulation of the distal closure tube 4040 and
ultimately tool assembly 100'' which is attached thereto about
multiple axes UA-UA and OA-OA relative to the closure tube assembly
5000. In addition, as will be further described below, in various
embodiments, the closure tube assembly 5000 may be rotatably
supported by the handle assembly such that it may be rotated around
the shaft axis C-C. Because the tool assembly 100'' is affixed to
the closure tube assembly 5000 (through the articulation joint
4006), the tool assembly 100'' is also rotated therewith. Such
arrangement, therefore, provides a tool assembly 100'' that may
have a cable driven knife assembly therein and a non-cable driven
anvil closure arrangement with the ability to be articulated about
several axes.
[0232] As can also be seen in FIGS. 73A and 74A, this embodiment
may further include a distal spine segment 4050 that may have an
annular retaining flange 4052 formed thereon that is received in a
locating groove 4044 in the distal closure tube 4040. In various
embodiments, the articulation joint 4006 may also include an
articulation joint locking assembly, generally designated as 4007,
which facilitates the locking of the articulation joint 4006 after
the tool assembly 100'' has been articulated to a desired
orientation. Such locking assembly 4007 may include a ball-shaped
member 4060 that is formed on a neck portion 4054 of the distal
spine segment 4050. The locking assembly 4007 may further include a
serrated socket member 5030 that is formed on the distal end 5022
of an intermediate spine segment 5020 located in a connector
segment 4004. Serrated socket member 5030 may comprise a plurality
of radially contractable fingers 5032 that define a socket 5034
therebetween in which the ball-shaped member 4060 may articulate in
multiple directions. The serrated socket member 5030 is mounted
within the universal ring 4070.
[0233] In various embodiments, a socket locking tube 5080 may be
coaxially received on the disposable spine segment 5020 such that
it is axially movable relative thereto as will be discussed in
further detail below. The distal end 5082 of the locking tube 5080
may be tapered for selective axial contact with the serrated socket
member 5030 as the locking tube 5080 is axially advanced in the
distal direction DD to cause the serrated fingers 5032 to radially
contract and close around the ball-shaped member 4060 to lock the
distal spine segment 4050 (and tool assembly 100'') in position
relative to the elongate closure tube assembly 5000.
[0234] The surgical instrument 4000 of various embodiments of the
present invention may further include an active articulation system
generally designated as 5090 for actively applying articulation
motions to the distal spine segment 4050. In various embodiments,
for example, the active articulation system 5090 may include four
articulating wires 5092 that may be fabricated from spring steel or
the like and be sufficiently stiff to transfer a compression force
applied to a proximal end portion thereof without collapsing. The
wires 5092 may be spaced around the serrated socket 5030 at ninety
degree intervals from each other and be received within
corresponding grooves 5033 in the outer surface of the
corresponding radially contractable fingers 5032. The distal end
5094 of each wire 5092 may be attached to the neck portion 4054 of
the distal spine segment 4050 and the proximal ends 5096 of each
wire 5092 may be attached to a hub portion 5102 of a distal wire
mount 5100 received within the closure tube 5000 as shown in FIG.
73B. As will be discussed in further detail below, the distal spine
segment 4050 (and tool assembly 100'' attached thereto) may be
actively articulated by pulling and pushing the wires 5092.
[0235] Also in various embodiments, the proximal facing portion of
ball-shaped member 4060 may have a substantially conical shaped
cavity 4062 therein to accommodate one or more knife actuation
cables 5040 that are attached to a dynamic clamping member (not
shown) and/or knife (not shown) mounted within the disposable tool
assembly 100''. The proximal end 5042 (FIG. 73A) of the cable 5040
may be attached to a knife nut 5050 that is threadably journaled on
a knife screw 5060. As can be seen in FIGS. 73A and 75, the knife
nut 5050 has a pair of laterally protruding tabs 5052 that are
axially received in corresponding axially extending slots 5024 in
the disposable spine segment 5020. The person of ordinary skill in
the art will appreciate that such arrangement permits the knife nut
5050 to move axially in the proximal direction PD or distal
direction DD as the knife screw 5060 is rotated.
[0236] As indicated above, the disposable reload unit 4002 in
various embodiments may be constructed to be disposable after one
use. To facilitate quick detachment of a reload unit 4002 and
reattachment of a new reload unit 4002 without the use of tools, a
quick disconnect joint 4008 may be employed. As used herein, the
term "quick disconnect" refers to the ability to detach one
component from another component without the use of tools. The
operation and construction of various embodiments of the quick
disconnect joint 4008 may be understood from reference to FIGS.
73B, 74B, and 76. As can be seen in FIGS. 73B and 74B, the closure
tube assembly 5000 comprises an intermediate closure tube segment
5001 and a proximal closure tube segment 5020. As can be seen in
FIGS. 73B and 76, the proximal end of the intermediate closure tube
segment 5001 has a series of radial gear teeth 5003 formed thereon
for meshing engagement with gear teeth 5124 (not shown in FIG. 76)
on a distal end 5122 of a proximal closure tube segment 5120 (not
shown in FIG. 76) when the disposable reload unit 4002 is attached
the proximal closure tube segment 5120.
[0237] To support the removable interconnection between the
disposable reload unit 4002 and the proximal closure tube segment
5120, a connection spider 5150 may be employed. The connection
spider 5150 may be partially received within the proximal end of
the intermediate closure tube segment 5001 and protrude therefrom
such that when the intermediate closure tube segment 5001 is
coupled to the proximal closure tube segment 5120, a portion of the
connection spider 5150 protrudes into the distal end 5122 of the
proximal closure tube segment 5120. In various embodiments, the
connection spider may be pinned within the proximal end of the
intermediate closure tube segment 5001 by a pin 5151, adhesive or
other suitable fastener arrangements. See FIG. 76.
[0238] In various embodiments, the connection spider 5150 may also
be journaled on a disposable spine segment 5020 and configured to
receive corresponding actuator bars 5104 that protrude from a
distal wire mount 5100. The proximal end 5106 of each actuator bar
5104 may contain a tapered detent to facilitate interconnection
with a plurality of proximal wire connector members 5160. In one
embodiment for example, four proximal wire connector members are
employed. The plurality of actuator bars 5104 may be provided with
a detent 5108 for receiving a corresponding connector ball 5164
mounted within tapered bore detent 5162 in each of the proximal
wire connectors 5160. See FIGS. 73B and 77. Thus, four connector
balls 5164 are employed--one for each proximal wire connector 5160.
As can also be seen in FIGS. 73B, 78, and 79, the proximal end 5021
of the disposable spine segment 5020 has a proximally extending
connection portion 5023 that may have an internal collar portion
5025 formed therein to support a proximal end portion 5062 of the
knife screw 5060. In addition, the proximally extending connection
portion 5023 may have an external spine key 5026 formed thereon for
receipt in a key slot 5206 formed in a distal end 5202 of the
proximal spine segment 5200. The proximal end 5062 of the knife
screw 5060 may be supported in a bearing 5064 and have a splined
drive portion 5066 for non-rotatable receipt in a spline drive
cavity 5224 in the distal end 5222 of a knife drive shaft 5220. See
FIG. 78
[0239] Turning next to FIGS. 74A and 74B, the attachment of the
locking tube 5080 may be understood. As can be seen in FIG. 74A,
the locking tube 5080 a pair of brake actuator arms 5084 protrude
proximally therefrom. FIG. 74B is a cross-section that is rotated
approximately 45 degrees from the cross-section shown in FIG. 73B.
As can be seen in FIG. 74B, each brake actuator arm 5084 has a
detent 5085 formed therein for receiving connector balls 5168
mounted within tapered bore detents 5166 in a corresponding
proximal brake actuator arm 5300. See FIGS. 74B and 77. To provide
the brake actuator arm 5084 with sliding lateral support, each
brake actuator arm 5084 may be slidably received in a corresponding
groove 5027 in the disposeable spine segment 5020. See FIGS. 75 and
76.
[0240] As can also be seen in FIG. 73B, an outer proximal spine
segment 5400 may be received within the proximal closure tube 5120
and cooperates therewith to define a spring cavity 5402 for
receiving a closure tube spring 5410 therein. The proximal end 5126
of the proximal closure tube segment 5120 may have an enlarged knob
portion 5128 thereon to facilitate the application of control
motions thereto by the clinician. A pocket 5130 may be formed in
the knob portion 5128 for receiving a clip ring 5132 therein that
is affixed to the outer proximal spine segment 5400. Thus, the
closure tube spring 5410 serves to bias the proximal closure tube
segment 5120 into meshing engagement with the disposable closure
tube segment 5000. As can be seen in FIGS. 73B and 78, the distal
end 5122 of the proximal closure tube segment 5120 has a larger
internal diameter 5123 that has a tapered surface 5125 To disengage
the tool assembly 100'' from the instrument 4000, the clinician
draws the knob 5128 in the proximal direction PD against the force
of the spring 5410 until the larger internal diameter portion 5123
is oriented in registration with the connector balls 5164 to enable
the connector balls 5164 to move out of engagement with the detents
5108 in the proximal ends 5106 of the actuator bars 5104 of the
distal wire mount 5100 when the user applies a removal force to the
tool assembly 100'' pulling it in the distal direction DD.
[0241] FIGS. 78-81 illustrate the attachment of a disposable reload
unit 4002 to the instrument portion 4000. With particular reference
to FIG. 78, the clinician orients the unit 4002 such that the
spline portion 5066 of the knife screw 5060 is aligned with the
internal spline cavity 5224 in the knife drive shaft 5220 and
inserts the proximal end of the spline drive portion 5066 therein.
See FIG. 79. Thereafter, the clinician aligns the spine key 5026 on
the proximal end 5021 of the disposable spine segment with the key
slot 5206 in the proximal spine segment 5200. See FIGS. 79 and 80.
The clinician then continues to insert the proximal end 5106 into
the area 5161 between the four proximal wire connectors 5160 and
the proximal spine segment 5200. See FIG. 80. The clinician may
then move the closure knob 5128 in the proximal direction to enable
the connector balls 5164 to move radially outward as the proximal
ends 5106 of the actuator bars 5104 are pushed proximally into
position. The clinician then releases the knob 5128 to permit the
proximal closure tube 5120 to move distally locking the connector
balls 5164 in the detents 5108 in the actuator bars 5104 of the
distal wire mount 5100 to affix the four proximal wire connectors
5160 to the distal wire mount 5100 and also lock the connector
balls 5168 in the detents 5085 in the brake actuator arms 5084. In
addition, the radial gears 5003, 5124 are retained in meshing
engagement with each other.
[0242] FIGS. 82-84 depict one embodiment that may be used to
articulate the tool assembly 100'' relative to the connector
segment 4004 and provide actuation thereto. As can be seen in FIG.
82, the instrument 4000 may further include a handle assembly 5500
that may be formed from two housing sections 5510 (only one housing
section 5510 is shown in FIG. 82) that may be connected together by
screws, snaps, adhesive, etc. In various embodiments, the handle
assembly 5500 may take the form of a "pistol-grip" type housing
with a hand grip portion 5512. As can be seen in FIG. 82, an
attachment flange 5404 may be formed on the proximal end of the
outer proximal spine segment 5400 for affixing the outer proximal
spine segment 5400 to the handle assembly 5500. The flange 5404 may
be attached to the handle housing 5500 by adhesive or other
mechanical fastener arrangements, screws, snaps, slots, etc.
Likewise, the proximal end 5204 of the proximal spine segment 5200
may have a flange 5210 for affixing the proximal spine segment 5200
to the handle assembly 5500. The flange 5210 may be attached to the
handle housing 5500 by adhesive or other mechanical fastener
arrangements, screws, snaps, slots, etc.
[0243] In various embodiments, the active articulation system 5090
may further comprise an articulation control system, generally
designated as 5600, that is operably supported by the handle
assembly 5500 and interfaces with the articulation wires 5092. As
can be seen in FIG. 82, articulation control system 5600 may
comprise a joy stick assembly 5602 to which the proximal ends 5170
of each of the proximal wire connectors 5160 are pivotally
connected. In one embodiment, for example, a joy stick assembly
5602 may include an articulation ball 5610 that is rotatably
supported in a socket 5520 in the handle assembly 5500. In various
embodiments, each proximal end 5170 of the proximal wire connectors
5160 may have a spherical ball bearing 5172 supported thereon to
receiving a bearing mount pin 5612 to attach the proximal wire
connectors 5160 to the articulation ball 5610. Other fastener
arrangements could also be employed however. In addition, an
articulation knob 5620 may be attached to the articulation ball
5610.
[0244] Thus, to articulate the tool assembly 100'' relative to the
connector segment 4004, the clinician can grasp the hand grip
portion 5512 in one hand and the articulation knob 5620 in the
other hand. By manipulating the articulation knob 5620, the
clinician can apply articulation motions to the distal wire mount
5100 and ultimately to the four articulation wires 5092 attached
thereto which, in turn, impart the articulation motion to the
distal spine segment 4050 which will cause the tool assembly 100''
to articulate relative to the connector segment 4004 of the
disposable reload unit 4002. Thus, the clinician can effectively
steer the tool assembly 100'' through use of the joy stick assembly
5602.
[0245] The position of the tool assembly 100'' may be locked in
position by a brake control system generally designated as 5640. As
can be seen in FIGS. 82 and 84, a brake control system 5640 may
include a driver disc 5642 that is movably journaled on the knife
drive shaft 5220 for selective axial movement therealong without
impeding the rotation of the knife drive shaft 5220. As can be seen
in FIG. 84, each proximal brake actuator arm 5300 has a proximal
end 5302 that is affixed to the drive disc 5642. A brake yoke 5650
may be coupled to the driver disc 5642 by a pair of pins 5643 that
protrude into circumferentially extending groove 5644 formed in the
driver disc 5642. The brake yoke 5650 may be pivotally supported by
the housing assembly 5500 on a brake yoke pivot pin 5652. As can be
seen in FIG. 84, in various embodiments, a brake trigger 5654 is
formed on the lower portion of the brake yoke 5650. The brake
trigger 5654 may have a lock arm 5656 protruding therefrom into an
opening 5506 in the housing assembly 5500. A lower portion of the
lock arm 5656 may have lock teeth 5658 formed thereon to engage a
locking wall portion 5508 of the housing assembly 5500.
[0246] Various embodiments of the present invention may also employ
a brake release mechanism 5660 for locking and unlocking the brake
trigger 5654. As can be seen in FIG. 84, one form of a release
mechanism 5660 may include a locking button 5662 that has a release
button portion 5664 and is movably supported by the handle assembly
5500 in the position illustrated in FIG. 84. As can be seen in that
Figure, the locking button 5664 may have a conical shaped end
portion 5666 that has a neck that extends to a conical portion (not
shown) of the release button portion 5664. When the clinician
pushes the release button portion 5664 in a first direction, the
conical portion 5666 contacts the lock arm 5656 and lifts it out of
engagement with the locking wall portion 5508 to thereby enable the
trigger 5654 to pivot. A spring (not shown) could be used to retain
the locking button 5662 in the locked position. Once the trigger
5654 is pivoted to the desired position, the user simply pushes the
release portion 5664 in an opposite direction to move the conical
portion 5666 out of engagement with the lock arm 5656 to permit it
to engage the locking wall portion 5508 once again. Thus, once the
clinician has articulated the tool assembly 100'' to the desired
position, the clinician squeezes the brake trigger 5654 toward the
handle assembly 5500. Such action causes the brake yoke 5650 and
the driver disc 5642 to move the brake arms 5300 in the distal
direction DD which drives the locking tube 5080 in the distal
direction DD to lock the fingers 5032 around the ball-shaped member
4060. Once the fingers 5032 have been locked around the ball-shaped
member 4060, the clinician can push the locking button in a
direction which permits one of the teeth 5658 on the locking arm
5656 to engage the locking wall portion 5508 and retain the brake
release mechanism in the locked position. When the clinician
desires to unlock the tool assembly 100'' and perhaps rearticulate
it, the clinician simply pushes the locking trigger release button
portion to permit the trigger 5654 to be pivoted away from the
handle assembly 5500 and thereby move the brake arms 5300
proximally.
[0247] In various embodiments of the present invention, rotational
motion may be applied to the knife drive shaft 5220 by means of a
drive system generally designated as 5700. As can be seen in FIGS.
82 and 83, in one embodiment, the drive system 5700 may include a
firing handle 5702 that is pivotally or otherwise actuatably
coupled to the handle assembly 5500. In one embodiment for example,
the firing handle 5702 may be pivotably attached to the handle
assembly 5500 by a pivot pin 5704. Attached to the firing handle is
a firing gear 5706 that is oriented to pivot with the firing handle
5702. The firing gear 5706 may be in meshing engagement with a
ratchet drive gear 5708 that is mounted to a ratchet drive shaft
5710. Ratchet drive shaft 5710 may be attached to a ratchet clutch
assembly 5720.
[0248] In various embodiments, a ratchet clutch assembly 5720 may
include a first clutch plate 5722 that is attached to the ratchet
shaft 5710 and which is in meshing engagement with a second ratchet
clutch plate 5724 that is mounted to an output shaft 5726. The
second clutch plate 5724 may be biased into meshing engagement with
the first clutch plate 5722, by ratchet spring 5730. A ratchet
output gear 5740 may be attached to the ratchet output shaft 5726
which is arranged for meshing engagement with a drive gear 5750
mounted to a bevel drive shaft 5752. An input bevel gear 5760 may
be mounted on the bevel drive shaft 5752 and be in meshing
engagement with an output bevel gear 5770 that is mounted to an
output shaft 5780. An output gear 5782 is mounted to the output
shaft 5780 and is in meshing engagement with a knife drive gear
5790 attached to the proximal end 5226 of the knife drive shaft
5220.
[0249] Thus, to rotate the knife drive shaft 5220 and drive the
knife nut 5050 in the proximal direction PD and actuate the dynamic
clamping assembly (not shown) and knife arrangement (not shown) by
means of the knife actuation cables 5040, the clinician grasps the
handle assembly and ratchets the firing handle 5702 back and forth
toward the grip portion 5512. Movement of the firing handle 5512 in
that manner will cause the drive system 5700 to impart a rotary
motion to the knife drive shaft 5220 and ultimately to the knife
screw 5060 to cause the knife nut 5050 to move in the proximal
direction. After the firing sequence has been completed, the
clinician can detach the reload unit 4002 and reattach another
reload unit and repeat the process. In alternative embodiments, the
knife drive shaft may be rotated by means of a motor and planetary
gear drive. The motors may be battery powered or powered with
alternating current. Other drive arrangements could also be
employed.
[0250] FIGS. 85-89 illustrate another surgical instrument
embodiment 6000 that employs an active or controllable articulation
joint arrangement 6010. As can be seen in FIGS. 85 and 86, one
embodiment may employ a closure tube 6020 of the type and
construction described above. The closure tube 6020 has a proximal
end (not shown) that may interface with various closure tube
control mechanisms supported by the handle assembly for providing
actuation forces thereto. The closure tube 6020 may also interface
with one of the various tool assemblies described above to apply
opening or opening and closing forces to the anvil assembly
thereof. Also in this embodiment, a spine member 6030 may extend
from the handle assembly (not shown) through the closure tube 6020.
Again, the proximal end (not shown) of the spine member 6030 may be
operably supported by the handle assembly (not shown) in the
various manners described above or in other known manners. In
various embodiments, the distal end 6032 of the spine member 6030
may be formed with a top spine arm 6034 and a bottom spine arm 6036
that protrude in the distal direction DD from the distal end 6032
of the spine member 6030. The top spine arm 6034 has a pivot hole
6037 therethrough and the bottom spine arm 6036 has a pivot hole
6039 that is substantially coaxially aligned with the pivot hole
6037 along a vertical axis VA-VA.
[0251] The various embodiments may also include a horizontal
locking tube 6040 that extends through the spine member 6030. The
horizontal locking tube 6040 has a proximal end (not shown) that is
supported by the handle assembly (not shown) and which may
interface with an actuation arrangement (not shown) for axially
advancing the horizontal locking tube 6040 axially in the proximal
direction PD and distal direction DD within the spine member 6030
and for selectively retaining or locking the horizontal locking
tube 6040 in a desired axial position. In addition, the actuation
arrangement for the horizontal locking tube 6040 may also employ a
spring or other arrangement for biasing the horizontal locking tube
6040 in the proximal direction PD after the horizontal locking tube
6040 has been unlocked. As can be seen in FIG. 86, the horizontal
locking tube 6040 has a top or first locking bar 6042 that has a
series of top or first teeth 6044 formed therein. The horizontal
locking bar 6040 further has a bottom or second locking bar 6046
that has a series of bottom or second teeth 6048 formed in the
distal end thereof.
[0252] Also in these embodiments, a vertical locking tube 6050 may
extend through the horizontal locking tube 6040. The vertical
locking tube 6050 has a proximal end (not shown) that is supported
by the handle assembly (not shown) and which may interface with an
actuation arrangement (not shown) for axially advancing the
vertical locking tube 6050 axially in the proximal direction PD and
distal direction DD within the horizontal locking tube 6040 and for
selectively retaining or locking the vertical locking tube 6050 in
a desired axial position. In addition, the actuation arrangement
for the vertical locking tube 6050 may also employ a spring or
other arrangement for biasing the vertical locking tube 6050 in the
proximal direction PD after the vertical locking tube 6050 has been
unlocked. In various embodiments, for example, the actuation
arrangement employed may be configured to actuate, lock and release
the horizontal locking tube 6040 and the vertical locking tube 6050
in simultaneous motions.
[0253] As can be seen in FIG. 86, in various embodiments, for
example, the vertical locking tube 6050 has a first vertical lock
tine 6052 and a second vertical lock tine 6054. Various embodiments
may employ a tool assembly of the types described above that use a
cable driven dynamic clamping member and/or knife arrangement. The
vertical locking tube may have a cable passage 6056 therethrough to
accommodate the drive cables (not shown) that pass from the tool
assembly to the handle assembly.
[0254] In various embodiments, the first and second vertical
locking tines 6052, 6054 are oriented for engagement with a
vertical locking block 6060. In one embodiment, for example, the
vertical locking block 6060 may have a first lateral locking column
6062 that has a series of first lateral teeth 6064 thereon and a
second lateral column 6066 that has a series of second lateral
teeth 6068 thereon. The first lateral locking column 6062 and the
second lateral locking column 6066 are arranged in a spaced apart
relation to each other by an upper or first lateral cross bar 6070
and a bottom or second lateral cross bar 6072 that are arranged in
a spaced apart relationship to each other to define an
actuator-receiving passage 6074 therebetween. In various
embodiments, the vertical locking block 6060 may be configured for
axial travel in the proximal direction PD and distal direction DD
relative to an articulation member or block 6080 in response to an
actuation motion from the vertical locking tube 6050. The vertical
locking block 6060 may be supported for axial travel toward and
away from the articulation block 6080 by a pair of pins 6076 and
6078 that extend into holes 6077, 6079 in the vertical lock block
6060 and holes (not shown) in articulation block 6080.
[0255] As can be seen in FIGS. 85 and 86, the articulation block
6080 may have a longitudinal passage 6082 therethrough for
accommodating the drive cables (not shown). In addition, a first
vertical pin 6084 is received in a hole 6083 in the articulation
block and protrudes therefrom to be received in the first pivot
hole 6037 in the top or first upper arm 6037 of the spine member
6030. Likewise, a lower pin 6089 protrudes from the bottom surface
of the articulation block 6080 to be pivotally received in the
bottom or second pivot hole in the bottom or second arm 6036 of the
spine member 6030 such that the articulation block 6080 may
selectively pivot about the vertical axis VA-VA. Also in various
embodiments, a proximal end of an elongate channel assembly 6090
that may comprise a portion of the tool assembly may have a first
clevis portion or arm 6092 and a second clevis portion or arm 6094
extending in the proximal direction therefrom. The proximal facing
face 6096 of the first clevis arm 6092 has a first set of
horizontal locking teeth 6068 formed thereon for selective
engagement with a corresponding set of second horizontal locking
teeth 6064 on the first lateral locking column 6062. Likewise, the
proximal facing face 6100 of the second clevis arm 6094 has another
set of first horizontal locking teeth 6102 formed thereon for
selective meshing engagement with another corresponding set of
second horizontal locking teeth 6068 on the second lateral locking
column 6062 on the vertical lock block 6060. The first clevis arm
6092 may have a first pivot hole 6093 therethrough that is adapted
to pivotally receive a pivot pin 6110 protruding from the
articulation block 6080 and the second clevis arm 6094 may have a
second pivot hole 6095 therethrough for pivotally receiving a
second pivot pin 6112 protruding from the articulation block 6080
such that the channel assembly 6090 may selectively pivot relative
to the articulation block 6080 about horizontal axis HA-HA.
[0256] As can also be seen in FIG. 86, a first horizontal lock
segment 6120 may be attached or integrally formed on an upper
surface 6081 of the articulation block 6080 and have a series of
first vertical locking teeth 6122 formed therein for engagement
with a corresponding set of second vertical locking teeth 6044
formed in the top or first horizontal locking bar 6042. Likewise, a
second horizontal lock segment 6130 may be attached to or
integrally formed with a bottom surface 6083 of the articulation
block 6080 and have another series of first vertical locking teeth
6132 formed therein for engagement with a corresponding set of
second vertical locking teeth 6048 on the second or bottom locking
bar 6046.
[0257] To enable the user to actively articulate the tool assembly
(channel assembly 6090) the articulation joint 6010 may be provided
with a horizontal actuator bar 6140 and a vertical actuator bar
6150. The horizontal actuator bar 6140 may be fabricated from
plastic material, spring steel, etc., for example. The distal end
6142 of the horizontal actuator bar 6140 may be formed with a
spherical ball bearing arrangement of the type described above and
be pinned to or otherwise attached to the articulation block 6080.
The proximal end (not shown) of the horizontal actuator bar 6140
may be operably attached to a joy stick assembly of the type
described above operably supported in the handle assembly or other
actuation arrangement for applying pushing and pulling motions to
the horizontal actuator bar 6140. As can be seen in FIGS. 85 and
86, the distal end 6152 of the vertical actuator bar 6150 may be
coupled to an extension block 6097 formed on the second clevis arm
6094. The distal end 6152 may be fixedly attached to the extension
block 6097 or have a spherical ball bearing formed thereon to be
pivotally attached thereto. The proximal end (not shown) of the
vertical actuator bar 6150 may be operably attached to a joy stick
assembly of the type described above operably supported in the
handle assembly or other actuation arrangement for applying pushing
and pulling motions to the vertical actuator bar 6150. in
alternative embodiments, either the vertical actuator bar 6150 or
the horizontal actuator bar 6140 may be omitted. In those
embodiments, for example, if the horizontal actuator bar 6140 is
omitted, the vertical actuator bar 6150 can be employed to
articulate the channel assembly 6090 (and tool assembly) about the
horizontal axis HA-HA and the clinician can articulate the channel
assembly 6090 (and tool assembly) about the vertical axis by
releasing (unlocking) the horizontal locking tube 6040 and bringing
the tool assembly into contact with a portion of the patient's body
or another surgical instrument to apply a pivoting force to the
channel assembly (and tool assembly) to cause them to pivot about
vertical axis VA-VA until they are positioned in the desired
position at which time the horizontal locking tube 6040 may be
advanced into locking engagement with the horizontal lock members
6120, 6130. Similarly, if the vertical actuator bar is omitted, the
horizontal actuator bar can be employed to articulate the channel
assembly 6090 (and tool assembly) about the vertical axis VA-VA and
the clinician can articulate the channel assembly 6090 (and tool
assembly) about the horizontal axis HA-HA by releasing (unlocking)
the vertical locking tube 6050 and bringing the tool assembly into
contact with a portion of the patient's body or another surgical
instrument to apply a pivoting force to the channel assembly 6090
(and tool assembly) to cause them to pivot about horizontal axis
HA-HA until they are positioned in the desired position at which
time the vertical locking tube 6050 may be advanced into locking
engagement with the horizontal locking teeth 6068, 6102 on the
channel devises 6092, 6094, respectively.
[0258] FIGS. 90-105 illustrate another surgical instrument
embodiment 7000 of the present invention, that may be disposed of
after use. However, the unique and novel features of these
embodiments may be employed in connection with several of the
embodiments discussed above without departing from the spirit and
scope of the present invention. As can be seen in FIG. 90, the tool
assembly 7002 includes an anvil assembly 7010 that is pivotally
coupled to a channel assembly 7020 of the type and construction
described above for operably receiving a staple cartridge 7021
therein. The anvil assembly 7020 has a proximal end 7012 that has
two anvil trunnions 7014 protruding therefrom that are adapted to
be received within corresponding open ended slots 7024 in the walls
7022 of the proximal end 7021 of the channel assembly 7020. As can
also be seen in FIGS. 90-95, the instrument 7000 may further
include a spine member 7030 that has a distal end 7032 that may be
attached to the proximal end 7021 of the channel assembly 7020.
[0259] These embodiments may also employ a closure tube 7040 that
may be constructed and operated in any one of the above-described
manners. For example, the distal end 7042 may be constructed for
selective axial contact with a proximal facing ledge 7016 formed in
the anvil assembly 7010 such that as the closure tube 7040 is moved
in the distal direction DD, the distal end 7042 contacts the ledge
7016 and causes the anvil assembly 7010 to pivot to the closed
position (FIGS. 90-92) while the trunnions 7014 are constrained to
pivot in their respective slots 7024 by a trunnion lock bar 7050 as
will be discussed in further detail below. The proximal end (not
shown) of the closure tube 7040 may be supported by actuation
components of the type and construction described above in the
handle assembly (not shown) to selectively control the axial
movement of the closure 7040 in the distal direction DD and
proximal direction PD.
[0260] As can be seen in FIG. 90, the trunnion lock bar 7050 may be
slidably supported in an axial slot 7034 provided in the spine
7030. The proximal end (not shown) of the trunnion lock bar 7050
may interact with actuation members in the handle assembly to move
the trunnion lock bar 7050 in the distal direction DD and the
proximal direction PD and selective retain the bar 7050 in those
positions. As can be further seen in FIGS. 92 and 94, the distal
end 7052 of the trunnion lock bar 7050 may have two trunnion
retention arms 7054 protruding therefrom.
[0261] FIGS. 90-92 illustrate the trunnion lock bar 7050 in the
locked position wherein the trunnion retention arms 7054 retain the
trunnions in their respective open ended slots 7024 in the channel
assembly 7020. As can be seen in those Figures, when in that
position, the anvil assembly 7010 may be in the closed (clamped)
position. After the stapling procedure has been completed (e.g.,
after the dynamic clamping member/knife assembly has been driven
from the proximal end 7004 of the tool assembly 7002 to the distal
end 7006 of the tool assembly 7002), the clinician can retract the
closure tube and the trunnion lock bar 7050 in the proximal
direction to permit the trunnions 7014 to popup through the open
end 7025 of each slot 7024 as shown in FIG. 95. When the proximal
end 7012 of the anvil assembly 7010 is in the position illustrated
in FIG. 95, the person of ordinary skill in the art will understand
that the tissue that was once clamped between the anvil assembly
7010 and the staple cartridge 7021 can now be released
therefrom.
[0262] FIGS. 104 and 105 illustrate an alternative surgical
instrument 4000' embodiment that may have portions that are
substantially identical in construction and operation as the
surgical instrument 4000 described above. In the embodiment
depicted in FIGS. 104 and 105, however, the slots 4014' are opened
ended to permit the trunnions 4022' to become disengaged therefrom.
As can be seen in FIG. 104, when the closure ring 4030 has been
advanced to its distal-most position to close the anvil assembly
4020, the closure ring 4030 also serves to retain the anvil
assembly 4020' in the clamped position by virtue of its bearing on
the proximal end portion 4024' of the anvil assembly 4020'. When
the closure ring 4030 is advanced to its proximal-most position as
shown in FIG. 105, the trunnions 4022' are free to move out of the
open ended slots 4014' in the elongate channel assembly 4012'.
Surgical instrument 4000' may otherwise operate in an identical
manner as surgical instrument 4000 which was described in detail
above.
[0263] Also in various embodiments, to completely release the anvil
assembly 7010, the anvil assembly 7010 may be provided with a
spring member 7100 that is attached to the underside 7011 of the
anvil assembly 7010 as shown in FIG. 95. As can be seen in that
Figure, the dynamic clamping member 150 which is configured to be
driven by one or more drive cables 7110, 7112 within the elongate
channel assembly 7020 by drive cables may be provided with a pin
159 that is oriented to be slidably received in a slot 7018 in the
anvil assembly 7010. The pin 159 serves to draw the anvil assembly
7010 toward to the elongate channel assembly 7020 as the dynamic
clamping assembly 150 is driven in the distal direction DD through
the elongate channel assembly 7010. As can be seen in FIG. 95, the
distal end 7102 of the spring member 7120 extends downwardly to
engage the pin 159 when the dynamic clamping assembly 150 has
reached its distal-most position as illustrated in FIG. 95.
Thereafter, pulling or otherwise moving the dynamic clamping
assembly 150 in the proximal direction will result in the spring
7102 dislodging the pin 159 from the slot 7018.
[0264] Various embodiments of a dynamic clamping assembly 150 are
illustrated in FIGS. 96-103. As can be seen in those Figures, a
dynamic clamping member 150 may include an upper portion 157, a
central support or upward extension 151, and a bottom portion 152
which cooperates to slidingly retain dynamic clamping member 150
along an ideal cutting path during longitudinal, distal movement
thereof within the elongate channel assembly 7020. The leading
cutting edge 155, here, knife blade 155a, is dimensioned to ride
within a slot formed in the staple cartridge 7021 and separate
tissue once stapled. It is envisioned that leading edge 155 of the
dynamic clamping member 150 may be serrated, beveled or notched to
facilitate tissue cutting. The dynamic clamping member 150 may be
driven by one or more drive cables 7100, 7112. To facilitate
attachment of said drive cables 7110, 7112, the dynamic clamping
assembly 150 may be provided with attachment apertures 7130 and
ledges 7132. However, other attachment arrangements and drive
configurations could be employed.
[0265] Turning to FIG. 96, the upper portion 157 of the dynamic
clamping member is provided with an open ended slot 7140 for
receiving the pin 159 therein. Once the pin 159 contacts the spring
7100, the pin 159 may be forced out of the open ended slot 7140.
The dynamic clamping member embodiment of FIG. 97 is substantially
identical to the embodiment of FIG. 96, except that the upper
portion 157 has a reinforcement member 7150 formed thereon. In the
embodiment of FIG. 98, an undercut portion 7160 is provided in the
upper portion and the slot 7162 is initially crimped closed. When
the pin 159 contacts the spring 7100, the bottom portion 7164
forming the slot is permitted to bend downward to release the pin
159. In the embodiment depicted in FIG. 99, the slot 7170
supporting the pin 159 is defined by a bendable flap 7172 that can
be bent or deformed to open the slot 7170 to permit the pin to be
removed therefrom as illustrated in FIG. 100. The embodiment
depicted in FIG. 101 has a second slot 7190 that communicates with
the first pin slot 7180 that enables the first pin slot to be
opened to a point wherein the pin can be released therefrom. In the
embodiments depicted in FIGS. 96-101, the pin 159 has a
substantially circular cross-sectional shape. In the embodiment
depicted in FIGS. 102 and 103, the pin 159' is provided with
lateral wings or gussets 7200 to provide additional support to the
pin 159' and minimize any likelihood of the pin bending as the
dynamic clamping member 150 is driven through the elongate channel
assembly 7020.
[0266] While several embodiments of the invention have been
described, it should be apparent, however, that various
modifications, alterations and adaptations to those embodiments may
occur to persons skilled in the art with the attainment of some or
all of the advantages of the invention. For example, according to
various embodiments, a single component may be replaced by multiple
components, and multiple components may be replaced by a single
component, to perform a given function or functions. This
application is therefore intended to cover all such modifications,
alterations and adaptations without departing from the scope and
spirit of the disclosed invention as defined by the appended
claims.
[0267] The devices disclosed herein can be designed to be disposed
of after a single use, or they can be designed to be used multiple
times. In either case, however, the device may be reconditioned for
reuse after at least one use. Reconditioning may include any
combination of the steps of disassembly of the device, followed by
cleaning or replacement of particular pieces, and subsequent
reassembly. In particular, the device may be disassembled, and any
number of particular pieces or parts of the device can be
selectively replaced or removed in any combination. Upon cleaning
and/or replacement of particular parts, the device may be
reassembled for subsequent use either at a reconditioning facility,
or by a surgical team immediately prior to a surgical procedure.
Those of ordinary skill in the art will appreciate that the
reconditioning of a device may utilize a variety of different
techniques for disassembly, cleaning/replacement, and reassembly.
Use of such techniques, and the resulting reconditioned device, are
all within the scope of the present application.
[0268] Preferably, the invention described herein will be processed
before surgery. First a new or used instrument is obtained and, if
necessary, cleaned. The instrument can then be sterilized. In one
sterilization technique, the instrument is placed in a closed and
sealed container, such as a plastic or TYVEK.RTM. bag. The
container and instrument are then placed in a field of radiation
that can penetrate the container, such as gamma radiation, x-rays,
or higher energy electrons. The radiation kills bacteria on the
instrument and in the container. The sterilized instrument can then
be stored in the sterile container. The sealed container keeps the
instrument sterile until it is opened in the medical facility.
[0269] Any patent, publication, or other disclosure material, in
whole or in part, that is said to be incorporated by reference
herein is incorporated herein only to the extent that the
incorporated materials does not conflict with existing definitions,
statements, or other disclosure material set forth in this
disclosure. As such, and to the extent necessary, the disclosure as
explicitly set forth herein supersedes any conflicting material
incorporated herein by reference. Any material, or portion thereof,
that is said to be incorporated by reference herein, but which
conflicts with existing definitions, statements, or other
disclosure material set forth herein will only be incorporated to
the extent that no conflict arises between that incorporated
material and the existing disclosure material.
[0270] The invention which is intended to be protected is not to be
construed as limited to the particular embodiments disclosed. The
embodiments are therefore to be regarded as illustrative rather
than restrictive. Variations and changes may be made by others
without departing from the spirit of the present invention.
Accordingly, it is expressly intended that all such equivalents,
variations and changes which fall within the spirit and scope of
the present invention as defined in the claims be embraced
thereby.
* * * * *