U.S. patent application number 12/622130 was filed with the patent office on 2011-04-14 for method for forming a staple.
This patent application is currently assigned to Ethicon Endo-Surgery, Inc.. Invention is credited to James J. Bedi, Adam R. Dunki-Jacobs.
Application Number | 20110087276 12/622130 |
Document ID | / |
Family ID | 43854038 |
Filed Date | 2011-04-14 |
United States Patent
Application |
20110087276 |
Kind Code |
A1 |
Bedi; James J. ; et
al. |
April 14, 2011 |
METHOD FOR FORMING A STAPLE
Abstract
A method for deforming a staple comprising a base, a first
staple leg, and a second staple leg, wherein the base, the first
staple leg, and the second staple leg are positioned within a
common plane prior to being deformed, the method comprising
positioning the first staple leg within a first cup of a staple
pocket, the first cup comprising a first inner surface, applying a
first compressive force to an end of the first staple leg to bend
the first staple leg toward the base and the second staple leg,
contacting the first inner surface with the end of the first staple
leg to bend the end of the first staple leg toward a first side of
the base, and deforming the first staple leg such that the end of
the first staple leg crosses a mid-line of the staple defined
between the first staple leg and the second staple leg.
Inventors: |
Bedi; James J.; (Cincinnati,
OH) ; Dunki-Jacobs; Adam R.; (Cincinnati,
OH) |
Assignee: |
Ethicon Endo-Surgery, Inc.
Cincinnati
OH
|
Family ID: |
43854038 |
Appl. No.: |
12/622130 |
Filed: |
November 19, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61250377 |
Oct 9, 2009 |
|
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Current U.S.
Class: |
606/219 ;
227/175.1 |
Current CPC
Class: |
A61B 17/07207 20130101;
A61B 2017/07285 20130101; A61B 17/0686 20130101; A61B 17/0644
20130101; A61B 2017/07264 20130101 |
Class at
Publication: |
606/219 ;
227/175.1 |
International
Class: |
A61B 17/064 20060101
A61B017/064; A61B 17/068 20060101 A61B017/068 |
Claims
1. A method of forming a surgical staple comprising a base, a first
staple leg, and a second staple leg, wherein the base, the first
staple leg, and the second staple leg are positioned within a
common plane prior to being deformed by an anvil, said method
comprising supporting the base of the staple; positioning a staple
pocket of the anvil in opposition to the staple, wherein the staple
pocket comprises a longitudinal axis; positioning the first staple
leg within a first cup of the staple pocket, wherein the first cup
comprises a first inner surface at least partially positioned on a
first side of the longitudinal axis; positioning the second staple
leg within a second cup of the staple pocket, wherein the second
cup comprises a second inner surface at least partially positioned
on a second side of the longitudinal axis; applying a first
compressive force to an end of the first staple leg to bend the
first staple leg toward the base and toward the second staple leg;
applying a second compressive force to an end of the second staple
leg to bend the second staple leg toward the base and toward the
first staple leg; contacting the first inner surface with the end
of the first staple leg to bend the end of the first staple leg
toward the first side of the longitudinal axis and toward a first
side of the common plane; and contacting the second inner surface
with the end of the second staple leg to bend the end of the second
staple leg toward the second side of the longitudinal axis and
toward a second side of the common plane; deforming the first
staple leg such that the end of the first staple leg crosses a
mid-plane of the staple, wherein the mid-plane of the staple is
defined between the first staple leg and the second staple leg; and
deforming the second staple leg such that the end of the second
staple leg crosses the mid-plane of the staple.
2. The method of claim 1, wherein the end of the first staple leg
is deformed in a first direction, wherein the end of the second
staple leg is deformed in a second direction, and wherein the first
direction is transverse to the second direction.
3. The method of claim 2, wherein an angle is defined between the
first direction and the second direction, and wherein the angle is
approximately 90 degrees.
4. The method of claim 2, wherein an angle is defined between the
first direction and the second direction, and wherein the angle is
between approximately 0.1 degrees and approximately 90 degrees.
5. The method of claim 1, wherein the first inner surface defines a
first plane oriented at an angle with respect to the longitudinal
axis, and wherein the second inner surface defines a second plane
oriented at an angle with respect to the longitudinal axis.
6. The method of claim 5, wherein the first plane and the second
plane are parallel to one another.
7. The method of claim 5, wherein the first cup and the second cup
are separated by a sidewall, wherein a first side of the sidewall
comprises the first inner surface, and wherein a second side of the
sidewall comprises the second inner surface.
8. The method of claim 5, wherein said positioning step further
comprises placing a tissue-contacting surface of the anvil against
tissue positioned intermediate the staple and the staple pocket,
wherein at least a portion of the first inner surface is
perpendicular to the tissue-contacting surface, and wherein at
least a portion of the second inner surface is perpendicular to the
tissue-contacting surface.
9. A surgical instrument capable of performing the method of claim
1.
10. A surgical staple produced by the method of claim 1.
11. A method of forming a surgical staple comprising a base, a
first staple leg, and a second staple leg, said method comprising
supporting the base of the staple; positioning a staple pocket of
an anvil in opposition to the staple, wherein the staple pocket
comprises a longitudinal axis; positioning the first staple leg
within a first cup of the staple pocket, wherein the first cup
comprises a first inner surface; positioning the second staple leg
within a second cup of the staple pocket, wherein the second cup
comprises a second inner surface; applying a first compressive
force to an end of the first staple leg to bend the first staple
leg toward the base and toward the second staple leg; applying a
second compressive force to an end of the second staple leg to bend
the second staple leg toward the base and toward the first staple
leg; contacting the first inner surface with the end of the first
staple leg to bend the end of the first staple leg toward a first
side of the base; and contacting the second inner surface with the
end of the second staple leg to bend the end of the second staple
leg toward a second side of the base, wherein the second side is
opposite the first side; deforming the first staple leg such that
the end of the first staple leg crosses a mid-line of the staple,
wherein the mid-line of the staple is defined between the first
staple leg and the second staple leg; and deforming the second
staple leg such that the end of the second staple leg crosses the
mid-line of the staple.
12. The method of claim 11, wherein the end of the first staple leg
is deformed in a first direction, wherein the end of the second
staple leg is deformed in a second direction, and wherein the first
direction is transverse to the second direction.
13. The method of claim 12, wherein an angle is defined between the
first direction and the second direction, and wherein the angle is
approximately 90 degrees.
14. The method of claim 12, wherein an angle is defined between the
first direction and the second direction, and wherein the angle is
between approximately 0.1 degrees and approximately 90 degrees.
15. The method of claim 11, wherein the first inner surface defines
a first plane oriented at an angle with respect to the longitudinal
axis, and wherein the second inner surface defines a second plane
oriented at an angle with respect to the longitudinal axis.
16. The method of claim 15, wherein the first plane and the second
plane are parallel to one another.
17. The method of claim 15, wherein the first cup and the second
cup are separated by a sidewall, wherein a first side of the
sidewall comprises the first inner surface, and wherein a second
side of the sidewall comprises the second inner surface.
18. The method of claim 15, wherein said positioning step further
comprises placing a tissue-contacting surface of the anvil against
tissue positioned intermediate the staple and the staple pocket,
wherein at least a portion of the first inner surface is
perpendicular to the tissue-contacting surface, and wherein at
least a portion of the second inner surface is perpendicular to the
tissue-contacting surface.
19. A surgical instrument capable of performing the method of claim
11.
20. A surgical staple produced by the method of claim 11.
21. The surgical staple of claim 20, wherein said staple is at
least partially coated by at least one of polytetrafluoroethylene
and silicon.
22. A method of forming a surgical staple comprising a base, a
first staple leg, and a second staple leg, wherein the base, the
first staple leg, and the second staple leg are positioned within a
common plane prior to being deformed by an anvil, said method
comprising supporting the base of the staple; positioning a staple
pocket of the anvil in opposition to the staple, wherein the staple
pocket comprises a longitudinal axis; positioning the first staple
leg within a first cup of the staple pocket, wherein the first cup
comprises a first inner surface at least partially positioned on a
first side of the longitudinal axis; positioning the second staple
leg within a second cup of the staple pocket, wherein the second
cup comprises a second inner surface at least partially positioned
on a second side of the longitudinal axis; applying a first
compressive force to an end of the first staple leg to bend the
first staple leg toward the base and toward the second staple leg;
applying a second compressive force to an end of the second staple
leg to bend the second staple leg toward the base and toward the
first staple leg; contacting the first inner surface with the end
of the first staple leg to bend the end of the first staple leg
toward the first side of the longitudinal axis and toward a first
side of the common plane; and contacting the second inner surface
with the end of the second staple leg to bend the end of the second
staple leg toward the second side of the longitudinal axis and
toward a second side of the common plane; deforming the first
staple leg such that the end of the first staple leg is positioned
along a first axis, wherein said first axis transects a mid-plane
of the staple at an angle, and wherein the mid-plane of the staple
is defined between the first staple leg and the second staple leg;
and deforming the second staple leg such that the end of the second
staple leg is positioned along a second axis, wherein said second
axis transects a mid-plane of the staple at an angle.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This non-provisional patent application claims the benefit
under 35 U.S.C. .sctn.119(e) of U.S. Provisional Patent Application
No. 61/250,377, entitled SURGICAL STAPLER, which was filed on Oct.
9, 2009, the entire disclosure of which is incorporated by
reference herein.
BACKGROUND
[0002] i. Technical Field
[0003] The present invention relates to stapling instruments and,
in various embodiments, to a surgical stapling instrument for
producing one or more rows of staples.
[0004] ii. Background of the Related Art
[0005] In recent years, there has been an increasing tendency for
surgeons to use stapling instruments to suture body tissues such as
a lung, an esophagus, a stomach, a duodenum and/or other organs in
the intestinal tract. The use of an appropriate stapling instrument
in many instances may perform a better job in less time and
simplify previously difficult surgical procedures such as
gastrointestinal anastomoses. Previous linear two and four row
cutting staplers comprised cartridge-less instruments into which
staples were individually hand-loaded. Other previous devices have
included a presterilized disposable staple loading unit and a
cutting member which could be utilized for dividing the tissue and
forming the rows of staples simultaneously. An example of such a
surgical stapler is disclosed in U.S. Pat. No. 3,499,591, entitled
INSTRUMENT FOR PLACING LATERAL GASTROINTESTINAL ANASTOMOSES, which
issued on Mar. 10, 1970, the entire disclosure of which is hereby
incorporated by reference herein.
[0006] A stapling instrument can include a pair of cooperating
elongate jaw members, wherein each jaw member can be adapted to be
inserted into an internal, tubular body organ to be anastomosed. In
various embodiments, one of the jaw members can support a staple
cartridge with at least two laterally spaced rows of staples, and
the other jaw member can support an anvil with staple-forming
pockets aligned with the rows of staples in the staple cartridge.
Generally, the stapling instrument can further include a pusher bar
and knife blade which are slidable relative to the jaw members to
sequentially eject staples from the staple cartridge via camming
surfaces on the pusher bar. In at least one embodiment, the camming
surfaces can be configured to activate a plurality of staple
drivers carried by the cartridge and associated with the individual
staples to push the staples against the anvil and form laterally
spaced rows of deformed staples in the tissue gripped between the
jaw members. In typical stapling instruments, however, the anvil is
unmovable relative to the staple cartridge once the jaw members
have been assembled together and the formed height of the staples
cannot be adjusted. In at least one embodiment, the knife blade can
trail the pusher bar and cut the tissue along a line between the
staple rows. Examples of such stapling instruments are disclosed in
U.S. Pat. No. 4,429,695, entitled SURGICAL INSTRUMENTS, which
issued on Feb. 7, 1984, the entire disclosure of which is hereby
incorporated by reference herein.
SUMMARY
[0007] In at least one form of the present invention, a surgical
stapler can comprise a first handle portion comprising a staple
cartridge channel configured to receive a staple cartridge and a
second handle portion comprising an anvil. The stapler further
comprises a rotatable latch and a latch projection, wherein the
latch is rotatably coupled to one of the first handle portion and
the second handle portion and wherein the latch projection extends
from the other of the first handle portion and the second handle
portion. The latch is configured to engage the latch projection to
move the first handle portion and the second handle portion toward
one another. In various embodiments, the latch projection comprises
a rotatable bearing wherein the latch is configured to contact the
rotatable bearing when the latch engages the latch projection.
[0008] In at least one form of the present invention, a surgical
stapler can comprise an anvil having a plurality of staple pockets
formed in a tissue contacting surface. Each staple pocket can
comprise a longitudinal axis, a first forming cup, and a second
forming cup. The first forming cup can comprise a first interior
sidewall comprising a first vertical portion which is substantially
perpendicular to the tissue contacting surface. The second forming
cup can comprise a second interior sidewall comprising a second
vertical portion which is substantially perpendicular to the tissue
contacting surface. In various embodiments, the first vertical
portion and the second vertical portion can extend through the
longitudinal axis, wherein the first interior sidewall and the
second interior sidewall can comprise a trap for deforming a first
staple leg of a staple to a first side of the longitudinal axis and
for deforming a second staple leg of the staple to a second side of
the longitudinal axis.
[0009] In at least one form of the present invention, a method for
deforming a staple comprising a base, a first staple leg, and a
second staple leg, wherein the base, the first staple leg, and the
second staple leg are positioned within a common plane prior to
being deformed, the method comprising positioning the first staple
leg within a first cup of a staple pocket, the first cup comprising
a first inner surface, applying a first compressive force to an end
of the first staple leg to bend the first staple leg toward the
base and the second staple leg, contacting the first inner surface
with the end of the first staple leg to bend the end of the first
staple leg toward a first side of the base, and deforming the first
staple leg such that the end of the first staple leg crosses a
mid-line of the staple defined between the first staple leg and the
second staple leg.
BRIEF DESCRIPTION OF DRAWINGS
[0010] The above-mentioned and other features and advantages of
this invention, and the manner of attaining them, will become more
apparent and the invention itself will be better understood by
reference to the following description of embodiments of the
invention taken in conjunction with the accompanying drawings,
wherein:
[0011] FIG. 1 is a perspective view of a surgical stapling
instrument in accordance with at least one embodiment of the
present invention;
[0012] FIG. 2 is an exploded perspective view of the surgical
stapling instrument of FIG. 1;
[0013] FIG. 3 is an exploded elevational view of the surgical
stapling instrument of FIG. 1;
[0014] FIG. 4 is a partial cross-sectional view of the surgical
stapling instrument of FIG. 1 illustrating first and second
portions being assembled together;
[0015] FIG. 5 is a partial cross-sectional view of the surgical
stapling instrument of FIG. 1 illustrating the proximal end of the
first portion of FIG. 4 being locked to the proximal end of the
second portion of FIG. 4 and illustrating the second portion being
rotated toward the first portion;
[0016] FIG. 6 is a partial cross-sectional view of the surgical
stapling instrument of FIG. 1 illustrating a latch rotatably
mounted to the first portion, wherein the latch is engaged with the
second portion and wherein the latch has been rotated into a
partially-closed position;
[0017] FIG. 7 is a partial cross-sectional view of the surgical
stapling instrument of FIG. 1 illustrating the latch of FIG. 6 in a
closed position;
[0018] FIG. 8 is a perspective view of a staple cartridge assembly
of the surgical stapling instrument of FIG. 1;
[0019] FIG. 9 is an exploded view of the staple cartridge assembly
of FIG. 8;
[0020] FIG. 10 is a cross-sectional view of the staple cartridge
assembly of FIG. 8 taken along line 10-10 in FIG. 9;
[0021] FIG. 11 is an exploded view of a staple sled and cutting
member assembly of the staple cartridge assembly of FIG. 8;
[0022] FIG. 12 is a perspective view of the staple sled and cutting
member assembly of FIG. 11;
[0023] FIG. 13 is a perspective view of the surgical stapling
instrument of FIG. 1 illustrating a firing actuator moved distally
along a first side of the surgical stapling instrument;
[0024] FIG. 14 is a perspective view of the surgical stapling
instrument of FIG. 1 illustrating the firing actuator of FIG. 13
moved distally along a second side of the surgical stapling
instrument;
[0025] FIG. 15 is a cross-sectional view of a surgical stapling
instrument in accordance with at least one alternative embodiment
of the present invention illustrating a latch in a partially-closed
position and a locking mechanism engaged with a firing
actuator;
[0026] FIG. 16 is a cross-sectional view of the surgical stapling
instrument of FIG. 15 wherein the latch has been moved into a
closed position and has disengaged the locking mechanism from the
firing actuator;
[0027] FIG. 17 is a perspective view of an anvil assembly of the
surgical stapling instrument of FIG. 1;
[0028] FIG. 18 is an exploded perspective view of the anvil
assembly of FIG. 17;
[0029] FIG. 19 is another exploded perspective view of the anvil
assembly of FIG. 17;
[0030] FIG. 20 is an exploded cross-sectional elevational view of
the anvil assembly of FIG. 17;
[0031] FIG. 21 is a cross-sectional assembly view of the anvil
assembly of FIG. 17 illustrating an anvil adjustment member in a
first position;
[0032] FIG. 22 is a cross-sectional assembly view of the anvil
assembly of FIG. 17 illustrating the anvil adjustment member of
FIG. 21 in a second position;
[0033] FIG. 23 is a cross-sectional assembly view of the anvil
assembly of FIG. 17 illustrating the anvil adjustment member of
FIG. 21 in a third position;
[0034] FIG. 24 is a perspective view of a surgical stapling
instrument in accordance with at least one alternative embodiment
of the present invention;
[0035] FIG. 25 is a cross-sectional view of the surgical stapling
instrument of FIG. 24 taken along line 25-25 in FIG. 24;
[0036] FIG. 26 is a partial exploded view of the proximal end of
the surgical stapling instrument of FIG. 24 including a detent
mechanism for releasably holding a rotatable anvil adjustment
member in position;
[0037] FIG. 27 is a perspective view of the surgical stapling
instrument of FIG. 24 with some components removed and others shown
in cross-section;
[0038] FIG. 28 is an exploded view of portions of the surgical
stapling instrument of FIG. 24 illustrating a rotatable anvil
adjustment member in a first orientation;
[0039] FIG. 29 is a perspective view of the rotatable anvil
adjustment member of FIG. 28;
[0040] FIG. 30 is an end view of the surgical stapling instrument
of FIG. 24 with some components removed and others shown in dashed
lines illustrating the rotatable anvil adjustment member in the
first orientation of FIG. 28;
[0041] FIG. 31 is a cross-sectional end view of the surgical
stapling instrument of FIG. 24 taken along line 31-31 in FIG.
24;
[0042] FIG. 32 is an end view of the surgical stapling instrument
of FIG. 24 illustrating the rotatable anvil adjustment member of
FIG. 28 rotated in a first direction into a second orientation;
[0043] FIG. 33 is a cross-sectional end view of the surgical
stapling instrument of FIG. 24 illustrating the anvil adjustment
member in the second orientation of FIG. 32;
[0044] FIG. 34 is an end view of the surgical stapling instrument
of FIG. 24 illustrating the rotatable anvil adjustment member of
FIG. 28 rotated in a second direction into a third orientation;
[0045] FIG. 35 is a cross-sectional end view of the surgical
stapling instrument of FIG. 24 illustrating the anvil adjustment
member in the third orientation of FIG. 34;
[0046] FIG. 36 is a perspective view of an actuator for rotating
the anvil adjustment member of FIG. 28;
[0047] FIG. 37 is a partial cross-sectional view of a surgical
stapling instrument including a spring configured to bias the
distal end of a first handle portion away from the distal end of a
second handle portion when the stapling instrument is in a
partially-closed configuration;
[0048] FIG. 38 is a similar perspective view of the surgical
stapling instrument of FIG. 1 to that of FIG. 17;
[0049] FIG. 39 is a detail view of a latch projection extending
from an anvil of a surgical stapling instrument in accordance with
at least one alternative embodiment of the present invention;
[0050] FIG. 40 is a diagram illustrating the latch projection of
FIG. 39 and a latch configured to engage the latch projection and
move the latch projection into a latch recess;
[0051] FIG. 41 is an elevational view of the latch projection of
FIG. 39;
[0052] FIG. 42 is a perspective view of a staple pocket in
accordance with at least one embodiment of the present
invention;
[0053] FIG. 43 is a top view of the staple pocket of FIG. 42;
[0054] FIG. 44 is a cross-sectional view of the staple pocket of
FIG. 42 taken along line 44-44 in FIG. 43;
[0055] FIG. 45 is a cross-sectional view of the staple pocket of
FIG. 42 taken along line 45-45 in FIG. 43;
[0056] FIG. 46 is another top view of the staple pocket of FIG.
42;
[0057] FIG. 47 is a cross-sectional view of the staple pocket of
FIG. 42 taken along line 47-47 in FIG. 46;
[0058] FIG. 48 is a cross-sectional view of the staple pocket of
FIG. 42 taken along line 48-48 in FIG. 46;
[0059] FIG. 49 is an elevational view of a surgical staple in an
undeformed shape;
[0060] FIG. 50 is an elevational view of the surgical staple of
FIG. 49 in a deformed shape in accordance with at least one
embodiment of the present invention;
[0061] FIG. 51 is a side view of the surgical staple of FIG. 49 in
the deformed shape of FIG. 50;
[0062] FIG. 52 is a plan view of the surgical staple of FIG. 49 in
the deformed shape of FIG. 50;
[0063] FIG. 52A is another plan view of the surgical staple of FIG.
49 in the deformed shape of FIG. 50;
[0064] FIG. 53 is an elevational view of a surgical staple in an
undeformed shape;
[0065] FIG. 54 is a bottom view of the surgical staple of FIG. 53
in an undeformed shape;
[0066] FIG. 55 is a bottom view of the surgical staple of FIG. 53
in a deformed shape in accordance with at least one embodiment of
the present invention;
[0067] FIG. 56 is a partial cross-sectional view of the surgical
staple of FIG. 53;
[0068] FIG. 57 is an elevational view of a surgical staple in a
deformed shape in accordance with at least one embodiment of the
present invention; and
[0069] FIG. 58 is an elevational view of a surgical staple in a
deformed shape.
[0070] Corresponding reference characters indicate corresponding
parts throughout the several views. The exemplifications set out
herein illustrate preferred embodiments of the invention, in one
form, and such exemplifications are not to be construed as limiting
the scope of the invention in any manner.
DETAILED DESCRIPTION
[0071] 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.
[0072] The entire disclosures of the following commonly-owned,
non-provisional United States patent applications are hereby
incorporated by reference herein: [0073] SURGICAL STAPLING
INSTRUMENT WITH CUTTING MEMBER ARRANGEMENT, U.S. patent application
Ser. No. 12/234,149, Atty. Docket No. END6414USNP/080203; [0074]
SURGICAL STAPLER WITH APPARATUS FOR ADJUSTING STAPLE HEIGHT, U.S.
patent application Ser. No. 12/234,133, Atty. Docket No.
END6406USNP/080195; [0075] LOCKOUT ARRANGEMENT FOR A SURGICAL
STAPLER, U.S. patent application Ser. No. 12/234,113, Atty. Docket
No. END6405USNP/080194; [0076] SURGICAL STAPLER HAVING AN
INTERMEDIATE CLOSING POSITION, U.S. patent application Ser. No.
12/234,143, Atty. Docket No. END6411USNP/080200; [0077] SURGICAL
STAPLER HAVING A CLOSURE MECHANISM, filed on even date herewith,
Atty. Docket No. END6612USNP/090242; and [0078] SURGICAL STAPLER
COMPRISING A STAPLE POCKET, filed on even date herewith, Atty.
Docket No. END6613USNP/090243.
[0079] Referring to FIG. 1, a surgical stapling instrument,
generally 100, can comprise a first handle portion 102 and a second
handle portion 104. In various embodiments, first handle portion
102 and second handle portion 104 can be configured to be grasped
by a surgeon, for example, and can comprise hand grip portion 106.
In at least one embodiment, first handle portion 102, referring to
FIGS. 2 and 3, can include a first cover 108 attached to a first
frame 110 and, similarly, second handle portion 104 can include a
second cover 112 attached to a second frame 114. Covers 108 and 112
can be ergonomically contoured, or otherwise suitably contoured, to
assist a surgeon in manipulating stapling instrument 100 within a
surgical site. In various embodiments, handle covers 108 and 112,
for example, can include enlarged protrusions 109 and 113,
respectively, which can facilitate the insertion of stapling
instrument 100 into a surgical site. In various embodiments, handle
covers 108 and 112 can be made of plastic, lightweight materials,
and/or any other suitable material, for example, while handle
frames 110 and 114 can be made of stainless steel, titanium, and/or
any other suitable material, for example.
[0080] In various embodiments, referring again to FIGS. 1-3, the
distal ends of handle portions 102 and 104 can comprise an
end-effector 120 which can be configured to treat tissue within a
surgical site, for example. In at least one such embodiment,
end-effector 120 can include a staple cartridge channel 122
configured to receive and/or retain a staple cartridge as described
in greater detail further below. In certain embodiments, staple
cartridge channel 122 can comprise a one-piece elongated
channel-shaped frame extending from first handle portion frame 110.
In at least one embodiment, staple cartridge channel 122 can
include a pair of opposed, elongated side walls 124 connected by a
bottom wall 126. Along the rearward, or proximal, portion of staple
cartridge channel 122, a pair of spaced, upstanding side flanges
128 can extend upwardly from opposed side walls 124. In various
embodiments, the width of staple cartridge channel 122 between side
flanges 128 can be greater than the width of the upper jaw member,
or anvil, 130 extending from second handle portion 104. In at least
one embodiment, the distance between flanges 128 can be configured
to permit at least a portion of anvil 130 to be received between
side flanges 128 when the stapling instrument is assembled for
operation. As shown in FIG. 2, each side flange 128 of can include
a notch, or recess, 127, for example, which can be configured to
receive one or more latch projections 131, for example, extending
from anvil 130, and/or any other suitable portion of second handle
portion 104, as described in greater detail further below.
[0081] As indicated above, referring once again to FIGS. 1-3,
staple cartridge channel 122 can be configured to support and/or
retain a staple cartridge, such as staple cartridge 150, for
example, within end-effector 120, wherein the staple cartridge can
include one or more staples (not illustrated) removably stored
therein. In various embodiments, referring to FIGS. 8-10, staple
cartridge 150 can include one or more staple cavities 151 which can
be configured to store staples in any suitable arrangement, such as
in at least two laterally-spaced longitudinal rows, for example. In
at least one embodiment, referring to FIGS. 9 and 10, staple
cartridge 150 can include staple cartridge body 152 and pan 154,
wherein staple cartridge body 152 and/or pan 154 can be configured
to define a channel, or path, for slidably receiving a staple sled
and/or cutting member therein. In at least one embodiment, pan 154
can include flexible arms 155, for example, which can be configured
to engage staple cartridge body 152 in a snap-fit and/or press-fit
arrangement. Referring to FIGS. 10-12, staple cartridge 150 can
further include staple sled assembly 160 which can include staple
sled portion 162 and, in addition, cutting member 164. In various
embodiments, cutting member 164 can include cutting edge 165 and
lock arm 166, for example, wherein lock arm 166 can be configured
to be press-fit and/or snap-fit into aperture 163 in staple sled
162 when cutting member 164 is assembled to staple sled portion
162. In other various embodiments, staple sled portion 162 can be
integrally molded to cutting member 164.
[0082] Further to the above, referring to FIGS. 8-10, staple
cartridge body 152 can include a slot, such as slot 156, for
example, which can be configured to receive at least a portion of
cutting member 164 therein, and/or any other portion of staple sled
assembly 160 and pusher bar assembly 200 (discussed below), wherein
slot 156 can be configured to permit cutting member 164 to be moved
between first and second positions within staple cartridge 150. In
various embodiments, slot 156 can be configured to permit cutting
member 164 to be moved between a proximal position (FIG. 10) and a
distal position in order to incise tissue positioned intermediate
staple cartridge 150 and anvil 130, for example. Referring again to
FIGS. 10-12, staple sled portion 162 can include cam, ramp, or
actuator, surfaces 167 which can be configured to engage staple
drivers positioned within staple cartridge 150. In various
embodiments, referring to FIG. 9, staple cartridge 150 can include
staple drivers 168 which can be lifted, or slid, upwardly within
staple cavities 151 by sled portion 162 such that the upward
movement of staple drivers 168 can eject, or deploy, staples at
least partially positioned within staple cavities 151. While staple
drives 168 can be, in fact, lifted vertically upwardly, the term
upward, and the like, can mean that staple drivers 168, for
example, are moved toward the top surface, or deck, 158 of the
staple cartridge and/or toward anvil 130, for example. In certain
embodiments, as illustrated in FIG. 9, each staple driver 168 can
include one or more sloped surfaces 169 oriented at the same angle
as a cam surface 167, and/or any other suitable angle, which can
provide a relatively flat, or at least substantially flat, sliding
contact surface between staple sled 162 and staple drivers 168. In
various embodiments, a staple driver can be configured to deploy
only one staple, while, in certain embodiments, a staple driver can
be configured to simultaneously deploy two or more staples located
in adjacent rows, for example. Other devices are disclosed in U.S.
patent application Ser. No. 12/030,424, entitled SURGICAL STAPLING
INSTRUMENT WITH IMPROVED FIRING TRIGGER ARRANGEMENT, which was
filed on Feb. 13, 2008, the entire disclosure of which is
incorporated by reference herein.
[0083] In various embodiments, as described above, a surgical
stapling instrument can include a cutting member/staple sled
assembly configured to incise tissue and deploy staples from a
staple cartridge. In certain embodiments, though, a surgical
stapling instrument may not require, or include, a cutting member.
In at least one such embodiment, a staple cartridge can include a
staple sled positioned therein and/or a surgical instrument can be
configured to move a staple sled into a staple cartridge in order
to staple tissue, for example, without otherwise dissecting it. In
certain other embodiments, a staple cartridge can include a staple
sled positioned therein where a surgical instrument can include a
cutting member movable into, or relative to, the staple cartridge.
In at least one such embodiment, the cutting member can be advanced
into contact with the staple sled such that the cutting member and
staple sled can be advanced together. Thereafter, the cutting
member can be sufficiently retracted to allow the staple cartridge
to be detached from the surgical instrument and replaced with a new
staple cartridge having a new staple sled. Such embodiments may be
useful when a staple sled may become worn or deformed during use.
Other embodiments are envisioned where a staple cartridge can
include a cutting member positioned therein where a surgical
instrument can include a staple sled movable into, or relative to,
the staple cartridge. In at least one such embodiment, similar to
the above, the staple sled can be advanced into contact with the
cutting member such that the cutting member and staple sled can be
advanced together. Thereafter, the staple sled can be sufficiently
retracted to allow the staple cartridge to be detached from the
surgical instrument and replaced with a new staple cartridge having
a new cutting member. Such embodiments may be useful when a cutting
member may become worn or deformed during use. In various
embodiments, as described in greater detail below, the staple
cartridge can include a protective housing or cover configured to
prevent, or at least reduce the possibility of, a surgeon or other
clinician from touching the cutting member positioned within the
staple cartridge while handling the staple cartridge, for
example.
[0084] In various embodiments, further to the above, staple
cartridge channel 122 and/or staple cartridge 150, for example, can
include one or more co-operating projections and/or recesses, for
example, which can be configured to removably retain staple
cartridge 150 within staple cartridge channel 122. Once staple
cartridge 150 has been inserted into staple cartridge channel 122,
in various embodiments, the first handle portion 102 can be
assembled to the second handle portion 104. In other various
embodiments, the staple cartridge may be inserted into the staple
cartridge channel after the first and second handle portions have
been assembled together. In either event, referring to FIGS. 1-7,
first handle portion 102 and second handle portion 104 can include
proximal ends 103 and 105, respectively, which can be assembled
together such that the first and second handle portions can be
rotatably or pivotably coupled to one another. In various
embodiments, referring to FIGS. 2 and 3, first handle portion 102
can include one or more pins, or projections, 111 extending
therefrom which can be configured to be slidably received within
one or more grooves, channels, or slots 115 in second handle
portion 104. In certain embodiments, slots 115 can be defined in
second handle frame 114 and projections 111 can extend from a
proximal end post 107 extending from first handle frame 110, for
example. In order to assemble first handle portion 102 and second
handle portion 104, referring to FIG. 4, the open ends of slots 115
can be aligned with projections 111 such that second handle portion
104, for example, can be translated relative to first handle
portion 102 and projections 111 can be slid within slots 115. In at
least one embodiment, as illustrated in FIGS. 2 and 3, the open
ends of slots 115 can be located proximally with respect to their
closed ends. In at least one such embodiment, proximal end 105 of
second handle portion 104 can be positioned distally with respect
to proximal end 103 of first handle portion 102 such that second
handle portion 104 can be moved proximally in order to position
projections 111 within slots 115. In various other circumstances,
first handle portion 102 can be positioned proximally with respect
to second handle portion 104 and slid distally in order to position
projections 111 within slots 115.
[0085] In various embodiments, referring to FIG. 5, second handle
portion 104 can be rotated toward first handle portion 102 such
that anvil 130 can be moved into position relative to staple
cartridge 150 and/or staple cartridge channel 122. In certain
embodiments, first handle portion 102 can be rotated toward second
handle portion 104 and/or the first and second handle portions can
be rotated toward each other. In any event, projections 111 and
slots 115, when engaged with one another, can comprise a pivot
about which one or both of the first and second handle portions can
be moved relative to each other. In various embodiments, second
handle portion 104 can be moved relative to first handle portion
102 such that anvil 130 is moved into close opposition to staple
cartridge 150. In certain embodiments, referring to FIG. 6, second
handle portion 104 can be moved relative to first handle portion
102 such that latch projections 131 extending from second handle
portion 104 can be aligned with and/or inserted into recesses 127
within first handle portion 102. In various embodiments, referring
primarily to FIGS. 2 and 3, first handle portion 102 can further
include latching mechanism 180 rotatably mounted thereto which can
be utilized to engage latch projections 131 extending from second
handle portion 104 and secure the first and second handle portions
together. Although not illustrated, other embodiments are
envisioned in which a latching mechanism is rotatably mounted to
the second handle portion and latch projections can extend from the
first handle portion. In any event, in at least one embodiment,
latching mechanism 180 can be mounted to first frame 110 by one or
more pivot pins 182 which can be configured to define an axis about
which latch 180 can be rotated.
[0086] In certain embodiments, referring now to FIGS. 4 and 5,
latching mechanism 180 can include latch frame 184 and, in
addition, latch cover 186 assembled to latch frame 184. In other
various embodiments, the latch cover and the latch frame can
comprise an integral unit or, in certain embodiments, the latching
mechanism may not even include a cover. In certain embodiments,
latch frame 184 can be channel-shaped and can include a pair of
opposed, elongated side walls 185 which are spaced apart by a
distance sufficient to span first frame portion 110. In at least
one embodiment, latch cover 186 can be made of plastic, lightweight
materials, and/or any other suitable materials, for example, while
latch frame 184 can be made of stainless steel and/or any other
suitable material, for example. In certain embodiments, when
latching mechanism 180 is closed, as illustrated in FIG. 7, latch
cover 186 can be aligned with first handle cover 108. Latch cover
186 can include contoured portion 187 which can be configured to
assist a surgeon in manipulating surgical instrument 100 wherein,
in at least one embodiment, contoured portion 187 can be aligned
with, or at least substantially aligned with, protrusion 109
extending from first handle cover 108. Latching mechanism 180 can
further include one or more latch arms 188 extending therefrom
which can be configured to engage one or more latch projections 131
extending from second handle portion 104 and pull and/or secure
projections 131 within recesses 127 as illustrated in FIG. 7. In at
least one embodiment, at least one of latch arms 188 can be
integrally-formed with latch frame 184. In certain embodiments,
referring to FIG. 6, at least one of latch arms 188 can include a
distal hook 189 which can be configured to wrap around at least a
portion of projections 131 so as to encompass or surround, or at
least partially encompass or surround, projections 131. In at least
one embodiment, latch arms 188 can act as an over-center latch to
maintain latching mechanism 180 in its latched, or closed,
position.
[0087] In use, in various circumstances, one of the first handle
portion 102 and the second handle portion 104 can be positioned on
a first side of tissue within a surgical site and the other handle
portion can be rotated into position on the opposite side of the
tissue. In such embodiments, staple cartridge 150 can be positioned
on one side of the tissue and anvil 130 can be positioned on the
other side of the tissue. Thereafter, as also outlined above,
latching mechanism 180 can be actuated such that it can be moved
between an open position and a closed position in order to latch
second handle portion 104 to first handle portion 102 and apply a
clamping force to the tissue positioned between staple cartridge
150 and anvil 130. In certain circumstances, latching mechanism 180
can be moved between an open position (FIG. 5), a partially-closed,
or intermediate, position (FIG. 6), and a closed position (FIG. 7).
In at least one such embodiment, referring to FIGS. 5 and 6,
latching mechanism 180 can be moved between an open position in
which latch arms 188 are not engaged with projections 131 and a
partially-closed position in which latch arms 188 are engaged with
projections 131 such that, although anvil 130 has been at least
partially brought into opposition to staple cartridge 150, a
sufficient gap can remain between anvil 130 and staple cartridge
150 which can allow end-effector 120 to be repositioned relative to
the tissue, for example. Once the anvil 130 and staple cartridge
150 have been sufficiently positioned relative to the tissue,
latching mechanism 180 can be moved between its partially-closed
position and a closed position, as illustrated in FIG. 7.
[0088] In various embodiments, further to the above, a surgical
stapling instrument can further include a biasing member which can
be configured to bias the first handle portion of a stapling
instrument away from a second handle portion. In at least one
embodiment, as described in greater detail further below, a spring,
and/or any suitably resilient material, can be positioned
intermediate the first and second handle portions such that the
anvil and staple cartridge of the stapling instrument can be biased
away from each other. In certain embodiments, the spring can be
configured to at least partially separate the first and second
handle portions such that a gap exists between the anvil and the
staple cartridge, wherein the gap can be sufficient to allow tissue
to be positioned therebetween. In use, a surgeon can position such
a surgical stapling instrument without having to separate and hold
the first and second handle portions apart from each other. Such an
instrument may be especially useful when the stapling instrument is
in a partially-closed configuration and the surgeon is manipulating
the instrument within a surgical site. After the surgeon is
satisfied with the positioning of the stapling instrument, the
surgeon can compress and/or disengage the spring and place the
stapling instrument in a closed configuration.
[0089] In various circumstances, as outlined above, the distal end
of first handle portion 102 can be moved relative to the distal end
of second handle portion 104, especially when latching mechanism
180 is not engaged with, or only partially engaged with,
projections 131 of second handle portion 104. In such
circumstances, projections 111 and slots 115 at the proximal ends
of the first and second handle portions can be configured to retain
at least the proximal ends of the first and second handle portions
together when the distal ends of the first and second handle
portions are being moved relative to each other, for example.
Stated another way, projections 111 and slots 115 can cooperate to
prevent, or at least inhibit, first handle portion 102 from
becoming completely detached from second handle portion 104. In
certain embodiments, a first handle portion can include a first
lock portion and a second handle portion can include a second lock
portion, wherein the first and second lock portions can be
configured to be engaged with one another and prevent the first
handle portion from becoming completely detached from the second
handle portion. In at least one embodiment, projections 111 can
comprise the first lock portion and slots 115 can comprise the
second lock portion. Previous stapling instruments lacked such lock
portions and instead relied on a sole latching mechanism to keep
the first and second handle portions together. In circumstances
where the latching mechanisms of these previous stapling
instruments were not fully engaged with both of the first and
second handle portions, the first and second handle portions could
become completely detached from one another, thereby requiring a
surgeon, for example, to reposition and reassemble the handle
portions. In certain circumstances, a complete detachment of the
first and second handle portions of these previous staples could
expose at least a portion of a cutting member.
[0090] In various embodiments, as outlined above, latching
mechanism 180 can be configured to be moved between an open
position, a partially-closed position, and a closed position. When
latching mechanism 180 is in its open position, as also outlined
above, projections 111 can be inserted into and/or removed from
slots 115. When latching mechanism 180 is in its partially-closed
position, referring to FIG. 6, latch arms 188 can be configured to
engage latch projections 131 such that projections 111 cannot be
removed from slots 115. In at least one such embodiment, latch arms
188 and latch projections 131 can be configured to prevent, or at
least inhibit, second handle portion 104 from being moved distally
with respect to first handle portion 102 and, as a result, prevent,
or at least inhibit, projections 111 from being disengaged from
slots 115. Correspondingly, latch arms 188 and latch projections
131 can be configured to prevent first handle portion 102 from
being moved proximally with respect to second handle portion 104.
Similar to the above, in various embodiments, latch arms 188 and
latch projections 131 can also be configured to prevent, or at
least inhibit, projections 111 from being removed from slots 115
when latching mechanism 180 is in its closed position (FIG. 7). In
certain embodiments, further to the above, latch projections 131
can extend from second handle portion 104 at a location which is
intermediate its proximal and distal ends. In at least one such
embodiment, projections 111 and slots 115 can be configured to hold
the first and second handle portions together at their proximal
ends while latching mechanism 180 can be utilized to hold the first
and second handle portions together at an intermediate location. In
any event, in certain embodiments, the first and second handle
portions cannot be disengaged from one another unless latching
mechanism 180 is moved into its fully open position. In at least
one such embodiment, projections 111 and slots 115 cannot be
disengaged from one another when latching mechanism 180 is in a
closed and/or partially-closed position.
[0091] Once anvil 130 and staple cartridge 150 have been
sufficiently positioned, the tissue positioned intermediate anvil
130 and staple cartridge 150 can be stapled and/or incised. In
various embodiments, referring to FIG. 3, surgical stapling
instrument 100 can further include pusher bar assembly 200 which
can be configured to advance and/or retract staple sled assembly
160 within staple cartridge 150, for example. In at least one
embodiment, pusher bar assembly 200 can include pusher bar 202 and
firing actuator 204, wherein firing actuator 204 can be configured
to move pusher bar 202 and staple sled assembly 160 distally to
deploy staples from staple cartridge 150 and deform the staples
against anvil 130 as described above. In at least one embodiment,
referring to FIGS. 11 and 12, staple sled 162 can include a groove,
channel, or slot 161 which can be configured to receive, and can be
operably connected to, a distal end 201 (FIG. 3) of pusher bar 202.
In certain embodiments, staple sled assembly 160 can be operably
engaged with pusher bar 202 when staple cartridge 150 is inserted
into staple cartridge channel 122. In at least one embodiment,
distal end 201 and slot 161 can include cooperating features which
can allow distal end 201 and slot 161 to be assembled in a
transverse direction but prevent, or at least inhibit, distal end
201 and slot 161 from being disassembled from one another in a
proximal direction and/or distal direction. In other embodiments,
pusher bar 202 can be advanced distally before contacting and
engaging staple sled assembly 160. In at least one such embodiment,
the staple sled assembly 160 can remain stationary until contacted
by pusher bar 202. In any event, as outlined above, actuator 204
can be operably connected to pusher bar 202 such that a pushing
and/or pulling force can be applied to actuator 204 and transmitted
to pusher bar 202. In certain embodiments, as described in greater
detail below, actuator 204 can be pivotably connected to a proximal
end 203 of pusher bar 202 such that actuator 204 can be selectively
rotated between at least first and second positions.
[0092] Further to the above, referring to FIGS. 1, 13, and 14,
actuator 204 can be movable between a first position on a first
side 116 of surgical stapling instrument 100 (FIG. 13), a second
position on a second side 117 (FIG. 14), and an intermediate
position (FIG. 1) located at the proximal ends 103 and 105 of the
first and second handle portions 102 and 104. Once actuator 204 has
been rotated into position on one of the first and second sides
116, 117, actuator 204 can be advanced distally. In various
circumstances, as a result, a surgeon may select whether to move
actuator 204 distally along first side 116 or second side 117. Such
circumstances may arise when it is more likely that actuator 204
may impinge on tissue surrounding the surgical site, for example,
when actuator 204 is moved distally along one side of the surgical
instrument as compared to the other. In various embodiments,
referring to FIGS. 2 and 3, actuator 204 can include arm 206
extending therefrom where arm 206 can be pivotably mounted to
proximal end 203 of pusher bar 202. In certain embodiments,
referring once again to FIGS. 1, 13, and 14, surgical instrument
100 can include a first slot (not illustrated) extending along
first side 116 and a second slot 118 extending along second side
117, wherein the first and second slots can be configured to
slidably receive at least a portion of actuator 204. In at least
one embodiment, the sidewalls of the first and second slots can
confine, or at least assist in confining, the movement of actuator
204 such that it can be moved along a predetermined path. Referring
to FIG. 14, second slot 118, for example, can be defined between
first handle portion 102 and second handle portion 104 such that,
when actuator 204 is moved distally along second side 117, arm 206
of actuator 204 can be slid intermediate the first and second
handle portions. Similar to the above, the first slot can also be
defined intermediate the first and second handle portions. In
various embodiments, referring again to FIGS. 13 and 14, surgical
instrument 100 can further include intermediate slot 119 which can
also be configured to allow arm 206, and/or any other suitable
portion of actuator 204, to slide therein. In at least one such
embodiment, intermediate slot 119 can connect the first and second
slots such that, when actuator 204 is positioned in its
intermediate position, actuator 204 can be moved into either one of
its first and second positions. In certain embodiments, the first
slot, second slot 117, and intermediate slot 119 can be parallel,
or at least substantially parallel, to one another and/or lie in
the same plane, although other embodiments are envisioned in which
one or more of the slots is not parallel to the others and/or lies
in a different plane. Furthermore, although the first and second
sides of the illustrated embodiment are located on opposite sides
of surgical instrument 100, other embodiments are envisioned where
the first and second slots, for example, are located on adjacent
sides and/or sides which are not directly opposite to each other.
Furthermore, other embodiments are envisioned in which the sides of
a stapling instrument are not readily discernable, such as
instruments having round and/or arcuate portions.
[0093] In various embodiments, further to the above, surgical
stapling instrument 100 can further include a locking mechanism
which can prevent, or at least inhibit, actuator 204 and,
correspondingly, staple sled assembly 160, from being advanced
prematurely. In at least one embodiment, the locking mechanism can
be configured to prevent, or at least inhibit, actuator 204 from
being advanced distally prior to latching mechanism 180 being moved
into a closed, or an at least partially-closed, position. In
certain embodiments, generally referring to FIG. 5, surgical
stapling instrument 100 can further including locking mechanism 220
which can be engaged with actuator 204 and can remain engaged with
actuator 204 while latching mechanism 180 is in a fully open
position (FIG. 5) and/or an at least substantially-open position.
In various embodiments, locking mechanism 220 can include lock 222
which can be biased into engagement with actuator 204 by a biasing
force applied thereto by lock spring 224, for example. In at least
one such embodiment, actuator 204 can include one or more grooves,
channels, or slots (not illustrated) which can be configured to
receive at least a portion of lock 222. In use, locking mechanism
220 can hold actuator 204 in position until latching mechanism 180
is moved into its fully closed position (FIG. 7) and/or an at least
substantially closed position. In such circumstances, in at least
one embodiment, latching mechanism 180 can be configured to engage
locking mechanism 220 and disengage lock 222 from actuator 204. In
at least one such embodiment, referring to FIGS. 5-7, latching
mechanism 180 can further include cam 183 which can be configured
to engage cam surface 223 on lock 222 when latching mechanism 180
is moved into its closed position and, as a result, slide, and/or
otherwise move, lock 222 away from actuator 204. In various
embodiments, cam 183 can comprise a wall, rib, and/or ridge
extending from latch cover 186 and/or latch frame 184. In any
event, once lock 222 has been sufficiently disengaged from actuator
204, in at least one embodiment, actuator 204 can be moved from its
intermediate position, illustrated in FIG. 1, into one of its first
and second positions, as illustrated in FIGS. 13 and 14.
[0094] As described above, locking mechanism 220 can be configured
to prevent, or at least inhibit, drive bar 202 from being advanced
distally prior to latching mechanism 180 being moved into a
predetermined position, such as, for example, a closed position
and/or partially-closed position. Advantageously, locking mechanism
220 may also prevent, or at least inhibit, staple sled assembly 160
from being advanced prior to the first handle portion 102 and the
second handle portion 104 being assembled together. In effect,
locking mechanism 220 can prevent tissue positioned intermediate
anvil 130 and staple cartridge 150 from being cut and/or stapled
prior to anvil 130 and staple cartridge 150 being properly
positioned relative to the tissue. Also, in effect, locking
mechanism 220 can prevent staples from being deployed into the
tissue prior to an appropriate clamping force being applied to the
tissue. In any event, when latching mechanism 180 is returned to
its fully open position, and/or a partially-open position, cam 183
can be moved away from lock 222 such that lock spring 124 can bias
lock 222 into engagement with actuator 204 once again. In various
other embodiments, referring to FIGS. 15 and 16, locking mechanism
220' can include a lock 222' comprising a cam surface 223' and, in
addition, a stop 226' which can limit the relative movement of lock
222'. In at least one embodiment, cam 183, for example, can be
configured to contact cam surface 223' and, owing to the contoured,
beveled, and/or angled surface of cam surface 223', cam 183 can be
configured to drive lock 222' distally as illustrated in FIG. 16.
Lock 222' can be driven distally such that pin 228', which extends
from lock 222', can be moved between a first position (FIG. 15) in
which it is positioned within aperture 229' in actuator 204' and a
second position (FIG. 16) in which pin 228' has been sufficiently
removed from aperture 229'. In various embodiments, stop 226' can
be configured such that, as lock 222' is driven distally, stop 226'
can come into contact with cam 183 once lock 222' has been
sufficiently displaced. In such embodiments, stop 226' can be
configured to control the second, or displaced, position of lock
222'. Similar to the above, as actuator 180 is moved out of its
closed position and cam 183 is disengaged from locking mechanism
220', lock spring 224' can move lock 222' into engagement with
actuator 204' once again.
[0095] In various embodiments, as described above, a firing
actuator can be utilized to move a pusher bar, staple sled, and/or
cutting member between first and second positions. As also
described above, pusher bar assembly 200, for example, can be
utilized to move a staple sled assembly, such as staple sled
assembly 160, for example, between a proximal position (FIG. 10)
and a distal position. In certain embodiments, a staple cartridge,
such as staple cartridge 150, for example, can include a staple
sled assembly 160 contained therein, wherein staple sled assembly
160 can be positioned in a distal position, as illustrated in FIG.
10, when the staple cartridge is assembled to or inserted into
staple cartridge channel 122. In at least one such embodiment,
referring to FIGS. 8-10, staple cartridge 150 can include further
housing 170 which can be configured to cover at least a portion of
cutting member 164 when staple sled assembly 160 is in its distal
position, for example. In various embodiments, housing 170 can be
configured to protect a surgeon, for example, when handling the
staple cartridge, when inserting the staple cartridge into the
surgical stapler, and/or assembling two or more portions of the
surgical stapler together, for example. In at least one such
embodiment, at least an upper portion of cutting edge 165 can
extend above deck, or top surface, 158 of staple cartridge 150 and,
absent a protective housing, such as housing 170, for example, the
upper portion of cutting edge 165 may be exposed.
[0096] In various embodiments, as described above, cutting member
165 can be at least partially positioned within slot, or channel,
156 and, as illustrated in FIG. 10, at least the upper, or top,
portion of cutting member 164 can extend above deck 158. In at
least one embodiment, referring to FIGS. 8-10, housing 170 can
include a first wall, or portion, 172 extending from a first
portion 157 of staple cartridge body 152, a second wall, or
portion, 174 extending from a second portion 159 of staple
cartridge body 152, and a top wall, or portion, 176 extending
between first wall 172 and second wall 174. In certain embodiments,
a housing may comprise only one support wall, or support portion,
extending from a staple cartridge body and, in addition, a top
wall, or top portion, extending therefrom. In other embodiments, a
housing may comprise one or more side walls, or portions, and no
top wall. In at least one such embodiment, the side walls of the
housing can be configured such that they extend above the top of
the cutting member, or at least extend above a cutting edge of the
cutting member, for example. In any event, as illustrated in FIG.
10, at least a portion of cutting member 164 can be positioned
underneath top wall 176 and/or between side walls 172 and 174 when
staple sled assembly 160 is in its proximal position. In certain
embodiments, cutting member 164 can be entirely positioned
underneath top wall 176, and/or entirely positioned within housing
170. In at least one embodiment, cutting member 164 can be
positioned underneath top wall 176 such that cutting surface 165
does not extend beyond the distal edge 175 and/or the proximal edge
177 of top wall 176. In at least one embodiment, housing 170 can
include a rear wall 178 which can be configured to limit the
proximal movement of cutting member 164 and/or any other portion of
staple sled assembly 160. In various embodiments, at least a
portion of housing 170, for example, can be integrally-formed with
staple cartridge body 152. In at least one such embodiment, first
wall 172, second wall 174, top wall 176, and/or rear wall 178 can
be formed when staple cartridge body 152 is injection molded, for
example. In certain embodiments, at least a portion of housing 170
can be assembled to staple cartridge body 152 via a snap-fit
arrangement, press-fit arrangement, and/or any other suitable
manner.
[0097] In various embodiments, further to the above, cutting member
164 can be defined by a planar, or an at least substantially
planar, body having a knife edge extending along at least one side
of the cutting member body. In at least one such embodiment, first
wall 172 and/or second wall 174 can be configured and arranged such
that they can include planar, or at least substantially planar,
interior surfaces 173 which are parallel, or at least substantially
parallel, to the side surfaces of cutting member 164. In certain
embodiments, cutting member 164 can be closely received between the
interior surfaces 173 of walls 172 and 174. In at least one such
embodiment, the distance between walls 172 and 174 may be the same
as, or at least substantially the same as, the width of slot 156.
In any event, a housing can be configured such that at least a
portion of the housing extends over at least a portion of slot 156,
for example. In certain embodiments, housing 170 can completely
enclose or surround a cutting member 164 and/or cutting surface
165. In at least one embodiment, although not illustrated, a
housing can include a break-away and/or incisable portion which can
be at least partially detached, separated, and/or otherwise
deformed in order to permit a cutting member to exit the housing.
In at least one such embodiment, the tissue cutting surface can be
configured to contact the housing to break and/or incise a housing
wall, for example. In various embodiments, the housing wall can
include a thin portion, a reduced-thickness portion, score mark,
and/or any other configuration to facilitate the deformation and/or
incision of the housing wall. In certain embodiments, a cutting
member can include one or more additional cutting surfaces and/or
anvils, for example, which can be configured to deform and/or
incise the housing. In at least one embodiment, the housing can
include a movable and/or flexible portion, such as a hinged member
and/or flexible flap, for example, which can be configured to
sufficiently move and/or flex to allow the cutting member to pass
thereby. In any event, embodiments are envisioned in which the
cutting member can have any suitable configuration for incising
tissue and the protective housing can have any suitable
configuration for at least partially enclosing or surrounding the
cutting member. Furthermore, although a cutting member can comprise
a sharpened edge as described above, other suitable cutting members
are envisioned, such as those supplied with an electrical current
sufficient to dissect tissue, for example.
[0098] As described above, housing 170 can be configured to at
least partially cover, enclose, and/or surround a cutting member
when it is in its proximal position. In various embodiments, the
cutting member can be advanced distally to incise tissue, for
example, and then retracted proximally in order to position the
cutting member within housing 170 once again. In such embodiments,
the cutting member can be at least partially covered by housing 170
when the staple cartridge is assembled to and removed from a
surgical stapling instrument. In certain embodiments, a new, or
unspent, staple cartridge can be inserted into the staple cartridge
channel to replace the at least partially spent staple cartridge.
In at least one such embodiment, the new staple cartridge can
include a new cutting member and/or staple sled assembly positioned
therein, although embodiments are envisioned in which the
previously-used cutting member and/or staple sled assembly can be
sufficiently withdrawn from the spent staple cartridge and advanced
into the new staple cartridge in order to be reused once again. In
embodiments where a new cutting member and/or staple sled assembly
is provided with each new staple cartridge, a sharp cutting edge,
for example, can be utilized with each staple cartridge.
[0099] In various embodiments, although not illustrated, a staple
cartridge can include two or more housings configured to at least
partially cover a cutting member when it is in two or more
positions. In at least one embodiment, a staple cartridge can
include a proximal housing configured to at least partially cover
the cutting member when it is in a proximal position, for example,
and, in addition, a distal housing configured to at least partially
cover the cutting member when it is in a distal position, for
example. In at least one such embodiment, the cutting member can be
positioned within the proximal housing when the staple cartridge is
assembled to a surgical stapling instrument and, in certain
embodiments, the cutting member can be advanced into the distal
housing after it has transected tissue positioned within the
end-effector, for example. In such embodiments, as a result, the
cutting member can be at least partially positioned within the
distal housing when the staple cartridge is removed from the
surgical stapler. Such embodiments may be particularly useful when
a vessel, for example, is positioned intermediate the proximal
housing and the distal housing of the staple cartridge. In various
embodiments, although not illustrated, a cutting member can be
moved proximally from a distal position to a proximal position,
and/or any other suitable position.
[0100] In various embodiments, further to the above, anvil 130 can
include one or more apertures, slots, or recesses 179 (FIG. 17)
which can be configured to receive at least a portion of housing
170 when anvil 130 is brought into close opposition to staple
cartridge 150, for example. In at least one embodiment, sufficient
clearance can be present between housing 170 and recess 179 such
that anvil 130 and staple cartridge 150 can be moved relative to
each other without interference, or at least substantial
interference, therebetween. In embodiments having more than one
cutting member housing as outlined above, an opposing anvil can
have more than one corresponding aperture for receiving the
housings. In various embodiments, an anvil can include a movable
cutting member and at least one housing for at least partially
covering, enclosing, and/or surrounding the cutting member. In
certain embodiments, although not illustrated, both an anvil and a
staple cartridge can comprise at least one movable cutting member
and/or at least one housing configured to at least partially cover,
surround, or enclose the cutting members when they are in a
proximal position, for example.
[0101] As outlined above, pusher bar assembly 200 can be advanced
distally in order to move staple sled assembly 160 within staple
cartridge assembly 150. In various embodiments, as also outlined
above, the wedge-like cam surfaces 167 of staple sled 162 can be
moved into engagement with the sloped surfaces 169 on staple
drivers 168 to sequentially, and/or simultaneously, drive staples
from staple cartridge 150 against anvil 130 and form the staples
into any suitable configuration, such as B-shaped configurations,
for example. In at least one such embodiment, referring to FIG. 17,
anvil 130 can include one or more staple forming surfaces, such as
staple pockets 132, for example, which can be configured to deform
the staples. In certain embodiments, anvil 130 can further include
a slot, channel, or groove 133 which can be configured to slidably
receive at least a portion of staple sled 162, cutting member 164,
and/or pusher bar 202, for example. In at least one embodiment,
although not illustrated, an anvil can include an anvil plate which
can be securely and/or immovably positioned within an anvil channel
defined within the anvil. In various other embodiments, as
illustrated in FIGS. 18 and 19 and described in greater detail
below, anvil 130 can include an anvil plate 134 movably positioned
within anvil channel 136. In certain embodiments, anvil channel 136
can include opposite side walls 137 and, in addition, a base 138
extending between side walls 137. In at least one embodiment, anvil
130 can further include a distal nose portion 139, for example,
assembled thereto wherein nose portion 139 can be configured to be
press-fit and/or snap-fit into anvil channel 136, for example, such
that nose portion 139 can be securely retained therein. In certain
embodiments, nose portion 139 can be comprised of a soft and/or
pliable material, such as rubber, for example, and can comprise any
suitable shape which can facilitate the insertion of anvil 130 into
a surgical site, for example. In some embodiments, referring to
FIG. 28, a nose portion, such as nose portion 139' can be retained
to an anvil by one or more fasteners 139a'. Similarly, referring to
FIG. 1, a staple cartridge channel and/or staple cartridge, such as
staple cartridge 150, for example, can include a nose portion, such
as nose portion 153, for example, which can facilitate the
insertion of staple cartridge 150 into a surgical site, for
example
[0102] As indicated above, staples can be deployed from a staple
cartridge and deformed against an anvil. In various circumstances,
the distance between the staple forming surfaces on anvil 130 and
staple sled 162 can determine the amount in which the staples are
deformed. For example, if the distance between anvil pockets 132 on
anvil 130 and top surfaces 135 on staple sled 162 (FIGS. 10-12) is
relatively large, the staples will be deformed a lesser amount as
compared to when the distance between anvil pockets 132 and sled
surfaces 135 is relatively small. Correspondingly, if the distance
between anvil pockets 132 and sled surfaces 135 is relatively
small, the staples will be deformed a greater amount as compared to
when the distance between anvil pockets 132 and sled surfaces 135
is relatively large. Often, the distance between anvil pockets 132
and sled surfaces 135 is referred to as the forming height of the
staples. Sometimes the forming height of the staples can be
measured between the top surface, or deck, of the staple cartridge
and the staple forming surfaces on the anvil. For the purpose of
this application, however, any reference to a staple forming
height, or the like, can include one or both manners of
measurement, where appropriate, and/or any other suitable manner of
measurement. In any event, as described in greater detail below, a
surgical stapling instrument, such as stapling instrument 100, for
example, can include means for adjusting the staple forming
height.
[0103] In various embodiments, further to the above, an anvil can
include one or more forming surfaces which can be moved toward
and/or away from a staple cartridge in order to set the forming
height of the staples. In at least one embodiment, referring to
FIGS. 17-23, anvil 130 can include anvil plate 134 which can be
movably and/or slidably positioned within anvil channel 136. In
certain embodiments, anvil 130 can further include one or more
retention, or guide, pins 140, wherein anvil plate 134 can include
one or more retention, or guide, slots 141 configured to slidably
receive at least a portion of pins 140. In at least one such
embodiment, pins 140 and/or slots 141 can be configured to define a
predetermined path along which anvil plate 134 can be moved.
Referring to FIG. 18, pins 140 and slots 141 can be structured and
arranged such that anvil plate 134 can be moved along a linear, or
at least substantially linear, path, wherein the linear path can be
at least partially defined by axes 142 and 143, for example. Other
embodiments are envisioned in which an anvil plate can be moved
along a non-linear path, such as a curved and/or curvi-linear path,
for example. In certain embodiments, at least a portion of pins 140
can be retained within apertures 144 in side walls 137 wherein, in
at least one embodiment, pins 140 can be press-fit within apertures
144. In any event, as described herein, pins 140 can guide anvil
plate 134 as it is moved toward and/or away from staple cartridge
150, for example.
[0104] In various embodiments, further to the above, a surgical
stapling instrument, such as stapling instrument 100, for example,
can include one or more adjustment members configured to position a
portion of an anvil, such as anvil plate 134, for example, relative
to other portions of an anvil assembly and/or an opposing staple
cartridge. In certain embodiments, referring to FIGS. 18 and 19,
stapling instrument 100 can include anvil plate adjustment member
230 which can be configured to limit the range of motion of anvil
plate 134. In at least one such embodiment, referring to FIGS. 20
and 21, adjusting member 230 can be positioned intermediate anvil
plate 134 in a first position in which first surface, or step, 231
of adjusting member 230 is positioned intermediate base 138 of
anvil channel 136 and first positioning surface 145 on anvil plate
134. In such a first position, first step 231 can define the amount
of relative movement possible, or permitted, between anvil plate
134 and anvil channel 136. For example, when anvil 130 is clamped
against tissue as described above, anvil plate 134 can contact the
tissue and slide upwardly toward base 138 until first positioning
surface 145 contacts first step 231. Once surface 145 and step 231
are in contact, adjusting member 230 can prevent, or at least
inhibit, anvil plate 134 from moving further toward base 138. In at
least one such embodiment, as a result, adjusting member 230 can
act as a stop such that the distance between base 138 and
tissue-contacting surface 148 on anvil plate 134 can be defined by
a first distance 234. While base 138 is used as a reference datum
in the present example, other portions of anvil 130 and/or an
opposing staple cartridge, for example, could be used as reference
datums. When adjusting member 230 is in its first position, as
described above, second surface, or step, 232 of adjusting member
230 can be positioned intermediate base 138 and second positioning
surface 146 on anvil plate 134, and, in addition, third surface, or
step, 233 can be positioned intermediate base 138 and third
positioning surface 147. Referring to FIG. 20, adjustment member
230 can include two or more sets of steps, 231, 232, and/or 233 and
anvil plate 134 can include two or more sets of positioning
surfaces 145, 146, and/or 147. While first step 231 and first
positioning surface 145 are described above as being configured to
control the position of anvil plate 134, the second and third steps
(232, 233) of adjustment member 230 and the second and third
positioning surfaces (146, 147) of anvil plate 134, respectively,
can also be configured to control the position of anvil plate 134.
For the sake of brevity, though, the present example will be
described in reference to the first surface, or step 231, as being
the surface which controls the position of anvil plate 134,
although the reader will understand that the steps 232 and 233 can
control the position of anvil plate 134 as well.
[0105] In certain embodiments, the first position of adjustment
member 230 can provide for a relatively small, or short, staple
forming height. In other embodiments, although not illustrated, the
first position of an adjustment member can provide for an
intermediate, a relatively large, and/or any other suitable staple
forming height. In the event that the forming height associated
with the first position of the adjustment member is suitable, a
surgeon can proceed to use the surgical stapling instrument to
staple and/or incise tissue as described above. In the event,
however, that the staple forming height is unsuitable, a surgeon,
or other clinician, can move adjustment member 230 such that
adjustment member 230 can permit anvil plate 134 to slide upwardly
a different distance when anvil plate 134 contacts tissue
positioned intermediate anvil 130 and staple cartridge 150. In at
least one such circumstance, the distance in which anvil plate 134
is permitted to slide upwardly can be larger, thereby providing a
larger forming height for the staples. Correspondingly, in other
circumstances, the adjustment member can be moved such that anvil
plate 134 can slide upwardly a shorter distance when anvil plate
134 contacts the tissue, for example, thereby providing a shorter
staple forming height. While the term "upward", and the like, can
mean vertically upward, the term is not so limited; rather,
"upward" can mean any direction which is toward the base of the
anvil and/or away from a staple cartridge, for example. In any
event, adjustment member 230 can be moved between its first
position, illustrated in FIG. 21, and a second position,
illustrated in FIG. 22, in order to increase the staple forming
height. As indicated by arrow "P" in FIG. 22, adjustment member 230
can be slid proximally in order to move adjustment member 230
between its first and second positions, although embodiments are
envisioned where an adjustment member can be slid distally and/or
any other suitable direction in order to adjust adjustment member
230. Once adjustment member 230 has been moved into its second
position, referring to FIG. 22, first surface, or step, 231 can be
positioned intermediate base 138 and second positioning surface 146
of anvil plate 134. In such a second position, first step 231 can
once again define the amount of relative movement permitted between
anvil plate 134 and anvil channel 136. In at least one embodiment,
similar to the above, adjusting member 230 can act as a stop such
that the distance between base 138 and tissue-contacting surface
148 on anvil plate 134 can be defined by a second distance 235.
[0106] Further to the above, adjustment member 230 can be moved
between its second position, illustrated in FIG. 22, and a third
position, illustrated in FIG. 23, in order to once again increase
the staple forming height. As indicated by arrow "P" in FIG. 23,
adjustment member 230 can be slid proximally in order to move
adjustment member 230 between its second and third positions. Once
adjustment member 230 has been moved into its third position,
referring to FIG. 23, first surface, or step, 231 can be positioned
intermediate base 138 and third positioning surface 147. In such a
third position, first step 231 can once again define the amount of
relative movement between anvil plate 134 and anvil channel 136. In
at least one embodiment, similar to the above, adjusting member 230
can act as a stop such that the distance between base 138 and
tissue-contacting surface 148 on anvil plate 134 can be defined by
a third distance 236. While adjustment member 230 can be
selectively moved between three positions as described above to
provide three different staple forming heights, other embodiments
are envisioned which comprise an adjustment member which can be
moved between more than three positions to provide more than three
different staple forming heights. For example, an adjustment member
can be movable between four positions in order to provide four
staple forming heights. Further embodiments are envisioned which
comprise an adjustment member which can be moved between two
positions to provide two staple forming heights. Furthermore, while
surfaces, or steps, 231, 232, and 233 of adjustment member 230 are
arranged in a descending order, other arrangements are envisioned
in which the surfaces, or steps, are arranged in an ascending
order. Other arrangements are envisioned in which the surfaces, or
steps, are not necessarily arranged in either an ascending or a
descending order. Similarly, positioning surfaces 145, 146, and 147
of anvil plate 134 can be arranged in an ascending order, a
descending order (FIG. 20), and/or any other suitable order.
Furthermore, while adjustment member 230 can be slid along an axis,
other embodiments are envisioned where an adjustment member can be
moved along any suitable path such as curved and/or curvi-linear
paths, for example.
[0107] As described above, referring to FIG. 21, adjustment member
230 can comprise three surfaces, or steps, 231, 232, and 233 while
anvil plate 134 can comprise three corresponding adjustment
surfaces 145, 146, and 147. When adjustment member 230 is in its
first position, for example, first surface 231 can be positioned
such that it abuts or is adjacent to first adjustment surface 145,
second surface 232 can be positioned such that it abuts or is
adjacent to second adjustment surface 146, and third surface 233
can be positioned such that it abuts or is adjacent to third
adjustment surface 147. As adjustment member 230 is slid relative
to anvil plate 134, as described above and referring to FIGS. 22
and 23, surfaces 231, 232, and 233 of adjustment member 230 can be
sequentially indexed relative to surfaces 145, 146, and 147 of
anvil plate 134. In at least one such embodiment, an adjustment
member can have the same number of steps as the number of
positioning surfaces on an anvil plate. Other embodiments are
envisioned where an adjustment member has more steps than
positioning surfaces on the anvil plate. In at least one such
embodiment, an anvil plate can include one positioning surface
wherein the steps of an adjustment member can be selectively
utilized to limit the upward movement of the anvil plate, for
example. In various embodiments, referring generally to adjustment
member 230 and anvil plate 134, an anvil plate may include one
positioning surface, such as positioning surface 145, for example,
where steps 231, 232, and 233 of adjustment member 230, for
example, can be selectively positioned intermediate base 138 and
positioning surface 145. In such embodiments, first step 231 can
have a first thickness or height which can stop, or limit, the
upward movement of anvil plate 134 so as to define a first staple
forming height, second step 232 can have a second thickness or
height which can stop, or limit, the upward movement of anvil plate
134 so as to define a second staple forming height, and, in
addition, third step 233 can have a third thickness or height which
can stop, or limit, the upward movement of anvil plate 134 so as to
define a third staple forming height. In at least one embodiment,
the thickness or height of steps 231, 232, and/or 233 can be
measured between a back surface 237 of adjustment member 230 and a
surface on the steps (231, 232, 233) which will contact anvil plate
134. In various embodiments, the difference in height, or
thickness, between first step 231 and second step 232 can be the
same, or at least substantially the same, as the difference in
height, or thickness, between second step 232 and third step 233.
In at least one such embodiment, as a result, the step heights can
increase at a linear rate, or an at least substantially linear
rate. In alternative embodiments, the difference in height, or
thickness, between the first and second steps can be different than
the difference in height, or thickness, between the second and the
third steps. In at least one such embodiment, the first, second,
and third steps may not increase or decrease in height, or
thickness, at a linear rate; rather, although not illustrated, the
steps may increase or decrease in height, or thickness, in a
non-linear and/or geometric rate.
[0108] As described above, an adjustment member, such as adjustment
member 230, for example, can be movable between two or more
positions. In various embodiments, a surgical stapling instrument
can include an actuator configured to move the adjustment member.
In at least one embodiment, referring to FIGS. 17-20, surgical
stapling instrument 100 can include actuator 250 which can be
operably attached to adjustment member 230 such that a force can be
applied to actuator 250 and transmitted to adjustment member 230.
In certain embodiments, actuator 250 can include grasping portions,
or handles, 252 which can be configured to be grasped by a surgeon,
for example, in order to advance or retract adjustment member 230
within anvil 130 as described above. In certain embodiments,
grasping portions 252 can extend from actuator body 251, wherein
actuator body 251 can include one or more apertures, slots, or
cavities 253 which can be configured to receive at least a portion
of adjustment member 230. In at least one such embodiment,
referring to FIG. 19, adjustment member 230 can include lock 254
extending therefrom, wherein at least a portion of lock 254 can be
received within aperture 253 so as to retain actuator body 251 to
adjustment member 230. In various embodiments, lock 254 can include
one or more resilient, or flexible, legs 255 which can be deflected
when they are inserted into aperture 253 but resiliently return, or
at least partially return, to their unflexed position after feet
256 of legs 255 are sufficiently pushed through aperture 253. In at
least one such embodiment, feet 256 can prevent, or at least
inhibit, actuator body 251 from being detached from adjustment
member 230.
[0109] In various embodiments, further to the above, surgical
stapling instrument 100 can further include a detent mechanism
which can be configured to hold, or releasably hold, actuator 250
and/or adjustment member 230 in position. In at least one
embodiment, referring to FIG. 19, detent member 260 can be attached
to actuator 250 wherein, in at least some embodiments, actuator
body 251 can include one or more channels, grooves, or recesses 257
which can be configured to receive and/or retain a detent body 261
of detent member 260 therein. In at least one embodiment, detent
body 261 can include one or more apertures 263, and/or any other
suitable channels, slots, or grooves, which can be configured to
receive one or more fasteners for securing detent body 261 to
actuator 251, for example. Detent member 260 can further include
detent legs 262 which can be configured to engage one or more
recesses, apertures, or grooves 101 (FIGS. 2-7) in first frame
portion 110, for example. More particularly, referring to FIGS. 2
and 3, each side flange 128 can include one or more recesses 101
(101a, 101b, and 101c) defined therein wherein detent legs 262 can
be biased into engagement with the top surfaces of side flanges 128
such that detent legs 262 can be slid into, and slid out of,
recesses 101. In the illustrated embodiment, each side flange can
include three recesses 101 which can be configured to removably
hold actuator 250 in a first, distal position, a second,
intermediate position, and a third, proximal position, wherein the
first, second, and third positions of actuator 250 can respectively
correspond with the first, second, and third positions of
adjustment member 230 described above. For example, when actuator
250 is in its first, distal position, detent legs 262 of detent
member 260 can be positioned within recess 101a so as to removably
retain actuator 250 and adjustment member 230 in their first
positions. Upon the application of a sufficient force, actuator 250
can be moved proximally into its second position such that detent
legs 162 are positioned within recess 101b and actuator 250 and
adjustment member 230 are retained in their second positions.
Similarly; upon the application of a sufficient force, actuator 250
can be moved proximally into its third position such that detent
legs 162 are positioned within recess 101c and actuator 250 and
adjustment member 230 are retained in their third positions. In
various embodiments, detent legs 162 can be configured such that
actuator 250 can be returned to its first and/or second
positions.
[0110] As described above, adjustment member 230 can be moved along
a pre-determined path between two or more positions by actuator
250. In various embodiments, surgical stapling instrument 100, for
example, can include one or more guides for controlling or limiting
the movement of adjustment member 230 and/or actuator 250. In some
embodiments, adjustment member 230 can be closely received between
side walls 137 of anvil 130 such that side walls 137 can guide
adjustment member 230. In at least one such embodiment, side walls
137 can be configured to control or limit the lateral or
side-to-side movement of adjustment member 230. In various
embodiments, detent legs 162 of detent member 160 can comprise
resilient members which can be configured to apply an upward
biasing or pulling force on adjustment member 230 so as to position
adjustment member 230 against, or at least adjacent to, base 138
and intermediate side walls 137. In certain embodiments, referring
to FIG. 19, base 138 of anvil 130 can further include guide slot
149 which can be configured to receive at least a portion of
adjustment member 230 and/or actuator 250 therein such that guide
slot 149 can limit the movement of adjustment member 230 and
actuator 250. In at least one such embodiment, lock 254 of
adjustment member 230 can be configured to extend through guide
slot 149 such that, when lock 254 is inserted into aperture 253 of
actuator 250 as described above, base 138 of anvil 130 can be
captured intermediate adjustment member 230 and actuator 250. In
certain embodiments, guide slot 149 can be configured to limit the
movement of lock 254 such that adjustment member 230 can be
prevented, or at least inhibited, from being moved distally when
adjustment member 230 is in its first, or distal-most, position
and/or, similarly, prevented, or at least inhibited, from being
moved proximally when adjustment member 230 is in its third, or
proximal-most, position.
[0111] In various embodiments, further to the above, a detent
member, similar to detent member 260, for example, can be utilized
to bias first handle portion 102 and second handle portion 104 away
from one another. In at least one embodiment, referring to FIG. 37,
surgical stapling instrument 100' can include a detent member 260'
configured to position first handle portion 102 and second handle
portion 104 such that a gap exists between anvil 130 and staple
cartridge 150. Such a feature, as outlined above, can allow a
surgeon to easily manipulate the surgical instrument without having
to hold the first and second handle portions apart from one
another. In certain embodiments, detent member 260' can be
sufficiently mounted to second handle portion 104 such that detent
legs 262' extending from detent member 260' can contact flanges 128
and, when compressed, apply a biasing force to the first and second
handle portions. As seen in FIG. 37, legs 262' can contact surfaces
101d on flanges 128. In order to compress detent legs 262', latch
mechanism 180 can be moved into a partially-closed position such
that latch arms 188 can engage, and at least partially surround,
latch projections 131. In this configuration, a surgeon can
manipulate the instrument and, when satisfied with its position,
move latch mechanism 180 into a closed position and further
compress detent legs 262'. Similar to the above, detent member 260'
can be affixed, or otherwise operably engaged with, actuator 250
such that, when actuator 250 is moved between its first, second,
and third positions as described above, legs 262' can engage
recesses 101a, 101b, and 101c, respectively. In at least one such
embodiment, as a result, actuator 250 can have a pre-staged
position in which actuator 250 is positioned distally with respect
to its first position and, in addition, surfaces 101d can comprise
pre-stage surfaces against which legs 262' can be positioned when
actuator 250 is in its pre-staged position.
[0112] As outlined above, an adjustment member can be slid, or
translated, between first and second positions so as to adjust the
forming height of staples deployed by a surgical stapling
instrument. In various embodiments, although not illustrated, an
adjustment member can be configured to positively displace an anvil
plate toward and/or away from an opposing staple cartridge, for
example. In at least one such embodiment, a surgical stapling
instrument can include one or more biasing members, such as
springs, for example, configured to position the anvil plate
against the adjustment member such that, when the adjustment member
is moved between its first and second positions, the adjustment
member can displace the anvil plate between first and second
positions in order to set first and second staple forming heights.
In various embodiments, as a result of the above, an adjustment
member can be configured to cam a portion of an anvil into
position. In at least one such embodiment, an adjustment member can
be slid along an axis in order to positively displace an anvil
plate. In other embodiments, a rotatable adjustment member can be
configured to positively displace an anvil plate toward and/or away
from a staple cartridge, for example.
[0113] Further to the above, as described in greater detail below,
an adjustment member can be rotated to adjust the staple forming
height. Referring to FIGS. 24-36, surgical instrument 100' can
include, similar to the above, a first handle portion 102', a
second handle portion 104', and a latching mechanism 180' which can
be utilized to clamp tissue intermediate anvil 130' and staple
cartridge 150'. Referring to FIG. 25, also similar to the above,
latching mechanism 180' can be pivotably coupled to first portion
102' by one or more pivot pins 182', wherein latching mechanism
180' can include one or more latch arms 188' which can be
configured to engage second portion 104' and latch the first and
second handle portions together. Also similar to the above,
referring to FIGS. 25 and 27, surgical instrument 100' can further
include pusher bar assembly 200' which can be configured to advance
a cutting member and/or staple sled within end-effector 120'. In at
least one such embodiment, pusher bar assembly 200' can include a
proximal end 203' and an actuator 204', wherein actuator 204' can
be rotatably mounted to proximal end 203' and selectively
positioned on first and second sides of stapling instrument 100'.
In various embodiments, surgical stapling instrument 100' can
comprise the same, or similar, features to those described in
connection with surgical stapling instrument 100 and can be
operated in the same manner, or a similar manner, as instrument 100
and, as a result, such details are not repeated herein.
[0114] In various embodiments, referring to FIG. 27, surgical
instrument 100' can include a rotatable adjustment member 230'
which can be selectively positioned in at least first and second
positions so as to provide different staple forming heights. In
certain embodiments, surgical instrument 100' can include an
actuator 250' which can be operably connected to adjustment member
230' such that actuator 250' can move adjustment member 230'
between at least its first and second positions. In at least one
embodiment, referring to FIG. 28, actuator 250' can include
actuator body 251' and grasping portion, or handle, 252'. Actuator
body 251' can include an aperture 258' which can be configured to
receive a proximal end 238' of adjustment member 230' such that
rotational motion, torque, and/or forces can be transmitted between
actuator 250' and adjustment member 230'. In at least one such
embodiment, referring to FIG. 36, aperture 258' can comprise a
non-circular profile and/or a profile which includes one or more
flat drive surfaces configured to transmit rotational motion
between actuator body 251' and actuator 230'. In certain
embodiments, aperture 258' can be sized and configured to closely
receive proximal end 238' of actuator 230'. In at least one
embodiment, aperture 258' can be configured to receive proximal end
238' in a press-fit and/or snap-fit arrangement. In various
embodiments, referring again to FIG. 28, handle portion 104' can
include one or more slots 259' which can be configured to permit at
least a portion of actuator body 251' to extend therethrough such
that grasping portion 252' can be assembled to actuator body 251'
with at least a portion of handle portion 104' positioned
therebetween. In at least one such embodiment, second handle
portion 104' can further include recess 253' which can be
configured such that at least a portion, if not all, of grasping
portion 252' is positioned within recess 253'. In certain
embodiments, recess 253' can be configured such that grasping
portion 252' does not extend above the top surface of second handle
portion 104' although, in other embodiments, an upper portion of
grasping portion 252' can extend above second handle portion 104,
as illustrated in FIG. 30, such that grasping portion 252' can be
easily accessed by a surgeon.
[0115] In various embodiments, as outlined above, an adjustment
member can be rotatable between at least first and second positions
in order to adjust the forming height of staples deployed by a
surgical stapler. In certain embodiments, referring to FIG. 28, a
surgical stapling instrument can include an adjustment member
rotatably positioned within an anvil wherein the adjustment member
can be configured to limit the relative movement of a movable anvil
portion. In at least one such embodiment, surgical stapling
instrument 100' can include an anvil plate 134' which can be
slidably retained within anvil channel 136' by retention, or guide,
pins 140', wherein guide pins 140' can be configured to allow anvil
plate 134' to slide upwardly when anvil plate 134' comes into
contact with tissue as described above. Referring to FIGS. 27, 30,
and 31, adjustment member 230' can be positionable in a first
position, or orientation, such that it can limit the upward
movement of anvil plate 134' within anvil channel 136' and dictate
the staple forming height of the staples. In at least one such
embodiment, referring to FIGS. 30 and 31, adjustment member 230'
can include opposing first surfaces 231' which can be positioned
intermediate base 138' of anvil channel 136' and positioning
surface 145' of anvil plate 134' such that, when positioning
surface 145' contacts one of first surfaces 231', tissue-contacting
surface 148' of anvil plate 134' can be positioned a first distance
234' away from a datum surface 129' on anvil 130', for example.
Correspondingly, forming surfaces 132' can be positioned a first
distance away from a staple cartridge such that, when staples are
deployed from the staple cartridge, the staples can be deformed to
a first staple height. Further to the above, a first diameter 241'
can be defined between first surfaces 231' wherein the first
diameter 241' can define the maximum upward position of anvil plate
134' within anvil channel 136'.
[0116] As indicated above, adjustment member 230' can be rotated in
order to adjust the forming height of the staples. In various
embodiments, adjustment member 230' can be rotated between its
first position, or orientation, (FIGS. 30 and 31) and a second
position, or orientation (FIGS. 32 and 33). In at least one
embodiment, referring to FIGS. 32 and 33, handle 252' can be
rotated in a direction indicated by arrow "A" in order to move
adjustment member 230' between its first and second positions.
Similar to the above, when actuator 230' is in its second position,
or orientation, actuator 230' can limit the upward movement of
anvil plate 134' within anvil channel 136' and dictate the staple
forming height of the staples. In at least one such embodiment,
referring to FIGS. 32 and 33, adjustment member 230' can include
opposing second surfaces 232' which can be positioned intermediate
base 138' and positioning surface 145' such that, when positioning
surface 145' contacts one of second surfaces 232',
tissue-contacting surface 148' of anvil plate 134' can be
positioned a second distance 235' away from datum surface 129', for
example. Correspondingly, forming surfaces 132' can be positioned a
second distance away from a staple cartridge such that, when
staples are deployed from the staple cartridge, the staples can be
deformed to a second staple height. In various embodiments, similar
to the above, a second diameter 242' can be defined between second
surfaces 232', wherein second diameter 242' can define the maximum
upward position of anvil plate 134' within anvil channel 136'.
Although first surfaces 231' and second surfaces 232' can be
defined by flat, or at least substantially flat, surfaces, other
embodiments are envisioned in which the first and second surfaces
231' and 232' can include at least partially arcuate, or curved,
contours. In any event, referring to FIG. 27, adjustment member
230' may include one or more clearance slots 240' which can be
configured to provide clearance between actuator 230' and retention
pins 140'. Clearance slots 240' can be configured to provide
clearance between actuator 230' and retention pins 140' when
actuator 230' is in its first position, second position, and/or any
other suitable position.
[0117] In various embodiments, further to the above, adjustment
member 230' can be rotated between its first position, or
orientation, (FIGS. 30 and 31) and a third position, or orientation
(FIGS. 34 and 35). In at least one embodiment, referring to FIGS.
34 and 35, handle 252' can be rotated in a direction indicated by
arrow "B" in order to move adjustment member 230' between its first
and third positions. Similar to the above, when actuator 230' is in
its third position, or orientation, actuator 230' can limit the
upward movement of anvil plate 134' within anvil channel 136' and
dictate the staple forming height of the staples. In at least one
such embodiment, referring to FIGS. 34 and 35, adjustment member
230' can include opposing third surfaces 233' which can be
positioned intermediate base 138' and positioning surface 145' such
that, when positioning surface 145' contacts one of third surfaces
233', tissue-contacting surface 148' of anvil plate 134' can be
positioned a third distance 236' away from datum surface 129', for
example. Correspondingly, forming surfaces 132' can be positioned a
third distance away from a staple cartridge such that, when staples
are deployed from the staple cartridge, the staples can be deformed
to a third staple height. In various embodiments, similar to the
above, a third diameter 243' can be defined between third surfaces
233', wherein third diameter 243' can define the maximum upward
position of anvil plate 134' within anvil channel 136'. Referring
once again to FIGS. 34 and 35, third surfaces 233' can be defined
by an at least partially arcuate contour, although other
embodiments are envisioned in which third surfaces 233' can include
flat, or at least substantially flat, contours. In at least one
embodiment, adjustment member 230' can be configured such that the
largest distance, or diameter, between the arcuate third surfaces
233' can be utilized to define the third staple height.
[0118] As described above, referring to FIGS. 30 and 31, adjustment
member 230' can be positioned in a first position, or orientation,
to set a first forming height for the staples deployed by surgical
stapling instrument 100'. As also described above, referring to
FIGS. 32 and 33, actuator 250' can be utilized to move adjustment
member 230' into its second position, or orientation, to set a
second forming height for the staples. To do this, in at least one
embodiment, a force can be applied to handle 252' which can cause
handle 252', and adjustment member 230' attached thereto, to rotate
in a direction indicated by arrow "A". In at least one embodiment,
adjustment member 230' and/or actuator 250' can be sufficiently
retained such that, when adjustment member 230' is rotated,
adjustment member 230' can be rotated about an axis, such as axis
245' (FIG. 27), for example. In at least one embodiment, referring
to FIG. 25, the proximal end 203' of pusher bar assembly 200' can
include one or more grooves, channels, or recesses 205' which can
be configured to receive and/or retain at least a portion of
adjustment member 230' and/or actuator 250' therein. In any event,
as illustrated in FIGS. 30-33, the second position, or orientation,
of adjustment member 230' can allow anvil plate 134' to slide a
larger distance within anvil channel 136' as compared to when
adjustment member 230' is in its first position. In at least one
embodiment, as a result, the second staple forming height can be
larger than the first staple forming height. As also described
above, referring to FIGS. 34 and 35, actuator 250' can be utilized
to move adjustment member 230' into its third position, or
orientation, to set a third forming height for the staples. To do
this, in at least one embodiment, a force can be applied to handle
252' which can cause handle 252', and adjustment member 230'
attached thereto, to rotate in a direction indicated by arrow "B".
As illustrated in FIGS. 30, 31, 34, and 35, the third position, or
orientation, of adjustment member 230' can allow anvil plate 134'
to slide a smaller distance within anvil channel 136' as compared
to when adjustment member 230' is in its first position. In at
least one embodiment, as a result, the first and second staple
forming heights can be larger than the third staple forming height.
In at least one such embodiment, the first position of adjustment
member 230', and actuator 250', can represent an intermediate
position, wherein adjustment member 230' can be selectively moved
into its second and third positions directly from its first
position. In effect, the first position of adjustment member 230'
can represent an intermediate staple height, wherein the second and
third staple positions of adjustment member 230' can represent
taller and shorter staple heights, respectively. In certain
embodiments, referring to FIG. 24, surgical stapling instrument
100' can include one or more indicia thereon which can be
configured to convey the staple forming heights, or at least
relative forming heights, that can be selected. For example, second
handle portion 104' can include a first indicium 245' which can
indicate an intermediate, or first, staple height, a second
indicium 246' which can indicate a taller, or second, staple
height, and, in addition, a third indicium 247' which can indicate
a shorter, or third, staple height.
[0119] In various embodiments, further to the above, one or more of
first surfaces 231', second surfaces 232', and third surfaces 233'
can comprise or define, or at least partially comprise or define, a
perimeter, or circumference, of adjustment member 230'. As
discussed above, owing to the first, second, and third diameters
(241', 242', and 243') defined by the first, second, and third
surfaces (231', 232', and 233'), respectively, the perimeter, or
circumference, of adjustment member 230' may be non-circular. In
certain embodiments, though, the perimeter, or circumference of
adjustment member 230', may be symmetrical, substantially
symmetrical, and/or non-symmetrical. In various embodiments,
further to the above, an adjustment member can comprise a cam
rotatably positioned intermediate base 138' of anvil 130' and
adjustment surface 145' of anvil plate 134', for example. In at
least one such embodiment, one or more of first surfaces 231',
second surfaces 232', and third surfaces 233', for example, can
comprise or define a cam profile which, similar to the above, can
be configured to either positively position anvil plate 134' and/or
provide a stop against which anvil plate 134' can be positioned. In
any event, although not illustrated, various embodiments are
envisioned in which an adjustment member can be slid and rotated in
order to set two or more staple forming heights for staples
deployed by a surgical stapling instrument. In at least one such
embodiment, an adjustment member can comprise a cam profile which
can be defined along the length of the adjustment member wherein
longitudinal and/or rotational movement can be utilized to move the
cam profile between at least first and second positions.
[0120] In various embodiments, similar to the above, surgical
instrument 100' can further include a detent mechanism configured
to hold, or at least releasably hold, actuator 250' in position. In
at least one embodiment, referring to FIGS. 25 and 26, surgical
instrument 100' can further include detent member 260' comprising
detent body 261' and one or more detent legs 262'. Referring to
FIG. 26, detent body 261' can include one or more grooves,
recesses, or channels 263' which can be configured to receive at
least a portion of proximal end 105' of second handle portion 104'
therein such that detent member 260' can be retained in position.
In at least one such embodiment, proximal end 105' can further
include one or more grooves, channels, or recesses 265' which can
be configured to closely receive detent member 260'. In certain
embodiments, at least a portion of detent body 261', such as
channel 263', for example, can be press-fit, snap-fit, and/or
otherwise suitably retained in recess 265'. As also illustrated in
FIG. 26, each detent leg 262' of detent member 260' can include one
or more projections 264' extending therefrom which can be
configured to engage actuator body 251' and releasably hold
actuator 250' in position. In at least one embodiment, referring to
FIG. 36, actuator body 251' can include one or more recesses, or
holes, 269' which can be configured to receive a projection 264'.
When a projection 264' is positioned within recess 269', the
projection can be configured to hold actuator 250' in its first
position, for example, until a sufficient force is applied to
actuator 250' so as to cause the projection 264' to be displaced
out of recess 269'. More particularly, the force applied to
actuator 250' can be transmitted to the projection 264' and, owing
to cooperating surfaces between the projection 264' and recess
269', the detent leg 262' associated with the projection 264' can
be flexed or moved proximally to allow actuator body 251' to be
moved relative thereto. In order to accommodate such proximal
movement, referring to FIG. 25, recess 265' can include elongate
portions 266' which can each be configured to receive at least a
portion of legs 262' such that legs 262' can move relative to
handle portion 104'. As actuator 250' is moved into either its
second or third position, actuator body 251' can contact a
projection 264' extending from another leg 262' and deflect the leg
262' proximally such that, once actuator 250' is in its second or
third positions, the leg 262' can spring forward, or distally, such
that the projection 264' can be secured within recess 269'. In at
least one embodiment, further to the above, the interaction between
projections 264' and the sidewalls of recess 269' can be such that
actuator 250' can be securely held in one of its first, second, and
third positions, for example, yet permit actuator 250' to be moved
upon a sufficient application of force. In such embodiments, the
detent member 260' can prevent, or at least inhibit, actuator 250'
and, correspondingly, adjustment member 230' from being
unintentionally displaced.
[0121] As discussed above and as shown in FIG. 2, each side flange
128 of first handle portion 102 can include a notch, or recess,
127, for example, which can be configured to receive one or more
latch projections 131, for example, extending from anvil 130,
and/or any other suitable portion of second handle portion 104. As
also discussed above, referring primarily to FIGS. 2 and 3, first
handle portion 102 can further include latching mechanism 180
rotatably mounted thereto which can be utilized to engage latch
projections 131 extending from second handle portion 104 and secure
the first and second handle portions 102, 104 together. Latching
mechanism 180 can include one or more latch arms 188 extending
therefrom which can be configured to engage latch projections 131
and pull and/or secure projections 131 within recesses 127 as
illustrated in FIG. 7. Referring to FIG. 6, at least one of latch
arms 188 can include a distal hook 189 which can be configured to
wrap around at least a portion of projections 131 so as to
encompass or surround, or at least partially encompass or surround,
projections 131. In at least one embodiment, latch arms 188 can act
as an over-center latch to maintain latching mechanism 180 in its
latched, or closed, position.
[0122] In various embodiments, referring now to FIG. 38, each
projection 131 can comprise a slot, or groove, 190 positioned
intermediate sidewall 191 and an enlarged end, or head, 192 of
projection 131, wherein the slot 190 can be configured to receive
at least a portion of latch arm 188. More particularly, in at least
one embodiment, the slot 190 can have a width which is greater than
the width of the latch arm 188 such that, when the latch arm 188 is
engaged with the projection 131, the latch arm 188 can enter into
slot 190. In some circumstances, the width of each slot 190 may be
slightly larger than the width of a latch arm 188 such that the
latch arm is closely received within the slot 190. In various
circumstances, the slot 190, the sidewall 191, and the head 192 of
projection 131 can be sized and configured so as to prevent, or at
least limit, relative lateral movement, i.e., movement away from or
to the sides of anvil 130, between latch arm 188 and projection
131. Further to the above, however, the latch arms 188 can slide
longitudinally within the grooves 190 as the latch arms 188 move
the projections 131 into the recesses 127 in first portion 102.
Owing to such relative sliding movement between latch arms 188 and
projections 131, frictional forces can be generated therebetween
which can resist the movement of latch arms 188. In various
circumstances, the magnitude of such frictional forces can be
significant when the normal, or perpendicular, contact forces
between the latch arms 188 and the sidewalls of groove 190 are
large. In many circumstances, as a result, the operator of the
surgical instrument has to overcome these frictional forces when
actuating clamping mechanism 180.
[0123] In various alternative embodiments, referring now to FIGS.
39 and 40, a surgical instrument can comprise one or more latch
projections having a rotatable bearing which can reduce the
magnitude of the friction forces between the latch arms of a
latching mechanism and the latch projections. In at least one
embodiment, an anvil 330, which can be substantially similar to
anvil 130 in many respects, can comprise a latch projection 331
extending from each side thereof, wherein each latch projection 331
can comprise a rotatable bearing 393. In use, the latch arms 188 of
latching mechanism 180, for example, can contact the rotatable
bearings 393 in order to position the latch projections 331 in
recesses 127. In various circumstances, the latch arms 188 can
slide across the surface, or outer diameter, of bearings 393;
however, as bearings 393 can rotate relative to the latch arms 188,
the magnitude of the frictional forces between the latch arms 188
and projections 331 can be lower than the magnitude of the
frictional forces between latch arms 188 and projections 131. Owing
to such lower frictional forces, a lower closing, or clamping,
force may be required to actuate clamping mechanism 180, for
example.
[0124] In various embodiments, referring primarily to FIG. 41, each
rotatable bearing 393 can comprise a circular, or round, outer
diameter 394 and, in addition, a circular, or round, bearing
aperture 395 extending therethrough. In certain embodiments, each
projection 331 can further comprise a shaft portion 396 extending
from sidewall 391 and an enlarged end, or head, 392 extending from
shaft portion 396, wherein, as illustrated in FIG. 31, the shaft
portion 396 can extend through the bearing aperture 395 of
rotatable bearing 393. In various embodiments, the shaft portion
396 can comprise a circular, or round, outer diameter which can be
closely received within bearing aperture 395 such that there is
little, if any, relative radial movement therebetween. The diameter
of the bearing aperture 395, however, may be sufficiently larger
than the outer diameter of shaft portion 396 such that bearing 393
can rotate relative to shaft portion 396 about an axis 399. In
various embodiments, the rotatable bearing 393 can be retained on
shaft portion 396 by the enlarged head 392. More particularly, in
at least one embodiment, the enlarged head 392 may be larger than,
or define a larger diameter than, the diameter of bearing aperture
395 such that rotatable bearing 393 cannot slide off the end of
shaft portion 396. In certain embodiments, the sidewall 391 and the
head 392 can define a gap distance therebetween and, in addition,
the bearing 393 can comprise a width, wherein the gap distance can
be larger than the width of bearing 393. In at least one
embodiment, the gap distance may be slightly larger than the width
of bearing 393 such that bearing 393 does not tilt, or at least
substantially tilt, relative to axis 399, for example.
[0125] As discussed above, the latch arms 188 of latching mechanism
180 can be configured to engage bearings 393 and position bearings
393 within recesses 127. In various alternative embodiments,
referring primarily to FIG. 40, a surgical instrument can comprise
a latching mechanism 380 which can comprise first and second latch
arms 388 extending therefrom on opposite sides of anvil 331 and
staple cartridge channel 324. In use, similar to the above, the
latch arms 388 can contact bearings 393 in order to move bearings
393 into recesses 327 in staple cartridge channel 324 and move
anvil 331 toward staple cartridge channel 324. Such movement is
illustrated with phantom lines in FIG. 41. In various embodiments,
each latch arm 388 can at least partially define a groove, or slot,
397 therein, wherein each slot 397 can be configured to receive a
bearing 393. In at least one embodiment, a slot 397 can comprise a
first drive surface, or sidewall, 398a which can be positioned
against bearing 393 and, as a closing force is applied to latching
mechanism 380, the latch arm 388 can apply a closing force to the
bearing 393. In such circumstances, the bearing 393 can move
further into slot 397 as latching mechanism 380 is rotated into its
closed position. In various circumstances, the slot 397 can further
comprise a second drive surface, or sidewall, 398b which can be
positioned against another and/or opposite side of bearing 393 such
that an opening force can be applied to the bearing 393 via latch
arm 388. As the latching mechanism 380 is moved into its open
position, the bearing 393 can move out of slot 397. In any event,
the first drive surface 398a and the second drive surface 398b can
define a slot width therebetween which can be larger than the
outside diameter of bearing 393 such that bearing 393 can move
within slot 397. In some embodiments, the slot width may be
slightly larger than the outside diameter of bearing 393. In at
least one embodiment, at least portions of the first drive surface
398a and the second drive surface 398b can be parallel, or at least
substantially parallel, to one another. In at least one such
embodiment, at least portions of the first drive surface 398a can
be positioned opposite the second drive surface 398b.
[0126] As described above, a surgical stapling instrument can be
configured to deform one or more surgical staples between a first,
undeployed, configuration and a second, deployed, configuration. In
various embodiments, referring now to FIG. 39, a surgical staple,
such as staple 400, for example, can comprise a base 402, a first
leg, or deformable member, 404 extending from base 402, and, in
addition, a second leg, or deformable member, 406 extending from
base 402. In certain embodiments, the base 402, the first leg 404,
and the second leg 406 can be comprised of a continuous wire,
wherein, in at least one embodiment, the first leg 404 and the
second leg 406 can each be bent in a direction which is
perpendicular to the base 402 prior to staple 400 being inserted
into and deformed by a surgical stapler. More particularly, the
staple 400 can be manufactured such that base 402 is oriented along
a baseline 401 and such that the legs 404 and 406 are oriented
along lines 409 and 411, respectively, which are perpendicular, or
at least substantially perpendicular, to the baseline 401. In
various embodiments, the first leg 404 can be positioned at a first
end of base 402 and the second end 406 can be positioned at a
second end of base 402, wherein, in at least one embodiment, a
mid-line 403 can be defined which extends through a midpoint of
base 402 and which extends in a direction which is perpendicular to
baseline 401. The staple 400 can be configured such that the base
402, first leg 404, and second leg 406 lie, or at least
substantially lie, in the same, or common, plane when the staple
400 is in its first, or undeployed, configuration. In such
embodiments, the baseline 401, along which the base 402 is
oriented, and the perpendicular lines 409 and 411, along which the
legs 404 and 406 are oriented, can lie in the same plane.
[0127] In various embodiments, further to the above, the continuous
wire comprising the base 402, the first leg 404, and the second leg
406 can be comprised of titanium and/or stainless steel, for
example. In at least one embodiment, the first leg 404 can comprise
a first end 405 and the second leg 406 can comprise a second end
407, wherein the ends 405 and 407 can each comprise a sharp, or
chisel, tip which can be configured to puncture bone and/or tissue.
In use, the staple 400 can be deformed by a surgical stapler in
order to capture tissue, for example, within the staple 400. In
various embodiments, the staple 400 can be deployed from a staple
cartridge such that the ends 405 and 407 of staple legs 404 and
406, respectively, contact an anvil positioned opposite the staple
400. In such circumstances, a first compressive force F1 can be
applied to the first leg 404 and a second compressive force F2 can
be applied to the second leg 406 while the base 402 is supported by
at least a portion of the staple cartridge. As described in greater
detail below, the anvil can comprise a staple pocket which can
apply the first compressive force F1 to the first leg 404 such that
the end 405 of staple leg 404 is moved toward the base 402.
Similarly, the staple pocket can apply the second compressive force
F2 to the second staple leg 406 such that the end 407 of staple leg
404 is also moved toward base 402. In addition to the above, as
also discussed in greater detail below, referring now to FIGS.
50-52, the staple pocket can bend the first staple leg 404 to a
first side of base 402 and the second staple leg 406 to a second,
or opposite, side of base 402.
[0128] In various embodiments, referring to FIGS. 49 and 50, the
first leg 404 of staple 400 can be bent such that the end 405 of
the first leg 404 is moved toward the base 402 and toward the
second leg 406 when the first leg 404 is deformed by the first
compressive force F1. In at least one embodiment, the end 405 can
be moved from a first side 410 of midline 403, as illustrated in
FIG. 49, to a second side 412 of midline 403, as illustrated in
FIG. 50. Similarly, the second leg 406 of staple 400 can be bent
such that the end 407 of the second leg 406 is moved toward the
base 402 and toward the first leg 404 when the second leg 406 is
deformed by the second compressive force F2. In at least one
embodiment, the end 407 can be moved from a second side 412 of
midline 403, as illustrated in FIG. 49, to a first side 410 of
midline 403, as illustrated in FIG. 50. In the deployed, or
deformed, configuration of staple 400, as illustrated in FIG. 50,
the ends 405 and 407 of staple legs 404 and 406 can extend across
the midline 403 in such a way that they form an angle therebetween.
More particularly, the end 405 of the first leg 404, when it is in
its deformed configuration, can extend along or with respect to a
first axis 414 and, similarly, the end 407 of the second leg 406,
when it is in its deformed configuration, can extend along or with
respect to a second axis 416 such that the first axis 414 and the
second axis 416 define an angle 417 therebetween. In some
embodiments, the angle 417 may be approximately 90 degrees, for
example. In certain embodiments, the angle 417 may be in a range
between approximately 0.1 degrees and approximately 89 degrees, for
example. In various embodiments, the angle 417 may be greater than
90 degrees, while, in at least one embodiment, the angle 417 may be
greater than approximately 90 degrees but less than 180 degrees,
for example.
[0129] In various embodiments, further to the above, the first axis
414 and the second axis 416 can, in various embodiments, be
oriented, or crossed, at a transverse angle with respect to each
other, i.e., at least when the staple 400 is viewed from the side
or elevational view of FIG. 50. More particularly, upon reviewing
FIG. 52, it becomes evident that, although axes 414 and 416 extend
in transverse directions when viewed from the side (FIG. 50), the
axes 414 and 416 may not, in at least one embodiment, actually
intersect one another. In such embodiments, when viewing the staple
400 from the top or bottom (FIG. 52), for example, the axes 414 and
416 may extend in parallel, or at least substantially parallel,
directions. Furthermore, in various embodiments, the reader will
note that the first axis 414 and the second axis 416 are not
perpendicular with baseline 401. Stated another way, the end 405 of
first staple leg 404 and the end 407 of second staple leg 406 are
not pointing directly downwardly toward base 402 and baseline 401.
In at least one such embodiment, the first axis 414 and the second
axis 416 can each extend at an acute angle with respect to baseline
401, for example.
[0130] As described above, a surgical instrument can be configured
to deform the staple 400 of FIG. 49, for example, between an
undeformed shape (FIG. 49) and a deformed shape (FIG. 50). In
various embodiments, as also described above, the surgical
instrument can comprise an anvil having a staple pocket configured
to receive and deform at least a portion of the staple. In certain
embodiments, referring now to FIG. 42, an anvil can comprise a
tissue-contacting surface 501 and a plurality of staple pockets 500
formed therein, wherein each staple pocket 500 can be configured to
deform a staple 400. In various embodiments, each staple pocket 500
can comprise a longitudinal axis 599 (FIG. 43) and, in addition, a
first forming cup 502 and a second forming cup 504 positioned
relative to the longitudinal axis 599. In use, the first forming
cup 502 can be configured to receive the first staple leg 404 of
staple 400 and the second forming cup 504 can be configured to
receive the second staple leg 406. More particularly, in at least
one embodiment, the staple pocket 500 can be positioned relative to
the staple 400 such that, as the staple 400 is ejected from a
staple cartridge, for example, the end 405 of first leg 404 can
enter the first forming cup 502 and the end 407 of second leg 406
can enter the second forming cup 504. Further to the above, the end
405 of first staple leg 404 can contact the base 506 of first
forming cup 502 such that the first compressive force F1 can be
applied to the first leg 404 and, similarly, the end 407 of second
staple leg 406 can contact the base 508 of second forming cup 504
such that the second compressive force F2 can be applied to the
second leg 406.
[0131] In various embodiments, further to the above, the first
forming cup 502 can comprise an inside portion 510 and an outside
portion 512, wherein, when the end 405 of first staple leg 404
enters into the first forming cup 502, the end 405 can enter into
the outside portion 512. Upon entering into the outside portion 512
of forming cup 502, the end 405 can contact base 506 and, owing to
a concave curve of base 506, the end 405 can be directed inwardly
toward the inside portion 510. More particularly, referring now to
FIGS. 46-48, the base 506 can be curved toward tissue-contacting
surface 501 such that, as the staple leg 404 contacts the base 506,
the end 405 can be directed downwardly, i.e., away from
tissue-contacting surface 501, and inwardly along the curved
concave surface toward an inflection point 595. In various
embodiments, the inflection point 595 can represent the point in
which the concave surface of base 506 will begin to deflect the end
405 of first leg 404 upwardly toward the tissue-contacting surface
501. In various embodiments, the radius of curvature, r, of the
concave surface can be constant, or at least substantially
constant, in the longitudinal direction along the length thereof as
illustrated in FIGS. 47 and 48. In certain embodiments, the radius
of curvature r of the concave surface of base 506 can be consistent
across the width of base 506 between a first interior sidewall 516
and a first exterior sidewall 517. In any event, as the end 405 of
first leg 404 is advanced into the inside portion 510 of forming
cup 502, the end 405 can come into contact with a radius transition
514 positioned intermediate the base 506 and the first interior
sidewall 516. In such embodiments, the radius transition 514 can be
configured to direct the end 405 against the first interior
sidewall 516.
[0132] As illustrated in FIG. 43, further to the above, the first
interior sidewall 516 can be oriented at an angle with respect to
staple pocket longitudinal axis 599. In certain embodiments, the
first interior sidewall 516 can be oriented at an acute angle, such
as 10 degrees, for example, with respect to longitudinal axis 599.
In various embodiments, the first interior sidewall 516 and the
longitudinal axis 599 may be neither perpendicular nor parallel to
one another. In any event, the first interior sidewall 516 can
extend through the axis 599 such that a first portion of the first
interior sidewall 516 is positioned on a first side 515 of axis 599
and a second portion of the first interior sidewall 516 is
positioned on a second side 517 of axis 599. In various
embodiments, as a result, the first interior sidewall 516 can
extend between the first outside portion 512 and the first inside
portion 510. When the end 405 of first leg 404 contacts the first
interior sidewall 516, as described above, the end 405 can be
directed along the first interior sidewall 516 and away from
longitudinal axis 599 such that the staple leg 404 is bent away
from the common plane of staple 400 toward the first side 515 of
axis 599. As the end 405 of first leg 404 is directed along, or
bent by, the first interior sidewall 516, as described above, the
staple leg 404 can also be directed, or bent, by base 506. Stated
another way, the first sidewall 516 and the first base 506 can
co-operate to deform the first staple leg 404 such that end 405 is
re-directed toward the base 402 and, at the same time, to a first
side of the base 402 as described above. At some point during the
insertion of first staple leg 404 into first forming cup 502, the
end 405 of first staple leg 404 can emerge from the first inside
portion 510 of first forming cup 502 and, as the staple leg 404 is
further deformed by the staple pocket 500, the end 405 can be
directed along the first axis 414 (FIG. 50) as described above.
[0133] In various embodiments, further to the above, the first
interior sidewall 516 can extend along an interior side of the
first base 506, wherein, in at least one embodiment, the first
forming cup 502 can further comprise a first exterior sidewall 517
extending along an opposite side of the first base 506. In certain
embodiments, similar to the above, the first forming cup 502 can
further comprise a transition radius 519 positioned intermediate
the base 506 and the exterior sidewall 517. In at least one
embodiment, referring now to FIG. 43, the exterior sidewall 517 can
extend in a direction which is parallel, or at least substantially
parallel, to the staple pocket longitudinal axis 599. As also
illustrated in FIG. 43, the first interior sidewall 516 and the
first exterior sidewall 517 can extend in directions which are
transverse to one another. In at least one embodiment, the interior
sidewall 516 can extend at an acute angle, such as approximately 15
degrees, for example, with respect to the exterior sidewall 517. In
various embodiments, as a result, the outside portion 512 of first
forming cup 502 can be wider than the inside portion 510. In at
least one such embodiment, the width of the outside portion 512 and
the inside portion 510 can taper between a first width and a second
width.
[0134] In various embodiments, referring once again to FIG. 43, the
outside portion 512 of first forming cup 502 can comprise a first
outside wall 513 which can extend in a direction which is
perpendicular to the first exterior wall 517 and/or the
longitudinal axis 599 and can define the outermost portion of
forming cup 502. In at least one embodiment, further to the above,
the width of the first outside wall 513 can be such that the
outside portion 512 can capture the end 405 of first leg 404 and
guide it into the inside portion 510 of cup 502 as described above.
In at least one such embodiment, the first outside wall 513 can be
at least as twice as wide as the diameter of the first leg 404. In
certain embodiments, the first forming cup 502 can further comprise
a channeling surface 528 surrounding the first inner portion 510
and the first outer portion 512 which can be configured to guide
the staple leg 404 into and/or out of the forming cup 502. In
various embodiments, the inside portion 510 can further comprise an
inside wall 511 which can define the innermost portion of forming
cup 502. Similar to the above, the inside wall 511 can also define
the narrowest portion of forming cup 502. In at least one
embodiment, the width of the inside wall 511 may be the same, or at
least substantially the same, as the diameter of first leg 404 such
that the inside wall 511 can control the location in which the end
405 emerges from staple forming cup 502.
[0135] In various embodiments, further to the above, the second
forming cup 504 can comprise an inside portion 520 and an outside
portion 522, wherein, when the end 407 of second staple leg 406
enters into the second forming cup 504, the end 407 can enter into
the outside portion 522. Upon entering into the outside portion 522
of forming cup 504, the end 407 can contact base 508 and, owing to
a concave curve of base 508, the end 407 can be directed inwardly
toward the inside portion 520. More particularly, similar to the
above, the base 508 can be curved toward tissue-contacting surface
501 such that, as the staple leg 406 contacts the base 508, the end
407 can be directed downwardly, i.e., away from tissue-contacting
surface 501, and inwardly along the curved concave surface toward
an inflection point 596. In various embodiments, the inflection
point 596 can represent the point in which the concave surface of
base 508 will begin to deflect the end 407 of second leg 406
upwardly toward the tissue-contacting surface 501. In various
embodiments, the radius of curvature, r, of the concave surface can
be constant, or at least substantially constant, in the
longitudinal direction along the length thereof, similar to the
base 506 of first forming cup 502 illustrated in FIGS. 47 and 48.
In any event, as the end 407 of second leg 406 is advanced into the
inside portion 520 of forming cup 504, the end 407 can come into
contact with a radius transition 524 positioned intermediate the
base 508 and a second interior sidewall 526. In such embodiments,
the radius transition 524 can be configured to direct the end 407
against the second interior sidewall 526.
[0136] As illustrated in FIG. 43, further to the above, the second
interior sidewall 526 can be oriented at an angle with respect to
staple pocket longitudinal axis 599. In certain embodiments, the
second interior sidewall 526 can be oriented at an acute angle,
such as 10 degrees, for example, with respect to longitudinal axis
599. In various embodiments, the second interior sidewall 526 and
the longitudinal axis 599 may be neither perpendicular nor parallel
to one another. In any event, the second interior sidewall 526 can
extend through the axis 599 such that a first portion of the second
interior sidewall 526 is positioned on a first side 515 of axis 599
and a second portion of the second interior sidewall 526 is
positioned on a second side 517 of axis 599. In various
embodiments, as a result, the second interior sidewall 526 can
extend between the second outside portion 522 and the second inside
portion 520. When the end 407 of second leg 406 contacts the
interior sidewall 526, as described above, the end 407 can be
directed along the interior sidewall 526 such that the staple leg
406 is bent away from the common plane of staple 400 toward the
second side 517 of axis 599. As the end 407 of second leg 406 is
directed along, and bent by, the interior sidewall 526, as
described above, the staple leg 406 can also be directed, and bent,
by base 508. Stated another way, the second interior sidewall 526
and the second base 508 can co-operate to deform the second staple
leg 406 such that end 407 is re-directed toward the base 402 and,
at the same time, toward a second, or opposite, side of the base
402 as described above. At some point during the insertion of
second staple leg 406 into second forming cup 504, the end 407 of
second staple leg 406 can emerge from the second inside portion 520
of second forming cup 504 and, as the staple leg 406 is further
deformed by the staple pocket 500, the end 407 can be directed
along the second axis 416 (FIG. 50) as described above.
[0137] In various embodiments, further to the above, the second
interior sidewall 526 can extend along an interior side of the
second base 508, wherein, in at least one embodiment, the second
forming cup 504 can further comprise a second exterior sidewall 527
extending along an opposite side of the second base 508. In certain
embodiments, similar to the above, the second forming cup 504 can
further comprise a transition radius 529 positioned intermediate
the base 508 and the exterior sidewall 527. In at least one
embodiment, referring now to FIG. 43, the exterior sidewall 527 can
extend in a direction which is parallel, or at least substantially
parallel, to the staple pocket longitudinal axis 599. As also
illustrated in FIG. 43, the second interior sidewall 526 and the
second exterior sidewall 527 can extend in directions which are
transverse to one another. In at least one embodiment, the interior
sidewall 526 can extend at an acute angle, such as approximately 15
degrees, for example, with respect to the exterior sidewall 527. In
various embodiments, as a result, the outside portion 522 of second
forming cup 504 can be wider than the inside portion 520. In at
least one such embodiment, the width of the outside portion 522 and
the inside portion 520 can taper between a first width and a second
width.
[0138] In various embodiments, referring once again to FIG. 43, the
outside portion 522 of second forming cup 504 can comprise a second
outside wall 523 which can extend in a direction which is
perpendicular to the second exterior wall 527 and/or the
longitudinal axis 599 and can define the outermost portion of
forming cup 504. In at least one embodiment, further to the above,
the width of the second outside wall 523 can be such that the
outside portion 522 can capture the end 407 of second leg 406 and
guide it into the inside portion 520 of cup 504 as described above.
In at least one such embodiment, the second outside wall 523 can be
at least as twice as wide as the diameter of the second leg 406. In
certain embodiments, the second forming cup 504 can further
comprise a channeling surface 529 surrounding the second inner
portion 520 and the second outer portion 522 which can be
configured to guide the staple leg 406 into and/or out of the
forming cup 504. In various embodiments, the inside portion 520 can
further comprise an inside wall 521 which can define the innermost
portion of forming cup 504. Similar to the above, the inside wall
521 can also define the narrowest portion of forming cup 504. In at
least one embodiment, the width of the inside wall 521 may be the
same, or at least substantially the same, as the diameter of second
leg 406 such that the inside wall 521 can control the location in
which the end 407 emerges from staple forming cup 504.
[0139] As discussed above, referring again to FIGS. 43-45, the
first forming cup 502 can comprise a first interior sidewall 516
and the second forming cup 504 can comprise a second interior
sidewall 526. As illustrated in FIG. 43, the first inside portion
510 of forming cup 502 can be positioned in close proximity to, or
close relation to, the second inside portion 520 of forming cup 504
such that the first interior sidewall 516 can be positioned
adjacent to the second interior sidewall 526. In at least one
embodiment, the first interior portion 510, or at least a
substantial portion thereof, can be offset from the staple pocket
longitudinal axis 599 in the first direction 515 while the second
interior portion 520, or at least a substantial portion thereof,
can be offset from the longitudinal axis 599 in the second
direction 517. In various embodiments, the staple pocket 500 can
comprise a wall 530 positioned intermediate the first inside
portion 510 and the second inside portion 520, wherein a first side
of wall 530 can comprise the first interior sidewall 516 and
wherein a second side of wall 530 can comprise the second interior
sidewall 526. In at least one such embodiment, the first interior
sidewall 516 can be parallel, or at least substantially parallel
to, the second interior sidewall 526. More particularly, in at
least one embodiment, the first interior sidewall 516 can define a
first plane and the second interior sidewall 526 can define a
second plane, wherein the first plane and the second plane can be
parallel, or at least substantially parallel, to one another. In
various embodiments, referring again to FIGS. 44 and 45, the first
interior sidewall 516 can be perpendicular, or at least
substantially perpendicular, to the tissue-contacting surface 501
and, similarly, the second interior sidewall 526 can be
perpendicular, or at least substantially perpendicular, to the
tissue-contacting surface 501.
[0140] In various embodiments, further to the above, the first
interior sidewall 516 can comprise a first vertical portion 516a
which is perpendicular, or at least substantially perpendicular, to
the tissue-contacting surface 501. In at least one embodiment, the
first vertical portion 516a can extend through, or transect, the
longitudinal axis 599. In various embodiments, the first vertical
portion 516a can extend along the entirety of, or only a portion
of, the first interior sidewall 516. Similarly, the second interior
sidewall 526 can comprise a second vertical portion 526a which is
perpendicular, or at least substantially perpendicular, to the
tissue-contacting surface 501. In at least one embodiment, such a
second vertical portion 526a can extend through, or transect, the
longitudinal axis 599. In various embodiments, the second vertical
portion 526a can extend along the entirety of, or only a portion
of, the second interior sidewall 526. During the deployment of
staple 400, further to the above, the end 405 of first leg 404 can
be in contact with the first vertical portion 516a of first
interior sidewall 516 at the same time the end 407 of second leg
406 is in contact with the second vertical portion 526a of second
interior sidewall 526. In such circumstances, the first vertical
portion 516a and the second vertical portion 526a can comprise a
vertical trap. More particularly, the vertical portions 516a and
526a can co-operate to control, deflect, and bend the staple legs
404 and 406 in opposite directions, i.e., in directions to the
sides of a common plane, as described above, when the legs 404 and
406 come into contact with the interior sidewalls 516 and 526 of
forming cups 502 and 504, respectively. For example, referring
again to FIG. 52, the first vertical portion 516a can be configured
to deflect and bend the staple leg 404 to a first side of base 402
and the second vertical portion 526a can be configured to deflect
and bend the staple leg 406 to a second, or opposite, side of base
402.
[0141] In various embodiments, further to the above, the vertical
trap comprising vertical portions 516a and 526a can extend along
the entire length of the first and second interior sidewalls 516
and 526, while, in other embodiments, the vertical trap may extend
along only a portion of the sidewalls 516 and 526. In at least one
embodiment, the vertical trap can be approximately 0.05 inches
long, i.e., the overlap of the first vertical surface 516a and the
second vertical surface 526a can be approximately 0.05 inches, for
example, along the lengths of interior surfaces 516 and 526. In
various embodiments, the length of the vertical trap can be between
approximately 0.03 inches and approximately 0.10 inches, for
example. In certain embodiments, the length of the vertical trap
can be approximately twice the radius of curvature (r) of the
curved concave surface of base 506, for example. In various
embodiments, the length of the vertical trap can be approximately
equal to the radius of curvature (r) of base 506, for example. In
at least one embodiment, the length of the vertical trap can be
between approximately 0.5*r and approximately 2*r, for example. In
various embodiments, further to the above, the vertical trap can
extend through the longitudinal axis 599 of staple pocket 500 such
that, in at least one embodiment, at least a portion of the
vertical trap can be positioned on a first side and/or a second
side of axis 599. In certain embodiments, the vertical trap can
extend through the central portions of the first and second forming
cups 502 and 504.
[0142] In various embodiments, the first interior sidewall 516 can
further comprise a first angled portion which, in at least one
embodiment, can be oriented at an acute angle with respect to the
tissue-contacting surface 501. In at least one such embodiment, the
first angled portion can be positioned outwardly with respect to
the first vertical portion 516a. In certain embodiments, the first
interior sidewall 516 can comprise an angled portion positioned
toward the outside portion 512 which can become progressively more
perpendicular toward the inside portion 510 of the first forming
cup 502 until the angled portion transitions into the first
vertical portion 516a. In various embodiments, the second interior
sidewall 526 can further comprise a second angled portion which, in
at least one embodiment, can be oriented at an acute angle with
respect to the tissue-contacting surface 501. In at least one such
embodiment, the second angled portion can be positioned outwardly
with respect to the second vertical portion 526a. In certain
embodiments, the second interior sidewall 526 can comprise an
angled portion positioned toward the outside portion 522 which can
become progressively more perpendicular toward the inside portion
520 of the second forming cup 504 until the angled portion
transitions into the second vertical portion 526a.
[0143] In various embodiments, referring now to FIG. 52A, the
staple pocket 500 can be configured to deform the first staple leg
404 such that the first end 405 is deflected a first distance X1
from baseline 401. Similarly, the second staple leg 406 can be
deformed such that the second end 407 is deflected a second
distance X2 from baseline 401. In certain embodiments, the distance
X1 and the distance X2 can be the same, or at least substantially
the same. In various other embodiments, the distances X1 and X2 can
be different. In at least one such embodiment, the first leg 404
can be deformed such that the first end 405 is positioned closer to
base 402 than the second end 407, for example. In such embodiments,
the first axis 414 of deformed staple leg 404 and the second axis
416 of deformed staple leg 406 may be non-parallel. More
particularly, in at least one embodiment, the first axis 414 can
extend at a first angle with respect to baseline 401 and the second
axis 416 can extend at a second angle with respect to baseline 401
wherein the second angle is different than the first angle. In
various embodiments, the first leg 404 and the second leg 406 can
extend across midline 403 at different angles. In certain other
embodiments, the first leg 404 and the second leg 406 can be extend
at different angles with respect to baseline 401 although one or
both of the legs 404 and 406 may not extend across the midline
403.
[0144] In various embodiments, further to the above, a surgical
stapler can comprise a staple pocket which can be configured to
deform one staple leg of staple 400 such that it lies within, or
substantially within, a common plane with base 402 and, in
addition, deform the other staple leg of staple 400 to a side of
base 402 as described above. In at least one embodiment, the first
leg 404 can be deformed such that it extends through midline 403 in
a direction which is co-planar, or at least substantially
co-planar, with base 402 and, in addition, the second leg 406 can
be deformed such that it extends through midline 403 in a direction
which is transverse to the plane. Stated another way, in at least
one embodiment, axis 414 and baseline 401 of staple 400 can be
coplanar, or at least nearly co-planar, with one another while
second axis 416 can extend in a direction which extends through
such a plane. In certain embodiments, at least one of the first leg
404 and the second leg 406 may not extend through the midline
403.
[0145] In various embodiments, further to the above, the staple
pocket 500 can be configured to deform the staple legs 404 and 406
of staple 400 simultaneously, or at least substantially
simultaneously. In at least one embodiment, the base 506 of first
forming cup 502 can contact end 405 of first staple leg 404 at the
same time, or at least substantially the same time, that the base
508 of second forming cup 504 contacts end 407 of second staple leg
406. In certain other embodiments, a staple pocket can be
configured to deform the staple legs 404 and 406 sequentially. In
at least one such embodiment, a first forming cup can be brought
into contact with the first staple leg 404 before a second forming
cup is brought into contact with the second staple leg 406, for
example. In various alternative embodiments, although not
illustrated, a surgical staple can comprise more than two staple
legs, such as three staple legs or four staple legs, for example,
and a staple pocket can comprise a corresponding quantity of staple
forming cups for deforming the staple legs.
[0146] In various embodiments, further to the above, the wire
comprising the surgical staple 400 can comprise a circular, or at
least substantially circular, cross-section. In various other
embodiments, referring now to FIGS. 53-56, a surgical staple, such
as staple 600, for example, can comprise a non-circular
cross-section. In at least one embodiment, the staple 600 can
comprise a base 602, a first leg 604, and a second leg 606, wherein
the base 602 and legs 604 and 606 can be comprised of a continuous
wire. In various embodiments, the continuous wire can comprise a
rectangular cross-section, for example. In at least one embodiment,
referring to FIG. 56, the rectangular cross-section can comprise a
base (b) and a height (h), wherein the base (b) can be defined
relative to a central lateral axis (x), and wherein the height (h)
can be defined relative to a central longitudinal axis (y). In
various circumstances, the rectangular cross-section can be defined
as having two moments of inertia, i.e., a first moment of inertia
(Ix) defined with respect to axis (x) and a second moment of
inertia (Iy) defined with respect to axis (y). In at least one
circumstance, the first moment of inertia (Ix) can be calculated as
(b*h 3)/12 while the second moment of inertia (Iy) can be
calculated as (h*b 3)/12. Although staple 600 comprises a
rectangular, or at least substantially rectangular cross-section,
any other suitable non-circular cross-section can be utilized, such
as oblate, elliptical, and/or trapezoidal cross-sections, for
example.
[0147] As illustrated in FIG. 56, the base (b) of surgical staple
600 is larger than the height (h) and, in view of the above, the
moment of inertia (Iy) of the rectangular cross-section is larger
than the moment of inertia (Ix). In various embodiments, as a
result, the moment of inertia ratio, i.e., Iy/Ix, of the
rectangular cross-section can be greater than 1.0. In certain
embodiments, the moment of inertia ratio can be between
approximately 2.0 and approximately 2.7, for example. In certain
other embodiments, the moment of inertia ratio can be between
approximately 1.1 and approximately 3.0, for example. As a result
of the above, the leg 604 is more likely to bend about axis (x)
than about axis (y) when a force, such as compressive load F1, for
example, is applied to the leg 604. In any event, absent all other
considerations, the leg 604, in such embodiments, is more likely to
bend within a common plane defined by the staple 600 when it is in
its undeformed state than bend to a side of staple base 602. In
various embodiments, however, a surgical stapler comprising an
anvil and staple pocket in accordance with the embodiments
described herein, such as staple pocket 500, for example, can be
utilized to cause the legs 604 and 606 of staple 600 to bend out of
their common plane when they are deformed. In such embodiments,
this lateral deflection can occur despite the fact that the moment
of inertia Iy, which resists such twisting, is greater than the
moment of inertia Ix. As illustrated in FIG. 55, the first leg 604
of staple 600 can be deformed such that it is bent relative to both
axis (x) and axis (y) of its cross-section and, as a result, the
first staple leg 604 can be twisted or deformed such that the end
605 of first staple leg 604 is positioned on a first side of base
602. Similarly, the second leg 606 can be deformed such that it is
bent relative to both axis (x) and axis (y) of its cross-section
and, as a result, the second staple leg 606 can be twisted or
deformed such that the end 607 of second staple leg 606 is
positioned on a second side of base 602.
[0148] In various embodiments, referring now to FIG. 57, a surgical
staple, such as surgical staple 700, for example, can comprise a
base 702 and, in addition, a first leg 704 and a second leg 706
extending from base 702. In certain embodiments, similar to the
above, the base 702, the first leg 704, and the second leg 706 can
lie, or at least substantially lie, in a common plane when the
staple 700 is an undeformed, or undeployed, configuration, i.e., a
configuration prior to being deformed by an anvil of a surgical
stapler, for example. In the deformed or deployed configuration of
staple 700, as illustrated in FIG. 57, the first leg 704 can be
deformed such that end 705 points toward base 702 and second leg
706. More particularly, in at least one embodiment, the end 705 can
lie along, or with respect to, a first axis 714 which is oriented
at angle with respect to midline 703. Similarly, the second leg 706
can be deformed such that end 707 points toward base 702 and first
leg 704. More particularly, in at least one embodiment, the end 707
can lie along, or with respect to, a second axis 716 which is
oriented at angle with respect to midline 703. In various
embodiments, the ends 705 and 707 of legs 704 and 706 may not cross
mid-line 703. In certain embodiments, similar to the above, the end
705 of first leg 704 may be deformed such that it extends to a
first side of base 702 and the end 707 of second leg 706 may be
deformed such that it extends to a second, or opposite, side of
base 702 such that legs 704 and 706 are not entirely positioned
in-plane with base 702 in their deformed configuration, for
example.
[0149] In various embodiments, a surgical staple, such as staple
800 (FIG. 58), for example, can comprise a base 802, a first leg
804, and a second leg 806, wherein the staple 800 can comprise a
substantially U-shaped configuration in its undeformed, or
undeployed, configuration. In at least one such embodiment, legs
804 and 806 can extend in a perpendicular, or at least
substantially perpendicular, direction with respect to base 802. In
various circumstances, the staple 800 can be deformed into a
B-shaped configuration as illustrated in FIG. 58. In at least one
such embodiment, the first leg 804 can be bent downwardly toward
base 802 such that axis 814 extending through end 805 is
perpendicular, or at least substantially perpendicular, to baseline
801. Similarly, the second leg 806 can be bent downwardly toward
base 802 such that axis 816 extending through end 807 is
perpendicular, or at least substantially perpendicular, to baseline
801. In at least one such circumstance, the legs 804 and 806 can be
bent such that axes 814 and 816 are parallel, or at least
substantially parallel, to one another. In various embodiments,
referring again to FIG. 58, the staple legs 804 and 806 can be
deformed such that they do not cross centerline 803. The staple
legs 804 and 806 can be deformed such that they remain in-plane, or
at least substantially in-plane, with base 802.
[0150] Various examples described below are envisioned which
incorporate one or more aspects of the various embodiments
described above. Such examples are exemplary and various aspects of
various embodiments described in this application can be combined
in a single embodiment. In each of the examples described below,
the surgical staple can comprise a base defining a baseline, a
first leg and a second leg which extend from the base, and a
midline midway between the first leg and the second leg.
Example 1
[0151] A surgical staple can be deformed such that:
TABLE-US-00001 First Leg Second Leg Crosses the midline (FIG. 50)
Crosses the midline (FIG. 50) Extends in-plane, or substantially
in- Extends out of plane with the plane, with the base (FIG. 58)
base (FIG. 52) The end extends in a non- The end extends in a non-
perpendicular direction with the perpendicular direction with the
baseline (FIG. 50) baseline (FIG. 50)
Example 2
[0152] A surgical staple can be deformed such that:
TABLE-US-00002 First Leg Second Leg Crosses the midline (FIG. 50)
Crosses the midline (FIG. 50) Extends out of plane with the Extends
out of plane with the base (FIG. 52) to the same side base (FIG.
52) to the same side of the base as the second leg, of the base as
the first leg, the distance X1 being different the distance X1
being different than X2 (FIG. 52A) than X2 (FIG. 52A) The end
extends in a non- The end extends in a non- perpendicular direction
with the perpendicular direction with the baseline (FIG. 50)
baseline (FIG. 50)
Example 3
[0153] A surgical staple can be deformed such that:
TABLE-US-00003 First Leg Second Leg Does not cross the midline Does
not cross the midline (FIG. 57) (FIG. 57) Extends out of plane with
the Extends out of plane with the base (FIG. 52) to a first side
base (FIG. 52) to a second side of the base, the distance X1 of the
base, the distance X1 being different than X2 (FIG. 52A) being
different than X2 (FIG. 52A) The end extends in a non- The end
extends in a non- perpendicular direction with the perpendicular
direction with the baseline (FIG. 50) baseline (FIG. 50)
Example 4
[0154] A surgical staple can be deformed such that:
TABLE-US-00004 First Leg Second Leg Does not cross the midline Does
not cross the midline (FIG. 57) (FIG. 57) Extends out of plane with
the Extends out of plane with the base (FIG. 52) to the same side
base (FIG. 52) to the same side of the base as the second leg, of
the base as the second leg, the distance X1 being different the
distance X1 being different than X2 (FIG. 52A) than X2 (FIG. 52A)
The end extends in a non- The end extends in a non- perpendicular
direction with the perpendicular direction with the baseline (FIG.
50) baseline (FIG. 50)
Example 5
[0155] A surgical staple can be deformed such that:
TABLE-US-00005 First Leg Second Leg Does not cross the midline Does
not cross the midline (FIG. 57) (FIG. 57) Extends in-plane, or
substantially in- Extends out of plane with the plane, with the
base (FIG. 58) base (FIG. 52) The end extends in a perpendicular
The end extends in a non- direction with the baseline (FIG. 58)
perpendicular direction with the baseline (FIG. 50)
Example 6
[0156] A surgical staple can be deformed such that:
TABLE-US-00006 First Leg Second Leg Crosses the midline (FIG. 50)
Does not cross the midline (FIG. 57) Extends out of plane with the
Extends out of plane with the base (FIG. 52) to a first side base
(FIG. 52) to a second side of the base, the distance X1 of the
base, the distance X1 being different than X2 (FIG. 52A) being
different than X2 (FIG. 52A) The end extends in a non- The end
extends in a non- perpendicular direction with the perpendicular
direction with the baseline (FIG. 50) baseline (FIG. 50)
Example 7
[0157] A surgical staple can be deformed such that:
TABLE-US-00007 First Leg Second Leg Crosses the midline (FIG. 50)
Does not cross the midline (FIG. 57) Extends out of plane with the
Extends out of plane with the base (FIG. 52) to the same side base
(FIG. 52) to the same side of the base as the second leg, of the
base as the second leg, the distance X1 being different the
distance X1 being different than X2 (FIG. 52A) than X2 (FIG. 52A)
The end extends in a non- The end extends in a non- perpendicular
direction with the perpendicular direction with the baseline (FIG.
50) baseline (FIG. 50)
Example 8
[0158] A surgical staple can be deformed such that:
TABLE-US-00008 First Leg Second Leg Crosses the midline (FIG. 50)
Does not cross the midline (FIG. 57) Extends out of plane with the
Extends in-plane, or substantially in- base (FIG. 52) plane, with
the base (FIG. 58) The end extends in a non- The end extends in a
perpendicular perpendicular direction with the direction to the
baseline (FIG. 58) baseline (FIG. 50)
Example 9
[0159] A surgical staple can be deformed such that:
TABLE-US-00009 First Leg Second Leg Crosses the midline (FIG. 50)
Does not cross the midline (FIG. 57) Extends in-plane, or
substantially Extends out of plane with the in-plane, with the base
(FIG. 58) base (FIG. 52) The end extends in a non- The end extends
in a non- perpendicular direction with the perpendicular direction
with the baseline (FIG. 50) baseline (FIG. 50)
[0160] Several of the deformed staples described above comprise one
or more staple legs which cross the mid-line of the staple base. In
various embodiments, as a result, the deformed staple legs may at
least partially overlap with one another. More particularly, the
deformed staple legs, when viewed from the side, may co-operate to
traverse the staple base from one end to the other leaving no gap
therebetween. Such embodiments can be particularly useful,
especially when used to staple vascular tissue. More specifically,
the overlapping staple legs can compress blood vessels within the
tissue regardless of where the blood vessels extend through the
staple. Staples having gaps between the legs, or legs which do not
extend along the entire length of the staple base when deformed,
may not be able to properly compress every blood vessel in the
tissue and, as a result, one or more blood vessels may leak.
[0161] In various embodiments, further to the above, a surgical
instrument can be configured to deploy a plurality of staples 400
in the manner described above and illustrated in FIGS. 50-52. In at
least one such embodiment, the surgical stapler can deploy the
staples 400 in a sequential manner along a staple path and/or in a
simultaneous manner, for example. In certain embodiments, a
surgical instrument can be configured to deploy a plurality of
staples 600 in the manner described above and illustrated in FIG.
55. In at least one such embodiment, similar to the above, the
surgical stapler can deploy the staples 600 in a sequential manner
along a staple path and/or in a simultaneous manner, for example.
In various embodiments, further to the above, a surgical instrument
can be configured to deploy a plurality of staples 700 in the
manner described above and illustrated in FIG. 57. In at least one
such embodiment, the surgical stapler can deploy the staples 700 in
a sequential manner along a staple path and/or in a simultaneous
manner, for example.
[0162] In various embodiments, further to the above, a surgical
staple can be comprised of titanium, such as titanium wire, for
example. In certain embodiments, a surgical staple can be comprised
of an alloy comprising titanium, aluminum, and/or vanadium, for
example. In at least one embodiment, the surgical staple can be
comprised of surgical stainless steel and/or an alloy comprised of
cobalt and chromium, for example. In any event, the surgical staple
can be comprised of metal, such as titanium, and a metal oxide
outer surface, such as titanium oxide, for example. In various
embodiments, the metal oxide outer surface can be coated with a
material. In certain embodiments, the coating material can be
comprised of polytetrafluoroethylene (PTFE), such as Teflon.RTM.,
and/or a tetrafluoroehtylene (TFE) such as
ethylene-tetrafluoroehtylene (ETFE),
perfluroralkoxyethylene-tetrafluoroehtylene (PFA), and/or
Fluorinated Ethylene Propylene (FEP), for example. Certain coatings
can comprise silicon. In various embodiments, such coating
materials can prevent, or at least inhibit, further oxidation of
the metal. In certain embodiments, the coating materials can
provide one or more lubricious surfaces against which the anvil, or
staple pockets, can contact the staples in order to reduce the
friction force therebetween. In various circumstances, lower
friction forces between the staples and the staple pockets can
reduce the force required to deform the staples.
[0163] 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 can be reconditioned for
reuse after at least one use. Reconditioning can 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 can be disassembled, and any
number of the 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 can be
reassembled for subsequent use either at a reconditioning facility,
or by a surgical team immediately prior to a surgical procedure.
Those skilled in the art will appreciate that reconditioning of a
device can utilize a variety of 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.
[0164] 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 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
high-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.
[0165] While this invention has been described as having exemplary
designs, the present invention may be further modified within the
spirit and scope of the disclosure. This application is therefore
intended to cover any variations, uses, or adaptations of the
invention using its general principles. Further, this application
is intended to cover such departures from the present disclosure as
come within known or customary practice in the art to which this
invention pertains.
* * * * *