U.S. patent application number 14/138475 was filed with the patent office on 2015-06-25 for surgical staples and staple cartridges.
This patent application is currently assigned to ETHICON ENDO-SURGERY, INC.. The applicant listed for this patent is ETHICON ENDO-SURGERY, INC.. Invention is credited to Chester O. Baxter, III, Jerome R. Morgan, Frederick E. Shelton, IV.
Application Number | 20150173749 14/138475 |
Document ID | / |
Family ID | 62186013 |
Filed Date | 2015-06-25 |
United States Patent
Application |
20150173749 |
Kind Code |
A1 |
Shelton, IV; Frederick E. ;
et al. |
June 25, 2015 |
SURGICAL STAPLES AND STAPLE CARTRIDGES
Abstract
A surgical staple and staple cartridge for removably storing the
surgical staple. The surgical staple can comprise staple legs
positioned in a staple leg plane and a staple base. An intermediate
portion of the staple base can be laterally offset from the staple
leg plane, and/or the center of mass of the staple can be laterally
offset from the staple leg plane. The surgical staple can be formed
and/or stamped from a sheet of material.
Inventors: |
Shelton, IV; Frederick E.;
(Hillsboro, OH) ; Morgan; Jerome R.; (Cincinnati,
OH) ; Baxter, III; Chester O.; (Loveland,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ETHICON ENDO-SURGERY, INC. |
Cincinnati |
OH |
US |
|
|
Assignee: |
ETHICON ENDO-SURGERY, INC.
Cincinnati
OH
|
Family ID: |
62186013 |
Appl. No.: |
14/138475 |
Filed: |
December 23, 2013 |
Current U.S.
Class: |
606/219 ;
227/176.1 |
Current CPC
Class: |
A61B 17/105 20130101;
A61B 2017/00398 20130101; Y10T 29/49995 20150115; A61B 2017/07228
20130101; A61B 17/068 20130101; A61B 2017/07257 20130101; A61B
2017/00526 20130101; A61B 17/064 20130101; A61B 34/37 20160201;
A61B 2017/07271 20130101; A61B 2017/07285 20130101; A61B 17/0686
20130101; A61B 17/0682 20130101; A61B 17/07207 20130101; A61B
17/072 20130101; A61B 2017/00734 20130101; A61B 2017/07278
20130101; A61B 17/0644 20130101 |
International
Class: |
A61B 17/064 20060101
A61B017/064; A61B 17/068 20060101 A61B017/068 |
Claims
1. A surgical staple, comprising: a base comprising an intermediate
portion; a first leg extending from the base; and a second leg
extending from the base, wherein the first leg and the second leg
define a plane; wherein the intermediate portion of the base
extends parallel to the plane, and wherein the intermediate portion
of the base is laterally offset from the plane.
2. The surgical staple of claim 1, wherein a gusset extends between
the first staple leg and the base.
3. The surgical staple of claim 1, further comprising a first
discrete drive surface laterally aligned with the plane and a
second discrete drive surface laterally offset from the plane.
4. The surgical staple of claim 3, wherein the first discrete drive
surface and the second discrete drive surface are integrally formed
in the base.
5. The surgical staple of claim 1, wherein the first leg extends
from a proximal portion of the base, and wherein the second leg
extends from a distal portion of the base.
6. A surgical staple, comprising: a base; a pair of staple legs
defining a leg plane; and a center of mass offset from the leg
plane.
7. The surgical staple of claim 6, wherein a longitudinal axis
extends between the staple legs, and wherein the base is
asymmetrical relative to the longitudinal axis.
8. The surgical staple of claim 6, wherein the base further
comprises a first discrete drive surface that is aligned with the
leg plane.
9. The surgical staple of claim 8, wherein the base further
comprises a second discrete drive surface that is laterally offset
from the leg plane.
10. The surgical staple of claim 9, wherein the first discrete
drive surface and the second discrete drive surface are integrally
formed in the base.
11. The surgical staple of claim 6, wherein the base further
comprises a drive surface comprising an inclined surface.
12. The surgical staple of claim 6, wherein the base further
comprises a drive surface comprising a nub.
13. The surgical staple of claim 6, wherein a gusset extends
between a first staple leg and the base.
14. The surgical staple of claim 6, wherein the base further
defines a contour.
15. A staple cartridge, comprising: a cartridge body; a staple
cavity defined in the cartridge body, wherein the staple cavity
comprises a longitudinal sidewall; and a staple comprising a
metallic base, wherein the base comprises a longitudinal guide
surface moveably positioned adjacent to the longitudinal sidewall
of the staple cavity.
16. The staple cartridge of claim 15, wherein the staple comprises:
a first staple leg; a second staple leg, wherein the first staple
leg and the second staple leg define a leg plane; and a center of
mass positioned outside the leg plane.
17. The staple cartridge of claim 16, wherein the base comprises a
drive surface that is laterally offset from the leg plane.
18. The staple cartridge of claim 15, wherein the staple cavity
further comprises: a proximal end configured to guide a first
staple leg; and a distal end configured to guide a second staple
leg, wherein the longitudinal sidewall is intermediate the proximal
end and the distal end.
19. The staple cartridge of claim 15, wherein a
longitudinally-driven sled directly lifts the longitudinal guide
surface of the staple along the longitudinal sidewall of the staple
cavity.
20. The staple cartridge of claim 15, wherein the staple is
asymmetrical relative to a longitudinal axis of the staple.
21. A surgical staple, consisting of: a base; a first staple leg; a
second staple leg, wherein the first staple leg and the second
staple leg define a leg plane; and a center of mass offset from the
leg plane.
22. A surgical staple stamped from a sheet of material, the
surgical staple comprising: a first leg; a second leg, wherein the
first leg and the second leg define a leg plane; and a base
contiguously connecting the first leg and the second leg, wherein
the base is bent out of the leg plane.
Description
FIELD
[0001] The present invention relates to surgical instruments and,
in various arrangements, to surgical cutting and fastening
instruments that are designed to cut and fasten tissue, fastener
cartridges therefor, and surgical fasteners that are designed for
use therewith.
BACKGROUND
[0002] Surgical staplers are often used to deploy staples into soft
tissue to reduce or eliminate bleeding from the soft tissue,
especially as the tissue is being transected, for example. Surgical
staplers, such as an endocutter, for example, can comprise an end
effector which can be moved, or articulated, with respect to an
elongated shaft assembly. End effectors are often configured to
secure soft tissue between first and second jaw members where the
first jaw member often includes a staple cartridge which is
configured to removably store staples therein and the second jaw
member often includes an anvil. Such surgical staplers can include
a closing system for pivoting the anvil relative to the staple
cartridge.
[0003] Surgical staplers, as outlined above, can be configured to
pivot the anvil of the end effector relative to the staple
cartridge in order to capture soft tissue therebetween. In various
circumstances, the anvil can be configured to apply a clamping
force to the soft tissue in order to hold the soft tissue tightly
between the anvil and the staple cartridge. If a surgeon is
unsatisfied with the position of the end effector, however, the
surgeon must typically activate a release mechanism on the surgical
stapler to pivot the anvil into an open position and then
reposition the end effector. Thereafter, staples are typically
deployed from the staple cartridge by a sled which traverses a
channel in the staple cartridge and causes the staples to be
deformed against the anvil and secures layers of the soft tissue
together. The sled can engage drivers positioned between the
staples and the sled to deploy the staples from the staple
cartridge. Often, as known in the art, the staples are deployed in
several staple lines, or rows, in order to more reliably secure the
layers of tissue together. Staples are typically deformed to a
"B-form" by the anvil of the end effector. The end effector may
also include a cutting member, such as a knife, for example, which
is advanced between rows of the staples to resect the soft tissue
after the layers of the soft tissue have been stapled together.
[0004] Such surgical staplers and end effectors may be sized and
configured to be inserted into a body cavity through a trocar or
other access opening. The end effector is typically coupled to an
elongated shaft that is sized to pass through the trocar or
opening. The elongated shaft assembly is often operably coupled to
a handle that supports control systems and/or triggers for
controlling the operation of the end effector. To facilitate proper
location and orientation of the end effector within the body, many
surgical instruments are configured to facilitate articulation of
the end effector relative to a portion of the elongated shaft.
[0005] The foregoing discussion is intended only to illustrate
various aspects of the related art in the field of the invention at
the time, and should not be taken as a disavowal of claim
scope.
DESCRIPTION OF THE FIGURES
[0006] The 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:
[0007] FIG. 1 is a perspective view of a surgical instrument
according to various embodiments of the present disclosure;
[0008] FIG. 2 is an exploded perspective view of a handle assembly
of the surgical instrument of FIG. 1 according to various
embodiments of the present disclosure;
[0009] FIG. 3 is an exploded perspective view of an end effector of
the surgical instrument of FIG. 1 according to various embodiments
of the present disclosure;
[0010] FIG. 4 is a perspective view of a staple cartridge of the
end effector of FIG. 3 according to various embodiments of the
present disclosure;
[0011] FIG. 5 is a cross-sectional perspective view of the staple
cartridge of FIG. 4 taken along the plane indicated in FIG. 4
according to various embodiments of the present disclosure;
[0012] FIG. 6 is a perspective view of the staple depicted in the
staple cartridge of FIG. 4 according to various embodiments of the
present disclosure;
[0013] FIG. 7 is a front elevation view of the staple of FIG.
6;
[0014] FIG. 8 is a rear elevation view of the staple of FIG. 6;
[0015] FIG. 9 is a top plan view of the staple of FIG. 6;
[0016] FIG. 10 is a bottom plan view of the staple of FIG. 6;
[0017] FIG. 11 is a right elevation view of the staple of FIG.
6;
[0018] FIG. 12 is a left elevation view of the staple of FIG.
6;
[0019] FIG. 13 is a perspective view of the staple of FIG. 6;
[0020] FIG. 14 is an elevation view of the staple of FIG. 6 and a
sled of the end effector of FIG. 3, depicting a leading surface of
the sled contacting an initial drive surface of the staple,
according to various embodiments of the present disclosure;
[0021] FIG. 15 is a perspective view of the staple and the sled of
FIG. 14, depicting the leading surface of the sled contacting the
initial drive surface of the staple;
[0022] FIG. 16 is an elevation view of the staple and the sled of
FIG. 14, depicting a trailing surface of the sled contacting a
secondary drive surface of the staple, according to various
embodiments of the present disclosure;
[0023] FIG. 17 is a perspective view of the staple and the sled of
FIG. 14, depicting the trailing surface of the sled contacting the
secondary drive surface of the staple;
[0024] FIGS. 18-21 are cross-sectional elevation views of the end
effector of FIG. 3, depicting a firing progression of staples from
the staple cartridge, according to various embodiments of the
present disclosure;
[0025] FIG. 22 is a cross-sectional elevation view of the staple
cartridge and the sleds of FIG. 3, depicting the staples in unfired
positions, according to various embodiments of the present
disclosure;
[0026] FIG. 23 is a cross-sectional perspective view of the
cartridge and the sleds of FIG. 22, depicting the staples in the
unfired positions depicted in FIG. 22;
[0027] FIG. 24 is a cross-sectional elevation view of the cartridge
and the sleds of FIG. 22, depicting a proximal pair of staples in
partially fired positions and the remaining staples in unfired
positions, according to various embodiments of the present
disclosure;
[0028] FIG. 25 is a cross-sectional perspective view of the
cartridge and the sleds of FIG. 22, depicting the proximal pair of
staples in the partially fired positions depicted in FIG. 24 and
the remaining staples in the unfired positions depicted in FIG.
24;
[0029] FIG. 26 is a cross-sectional elevation view of the cartridge
and the sleds of FIG. 22, depicting multiple pairs of staples in
partially fired positions and the proximal pair of staples in
partially deformed configurations, according to various embodiments
of the present disclosure;
[0030] FIG. 27 is a cross-sectional perspective view of the
cartridge and the sleds of FIG. 22, depicting the multiple pairs of
staples in the partially fired positions of FIG. 26 and the
proximal pair of staples in the partially deformed configurations
depicted in FIG. 26;
[0031] FIG. 28 is a cross-sectional elevation view of the cartridge
and the sleds of FIG. 22, depicting multiple pairs of staples in
further fired positions and the proximal pair of staples in further
deformed configurations, according to various embodiments of the
present disclosure;
[0032] FIG. 29 is a cross-sectional perspective view of the
cartridge and the sleds of FIG. 22, depicting the multiple pairs of
staples in the partially fired positions depicted in FIG. 28 and
the proximal pair of staples in the partially deformed
configurations depicted in FIG. 28;
[0033] FIG. 30 is a cross-sectional elevation view of the cartridge
and the sleds of FIG. 22, depicting multiple pairs of staples in
partially fired positions and in partially deformed configurations
and the proximal pair of staples in ejected positions and in fully
deformed configurations, according to various embodiments of the
present disclosure;
[0034] FIG. 31 is a cross-sectional perspective view of the
cartridge and the sleds of FIG. 22, depicting the multiple pairs of
staples in the partially fired positions and in the partially
deformed configurations depicted in FIG. 30 and the proximal pair
of staples in the ejected positions and in the fully deformed
configurations depicted in FIG. 30;
[0035] FIGS. 32A-32C illustrate a method for forming staples from a
sheet of material according to various embodiments of the present
disclosure;
[0036] FIG. 33 is a perspective view of the staple formed from the
method depicted in FIGS. 32A-32C, according to various embodiments
of the present disclosure;
[0037] FIG. 34 is a plan view of the staple of FIG. 33;
[0038] FIG. 35 is a front elevation view of the staple of FIG.
33;
[0039] FIG. 36 is a side elevation view of the staple of FIG.
33;
[0040] FIG. 37 is a perspective view of a staple according to
various embodiments of the present disclosure;
[0041] FIG. 38 is a plan view of the staple of FIG. 37;
[0042] FIG. 39 is a front elevation view of the staple of FIG.
37;
[0043] FIG. 40 is a side elevation view of the staple of FIG.
37;
[0044] FIG. 41 is a perspective view of a staple according to
various embodiments of the present disclosure;
[0045] FIG. 42 is a plan view of the staple of FIG. 41;
[0046] FIG. 43 is a front elevation view of the staple of FIG.
41;
[0047] FIG. 44 is a side elevation view of the staple of FIG.
41;
[0048] FIG. 45 is a perspective view of a staple cartridge
according to various embodiments of the present disclosure;
[0049] FIG. 46 is a cross-sectional perspective view of the staple
cartridge of FIG. 45 taken along the plane indicated in FIG.
45;
[0050] FIG. 47 is a plan view of the staple cartridge of FIG.
45;
[0051] FIG. 48 is a perspective view of a staple according to
various embodiments of the present disclosure;
[0052] FIG. 49 is a plan view of the staple of FIG. 48;
[0053] FIG. 50 is a front elevation view of the staple of FIG.
48;
[0054] FIG. 51 is a side elevation view of the staple of FIG.
48;
[0055] FIG. 52 is a perspective view of a staple according to
various embodiments of the present disclosure;
[0056] FIG. 53 is a plan view of the staple of FIG. 52;
[0057] FIG. 54 is a front elevation view of the staple of FIG.
52;
[0058] FIG. 55 is a side elevation view of the staple of FIG.
52;
[0059] FIG. 56 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 4, depicting a staple in a partially-fired
position in a staple cavity, according to various embodiments of
the present disclosure;
[0060] FIG. 57 is a partial plan view of the staple cartridge of
FIG. 56, depicting the staple in the partially-fired position
depicted in FIG. 56;
[0061] FIG. 58 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 56, depicting the staple in the
partially-fired position depicted in FIG. 56;
[0062] FIG. 59 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 56, depicting the staple in another
partially-fired position, according to various embodiments of the
present disclosure;
[0063] FIG. 60 is a partial, plan view of the staple cartridge of
FIG. 56, depicting the staple in the partially-fired position
depicted in FIG. 59;
[0064] FIG. 61 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 56, depicting the staple in the
partially-fired position depicted in FIG. 59;
[0065] FIG. 62 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 56, depicting the staple in an ejected
position and in a deformed configuration, according to various
embodiments of the present disclosure;
[0066] FIG. 63 is a partial plan view of the staple cartridge of
FIG. 56, depicting the staple in the ejected position and in the
deformed configuration depicted in FIG. 62;
[0067] FIG. 64 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 56, depicting the staple in the ejected
position and the deformed configuration depicted in FIG. 62;
[0068] FIG. 65 is an exploded perspective view of an end effector
comprising a plurality of fasteners and a firing actuator
configured to eject the fasteners from the end effector according
to various embodiments of the present disclosure;
[0069] FIG. 66 is a plan view of a first portion of the fastener
firing actuator of FIG. 65;
[0070] FIG. 67 is an elevational view of the first portion of FIG.
66;
[0071] FIG. 68 is a plan view of a second portion of the fastener
firing actuator of FIG. 65;
[0072] FIG. 69 is an elevational view of the second portion of FIG.
68;
[0073] FIG. 70 is a cross-sectional view of the end effector of
FIG. 65 illustrating the firing actuator in an unfired, unextended
condition;
[0074] FIG. 71 is a cross-sectional view of the end effector of
FIG. 65 illustrating the firing actuator in an extended
condition;
[0075] FIG. 72 is a cross-sectional view of the end effector of
FIG. 65 illustrating the firing actuator in an extended, advanced
condition;
[0076] FIG. 73 is a cross-sectional view of the end effector of
FIG. 65 illustrating an anvil of the end effector in an open
position and the firing actuator in an unfired, unextended
condition;
[0077] FIG. 74 is a cross-sectional view of the end effector of
FIG. 65 illustrating the anvil in a closed position and the firing
actuator in an unfired, unextended condition;
[0078] FIG. 75 is a cross-sectional perspective view of the end
effector of FIG. 65 illustrated in the configuration depicted in
FIG. 73;
[0079] FIG. 76 is a cross-sectional view of the end effector of
FIG. 65 illustrated in the configuration depicted in FIG. 74;
[0080] FIG. 77 is a cross-sectional view of the end effector of
FIG. 65 illustrating the firing actuator in an extended condition
and, in addition, a knife member in an unadvanced position;
[0081] FIG. 78 is a cross-sectional view of the end effector of
FIG. 65 illustrating the firing actuator in an advanced, extended
condition and the knife member in an advanced position;
[0082] FIG. 79 is a cross-sectional perspective view of the end
effector of FIG. 65 illustrated in the configuration depicted in
FIG. 78;
[0083] FIG. 80 is a partial cross-sectional plan view of the end
effector of FIG. 65 illustrated in a fully-fired condition;
[0084] FIG. 81 is a cross-sectional elevational view of the end
effector of FIG. 65 illustrated in the configuration depicted in
FIG. 80;
[0085] FIG. 82 is a cross-sectional perspective view of the end
effector of FIG. 65 illustrated in the configuration depicted in
FIG. 80;
[0086] FIG. 83 is a cross-sectional elevational view of the end
effector of FIG. 65 illustrating the knife member in a retracted
position;
[0087] FIG. 84 is a cross-sectional perspective view of the end
effector of FIG. 65 illustrated in the configuration depicted in
FIG. 83;
[0088] FIG. 85 is a perspective view of the firing member of the
end effector of FIG. 65 illustrated in the unextended configuration
depicted in FIG. 74;
[0089] FIG. 86 is a perspective view of the firing member of the
end effector of FIG. 65 illustrated in the extended configuration
depicted in FIG. 77;
[0090] FIG. 87 is a perspective view of the firing member of the
end effector of FIG. 65 illustrated in a configuration just prior
to the fully-fired configuration depicted in FIG. 80;
[0091] FIG. 88 is a perspective view of the firing member of the
end effector of FIG. 65 illustrated in the fully-fired
configuration depicted in FIG. 80;
[0092] FIG. 89 is a cross-sectional view of an end effector
including a firing actuator configured to eject fasteners from a
fastener cartridge illustrating the firing actuator in an unfired
position;
[0093] FIG. 90 is a cross-sectional view of the end effector of
FIG. 89 illustrating the firing actuator in a partially fired
position;
[0094] FIG. 91 is a plan view of a staple cartridge body of the end
effector of FIG. 89;
[0095] FIG. 92 is a perspective view of a firing actuator for use
with the cartridge body of FIG. 91;
[0096] FIG. 93 is a perspective view of the cartridge body of FIG.
91; and
[0097] FIG. 94 is a cross-sectional view of the cartridge body of
FIG. 91 taken along line 94-94 in FIG. 93.
DETAILED DESCRIPTION
[0098] Applicant of the present application also owns the following
patent applications that were filed on even date herewith and which
are each incorporated by reference herein in their respective
entireties:
[0099] U.S. patent application entitled SURGICAL INSTRUMENTS WITH
ARTICULATABLE SHAFT ARRANGEMENTS, Attorney Docket No.
END7343USNP/130300;
[0100] U.S. patent application entitled SURGICAL STAPLES AND STAPLE
CARTRIDGES, Attorney Docket No. END7341USNP/130301;
[0101] U.S. patent application entitled ARTICULATABLE SURGICAL
INSTRUMENTS WITH SEPARATE AND DISTINCT CLOSING AND FIRING SYSTEMS,
Attorney Docket No. END7333USNP/130322;
[0102] U.S. patent application entitled SURGICAL CUTTING AND
STAPLING INSTRUMENTS WITH INDEPENDENT JAW CONTROL FEATURES,
Attorney Docket No. END7336USNP/130303;
[0103] U.S. patent application entitled SURGICAL STAPLES AND
METHODS FOR MAKING THE SAME, Attorney Docket No.
END7335USNP/130305;
[0104] U.S. patent application entitled SURGICAL STAPLES, STAPLE
CARTRIDGES AND SURGICAL END EFFECTORS, Attorney Docket No.
END7332USNP/130306;
[0105] U.S. Design patent application entitled SURGICAL FASTENER,
Attorney Docket No. END7338USDP/130307;
[0106] U.S. patent application entitled FASTENER CARTRIDGE
COMPRISING AN EXTENDABLE FIRING MEMBER, Attorney Docket No.
END7344USNP/130308;
[0107] U.S. patent application entitled FASTENER CARTRIDGE
COMPRISING A FIRING MEMBER CONFIGURED TO DIRECTLY ENGAGE AND EJECT
FASTENERS FROM THE FASTENER CARTRIDGE, Attorney Docket No.
END7339USNP/130309;
[0108] U.S. patent application entitled FASTENER CARTRIDGE
COMPRISING A FIRING MEMBER INCLUDING FASTENER TRANSFER SURFACES,
Attorney Docket No. END7340USNP/130310;
[0109] U.S. patent application entitled MODULAR SURGICAL
INSTRUMENTS, Attorney Docket No. END7342USNP/130311;
[0110] U.S. patent application entitled SURGICAL CUTTING AND
STAPLING INSTRUMENTS WITH ARTICULATABLE END EFFECTORS, Attorney
Docket No. END7334USNP/130312; and
[0111] U.S. patent application entitled SURGICAL CUTTING AND
STAPLING METHODS, Attorney Docket No. END7330USNP/130313.
[0112] 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.
[0113] Reference throughout the specification to "various
embodiments," "some embodiments," "one embodiment," or "an
embodiment", or the like, means that a particular feature,
structure, or characteristic described in connection with the
embodiment is included in at least one embodiment. Thus,
appearances of the phrases "in various embodiments," "in some
embodiments," "in one embodiment", or "in an embodiment", or the
like, in places throughout the specification are not necessarily
all referring to the same embodiment. Furthermore, the particular
features, structures, or characteristics may be combined in any
suitable manner in one or more embodiments. Thus, the particular
features, structures, or characteristics illustrated or described
in connection with one embodiment may be combined, in whole or in
part, with the features structures, or characteristics of one or
more other embodiments without limitation. Such modifications and
variations are intended to be included within the scope of the
present invention.
[0114] The terms "proximal" and "distal" are used herein with
reference to a clinician manipulating the handle portion of the
surgical instrument. The term "proximal" referring to the portion
closest to the clinician and the term "distal" referring to the
portion located away from the clinician. It will be further
appreciated that, for convenience and clarity, spatial terms such
as "vertical", "horizontal", "up", and "down" may be used herein
with respect to the drawings. However, surgical instruments are
used in many orientations and positions, and these terms are not
intended to be limiting and/or absolute.
[0115] Various exemplary devices and methods are provided for
performing laparoscopic and minimally invasive surgical procedures.
However, the person of ordinary skill in the art will readily
appreciate that the various methods and devices disclosed herein
can be used in numerous surgical procedures and applications
including, for example, in connection with open surgical
procedures. As the present Detailed Description proceeds, those of
ordinary skill in the art will further appreciate that the various
instruments disclosed herein can be inserted into a body in any
way, such as through a natural orifice, through an incision or
puncture hole formed in tissue, etc. The working portions or end
effector portions of the instruments can be inserted directly into
a patient's body or can be inserted through an access device that
has a working channel through which the end effector and elongated
shaft of a surgical instrument can be advanced.
[0116] Referring to an exemplary embodiment depicted in FIGS. 1-3,
a surgical instrument 100 can include a handle assembly 104, a
shaft 114 extending from the handle assembly 104, and an end
effector 120 extending from the shaft 114. Referring primarily to
FIG. 3, a staple cartridge 140 can be loaded into an elongate
channel 122 of a first jaw 123 of the end effector 120. In certain
embodiments, the staple cartridge 140 can be disposable and/or
replaceable, for example. Additionally or alternatively, the staple
cartridge 140 can be integrated into the end effector 120, for
example, and/or the end effector 120 can be disposable and/or
replaceable, for example. In various embodiments, the surgical
instrument 100 can be motor-driven. For example, referring
primarily to FIG. 2, a motor 106 can be positioned in the handle
assembly 104. The handle assembly 104 of the surgical instrument
100 can also include a trigger 108. Actuation of the trigger 108
can affect closure of the jaws 123, 124 of the end effector 120,
firing of staples 160 from the staple cartridge 140, and/or
translation of a firing bar 156 and cutting element 158 through the
end effector 120, for example.
[0117] Referring primarily to FIG. 3, staples 160 can be ejectably
positioned in the staple cartridge 140. For example, at least one
sled 190 can translate through the staple cartridge 140 to eject
the staples 160 from the staple cartridge 140. The firing bar 156
having the cutting element or knife 158 can also translate through
the staple cartridge 140 to cut tissue captured between the end
effector jaws, 123, 124, for example. As depicted in FIG. 3, the
firing bar 156 and cutting element 158 can move from a proximal
position in the first jaw 123 to a distal position in the first jaw
123. In various embodiments, tissue positioned intermediate the
staple cartridge 140 and the anvil 124 can be stapled by the
staples 160, and then cut by the cutting element 158, for example.
Referring primarily to FIGS. 4 and 5, the staple cartridge 140 can
include a cartridge body 142 and staple cavities 144 defined in the
cartridge body 142. Staples, such as staples 160, for example, can
be removably positioned in the staple cavities 144. In certain
embodiments, each staple cavity 144 can removably store a single
staple 160. Each staple cavity 144 can have a proximal end 146 and
a distal end 148, for example, and longitudinal sidewalls 150 can
extend between the proximal end 146 and the distal end 148 of each
staple cavity 144. As described in greater detail herein, the
proximal ends 146, the distal ends 148, and/or the longitudinal
sidewalls 150 of the staple cavity 144 can guide and/or support the
staple 160 during deployment from the staple cavity 144.
[0118] Referring now to FIGS. 6-13, the staple 160 can include a
base 162, a first staple leg 164 extending from the base 162, and a
second staple leg 166 extending from the base 162. The base 162 can
have a proximal portion 168 and a distal portion 170, for example,
and an intermediate portion 172 of the base 162 can be positioned
between the proximal portion 168 and the distal portion 170, for
example. As depicted in FIGS. 6-13, the first staple leg 164 can
extend from the proximal portion 168 of the base 162, and the
second staple leg 166 can extend from the distal portion 170 of the
base 162. The staple legs 164, 166 can include a tip 174, for
example, which can have a pointed or substantially pointed end. In
various embodiments, the tip 174 can facilitate piercing into
and/or through tissue, for example. In certain embodiments, the
staple legs 164, 166 can include corner edges 176, which can be
sharp, or substantially sharp, for example, and can also facilitate
piercing into and/or through tissue, for example. In other
embodiments, the staple legs 164, 166 can include rounded corner
edges.
[0119] Referring still to FIGS. 6-13, chamfers 184, 186 can be
positioned between the staple legs 164, 166 and the base 162. For
example, an upper chamfer 184 can extend between the staple legs
164, 166 and the base 162, and/or a lower chamfer 186 can extend
between the staple legs 164, 166 and the base 162. When tissue is
captured by the staple 160, the tissue can be compressed between
the base 162 and the deformed staple legs 164, 166, and the
chamfers 184, 186 may contact the compressed tissue. In various
embodiments, the chamfers 184, 186 can compress the captured
tissue, for example, and may prevent the base 162 from
unintentionally piercing and/or cutting the captured tissue, for
example.
[0120] In various embodiments, the base 162 of the staple 160 may
be asymmetrical relative to the staple legs 174, 176. For example,
referring primarily to FIG. 10, a first axis A may be defined
between the first and second staple legs 174, 176, and the base 162
can be asymmetrical relative to the first axis A. The base 162 can
be non-linear, for example, and can include at least one laterally
contoured portion 178 that bends or curves away from the axis A.
The base 162, or at least a portion of the base 162, can be defined
by a second axis B. The contoured portion 178 can be include
straight and/or curved regions, and may be generally non-parallel
to the first axis A and the second axis B, for example. For
example, the contoured portion 178 can bend or curve away from the
first axis A, include a straight or substantially straight portion,
and bend or curve toward the second axis B (FIG. 10).
[0121] Referring still to FIG. 10, the center of mass (COM) of the
staple 160 can be offset from the first axis A. In various
embodiments, a portion of the base 162 can extend along the second
axis B, for example, which can be parallel or substantially
parallel to the first axis A. For example, the intermediate portion
172 of the base 162 can be parallel or substantially parallel to
the first axis A. A contoured portion 178 can be positioned between
the proximal portion 168 and the intermediate portion 172, for
example, and another contoured portion 178 can be positioned
between the distal portion 170 and the intermediate portion 172,
for example. The contoured portions 178 can laterally offset the
intermediate portion 172 of the base 162 from the staple legs 164,
166 and from the first axis A, for example. In certain embodiments,
the staple legs 164, 166 can be positioned in a first plane defined
by the first axis A, for example, and the intermediate portion 172
of the base 162 can be positioned in a second plane defined by the
second axis B. The second plane can be parallel, or substantially
parallel, to the first plane, for example, and the center of mass
(COM) of the staple 160 can be positioned between the first plane
and the second plane. In such embodiments, the staple 160 can
include a leg formation plane, e.g., the plane defined by the first
axis A, which can be offset from the COM of the staple 160. For
example, deformation of the staple 160 can form a modified
"B-form", for example, and the staple legs 164, 166 may be
non-coplanar and/or laterally offset from the intermediate portion
172 of the staple base 162. In various instances, the modified
"B-form" staple formation can engage, capture, compress, and/or
affect a greater volume of tissue, for example. Additionally, in
certain instances, the modified "B-form" staple formation can exert
forces on the engaged tissue in different and/or divergent
directions, for example. Modified "B-form" can define a tissue
entrapment area extending in three different directions. For
instance, a portion of the tissue entrapment area can be defined in
two directions by the legs 164 and 166 and another portion of the
tissue entrapment area can be defined in a third direction between
the base 162 and the legs 164, 166.
[0122] In various embodiments, the intermediate portion 172 of the
staple base 162 can include a longitudinal guide surface 173. For
example, as described in greater detail herein, the longitudinal
guide surface 173 can slide and/or move against a guide surface 150
in the staple cavity 144 (FIGS. 4 and 5) as the staple 160 is fired
and/or ejected from the cartridge body 142 (FIGS. 4 and 5), for
example. In such embodiments, the longitudinal guide surface 173
can balance and/or stabilize the staple 160 during deployment.
Furthermore, the intermediate portion 172 of the staple base 162
can include a tissue-contacting surface 175 (FIG. 9), which can be
flat or substantially flat, for example. In various instances, the
tissue-contacting surface 175 of the base 162 can form a flat
surface for contacting captured tissue, which can provide a broad
and/or smooth surface for applying and/or distributing pressure on
the captured and/or compressed tissue. In such embodiments, tissue
tearing and/or trauma within the staple 160 may be reduced and/or
minimized, for example.
[0123] In various embodiments, the base 162 of the staple 160 can
include one of more drive surfaces. For example, the base 162 can
include an initial drive surface 180 and a secondary drive surface
182. Referring still to FIGS. 6-13, the proximal portion 168 of the
base 162 can include the initial drive surface 180, for example,
and/or the intermediate portion 172 of the base 172 can include the
secondary drive surface 182. For example, the proximal portion 168
can include a nub having the first drive surface 180. The nub of
the first drive surface 180 can include a rounded and/or sloped
surface, for example. The secondary drive surface 182 can comprise
a ramp on the intermediate portion 172 of the base 162. For
example, the secondary drive surface 182 can be positioned distal
to the initial drive surface 180 and/or between the proximal
portion 168 and the distal portion 170 of the base 162, for
example. The secondary drive surface 182 can include an inclined
surface or plane, for example, and can slope downward in the
direction of the distal portion 170 (see FIGS. 7 and 8).
[0124] Referring primarily to FIGS. 7 and 8, a staple midline M can
be defined intermediate the first staple leg 164 and the second
staple leg 166. The staple midline M can bisect the staple 160, and
can pass through the center of mass (COM) of the staple 160, for
example. In various embodiments, the secondary drive surface 182
can extend across the midline M. For example, the secondary drive
surface 182 can extend along the intermediate portion 172 of the
base 162, and can cross from a proximal side of the midline M to a
distal side of the midline M. In such embodiments, during
deployment of the staple 160 via the sled 190, as described in
greater detail herein, a ramp 192 of the sled 190 can drive the
staple 160 at and/or near the midline M of the staple 160 during a
portion of the staple's deployment. In various embodiments, the
distal end of the secondary drive surface 182 can also include a
staple overdrive 188, which is described in greater detail herein.
Referring primarily to FIG. 7, the staple overdrive 188 can include
the lowest point of the intermediate portion 172 of the base 162
and, in some embodiments, can be vertically aligned with the lowest
point of the proximal portion 168 and/or the distal portion 170 of
the base 162, for example. In other embodiments, the staple
overdrive 188 may be positioned vertically below or above the
lowest portion of the proximal portion 168 and/or the distal
portion 170 of the base 162.
[0125] In various embodiments, the drive surfaces 180, 182 of the
staple 160 can be separate and distinct. For example, the drive
surfaces 180, 182 can be laterally and/or longitudinally offset,
such that the drive surfaces 180, 182 are unconnected and/or
nonadjacent. Each drive surface can be discrete, for example. The
initial drive surface 180 can overlap a first plane (see axis A in
FIG. 10), for example, and the secondary drive surface 182 can
overlap a second plane (see axis B in FIG. 10), for example. In
certain embodiments, the drive surfaces 180, 182 can be parallel.
For example, the initial drive surface 180 can extend along the
first axis A (FIG. 10), and the secondary drive surface 180 can
extend along the second axis B (FIG. 10). In various embodiments, a
lateral gap having a width x (FIGS. 10 and 11) can be defined
between the initial drive surface 180 and the secondary drive
surface 182, for example. In some embodiments, a longitudinal gap
having a width y (FIG. 10) can be defined between the initial drive
surface 180 and the secondary drive surface 182, for example. The
initial drive surface 180 can be proximal to the secondary drive
surface 182, for example. Furthermore, a non-driven portion of the
base, such as the lower chamfer 186 of the contoured portion 178
between the proximal portion 168 and the intermediate portion 172,
for example, can separate the initial drive surface 180 and the
secondary drive surface 182, for example. In various embodiments,
the contoured portions 178 can traverse between the first plane
defined by axis A and the second plane defined by axis B, for
example.
[0126] Referring still to FIGS. 6-13, at least one of the drive
surfaces 180, 182 of the staple 160 can be integrally formed with
the staple 160. For example, the drive surfaces 180, 182 can be
defined in the base 162 of the staple 160. The staple 160 can
comprise a single, unitary piece, for example, which may integrally
include the drive surfaces 180, 182. The drive surfaces 180, 182
can comprise a boundary or perimeter surface of the single, unitary
piece, for example. In various circumstances, the staple 160 can be
seamless, for example, and many not include any adhered and/or
overmolded features, for example. Furthermore, the base 162 and the
staple legs 164, 166 can be a contiguous part, and the base 162 can
integrally define the drive surfaces 180, 182, for example. In
certain instances, as described in greater detail herein, the
staple 160 can be stamped or otherwise formed from a single piece
of material, for example, and can remain a single piece of
material, for example. In various instances, the drive surfaces
180, 182 can comprise a surface or flat of the formed piece.
[0127] Referring now to FIGS. 14-17, the sled 190 can drive the
staples 160 from the cavities 144 in the cartridge body 142 (FIG.
3). In various instances, the sled 190 can directly contact the
staples 160 and/or can directly drive the staples 160. For example,
the sled 190 can include a ramp or inclined surface 192, which can
contact at least one drive surface 180, 182 of the staple 160. As
the sled 190 translates relative to the staple 160, the ramp 192
can push the drive surfaces 180, 182 to lift the staples 160. In
various embodiments, the degree of incline of the ramp 192 can vary
along the length thereof. For example, the ramp 192 can be designed
to lift the staple 160 faster and/or slower during at least part of
the staple's deployment. Moreover, the degree of incline of the
ramp 192 can be designed and/or selected based on the degree of
incline of a staple drive surface 180, 182. For example, the ramp
192 can define an incline that is greater than, less than, and/or
equal to the incline of the initial drive surface 180 and/or the
secondary drive surface 182. The relationship between the ramp 192
incline and the drive surface 180, 182 incline can affect the speed
of staple deployment, for example.
[0128] Referring still to FIGS. 14-17, the sled 190 can include at
least one lateral portion 191a, 191b. For example, the sled 190 can
include a single lateral portion, a pair of lateral portions,
and/or more than two lateral portions. In various instances, each
lateral portion 191a, 191b can correspond to a row of staples 160
removably positioned in the cartridge body 142. As further depicted
in FIGS. 14-17, the lateral portions 191a, 191b can be
longitudinally staggered. For example, in certain embodiments, the
first lateral portion 191a can lag behind or follow the second
lateral portion 191b by a length of distance L (FIGS. 14 and 16).
In other embodiments, the lateral portions 191a, 191b can be
longitudinally aligned and/or the second lateral portion 191b can
lag or follow the first lateral portion 191a, for example. In
embodiments where the sled 190 comprises multiple lateral portions
191a, 191b, an intermediate portion 193 can connect and/or bridge
the lateral portions 191a, 191b, for example.
[0129] Referring primarily to FIGS. 14-17, the sled 190 can
transfer between the drive surfaces 180, 182 of the staple 160.
Stated differently, the sled 190 can exert a driving force on the
initial driving surface 180 of the staple 160, for example, and can
then transition to exert a driving force on the second, or
secondary, driving surface 182 of the staple 160. In certain
embodiments, the sled ramp 192 can include a leading surface 194
and a trailing surface 196. The leading surface 194 can be adjacent
to and/or connected to the trailing surface 196, for example, and
the staple 160 can smoothly transition between the leading surface
194 and the trailing surface 196. For example, the leading surface
194 can contact the staple 160 and begin to lift the staple 160,
and the trailing surface 196 can move into contact with the staple
160 and continue to lift the staple 160. In certain instances, the
trailing surface 196 can smoothly lift the staple 160 out of and/or
away from engagement with the leading surface 194, for example.
[0130] Referring still to FIGS. 14-17, the leading surface 194 can
be aligned with the initial drive surface 180 and the trailing
surface 196 can be aligned with the secondary drive surface 182,
for example. In operation, the leading surface 194 of the ramp 192
can initially contact the staple 160. For example, referring to
FIGS. 14 and 15, as the sled 190 translates, the leading surface
194 can contact the initial drive surface 180 of the staple 160.
The inclined leading surface 194 can exert a driving force on the
initial drive surface 180, which can begin to the lift the base 162
of the staple 160. For example, the staple 160 can be lifted a
first distance or height by the leading surface 194. As the sled
190 continues to translate, referring now to FIGS. 16 and 17, the
trailing surface 196 can move into contacting engagement with the
secondary drive surface 182 of the staple 160, for example. The
inclined trailing surface 196 can exert a driving force on the
secondary drive surface 182, for example, which can continue to the
lift the base 162 of the staple 160. For example, the staple 160
can be lifted a second distance or height by the trailing surface
194.
[0131] In various instances, the trailing surface 196 can lift the
initial drive surface 180 away from and/or out of contact with the
leading surface 194 of the ramp 192, for example. For example, the
trailing surface 196 can contact the secondary drive surface 182
and immediately lift the staple 160 such that the primary drive
surface 180 is moved out of driving contact with the leading
surface 194. In other embodiments, the leading surface 194 can
drive the initial drive surface 180 and the trailing surface 196
can drive the secondary drive surface simultaneously for at least a
portion of the staple's deployment. As the sled 190 continues to
translate, the trailing surface 196 can lift the base 162 out of
the staple cavity 144 (FIGS. 4 and 5) and/or can eject the staple
160 from the cartridge 140 (FIGS. 4 and 5). For example, the
proximal portion of the trailing surface 196 can include a sled
overdrive 198. In various embodiments, the sled overdrive 198 can
extend out of the staple cavity 144 and can lift the staple
overdrive 188, i.e., the lowest portion of the intermediate portion
172 of the base 162 (see FIG. 7), out of the staple cavity 144.
[0132] Deployment of multiple staples 160 according to an exemplary
application of the present disclosure is depicted in FIGS. 18-21.
In certain embodiments, multiple rows of staple cavities 144 can be
defined in the cartridge body 142. For example, multiple rows of
staple cavities 144 can be defined on a first side of the cartridge
slot 143 (FIG. 3), and multiple rows of staple cavities 144 can be
defined on a second side of the cartridge slot 143. FIGS. 18-21
depict two rows of staples 160 positioned in two rows of staples
cavities 144 in the cartridge body 142. Referring still to FIGS.
18-21, the staples 160a, 160c, and 160e can be positioned in a more
inner row of staple cavities 144, for example, and the staples
160b, 160d, and 160f can be positioned in a more outer row of
staple cavities 144, for example. In various embodiments, the first
inner staple 160a can be positioned nearer to the cartridge slot
143 than the first outer staple 160b. For example, the first inner
staple 160a can be adjacent to the cartridge slot 143, and the
first outer staple 160b can be intermediate the first inner staple
160a and the side of the cartridge body 142, for example. In
various embodiments, additional rows of staples 160 can be defined
in the cartridge body 142. For example, at least one row of staples
can be positioned intermediate the first staple 160a and the
cartridge slot 143, and/or at least one row of staples 160 can be
positioned intermediate the first outer staple 160b and the side of
the cartridge body 142, for example.
[0133] Referring primarily to FIG. 18, as the sled 190 moves
distally, the second lateral portion 191b can contact the first
inner staple 160a. The leading surface 194 (FIGS. 14-17) of the
second lateral portion 191b can begin to lift the first inner
staple 160a, for example. Referring now to FIG. 19, as the sled 190
continues to move distally, the trailing surface 196 (FIGS. 14-17)
of the second lateral portion 191b can continue to lift the first
inner staple 160a, and can move the first inner staple 160a into
forming contact with the anvil 152 of the end effector 120, for
example. Additionally, the leading surface 194 of the second
lateral portion 191b can move into contact with the second inner
staple 160c, for example. In various instances, the first lateral
portion 191a can move into contact with the first outer staple 160b
at the same time that the second lateral portion 191b moves into
contact with the second inner staple 160c, for example. In certain
embodiments, the longitudinal lag or offset between the first
lateral portion 191a and the second lateral portion 191b can
correspond to the longitudinal distance between the first outer
staple 160b and the second inner staple 160c. For example, the
first lateral portion 191a can lag behind the second lateral
portion 191b a length L (FIGS. 14 and 16), and the first outer
staple 160b can be longitudinally offset from the second inner
staple 160c by the length L. In such embodiments, deployment of the
first outer staple 160b and the second inner staple 160c can be
simultaneous and/or synchronized, for example.
[0134] Referring now to FIG. 20, as the sled 190 continues to
progress, the trailing surface 196 of the second lateral portion
191b can continue to lift the first inner staple 160a toward the
anvil 152. The staple forming pockets 154 defined in the anvil 152
can catch the staple legs 164, 166, and can deform the first inner
staple 160a. Furthermore, the second lateral portion 191b can
continue to lift the second inner staple 160c, and the first
lateral portion 191a can continue to lift the first outer staple
160b, for example. Referring now to FIG. 21, as the sled 190
continues to move distally, the second lateral portion 191b can
eject the first inner staple 160a from the staple cavity 144. In
various instances, the sled overdrive 198 (FIGS. 14-17), can lift
the staple overdrive 188 to clear the staple base 162 over the
cartridge body 142, for example. As the staple forming pockets 154
of the anvil 124 continue to form the first inner staple 160a, the
second lateral portion 191b can continue to lift the second inner
staple 160c, for example, and the first lateral portion 191a can
continue to lift the first outer staple 160b. Additionally, the
second lateral portion 191b can move into contact with the third
inner staple 160e, for example, and the first lateral portion 191a
can move into contact with the second outer staple 160d, for
example. In various instances, similar to the above, the second
outer staple 160d can be longitudinally offset from the third inner
staple 160e by the length L (FIGS. 14 and 16).
[0135] As described herein, the staples 160 can be sequentially
fired from the cartridge 140. For example, as the sled 190 moves
distally, the sled 190 can sequentially fire staples 160 from a
proximal portion of the cartridge body 142 toward a distal portion
of the cartridge body 142. As described herein, the sled 190 can
fire a first, more proximal, inner staple 160a before firing a
second, more distal, inner staple 160c. In other embodiments, the
sled 190 may translate proximally to fire staples 160 from a staple
cartridge. In such embodiments, the sled 190 can sequentially fire
staples 160 from a distal portion of the staple cartridge 140
toward a proximal portion of the staple cartridge 140. Moreover,
firing of the staples 160 from the staple cartridge 140 can be
paced or synchronized. For example, the first outer staple 160b and
the second inner staple 160c can be fired simultaneously, and/or
the second outer staple 160d and the third inner staple 160e can be
fired simultaneously, for example. For example, the longitudinal
offset between the first lateral portion 191a of the sled 190 and
the second lateral portion 191b of the sled 190 can correspond to
the longitudinal distance between a staple 160 in a first row of
staple cavities and a staple 160 in a second, different row of
staple cavities. In such embodiments, deployment of the staples 160
can be timed such that a staple 160 in the first row of staple
cavities is fired at the same time as a staple 160 in the second
row of staple cavities. The timing or pacing of staple deployment
can improve tissue positioning and/or placement during firing. For
example, sections of the tissue can be held in position by the end
effector jaws 123, 124 (FIG. 3), and the sections can be stapled
simultaneously. In other instances though, the offset between 191a
and 191b may not be the same as the offset between the staples in
the staple rows.
[0136] An exemplary embodiment of staple deployment is further
illustrated in FIGS. 22-31. For example, the staples 160a, 160b,
160c, and 160d can be positioned on both sides of the cartridge
slot 140, and can be ejectably positioned in staple cavities 144
defined in the cartridge body 142. Referring primarily to FIGS. 22
and 23, the staples 160a, 160b, 160c, and 160d can be unfired, and
the sleds 190 can be positioned proximal to the cartridge body 142.
The sleds 190 can be aligned with the rows of staple cavities 144
in the cartridge body 142. For example, a first sled 190 can be
aligned with the staples 160a, 160c in the first inner row of
staple cavities 144 and with the staples 160b, 160d in the first
outer row of staple cavities 144, and a second sled 190 can be
aligned with the staples 160a, 160c in the second inner row of
staple cavities 144 and with the staples 160b, 160d in the second
outer row of staple cavities 144. The first lateral portions 191a
of each sled 190 can be aligned with the outer staples 160b, 160d,
and the second lateral portions 191b of each sled 190 can be
aligned with the inner staples 160a, 160c, for example.
[0137] Referring primarily to FIGS. 24 and 25, the first inner
staples 160a can be moved or lifted to partially fired positions
relative to the cartridge body 142. For example, the second lateral
portions 191b of each sled 190 can move into engagement with the
first inner staples 160a. The leading surfaces 194 of the second
lateral portions 191b can lift the first inner staples 160a a first
distance. Subsequently, the trailing surfaces 196 can move into
engagement with the first inner staples 160a to further lift the
first inner staples 160a. In various embodiments, distal
translation of the sleds 190 can be coordinated, and the first
inner staples 160a on each side of the slot 143 can be fired
simultaneously, for example. As the first inner staples 160a are
lifted, a portion of each staple 160a can slide or move against a
longitudinal guide surface 150 of the staple cavity 144, and the
longitudinal guide surface 150 can support and/or balance the
torque generated by the sled 190, as described in greater detail
herein.
[0138] Referring now to FIGS. 26 and 27, as the sleds 190 continue
to translate relative to the cartridge 140, the sleds 190 can move
into engagement with the first outer staples 160b and the second
inner staples 160c. In various instances, the sleds 190 can contact
the first outer staples 160b and the second inner staples 160c
simultaneously. For example, the first lateral portions 191a of
sleds 190 can contact the first outer staples 160b as the second
lateral portions 191b of the sleds 190 contact the second inner
staples 160c, for example. Referring primarily to FIG. 27, the
leading surfaces 194 of the first lateral portions 191a and the
second lateral portions 191b of the sleds 190 can engage the
initial drive surfaces 180 of the staples 160b, 160c, and can lift
the staples 160b, 160c relative to the cartridge body 142.
Additionally, the trailing surfaces 196 of the second lateral
portions 191b of the sleds 190 can continue to lift the first inner
staples 160a, for example. As the first inner staples 160a continue
to move out of the staple cavities 144, an anvil 152 (FIGS. 18-21)
can begin to deform the first inner staples 160a. For example,
staple forming pockets 154 (FIGS. 18-21) can catch, turn and/or
bend the legs 164, 166 of the first inner staples 160a. As
described herein, the anvil 152 can deform the staples 160a into
modified "B-forms", for example.
[0139] Referring now to FIGS. 28 and 29, as the sleds 190 continue
to translate relative to the staple cartridge 140, the second
lateral portions 191b of the sleds 190 can continue to lift the
first inner staples 160a, for example, and the anvil 152 (FIGS.
18-21) can continue to deform the first inner staples 160a, for
example. In various instances, the sleds 190 can also continue to
lift the first outer staples 160b and the second inner staples
160c. For example, the trailing surfaces 196 of the sleds 190 can
move into engagement with the secondary drive surfaces 182 of the
first outer staples 160b and the second inner staples 160c, and can
lift the staple bases 162 upward, for example, such that the
staples legs 164, 166 continue to move out of the cartridge body
142.
[0140] Referring now to FIGS. 30 and 31, as the sleds 190 continue
to translate relative to the cartridge 140, the second lateral
portions 191b of the sleds 190 can continue to simultaneously lift
the first inner staples 160a. For example, the sled overdrives 198
(FIGS. 16 and 17), can lift the first inner staples 160a entirely
out of the cartridge body 142, such that the first inner staples
160a are entirely ejected from the staple cartridge 140. In various
instances, the anvil 152 (FIGS. 18-21) can continue to deform the
first inner staples 160a, for example, and the first inner staples
160a can be fully deformed when lifted entirely out of the
cartridge body 142. Additionally, the trailing surfaces 196 of the
sleds 190 can also continue to simultaneously lift the first outer
staples 160b and the second inner staples 160c. For example, the
trailing surfaces 196 of the first lateral portions 191a can lift
or drive the first outer staples 160b, and the trailing surfaces
196 of the second lateral portions 191b can lift or drive the
second inner staples 160c, for example. Moreover, as the first
outer staples 160b and the second inner staples 160c continue to
move out of the staple cavities 144, the anvil 152 (FIGS. 18-21)
can begin to deform the first outer staples 160b and the second
inner staples 160c. For example, staple forming pockets 154 (FIGS.
18-21) can catch, turn and/or bend the legs 164, 166 of the first
outer staples 160b and the second inner staples 160c. In various
instances, the sleds 190 can continue to translate relative to the
cartridge body 142, and the first and second lateral portions 191a,
191b of the sleds 190 can continue to pace and/or time the
deployment of the staples 160 from adjacent and/or neighboring
staple rows. The sleds 190 can sequentially fire staples 160 from
the proximal portion of the staple cartridge 140 to the distal
portion of the staple cartridge 140. In other embodiments, the
sleds 190 can move proximally, and can fire staples 160 from the
distal portion of the staple cartridge 140 toward a proximal
portion of the staple cartridge 140, for example. Moreover, in
certain instances, the spacing between the staples and the lateral
sled portions can affect non-synchronized deployment of the
staples, for example.
[0141] Referring now to FIGS. 56-64, in various instances, the
staple cavity 144 can guide the staple 160 as the sled 190 moves
the staple 160 through a firing progression. For example, in
various instances, the leading surface 194 of the sled 190 can
contact the initial drive surface 180 of the staple 160, and can
exert a driving force D.sub.1 (FIG. 58) on the staple 160 via the
initial drive surface 180 (FIGS. 56-58). The leading surface 194
can lift the staple 160 upward along a plane defined by axis E
(FIG. 57) and axis F (FIG. 58). As indicated in FIGS. 57 and 58,
the staple's center of mass (COM) can be offset from the axes E and
F and, in such embodiments, the driving force D.sub.1 (FIG. 58)
exerted on the initial drive surface 180 in the plane defined by
axes E and F can generate a torque T.sub.1 (FIG. 58). As described
in greater detail herein, the staple cavity 144 can include a
longitudinal sidewall 150 between the proximal end 146 and the
distal end 148 of the staple cavity 144. In certain embodiments,
the staple cavity 144 can include a first sidewall 150a and a
second sidewall 150b. Moreover, as described herein, the sidewalls
150a, 150b can resist torsion of the staple 160 during firing. For
example, when the leading surface 194 of the sled 190 drives the
initial drive surface 180 of the staple 160 along the plane defined
by axes E and F, the second sidewall 150b can resist the
counterclockwise torque T.sub.1 (FIG. 58) corresponding to the
driving force D.sub.1 generated by the sled 190. As the staple 160
is lifted a first distance by the leading surface 194 of the sled
190, the second sidewall 150b can guide and support the
intermediate portion 172 of the staple base 162. For example, the
flat surface 173 of the intermediate portion 172 of the staple base
162 can slide along and/or move against the second sidewall
150b.
[0142] Referring now to FIGS. 59-61, when the sled 190 transitions
between the initial drive surface 180 and the secondary drive
surface 182, as described herein, the trailing surface 196 of the
sled 190 can exert a driving force D.sub.2 (FIG. 61) on the staple
160 via the secondary drive surface 182. In various instances, the
trailing surface 196 of the sled 190 can lift the base 162 of the
staple 160 upward along a plane defined by axis I (FIG. 60) and
axis J (FIG. 61). As indicated in FIGS. 60 and 61, the staple's
center of mass (COM) can be offset from the plane defined by axes I
and J and, in such embodiments, the driving force D.sub.2 (FIG. 61)
exerted on the secondary drive surface 182 by the trailing surface
196 of the sled 190 can generate a torque T.sub.2 (FIG. 61). Upon
comparing FIGS. 58 and 61, it can be seen that the driving force
D.sub.1 is applied to the staple 160 on a first side of the COM and
the driving force D.sub.2 is applied on the opposite side of the
COM. In various instances, the torque T.sub.1 can be in a first
direction, and the torque T.sub.2 can be in second direction, and
the second direction can be opposite to the first direction, for
example. When the trailing surface 196 drives the secondary drive
surface 182 of the staple 160 along the plane defined by axes I and
J, the first sidewall 150a can resist the clockwise torque T.sub.2
(FIG. 61). As the staple 160 is lifted the second distance by the
trailing surface 194, the first sidewall 150a can guide and support
the proximal and distal ends 168, 170 of the staple base 162. For
example, the proximal and distal ends 168, 170 of the base 162 can
slide along and/or move against the first sidewall 150a.
[0143] The reader will appreciate that, in certain embodiments,
various staples and/or features thereof, which are described herein
with respect to the staple's COM, can be similarly applicable to
the staple's center of geometry. In various instances, a staple,
such as staple 160, for example, can comprise a single material
and/or can have a uniform composition. In such embodiments, the COM
of the staple can correspond to the center of geometry of the
staple. In other embodiments, a staple can comprise multiple
materials and/or a non-uniform composition. For example, the staple
can be formed from multiple pieces and/or materials that have been
welded and/or otherwise joined together. In certain embodiments,
multiple sheets of at least two different materials can be welded
together, for example, and the staple can be cut from a portion of
the welded sheet comprising more than one material. In other
embodiments, multiple sheets of at least two different materials
can be layered, rolled and/or sealed together, for example, and the
staple can be cut from a portion of the sheet comprising more than
one material. In such embodiments, the COM of the staple can be
offset from the center of geometry of the staple. For example, the
COM of the staple can be laterally and/or longitudinally offset
from the staple's center of geometry.
[0144] As depicted in FIGS. 58 and 61, the sled 190 can exert a
vertical driving force D.sub.1, D.sub.2 on the staple 160 during
deployment. The reader will appreciate that a driving force
generated by the sled 190 can also comprise a horizontal component.
In various embodiments, the proximal and/or distal ends 146, 148 of
the staple cavity 144 can guide and support the staple legs 164,
166, as the staple 160 is lifted by the sled 190. In various
embodiments, the proximal and/or distal ends 146, 148 of the staple
cavity 144 can balance the torque generated by the horizontal
component of the driving force. For example, as the sled 190 moves
distally, the distal end 148 of the staple cavity 144 can resist
rotation and/or torqueing of the staple 160 during deployment.
Referring now to FIGS. 62-64, the trailing surface 196 can continue
to lift the staple 160 out of the staple cavity 144. For example,
the sled overdrive 198 can contact the staple overdrive 188 to lift
the base 162 of the staple 160 out of the cartridge body 140.
[0145] Referring now to FIGS. 45-47, a staple cartridge, such as a
staple cartridge 240, for example, can be loaded into the elongate
channel 122 of the end effector 120 (FIG. 3). Staples, such as
staples 160, for example, can be ejectably positioned in the staple
cartridge 240. For example, sleds 190 (FIGS. 14-17) can translate
through the staple cartridge 240 to eject the staples 160
therefrom. In various instances, the staple cartridge 240 can
include a cartridge body 242 and cavities 244 defined in the
cartridge body 242. Staples 160 can be removably positioned in the
staple cavities 244, for example. For example, each staple cavity
244 can removably store a single staple 160. Moreover, each staple
cavity 244 can have a proximal end 246 and a distal end 248, for
example, and longitudinal sidewalls 250 can extend between the
proximal end 246 and the distal end 248 of each staple cavity 244.
Similar to the cavities 144 described herein, the proximal ends
246, distal ends 248, and/or longitudinal sidewalls 250 can guide
and/or support the staples 160 during firing. For example, the
longitudinal sidewalls 250 can counterbalance the torque exerted on
the staple 160 by the translating sled 190. In various instances,
the cavities 244 can also include diagonal guide surfaces 251
between the sidewalls 250. For example, a proximal diagonal guide
surface 251a can extend between the proximal end 246 of the cavity
244 and a sidewall 250 of the cavity 244. Additionally or
alternatively, a distal diagonal guide surface 251b can extend
between the distal end 248 of the cavity 244 and a sidewall 250 of
the cavity 244. The diagonal guide surfaces 251a, 251b can guide
and/or support the contoured portions 178 (FIGS. 6-13) of the
staple 160, for example, as the staple 160 is lifted within the
staple cavity 244. For example, a portion of the contoured portion
178 can slide along and/or move against the diagonal guide surfaces
251a, 251b. In such an arrangement, the diagonal guide surfaces
251a, 251b can balance the torque exerted on the staple 160, for
example.
[0146] Referring now to FIGS. 32A-32C, staples, such as the staples
160, for example, can be cut, formed and/or stamped from a sheet of
material, such as a sheet of material 130, for example. The sheet
of material 130 can be metallic, for example, and can comprise
stainless steel and/or titanium, for example. In various instances,
the sheet of material 130 can be substantially flat and/or smooth.
Moreover, in certain instances, the sheet of material 130 can be
bent, folded, contoured and/or crimped at various regions, such as
a first region 134 and a second region 136, for example. The sheet
of material 130 can be bent using a punch and/or stamp, for
example. Flat or substantially flat portions 135a, 135b, and 135c
of the sheet of material 130 can be positioned intermediate the
regions 134, 136, for example. The first region 134 can be
intermediate the flat portions 135a and 135b, for example, and the
second region 136 can be intermediate the flat portions 135b and
135c, for example. In various instances, the flat portions 135a and
135c can be coplanar, for example, and/or the flat portion 135b can
be parallel and/or substantially parallel to the flat portions 135a
and/or 135c, for example. Referring primarily to FIG. 32A, multiple
flat sheets 130a, 130b, 130c, 130d, 130e, 130f can be stacked, and
then bent at the regions 134 and 136 simultaneously. In other
embodiments, the sheets 130a, 130b, 130c, 130d, 130e, 130f can be
individually bent, for example, and then stacked.
[0147] In various instances, the staples 160 can be cut, formed
and/or stamped from the bent sheets 130. For example, referring
primarily to FIG. 32B, a staple outline 132 can be traced, etched,
and/or cut into the bent sheets 130. The staple outline 132 can be
machined and/or laser cut into the bent sheets 130, for example. In
various instances, an electron discharge machining (EDM) wire 138
can be used to cut the staple outline 132. Furthermore, in certain
instances, multiple stacked sheets 130 can be cut simultaneously.
In certain embodiments, referring primarily to FIG. 32C, the staple
outline 132 can form the boundary or perimeter of the staple 160.
For example, the staple outline 132 can form the staple 160 (FIGS.
6-13 and 33-36), and/or can form a staple having various similar
features to the staple 160, for example. In various instances,
multiple staple outlines 132 can be cut into the sheet of material
130, and multiple staples 160 can be formed from a single sheet of
material 130. As illustrated in FIGS. 32B and 32C, the EDM wire 138
can pass through more than one sheet of material 130 at a time to
cut more than one staple 160 at a time. While six sheets 130 are
being simultaneously cut by the EDM wire 138, any suitable number
of sheets 130 can be cut at the same time. For instance, a wire 138
can cut less than six sheets 130 at the same time or more than six
sheets 130 at the same time.
[0148] For example, referring to FIGS. 32C and 33-36, the staple
outline 132 can form the base 162 and/or the staple legs 164, 166,
for example. Furthermore, the staple outline 132 can include at
least one integrally-formed staple drive surface. For example, the
staple outline 132 can include the initial drive surface 180 and/or
the secondary drive surface 182. In other words, the initial drive
surface 180 and/or the secondary drive surface 182 can be machined
and/or formed at the time the staple 160 is cut from the sheet of
material 130. In certain instances, the bent or contoured regions
134, 136 of the sheet 130 (FIGS. 32A and 32B) can form the
contoured portions 178 of the staple 160. Moreover, the lateral
flat portions 135a and 135c of the sheet 130 (FIGS. 32A and 32B)
can correspond to the staple legs 164 and 166, and the intermediate
flat portion 135b of the sheet 130 (FIGS. 32A and 32B) can
correspond to the intermediate portion 172 of the base 162, for
example.
[0149] In various instances, the depth D.sub.1 (FIGS. 34 and 36) of
the staple 160 can determined by the depth of the sheet of material
130. For example, the sheet of material 130 can be selected based
on the depth thereof, and the staple 160 formed from that sheet of
material 130 can have the same depth as the sheet of material 130.
Furthermore, the height H.sub.1 (FIG. 35), and width W.sub.1 (FIG.
35) of the base 162 and the staple legs 164, 166 can be determined
by the staple outline 132. In various instances, the staple outline
132 can provide variations in the height and/or width of the staple
components along the length of each component. For example, the
height H.sub.1 of the base 162 and/or the width W.sub.1 of the
staple legs 164, 166 can vary along the length thereof.
Furthermore, tapers, steps, and/or other variations can be defined
by the staple outline 132, and thus, the geometry of the staple 160
can be selected and/or manipulated based on the purpose,
application, and/or design of the staple 160 and/or the end
effector 120 with which the staple 160 may be used.
[0150] Referring primarily to FIGS. 33-36, in various instances,
the staple 160 can be cut such that the height H.sub.1 of the base
162 is independent of and/or different than the depth D.sub.1 of
the staple legs 164, 166. For example, the depth D.sub.1 of the
staple legs 164, 166 can correspond to the depth of the sheet of
material 130, and the base 162 can be cut to an appropriate height
H.sub.1, which can be independent of the depth of the sheet of
material 130 and/or the corresponding leg depth D.sub.1, for
example The appropriate height H.sub.1 can be based on the purpose,
application, and/or design of the staples 160 and/or the end
effector 120 (FIG. 3) with which the staple 160 may be used, for
example. Furthermore, the height H.sub.1 of the base 162 can also
vary along the length thereof. For example, the height H.sub.1 can
vary at and/or near a drive surface of the staple 160, and/or at a
gusset between one of the staple legs 164, 166 and the base 162,
for example. The staple outline 132 can provide at least one taper
and/or step along the length of the base 162, for example. The
staple outline 132 can comprise a taper or ramp, for example, which
can form the secondary drive surface 182 of the base 162. The
degree of incline of the secondary drive surface 182 can be
selected, designed and implemented via the staple outline 132. In
certain embodiments, the height H.sub.1 of the base 162 can be
greater than the depth D.sub.1 of the staple legs 164, 166. In
other embodiments, the height H.sub.1 of the base 162 can be equal
to or less than the depth D.sub.1 of the staple legs 164, 166.
Comparatively, the geometry of a staple that is formed from a bent
wire may be constrained and/or limited based on the dimensions of
the initial wire. For example, in a wire-formed staple, the height
of the staple base typically corresponds to the width of the staple
legs, which typically corresponds to the diameter of the wire.
Though drawing and/or rolling, for example, can modify the diameter
of the wire, the volume of material limits and/or restrains the
permissible modifications.
[0151] In various instances, the width W.sub.1 of the staple legs
164, 166 can also be independent of the depth D.sub.1 of the staple
legs 164, 166 and the height H.sub.1 of the base 162, for example.
The staple legs 164, 166 can be cut to an appropriate width W.sub.1
based on the application, purpose and/or design of the staple 160
and/or the end effector 120 (FIG. 3) with which the staple 160 may
be used, for example. In certain embodiments, the staple legs 164,
166 can comprise different widths, for example, and/or the width of
the staple legs 164, 166 can taper, step, or otherwise vary along
the length thereof. For example, the staple legs 164, 166 can taper
at the tips 174 to form a piercing edge or point.
[0152] Referring now to FIGS. 37-40, a staple outline 232 can be
traced, cut, etched, and/or machined into the sheet of material 130
(FIGS. 32A and 32B), and a staple 260, similar to the staple 160
(FIGS. 33-36), for example, can be formed from the sheet of
material 130. For example, the staple 260 can include a base 262
and staple legs 264, 266 extending from the base 262. In various
embodiments, the staple 260 can include contoured portions 278,
which can correspond to the bent and/or contoured regions 134, 136
of the sheet of material 130 (FIGS. 32A and 32B) from which the
staple 260 was formed. In certain embodiments, the staple 260 can
include an intermediate portion 272 between the contoured portions
278, for example. Moreover, at least one drive surface 280, 282 can
be formed along the perimeter of the staple 260 via the staple
outline 232.
[0153] Similar to the staple 160, the depth D.sub.1 of the staples
legs 264, 266 can correspond to the depth of the sheet of material
130. Furthermore, in various instances, the height H.sub.2 of the
staple base 262 can be independent of the depth D.sub.1 of the
staple legs 264, 266 and/or independent of the depth of the sheet
of material 130. For example, as depicted in FIGS. 37-40, the
height H.sub.2 of the staple base 262 is less than the height
H.sub.1 of the staple base 162 (FIGS. 33-36), and the depth D.sub.2
of the staples legs 264, 266 is equal to the depth D.sub.1 of the
staple legs 164, 166, for example. In various embodiments, the
width W.sub.2 of the staple legs 264, 266 can also be independent
of the depth D.sub.2 of the staple legs 264, 266. The height
H.sub.1 of the staple base 262 and the width W.sub.2 of the staple
legs 264, 266 can be selected based on the purpose, application,
and/or design of the staple 260 and/or the end effector 120 (FIG.
3), for example.
[0154] Referring now to FIGS. 41-44, a staple outline 332 can be
traced, cut, etched, and/or machined into the sheet of material 130
(FIGS. 32A and 32B), and a staple 360, similar to the staples 160
and 260 (FIGS. 33-40), for example, can be formed from the sheet of
material 130. For example, the staple 360 can include a base 362
and staple legs 364, 366 extending from the base 362. In various
embodiments, the staple 360 can include contoured portions 378,
which can correspond to the bent and/or contoured regions 134, 136
of the sheet of material 130 (FIGS. 32A and 32B) from which the
staple 360 was formed. In certain embodiments, the staple 360 can
include an intermediate portion 372 between the contoured portions
378, for example. Moreover, at least one drive surface 380 and 382
can be formed along the perimeter of the staple 360 via the staple
outline 332.
[0155] Similar to the staples 160 and 260, the depth D.sub.3 of the
staples legs 364, 366 can correspond to the depth of the sheet of
material 130. Furthermore, in various instances, the height H.sub.3
of the staple base 362 can be independent of the depth D.sub.3 of
the staple legs 364, 366 and/or independent of the depth of the
sheet of material 130. For example, as depicted in FIGS. 41-44, the
height H.sub.3 of the staple base 362 is greater than the height
H.sub.1 of the staple base 162 (FIGS. 33-36) and greater than the
height H.sub.2 of the staple base 262 (FIGS. 37-40), and the depth
D.sub.3 of the staples legs 364, 366 is equal to the depth D.sub.1
of the staple legs 164, 166 and equal to the depth D.sub.2 of the
staple legs 264, 266, for example. In various embodiments, the
width W.sub.3 of the staple legs 364, 366 can also be independent
of the depth D.sub.3 of the staple legs 364, 366. The height
H.sub.3 of the staple base 362 and the width W.sub.3 of the staple
legs 364, 366 can be selected based on the purpose, application,
and/or design of the staple 360 and/or the end effector 120 (FIG.
3), for example.
[0156] Referring now to FIGS. 48-51, a staple, such as a staple
460, for example, can be used in a staple cartridge, such as the
staple cartridge 140 (FIGS. 3-5) and/or the staple cartridge 240
(FIGS. 45-47), for example. The staple 460 can include a base 462
having a proximal portion 468 and a distal portion 470. An
intermediate base portion 472 can be positioned between the
proximal portion 468 and the distal portion 470, for example. As
depicted in FIGS. 48-51, a first staple leg 464 can extend from the
proximal portion 468 of the base 462, and a second staple leg 466
can extend from the distal portion 470 of the base. In various
instances, the staple legs 464, 466 can be cylindrical or
substantially cylindrical, for example, and can include a staple
tip 474, which can be tapered and/or include a sharp edge or point
for piercing tissue, for example. In other embodiments, the staple
legs 464, 466 can include a rounded and/or polygonal perimeter, for
example. The intermediate portion 472 of the staple base 462 can
include a tissue-contacting surface 473, which can be flat or
substantially flat, for example. In various instances, the staple
460 can be formed from a wire, for example, which can be bent,
twisted, and/or otherwise manipulated to form the staple legs 464,
466 and/or the staple base 462, for example. In various
embodiments, the diameter of the wire can define the width and
depth of the staple legs 464, 466, for example. In some
embodiments, the wire can be drawn and/or rolled to modify the
dimensions of the staple 460. In certain instances, the
intermediate portion 462 of the wire base 462 can be formed and/or
flattened to form the tissue-contacting surface 473. In various
instances, the base 462 can be flattened between two parallel or
substantially parallel plates, for example, such that the
tissue-contacting surface 473 and a bottom surface 475 of the base
462 are flat or substantially flat and/or parallel or substantially
parallel. Modifications to the base 162 may be limited and/or
constrained by the volume of material of the wire, for example.
[0157] Referring still to FIGS. 48-51, the staple 460 can include
chamfers and/or gussets. For example, a chamfer 484 can extend
between the first staple leg 464 and the base 462, and/or a chamfer
484 can extend between the second staple leg 466 and the base 462.
In certain embodiments, the chamfers 484 can be asymmetrical
relative to a longitudinal axis G (FIG. 49) extending between the
first staple leg 464 and the second staple leg 466, and/or relative
to a vertical axis H (FIG. 51) extending along the length of the
staple legs 464, 466, for example. The chamfers 484 can extend away
from the axis G and/or the axis H, for example, and thus, in
certain embodiments, the intermediate portion 472 of the base 462
can be offset from the axis G and/or the axis H. For example, the
center of mass of the base 462 can be offset from the plane defined
by the axis G and the axis H. In various instances, the offset
intermediate portion 472 of the base 462 can form a wide and/or
flat surface for contacting captured tissue, which can provide a
broad and/or smooth surface for applying and/or distributing
pressure on the captured tissue. In such embodiments, tissue
tearing and/or trauma within the staple 460 may be reduced and/or
minimized. Moreover, similar to the staples 160, 260, and/or 360
described herein, the staple 460 can include a leg formation plane,
e.g., the plane defined by the axis G and the axis H, which can be
offset from the center of mass of the base 462 of the staple 460,
for example.
[0158] Referring now to FIGS. 52-55, a staple, such as a staple
560, for example, can be used in a staple cartridge, such as the
staple cartridge 140 (FIGS. 3-5) and/or the staple cartridge 240
(FIGS. 45-47), for example. The staple 560 can include a base 562
having a proximal portion 568 and a distal portion 570. An
intermediate base portion 572 can be positioned between the
proximal portion 568 and the distal portion 570, for example. As
depicted in FIGS. 52-55, a first staple leg 564 can extend from the
proximal portion 568 of the base 562, and a second staple leg 566
can extend from the distal portion 570 of the base 562. In certain
embodiments, the intermediate portion 572 of the base 560 can
extend along an axis D (FIG. 53), which can be parallel and/or
substantially parallel to an axis C (FIG. 53) defined between the
first staple leg 564 and the second staple leg 566, for
example.
[0159] In various instances, the staple legs 564, 566 can be
cylindrical or substantially cylindrical, for example, and can
include a staple tip 574, which can be tapered and/or include a
sharp edge or point for piercing tissue, for example. In various
instances, the staple 560 can be formed from a wire. For example, a
wire can be bent, twisted and/or otherwise manipulated to form the
staple 560. Referring still to FIGS. 52-55, the wire can be
manipulated at curves 579a, 579b, 579c, and/or 579d. For example,
the staple base 562 can include angled portions 578, which can be
angularly oriented relative to the intermediate portion 572 of the
staple base 562 and/or relative to the axis C defined between the
first and second staple legs 564, 566, for example. In various
embodiments, the wire forming the staple 560 can curve at 579a
between the first staple leg 564 and the angled portion 578a, curve
at 579b between the angled portion 578a and the intermediate
portion 572, curve at 579c between the intermediate portion 572 and
the angled portion 578b, and/or curve at 579d between the angled
portion 578b and second staple leg 566, for example. For example,
the intermediate portion 572 of the base 562 can be laterally
offset from the axis C (FIG. 53) extending between the first staple
leg 564 and the second staple leg 566.
[0160] In various embodiments, the diameter of the wire can define
the width and depth of the staple legs 564, 566 and/or the staple
base 562, for example. In some embodiments, the wire and/or
portions thereof can be drawn and/or rolled to modify the
dimensions of the staple 560 and/or elements of the staple 560.
Furthermore, the wire can have a rounded and/or polygonal
perimeter. In certain embodiments, the wire can be cut at an angle
to form the staple tips 574, for example. Similar to the staples
160, 260, 360 and/or 460 described herein, the staple 560 can
include a leg formation plane, e.g., the plane defined by the axis
C, which can be offset from the center of mass of the base 562 of
the staple 560, for example.
[0161] Further to the above, turning now to FIG. 65, an end
effector, such as end effector 120, for example, can include a
staple cartridge 240 positioned within an elongate channel 122 and,
in addition, an anvil 124 positionable opposite the staple
cartridge 240. In various instances, the cartridge 240 can include
a plurality of staple cavities 244, a fastener, such as staple 460,
for example, positioned in each of the staple cavities 244, and a
longitudinal slot 243 configured to slidably receive a knife 158
therein. While staples 460 are depicted in connection with the
embodiment depicted in FIG. 65, any suitable staple or fastener
could be used with this embodiment, such as staples 160, for
example. Referring generally to FIGS. 73 and 74, the end effector
120 can extend from a shaft 114 which can include a closure tube
115. When the closure tube 115 is advanced distally, the closure
tube 115 can contact the anvil 124 and rotate the anvil 124 between
an open position (FIG. 73) and a closed position (FIG. 74). Once
the anvil 124 has been closed, the knife 158 can be advanced
distally to transect tissue captured between the anvil 124 and the
cartridge 240. In certain end effectors disclosed herein, the
cartridge positioned within the end effector 120 can further
include a fastener firing actuator, such as sled 190, for example,
which is pushed distally by the knife 158 to deploy staples from
the cartridge at the same time that the knife 158 transects the
tissue. With regard to the embodiment depicted in FIG. 65, a staple
cartridge can include a fastener firing actuator, such as sled
assembly 790, for example, which can be advanced distally with, or
alongside, the knife 158 to eject the staples 460 from the
cartridge 240. For instance, the shaft 114 of the stapler can
include a firing bar 157 configured to advance the knife 158 and,
in addition, pusher bars 159 configured to advance the sled
assembly 790. While the firing bar 157 and the pusher bars 159 may
be advanced concurrently, in various circumstances, their operation
can be timed in such a way that their initial distal movement can
be staggered relative to one another, as described in greater
detail further below. In addition to the initial relative movement
between the firing bar 157 and the pusher bars 159, the sled
assembly 790 can include two or more portions which can move
relative to one another, as will also be described in greater
detail further below.
[0162] Referring primarily to FIGS. 66-69, the sled assembly 790
can include a first sled portion 792 and a second sled portion 793.
The first sled portion 792 can include an inner ramp portion 791a
and an outer ramp portion 791b. As illustrated in FIGS. 66 and 67,
the outer ramp portion 791b is positioned laterally with respect to
the inner ramp portion 791a. The outer ramp portion 791b also
extends distally with respect to the inner ramp portion 791a.
Similarly, the second sled portion 793 can include an inner ramp
portion 794a and an outer ramp portion 794b. As illustrated in
FIGS. 68 and 69, the outer ramp portion 794b is positioned
laterally with respect to the inner ramp portion 794a. The outer
ramp portion 794b also extends distally with respect to the inner
ramp portion 794a. In various instances, the inner ramp portion
791a can be configured to lift, or at least partially lift, an
inner row of staples while the outer ramp portion 791b can be
configured to lift, or at least partially lift, an outer row of
staples. As primarily depicted in FIG. 67, the inner ramp portion
791a and the outer ramp portion 791b can each include a ramp
surface, such as ramp surfaces 795a and 795b, respectively, which
can slide underneath the staples in the inner row of staples and
the outer row of staples, respectively. The ramp surfaces 795a and
795b of the inner ramp portion 791a and the outer ramp portion 791b
can be configured to lift staples from an unfired position to an at
least partially-fired position. In various instances, the ramp
surfaces 795a and 795b of the inner ramp portion 791a and the outer
ramp portion 791b can each comprise at least one inclined surface,
curved surface, actuate surface, and/or convex surface, for
example.
[0163] Further to the above, the inner ramp portion 794a of the
second sled portion 793 can include an inner ramp surface 796a and,
similarly, the outer ramp portion 794b of the second sled portion
793 can include an outer ramp surface 796b. In various instances,
the inner ramp surface 795a of the first sled portion 792 can be
configured to co-operate with the inner ramp surface 796a of the
second sled portion 793 to lift the staples in the inner row of
staples from their unfired positions and their fully-fired
positions. More particularly, the inner ramp portion 791a can lift
the staples in the inner row of staples from an unfired position to
a partially-fired position wherein the inner ramp portion 794a can
then lift the staples from their partially-fired positions to a
fully-fired position, for instance. In such circumstances, the
lifting motion of the staples in the inner row of staples can be
initiated by the inner ramp portion 791a of the first sled portion
792, transferred to the inner ramp surface 796a of the second ramp
portion 793, and then completed by the second ramp portion 793.
Similarly, the outer ramp surface 795b of the first sled portion
792 can be configured to co-operate with the outer ramp surface
796b of the second sled portion 793 to lift the staples in the
outer row of staples from their unfired positions and their
fully-fired positions. More particularly, the outer ramp portion
791b can lift the staples in the outer row of staples from an
unfired position to a partially-fired position wherein the outer
ramp portion 794b can then lift the staples from their
partially-fired positions to a fully-fired position, for instance.
In such circumstances, the lifting motion of the staples in the
outer row of staples can be initiated by the outer ramp portion
791b of the first sled portion 792, transferred to the outer ramp
surface 796b of the second ramp portion 793, and then completed by
the second ramp portion 793. The firing, or lifting, motion of the
staples in the inner row of staples can be completed once the apex
798 of the inner ramp portion 794a has passed underneath the
staples. Similarly, the firing, or lifting, motion of the staples
in the outer row of staples can be completed once the apex 798 of
the outer ramp portion 794b has passed underneath the staples.
[0164] Referring again to FIG. 65, the sled assembly 790 can
include more than one first sled portion 792 and/or more than one
second sled portion 793. In various instances, the sled assembly
790 can comprise a first set of sled portions comprising a first
sled portion 792 and a second sled portion 793 and a second set of
sled portions comprising a first sled portion 792 and a second sled
portion 793. In certain instances, the second set of sled portions
can constitute a mirror image of the first set. For the purposes of
simplifying the description of the sled assembly 790 herein,
reference may be made to only one set of sled portions; however,
the reader should appreciate that the description regarding the
operation of one set of sled portions could also apply to the
concurrent operation of any suitable number sets of sled
portions.
[0165] Further to the above, the outer staple rows of the cartridge
240, i.e., the rows furthest away from the channel 243, can lead
the inner staple rows, i.e., the rows closest to the channel 243.
Stated another way, the deformation of the staples in the outer row
can begin before, or at least slightly before, the deformation of
the laterally adjacent staples in the inner row. In other
instances, the outer staple rows of the cartridge 240, i.e., the
rows furthest away from the channel 243, can lag the inner staple
rows, i.e., the rows closest to the channel 243. Stated another
way, the deformation of the staples in the inner row can begin
before, or at least slightly before, the deformation of the
laterally adjacent staples in the outer row. Moreover, while two
staples rows are disclosed on each side of the channel 243 defined
in the cartridge 240, other embodiments are envisioned in which
more than two staple rows, such as three staple rows, for example,
are present on each side of the channel 243. In such embodiments,
the sled assemblies can be configured to deploy an additional row
of staples at the same time as the inner row of staples, at the
same time as the outer row of staples, and/or at a time which is
staged sequentially with respect to the inner row of staples and
the outer row of staples.
[0166] As mentioned above, the first sled portion 792 is movable
relative to the second sled portion 793 of the sled assembly 790.
Turning now to FIGS. 70-72, the sled assembly 790 is movable
between an initial, unfired configuration (FIG. 70) and a second,
extended configuration (FIGS. 71 and 72). In the initial, unfired
configuration of sled assembly 790, referring primarily to FIG. 70,
the first sled portion 792 is collapsed within, or retracted
relative to, the second portion 793. In at least one such instance,
the distal end of the first sled portion 792 may not extend beyond
the distal end of the second sled portion 793. In other instances,
although not illustrated, the distal end of the first sled portion
792 may extend beyond the distal end of the second sled portion 793
when the first sled portion 792 is collapsed within the second
portion 793. With further reference to FIG. 70, the reader will
further appreciate that the staples 460 are in an unfired position
as they have not yet been lifted toward the anvil 124. Upon
comparing FIGS. 70 and 71, the reader will notice that the first
sled portion 792 has been extended relative to the second sled
portion 793. In such circumstances, the distal end of the first
sled portion 792 is positioned distally with respect to the distal
end of the second sled portion 793. The movement of the first sled
portion 792 from its initial, unfired position to its extended
position can position the inner ramp portion 791a and/or the outer
ramp portion 791b of the first sled portion 792 underneath one or
more staples 460. In other configurations, the movement of the
first sled portion 792 from its initial, unfired position to its
extended position may not position the inner ramp portion 791a
and/or the outer ramp portion 791b underneath one or more staples
460. In any event, as illustrated in FIG. 71, the extension of the
first sled portion 792 can at least partially lift at least one
staple 460 toward the anvil 124 and/or at least partially deform at
least one staple 460 against the anvil 124. In certain instances,
the extension of the first sled portion 792 can completely lift, or
completely deform, at least one staple 460 against the anvil 124.
In various circumstances, the second sled portion 793 may not be
advanced distally when the first sled portion 792 is moved into its
extended position; however, in certain circumstances, at least some
distal movement of the second sled portion 793 may occur when the
first sled portion 792 is moved into its extended position.
[0167] Upon comparing FIGS. 71 and 72, it can be noted that the
first sled portion 792 and the second sled portion 793 have been
advanced distally to lift staples 460 toward the anvil 124. The
first sled portion 792 and the second sled portion 793 can then be
advanced to the distal end of the end effector 120 to complete the
firing stroke of the end effector 120, which will be discussed in
greater detail further below. In any event, the initial progression
of the sled assembly 790 during the firing stroke of the end
effector 120 is depicted in FIGS. 70-72. FIG. 70 depicts the sled
assembly 790 in a retracted, unfired position; FIG. 71 depicts the
sled assembly 790 in an extended, partially-fired position; and
FIG. 72 depicts the sled assembly 790 in an extended, fired
position. As outlined above, the pusher bar, or bars, 159 can be
moved distally in order to advance the sled assembly 790 through
the progression depicted in FIGS. 70-72. With reference to FIG. 70,
a pusher bar 159 is illustrated in an initial, unfired position in
which it is in contact with the proximal end of the first sled
portion 792. In various embodiments, the pusher bar 159 can include
a contact flange 155 extending from the distal end thereof which
can engage the first sled portion 792. With further reference to
FIG. 70, the pusher bar 159 may not be in contact with the second
sled portion 793 when the pusher bar 159 is in its initial, unfired
position. As the pusher bar 159 is advanced distally, the pusher
bar 159 can move the first sled portion 792 distally until the
contact flange 155 comes into contact with the proximal end of the
second sled portion 793, as illustrated in FIG. 71. It is this
relative motion between the first sled portion 792 and the second
sled portion 793 which extends the sled assembly 790 as discussed
above. Thereafter, the pusher bar 159 can be advanced distally in
order to advance the first sled portion 792 and the second sled
portion 793 distally at the same time, as illustrated in FIG.
72.
[0168] As discussed above, the end effector 120 can be configured
to staple and transect tissue at the same time. Referring again to
FIG. 65, the end effector 120 can include a firing member, or knife
bar, 156 comprising a knife edge 158 configured to transect the
tissue as the knife bar 156 is advanced distally. Referring again
to FIGS. 70 and 71, the initial distal movement of the pusher bar,
or bars, 159 may not be transferred to the knife bar 156. Stated
another way, the knife bar 156 may remain stationary, or at least
substantially stationary, while the sled assembly 790 is moved
between its retracted position (FIG. 70) and its extended position
(FIG. 71). In such circumstances, relative movement between the
pusher bars 159 and the knife bar 156 can occur, at least during
the initial portion of the end effector firing stroke. Upon
comparing FIGS. 74 and 77, it can be seen that, one, the pusher
bars 159 have been advanced distally to extend the sled assembly
790 and, two, the knife bar 156 has not been advanced distally.
Particular attention can be paid to the proximal ends of the knife
bar 156 and the pusher bars 159. More particularly, the pusher bars
159 can include a drive pin 759 extending therebetween which
extends through a drive slot 757 defined in the drive bar 157
extending proximally from the knife bar 156. When the pusher bars
159 are in their proximal unfired position, as illustrated in FIG.
74, the drive pin 759 is positioned in the proximal end of the
drive slot 757. When the pusher bars 159 are advanced distally, as
illustrated in FIG. 77, the drive pin 759 can slide distally within
the drive slot 757 until the drive pin 759 reaches the distal end
of the drive slot 757. In such a position, the sled 790 has been
fully extended and the knife bar 156 has not yet been advanced
distally with the pusher bars 159. Once the drive pin 759 is in
contact with the distal end of the drive slot 757, as illustrated
in FIGS. 78 and 79, the pusher bars 156 and the knife bar 159 can
be advanced distally together.
[0169] Further to the above, the knife bar 156 can include flanges
153 and 155 which can be configured to engage the anvil 124 and the
staple cartridge channel 123, respectively. When the knife bar 156
is in its proximal, unadvanced position, as illustrated in FIG. 77,
the flange 153 can be positioned proximally with respect to a slot
121 defined in the anvil 124. In such a position of the knife bar
156, the flange 155 may or may not be positioned within a slot
defined within and/or in the exterior of the cartridge channel 123.
As the knife bar 156 is advanced distally, the flange 153 can enter
into the anvil slot 121 and the flange 155 can be positioned within
the cartridge channel slot. In such circumstances, the knife bar
156 can set the gap, or tissue gap distance, between the anvil 124
and the staple cartridge positioned within the cartridge channel
123. In various circumstances, the knife bar 156 can control the
forming height and/or the compression of the tissue within the end
effector 120 as the knife bar 156 is advanced distally.
[0170] The arrangement described above in which the pusher bars 159
move the sled assembly 790 before the pusher bars 159 advance the
knife 158 can be advantageous in many circumstances. For instance,
it is often desirable to staple tissue before it is incised and,
thus, the formation of the staples leads, or at least sufficiently
leads, the transection of the tissue by the knife bar 156. The
staggered deployment of the sled 790 and the knife bar 156 can
facilitate such a relative progression between the staple formation
and the tissue incision. Moreover, the sled 790 can be compactly
stored in the end effector 120 in its retracted, unfired
configuration in order to permit a shorter proximal-to-distal, or
longitudinal, length of the end effector 120. Stated another way,
less longitudinal room may be required for a sled assembly that can
begin its firing stroke in at least partially collapsed state.
Furthermore, owing to the longitudinal extendibility of the sled
assembly 790, the staple lifting surfaces of the sled assembly 790
can be longer and can include a shallower, or less aggressive, ramp
angle than a unitary sled, for instance. Stated another way, the
mechanical advantage of the sled assembly 790 can be improved owing
to longer longitudinal lengths available for the ramps of the sled
assembly 790.
[0171] Turning now to FIGS. 80-82, the sled assembly 790 and the
knife bar 156 can be advanced distally toward the distal end of the
end effector 120 to complete the firing stroke of the end effector
120. As the sled 790 approaches the distal end of the end effector
120, in various instances, the first sled portion 792 can contact a
distal end 245 of the staple cartridge and retract relative to
and/or within the second sled portion 793. More particularly, the
distal end 245 can block the distal movement of the first sled
portion 792 while the second sled portion 793 is advanced distally
relative to the first sled portion 792 in order to complete the
firing stroke. In various instances, the second sled portion 793
can be advanced distally until it also contacts the distal end 245
of the staple cartridge while, in other instances, the firing
stroke can be completed before the second sled portion 793 contacts
the distal end 245. In either event, in embodiments where the
distal flanges 155 of the pusher bars 159 push the first sled
portion 792 and the second sled portion 793 toward the distal end
of the end effector 120, the first sled portion 792 may become
disengaged from the pusher bars 159 when the first sled portion 792
reaches the distal end so that that the pusher bars 159 can push
the second sled portion 793 relative to the first sled portion 792.
In at least one such instance, referring primarily to FIG. 77, the
distal end of the staple cartridge can include a boss 241 which can
be configured to lift the first sled portion 792 upwardly toward
the anvil 124 so that the pusher bars 159 can slide underneath the
first sled portion 792. In such circumstances, the first sled
portion 792 can be operatively disengaged from the second sled
portion 793 and the pusher bars 159. In various instances, the boss
241 can be positioned and arranged such that the first sled portion
792 is lifted upwardly after all of the staples of the staple
cartridge have been deployed and/or transferred to the second sled
portion 793, as discussed above. Moreover, further to the above,
the distal end of the staple cartridge can include a first boss 241
configured to lift a first sled portion 792 and a second boss 241
configured to lift an additional first sled portion 792. In various
instances, the bosses 241 can be configured to synchronously lift
the first sled portions 792 at the same time. In some instances,
the bosses 241 can be configured to lift the first sled portions
792 sequentially.
[0172] Referring now to FIGS. 85-88, FIG. 85 depicts the sled
assembly 790 in its initial, unfired configuration. Further to the
above, a pusher bar 159 can contact a proximal end 789 of the first
sled portion 792 and push the first sled portion 792 distally until
the proximal end 789 of the first sled portion 792 is flush with a
proximal end 787 of the second sled portion 793, as illustrated in
FIG. 86. At such point, the first sled portion 792 can be fully
extended relative to the second sled portion 793. Thereafter, the
pusher bar 156 can push on the proximal end 787 and the proximal
end 789 simultaneously to advance the sled assembly 790 distally.
As also discussed above, referring now to FIG. 87, the first sled
portion 792 can be stopped by the distal end 245 of the staple
cartridge and lifted upwardly by the boss 241 of the staple
cartridge, for instance. At such point, the first sled portion 792
can be elevated relative to the second sled portion 793, and the
distal flange 155, such that the second sled portion 793 can be
slid relative to, and at least partially underneath, the first sled
portion 792, in order to collapse the sled assembly 790, as
illustrated in FIG. 88. Upon comparing FIGS. 87 and 88, it can be
seen that the second sled portion 793 is moved closer toward ledge
788 defined in the bottom surface of the first sled portion 792 and
that the distal end 789 of the first sled portion 792 is no longer
aligned with the distal end 787 of the second sled portion 793.
[0173] After the firing stroke has been completed, referring now to
FIGS. 83 and 84, the knife bar 156 and the pusher bars 159 can be
retracted proximally. In various circumstances, the knife bar 156
can be pulled proximally by the pusher bars 159. More particularly,
the pusher bars 159 can be retracted proximally relative to the
knife bar 159 until the drive pin 759 contacts the proximal end of
the drive slot 759. At such point, the pusher bars 159 can pull the
knife bar 156 proximally until the flange 153 of the knife bar 156
is no longer positioned within the slot 121 of the anvil 124.
Thereafter, the anvil 124 can be moved into its open position when
the closure tube 115 is pulled proximally. In certain instances,
the staple cartridge can comprise a replaceable staple cartridge.
In such instances, the spent staple cartridge can be removed from
the cartridge channel 122 and, if desired, an unspent staple
cartridge can be positioned within the cartridge channel 122 so
that the surgical instrument can be used once again.
[0174] As illustrated in FIGS. 83 and 84, the collapsed sled
assembly 790 can be left behind in the distal end of the end
effector 120 when the knife bar 156 and the pusher bars 159 are
retracted. In the event that the spent staple cartridge is removed
from the cartridge channel 122, the collapsed sled assembly 790 can
be removed from the end effector 120 with the cartridge. In certain
instances, a staple cartridge may not be completely spent before
the pusher bars 159 and the knife bar 156 are retracted. In such
instances, the sled assembly 790 may only be partially advanced
within the staple cartridge and may not be collapsed back into its
unextended configuration. When the staple cartridge is then removed
from the cartridge channel 123, some of the staples may still be
positioned within their staple cavities.
[0175] As discussed herein, a firing actuator, or sled, of a staple
cartridge and/or stapling instrument can include one or more
inclined ramp surfaces configured to lift, or deploy, staples
between an unfired position and a fired position. For instance, a
sled can include a first inclined ramp surface configured to deploy
a first row of staples, a second inclined ramp surface configured
to deploy a second row of staples, and so forth. Each inclined ramp
surface can comprise a contiguous surface which is configured to
engage each staple in the corresponding row of staples and lift the
staples until they have been fully deformed against an anvil
positioned opposite the staple cartridge. The contiguous surface
which defines each inclined ramp surface can include any suitable
number of contours such as, for instance, one or more linear
surfaces and/or one or more curved surfaces. In various instances,
the contiguous surface can directly engage each staple in the
corresponding row of staples and can remain continuously engaged
with a staple in that row as it moved from its unfired position to
its fully-fired position. After a staple has reached its
fully-fired position, the inclined ramp surface may become
disengaged from that staple. This arrangement can be possible for
sleds with relatively movable components, such as sled assembly
790, for instance, and/or sleds that are not comprised of
relatively movable components, such as sleds comprised of a unitary
piece of material, for example.
[0176] In various circumstances, a firing actuator, or sled, can
comprise one or more inclined ramp surfaces, wherein each inclined
ramped surface is comprised of two or more co-operating drive
surfaces. For instance, turning now to FIG. 92, a sled 890 can
include a first inclined ramp surface 891a which is comprised of an
initial, or first, drive surface 895a and a second, or final, drive
surface 896a. The initial drive surface 895a and the final drive
surface 896a of the first inclined ramp surface 891a can be
configured to co-operatively lift the staples in a first staple row
between an unfired position and a fired position. As the sled 890
is moved distally through a staple cartridge, referring to FIGS.
89-92, the initial drive surface 895a can contact a staple 160, for
instance, and lift the staple 160 from its unfired position (FIG.
89) to a partially-fired position (FIG. 90). Thereafter, the sled
890 can be advanced distally such that the final drive surface 896a
can lift the staple 160 between its partially-fired position and
its fully-fired position. In various instances, the initial drive
surface 895a can contact the initial drive surfaces 180 of the
staples 160 to lift the staples 160 into their partially-fired
positions and the final drive surface 896a can contact the second
drive surfaces 182 of the staples 160 to lift the staples 160 into
their finally-fired positions. In such instances, the staples 160
can be transferred from the initial drive surface 895a to the final
drive surface 896a to complete the deployment, or firing, thereof.
Referring to FIG. 92, the deployment, or firing, of a staple 160
can be complete once the apex 898 of the first inclined ramp
surface 891a has passed under the second drive surface 182 of the
staple 160.
[0177] Further to the above, referring again to FIG. 92, the
initial drive surface 895a and the final drive surface 896a of the
first inclined ramp surface 891a can be configured to
co-operatively deploy staples within a first row of staples. The
sled 890 can include additional inclined ramp surfaces to deploy
additional rows of staples. For instance, the sled 890 can include
a second inclined ramp surface 891b comprising an initial drive
surface 895b and a final drive surface 896b which can be configured
to co-operatively deploy staples within a second row of staples. In
various instances, the sled 890 can further include any suitable
number of inclined ramp surfaces, such as a third inclined ramp
surface, similar to first inclined ramp surface 891a, configured to
deploy staples within a third row of staples and a fourth inclined
ramp surface, similar to second inclined ramp surface 891b,
configured to deploy staples within a fourth row of staples, for
example. In any event, the drive surfaces of an inclined drive
surface, such as drive surfaces 895a, 895b, 896a, and 896b, for
example, can include any suitable configuration such as a linear
profile and/or a curved profile, for example. With further
reference to FIG. 92, the first inclined ramp surface 891a can
include a transition drive surface 897a intermediate the initial
drive surface 895a and the final drive surface 896a. Similarly, the
second inclined ramp surface 891b can include a transition drive
surface 897b intermediate the initial drive surface 895b and the
final drive surface 896b. In various instances, a transition drive
surface can comprise a transition between one drive surface and
another drive surface. In some instances, a transition drive
surface can comprise a surface which simultaneously drives the
initial drive surface 180 and the second drive surface 182 of a
staple 160, for example. In various instances, an inclined ramp
surface can include any suitable number of drive surfaces.
[0178] In various instances, further to the above, the initial
drive surface 895a can be positioned laterally with respect to the
final drive surface 896a. In certain instances, the initial drive
surface 895a and the final drive surface 896a can be connected to
one another. In other instances, the initial drive surface 895a and
the final drive surface 896a may not be connected to one another.
In various circumstances, the initial drive surface 895a can be
defined by a first height and the final drive surface 896a can be
defined by a second height which is taller than the first height.
In certain circumstances, the initial drive surface 895a can be
defined along a first longitudinal axis and the final drive surface
896a can be defined along a second longitudinal axis. In certain
instances, the first longitudinal axis and the second longitudinal
axis can be parallel. In some instances, the initial drive surface
895a can be defined by a first plane and the final drive surface
896a can be defined by a second plane which is parallel to the
first plane. In other instances, the first longitudinal axis and
the second longitudinal axis can be non-parallel. In some
instances, the first longitudinal axis and the second longitudinal
axis can extend in directions which converge. In other instances,
the first longitudinal axis and the second longitudinal axis can
extend in directions which do not converge. In various instances,
further to the above, the transition drive surface 897a of the
first inclined surface 891a can be defined along an axis which is
parallel to the first longitudinal axis and/or the second
longitudinal axis. In certain instances, the transition drive
surface 897a can be defined along an axis which is not parallel to
the first longitudinal axis and/or the second longitudinal axis. In
various instances, further to the above, the transition drive
surface 897a of the first inclined surface 891a can be defined
within a plane which is parallel to the first plane and/or the
second plane. In some instances, the transition drive surface 897a
can be co-planar with the initial drive surface 895a and/or the
final drive surface 896a. In certain instances, the transition
drive surface 897a can be defined within a plane which is different
than the first plane and/or the second plane. In various instances,
further to the above, the transition drive surface 897a can connect
the initial drive surface 895a to the final drive surface 896a.
[0179] The discussion provided above in connection with inclined
ramp surface 891a, initial drive surface 895a, final drive surface
896a, and transition drive surface 897a can be equally applicable
to inclined ramp surface 891b, initial drive surface 895b, final
drive surface 896b, and transition drive surface 897b, for
example.
[0180] In various circumstances, further to the above, the first
inclined ramp surface 891a can be parallel to the second inclined
ramp surface 891b. In other instances, the first inclined ramp
surface 891a may not be parallel to the second inclined ramp
surface 891b. In various instances, the first inclined ramp surface
891a can be defined by a first height and the second inclined ramp
surface 891b can be defined by a second height. In some instances,
the first height can be the same as the second height. In such
instances, a first row of staples formed by the first inclined ramp
surface 891a and a second row of staples formed by the second
inclined ramp surface 891b can be formed to the same height. In
other instances, the first height can be different that the second
height. In such instances, a first row of staples formed by the
first inclined ramp surface 891a and a second row of staples formed
by the second inclined ramp surface 891b can be formed to different
heights. The disclosure of U.S. Pat. No. 8,317,070, entitled
SURGICAL STAPLING DEVICES THAT PRODUCE FORMED STAPLES HAVING
DIFFERENT LENGTHS, which issued on Nov. 27, 2012, is incorporated
by reference in its entirety.
[0181] As discussed above, a sled can directly drive and deploy a
staple and/or any other suitable fastener stored within a
cartridge. Stated another way, the sled can directly contact the
staples wherein a driver is not present intermediate the sled and
the staples. Such an arrangement is different than arrangements
which include a plurality of drivers which support the staples. In
such arrangements, the sled engages the drivers to lift the
staples. In these arrangements, the drivers are often configured to
completely eject the staples from the staple cavities in which they
are stored. More particularly, the drivers are configured to lift
the staples such that the staples are completely positioned above
the top surface, or deck, of the staple cartridge when the staples
are in their fully-fired position. In order to completely lift the
staples above the deck of the staple cartridge, the drivers may
also be at least partially lifted above the deck. Such an
arrangement can be characterized as overdriving the staples. Many
of the teachings discussed herein can be applied to embodiments
including one or more sleds which directly drive staples and, in
addition, embodiments including a plurality of drivers which are
driven by one or more sleds in order to drive the staples. For
instance, sled 890 is discussed in connection with embodiments in
which it directly drives staples 160; however, sled 890 could also
be used in embodiments which include drivers configured to deploy
staples from the staple cavities. In such embodiments, each driver
could include a first drive surface similar to first drive surface
180 configured to be engaged by the initial drive surface 895a, for
instance, and a second drive surface similar to second drive
surface 182 configured to be engaged by the final drive surface
896a, for instance.
[0182] In the embodiments disclosed herein in which the staples are
driven directly by the sled, i.e., without the use of drivers,
further to the above, the staples can be completely lifted above
the deck, or overdriven, by the sled itself. Turning now to FIGS.
91-94, the sled 890 is configured to partially extend above the
deck surface 141 of the cartridge 142. More particularly, the apex
898 of the first inclined ramp surface 891a and the apex 898 of the
second inclined ramp surface 891b can extend above the deck surface
141 as the inclined ramp surfaces 891a and 891b pass through and/or
between the cavities 144 to eject the staples 160, for example,
from the staple cavities 144. In such circumstances, the sled 890
is configured to partially extend above the staple cavity openings
defined in the deck surface 141. In various instances, the
cartridge 142 can further comprise a plurality of coverings 145
positioned within and/or aligned with the rows of staple cavities
144. For instance, a covering 145 can be positioned intermediate
adjacent staple cavities 144 within a staple cavity row. In certain
instances, a covering 145 can be positioned proximally and/or
distally with respect to a staple cavity 144. In various instances,
referring primarily to FIG. 94, the apexes 898 of the inclined ramp
surfaces 891 can pass underneath the coverings 145. In such
instances, each covering 145 can include a bottom surface, such as
an arched bottom surface 147, for example, configured to permit the
inclined ramp surfaces 891 to pass thereunder. With further
reference to FIG. 94, the cartridge 142 can include a first
longitudinal slot 149 configured to slidably receive the first
inclined ramp surface 891a therein and a second longitudinal slot
149 configured to receive the second inclined ramp surface 891b,
for example. In various instances, the cartridge 142 can include a
plurality of longitudinal slots 149 configured to receive the
inclined ramp surfaces of the sled 890. In certain instances, the
longitudinal slots 149 can be defined by the coverings 145 and the
staple cavities 144. In some circumstances, each longitudinal slot
149 can correspond to a longitudinal row of staple cavities 144
wherein a longitudinal slot 149 can place the staple cavities 144
within a staple cavity row in communication with each other such
that an inclined ramp surface passing through the longitudinal slot
149 can pass through the staple cavities 144 as outlined above.
[0183] In various instances, the deck of a cartridge can be
configured to directly contact the tissue being fastened and/or
support the tissue being fastened. In certain circumstances, a
cartridge assembly can include a layer positioned on the deck, such
as a tissue thickness compensator, for example, which is disclosed
in U.S. patent application Ser. No. 12/894,369, entitled
IMPLANTABLE FASTENER CARTRIDGE COMPRISING A SUPPORT RETAINER, now
U.S. Patent Application Publication No. 2012/0080344, which was
filed on Sep. 30, 2010, U.S. patent application Ser. No.
13/097,856, entitled STAPLE CARTRIDGE COMPRISING STAPLES POSITIONED
WITHIN A COMPRESSIBLE PORTION THEREOF, now U.S. Patent Application
Publication No. 2012/0080336, which was filed on Apr. 29, 2011, and
U.S. patent application Ser. No. 13/242,066, entitled CURVED END
EFFECTOR FOR A STAPLING INSTRUMENT, now U.S. Patent Application
Publication No. 2012/0080498, which was filed on Sep. 23, 2011. The
entire disclosures of U.S. patent application Ser. No. 12/894,369,
entitled IMPLANTABLE FASTENER CARTRIDGE COMPRISING A SUPPORT
RETAINER, now U.S. Patent Application Publication No. 2012/0080344,
which was filed on Sep. 30, 2010, U.S. patent application Ser. No.
13/097,856, entitled STAPLE CARTRIDGE COMPRISING STAPLES POSITIONED
WITHIN A COMPRESSIBLE PORTION THEREOF, now U.S. Patent Application
Publication No. 2012/0080336, which was filed on Apr. 29, 2011, and
U.S. patent application Ser. No. 13/242,066, entitled CURVED END
EFFECTOR FOR A STAPLING INSTRUMENT, now U.S. Patent Application
Publication No. 2012/0080498, which was filed on Sep. 23, 2011, are
incorporated herein by reference. In various instances, referring
again to FIG. 93, the deck 141 and the coverings 145 can be
configured to directly contact tissue. In such instances, coverings
145 can extend above the deck 141 and, as a result, the deck 141
and the coverings 145 can comprise an uneven support surface. The
coverings 145, in various instances, can apply an additional
compressive pressure to the tissue positioned directly above and/or
adjacent to each longitudinal row of staples. This additional
compressive pressure can push fluids present within the tissue away
from the staple lines prior to, during, and/or after the staple
forming process which, as a result, can promote better staple
formation and/or staple retention within the tissue. The coverings
145 can also be configured to grip the tissue positioned between a
staple cartridge and an anvil, especially along the staple lines
where the staple formation occurs. The coverings can also be
configured to support the staples as the staples are being ejected
from the staple pockets to provide a localized control over the
staple forming process. The entire disclosures of U.S. patent
application Ser. No. 12/893,461, entitled STAPLE CARTRIDGE, now
U.S. Patent Application Publication No. 2012/0074198, which was
filed on Sep. 29, 2010, and U.S. patent application Ser. No.
13/851,676, entitled TISSUE THICKNESS COMPENSATOR COMPRISING A
CUTTING MEMBER PATH, which was filed on Mar. 27, 2013, are
incorporated by reference herein.
[0184] As discussed above, referring primarily to FIGS. 58, 61, and
64, a staple cavity, such as staple cavity 144, for example, can
include a first sidewall 150a and a second sidewall 150b which can
be configured to guide a staple, such as a staple 160, for example,
as it is lifted between an unfired position and a fired position.
In various instances, the sidewalls 150a, 150b can be configured
and arranged such that the entirety of the staple 160 is positioned
intermediate the sidewalls 150a, 150b when the staple 160 is in its
unfired position. In other circumstances, referring primarily to
FIGS. 22-31, the sidewalls 150 of the staple cavity 144 may be
configured such that less than the entirety of the staple 160 is
positioned intermediate the sidewalls 150 when the staple 160 is in
its unfired position. For instance, the base 162 of the staples 160
in the outermost rows of staple cavities 144 defined in the
cartridge body 142 may be unsupported by at least one of the
sidewalls 150 when the staples 160 are in their unfired positions.
As the staples 160 are lifted upwardly, however, the bases 162 of
the staples 160 may then be supported by both of the sidewalls 150.
Turning now to FIGS. 93 and 94, some of the staple cavities 144 of
the cartridge 142, such as cavities 144a, for example, may only
support both sides of the bases 162 at the end of their lifting
motion. In any event, even though the sidewalls of the staple
cavities 144 defined in the cartridge body 142 may not entirely
support the staples 160 in their unfired positions, the cartridge
channel 123 of jaw 122, referring again to FIGS. 3 and 65, may at
least partially support the staples 160. Stated another way, the
cartridge body 142 and the cartridge channel 123 may co-operate to
define the staple cavities 144 in order to support and/or surround
the staples 160 throughout the lifting motion of the staples 160.
For instance, the cartridge body 142 and the cartridge channel 123
can co-operate to support and/or surround a staple 160 when the
staple 160 is in its unlifted position. At some point during the
lifting motion of the staple 160, in some circumstances, the
cartridge channel 123 may no longer support and/or the staple 160
and, in such circumstances, the cartridge body 142 may entirely
support the staple 160 for the remainder of the lifting motion. In
at least one embodiment, the cartridge channel 123 and the
cartridge body 142 may co-operate to support the staple 160 for
half, or approximately half, of the lifting motion. In other
embodiments, the cartridge channel 123 and the cartridge body 142
may co-operate to support the staple 160 for less than half or more
than half of the lifting motion. In some instances, the cartridge
body 142 and the cartridge channel 123 may co-operatively support
and/or surround the staple 160 throughout the entire lifting motion
of the staple 160.
[0185] Various embodiments described herein are described in the
context of linear end effectors and/or linear fastener cartridges.
Such embodiments, and the teachings thereof, can be applied to
non-linear end effectors and/or non-linear fastener cartridges,
such as, for example, circular and/or contoured end effectors. For
example, various end effectors, including non-linear end effectors,
are disclosed in U.S. patent application Ser. No. 13/036,647, filed
Feb. 28, 2011, entitled SURGICAL STAPLING INSTRUMENT, now U.S.
Patent Application Publication No. 2011/0226837, which is hereby
incorporated by reference in its entirety. Additionally, U.S.
patent application Ser. No. 12/893,461, filed Sep. 29, 2012,
entitled STAPLE CARTRIDGE, now U.S. Patent Application Publication
No. 2012/0074198, is hereby incorporated by reference in its
entirety. U.S. patent application Ser. No. 12/031,873, filed Feb.
15, 2008, entitled END EFFECTORS FOR A SURGICAL CUTTING AND
STAPLING INSTRUMENT, now U.S. Pat. No. 7,980,443, is also hereby
incorporated by reference in its entirety. The entire disclosure of
U.S. Pat. No. 7,845,537, entitled SURGICAL INSTRUMENT HAVING
RECORDING CAPABILITIES, which issued on Dec. 7, 2010 is
incorporated by reference herein. The entire disclosure of U.S.
application Ser. No. 13/118,241, entitled SURGICAL STAPLING
INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S.
Patent Application Publication No. 2012/0298719, which was filed on
May 27, 2011, is incorporated by reference herein.
[0186] 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.
[0187] 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.
[0188] Any patent, publication, or other disclosure material, in
whole or in part, that is said to be incorporated by reference
herein is incorporated herein only to the extent that the
incorporated materials does not conflict with existing definitions,
statements, or other disclosure material set forth in this
disclosure. As such, and to the extent necessary, the disclosure as
explicitly set forth herein supersedes any conflicting material
incorporated herein by reference. Any material, or portion thereof,
that is said to be incorporated by reference herein, but which
conflicts with existing definitions, statements, or other
disclosure material set forth herein will only be incorporated to
the extent that no conflict arises between that incorporated
material and the existing disclosure material.
[0189] 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.
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