U.S. patent application number 14/138516 was filed with the patent office on 2015-06-25 for surgical cutting and stapling methods.
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 | 20150173756 14/138516 |
Document ID | / |
Family ID | 52350299 |
Filed Date | 2015-06-25 |
United States Patent
Application |
20150173756 |
Kind Code |
A1 |
Baxter, III; Chester O. ; et
al. |
June 25, 2015 |
SURGICAL CUTTING AND STAPLING METHODS
Abstract
Surgical methods for cutting and fastening tissue are disclosed.
The methods may include employing a surgical end effector that
includes a pair of jaws wherein an upper jaw is movable relative to
a lower jaw that supports a surgical fastener cartridge. The
methods may include manipulating the end effector to a compact
configuration to facilitate its insertion through a trocar port and
then manipulating and actuating the end effector to treat target
tissue.
Inventors: |
Baxter, III; Chester O.;
(Loveland, OH) ; Shelton, IV; Frederick E.;
(Hillsboro, OH) ; Morgan; Jerome R.; (Cincinnati,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ethicon Endo-Surgery, Inc. |
Cincinnati |
OH |
US |
|
|
Assignee: |
Ethicon Endo-Surgery, Inc.
Cincinnati
OH
|
Family ID: |
52350299 |
Appl. No.: |
14/138516 |
Filed: |
December 23, 2013 |
Current U.S.
Class: |
227/177.1 |
Current CPC
Class: |
A61B 17/07207 20130101;
A61B 2017/00309 20130101; A61B 2017/00526 20130101; A61B 2017/07228
20130101; A61B 2017/07278 20130101; A61B 2017/07271 20130101; A61B
2017/00473 20130101; A61B 2017/00327 20130101; A61B 2017/07257
20130101; A61B 17/0644 20130101; A61B 17/064 20130101 |
International
Class: |
A61B 17/072 20060101
A61B017/072 |
Claims
1. A surgical method for treating target tissue within a patient,
the method comprising the steps of: installing a hollow trocar port
into a patient; providing a surgical end effector comprising: an
elongated shaft assembly defining a longitudinal tool axis; a lower
jaw operably coupled to the elongated shaft assembly, the lower jaw
including elastic biasing means; an upper jaw supported for
movement relative to the lower jaw upon application of actuation
motions thereto, the upper jaw being movable between a first
insertion position wherein the upper jaw is compressible against
the biasing means on the lower jaw to provide the surgical end
effector with a smallest cross-sectional shape to facilitate
passage of the surgical end effector through the hollow trocar port
into the patient and a primary opened position whereupon
application of an actuation motion thereto, the upper jaw is
movable into a fully open position for admitting target tissue
between the upper and lower jaws and upon application of another
actuation motion to the upper jaw, the upper jaw is moved to a
fully clamped position wherein the target tissue is clamped between
the upper and lower jaws; and a firing member operably supported
for selective operable travel within the surgical end effector upon
application of a firing motion thereto and wherein the surgical
method further comprises: inserting the surgical end effector into
the hollow trocar port such that an inner surface of the hollow
trocar port compresses the upper jaw into the insertion position
until the surgical end effector has exited the distal end of the
trocar port whereupon the biasing means moves the upper jaw into
the primary opened position; applying the actuation motion to the
upper jaw to move the upper jaw to the fully opened position;
manipulating the end effector such that the target tissue is
positioned between the upper and lower jaws; applying the another
actuation motion to the upper jaw to move the upper jaw into the
fully clamped position; and applying the firing motion to the
firing member to cause the firing member to travel from a starting
position to an ending position within the end effector.
2. The surgical method of claim 1 wherein the firing member
comprises a body that includes an upper portion that is configured
to engage the upper jaw and a lower portion that is configured to
engage the lower jaw and wherein the upper portion is movable
relative to the lower portion between a collapsed position when the
surgical end effector has the smallest cross-sectional shape and an
operating position when the surgical end effector has exited the
trocar port to enable the firing member to move from the starting
position to the ending position upon application of the firing
motion thereto.
3. The surgical method of claim 2 wherein the upper portion of the
firing member includes a tissue cutting edge.
4. The surgical method of claim 3 wherein the lower jaw supports a
surgical staple cartridge including a plurality of unformed
surgical staples operably supported therein and wherein the upper
jaw comprises an anvil and wherein the firing member cuts the
target tissue clamped between the anvil and the surgical staple
cartridge and drives the unformed surgical staples within the
surgical staple cartridge into forming contact with the anvil as
the firing member travels from the starting position to the ending
position within the end effector.
5. The surgical method of claim 4 wherein the anvil comprises an
anvil body including an anvil mounting portion, the anvil mounting
portion movably engaging a control insert movably supported in the
lower jaw for travel along an insert axis that is transverse to the
longitudinal tool axis between a first position corresponding to
the insertion position and a second position corresponding to the
primary opened position, the anvil mounting portion automatically
moving along the insert axis from the first position to the second
position after the surgical end effector has exited the trocar
port.
6. The surgical method of claim 5 wherein the control insert is
biased into the second position by a biasing member supported on
the lower jaw.
7. The surgical method of claim 4 further comprising the step of
applying a retraction motion to the firing member to move the
firing member from the ending position back to the starting
position.
8. The surgical method of claim 7 further comprising the step of
re-applying the actuation motion to the anvil to enable the target
tissue to be released from the end effector.
9. The surgical method of claim 8 further comprising the steps of:
discontinuing the re-application of the actuation motion to the
anvil to enable the anvil to return to the primary opened position;
and withdrawing the surgical end effector back through the trocar
port such that the inner surface of the trocar port compresses the
anvil into the first insertion position.
10. The surgical method of claim 1 wherein the elastic biasing
means comprises compressible foam attached to the lower jaw.
11. A surgical method for treating target tissue within a patient,
the method comprising the steps of: installing a hollow trocar port
into a patient; providing a surgical end effector comprising: an
elongated shaft assembly; a lower jaw operably coupled to the
elongated shaft assembly, the lower jaw including elastic biasing
means; an upper jaw supported for movement relative to the lower
jaw upon application of actuation motions thereto, the upper jaw
being movable between a first insertion position wherein the upper
jaw is compressible against the elastic biasing means to provide
the surgical end effector with a smallest cross-sectional shape to
facilitate passage of the surgical end effector through the trocar
port into the patient and a primary opened position and whereupon
application of an actuation motion thereto, the upper jaw is
movable into a fully open position for admitting target tissue
between the upper and lower jaws and upon application of another
actuation motion thereto, the upper jaw is moved to a fully clamped
position wherein the target tissue is clamped between the upper and
lower jaws; a control insert operably supporting a portion of the
upper jaw therein and being selectively movably supported in the
lower jaw for travel between a first position corresponding to the
insertion position and a second position corresponding to the
primary opened position; means for moving the control insert
between the first and second positions; and a firing member
operably supported for selective operable travel within the
surgical end effector upon application of a firing motion thereto
and wherein the surgical method further comprises: moving the
control insert into the first position; inserting the surgical end
effector through the hollow trocar port into the patient; moving
the control insert to the second position to enable the biasing
means to move the upper jaw into the primary opened position;
applying the actuation motion to the upper jaw to move the upper
jaw to the fully opened position; manipulating the end effector
such that the target tissue is positioned between the upper and
lower jaws; applying the another actuation motion to the upper jaw
to move the upper jaw into the fully clamped position; and applying
the firing motion to the firing member to cause the firing member
to travel from a starting position to an ending position within the
end effector.
12. The surgical method of claim 11 wherein the firing member
comprises a body that includes an upper portion that is configured
to engage the upper jaw and a lower portion that is configured to
engage the lower jaw and wherein the upper portion is movable
relative to the lower portion between a collapsed position when the
surgical end effector has the smallest cross-sectional shape and an
operating position when the surgical end effector has exited the
trocar port to enable the firing member to move from the starting
position to the ending position upon application of the firing
motion thereto.
13. The surgical method of claim 12 wherein the upper portion of
the firing member includes a tissue cutting edge.
14. The surgical method of claim 13 wherein the lower jaw supports
a surgical staple cartridge including a plurality of unformed
surgical staples operably supported therein and wherein the upper
jaw comprises an anvil and wherein the firing member cuts the
target tissue clamped between the anvil and the surgical staple
cartridge and drives the unformed surgical staples within the
surgical staple cartridge into forming contact with the anvil as
the firing member travels from the starting position to the ending
position within the end effector.
15. The surgical method of claim 14 further comprising the step of
applying a retraction motion to the firing member to move the
firing member from the ending position back to the starting
position.
16. The surgical method of claim 15 further comprising the step of
re-applying the actuation motion to the anvil to enable the target
tissue to be released from the end effector.
17. The surgical method of claim 16 further comprising the steps
of: discontinuing the re-application of the actuation motion to the
anvil to enable the anvil to return to the primary opened position;
returning the control insert to the first position; and withdrawing
the surgical end effector back through the trocar port.
18. A surgical method for treating target tissue within a patient,
the method comprising the steps of: installing a hollow trocar port
into a patient; providing a surgical end effector comprising: a
lower jaw; an upper jaw supported for movement relative to the
lower jaw between a first insertion position wherein the upper jaw
is compressible against the lower jaw to provide the surgical end
effector with a smallest cross-sectional shape to facilitate
passage of the surgical end effector through the hollow trocar port
into the patient and a primary opened position whereupon
application of an actuation motion thereto, the upper jaw is
movable into a fully open position for admitting target tissue
between the upper and lower jaws and upon application of another
actuation motion to the upper jaw, the upper jaw is moved to a
fully clamped position wherein the target tissue is clamped between
the upper and lower jaws; and a firing member operably supported
for selective operable travel within the surgical end effector upon
application of a firing motion thereto and wherein the surgical
method further comprises: operably coupling an elongated shaft
assembly to the surgical end effector, the elongated shaft assembly
defining a longitudinal tool axis and including a distal closure
tube portion supported for axial travel relative to the upper jaw
to apply the actuation motions thereto, the distal closure tube
portion including biasing means to automatically bias the upper jaw
to the primary opened position upon exiting of the upper jaw from
the trocar port; inserting the surgical end effector into the
hollow trocar port such that an inner surface of the hollow trocar
port compresses the upper jaw into the insertion position until the
surgical end effector has exited the distal end of the trocar port
whereupon the biasing means moves the upper jaw into the primary
opened position; applying the actuation motion to the upper jaw to
move the upper jaw to the fully opened position; manipulating the
end effector such that the target tissue is positioned between the
upper and lower jaws; applying the another actuation motion to the
upper jaw to move the upper jaw into the fully clamped position;
and applying the firing motion to the firing member to cause the
firing member to travel from a starting position to an ending
position within the end effector.
19. The surgical method of claim 18 wherein the firing member
comprises a body that includes an upper portion that is configured
to engage the upper jaw and a lower portion that is configured to
engage the lower jaw and wherein the upper portion is movable
relative to the lower portion between a collapsed position when the
surgical end effector has the smallest cross-sectional shape and an
operating position when the surgical end effector has exited the
trocar port to enable the firing member to move from the starting
position to the ending position upon application of the firing
motion thereto.
20. The surgical method of claim 19 wherein the upper portion of
the firing member includes a tissue cutting edge.
Description
BACKGROUND
[0001] The present invention relates to surgical instruments and,
in various embodiments, to surgical cutting and stapling
instruments and staple cartridges therefor that are designed to cut
and staple tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] The various 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:
[0003] FIG. 1 is a perspective view of one surgical instrument
arrangement;
[0004] FIG. 2 is an enlarged perspective view of an end effector
and a portion of the elongated shaft assembly of the surgical
instrument of FIG. 1;
[0005] FIG. 3 is an exploded perspective view of the end effector
and portion of the elongated shaft assembly of FIGS. 1 and 2;
[0006] FIG. 4 is a perspective view of a portion of a distal anvil
portion of the end effector of FIGS. 2 and 3;
[0007] FIG. 5 is a lower perspective view of a proximal anvil
mounting tube arrangement of the end effector of FIGS. 2 and 3;
[0008] FIG. 6 is an elevational view of the distal end of the
proximal anvil mounting tube of FIG. 5;
[0009] FIG. 7 is an end cross-sectional view of the distal anvil
portion and proximal anvil mounting tube assembled together;
[0010] FIG. 8 is an exploded perspective assembly view of a portion
of the handle assembly of the surgical instrument of FIG. 1;
[0011] FIG. 9 is another perspective view of the end effector and
elongated shaft assembly of FIG. 2 with the anvil assembly in an
open position;
[0012] FIG. 10 is a perspective view of portions of the elongated
shaft assembly, articulation system and firing system of the
surgical instrument of FIG. 1;
[0013] FIG. 11 is a side view of a portion of the articulation
system of the surgical instrument of FIG. 1 with portions thereof
shown in cross-section;
[0014] FIG. 12 is a cross-sectional view of the end effector and
elongated shaft assembly portion of FIGS. 2 and 9 with the anvil
assembly in a closed, but unfired position;
[0015] FIG. 13 is a cross-sectional view of the end effector and
elongated shaft assembly portion of FIGS. 2, 9 and 12 in an
articulated position and after the cutting head assembly has been
retracted to a starting position after being fired;
[0016] FIG. 14 is a partial perspective view of the end effector
and portion of the elongated shaft assembly after the cutting head
assembly has been retracted to a starting position after being
fired;
[0017] FIG. 15 is a partial perspective view of an another end
effector and elongated shaft assembly with the end effector in a
closed position;
[0018] FIG. 16 is a cross-sectional perspective view of the end
effector and elongated shaft assembly of FIG. 15;
[0019] FIG. 17 is an exploded perspective assembly view of the end
effector and elongated shaft assembly of FIGS. 15 and 16;
[0020] FIG. 18 is a cross-sectional perspective view of the end
effector and elongated shaft assembly of FIGS. 15-17;
[0021] FIG. 19 is an exploded perspective assembly view of a handle
assembly portion of a surgical instrument;
[0022] FIG. 20 is a perspective view of another surgical
instrument;
[0023] FIG. 21 is a partial perspective view of the end effector of
the surgical instrument of FIG. 20 in a closed position;
[0024] FIG. 22 is a cross-sectional perspective view of the end
effector of FIG. 21;
[0025] FIG. 23 is an exploded perspective assembly view of the end
effector of FIGS. 21 and 22;
[0026] FIG. 24 is a cross-sectional elevational view of the end
effector of FIGS. 21-23 with the anvil assembly thereof in an open
position;
[0027] FIG. 25 is another cross-sectional view of the end effector
of FIGS. 21-24 in an articulated position and with the anvil
assembly thereof in an open position;
[0028] FIG. 26 is another cross-sectional view of the end effector
of FIG. 24 after the anvil has been closed onto tissue;
[0029] FIG. 27 is a perspective view of another surgical
instrument;
[0030] FIG. 28 is a partial perspective view of the end effector of
the surgical instrument of FIG. 27 in a closed position;
[0031] FIG. 29 is an exploded perspective assembly view of the end
effector and elongated shaft assembly of FIGS. 27 and 28;
[0032] FIG. 30 is a cross-sectional perspective view of the end
effector of FIGS. 28 and 29;
[0033] FIG. 31 is a cross-sectional side view of the end effector
of FIGS. 28-30 with the anvil assembly thereof in a closed
position;
[0034] FIG. 32 is another cross-sectional side view of the end
effector of FIGS. 28-31 with the anvil assembly thereof in an open
position;
[0035] FIG. 33 is a cross-sectional side view of the end effector
of FIGS. 28-32 in an articulated position and with the anvil
assembly thereof in an open position;
[0036] FIG. 34 is a perspective assembly view of portions of the
articulation system and firing system of the surgical instrument of
FIG. 27;
[0037] FIG. 35 is a side view of a portion of the articulation
system of FIG. 34 with portions thereof shown in cross-section;
[0038] FIG. 36 is a perspective view of another surgical
instrument;
[0039] FIG. 37 is a partial perspective view of the end effector of
the surgical instrument of FIG. 36 in a closed position;
[0040] FIG. 38 is a distal exploded perspective assembly view of
the end effector and elongated shaft assembly of FIGS. 36 and
37;
[0041] FIG. 39 is a proximal exploded perspective assembly view of
the end effector and elongated shaft assembly of FIGS. 36-38;
[0042] FIG. 40 is a cross-sectional end view of a portion of the
end effector of FIGS. 36-39;
[0043] FIG. 41 is a partial perspective view of portions of the end
effector of FIGS. 36-40 with the anvil assembly thereof in an open
position;
[0044] FIG. 42 is another partial perspective view of portions of
the end effector of FIGS. 36-41 with the anvil assembly thereof in
an open position;
[0045] FIG. 43 is a partial side view of a cutting beam head in its
uncompressed state;
[0046] FIG. 44 is another partial side view of the cutting beam
head of FIG. 43 in its maximum compressed state;
[0047] FIG. 45 is a cross-sectional end view of an end effector and
a cutting beam head of FIGS. 43 and 44 in its maximum compressed
state;
[0048] FIG. 46 is another cross-sectional view of the end effector
and cutting beam head of FIG. 45 after the end effector has cut and
stapled tissue;
[0049] FIG. 47 is a perspective view of another surgical
instrument;
[0050] FIG. 48 is an exploded perspective view of another surgical
end effector of the present invention;
[0051] FIG. 49 is an exploded assembly view of the handle assembly
of the surgical instrument of FIG. 47;
[0052] FIG. 50 is an exploded assembly view of an elongated shaft
assembly of the surgical instrument of FIGS. 47-49;
[0053] FIG. 51 is a cross-sectional side view of a portion of the
surgical instrument of FIGS. 47-50 inserted through a portion of a
trocar port;
[0054] FIG. 52 is another cross-sectional side view of the surgical
instrument of FIG. 51 after it has exited through the trocar port
inside the patient;
[0055] FIG. 53 is another cross-sectional side view of the surgical
instrument of FIGS. 51 and 52 after the anvil assembly has been
moved to an open position;
[0056] FIG. 54 is another cross-sectional side view of the surgical
instrument of FIGS. 51-53 with the anvil in the closed firing
position;
[0057] FIG. 55 is a cross-sectional side view of a portion of
another surgical instrument inserted through a portion of a trocar
port;
[0058] FIG. 56 is another cross-sectional side view of the surgical
instrument of FIG. 55 after the end effector has passed through the
trocar port into the patient;
[0059] FIG. 57 is a perspective view of one form of a control
insert;
[0060] FIG. 58 is a cross-sectional side view of a portion of
another end effector inserted through a portion of a trocar
port;
[0061] FIG. 59 is another cross-sectional side view of the end
effector of FIG. 58 exiting the trocar port;
[0062] FIG. 60 is a cross-sectional view of another end effector
arrangement;
[0063] FIG. 61 is a cross-sectional view of another end effector
arrangement;
[0064] FIG. 62 is a cross-sectional side view of a portion of
another end effector and distal closure tube arrangement wherein a
portion of the end effector is inserted through a portion of a
trocar port;
[0065] FIG. 63 is another cross-sectional side view of the end
effector of FIG. 62 exiting the trocar port;
[0066] FIG. 64 is a perspective view of one form of a surgical
instrument of the present invention;
[0067] FIG. 65 is an exploded perspective view of one form of
surgical end effector of the present invention;
[0068] FIG. 66 is an exploded perspective view of a portion of the
surgical instrument of FIG. 64;
[0069] FIG. 67 is an exploded perspective assembly view of another
portion of the surgical instrument of FIG. 64;
[0070] FIG. 68 is an exploded perspective assembly view of a
portion of the elongated shaft assembly of the surgical instrument
of FIG. 64;
[0071] FIG. 69 is a perspective view of the surgical end effector
of FIG. 65 and a distal closure tube segment;
[0072] FIG. 70 is a rear perspective view of a portion of an anvil
embodiment;
[0073] FIG. 70A is an exploded perspective assembly view of another
surgical end effector assembly;
[0074] FIG. 70B is a rear perspective view of a portion of another
anvil assembly embodiment and another closure tube segment
embodiment;
[0075] FIG. 70C is a perspective view of a portion of another anvil
assembly and another distal closure tube segment;
[0076] FIG. 70D is an exploded perspective assembly view of another
surgical end effector embodiment;
[0077] FIG. 70E is an exploded perspective assembly view of another
surgical end effector embodiment;
[0078] FIG. 71 is a side cross-sectional view of a surgical end
effector and distal closure tube segment with the anvil assembly in
an open position;
[0079] FIG. 72 is another side cross-sectional view of the surgical
end effector and distal closure tube segment of FIG. 71;
[0080] FIG. 73 is a perspective view of a portion of the surgical
instrument of FIG. 64 with a portion of the handle housing
removed;
[0081] FIG. 74 is a perspective view of a portion of a firing drive
system;
[0082] FIG. 75 is a perspective view of an intermediate portion of
an elongated shaft assembly embodiment;
[0083] FIG. 76 is an elevational view of the distal end of the
intermediate shaft portion of FIG. 75;
[0084] FIG. 77 is side elevational view of the intermediate shaft
portion of FIGS. 74 and 75;
[0085] FIG. 78 is a plan view of the intermediate shaft portion of
FIGS. 74-77;
[0086] FIG. 79 is an enlarged side elevational view of portions of
adjacent ribs of the intermediate shaft portion of FIGS. 74-78;
[0087] FIG. 80 is a plan view of another intermediate shaft portion
embodiment;
[0088] FIG. 81 is a side elevational view of the intermediate shaft
portion of FIG. 80;
[0089] FIG. 82 is a cross-sectional plan view of the intermediate
shaft portion of FIGS. 80 and 81 articulated into a substantial
U-shape;
[0090] FIG. 83 is a perspective view of one surgical instrument
arrangement;
[0091] FIG. 84 is an exploded perspective assembly view of a
surgical end effector arrangement;
[0092] FIG. 85 is a side elevational view of an anvil;
[0093] FIG. 86 is a side cross-sectional view of an end effector
and portion of an elongated shaft assembly with the end effector
shown in an unarticulated position in solid lines and the end
effector shown in articulated positions in broken lines;
[0094] FIG. 87 is another side cross-sectional view of an end
effector and portion of an elongated shaft assembly with the anvil
in a closed position and the cutting head in an end position after
being fired distally through the staple cartridge;
[0095] FIG. 88 is another side cross-sectional view of the end
effector and elongated shaft assembly portion of FIG. 87 after the
cutting head has been retracted proximally back to its starting
position;
[0096] FIG. 89 is another side cross-sectional view of an end
effector and portion of an elongated shaft assembly with the anvil
in an open position and the cutting head in a starting
position;
[0097] FIG. 90 is an enlarged cross-sectional view of the end
effector and portion of the elongated shaft assembly of FIG.
89;
[0098] FIG. 91 is a cross-sectional perspective view of the end
effector and portion of the elongated shaft assembly of FIG.
89;
[0099] FIG. 92 is a perspective assembly view of an end effector
and elongated shaft assembly;
[0100] FIG. 93 is a cross-sectional view of a distal portion of an
elongated shaft assembly;
[0101] FIG. 94 is a cross-sectional view of a proximal portion of
the elongated shaft assembly of FIG. 11 along with a portion of an
articulation system;
[0102] FIG. 95 is a perspective view of an elongated shaft assembly
and end effector;
[0103] FIG. 96 is a partial perspective exploded view of a handle
assembly;
[0104] FIG. 97 is a perspective view of a surgical instrument
arrangement of the present invention;
[0105] FIG. 98 is a perspective view of an exemplary loading unit
that may be employed in connection with various surgical
instruments disclosed herein;
[0106] FIG. 99 is another partial cross-sectional view of a portion
of the loading unit depicted in FIG. 98;
[0107] FIG. 100 is an exploded perspective view of the loading unit
of FIGS. 98 and 99;
[0108] FIG. 101 is a partial perspective view of a portion of a
carrier and an articulation ball assembly embodiment;
[0109] FIG. 102 is a perspective view of an articulation tube
embodiment;
[0110] FIG. 103 is a partial cross-sectional view of a loading unit
of FIGS. 98-100;
[0111] FIG. 104 is another cross-sectional view of the loading unit
of FIG. 103 in an unarticulated position;
[0112] FIG. 105 is another cross-sectional view of the loading unit
of FIGS. 103 and 104 with the carrier and anvil assembly
articulated as a unit in a second direction;
[0113] FIG. 106 is a partial perspective view of a loading unit and
a portion of an elongated shaft assembly prior to commencing a
coupling operation between the loading unit and a distal end of the
elongated shaft assembly;
[0114] FIG. 107 is another perspective view of portions of the
loading unit and elongated shaft assembly of FIG. 106 after being
coupled together;
[0115] FIG. 108 is a partial exploded perspective view of portions
of the elongated shaft assembly, a coupling assembly and the
loading unit of FIG. 106;
[0116] FIG. 109 is another partial exploded perspective view of the
shaft assembly, the coupling assembly and the loading unit of FIG.
106;
[0117] FIG. 110 is a perspective view of a distal attachment
portion of the loading unit of FIG. 106;
[0118] FIG. 111 is another perspective view of the distal
attachment portion of the loading unit of FIG. 106;
[0119] FIG. 112 is a perspective view of a proximal attachment
portion of the elongated shaft assembly of FIG. 109;
[0120] FIG. 113 is another perspective view of the proximal
attachment portion of the elongated shaft assembly of FIG. 109;
[0121] FIG. 114 is a perspective view of the collar and a firing
shaft arrangement;
[0122] FIG. 115 is a partial perspective, cross-section view of the
loading unit, the coupling assembly, and a proximal end of the
elongated shaft assembly of FIG. 109, depicting the loading unit
attached to the elongated shaft assembly;
[0123] FIG. 116 is a partial elevation, cross-sectional view of the
loading unit, the coupling assembly, and the elongated shaft
assembly of FIG. 109, depicting the loading unit unattached to the
elongated shaft assembly;
[0124] FIG. 117 is a partial elevation, cross-sectional view of the
loading unit, the coupling assembly and the elongated shaft
assembly of FIG. 109, depicting the loading unit attached to the
elongated shaft assembly;
[0125] FIG. 118 is an elevational view of the coupling assembly and
the elongated shaft assembly of FIG. 109 taken along the plane
indicated in FIG. 115;
[0126] FIG. 119 is a perspective, partial cross-sectional view of
the loading unit, the coupling assembly, and the elongated shaft
assembly of FIG. 109, depicting the loading unit unattached to the
elongated shaft assembly, and further depicting the coupling collar
in an initial orientation relative to the elongated shaft
assembly;
[0127] FIG. 120 is a perspective, partial cross-sectional view of
the loading unit, the coupling assembly, and the elongated shaft
assembly of FIG. 109, depicting the loading unit unattached to the
shaft, and further depicting the coupling collar in the initial
orientation relative to the elongated shaft assembly;
[0128] FIG. 121 is a perspective, partial cross-sectional view of
the loading unit, the coupling assembly, and the elongated shaft
assembly of FIG. 109, depicting the loading unit entering the
elongated shaft assembly, and further depicting the coupling collar
in the initial orientation relative to the elongated shaft
assembly;
[0129] FIG. 122 is a perspective, partial cross-sectional view of
the loading unit, the coupling assembly, and the elongated shaft
assembly of FIG. 109, depicting the loading unit entering the
elongated shaft assembly, and further depicting the coupling collar
in a secondary, rotated orientation relative to the elongated shaft
assembly;
[0130] FIG. 123 is a perspective, partial cross-sectional view of
the loading unit, the coupling assembly, and the elongated shaft
assembly of FIG. 109, depicting the loading unit entering the
elongated shaft assembly, and further depicting the coupling collar
in the secondary, rotated orientation relative to the elongated
shaft assembly;
[0131] FIG. 124 is a perspective, partial cross-sectional view of
the loading unit, the coupling assembly, and the elongated shaft
assembly of FIG. 109, depicting the loading unit fully inserted
into the elongated shaft assembly, and further depicting the
coupling collar in the secondary, rotated orientation relative to
the elongated shaft assembly;
[0132] FIG. 125 is a perspective, partial cross-sectional view of
the loading unit, the coupling assembly, and the elongated shaft
assembly of FIG. 109, depicting the loading unit fully inserted
into the elongated shaft assembly, and further depicting the
coupling collar in the initial orientation relative to the
elongated shaft assembly;
[0133] FIG. 126 is a perspective, partial cross-sectional view of
the loading unit, the coupling assembly, and the elongated shaft
assembly of FIG. 109, depicting the loading unit fully inserted
into the elongated shaft assembly, and further depicting the
coupling collar in the initial orientation relative to the
elongated shaft assembly;
[0134] FIG. 127 is a perspective view of a surgical instrument
according to various embodiments of the present disclosure;
[0135] FIG. 128 is an exploded perspective view of a handle
assembly of the surgical instrument of FIG. 127 according to
various embodiments of the present disclosure;
[0136] FIG. 129 is an exploded perspective view of an end effector
of the surgical instrument of FIG. 127 according to various
embodiments of the present disclosure;
[0137] FIG. 130 is a perspective view of a staple cartridge of the
end effector of FIG. 129 according to various embodiments of the
present disclosure;
[0138] FIG. 131 is a cross-sectional perspective view of the staple
cartridge of FIG. 130 taken along the plane indicated in FIG. 130
according to various embodiments of the present disclosure;
[0139] FIG. 132 is a perspective view of the staple depicted in the
staple cartridge of FIG. 130 according to various embodiments of
the present disclosure;
[0140] FIG. 133 is a front elevation view of the staple of FIG.
132;
[0141] FIG. 134 is a rear elevation view of the staple of FIG.
132;
[0142] FIG. 135 is a top plan view of the staple of FIG. 132;
[0143] FIG. 136 is a bottom plan view of the staple of FIG.
132;
[0144] FIG. 137 is a right elevation view of the staple of FIG.
132;
[0145] FIG. 138 is a left elevation view of the staple of FIG.
132;
[0146] FIG. 139 is a perspective view of the staple of FIG.
132;
[0147] FIG. 140 is an elevation view of the staple of FIG. 132 and
a sled of the end effector of FIG. 129, depicting a leading surface
of the sled contacting an initial drive surface of the staple,
according to various embodiments of the present disclosure;
[0148] FIG. 141 is a perspective view of the staple and the sled of
FIG. 140, depicting the leading surface of the sled contacting the
initial drive surface of the staple;
[0149] FIG. 142 is an elevation view of the staple and the sled of
FIG. 140, depicting a trailing surface of the sled contacting a
secondary drive surface of the staple, according to various
embodiments of the present disclosure;
[0150] FIG. 143 is a perspective view of the staple and the sled of
FIG. 140, depicting the trailing surface of the sled contacting the
secondary drive surface of the staple;
[0151] FIGS. 144-147 are cross-sectional elevation views of the end
effector of FIG. 129, depicting a firing progression of staples
from the staple cartridge, according to various embodiments of the
present disclosure;
[0152] FIG. 148 is a cross-sectional elevation view of the staple
cartridge and the sleds of FIG. 129, depicting the staples in
unfired positions, according to various embodiments of the present
disclosure;
[0153] FIG. 149 is a cross-sectional perspective view of the
cartridge and the sleds of FIG. 148, depicting the staples in the
unfired positions depicted in FIG. 148;
[0154] FIG. 150 is a cross-sectional elevation view of the
cartridge and the sleds of FIG. 148, 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;
[0155] FIG. 151 is a cross-sectional perspective view of the
cartridge and the sleds of FIG. 148, depicting the proximal pair of
staples in the partially fired positions depicted in FIG. 150 and
the remaining staples in the unfired positions depicted in FIG.
150;
[0156] FIG. 152 is a cross-sectional elevation view of the
cartridge and the sleds of FIG. 148, 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;
[0157] FIG. 153 is a cross-sectional perspective view of the
cartridge and the sleds of FIG. 148, depicting the multiple pairs
of staples in the partially fired positions of FIG. 152 and the
proximal pair of staples in the partially deformed configurations
depicted in FIG. 152;
[0158] FIG. 154 is a cross-sectional elevation view of the
cartridge and the sleds of FIG. 148, 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;
[0159] FIG. 155 is a cross-sectional perspective view of the
cartridge and the sleds of FIG. 148, depicting the multiple pairs
of staples in the partially fired positions depicted in FIG. 154
and the proximal pair of staples in the partially deformed
configurations depicted in FIG. 154;
[0160] FIG. 156 is a cross-sectional elevation view of the
cartridge and the sleds of FIG. 148, 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;
[0161] FIG. 157 is a cross-sectional perspective view of the
cartridge and the sleds of FIG. 148, depicting the multiple pairs
of staples in the partially fired positions and in the partially
deformed configurations depicted in FIG. 156 and the proximal pair
of staples in the ejected positions and in the fully deformed
configurations depicted in FIG. 156;
[0162] FIGS. 158A-158C illustrate a method for forming staples from
a sheet of material according to various embodiments of the present
disclosure;
[0163] FIG. 159 is a perspective view of the staple formed from the
method depicted in FIGS. 158A-158C, according to various
embodiments of the present disclosure;
[0164] FIG. 160 is a plan view of the staple of FIG. 159;
[0165] FIG. 161 is a front elevation view of the staple of FIG.
159;
[0166] FIG. 162 is a side elevation view of the staple of FIG.
159;
[0167] FIG. 163 is a perspective view of a staple according to
various embodiments of the present disclosure;
[0168] FIG. 164 is a plan view of the staple of FIG. 163;
[0169] FIG. 165 is a front elevation view of the staple of FIG.
163;
[0170] FIG. 166 is a side elevation view of the staple of FIG.
163;
[0171] FIG. 167 is a perspective view of a staple according to
various embodiments of the present disclosure;
[0172] FIG. 168 is a plan view of the staple of FIG. 167;
[0173] FIG. 169 is a front elevation view of the staple of FIG.
167;
[0174] FIG. 170 is a side elevation view of the staple of FIG.
167;
[0175] FIG. 171 is a perspective view of a staple cartridge
according to various embodiments of the present disclosure;
[0176] FIG. 172 is a cross-sectional perspective view of the staple
cartridge of FIG. 171 taken along the plane indicated in FIG.
171;
[0177] FIG. 173 is a plan view of the staple cartridge of FIG.
171;
[0178] FIG. 174 is a perspective view of a staple according to
various embodiments of the present disclosure;
[0179] FIG. 175 is a plan view of the staple of FIG. 174;
[0180] FIG. 176 is a front elevation view of the staple of FIG.
174;
[0181] FIG. 177 is a side elevation view of the staple of FIG.
174;
[0182] FIG. 178 is a perspective view of a staple according to
various embodiments of the present disclosure;
[0183] FIG. 179 is a plan view of the staple of FIG. 178;
[0184] FIG. 180 is a front elevation view of the staple of FIG.
178;
[0185] FIG. 181 is a side elevation view of the staple of FIG.
178;
[0186] FIG. 182 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 130, depicting a staple in a
partially-fired position in a staple cavity, according to various
embodiments of the present disclosure;
[0187] FIG. 183 is a partial plan view of the staple cartridge of
FIG. 182, depicting the staple in the partially-fired position
depicted in FIG. 182;
[0188] FIG. 184 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 182, depicting the staple in the
partially-fired position depicted in FIG. 182;
[0189] FIG. 185 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 182, depicting the staple in another
partially-fired position, according to various embodiments of the
present disclosure;
[0190] FIG. 186 is a partial, plan view of the staple cartridge of
FIG. 182, depicting the staple in the partially-fired position
depicted in FIG. 185;
[0191] FIG. 187 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 182, depicting the staple in the
partially-fired position depicted in FIG. 185;
[0192] FIG. 188 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 182, depicting the staple in an ejected
position and in a deformed configuration, according to various
embodiments of the present disclosure;
[0193] FIG. 189 is a partial plan view of the staple cartridge of
FIG. 182, depicting the staple in the ejected position and in the
deformed configuration depicted in FIG. 188;
[0194] FIG. 190 is a partial, cross-sectional elevation view of the
staple cartridge of FIG. 182, depicting the staple in the ejected
position and the deformed configuration depicted in FIG. 188;
[0195] FIG. 191 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;
[0196] FIG. 192 is a plan view of a first portion of the fastener
firing actuator of FIG. 191;
[0197] FIG. 193 is an elevational view of the first portion of FIG.
192;
[0198] FIG. 194 is a plan view of a second portion of the fastener
firing actuator of FIG. 191;
[0199] FIG. 195 is an elevational view of the second portion of
FIG. 194;
[0200] FIG. 196 is a cross-sectional view of the end effector of
FIG. 191 illustrating the firing actuator in an unfired, unextended
condition;
[0201] FIG. 197 is a cross-sectional view of the end effector of
FIG. 191 illustrating the firing actuator in an extended
condition;
[0202] FIG. 198 is a cross-sectional view of the end effector of
FIG. 191 illustrating the firing actuator in an extended, advanced
condition;
[0203] FIG. 199 is a cross-sectional view of the end effector of
FIG. 191 illustrating an anvil of the end effector in an open
position and the firing actuator in an unfired, unextended
condition;
[0204] FIG. 200 is a cross-sectional view of the end effector of
FIG. 191 illustrating the anvil in a closed position and the firing
actuator in an unfired, unextended condition;
[0205] FIG. 201 is a cross-sectional perspective view of the end
effector of FIG. 191 illustrated in the configuration depicted in
FIG. 199;
[0206] FIG. 202 is a cross-sectional view of the end effector of
FIG. 191 illustrated in the configuration depicted in FIG. 200;
[0207] FIG. 203 is a cross-sectional view of the end effector of
FIG. 191 illustrating the firing actuator in an extended condition
and, in addition, a knife member in an unadvanced position;
[0208] FIG. 204 is a cross-sectional view of the end effector of
FIG. 191 illustrating the firing actuator in an advanced, extended
condition and the knife member in an advanced position;
[0209] FIG. 205 is a cross-sectional perspective view of the end
effector of FIG. 191 illustrated in the configuration depicted in
FIG. 204;
[0210] FIG. 206 is a partial cross-sectional plan view of the end
effector of FIG. 191 illustrated in a fully-fired condition;
[0211] FIG. 207 is a cross-sectional elevational view of the end
effector of FIG. 191 illustrated in the configuration depicted in
FIG. 206;
[0212] FIG. 208 is a cross-sectional perspective view of the end
effector of FIG. 191 illustrated in the configuration depicted in
FIG. 206;
[0213] FIG. 209 is a cross-sectional elevational view of the end
effector of FIG. 191 illustrating the knife member in a retracted
position;
[0214] FIG. 210 is a cross-sectional perspective view of the end
effector of FIG. 191 illustrated in the configuration depicted in
FIG. 209;
[0215] FIG. 211 is a perspective view of the firing member of the
end effector of FIG. 191 illustrated in the unextended
configuration depicted in FIG. 200;
[0216] FIG. 212 is a perspective view of the firing member of the
end effector of FIG. 191 illustrated in the extended configuration
depicted in FIG. 203;
[0217] FIG. 213 is a perspective view of the firing member of the
end effector of FIG. 191 illustrated in a configuration just prior
to the fully-fired configuration depicted in FIG. 206;
[0218] FIG. 214 is a perspective view of the firing member of the
end effector of FIG. 191 illustrated in the fully-fired
configuration depicted in FIG. 206;
[0219] FIG. 215 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;
[0220] FIG. 216 is a cross-sectional view of the end effector of
FIG. 215 illustrating the firing actuator in a partially fired
position;
[0221] FIG. 217 is a plan view of a staple cartridge body of the
end effector of FIG. 215;
[0222] FIG. 218 is a perspective view of a firing actuator for use
with the cartridge body of FIG. 217;
[0223] FIG. 219 is a perspective view of the cartridge body of FIG.
217; and
[0224] FIG. 220 is a cross-sectional view of the cartridge body of
FIG. 217 taken along line 220-220 in FIG. 219.
[0225] Corresponding reference characters indicate corresponding
parts throughout the several views. The exemplifications set out
herein illustrate preferred embodiments of the invention, in one
form, and such exemplifications are not to be construed as limiting
the scope of the invention in any manner.
DETAILED DESCRIPTION
[0226] Applicant of the present application also owns the following
patent applications that were filed on even date herewith and which
are each herein incorporated by reference in their respective
entireties:
[0227] U.S. patent application entitled SURGICAL STAPLES AND STAPLE
CARTRIDGES, Attorney Docket No. END7341USNP/130301;
[0228] U.S. patent application entitled SURGICAL STAPLES AND STAPLE
CARTRIDGES, Attorney Docket No. END7331USNP/130304:
[0229] U.S. patent application entitled SURGICAL STAPLES AND
METHODS FOR MAKING THE SAME, Attorney Docket No.
END7335USNP/130305;
[0230] U.S. patent application entitled SURGICAL STAPLES, STAPLE
CARTRIDGES AND SURGICAL END EFFECTORS, Attorney Docket No.
END7332USNP/130306;
[0231] U.S. Design patent application entitled SURGICAL FASTENER,
Attorney Docket No. END7338USDP/130307;
[0232] U.S. patent application entitled FASTENER CARTRIDGE
COMPRISING AN EXTENDABLE FIRING MEMBER, Attorney Docket No.
END7344USNP/130308;
[0233] 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;
[0234] U.S. patent application entitled FASTENER CARTRIDGE
COMPRISING A FIRING MEMBER INCLUDING FASTENER SURFACES, Attorney
Docket No. END7340USNP/130310;
[0235] U.S. patent application entitled SURGICAL INSTRUMENTS WITH
ARTICULATABLE SHAFT ARRANGEMENTS, Attorney Docket No.
END7343USNP/130300;
[0236] U.S. patent application entitled ARTICULATABLE SURGICAL
INSTRUMENTS WITH SEPARATE AND DISTINCT CLOSING AND FIRING SYSTEMS,
Attorney Docket No. END7333USNP/130322;
[0237] U.S. patent application entitled SURGICAL CUTTING AND
STAPLING INSTRUMENTS WITH INDEPENDENT JAW CONTROL FEATURES,
Attorney Docket No. END7336USNP/130303;
[0238] U.S. patent application entitled SURGICAL CUTTING AND
STAPLING INSTRUMENTS WITH ARTICULATABLE END EFFECTORS, Attorney
Docket No. END7334USNP/130312; and
[0239] U.S. patent application entitled MODULAR SURGICAL
INSTRUMENTS, Attorney Docket No. END7342USNP/130311.
[0240] 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.
[0241] 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.
[0242] 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.
[0243] 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.
[0244] Turning to the Drawings wherein like numerals denote like
components throughout the several views, FIG. 1 depicts a surgical
instrument 10010 that is capable of practicing several unique
benefits of the present invention. The surgical instrument 10010 is
designed to manipulate and/or actuate various forms and sizes of
end effectors 10012 that are operably attached to an elongated
shaft assembly 10100 of the surgical instrument. In the depicted
embodiment, for example, the end effector 10012 comprises a
surgical stapling device that has openable and closable jaws 10013
and 10015. More specifically, the end effector 10012 includes an
elongated channel 10014 that forms a lower jaw 10013 of the end
effector 10012. See FIG. 2. In the illustrated arrangement, the
elongated channel 10014 is configured to operably support a staple
cartridge 10030 and also movably supports an anvil assembly 10020
that functions as an upper jaw 10015 of the end effector 10012.
[0245] In various implementations, the end effector 10012 is
configured to be coupled to an elongated shaft assembly 10100 that
protrudes from a handle assembly or housing 10400. See FIG. 1. The
end effector 10012 (when closed) and the elongated shaft assembly
10100 may have similar cross-sectional shapes and be sized to
operably pass through a trocar tube or working channel in another
form of access instrument. As used herein, the term "operably pass"
means that the end effector and at least a portion of the elongated
shaft assembly 10100 may be inserted through or passed through the
channel or tube opening and can be manipulated therein as needed to
complete the surgical stapling procedure. In some embodiments, for
example, when in a closed position, the jaws 10013 and 10015 of the
end effector 10012 may provide the end effector with a roughly
circular cross-sectional shape that facilitates its passage through
a circular passage/opening. However, the end effectors of various
embodiments of the present invention, as well as the elongated
shaft assembly embodiments, could conceivably be provided with
other cross-sectional shapes that could otherwise pass through
access passages and openings that have non-circular cross-sectional
shapes. Thus, an overall size of a cross-section of a closed end
effector will be related to the size of the passage or opening
through which it is intended to pass. Thus, one end effector for
example, may be referred to as a "5 mm" end effector which means it
can operably pass through an opening that is at least approximately
5 mm in diameter.
[0246] In various implementations, the elongated shaft assembly
10100 may have an outer diameter that is substantially the same as
the outer diameter of the end effector 10012 when the end effector
10012 is in a closed position. For example, a 5 mm end effector may
be coupled to an elongated shaft assembly 10100 that has 5 mm
cross-sectional diameter. However, as the present Detailed
Description proceeds, it will become apparent that various
embodiments of the present may be effectively used in connection
with different sizes of end effectors. For example, a 10 mm end
effector may be attached to an elongated shaft that has a 5 mm
cross-sectional diameter. Conversely, for those applications
wherein a 10 mm or larger access opening or passage is provided,
the elongated shaft assembly 10100 may have a 10 mm (or larger)
cross-sectional diameter, but may also be able to actuate a 5 mm or
10 mm end effector. Accordingly, the outer shaft assembly 10100 may
have an outer diameter that is the same as or is different from the
outer diameter of a closed end effector 10012 attached thereto.
[0247] Referring now to FIGS. 2 and 3, the elongated channel 10014
may comprise an elongated trough 10700 that is configured to
removably support a surgical staple cartridge 10030 thereon. In
various implementations, for example, the elongated channel 10014
may be fabricated from, for example, 300 & 400 Series, 17-4
& 17-7 stainless steel, titanium, etc. and be formed with
spaced side walls 10702. As will be discussed in further detail
below, the anvil assembly 10020 may include a distal anvil portion
10800 and a proximal anvil mounting tube 10820. The distal anvil
portion 10800 may, for the most part, be substantially coextensive
with the portion of the elongated channel 10014 that supports the
staple cartridge 10030. The distal anvil portion 10800 may be
fabricated from, for example, 300 & 400 Series, 17-4 & 17-7
stainless steel, titanium, etc. and have a staple forming
undersurface, generally labeled as 10022 that has a plurality of
staple forming pockets (not shown) formed therein.
[0248] The elongated channel 10014 may be configured to support a
variety of different surgical staple cartridges that are designed
to be "implanted" within the patient. For example, the implantable
surgical staple cartridge 10030 may comprise any of the various
surgical staple cartridge arrangements disclosed in U.S. Patent
Application Publication No. US 2012/0080484, filed on Sep. 30,
2010, and entitled SURGICAL STAPLING INSTRUMENT WITH A VARIABLE
STAPLE FORMING SYSTEM, the entire disclosure of which is hereby
incorporated by reference herein. In at least one implementation
for example, the staple cartridge 10030 includes a body portion
10031 that consists of a compressible hemostat material such as,
for example, oxidized regenerated cellulose ("ORC") or a
bio-absorbable foam in which lines of unformed metal staples 10032
are supported. In at least some embodiments, in order to prevent
the staple from being affected and the hemostat material from being
activated during the introduction and positioning process, the
entire cartridge may be coated or wrapped in a biodegradable film
such as a polydioxanon film sold under the trademark PDS.RTM. or
with a Polyglycerol sebacate (PGS) film or other biodegradable
films formed from PGA (Polyglycolic acid, marketed under the trade
mark Vicryl), PCL (Polycaprolactone), PLA or PLLA (Polylactic
acid), PHA (polyhydroxyalkanoate), PGCL (poliglecaprone 25, sold
under the trademark Monocryl) or a composite of PGA, PCL, PLA, PDS
that would be impermeable until ruptured. The body 10031 of staple
cartridge 10030 is sized to be removably supported within the
elongated channel 10014 as shown such that each staple 10032
therein is aligned with corresponding staple forming pockets in the
distal anvil portion 10800 when the distal anvil portion 10800 is
driven into forming contact with the staple cartridge 10030.
[0249] Referring to FIG. 3, the elongated channel 10014 may further
include a boxed mounting end 10710 that includes a pair of spaced
side walls 10712 and a top wall 10714. In at least one
implementation, the end effector 10012 is configured to be
articulated relative to the elongated shaft assembly 10100 about an
articulation and pivot axis A-A about which the anvil assembly
10020 is pivoted relative to the elongated channel 10014. The
elongated shaft assembly 10100 defines a longitudinal tool axis
LT-LT. The articulation and pivot axis A-A is transverse to the
longitudinal tool axis LT-LT. The elongated shaft assembly 10100
comprises a hollow outer shaft 10300 and serves to function as the
shaft spine of the elongated shaft assembly 10100. The proximal end
of the elongated shaft assembly 10100 may be rotatably supported by
the handle assembly 10400 so that the clinician may selectively
rotate the elongated shaft assembly 10100 and the end effector
10012 attached thereto about the longitudinal tool axis LT-LT. The
distal end 10302 of the outer shaft 10300 is formed with a clevis
arrangement 10304 that comprises a pair of spaced attachment tabs
10306. Each attachment tab 10306 has a mounting hole 10308 therein
that is adapted to receive a corresponding pivot pin 10310
therethrough.
[0250] In various implementations, the anvil assembly 10020
includes a distal anvil portion 10800 and a proximal anvil mounting
tube 10820. As can be seen in FIGS. 2, 3 and 5, the proximal anvil
mounting tube 10820 includes a body portion 10821 that has a
proximally extending clevis portion 10822 that is formed by two
proximally extending anvil attachment tabs 10824. Each anvil
attachment tab 10824 has an anvil mounting hole 10826 therethrough
that is configured to be pivotally journaled on the pivot pins
10310. In various implementations, the distal anvil portion 10800
is configured to be coupled to the proximal anvil mounting tube
10820 such that the distal anvil portion 10800 may "float" relative
to the proximal anvil mounting tube 10820. Referring to FIG. 5, the
body 10821 of the proximal anvil mounting tube 10820 may be formed
with a series of opposed, vertically-extending opened ended grooves
10830. Grooves 10830 are sized to slidably receive therein
corresponding vertically extending attachment lugs 10812 formed on
a proximal end 10810 of the distal anvil portion 10800. See FIG. 4.
Each attachment lug 10812 has a stop lug 10814 formed thereon that
is sized to be movably received in a stop groove 10832 formed in
each groove 10830 as shown in FIG. 5. Each stop groove 10832 has a
closed end 10834. The proximal end 10810 of the distal anvil
portion 10800 is movably coupled to the proximal anvil mounting
tube 10820 by aligning the attachment lugs 10812 with the open
bottom ends of the corresponding grooves 10830 and then inserting
the proximal end upward into the proximal anvil mounting tube
10820. This assembly may be completed before the anvil assembly
10020 is pivotally journaled on the pivot pins 10310. Once
assembled and pivotally coupled to the elongated channel 10014, the
distal anvil portion 10800 will be unable to slidably disengage the
proximal anvil mounting tube 10820 due to contact with elongated
channel 10014. The stop lugs 10812 will likewise contact the closed
ends 10834 of the corresponding stop groove 10832 to prevent the
proximal end 10810 of the distal anvil portion 10800 from becoming
disconnected from the proximal anvil mounting tube 10820. See FIG.
7. As can be seen in FIG. 7, the distal anvil portion 10820 may
move upward (arrow "U") and downward (arrow "D") relative to the
proximal anvil mounting tube 10820. Such range of vertical travel
of the distal anvil portion 10800 relative to the proximal anvil
mounting portion 10820 may be referred to herein as "floating"
vertical travel or movement.
[0251] Referring now to FIG. 8, initial closure of the anvil
assembly 10020 relative to the elongated channel assembly 10014 and
the surgical staple cartridge 10030 operably supported therein may
be accomplished by a unique and novel closure system, generally
designated as 10110. The closure system 10110 may also be referred
to herein as the "second jaw closure system". In one
implementation, the closure system 10110 includes an anvil closure
rod 10112 that has a proximal end 10114 that has a flanged end
10116 that is configured to be rotatably attached to a closure
carriage 10420 of the closure system that is operably supported
within the housing assembly 10400. See FIG. 8. The anvil closure
rod 10112 may also be referred to herein as the "second jaw
actuator bar 10112." The closure carriage and firing system may be
similar in construction and operation to the closure carriage and
closure system disclosed in U.S. Patent Application Publication No.
2012/0074200, entitled SURGICAL INSTRUMENT WITH SELECTIVELY
ARTICULATABLE END EFFECTOR, which was filed on Sep. 23, 2011, the
entire disclosure of which is hereby incorporated by reference
herein.
[0252] Referring again to FIG. 8, the closure carriage 10420 may
comprise two carriage segments 10422 (only one is illustrated) that
are interconnected together by adhesive, snap features, screws,
etc. As used herein, the term "snap feature" includes, but is not
limited to, for example, a tab that has a protrusion thereon that
is configured to retainingly engage a corresponding mating portion
of another component. Such features may be designed to releasably
engage the mating portion or it may not be designed or intended to
be removed. In at least one form, the closure carriage 10420 has a
distal end 10424 that has a groove arrangement 10426 that is
adapted to receive the flanged end 10116 of the anvil closure rod
10112. Such arrangement serves to attach the proximal end 10114 of
the anvil closure rod 10112 to the closure carriage 10420 while
facilitating its selective rotation of the anvil closure rod 10112
relative to the closure carriage 10420. Therefore, the elongated
shaft assembly 10100 and the end effector 10012 that is operably
coupled thereto may be selectively rotated about the longitudinal
tool axis LT-LT relative to the housing assembly 10400.
[0253] Still referring to FIG. 8, in various implementations, the
housing assembly 10400 comprises a pistol-shaped handle housing
that may be fabricated in two or more pieces for assembly purposes.
For example, the housing assembly 10400 as shown comprises a right
hand case member 10402 and a left hand case member 10404 (FIG. 1)
that are molded or otherwise fabricated from a polymer or plastic
material and are designed to mate together. Such case members 10402
and 10404 may be attached together by snap features, pegs and
sockets molded or otherwise formed therein and/or by adhesive,
screws, etc. When assembled, the housing assembly 10400 movably
supports the closure carriage 10420 for selective axial travel
therein in response to actuation motions from a trigger, generally
designated as 10430. As the present Detailed Description proceeds,
however, it will be understood that the various unique and novel
aspects and attributes of the various implementations of the
present invention may be effectively attained when employed with
robotically controlled or otherwise remotely controlled systems.
Thus, the term "housing" or "housing assembly" may also encompass a
housing or similar portion of a robotic or automated control system
that houses or otherwise operably supports at least one drive
system that is configured to generate and apply at least one
control motion which could be used to actuate various forms of
surgical end effectors attached thereto. For example, various
implementations of the surgical instruments described herein may be
used in connection with those robotic systems and arrangements
disclosed in U.S. patent application Ser. No. 13/536,323, entitled
ROBOTICALLY POWERED SURGICAL DEVICE WITH MANUALLY ACTUATABLE
REVERSING SYSTEM, and filed Jun. 28, 2012, the entire disclosure of
which is hereby incorporated by reference herein.
[0254] The trigger assembly 10430 may, for example, comprise a
primary trigger 10440 and a secondary trigger 10460. The primary
and secondary triggers 10440 and 10460 are pivotally journaled on a
pivot pin assembly 10430 formed in the housing assembly 10400 such
that the triggers 10440 and 10460 may essentially move relative to
each other. Such arrangement permits the trigger assembly 10430 to
pivot relative to the housing assembly 10400 about a pivot axis
PA-PA. See FIG. 8. The primary trigger 10440 has an elongated,
grippable primary trigger paddle 10442 that protrudes from a
primary drive portion 10444 that has a firing rack 10446 formed
thereon. In one embodiment, the secondary trigger 10460 has a
secondary trigger paddle 10462 that protrudes from a secondary
drive portion 10464 that is pivotally journaled on the pivot pin
assembly 10430. The primary drive portion 10444 has a slot 10448
that is adapted to receive the secondary drive portion 10464 of the
secondary trigger 10460 therein as the primary trigger paddle 10442
is pivoted towards a pistol grip portion 10406 of the housing
assembly 10400. Such arrangement essentially enables the secondary
trigger 10460 to "nest" within the primary trigger 10440 during
actuation. As will be discussed in detail below, the secondary
trigger 10460 is pivotally actuated by pivoting the primary trigger
10440. Thus, in other embodiments, the secondary trigger 10460 may
lack the secondary trigger paddle 10442. In various forms, the
trigger assembly 10430 may be biased into the unactuated position
by a trigger spring (not shown).
[0255] As can be seen in FIG. 8, the secondary drive portion 10464
of the secondary trigger 10460 may have a closure gear segment
10466 formed thereon that is configured for meshing engagement with
a carriage gear rack 10423 formed on the underside of the closure
carriage 10420. Thus, when the secondary trigger 10460 is pivoted
toward the pistol grip 10406, the closure carriage 10420 is driven
in the distal direction "DD" which thereby drives the anvil closure
rod 10112 in the distal direction.
[0256] Referring again to FIG. 3, a distal end 10118 of the anvil
closure rod 10112 is configured to be pinned to an anvil closure
link 10120. The anvil closure link 10120 is pivotally pinned to an
anvil pin slide 10122. An anvil cam pin 10124 is mounted to the
anvil pin slide 10122 an is configured to be received within anvil
pin slots 10720 provided in each of the lateral side walls 10712 of
the boxed mounting end 10710 of the elongated channel 10014 as well
as anvil cam slots 10840 in the proximal anvil mounting tube 10820.
Movement of the anvil closure rod 10112 in the distal direction
"DD" will cause the anvil assembly 10020 to move from an open
position towards the elongated channel 10014 (referred to herein as
the "closing direction "CD") and movement of the anvil closure rod
10112 in the proximal direction "PD" will cause the anvil assembly
10020 to move from a closed position to an open position (referred
to herein as the opening direction "OD"). Such opening and closing
of the anvil assembly 10020 is accomplished by the camming action
or movement of the anvil pin 10124 in the anvil camming slots 10840
in the proximal anvil mounting tube 10820. Thus, actuation of the
closure system 10110, also known as the "second jaw closure system"
will result in movement of the anvil assembly 10020, also known as
the "second jaw 10015" relative to the elongated channel 10014,
also known as the "first jaw 10013". Such movement may, for
example, comprise pivotal travel of the second jaw (anvil assembly
10020) relative to the first jaw (elongated channel 10014) about a
common pivot axis A-A that is established at their points of
attachment to the distal end of the elongated shaft assembly
10100.
[0257] In various arrangements, the end effector 10012 may be
configured to be selectively articulated relative to the
longitudinal tool axis LT-LT. Stated another way, however, the
first jaw 10013 which comprises the elongated channel 10014 may be
selectively movable relative to the second jaw 10015 which
comprises the anvil assembly 10020. As described above, the
elongated channel 10014 is pivotally coupled to the distal end
10302 of the outer tube 10300 by pivot pins 10310. Such attachment
arrangement permits the elongated channel 10014 to articulate or
move in a first direction "FD" about the pivot axis A-A which is
essentially the same direction that the anvil assembly 10020 moves
in when the anvil assembly 10020 is moved from a closed position to
an open position (the anvil opening direction "OD"). See FIG. 9.
Such arrangement further facilitates movement or articulation in a
second articulation direction "SD" that is essentially the same as
the direction that the anvil assembly 10020 moves from an open
position to a closed position (the anvil closing direction "CD").
To facilitate such movement of the elongated channel 10014, a
reciprocatable articulation rod 10150 is employed. The articulation
rod 10150 may also be referred to herein as the "first jaw actuator
bar 10150". More specifically and with reference to FIG. 3, the
articulation rod 10150 is sized to be movably received with the
outer tube 10300 and has a distal end 10152 that is pivotally
pinned to an articulation link 10160. The articulation link 10160
is pivotally pinned to a proximal attachment lug 10722 on the
proximal boxed mounting end 10710 of the elongated channel 10014.
As can be seen in FIG. 10, a proximal end 10154 of the articulation
rod 10150 has an articulation rack 10156 formed thereon that
drivingly interfaces with an articulation control system 10200. The
articulation control system 10200 may also be referred to herein as
the "first jaw closure system 10200".
[0258] The component parts of one form of articulation control
system 10200 are illustrated in FIGS. 10 and 11. In one form, the
articulation control system 10200 may include an actuator 10210, an
articulation body 10220 and a nozzle 10250. Rotational movement of
the actuator 10210 causes corresponding rotation of the
articulation body 10220 within the nozzle 10250. Rotation of the
actuator 10210 thereby results in the axial travel of the
articulation rod 10150 within the outer shaft 10300 to cause the
remote articulation of the end effector 10012.
[0259] Still referring to FIG. 10, the articulation body 10220 has
a deck 10222 consisting of first and second spaced-apart,
semicircular deck halves, 10224, 10226. The deck halves are
mutually opposed to each other and essentially represent mirror
images of each other. The first and second deck halves 10224, 10226
have protruding from their surfaces mutually opposed first and
second detents 10225, 10227, respectively. Each deck half 10224,
10226 has a set of deck teeth 10228 spaced about 180 degrees from
the set of deck teeth on the other deck half. The articulation body
10220 has a pair of rotation stops 10230 protruding from its
surface as well as a pair of finger recesses 10232. A drive gear
10240 protrudes laterally from the articulation body 10220. The
drive gear 10240 has a flared opening 10242 through it, and a
lateral pivot 10244. Within the flared opening 10242 of the drive
gear 10240, there is a firing rod orifice (not shown) for receiving
a firing rod 10530 therethrough enabling the application of a
firing motion to the end effector 10012. The drive gear 10240 is
configured to intermesh with the articulation rack 10156 to effect
the desired reciprocating movement of the articulation rod
10150.
[0260] The nozzle 10250 of the articulation control system 10200
may include a nozzle body 10252. The nozzle body 10252 may have an
axial bore 10254 therethrough that facilitates the passage of the
articulation rod 10150 and other operative components of the
instrument 10010 including a the proximal end 10306 of the outer
shaft 10300. See FIG. 11. The nozzle body 10252 may also have a
frame groove 10256 and flange 10258 to rotatably fasten the nozzle
body 10252 to the housing 10400. In various forms, a detent housing
10260 comprises a portion of the nozzle body 10252. See FIG. 1. An
annular array of detent teeth (not shown) is formed within the
detent housing 10260. A detent housing floor is spaced from the
detent teeth. The floor may have a pair of ledges which interact
within the rotation stops 10230 of the articulation body 10220 to
limit the degree of rotation. When the articulation body 10220 is
inserted into the detent housing 10260, the base of the
articulation body 10220 is supported on the floor within the detent
housing 10260, and the deck teeth 10228 of the first and second
deck halves, 10224, 10226 are aligned for meshing engagement with
the detent teeth of the detent housing 10260. A spring member 10268
is supported within the articulation body to bias the deck teeth
10228 into meshing engagement with the detent teeth.
[0261] Referring again to FIG. 10, the actuator 10210 may consist
of a lever arm 10212, a cap 10214 and a pair of retaining fingers
10216. The lever arm 10212 is mounted on the top of the cap 10214.
The pair of retaining fingers 10216 protrudes laterally from the
underside of the cap 10214. Each of the retaining fingers 10216 has
a retaining clip. The retaining fingers 10216 are received within
the finger recesses 10232 of the articulation body 10220. First and
second detents, 10225, 10227, on the deck halves of the
articulation body are inserted into a slot depression within the
underside of the circular cap 10214. Advantageously, each of the
three significant components of the articulation control system,
namely the actuator, articulation body and nozzle, may be injection
molded components. Such components, for example, may be fabricated
from a glass fiber-reinforced amorphous polyamide, sold
commercially under the trade name Grivory GV-4H by EMS--American
Grilon 150.
[0262] Ratcheting rotation of the actuator 10210 causes
articulation of the elongated channel 10014 in the first or second
directions relative to the longitudinal tool axis LT-LT. FIGS. 1,
2, 9 and 12 illustrate the elongated channel 10014 in an
unarticulated position. When the drive gear 10240 on the
articulation body 10220 of the articulation transmission 10200 is
rotated to thereby push the articulation rod 10150 in the distal
direction "DD", the elongated channel 10014 will articulate in the
first articulation direction "FD" relative to the longitudinal tool
axis LT-LT as shown in FIG. 13. When the drive gear 10240 on the
articulation body 10220 of the articulation transmission 10200 has
been rotated to thereby pull the articulation rod 10112 in the
proximal direction "PD", the elongated channel 10014 will pivot in
a second direction "SD" relative to the longitudinal tool axis
LT-LT. The second direction "SD" is the same as the closure
direction "CD". See FIG. 9.
[0263] The surgical instrument 10010 may include a firing system
generally designated as 10410 that is supported within the housing
assembly 10400 and is operable to actuate various components of the
instrument 10010. Referring to FIG. 8, the firing system 10410 may,
for example, include an actuation bar 10470. The actuation bar
10470 has a first actuation rack 10472 formed thereon that is
configured for meshing engagement with the firing rack 10446 on the
primary trigger 10440. Thus, when the firing rack 10446 is in
meshing engagement with the first actuation rack 10472, the
actuation bar 10470 is driven in the distal direction "DD" when the
primary trigger 10440 is pivoted toward the pistol grip 10406. The
actuation bar 10470 has a second actuation rack 10474 formed
thereon configured to meshingly engage clutch teeth 10484 on a
clutch shaft 10482 of a clutch assembly 10480. In various
embodiments, the clutch shaft 10482 is rotatably is supported
within the housing assembly 10400 and is also laterally movable
therein. The clutch shaft 10482 has a hub portion 10486 that has a
plurality of spaced teeth 10488 that are configured to drivingly
engage teeth openings 10492 in a drive gear 10490 that is rotatably
supported on the clutch shaft 10482. The drive gear 10490 has a
segment of drive gears 10494 thereon that are adapted for meshing
engagement with a firing rack 10500 that is movably supported in
the housing assembly 10400.
[0264] Various embodiments of the clutch assembly 10480 may further
comprise a clutch plate 10510 that is slidably journaled on a
clutch pin 10449 provided on the primary drive portion 10444 of the
primary trigger 10440. The clutch pin 10449 may be movably received
within a vertical slot 10512 in the clutch plate 10510. The clutch
plate 10510 also has a distally-extending clutch arm 10514 that is
adapted to actuatably engage a bevel plate 10489 formed on the
clutch shaft 10482. In addition, a clutch spring 10520 is employed
to bias the clutch shaft 10480 laterally such that the teeth 10488
on the clutch shaft 10482 are brought into meshing engagement with
the teeth openings 10492 in the drive gear 10490.
[0265] As can be seen in FIG. 8, the firing rack 10500 is coupled
to a firing rod 10530 that is attached to the proximal end of a
knife bar assembly 10600. In various embodiments, the knife bar
assembly 10600 may comprise a three-ply flexible knife bar 10602
that is flexible enough to accommodate articulation of the end
effector 10012, while remaining sufficiently rigid to be driven
distally through the elongated shaft assembly 10100. An axial
passage 10157 may be provided in the articulation bar 10150 for
axially receiving the knife bar 10602 therein. See FIG. 10. In the
depicted embodiment, the knife bar 10602 is attached to an I beam
cutting head 10610. As can be seen in FIG. 3, for example, the
I-beam cutting head 10610 includes a vertically oriented body
portion 10612 that has a bottom foot 10614 and an upper tab 10616
formed thereon. A tissue cutting edge 10620 is formed on the
vertically oriented body portion 10612.
[0266] Still referring to FIG. 3, the vertically oriented body
portion 10612 extends through a longitudinally extending slot 10704
in the elongated channel 10014 and a longitudinally extending slot
806 in the distal anvil portion 10800. The distal anvil portion
10800 further has a trough 10809 formed in the upper surface for
slidably receiving the upper tab 10616 therein. The distal end
10618 of the upper tab 10616 is sloped to interface with sloped
surfaces 10811 formed on the portions 10805 of the distal anvil
portion 10800 forming the slot 806. See FIG. 14. The flexible
firing bar 10602 extends through the elongated shaft assembly 10100
to be coupled to a distal end portion 10532 of a firing rod 10530
are supported in a contiguous orientation relative to each other as
shown in FIG. 10. The proximal end of the firing bar 10602 may be
attached to the distal end portion 10532 of the firing rod 10530 by
a coupler member 10650. As will be discussed in further detail
below, the firing rod 10530 facilitates the application of firing
and retraction motions to the knife bar assembly 10600 by the
firing system 10410.
[0267] Referring again to FIG. 8, the firing rod 10530 extends
through a closure bushing 10540 that is mounted within the housing
assembly 10400. In at least one form, a pair of mounting studs
10407 protrude from the handle case members 10402, 10404 and extend
through corresponding slots in the closure carriage 10420 to be
received in a retaining slot in the bushing 10540. A closure spring
10550 that is attached to a retainer clip 10552 is journaled on the
closure bushing 10540. The closure spring 10550 extends between the
nozzle body 10252 and an internal wall 10425 in the closure
carriage 10420. Thus, the closure spring 10550 serves to bias the
closure carriage 10420 in the proximal direction "PD".
[0268] Various embodiments may also include a releasable closure
locking assembly 10560 that interfaces with the closure carriage
10420 to selectively retain the closure carriage 10420 in its
distal-most closed or clamped position. In at least one form, the
closure locking assembly 10560 includes a locking button 10562 that
is pivotally supported in the housing assembly 10400. The locking
button 10562 has a latch arm 10564 that is configured to abut a
locking ledge 10421 formed on the closure carriage 10420 when the
button 10562 is in the locked position. In addition, the latch arm
10564 has a catch 10566 formed thereon that is configured to
releasably latch with a locking latch 10502 on the proximal end of
the firing rack 10500. A locking spring 10568 serves to bias the
locking button 10562 into the locked position.
[0269] Operation of the surgical instrument 10010 will now be
described. FIG. 9 illustrates the jaws 10013 and 10015 of the end
effector 10012 in an open position. When the end effector 10012 is
in the open position, the latch arm 10564 is located on top of the
locking ledge 10421 formed on the closure carriage 10420 such that
the catch 10566 of the latch arm 10564 is in retaining engagement
with the locking latch 10502 on the firing rack 10500. See FIG. 8.
Thus, when in this initial starting position, the knife bar
assembly 10600 cannot be inadvertently actuated. The clutch plates
10510, as well as the closure carriage, are each in their
proximal-most unactuated positions. When in those positions, the
clutch drive bevel 10489 on the clutch shaft 10482 is in contact
with a portion of the closure carriage 10420, which prevents the
clutch shaft 10482 from laterally moving into meshing engagement
with the drive gear 10490 under the bias of the clutch spring
10520.
[0270] To initiate the closure process, a first stroke is applied
to the trigger assembly 10430. That is, the trigger assembly 10430
is initially pivoted toward the pistol grip 10406. Such pivoting
action serves to drive the closure carriage 10420 in the distal
direction "DD" by virtue of the meshing engagement between the
closure gear segment 10466 on the secondary trigger 10460 and the
carriage rack 10423 formed on the underside of the closure carriage
10420. Such distal movement of the closure carriage 10420 also
axially advances the anvil closure rod 10112 in the distal
direction "DD". As the anvil closure rod 10112 moves distally, the
closure link 10120 moves the anvil pin slide 10122 distally. As the
anvil pin slide 10122 moves distally, anvil pin 10124 moves up cam
slots 10840 in the proximal anvil portion 10820 to cam the anvil
assembly 10020 towards the elongated channel 10014 and the staple
cartridge 10030 supported therein. If the surgeon desires to simply
grasp and manipulate tissue prior to clamping it between the anvil
assembly 10020 and the surgical staple cartridge 10030, the trigger
assembly 10430 may be pivoted to open and close the anvil assembly
10020 without fully pivoting the trigger assembly 10430 to the
fully closed position.
[0271] Those of ordinary skill in the art will understand that, as
the trigger assembly 10430 is pivoted toward the pistol grip 10406,
the actuation bar 10470 will necessarily also be driven distally by
virtue of the meshing engagement between the primary gear segment
10446 on the primary trigger 10440 and the first actuation rack
10472 on the actuation bar 10470. The distal movement of the
actuation bar 10470 will also result in the an application of a
rotary actuation motion to the clutch shaft 10482 by virtue of the
meshing engagement between the clutch teeth 10484 on the clutch
shaft 10482 and the second actuation rack 10474 on the actuation
bar 10470. However, such rotary motion is not applied to the drive
gear 10490 because the clutch arm 10514 of the clutch plate 10510,
in contact with the clutch drive bevel 10489 on the clutch shaft
10482, prevents the axial movement of the clutch shaft 10482 into
meshing engagement with the drive gear 10490. Thus, the clutch
shaft 10482 freely rotates relative to the drive gear 10490.
Accordingly, the clutch assembly 10480 automatically prevents the
activation of the firing rack 10500 during the initial actuation of
the trigger assembly 10430.
[0272] Once the trigger assembly 10430 has been initially fully
compressed into the closed position, the anvil assembly 10020 will
be locked in the closed position by the closure locking assembly
10560 which prevents the proximal movement of the closure carriage
10420. To drive the knife bar assembly 10600 distally through the
tissue clamped in the end effector 10012, the surgeon again pivots
the primary trigger 10440 toward the pistol grip 10406 of the
housing assembly 10400. As the primary trigger 10440 is pivoted,
the firing rack 10500, the firing rod 10530, and the knife bar
assembly 10600 are driven in the distal direction "DD". As the
knife bar assembly 10600 is driven in the distal direction, the
cutting head 10610 also moves distally. As the cutting head 10610
moves distally, the sloped surface 10618 on the upper tab 10616
travels up the sloped surfaces 10811 on the distal anvil portion
10800 moving the floating distal anvil portion 10800 in the down
direction "D" towards the staple cartridge 10030. As the distal
anvil portion 10800 is driven downwardly towards the clamped tissue
and the staple cartridge 10030, the clamping or crushing action
causes the staples to be formed against the underside of the distal
anvil portion 10800. Thus, as the cutting head 10610 is driven
distally through the end effector 10012, the tissue cutting surface
10620 thereon severs the clamped tissue while forming the staples
in the staple cartridge 10030 on both sides of the cut tissue. Such
two part anvil assembly enables the distal anvil portion to
essentially remain parallel to the elongated channel and top of the
surgical staple cartridge during firing. Stated even more
succinctly, the two part floating anvil arrangement enables the
staple-forming undersurfaces to remain parallel with the top of the
surgical staple cartridge and the elongated channel during
firing.
[0273] After the cutting head 10610 has been driven through the
tissue clamped in the end effector 10012, the surgeon then releases
the primary trigger 10440 to thereby permit the primary trigger
10440 to pivot to its unactuated position under the bias of the
firing spring 10432. As the primary trigger 10440 pivots back to
the starting position, the firing rack 10500, firing rod 10530, and
knife bar assembly 10600 are drawn proximally back to their
respective starting positions. The end effector 10012 remains in
its clamped position as shown in FIG. 13.
[0274] To unlock the closure carriage 10420 and the secondary
trigger 10460, the surgeon depresses the locking button 10562. As
the locking button 10562 is depressed, the locking arm 10564 is
pivoted out of abutting engagement with the locking ledge 10426 on
the closure carriage 10420. Further details regarding the operation
of the firing and closure systems may be found in U.S. Patent
Application Publication No. US 2012/0074200 which has been herein
incorporated by reference in its entirety. As the closure carriage
10420 moves proximally, the anvil closure rod 10112 is also drawn
proximally. As the anvil closure rod 10112 moves proximally, the
anvil pin slide 10122 and anvil pin 10124 move proximally camming
the anvil assembly 10020 to the open position.
[0275] The surgical instrument 10010 provides a host of advantages
over prior surgical instruments. For example, the unique and novel
floating anvil arrangement is able to automatically adjust the
anvil gap between the undersurface of the anvil and the staple
cartridge or elongated channel. Thus, the floating anvil
arrangement can automatically compensate for different thickness of
tissue while enabling the staple forming undersurface(s) of the
anvil to remain parallel to the staple cartridge and elongated
channel. This is all accomplished without sacrificing anvil
stability.
[0276] Another distinct advantage that the surgical instrument
10010 enjoys over prior surgical instruments with an articulatable
end effector is the nature in which the present end effector is
articulatable relative to the elongated shaft assembly. As
described in detail above, the elongated channel portion of the end
effector is pivotally mounted to the elongated shaft assembly for
selective pivotal travel relative thereto about a pivot axis. The
pivot axis is transverse to the longitudinal tool axis defined by
the elongated shaft assembly. The anvil assembly is also pivotally
coupled to the elongated channel for selective pivotal travel
relative thereto about the same pivot axis. This provides another
distinct advantage over prior articulatable end effector
arrangements for at least the following reason.
[0277] During typical surgical procedures, the surgeon is viewing
the surgical site and the end effector through a camera that can
provide somewhat limited viewing. For example, such camera
arrangements commonly only afford the surgeon with a view of a
portion of the surgical end effector. When using an endocutter for
example, the camera may only afford the surgeon a view of a portion
of the endocutter's anvil and/or channel. In prior articulatable
endocutter arrangements, the endocutter was coupled to the end of
the elongated shaft by a flexible joint or other arrangement that
did not always afford a consistent reference axis about which the
end effector would pivot relative to the elongated shaft. So it was
difficult for the surgeon when viewing a portion of the end
effector to have a reliable frame of reference to know where the
pivot axis resided. By having the articulation axis also be the
axis about which the anvil pivots, the surgeon has a much more
reliable frame of reference regarding the location of the pivot
axis when viewing the endocutter's anvil through the camera. Stated
another way, when using the end effector arrangement of the
surgical instrument 10010 the surgeon can determine where the
elongated channel is going to pivot relative to the elongated shaft
by viewing where the anvil is pivotally mounted to the elongated
channel.
[0278] The surgical instrument 10010 also employs separate control
systems for moving the end effector jaws 10013 and 10015 relative
to each other. For example, the clinician may elect to move or
articulate the lower jaw 10013 (elongated channel 10014) about the
pivot axis A-A toward or way from the upper jaw 10015 (anvil
assembly 10020) without actuating the upper jaw 10015 (anvil
assembly 10020). This may be accomplished by actuating the
articulation control system (or first jaw closure system) without
actuating the second jaw closure system 10110. Thus, the elongated
channel 10014 may be selectively pivoted about the pivot axis A-A
while the anvil assembly 10020 remains in an open or closed
position. Similarly, the anvil assembly 10020 may be actuated or
moved without moving the elongated channel 10014 by actuating the
closure system 10110 without actuating the articulation control
system. Such unique and novel arrangement provides the clinician
with more flexibility when positioning the end effector jaws within
the patient.
[0279] FIGS. 15-19 illustrate another surgical instrument 1010 that
is capable of practicing several unique benefits of the present
invention. The surgical instrument 1010 is designed to manipulate
and/or actuate various forms and sizes of end effectors 1012 that
are operably attached to an elongated shaft assembly 1100 of the
surgical instrument. In the depicted embodiment, for example, the
end effector 1012 comprises a surgical stapling device that has
openable and closable jaws 1013 and 1015. More specifically, the
end effector 1012 includes a jaw channel 1014 that forms a lower
jaw 1013 of the end effector 1012. See FIG. 16. In the illustrated
arrangement, the jaw channel 1014 is configured to operably support
a staple cartridge 10030 and also movably supports an anvil
assembly 1020 that functions as an upper jaw 1015 of the end
effector 1012.
[0280] Referring now to FIGS. 15 and 17, the anvil assembly 1020
comprises a two-part arrangement including an anvil body portion
1021 and an anvil cap member 1023. The anvil body portion 1021 may
include a mounting portion 1022 that has mounting trunnions 1024
protruding therefrom. The mounting trunnions 1024 are configured to
be received in vertically elongated mounting slots 1018 in the
upstanding side walls 1017 of a proximal mounting portion 1016 of
the jaw channel 1014. Such arrangement permits the anvil assembly
to somewhat float up and down relative to the elongated channel.
Stated another way, the anvil body portion 1021 may move relative
to the elongated channel or the top of a staple cartridge supported
in the elongated channel such that the staple forming undersurfaces
of the anvil body portion 1021 are parallel to the top of the
staple cartridge and the elongated channel. As will be discussed in
further detail below, the anvil assembly 1020 is moved between open
and closed positions by manipulating the position of a tissue
cutting head 1190.
[0281] In various arrangements, the end effector 1012 may be
configured to be selectively articulated about a longitudinal tool
axis LT-LT that is defined by the elongated shaft assembly 1100. As
can be seen in FIGS. 15-18, for example, the elongated shaft
assembly 1100 may include a flexible neck assembly 1110 to
facilitate such articulation. Various flexible neck assemblies are
know and may be employed. For example, flexible neck assemblies are
disclosed in U.S. Provisional Patent Application Ser. No.
61/386,117, entitled ARTICULATING SURGICAL DEVICE, and filed Sep.
24, 2010, the entire disclosure of which is herein incorporated by
reference. Other flexible neck assemblies which may be employed are
disclosed in U.S. Pat. No. 5,704,534, entitled ARTICULATION
ASSEMBLY FOR SURGICAL INSTRUMENTS, and issued on Jan. 6, 1998; U.S.
Patent Application Publication No. US 2012/0074200, entitled
SURGICAL INSTRUMENT WITH SELECTIVELY ARTICULATABLE END EFFECTOR,
and filed on Sep. 23, 2011; and U.S. Patent Application Publication
No. US 2009/0090764, entitled SURGICAL STAPLER HAVING AN
ARTICULATION MECHANISM, and filed Oct. 3, 2008, the entire
disclosures of each being hereby incorporated by reference herein
in their respective entireties. As will be discussed in further
detail below, however, the flexible neck assembly 1110 is
configured to facilitate articulation of the end effector 1012 in
directions that are the same directions in which the jaws of the
end effector travel between open and closed positions.
[0282] In at least one implementation, the flex neck assembly 1110
may, for example, be fabricated in two pieces 1110R and 1110L that
are configured to be coupled together by, fasteners such as snap
features, screws, bolts, adhesive, etc. The flexible neck pieces
1110R and 1110L may be composed of rigid thermoplastic polyurethane
sold commercially as ISOPLAST grade 2510 by the Dow Chemical
Company. The right flexible neck portion 1110R includes a right
upper rib segment 1112R and a right lower rib segment 1112L that
are separated by an elongated right lateral spine (not shown).
Similarly, the left flexible neck portion 1110L includes a left
upper rib segment 1112L and a left lower rib segment 1114L that are
separated by a left elongated lateral spine 1116. See FIG. 17. When
assembled together, the right upper rib segments 1112R and the left
upper rib segments 1112L form upper ribs 1112 and the right lower
rib segments 1114R and the left lower rib segments 1114L form lower
ribs 1114 that are spaced from each other and which together form a
cylindrical configuration as shown in FIG. 15. Such arrangement
enables the end effector 1012 to articulate in a first direction
"FD" that is essentially the same direction that the anvil assembly
1020 moves in when the anvil assembly 1020 is moved from a closed
position to an open position (hereinafter referred to as the anvil
opening direction "OD"). See FIG. 18. The flexible neck assembly
1110 will further facilitate articulation of the end effector 1012
in a second articulation direction "SD" that is essentially the
same as the direction that the anvil moves from an open position to
a closed position (hereinafter referred to the anvil closing
direction "CD"). In various embodiments, the right flexible neck
portion 1110R further has a right tubular portion 1113R and the
left flexible neck portion 1110L has a left tubular portion 1113L.
When joined together, the right and left tubular portions 1113R,
1113L serve to receive therein two distally protruding attachment
arms 1019 that protrude proximally from the jaw channel 1014. See
FIGS. 16 and 17. The attachment arms 1019 have attachment tabs
thereon that engage the tubular portions 1113R, 1113L to affix the
jaw channel 1014 to the elongated shaft assembly 1100. Other
methods of attaching the jaw channel 1014 to the elongated shaft
assembly 1100 may also be employed. In at least one embodiment, the
elongated shaft assembly 1100 includes a substantially rigid
proximal outer shaft segment 1300 that has a distal end 1302. The
distal end 1302 has a pair of opposed lateral slots 1303 therein
for receiving the corresponding proximally protruding ends of the
lateral spine portions 1116L (the right spine portion is not
shown). See FIGS. 15 and 17. The outer shaft segment 1300 may be
pressed onto the flexible neck assembly 1110 or otherwise attached
thereto by fasteners, pins, screws, etc.
[0283] The proximal end of the outer shaft segment 1300 may be
attached to a handle assembly of the type disclosed in U.S. Patent
Application Publication No. 2012/0074200, entitled SURGICAL
INSTRUMENT WITH SELECTIVELY ARTICULATABLE END EFFECTOR, which has
been herein incorporated by reference in its entirety. Further
details regarding at least one method of attaching the outer shaft
segment to the handle assembly and operation of the outer shaft
segment and related components may be gleaned from reference to
that publication. Such arrangement permits the surgeon to rotate
the outer shaft segment 1300 and the end effector 1012 operably
coupled thereto about the longitudinal tool axis LT-LT by rotating
the nozzle member relative to the handle assembly as discussed in
detail therein.
[0284] Referring to FIGS. 16 and 18, an upper slot 1120 extends
through each of the upper ribs 1112 to form a passage through the
flexible neck assembly 1110 for receiving a first flexible
articulation band assembly 1150 therethrough. Similarly, a lower
slot 1121 extends through each of the lower ribs 1114 in the
flexible neck assembly 1110 to form a passage for receiving a
second flexible articulation band assembly 1170 therethrough.
Referring to FIG. 17, in at least one embodiment, the first
flexible articulation band assembly 1150 comprises a flexible first
distal segment 1152 that is fabricated from, for example, spring
steel, 420 stainless steel, titanium, 400 or 300 grade stainless
steel and has a first hook 1154 formed in its distal end. The first
hook 1154 is configured to hookingly engage a first or upper
hook-receiving feature 1155U formed in the proximal end of the jaw
channel 1014. The first articulation band assembly 1150 further
includes a first structural band portion 1156 that is attached to
(e.g., pinned) to the first distal segment 1152. The first
structural band portion 1156 may be fabricated from, for example,
spring steel, 420 stainless steel, titanium. Likewise, the second
articulation band assembly 1170 comprises a flexible second distal
segment 1172 that is fabricated from, for example, spring steel,
420 stainless steel, and titanium and has a second or lower hook
1174 formed in its distal end. See FIG. 17. The second hook 1174 is
configured to hookingly engage a second or lower hook-receiving
feature 1155L formed in the jaw channel 1014. See FIG. 18. The
second articulation band assembly 1170 further includes a second
structural band portion 1176 that is attached to (e.g., pinned) to
the second distal segment 1172. The second structural band portion
1176 may be fabricated from, for example, 400 or 300 grade
stainless steel. The upper and lower articulation band assemblies
1150, 1170 may interface with and be controlled by an articulation
transmission and control system 2000 of the type described in U.S.
Patent Publication No. 2012/0074200 which has been incorporated by
reference herein in its entirety.
[0285] Referring to FIG. 19, various embodiments of the
articulation system 2000 include a novel articulation transmission
2030 that is supported within the handle assembly 1900 for applying
articulation motions to the first and second articulation band
assemblies 1150, 1170. In various forms, the articulation
transmission 2030 includes an actuator wheel 2040 that is rotatably
supported on the handle assembly 1900 for selective rotation about
an actuation axis. In at least one embodiment, the actuation axis
coincides with or is substantially coaxial with the longitudinal
tool axis LT-LT. Thus the actuation axis does not transversely
intersect the longitudinal axis. In other embodiments, the
actuation axis may be substantially parallel to the longitudinal
axis. To facilitate ease of assembly and manufacturing, the
actuator wheel 2040 is fabricated in two pieces 2040A that may be
attached together by screws, snap features, adhesive etc. When
assembled, the actuator wheel 2040 has a first set of actuator
threads 2042 which are configured in a first direction for threaded
engagement with a first thread nut assembly 2060. In addition, the
actuator wheel 2040 also has a second set of actuator threads 2044
which are configured in a second direction that differs from the
first direction. For example, the first threads 2042 may comprise
"right hand" threads and the second threads 2044 may comprise "left
hand" threads or visa versa. The second threads 2044 are adapted to
threadably engage a second threaded nut assembly 2070.
[0286] In various embodiments, the first threaded nut assembly 2060
comprises a first disc 2062 that has first threads 2064 formed
thereon. The first disc 2062 is supported on a knife tube 1800 by a
first bearing bushing 2066. The first bearing bushing 2066
facilitates movement of the first disc 2062 relative to the knife
tube 1800. Similarly, the second threaded nut assembly 2070
comprises a second disc 2072 that has second threads 2074 formed
thereon. The second disc 2072 is supported on the knife tube 1800
by a second bearing bushing 2076 that facilitates movement of the
second disc 2072 relative to the knife tube 1800. The first and
second discs 2062, 2072 are also movably supported on upper and
lower nut rails 2050, 2052 that are mounted to standoff posts 1905
molded into the handle cases 1904. See FIG. 19. The upper and lower
nut rails 2050, 2052 serve to prevent the first and second discs
2062, 2072 from rotating relative to the handle housing and
therefore, as the actuator wheel 2040 is rotated relative to the
handle housing, the first and second bearing bushings 2066, 2076
move axially on the knife tube 1800 in different directions.
[0287] The first and second articulation band assemblies 1150, 1170
are controlled by rotating the actuator wheel 2040 relative to the
handle assembly 1900. To facilitate the application of such control
motions, the first structural band portion 1156 has a first catch
member configured to retainingly engage the first bearing bushing
2066 and the second structural band portion 1176 has a second catch
member configured to retainingly engage the second bearing bushing
2076. In addition, the articulation system 2000 in at least one
form includes an elongated support beam 2080 that extends
longitudinally within the knife tube 1800 to provide lateral
support to the first and second structural band portions 1156, 1176
within the knife tube 1800. The support beam 2080 may be fabricated
from, for example, 400 or 300 grade stainless steel and is
configured to facilitate axial movement of the first and second
structural band portions 1156, 1176 while providing lateral support
thereto.
[0288] FIGS. 15 and 16 illustrate the surgical instrument 1010 in
an unarticulated position. That is, when in an unarticulated
position, the end effector 1012 is substantially axially aligned on
the longitudinal tool axis LT-LT. When in that "neutral" position,
the first and second discs 2062, 2072 are spaced away from each
other. To provide the surgeon with an indication when the
articulation system 2000 has been parked in the neutral position, a
detent assembly 2090 is mounted within the handle housing. The
detent assembly 2090 into the housing and is adapted to engage a
recess (not shown) in the hub portion 2041 of the actuator wheel
2040. See FIG. 19. The detent assembly 2090 is configured to engage
the recess when the actuator wheel 2040 is in the neutral position.
When the detent 2090 engages the recess, the surgeon may receive a
tactile and/or audible indication.
[0289] The articulation system 2000 may articulate the end effector
1012 about the flexible neck assembly 1110 in the following manner.
First, the surgeon rotates the articulation actuator wheel 2040 in
a first rotary direction which causes the first and second discs
2062, 2072 to move toward each other. As the first disc 2062 moves
in the proximal direction "PD", the first articulation band
assembly 1150 is pulled in the proximal direction "PD" by virtue of
the first catch feature 2017 which is coupled to the first bearing
bushing 2066. Likewise, as the second disc 2072 moves in the distal
direction "DD", the second articulation band assembly 1170 is
pushed in the distal direction "DD" by virtue of the second catch
feature 2027 which is coupled to the second bearing bushing 2076.
Such action of the first and second articulation band assemblies
1150, 1170 causes the end effector 10612 to articulate in the first
articulation direction "FD" by virtue of the first and second
articulation bands 1150, 1170 interconnection with the end effector
1012. To articulate the end effector in the second articulation
direction "SD", the user simply rotates the articulation actuator
wheel 2040 in a second rotary direction that is opposite to the
first rotary direction.
[0290] As indicated above, the articulation system 2000 in at least
one form also includes an elongated support beam 2080 that extends
longitudinally within the knife tube 1800 to provide lateral
support to the first and second structural band portions 1150 and
1170 within the knife tube 1800. The support beam 2080 may be
fabricated from, for example, 400 or 300 grade stainless steel and
is configured to facilitate axial movement of the first and second
structural band portions 1156, 1176 while providing lateral support
thereto. In addition, the right and left segments 1110R, 1110L of
the flexible neck assembly 1110, when joined together, form a
passage 1118 for receiving a knife bar assembly 1180. In various
forms, the knife bar assembly 1180 includes a distal knife bar
portion 1182 that includes an upper knife bar 1184 and a lower
knife bar 1186 that are attached to a tissue cutting head 1190. The
upper knife bar 1184 is attached to a top portion 1192 of the
tissue cutting head 1190 and the lower knife bar 1186 is attached
to a lower portion 1194 of the tissue cutting head 1190. The upper
knife bar 1184 and the lower knife bar 1186 are configured to flex
as the flexible neck assembly 1110 flexes.
[0291] As will be discussed in further detail below, in at least
one embodiment, the axial advancement and withdrawal of the knife
bar assembly 1180 may be controlled by, for example, the manual
activation of a firing trigger that is operably supported on the
handle assembly 1900. As can be seen in FIG. 19, a connector member
1790 is coupled to a proximal end 1183 of the distal knife bar
portion 1182. In at least one embodiment, for example, the
connector member 1790 is pinned to the proximal end 1787 of the
distal knife bar portion 1182 and has a proximally protruding
attachment feature 1792 that is configured to be coupled to a
distal end 1802 of the hollow knife tube 1800. The hollow knife
tube 1800 extends through the outer shaft segment 1300 and into the
handle assembly 1900 and is attached to a carriage assembly 1810.
In various embodiments, for example, the carriage assembly 1810
comprises a flanged carriage bushing 1812 that is press fit onto a
portion of the knife tube 1800. The carriage assembly 1810 further
comprises a firing carriage 1814 that has a saddle formed therein
configured to extend over the carriage bushing 1812 between the
bushing flanges 1813. In at least one form, the firing carriage
1814 also has a pair of laterally extending portions 1816 that each
have a support tab 1818 formed thereon. The support tabs 1818 are
configured to be slidably received in a corresponding slide passage
(not shown) formed in the handle housing 1904. Such arrangement
permits the firing carriage 1814 to move axially within the handle
assembly 1900 and thereby apply axial actuation motions to the
knife tube 1800 while permitting the knife tube 1800 to rotate
about the longitudinal tool axis LT-LT relative to the firing
carriage 1814 as the nozzle assembly 1770 is rotated.
[0292] In at least one embodiment, actuation motions may be
manually applied to the firing carriage 1814 by a firing trigger
assembly 1820 that is pivotally supported on the handle assembly
1900. The firing trigger assembly 1820 includes a firing trigger
1822 that has an attachment plate 1824 that is configured to
operably interface with a pair of actuation plates 1826. As can be
seen in FIG. 19, the attachment plate 1824 is located between the
actuation plates 1826 and is pivotally pinned thereto by a first
pivot pin 1828 that extends through slots 1830 in the actuation
plates 1826 and a hole 1825 in the attachment plate 1824. A second
pivot pin 1832 is received within or is supported by mounting lugs
in the handle cases 1904 and extends between holes 1834 in the
actuation plates 1826. Each of the actuation plates 1826 have a lug
1836 that extends into a corresponding pocket or opening 1815 in
the firing carriage 10814. Such arrangement facilitates the
application of axial actuation motions to the knife tube 1800 by
pivoting the firing trigger 1822 relative to the handle housing
1900. As the firing trigger 10822 is pivoted towards the pistol
grip portion 1908 of the handle housing 1900, the firing carriage
1814 is driven in the distal direction "DD". As the firing trigger
1822 is pivoted away from the pistol grip portion 1908 of the
handle housing 1900, the firing carriage 1814 draws the knife tube
1800 in the proximal direction "PD".
[0293] Various embodiments of the surgical instrument 1010 may
further include a locking system 1840 that includes a locking
trigger 1842 that is pivotally coupled to the handle housing 1900.
The locking trigger 1842 includes a locking bar portion that is
configured to operably engage a locking member 1846 that is
pivotally attached to the attachment plate 1824 of the firing
trigger 1822 by pin 1849. Further discussion regarding the
operation of the locking system 1840 may be found in U.S. Patent
Application Publication No. US 2012/0074200 A1.
[0294] Actuation of the end effector 1012 will now be explained.
While grasping the pistol grip portion 1908 of the handle assembly
1900, the surgeon may apply a closing motion to the anvil assembly
1020 of the end effector 1012 by applying an actuation force to the
firing trigger 1822. Such action results in the application of an
actuation motion to the firing carriage 1814 by the actuation
plates 1826 which ultimately results in the axial displacement of
the knife tube 1800 in the distal direction "DD". As the knife tube
1800 is advanced in the distal direction "DD", the knife bar
assembly 1180 is likewise driven in the distal direction "DD". As
the knife bar assembly 1180 and, more particularly the tissue
cutting head 1190, is driven in the distal direction "DD", the
upper tab portions 1196 on the tissue cutting head 1190 contact
sloped surfaces 1025 on the anvil body 1021 to start to apply a
closing motion to the anvil assembly 1020. Further application of
the actuation force to the firing trigger 1822 results in further
axial displacement of the knife tube 1800 and the tissue cutting
head 1090. Such action further moves the anvil assembly 1020
towards the elongated jaw channel 1014. As the firing trigger 1822
is pivoted towards the pistol grip portion 1908 of the handle
assembly 1900, the locking member 1848 also pivots in the
counterclockwise "CCW" direction about the pin 1849. At this point,
the tissue cutting head 1190 is prevented from moving any further
in the distal direction "DD" by virtue of the locking system 1840.
Thus, the surgeon may move the anvil assembly 1020 to capture and
manipulate tissue in the end effector 1012 without risk of actually
"firing" the end effector 1012 (i.e., or cutting the tissue and
forming the staples).
[0295] Once the surgeon desires to cut tissue and form staples, a
second actuation force is applied to the locking trigger 1842. When
the locking trigger 842 is depressed, the locking bar portion 1844
pivots to a forward position which thereby permits the locking
member 1848 to continue to pivot in the counterclockwise direction
as the surgeon continues to apply the actuation force to the
trigger 1822. Such actuation of the firing trigger 1822 results in
the axial displacement of the tissue cutting head 1190 through the
anvil assembly 1020 and the elongated jaw channel 1014. At this
point, the upper tab portions 1196 and the lower foot 1198 on the
tissue cutting head 1190 serves to space the anvil assembly 1020
relative to the elongated jaw channel 1014 such that the staples
10032 in the staple cartridge 10030 are formed into the tissue on
each side of the tissue cut line.
[0296] After completing the cutting and stapling process, the
firing trigger 1822 may be released. A return spring (not shown)
attached to the firing trigger 1822 returns the firing trigger 1822
to the unactuated position. Alternative, the user can use the hook
feature of the trigger to "pull" open the trigger if no spring is
used. As the firing trigger 1822 moves in the clockwise "CW"
direction, the firing carriage 1814 is moved in the proximal
direction "PD" which also moves the knife bar assembly 1180 in the
proximal direction "PD". As the tissue cutting head 1190 returns to
its starting position, the upper tabs 1196 on the tissue cutting
head 1190 contact an arcuate opening surface 1027 on the underside
of the anvil cap 1023 as shown in FIG. 18. Continued movement of
the tissue cutting head 1190 in the proximal direction "PD" causes
the anvil assembly 1020 to pivot open by virtue of its contact with
the arcuate surface 1027.
[0297] The surgical instrument 1010 also provides advantages over
prior surgical instruments. For example, the unique and novel
floating anvil arrangement is able to automatically adjust the
anvil gap between the undersurface of the anvil and the staple
cartridge or elongated channel. Thus, the floating anvil
arrangement can automatically compensate for different thickness of
tissue while enabling the staple forming undersurface(s) of the
anvil to remain parallel to the staple cartridge and elongated
channel. This is all accomplished without sacrificing anvil
stability.
[0298] FIGS. 20-26 depict another surgical instrument 3010 that is
capable of practicing several unique benefits of the present
invention. The surgical instrument 3010 is designed to manipulate
and/or actuate various forms and sizes of end effectors 3012 that
are operably attached to an elongated shaft assembly 3100 of the
surgical instrument. In the depicted embodiment, for example, the
end effector 3012 comprises a surgical stapling device that has
openable and closable jaws 3013 and 3015. More specifically, the
end effector 3012 includes an elongated channel 3014 that forms a
lower jaw 3013 of the end effector 3012. See FIGS. 21 and 10022. In
the illustrated arrangement, the elongated channel 3014 is
configured to operably support a staple cartridge 10030 of the type
and construction described herein. For example, the surgical staple
cartridge includes a cartridge body 10031 that operably supports a
plurality of unformed surgical staples 10032 therein. The elongated
channel 3014 also movably supports an anvil assembly 3020 that
functions as an upper jaw 3015 of the end effector 3012.
[0299] In various implementations, the end effector 3012 is
configured to be coupled to an elongated shaft assembly 3100 that
protrudes from a handle assembly or housing 3400. See FIG. 20. The
handle assembly 3400 may be similar to one of the handle assemblies
disclosed herein and/or in U.S. Patent Application Publication No.
US 2012/0074200 A1 except for the differences discussed herein.
[0300] Referring to FIG. 23, the elongated channel 3014 may
comprise an elongated trough 3016 that is configured to removably
support a surgical staple cartridge 10030 thereon. In various
implementations, for example, the elongated channel 3014 may be
fabricated from, for example, 300 & 400 Series, 17-4 & 17-7
stainless steel, titanium, etc. and be formed with spaced side
walls 3018. The body 10031 of staple cartridge 10030 is sized to be
removably supported within the elongated channel 3014 as shown such
that each staple 10032 therein is aligned with corresponding staple
forming pockets in the anvil assembly 3020 when the anvil assembly
3020 is driven into forming contact with the staple cartridge
10030. The elongated channel 3014 may further include a proximal
end 3200 that includes a pair of spaced side walls 3202. In at
least one implementation, the end effector 3012 is configured to be
articulated relative to the elongated shaft assembly 3100 about an
articulation and pivot axis A-A about which the anvil assembly 3020
is pivoted relative to the elongated channel 3014. The elongated
shaft assembly 3100 defines a longitudinal tool axis LT-LT. The
articulation and pivot axis A-A is transverse to the longitudinal
tool axis LT-LT. The elongated shaft assembly 3100 comprises a
hollow outer shaft 3300 and serves to function as the shaft spine
of the elongated shaft assembly 3100. The proximal end of the outer
shaft 3300 may be rotatably supported by the handle assembly 3400
so that the clinician may selectively rotate the elongated shaft
assembly 3100 and the end effector 3012 attached thereto about the
longitudinal tool axis LT-LT. For example, the proximal end of the
elongated shaft assembly may be operably coupled to a nozzle
assembly 3250 that is rotatably supported on the handle assembly
3400. Rotation of nozzle assembly 3250 relative to the handle
assembly 3400 (represented by arrow "R") will result in rotation of
the elongated shaft assembly 3100 as well as the end effector 3012
coupled thereto. See FIG. 20.
[0301] Referring again to FIG. 23, the distal end 3302 of the outer
shaft 3300 is formed with a clevis arrangement 3304 that comprises
a pair of spaced attachment tabs 3306. Each attachment tab 3306 has
a mounting hole 3308 therein that is adapted to receive a
corresponding pivot pin 3204 that is formed on each upstanding side
wall 3202. Thus, the elongated channel 3014 is selectively
pivotable or articulatable about the pivot axis A-A relative to the
elongated shaft assembly 3100. The anvil assembly 3020 includes a
distal anvil portion 3022 and a proximal anvil mounting portion
3030. The distal anvil portion 3022 may, for the most part, be
substantially coextensive with the portion of the elongated channel
3014 that supports the staple cartridge 10030 and be fabricated
from, for example, 300 & 400 Series, 17-4 & 17-7 stainless
steel, titanium, etc. The distal anvil portion 3022 comprises two
spaced apart anvil arms 3024 that protrude distally from the anvil
mounting portion 3030 to define an elongated slot 3026
therebetween. Each of the spaced-apart anvil arms 3024 has a staple
forming undersurface, generally labeled as 3028 that has a
plurality of staple forming pockets (not shown) formed therein.
[0302] The anvil mounting portion 3030 has a pair of mounting holes
3032 (only one is shown in FIG. 23) that are adapted to pivotally
receive therein the corresponding pivot pins 3204 that protrude
from the side walls 3202 of the proximal end 3200 of the elongated
channel 3014. Such arrangement serves to pivotally mount the anvil
assembly 3020 to the elongated channel 3014 for selective pivotal
travel about pivot axis A-A between an open position (FIGS. 24 and
25) and a closed position (FIGS. 21, 22 and 26).
[0303] Articulation of the end effector 3012 about the pivot axis
A-A as well as actuation of the anvil assembly 3020 between open
and closed positions may be controlled by a single firing system
generally designated as 3500. In at least one implementation, for
example, the firing system 3500 includes an actuation pivot 3510
that is movably supported between the upstanding side walls 3202 of
the elongated channel 3014. The actuation pivot 3510 includes a
distal cam surface 3512 and a proximal cam surface 3514. The distal
cam surface 3512 is configured to operably interface with an
inwardly protruding distal anvil pin 3034 that protrudes from the
anvil mounting portion 3030. The proximal cam surface 3514 is
configured to operably interface with an inwardly protruding
proximal anvil pin 3036 that also protrudes inwardly from the anvil
mounting portion 3030. As can be seen in FIG. 23, the distal anvil
pin 3034 extends inwardly through the corresponding elongated
distal slots 3206 in the upstanding side walls 3202 of the proximal
end 3200 of the elongated channel 3014. Likewise, the proximal
anvil pin 3036 extends inwardly through corresponding elongated
slots 3208 in the upstanding side walls 3202 of the proximal end
3200 of the elongated channel 3014.
[0304] The firing system 3500 may be controlled, for example, by a
closure trigger arrangement on a handle assembly 3400 of the type
disclosed in U.S. Patent Application Publication No. US
2012/0074200 A1. For example, the firing system 3500 may include an
actuation bar 3520 that is movably coupled to the actuation pivot
3510. The actuation bar 3520 may have, for example, an attachment
ball member 3522 formed on the distal end thereof that is rotatably
received within a semi-circular groove 3516 in the actuation pivot
3510. Such arrangement permits the actuation pivot 3510 to pivot or
otherwise move relative to the actuation bar 3520. Other methods of
movably coupling the actuation bar 3520 to the actuation pivot 3510
may also be employed. The actuation bar 3520 may extend through the
hollow outer shaft 3300 and be operably coupled to, for example,
the closure carriage arrangement disclosed in the aforementioned
published patent application such that actuation of the trigger
10440 will result in the axial travel of the actuation bar 3520
within the outer shaft 3330. In various implementations, a series
of support collars 3530, 3532, 3534 may be provided in the outer
shaft 3300 to provide support to the actuation bar 3520 within the
outer shaft 3300.
[0305] In use, the end effector 3012 is articulated into a desired
position prior to closing the anvil assembly 3020. Of course, if
the end effector 3012 must be inserted through a trocar or other
opening in the patient, the clinician can move the anvil assembly
3020 to the closed position (FIG. 21) without articulating the end
effector 3012 so that the end effector 3012 is coaxially aligned
with the elongated shaft assembly 3100. The clinician manipulates
the trigger 10440 to position the actuation pivot 3510 so that the
cam surfaces 3512 and 3514 interact with the pins 3034, 3036 to
result in the closure of the anvil assembly 3020 without
articulating the end effector 3012. Once the end effector 3012 has
been inserted through the trocar or other opening, the clinician
may actuate the trigger 10440 to move the actuation pivot 3510 to
the position shown in FIG. 24. When in that position, the actuation
pivot 3510 causes the anvil assembly 3520 to move to the open
position without being articulated. The clinician may then
articulate the end effector 3012 about the pivot axis A-A relative
to the elongated shaft assembly 3100 by further actuating the
trigger 10440 to move the actuation pivot 3510 to the position
shown, for example, in FIG. 25. As can be seen in that Figure, the
end effector 3012 has pivoted in a first direction "FD" which is
the same general direction that the anvil assembly 3020 moves when
it moves from a closed position to the open position (referred to
herein as the "opening direction `OD`"). If desired, the user may
actuate the trigger 10440 to thereby cause the end effector 3012 to
move in a second direction "SD" that is the same general direction
that the anvil assembly 3020 moves when it is moved from the open
position to a closed position (referred to herein as the "closing
direction "CD`"). Once the user has positioned the end effector
3012 in the desired position, the user further actuates trigger
10440 to manipulate the actuation pivot to the position illustrated
in FIG. 26 to thereby clamp the target tissue "T" between the anvil
assembly 3020 and the staple cartridge 10030.
[0306] The surgical instrument 3010 further includes a knife bar
assembly 3600 that can be attached to the firing bar and firing
rack arrangement disclosed herein and/or in U.S. Patent Application
Publication No. US 2012/0074200 A1 such that it can be controlled
by actuating the secondary trigger 10460. In various embodiments,
the knife bar assembly 3600 may comprise an upper bar segment 3602
and a lower bar segment 3604. Such arrangement may enable the knife
bar assembly 3600 to flex as the end effector 3012 is articulated,
while remaining sufficiently rigid to be driven distally through
the shaft assembly 3100. In the depicted embodiment, the upper and
lower knife bar segments 3602, 3604 are each attached to a cutting
head 3610. In the depicted configuration, the cutting head 3610
includes a vertically oriented body portion 3612 that has an upper
portion 3615 and a lower portion 3617. A bottom foot 3614 is formed
on or attached to the lower portion 3617. Similarly, an upper tab
3616 is formed on or otherwise attached to the upper portion 3615
of the vertically oriented body portion 3612. In addition, as can
be seen in FIG. 23, the vertically oriented body portion 10612
further includes a tissue cutting edge 3620.
[0307] Referring to FIG. 23, the vertically oriented body portion
3612 extends through a longitudinally extending slot 3210 in the
elongated channel 3014 and the longitudinally extending slot 3026
in the anvil assembly 3020. When assembled, the upper portion 3615
of the cutting head 3610 extends through a proximal upper opening
3031 in the anvil mounting portion 3030 of the anvil assembly 3020.
Thus, when the cutting head 3610 is distally advanced, the upper
tab portions 3616 ride on the anvil arms 3024. Likewise the bottom
foot 3614 protrudes through a lower opening 3212 in the elongated
channel 3014 such that it rides below the elongated channel as the
cutting head 3610 is advanced distally. As the cutting head 3610 is
advanced distally, the cutting edge 3620 thereon severs the tissue
clamped in the end effector 3012. The surgical staple cartridge
10030 is crushed between the anvil assembly 3020 and the elongated
channel 3014 thereby causing the staples 10032 supported therein to
be formed on both sides of the tissue cut line as they are brought
into contact with the staple forming underside of the anvil
assembly 3020. After the cutting head 3610 has been advanced to the
distal end of the end effector, 3012, the user retracts the cutting
head 3610 to the starting position in the manner discussed herein
and the trigger 10440 is actuated to open the anvil assembly 3020
to release the staple cartridge and stapled tissue.
[0308] As was discussed in detail above, by having the articulation
axis also be the axis about which the anvil pivots, the surgeon has
a much more reliable frame of reference regarding the location of
the pivot axis when viewing the endocutter's anvil through the
camera. Stated another way, when using the end effector arrangement
of the surgical instrument 10010 the surgeon can determine where
the elongated channel is going to pivot relative to the elongated
shaft by viewing where the anvil is pivotally mounted to the
elongated channel.
[0309] FIGS. 27-35 illustrate another surgical instrument
arrangement 4010 that may employ various components of other
surgical instruments disclosed herein except for the differences
discussed below. The surgical instrument 4010 is designed to
manipulate and/or actuate various forms and sizes of end effectors
4012 that are operably attached to an elongated shaft assembly 4100
of the surgical instrument. In the depicted embodiment, for
example, the end effector 4012 comprises a surgical stapling device
that has openable and closable jaws 4013 and 4015. More
specifically, the end effector 4012 includes an elongated channel
4014 that forms a lower jaw 4013 of the end effector 4012. See FIG.
28. In the illustrated arrangement, the elongated channel 4014 is
configured to operably support a staple cartridge 10030 and also
movably supports an anvil assembly 4020 that functions as an upper
jaw 4015 of the end effector 4012.
[0310] In various implementations, the end effector 4012 is
configured to be coupled to an elongated shaft assembly 4100 that
protrudes from a handle assembly or housing 4400. See FIG. 27. The
handle assembly 4400 may be similar to one of the handle assemblies
disclosed herein and/or in U.S. Patent Application Publication No.
US 2012/0074200 A1 except for any differences discussed below.
Alternative embodiments, however, may be employed with and actuated
by robotic systems as was discussed hereinabove.
[0311] Referring to FIGS. 28 and 29, the elongated channel 4014 may
comprise an elongated trough 4016 that is configured to removably
support a surgical staple cartridge 10030 thereon. In various
implementations, for example, the elongated channel 3014 may be
fabricated from, for example, 300 & 400 Series, 17-4 & 17-7
stainless steel, titanium, etc. and be formed with spaced side
walls 4018. The body 10031 of staple cartridge 10030 is sized to be
removably supported within the elongated channel 3014 as shown such
that each staple 10032 therein is aligned with corresponding staple
forming pockets in the anvil assembly 4020 when the anvil assembly
4020 is driven into forming contact with the staple cartridge
10030. The elongated channel 4014 may further include a somewhat
box-like proximal end 4200 that includes a pair of spaced side
walls 4202 that have a top flap 4203 protruding inwardly therefrom
to define a slot 4205 therebetween. The sidewalls 4202 are coupled
together by a support bar 4207 that extends therebetween. See FIGS.
29, 31 and 32.
[0312] In at least one implementation, the elongated channel 4014
is configured to be moved or articulated relative to the elongated
shaft assembly 4100 and the anvil assembly 4020 about a pivot axis
A-A about which the anvil assembly 4020 is also pivotally mounted.
The elongated shaft assembly 4100 defines a longitudinal tool axis
LT-LT. The pivot axis A-A is transverse to the longitudinal tool
axis LT-LT. The elongated shaft assembly 4100 comprises a hollow
outer shaft 4300 and serves to function as the shaft spine of the
elongated shaft assembly 4100. The proximal end of the outer shaft
4300 may be rotatably supported by the handle assembly 4400 so that
the clinician may selectively rotate the elongated shaft assembly
4100 and the end effector 4012 attached thereto about the
longitudinal tool axis LT-LT.
[0313] Referring again to FIG. 29, the distal end 4302 of the outer
shaft 4300 is formed with a clevis arrangement 4304 that comprises
a pair of spaced attachment tabs 4306. Each attachment tab 4306 has
a mounting hole 4308 therein that is adapted to receive a
corresponding pivot pin 4310 that defines the pivot axis A-A. The
pivot pins 4310 also extend through corresponding openings 4210 in
the upstanding side walls 4202 of the proximal mounting end 4200 of
the elongated channel 4014. Thus, the elongated channel 4014 is
selectively pivotable or articulatable about the pivot axis A-A
relative to the elongated shaft assembly 4100 and the anvil
assembly 4020. The anvil assembly 4020 includes a distal anvil
portion 4022 and an proximal anvil mounting portion 4030. The
distal anvil portion 4022 may, for the most part, be substantially
coextensive with the portion of the elongated channel 3014 that
supports the staple cartridge 10030 and be fabricated from, for
example, 300 & 400 Series, 17-4 & 17-7 stainless steel,
titanium, etc. The distal anvil portion 4022 comprises two spaced
apart anvil arms 4024 that protrude distally from the anvil
mounting portion 4030 to define an elongated slot 4026
therebetween. Each of the spaced-apart anvil arms 4024 has a
staple-forming undersurface, generally labeled as 4028 that has a
plurality of staple forming pockets (not shown) formed therein. The
anvil mounting portion 4030 has a pair of mounting holes 4032 that
are adapted to pivotally receive therein the corresponding pivot
pins 4310. Such arrangement serves to pivotally mount the anvil
assembly 4020 to the outer shaft 4300 for selective pivotal travel
about pivot axis A-A between an open position (FIGS. 32 and 33) and
a closed position (FIGS. 28, 30 and 31) relative to the elongated
channel assembly 4014.
[0314] Initial closure of the anvil assembly 4020 relative to the
elongated channel assembly 4014 and the surgical staple cartridge
10030 operably supported therein may be accomplished by a unique
and novel closure system, generally designated as 4110. The closure
system 4110 may also be referred to herein as the "second jaw
closure system". In one implementation, the closure system 4110
includes an anvil closure rod 4112 that has a proximal end that may
be operably coupled to the closure carriage in the handle assembly
4400 in the various manners discussed herein and also disclosed in
further detail in U.S. Patent Application Publication No. US
2012/0074200 A1. For example, the proximal end of the closure rod
4112 may have a flange (not shown) that is configured to be
rotatably attached to a closure carriage that is operably supported
within the housing assembly 4400. Thus, actuation of the trigger
10440 will result in the axial advancement of the anvil closure rod
4112 within the outer shaft 4300.
[0315] Such arrangement also enables the elongated shaft assembly
4100 and the end effector 4012 that is operably coupled thereto may
be selectively rotated about the longitudinal tool axis LT-LT
relative to the housing assembly 4400. The anvil closure rod 4112
may also be referred to herein as the "second jaw actuator
bar."
[0316] Referring again to FIG. 29, a distal end 4118 of the anvil
closure rod 4112 is configured to be pinned to an anvil closure
link 4120. The anvil closure link 4120 is pivotally pinned to an
anvil pin slide 4122 by a pin 4123. The anvil pin slide 4122
includes two spaced side walls 4124 that define a space 4125
therebetween that is configured to receive a portion of a tissue
cutting head 4610 as will be discussed in further detail below. An
anvil cam pin 4034 is mounted to the anvil mounting portion 4030
and extends through elongated slots 4208 in the upstanding side
walls 4202 of the proximal end 4200 of the elongated channel 4014
as well as through cam slots 4126 provided through the side walls
4124 of the anvil pin slide 4122. FIG. 32 illustrates the positions
of the anvil slide 4122 and the anvil cam pin 4034 when the anvil
assembly 4020 is in the open position. To move the anvil assembly
4020 to a closed position relative to the elongated channel
assembly 4014 (FIG. 31), the clinician can actuate the trigger
10440 which drives the anvil closure rod 4112 in the distal
direction "DD". Such movement of the anvil closure rod 4112 in the
distal direction also moves the anvil pin slide 4122 in the distal
direction "DD". As the anvil pin slide 4122 moves in the distal
direction, the camming action of the anvil pin 4034 in the slots
4126 and 4208 cams the anvil assembly 4020 in the closing direction
"CD" to the closed position as shown in FIG. 31. Movement of the
anvil closure rod 4112 in the proximal direction "PD" will cause
the anvil assembly 4020 to move in the opening direction "OD".
[0317] In various arrangements, the end effector 4012 may be
configured to be selectively articulated relative to the
longitudinal tool axis LT-LT. Stated another way, the elongated
channel assembly 4014 may be selectively articulatable or movable
relative to the anvil assembly 4020. As described above, the
elongated channel 4014 is pivotally coupled to the distal end 4302
of the outer tube 4300 by pivot pins 4310. Such attachment
arrangement permits the end elongated channel assembly 4014 to
articulate in a first direction "FD" about the articulation and
pivot axis A-A which is essentially the same direction that the
anvil assembly 4020 moves in when the anvil assembly 4020 is moved
from a closed position to an open position (the anvil opening
direction "OD"). Such arrangement further facilitates articulation
or movement in a second articulation direction "SD" that is
essentially the same as the direction that the anvil assembly 4020
moves from an open position to a closed position (the anvil closing
direction "CD"). To facilitate such movement of the elongated
channel assembly 4014 relative to the anvil assembly 4020, a
reciprocatable articulation rod 4150 is employed. The articulation
rod 4150 may also be referred to herein as the "first jaw actuator
bar". More specifically and with reference to FIG. 29, the
articulation rod 4150 is sized to be movably received with the
outer tube 4300 and has a distal end 4152 that is pivotally pinned
to a pair of articulation links 4160. The articulation links 4160
are pivotally pinned to the proximal portion of the elongated
channel 4014 by an articulation pin 4161. As can be seen in FIG.
34, a proximal end 4154 of the articulation rod 4150 has an
articulation rack 4156 formed thereon that drivingly interfaces
with an articulation control system 10200 of the type described
hereinabove. As indicated above, the articulation control system
10200 may also be referred to herein as the "first jaw closure
system". Ratcheting rotation of the actuator 10210 of the
articulation transmission 10200 causes articulation of the
elongated channel assembly 4014 in the first or second directions
relative to the anvil assembly 4020. FIGS. 28, 30, 31 and 31
illustrate the elongated channel assembly 4014 in an unarticulated
position. When the drive gear 10240 on the articulation body 10220
of the articulation transmission 10200 is rotated to thereby push
the articulation rod 4150 in the distal direction "DD", the
elongated channel assembly 4014 will move in the first articulation
direction "FD" relative to the anvil assembly 4020 as shown in FIG.
33. When the drive gear 10240 on the articulation body 10220 of the
articulation transmission 10200 has been rotated to thereby pull
the articulation rod 10112 in the proximal direction "PD", the
elongated channel assembly 4014 will pivot in a second direction
"SD" relative to the anvil assembly 4020. The second direction "SD"
is the same as the closure direction "CD". See FIG. 33.
[0318] The surgical instrument 4010 as illustrated in FIG. 27 may
further include an firing system of the type described herein
and/or in U.S. Patent Application Publication No. US 2012/0074200
A1 that may be controlled by actuating trigger 10460. Referring to
FIG. 34, a firing rack 10500 is coupled to a firing rod 10530 that
is attached to the proximal end of a knife bar assembly 4600. In
various forms, the knife bar assembly 4600 includes a distal knife
bar portion 4602 that includes an upper knife bar 4604 and a lower
knife bar 4606 that are attached to an I-beam cutting head 4610.
The upper knife bar 4604 and the lower knife bar 4606 are
configured to flex as the end effector 4012 is articulated. As can
be seen in FIG. 29, for example, the I-beam cutting head 4610
includes a vertically oriented body portion 4612 that has a bottom
foot 4614 and an upper tab 4616 formed thereon. A tissue cutting
edge 4620 is formed on the vertically oriented body portion
4612.
[0319] Still referring to FIG. 29, the vertically oriented body
portion 4612 extends through a longitudinally extending slot 4704
in the elongated channel 4014 and the longitudinally extending slot
4026 in the distal anvil portion 4024. The distal anvil portion
4024 further has a trough 4025 formed in the upper surface for
slidably receiving the upper tab 4616 therein. The distal end of
the upper tab 6616 may be sloped to interface with sloped surfaces
4027 formed on the anvil arms 4024 of the distal anvil portion
4022. The flexible firing bars 4604, 4606 extend through the
elongated shaft assembly 4100 to be coupled to a distal end portion
10532 of a firing rod 10530 by a coupler member 10650. As was
discussed above, actuation of the trigger 10460 will result in the
axial advancement of the firing rod 10530 within the elongated
shaft assembly 4100 to apply firing and retraction motions to the
knife bar assembly 4600.
[0320] Operation of the surgical instrument 4010 will now be
described. To initiate the closure process, a first stroke is
applied to the trigger assembly 10430. That is, the trigger
assembly 10430 is initially pivoted toward the pistol grip 10406.
Such pivoting action serves to drive the closure carriage in the
distal direction "DD". Such distal movement of the closure carriage
also axially advances the anvil closure rod 4112 in the distal
direction "DD". As the anvil closure rod 4112 moves distally, the
closure link 4120 moves the anvil pin slide 4122 distally. As the
anvil pin slide 4122 moves distally, the anvil assembly 4020 is
pivoted to the closed position by virtue of the camming interaction
of the anvil pin 4034 within the slots 4208, 4126. See FIG. 31. In
the various manners discussed herein, if the surgeon desires to
simply grasp and manipulate tissue prior to clamping it between the
anvil assembly 4020 and the surgical staple cartridge 10030, the
trigger assembly 10430 may be pivoted to open and close the anvil
assembly 4020 without fully pivoting the trigger assembly 10430 to
the fully closed position. Once the trigger assembly 10430 has been
initially fully compressed into the closed position, the anvil
assembly 4020 will be retained in the locked or clamped position by
the closure locking assembly which prevents the proximal movement
of the closure carriage as was discussed above. To drive the knife
bar assembly 4600 distally through the tissue clamped in the end
effector 4012, the surgeon again pivots the primary trigger 10440
toward the pistol grip 10406 of the housing assembly 10400. As the
primary trigger 10440 is pivoted, the firing rack 10500, the firing
rod 10530, and the knife bar assembly 4600 are driven in the distal
direction "DD". As the knife bar assembly 4600 is driven in the
distal direction, the cutting head 4610 also moves distally. As the
cutting head 4610 moves distally, the sloped surface on the upper
tab 4616 travels up the sloped surfaces 4027 on the distal anvil
portion 4022 moving the floating distal anvil portion 4022 in the
down direction "D". As the distal anvil portion 4022 is driven
downwardly towards the clamped tissue and the staple cartridge
10030, the clamping or crushing action causes the staples to be
formed against the underside of the distal anvil portion 4022.
Thus, as the cutting head 4610 is driven distally through the end
effector 4012, the tissue cutting surface 4620 thereon severs the
clamped tissue while forming the staples in the staple cartridge
which are situation on both sides of the cut tissue. After the
knife bar assembly 4600 has been driven through the tissue clamped
in the end effector 4012, the surgeon then releases the primary
trigger 10440 to thereby permit the primary trigger 10440 to pivot
to its unactuated position under the bias of the firing spring. As
the primary trigger 10440 pivots back to the starting position, the
firing rack 10500, firing rod 10530, and knife bar assembly 4600
are drawn proximally back to their respective starting positions.
The end effector 4012 remains in its clamped position as shown in
FIG. 31. The anvil assembly 4020 may then be unlocked and moved to
the open position in the manner discussed above.
[0321] As was discussed in detail above, by having the articulation
axis also be the axis about which the anvil pivots, the surgeon has
a much more reliable frame of reference regarding the location of
the pivot axis when viewing the endocutter's anvil through the
camera. Stated another way, when using the end effector arrangement
of the surgical instrument 10010 the surgeon can determine where
the elongated channel is going to pivot relative to the elongated
shaft by viewing where the anvil is pivotally mounted to the
elongated channel.
[0322] The surgical instrument 4010 also employs separate control
systems for moving the end effector jaws 4013 and 4015. For
example, the clinician may elect to move or articulate the lower
jaw 4013 (elongated channel 10014) about the pivot axis A-A toward
or way from the upper jaw 4015 without actuating the upper jaw 4015
(anvil assembly 4020). This may be accomplished by actuating the
articulation control system 10200 without actuating the closure
system 4110. Thus, the elongated channel 4014 may be selectively
pivoted about the pivot axis A-A while the anvil assembly 4020 is
open or closed. Similarly, the anvil assembly 4020 may be actuated
or moved without moving the elongated channel 4014 by actuating the
closure system 4110 without actuating the articulation control
system 10200. Such unique and novel arrangement provides the
clinician with more flexibility when positioning the end effector
jaws within the patient.
[0323] FIGS. 36-42 depict another surgical instrument 5010 that is
capable of practicing several unique benefits of the present
invention. The surgical instrument 5010 is designed to manipulate
and/or actuate various forms and sizes of end effectors 5012 that
are operably attached to an elongated shaft assembly 5100 of the
surgical instrument. In the depicted embodiment, for example, the
end effector 5012 comprises a surgical stapling device that has
openable and closable jaws 5013 and 5015. More specifically, the
end effector 5012 includes an elongated channel 5014 that forms a
lower jaw 5013 of the end effector 5012. See FIG. 37. In the
illustrated arrangement, the elongated channel 5014 is configured
to operably support a staple cartridge 10030 of the type and
construction described herein. For example, the surgical staple
cartridge includes a cartridge body 10031 that operably supports a
plurality of unformed surgical staples 10032 therein. The elongated
channel 5014 also movably supports an anvil 3020 that functions as
an upper jaw 5015 of the end effector 5012.
[0324] In various implementations, the end effector 5012 is
configured to be coupled to an elongated shaft assembly 5100 that
protrudes from a handle assembly or housing 5400. See FIG. 36. The
handle assembly 5400 may be similar to one of the handle assemblies
disclosed herein and/or in U.S. Patent Application Publication No.
US 2012/0074200 A1 except for the differences discussed below.
[0325] Referring to FIG. 38, the elongated channel 5014 may
comprise an elongated trough 5016 that is configured to removably
support a surgical staple cartridge 10030 thereon. In various
implementations, for example, the elongated channel 5014 may be
fabricated from, for example, 300 & 400 Series, 17-4 & 17-7
stainless steel, titanium, etc. and be formed with spaced side
walls 5018. The body 10031 of staple cartridge 10030 is sized to be
removably supported within the elongated channel 5014 as shown such
that each staple 10032 therein is aligned with corresponding staple
forming pockets in the anvil 5020 when the anvil 5020 is driven
into forming contact with the staple cartridge 10030. The elongated
channel 5014 may further include a proximal end 5200 that includes
a pair of spaced side walls 5202 and 5204. Each side wall 5202,
5204 has a hole 5205, 5207, respectively therethrough for
attachment to the elongated shaft assembly 5100 by corresponding
pivot pins 5310R and 5310L.
[0326] In at least one implementation, for example, the end
effector 5012 is configured to be articulated relative to the
elongated shaft assembly 5100 about an articulation and pivot axis
A-A about which the anvil assembly 5020 is pivoted relative to the
elongated channel 5014. The elongated shaft assembly 5100 defines a
longitudinal tool axis LT-LT. The articulation and pivot axis A-A
is transverse to the longitudinal tool axis LT-LT. The elongated
shaft assembly 5100 comprises a hollow outer shaft 5300 and serves
to function as the shaft spine of the elongated shaft assembly
5100. The proximal end of the elongated shaft assembly 5100 may be
rotatably supported by the handle assembly 5400 so that the
clinician may selectively rotate the elongated shaft assembly 5100
and the end effector 5012 attached thereto about the longitudinal
tool axis LT-LT. For example, the proximal end of the elongated
shaft assembly 5100 may be operably coupled to a nozzle assembly
5250 that is rotatably supported on the handle assembly 5400.
Rotation of nozzle assembly 5250 relative to the handle assembly
5400 (represented by arrow "R") will result in rotation of the
elongated shaft assembly 5100 as well as the end effector 5012
coupled thereto. See FIG. 36.
[0327] Referring again to FIG. 38, the distal end 5302 of the outer
shaft 5300 is formed with a clevis arrangement 5304 that comprises
a pair of spaced attachment tabs 5306R and 5306L. Each attachment
tab 5306R, 5306L has a mounting hole 5308R, 5308L, respectively
therein that is adapted to receive a corresponding pivot pin 5310R,
5310L, respectively. Thus, the elongated channel 5014 is
selectively pivotable or articulatable about the pivot axis A-A
relative to the elongated shaft assembly 5100. The anvil assembly
5020 includes a distal anvil portion 5022 and a proximal anvil
mounting portion 5030. The distal anvil portion 5022 may, for the
most part, be substantially coextensive with the portion of the
elongated channel 5014 that supports the staple cartridge 10030 and
be fabricated from, for example, 300 & 400 Series, 17-4 &
17-7 stainless steel, titanium, etc. The distal anvil portion 5022
comprises two spaced apart anvil portions 5024 that protrude
distally from the anvil mounting portion 5030 to define an
elongated slot 5026 therebetween. Each of the spaced-apart anvil
portions 5024 has a staple forming undersurface, generally labeled
as 5028 that has a plurality of staple forming pockets (not shown)
formed therein. The anvil mounting portion 5030 includes a right
mounting wall 5032 and a left mounting wall 5034. Each mounting
wall 5032, 5034 has a mounting hole 5036 extending therethrough
that are adapted to pivotally receive therein the corresponding
pivot pins 5310R, 5310L. Such arrangement serves to pivotally mount
the anvil assembly 5020 to the elongated channel 5014 for selective
pivotal travel about pivot axis A-A between an open position and a
closed position.
[0328] The anvil assembly 5020 is selectively movable between open
and closed positions by means of an anvil bar 5110. The anvil bar
5110 may be coupled to a closure carriage of the type disclosed
herein and/or in U.S. Patent Application Publication No. US
2012/0074200 A1 such that actuation of a trigger mounted on the
handle assembly will result in the axial movement of the anvil bar
5110 within elongated shaft assembly 5100. The anvil bar 5110 is
configured for movable attachment to an actuator cam 5510 that is
pivotally journaled on an anvil pin 5038 that protrudes inwardly
from the left mounting wall 5034 of the anvil mounting portion
5030. See FIGS. 39 and 40. As can be seen in FIG. 41, for example,
the anvil pin 5034 is rotatably received within a corresponding
anvil cam slot 5512 within the actuator cam 5510. The distal end
5112 of the anvil bar 5110 is pivotally pinned to the actuator cam
5510 by a pivot pin 5114 defines an anvil actuation axis B-B. See
FIG. 40.
[0329] The end effector 5012 may also be articulatable or pivotable
relative to the elongated shaft assembly 5100 about the pivot axis
A-A by an articulation system of the type described herein and/or
in U.S. Patent Application Publication No. US 2012/0074200 A1. The
articulation system may be employed to axially actuate an
articulation bar 5150 that is pivotally coupled to the actuator cam
5510. Referring to FIGS. 38 and 39 for example, the distal end 5152
of the articulation bar 5150 pin is rotatably mounted on a pin hub
5514 protruding from the actuator cam 5510. The pin hub 5514 has a
cavity 5516 therein for rotatably receiving an inwardly protruding
channel pin 5209 for selective rotation relative thereto about a
channel axis C-C. See FIG. 40.
[0330] FIGS. 41 and 42 illustrate the position of the end effector
5012 in a neutral or unarticulated position with the anvil assembly
5020 thereof in an open position. When the user desires to close
the anvil assembly 5020, the anvil rod 5110 is advanced distally in
the distal direction "DD". Movement of the anvil rod 5110 in the
distal direction causes the actuator cam 5510 to interact with the
anvil pin 5038 to pivot the anvil assembly 5020 to a closed
position about the pivot axis A-A. When the clinician desires to
articulate the end effector 5012, the articulation rod 5150 is
moved axially within the elongated shaft 5100. Movement of the
articulation rod in the distal direction "DD" will, for example,
cause the end effector 5012 to pivot in a first direction "FD" that
is essentially the same direction in which the anvil assembly 5020
is moved from a closed position to an open position (referred to
herein as the opening direction "OD"). Movement of the articulation
rod in a proximal direction "PD" will cause the end effector 5012
to pivot in a second direction "SD" about the pivot axis A-A which
is essentially the same direction in which the anvil assembly 5020
moves when moving from an open position to a closed position
(referred to herein as the closing direction "CD").
[0331] As can also be seen in FIGS. 38 and 39, the surgical
instrument 5010 further includes a knife bar assembly 5600 that can
be attached to the firing bar and firing rack arrangement disclosed
herein and/or in U.S. Patent Application Publication US
2012/0074200 A1 such that it can be controlled by actuating the
secondary trigger in the various manners described herein 460. The
knife bar assembly 5600 may comprise a knife bar 5602 that may flex
as the end effector 5012 is articulated, while remaining
sufficiently rigid to be driven distally through the shaft assembly
5100. In the depicted embodiment, the knife bar 5602 is attached to
a cutting head 5610. In the depicted configuration, the cutting
head 5610 includes a vertically oriented body portion 5612 that has
an upper portion 5615 and a lower portion 5617. A bottom foot 5614
is formed on or attached to the lower portion 5617. Similarly, an
upper tab 5616 is formed on or otherwise attached to the upper
portion 5615 of the vertically oriented body portion 5612. In
addition, as can be seen in FIGS. 38 and 39, the vertically
oriented body portion 5612 further includes a tissue cutting edge
5620. The vertically oriented body portion 5612 extends through a
longitudinally extending slot 5210 in the elongated channel 5014
and the longitudinally extending slot 5026 in the anvil assembly
5020. Thus, when the cutting head 5610 is distally advanced, the
upper tab portions 5616 ride on the anvil arms 5024. Likewise the
bottom foot 5614 protrudes through a lower opening in the elongated
channel 5014 such that it rides below the elongated channel 5014 as
the cutting head 5610 is advanced distally. As the cutting head
5610 is advanced distally, the cutting edge 5620 thereon severs the
tissue clamped in the end effector 5012. The surgical staple
cartridge 10030 is crushed between the anvil assembly 5020 and the
elongated channel 5014 thereby causing the staples 10032 supported
therein to be formed on both sides of the tissue cut line as they
are brought into contact with the staple forming underside of the
anvil assembly 5020. After the cutting head 5610 has been advanced
to the distal end of the end effector 5012, the user retracts the
cutting head 5610 to the starting position in the manner discussed
herein and the trigger is actuated to open the anvil assembly 5020
to release the staple cartridge and stapled tissue.
[0332] As was discussed in detail above, by having the articulation
axis also be the axis about which the anvil pivots, the surgeon has
a much more reliable frame of reference regarding the location of
the pivot axis when viewing the endocutter's anvil through the
camera. Stated another way, when using the end effector arrangement
of the surgical instrument 10010 the surgeon can determine where
the elongated channel is going to pivot relative to the elongated
shaft by viewing where the anvil is pivotally mounted to the
elongated channel.
[0333] In various implementations, when employing surgical end
effectors of the types disclosed herein, the end effector is
configured to be coupled to an elongated shaft assembly that
protrudes from a housing. The housing may comprise a
hand-manipulatable handle arrangement or it may, for example,
comprise a portion of a robotic system or other automated control
system arrangement. The end effector and elongated shaft may
typically be introduced to the surgical site within the patient
through a trocar tube or working channel in another form of access
instrument. In at least some surgical procedures, it is desirable
and indeed, even sometimes necessary, to limit the size of trocar
tubes/access tubes that are employed. This limits the size of end
effector and elongated shaft arrangements that may be employed. For
example, if a trocar is employed that has a 5 mm diameter opening
through the trocar tube, the end effector as well as the elongated
shaft must be sized to enable them to be passed through that
opening. When employing cutting and stapling end effectors that
essentially comprise jaws that are moveable between open and closed
positions, the clinician passes the end effector through the trocar
when the jaws are in their closed position. Typically when the jaws
are in their fully closed position, the end effector is in its
smallest cross-sectional shape to facilitate such insertion through
the tube or access opening. Once the end effector has been passed
through the tube or opening, the clinician may then open the jaws
to grasp and manipulate the target tissue. Once the target tissue
is properly positioned between the jaws, the clinician may cause
the jaws to be closed onto or clamped onto the tissue in
preparation for firing the instrument (i.e., causing the instrument
to cut and staple the tissue). Thus, the size of the end effector
that may be employed to complete a surgical procedure may
necessarily be limited by the size of access opening or access tube
that it must pass through. Such limitations can become problematic,
however, in instances wherein the jaws cannot sufficiently
accommodate the target tissue due to the thickness of the target
tissue to be cut and stapled. In some applications, for example,
the tissue may be over compressed by the jaws if the tissue is
thicker than anticipated.
[0334] Over the years, a variety of end effector arrangements have
been developed to effectively accommodate various tissue
thicknesses. For example, U.S. Pat. No. 7,665,647, entitled
SURGICAL CUTTING AND STAPLING DEVICE WITH CLOSURE APPARATUS FOR
LIMITING MAXIMUM TISSUE COMPRESSION, and issued on Feb. 23, 2010,
the entire disclosure of which is hereby incorporated by reference
herein discloses cutting head configurations referred to as
"E-Beam" arrangements that are configured to limit an amount of
compression applied to the tissue as the E-beam is fired down the
end effector. While effective, there is a need for an end effector
that has a fully closed height that is smaller than a closed
"operating height" or "stapling height" when stapling tissue.
[0335] FIGS. 43-46 illustrate a cutting beam assembly 6610 that may
be employed with various end effectors 6012 of the type, for
example, disclosed herein as well as those disclosed in U.S. Pat.
No. 7,665,647. As can be seen in FIGS. 43 and 44, the cutting beam
assembly 6610 may include a firing bar 6620 that has a proximal
portion 6622 that is attached to a distal cutting beam head 6630
that translates within a staple cartridge 6670. See FIGS. 45 and
46. The distal cutting beam head 6630 may also be referred to as a
"firing member". The staple cartridge 6670 may comprise a staple
cartridge of the type disclosed in U.S. Pat. No. 7,665,647 and be
configured to be operably supported in the elongated channel 6014
of the end effector 6012. As discussed therein, the staple
cartridge 6670 includes a series of staple drivers 6642 that
operably support the surgical staples 6674 thereon. The drivers
6672 are driven upwardly toward the anvil 6020 as a wedge sled 6676
is advanced distally through the staple cartridge 6670.
[0336] Referring to FIGS. 43 and 44, the distal cutting beam head
6630 includes a body portion 6632 that is attached to the proximal
portion 6622 of the firing bar 6620. The firing bar 6622 may be
actuated by any of the firing arrangements disclosed herein
including those firing arrangements disclosed in U.S. Pat. No.
7,665,647. As can be seen in those Figures, the body portion
includes an upper portion 6640 and a lower portion 6650. The upper
portion 6640 includes a flexible extension arm 6642 that protrudes
from the lower portion 6650. Essentially, the extension arm 6642
comprises a cantilever-type beam arrangement that includes a
distally protruding nose 6644 that includes upper pins or tabs 6645
that protrude laterally therefrom. The upper portion 6640 further
includes a lower tab portion 6646 that includes a
distally-protruding lower nose portion 6647 and a
proximally-protruding hook, bumper, or catch formation 6648 that is
designed to engage a complementary body hook 6654 formed on the
lower portion 6650 as shown in FIG. 44. As can be most particularly
seen in FIGS. 43 and 44, a cutting surface 6649 is provided on the
movable upper portion 6640 and is oriented such that it located
proximal to the end of the upper nose 6644 and the end of the lower
nose portion 6647 such that a tissue-capturing pocket 6659 is
established between the upper nose 6644 and the lower nose 6647.
Such pocket 6659 enables tissue to be captured therein just distal
of cutting surface 6649. As can be appreciated from reference to
FIGS. 43 and 44, the cutting surface 6649 as well as the upper nose
portion 6644 and upper tabs 6645 move as a unit (e.g., they move
together) relative to the lower portion 6650 of the cutting beam
head 6630. As will be discussed in further detail below, such
arrangement enables the cutting beam head 6630 to assume a
compressed state that facilitates passage of the cutting beam head
6630 through, for example, an access opening or a trocar port that
has a somewhat limited cross-sectional area, while still being able
to accommodate various thicknesses of tissue when the end effector
has exited though the opening and has been clamped onto the tissue
in preparation for firing.
[0337] The lower portion 6650 of the cutting beam head 6630 further
includes lower foot tabs 6652 that protrude laterally from the
lower portion 6650. As can be seen in FIGS. 45 and 46, the
elongated channel 6014 includes an elongated slot 6016 that
corresponds with an elongated slot 6678 in the staple cartridge
6670 for accommodating the body portion 6632 of the cutting beam
head 6630. The elongated channel further has a channel track 6018
that is configured to receive the lower foot tabs 6652. Likewise,
the anvil assembly 6020 includes an elongated slot 6022 that
accommodates the body portion 6632 and an upper anvil track 6024
that accommodates the upper tabs 6645 therein.
[0338] FIG. 43 illustrates the cutting beam head 6630 in its
compressed state. The overall maximum height of the cutting beam
head in this compressed state is represented by "H1". FIG. 44
illustrates the cutting beam head 6630 in its uncompressed maximum
height state. The overall maximum height of the cutting beam head
in this uncompressed state is represented by "H2". It will be
understood that the overall height of the E-beam 6630 can vary
between H1 and H2 depending upon the cutting beam head's compressed
state. Referring now to FIG. 45, the end effector 6012 is
illustrated in its most cross-sectionally compact state which may
be referred to herein as its insertion state or position. The
overall height (or diameter) of the end effector 6012 is
represented in FIG. 45 by "E1". This would be the state, for
example, in which the end effector 6012 might be inserted through
an access opening or a trocar port. Once the end effector 6012 has
been inserted through the opening or trocar port to the surgical
site, the clinician may open and close the anvil assembly 6020 as
needed to grasp and manipulate the target tissue T. Once the target
tissue T has been captured between the anvil assembly 6020 and the
staple cartridge 6670, the clinician may lock the anvil assembly
6020 in the closed position in the various manners disclosed herein
or otherwise known. The unique and novel cutting beam head 6630
enables the over all height of the end effector 6012 to increase to
accommodate various thicknesses of tissue and or different surgical
staple cartridges that have different lengths/sizes of
staples/fasteners. FIG. 46 illustrates the target tissue T after it
has been "fully clamped" in the end effector 6012 and the end
effector 6012 has been fired to cut and sever the tissue T. The
overall height of the end effector 6012 is represented by "E2".
Such cutting beam head arrangement is capable of assuming a
compressed insertion height for insertion into the surgical site
and then automatically reconfiguring to a firing height. Such
reconfiguration is accomplished by the extension arm 6642 which
acts as a spring and which is normally biased into its uncompressed
state as illustrated in FIG. 44. Thus, the cutting beam head 6630
has a range of operating heights extending between H1 and H2. This
range may be represented by "H3" and may be equal to the distance
between the lower edge of the extension arm 6642 and the upper-most
edge of the body hook portion 6636. See FIG. 44.
[0339] FIGS. 47-54 depict another surgical instrument 7010 that is
capable of practicing several unique benefits of the present
invention. The surgical instrument 7010 depicted in the FIG. 47
comprises a housing 7020 that consists of a handle 7022 that is
configured to be grasped, manipulated and actuated by a clinician.
The handle 7022 may comprise a pair of interconnectable housing
segments 7024, 7026 that may be interconnected by screws, snap
features, adhesive, etc. As the present Detailed Description
proceeds, however, it will be understood that the various unique
and novel arrangements of the various forms of shaft arrangements
and end effector arrangements disclosed herein may also be
effectively employed in connection with robotically-controlled
surgical systems such as those robotic systems and arrangements
disclosed in U.S. patent application Ser. No. 13/536,323, entitled
ROBOTICALLY POWERED SURGICAL DEVICE WITH MANUALLY ACTUATABLE
REVERSING SYSTEM, and filed Jun. 28, 2012, the entire disclosure of
which is has been herein incorporated by reference.
[0340] As can be seen in FIG. 48, the surgical end effector 7100
may comprise an elongated channel 7102 that is configured to
receive a surgical fastener cartridge 7110 therein. The surgical
fastener cartridge 7110 may include a cartridge body 7112 that has
a centrally disposed elongated slot 7114 therein. The cartridge
body 7112 may further include rows of fastener pockets 7116 that
are located on each side of the elongated slot 7114 and which are
configured to support corresponding surgical fasteners 7120
therein. The elongated channel 7102 may further operably support a
"firing member" in the form of a tissue-cutting member or knife
assembly 7150. The knife assembly 7150 is configured to axially
travel in the slot 7114 in the cartridge body 7112 when the
cartridge body 7112 has been installed in the elongated channel
7102. The knife assembly 7150 may be configured with a tissue
cutting edge 7152 that is centrally disposed between a lower foot
7154 and an upper foot or tab 7156. In a preferred arrangement, the
knife assembly 7150 has the same construction and features as
cutting head assembly 6610 described in detail above. As will be
discussed in further detail below, the knife assembly 7150 is
configured to be axially driven within the elongated channel 7102
and the surgical fastener cartridge 7110 in response to motions
applied thereto by a firing drive system 7300.
[0341] As can also be seen in FIG. 48, the surgical end effector
7100 may further include an anvil assembly 7130 that is supported
for movement relative to the elongated channel 7102. The anvil
assembly 7130 may be movable relative to the surgical fastener
cartridge 7110, for example, in response to "actuation motions"
which may comprise, for example, closing and opening motions that
are transferred thereto from a closure drive system 7200. In one
arrangement, for example, the anvil assembly 7130 includes an anvil
body portion 7132 that has a fastener forming surface 7134 formed
on the underside thereof. The fastener forming surface 7134 may
comprise a series of forming pockets (not shown) that correspond to
the surgical fasteners 7120 supported in the surgical fastener
cartridge 7110. As the legs of the surgical fasteners 7120 are
driven into forming contact with the corresponding forming pockets
in the anvil assembly 7130, they are formed into a desired
tissue-retaining configuration. The anvil assembly 7130 may further
includes an anvil mounting portion 7136 that has a pair of
trunnions 7138 protruding therefrom that are received within
corresponding trunnion slots 7610 formed in a U-shaped control
insert 7602 that is movably supported in a proximal mounting
portion 7104 of the elongated channel 7102. In various
arrangements, the surgical fasteners 7120 are driven out of their
respective fastener pockets 7116 in the surgical fastener cartridge
7110 by corresponding sled assemblies 7160 and 7170 that are
movably supported within the elongated channel 7102 and are movable
in response to firing motions applied thereto by the firing drive
system 7300.
[0342] As indicated above, the anvil assembly 7130 is also
responsive to actuation motions in the form of opening and closing
motions that are applied thereto by a closure drive system 7200.
Various details regarding the certain aspects of the construction
and operation of the closure drive system 7200 may be found in U.S.
patent application Ser. No. 13/803,097, filed Mar. 14, 2013, and
entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING
DRIVE, the entire disclosure of which is incorporated by reference
herein. As discussed in that reference and as shown in FIG. 49
herein, the closure drive system 7200 includes a closure trigger
7202 that is configured to cooperate with a closure release
assembly 7220 that is pivotally coupled to a frame 7030. In at
least one form, the closure release assembly 7220 may comprise a
release button assembly 7222 that may be pivoted in a
counterclockwise direction by a release spring (not shown). As the
clinician depresses the closure trigger 7202 from its unactuated
position towards the pistol grip portion 7028 of the handle 7022,
the closure release assembly 7220 serves to lock the closure
trigger 7202 in the fully actuated position. When the clinician
desires to unlock the closure trigger 7202 to permit it to be
biased to the unactuated position, the clinician simply pivots the
closure release button assembly 7220 to cause it to disengage the
closure trigger arrangement and thereby permit the closure trigger
7202 to pivot back to the unactuated position. Other closure
trigger locking and release arrangements may also be employed.
[0343] Referring to FIGS. 49-50, the closure drive system 7200 may
further comprise a proximal closure tube segment 7210 that has a
proximal end 7212 that is adapted to be rotatably coupled to a
closure tube attachment yoke 7230. The proximal end 7212 of the
proximal closure tube segment 7210 is configured to be received
within a cradle 7232 (FIG. 49) in the closure tube attachment yoke
7230 to permit relative rotation relative thereto. The proximal
closure tube segment 7210 may be rotatably attached to the closure
tube attachment yoke 7230 by a U-shaped connector (not shown) that
is configured to be received in an annular slot 7214 in the
proximal end 7212 of the proximal closure tube segment 7210 and be
seated in a slot 7234 (FIG. 49) in the closure tube attachment yoke
7230. Such arrangement serves to rotatably couple the proximal
closure tube segment 7210 to the closure tube attachment yoke 7230
such that the proximal closure tube segment 7210 may rotate
relative thereto. More specifically, such arrangement facilitates
manual rotation of the elongated shaft assembly 7050 relative to
the handle 7022 about a longitudinal tool axis "LT-LT" defined by
the elongated shaft assembly 7050 to enable the clinician to rotate
the surgical end effector 7100 in the manner represented by arrow
"R" in FIG. 47.
[0344] In various arrangements, the closure tube attachment yoke
7230 is movably mounted on a proximal articulation tube 7402 of an
articulation system 7400 which will be discussed in further detail
below. Such arrangement permits the closure tube attachment yoke
7230 to move axially on the proximal articulation tube 7402 in
response to actuation of the closure trigger 7202. In particular,
the closure tube attachment yoke 7230 may be pivotally coupled to
the closure trigger 7202 by a closure linkage bar 7240. See FIG.
49. Thus, when the clinician pivots the closure trigger 7202 inward
toward the pistol grip portion 7028 of the handle 7022, the closure
tube attachment yoke 70230 will be advanced in the distal direction
"DD". When the firing trigger 7202 is returned to the unactuated
position, the closure tube attachment yoke 7230 will be advanced
proximally (direction "PD") on the proximal articulation tube 7402
to a starting position.
[0345] The closure drive system 7200 may further include an
intermediate tube segment 7250 that is configured for attachment to
the distal end 7218 of the proximal closure tube segment 7210. As
can be seen in FIG. 50, the intermediate tube segment 7250 may
include a flexible articulation portion 7260 and an attachment stem
portion 7252. The attachment stem portion 7252 may be sized to
extend into the open distal end 7218 of the proximal closure tube
segment 7210 in frictional engagement therewith. The flexible
articulation portion 7260 may be integrally formed with the
attachment stem portion 7252 and include an articulation spine 7262
that includes proximal end portions 7264 (only one can be seen in
FIG. 50) that are configured to be received in corresponding
notches 7219 in the distal end 7218 of the proximal closure tube
segment 7210 to prevent relative rotation between the proximal
closure tube segment 7210 and the intermediate tube segment 7250.
The intermediate tube segment 7250 may be non-rotatably (i.e.,
attached to prevent relative rotation between these components)
attached to the proximal closure tube segment 7210 by, for example,
screws, detents, adhesive, etc.
[0346] The closure drive system 7200 may further include a distal
closure tube segment 7280 that is configured to axially engage and
apply opening and closing motions to the anvil assembly 7130. The
distal closure tube segment 7280 may be attached to the distal end
of intermediate tube segment 7250 for axial travel therewith. The
articulation spine 7262 may further include distal end portions
7266 that are configured to be received in corresponding notches
7284 in the proximal end 7282 of the distal closure tube segment
7280 to prevent relative rotation between the distal closure tube
segment 7280 and the intermediate tube segment 7250. See FIG. 50.
The proximal end 7282 of the distal closure tube segment 7280 may
inwardly extending attachment tabs 7286 that are adapted to be bent
into corresponding notches 7266 in the intermediate tube segment
7250. See FIG. 50. Such arrangement serves to facilitate attachment
of the distal closure tube segment 7280 to the intermediate tube
segment 7250 for axial travel therewith.
[0347] The distal closure tube segment 7280 is configured to apply
opening and closing motions to the anvil assembly 7130. The anvil
mounting portion 7136 may be formed with an anvil tab 7142. The
distal end 7288 of the distal closure tube segment 7280 has an
inwardly extending actuation tab 7290 formed therein that is
configured to interact with the anvil tab 7142. For example, when
the distal closure tube segment 7280 is in the open position, the
actuation tab 7290 is in biasing contact with the anvil tab 7142
which serves to pivot the anvil assembly 7130 to the open
position.
[0348] Operation of the closure drive system 7200 will now be
described. The anvil assembly 7130 may be moved relative to the
surgical fastener cartridge 7110 by pivoting the closure trigger
7202 toward and away from the pistol grip portion 7028 of the
handle 7022. Thus, actuating the closure trigger 7202 causes the
proximal closure tube segment 7210, the intermediate tube segment
7250 and the distal closure tube segment 7280 to move axially in
the distal direction "DD" to contact the end wall 7144 of the anvil
body portion 7132 to pivot or otherwise move the anvil assembly
7130 toward the surgical fastener cartridge 7110. The clinician may
grasp and manipulate tissue between the anvil assembly 7130 and the
fastener cartridge 7110 by opening and closing the anvil assembly
7130. Once the target tissue is captured between the anvil assembly
7130 and fastener cartridge 7110, the clinician may pivot the
closure trigger 7202 to the fully actuated position wherein it is
locked in place for firing.
[0349] Referring again to FIG. 49, the frame 7030 may also be
configured to operably support the firing drive system 7300 that is
configured to apply firing motions to corresponding portions of the
elongated shaft assembly 7050 and ultimately to the knife assembly
7150 and the sled assemblies 7160, 7170. As can be seen in FIG. 49,
the firing drive system 7300 may employ an electric motor 7302 that
is supported in the pistol grip portion 7028 of the handle 7022. In
various forms, the motor 7302 may be a DC brushed driving motor
having a maximum rotation of, approximately, 25,000 RPM, for
example. In other arrangements, the motor 7302 may include a
brushless motor, a cordless motor, a synchronous motor, a stepper
motor, or any other suitable electric motor. A battery 7304 (or
"power source" or "power pack"), such as a Li ion battery, for
example, may be coupled to the handle 7022 to supply power to a
control circuit board assembly 7306 and ultimately to the motor
7302.
[0350] The electric motor 7302 can include a rotatable shaft 7308
that operably interfaces with a gear reducer assembly 7310 that is
mounted in meshing engagement with a with a set, or rack, of drive
teeth 7322 on a longitudinally-movable drive member 7320. The gear
reducer assembly 7310 can include, among other things, a housing
and an output pinion gear 7314. In certain embodiments, the output
pinion gear 7314 can be directly operably engaged with the
longitudinally-movable drive member 7320 or, alternatively,
operably engaged with the drive member 7320 via one or more
intermediate gears. In use, the electric motor 7302 can move the
drive member distally, indicated by an arrow "DD", and/or
proximally, indicated by an arrow "PD", depending on the direction
in which the electric motor 7302 rotates. For example, a voltage
polarity provided by the battery can operate the electric motor
7302 in a clockwise direction wherein the voltage polarity applied
to the electric motor by the battery can be reversed in order to
operate the electric motor 7302 in a counter-clockwise direction.
When the electric motor 7302 is rotated in one direction, the drive
member 7320 will be axially driven in the distal direction "DD".
When the motor 7302 is driven in the opposite rotary direction, the
drive member 320 will be axially driven in a proximal direction
"PD". The handle 7022 can include a switch which can be configured
to reverse the polarity applied to the electric motor 7302 by the
battery. The handle 7022 can also include a sensor that is
configured to detect the position of the movable drive member 7320
and/or the direction in which the movable drive member 7320 is
being moved.
[0351] Actuation of the motor 7302 can be controlled by a firing
trigger 7330 that is pivotally supported on the handle 7022. The
firing trigger 7330 may be pivoted between an unactuated position
and an actuated position. The firing trigger 7330 may be biased
into the unactuated position by a spring (not shown) or other
biasing arrangement such that when the clinician releases the
firing trigger 7330, it may be pivoted or otherwise returned to the
unactuated position by the spring or biasing arrangement. In at
least one form, the firing trigger 7330 can be positioned
"outboard" of the closure trigger 7202 as discussed in further
detail in U.S. patent application Ser. No. 13/803,097 which has
been previously incorporated by reference in its entirety herein.
In at least one form, a firing trigger safety button 7332 may be
pivotally mounted to the closure trigger 7202. The safety button
7332 may be positioned between the firing trigger 7330 and the
closure trigger 7202 and have a pivot arm (not shown) protruding
therefrom. When the closure trigger 7202 is in the unactuated
position, the safety button 7332 is contained in the handle housing
where the clinician cannot readily access it and move it between a
safety position preventing actuation of the firing trigger 7330 and
a firing position wherein the firing trigger 7330 may be fired. As
the clinician depresses the closure trigger 7202, the safety button
7332 and the firing trigger 7330 pivot down to a position wherein
they can then be manipulated by the clinician.
[0352] As indicated above, in at least one form, the longitudinally
movable drive member 7320 has a rack of teeth 7322 formed thereon
for meshing engagement with a corresponding drive gear of the gear
reducer assembly 7310. At least one form may also include a
manually-actuatable "bailout" assembly that is configured to enable
the clinician to manually retract the longitudinally movable drive
member 7320 should the motor become disabled. U.S. patent
application Ser. No. 13/803,097 contains further details of one
form of bailout assembly that may be employed. U.S. Patent
Application Publication No. US 2010/0089970 also discloses
"bailout" arrangements and other components, arrangements and
systems that may also be employed with the various instruments
disclosed herein. U.S. patent application Ser. No. 12/249,117,
entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH
MANUALLY RETRACTABLE FIRING SYSTEM, filed on Oct. 10, 2008, now
U.S. Patent Application Publication No. 2010/0089970, is
incorporated by reference in its entirety.
[0353] Referring to FIG. 50, various forms of the elongated shaft
assembly 7050 may include a firing member assembly 7060 that is
supported for axial travel within an articulation shaft assembly
7400 that essentially functions as shaft frame or spine. The firing
member assembly 7060 may further include a proximal firing shaft
7062 that has a proximal end portion 7064 that is configured to be
rotatably received in a distal cradle 7326 provided in a distal end
7324 of the movable drive member 7320. Such arrangement permits the
proximal firing shaft 7062 to rotate relative to the movable drive
member 7320 while also axially moving therewith. The proximal
firing shaft 7062 may further have a slot 7068 formed in its distal
end for receiving a proximal end 7072 of a flexible distal firing
shaft assembly 7070 therein. See FIG. 50. As can be seen in that
Figure, the proximal end 7072 of the distal firing shaft assembly
7070 may be received within the slot 7068 in the distal firing
shaft 7062 and may be pinned thereto with a pin 7073.
[0354] The distal firing shaft assembly 7070 may include a central
firing beam 7074 that is located between a right sled pusher beam
7076 and a left sled pusher beam 7078. The central firing beam 7074
and the pusher beams 7076, 7078 may, for example, each be
fabricated from metal that facilitates axial actuation of the sled
assemblies 7160, 7170 in the surgical end effector 7100 while also
facilitating flexing thereof when the end effector 7100 is
articulated. In at least one arrangement, the central pusher beam
7074, the right sled pusher beam 7076 and the left sled pusher beam
7078 may extend through a slot 7146 in the anvil mounting portion
7136. The right sled pusher beam 7076 corresponds to the right sled
assembly 7160 and the left sled pusher beam 7078 corresponds to the
left sled assembly 7170 movably supported within the elongated
channel 7102. Axial movement of the right sled pusher beam 7076 and
the left sled pusher beam 7078 will result in the axial advancement
of the right and left sled assemblies 7160, 7170, respectively,
within the elongate channel 7102. As the right sled assembly 7160
is axially advanced within the elongated channel 7102, it drives
the surgical fasteners 7120 supported in the cartridge body 7112 on
the right side of the slot 7114 out of their respective pockets
7116 and as the left sled assembly 7170 is axially advanced within
the elongated channel 7102, it drives the surgical fasteners 7120
supported within the cartridge body 7112 on the left side of the
slot 7114 out of their respective pockets 7116.
[0355] The central firing beam 7074 has a distal end 7080 that may
be configured to be received within a slot provided in the body
portion 7155 of the knife assembly 7154 and retained therein by,
for example, a frictional fit, adhesive, welding, etc. In at least
one form, the elongated channel 7102 is formed with a right
upstanding wall 7107 and a left upstanding wall 7108 that define a
centrally-disposed channel slot 7109. Once the knife assembly 7150
is inserted into the bottom window in the elongated channel 7102,
the body portion 7151 of the knife assembly 7150 may be inserted
into the channel slot 7109 and advanced proximally in the elongated
channel 7102 to be coupled with the distal end 7080 of the central
firing beam 7074. A lower channel cover 7111 may be attached to the
bottom of the elongated channel 7102 to prevent tissue, body
fluids, etc. from entering into the elongated channel 7102 which
might hamper the movement of the knife assembly 7150 therein.
[0356] The surgical instrument 7010 may also include an
articulation system 7400 of the type described in detail in U.S.
patent application Ser. No. 13/803,097. In one implementation, for
example, the articulation system 7400 includes an articulation
shaft assembly 7430 that may be operably controlled by an
articulation control system 7460. In one form, for example, the
articulation shaft assembly 7430 may include a right articulation
shaft segment 7440 and a left articulation shaft segment 7450. The
right articulation shaft segment 7440 includes a proximal end 7442
that has a right passage segment 7444 formed therein. Likewise the
left articulation shaft segment 7450 includes a proximal end
portion 7452 that has a left passage segment 7454 formed therein.
When the right articulation shaft segment 7440 and the left
articulation shaft segment 7450 are installed within the proximal
closure tube segment 7210, they form the articulation shaft
assembly 7430. The right passage segment 7444 and the left passage
segment 7454 cooperate to receive a portion of the proximal firing
shaft 762 therein. The right articulation shaft segment 7440 and
the left articulation shaft segment 7450 may be, for example,
composed of a plastic, especially a glass fiber-reinforced
amorphous polyamide, sold commercially under the trade name Grivory
GV-6H by EMS-American Grilon.
[0357] Still referring to FIG. 50, the articulation shaft assembly
7430 may further include a right articulation band 7490 and a left
articulation band 7500. In one form, a proximal end portion 7492 of
the right articulation band 7490 may be attached to a distal
portion 7448 of the right articulation shaft segment such that a
distal portion 7494 of the right articulation band 7490 protrudes
out of a right passage 7449 therein. The proximal end portion 7492
of the right articulation band 7490 may include holes or cavities
7493 that are configured to receive corresponding lugs (not shown)
in the right articulation shaft segment 7440 to facilitate
attachment of the right articulation band 7490 to the right
articulation shaft segment 7440. Likewise, a proximal end portion
7502 of the left articulation band 7500 may have holes or cavities
7503 therein that are configured to receive lugs (not shown) in the
distal portion 7458 of the left articulation shaft segment 7450 to
facilitate attachment of the left articulation band 7500 to the
articulation shaft segment 7450. The articulation bands 7490 and
5700 may be composed of a metal, advantageously full hard 301
stainless steel or its equivalent. The distal end of the left
articulation band 7500 may have a left hook portion 7506 that is
adapted to be coupled to a left attachment portion 7507 of the
elongated channel 7102. Likewise, the distal end of the right
articulation band 7494 has a right hook portion 7496 for attachment
to a right attachment portion 7497. As discussed in further detail
in U.S. patent application Ser. No. 13/803,097, when the clinician
wishes to articulate the end effector 7100 to the right relative to
the longitudinal tool axis LT-LT, the clinician simply rotates the
articulation control knob 7570 in the appropriate direction.
[0358] The surgical instrument 7010 may be used in a minimally
invasive procedure wherein it is inserted through a trocar port
that has been installed in a patient. In such applications, it is
generally advantageous to minimize the overall cross-sectional
shape of the end effector during insertion into the patient in
order to minimize the size of the trocar port that must be
employed. The smallest cross-sectional configuration that the end
effector 7100 may adopt is achieved when the upper jaw or anvil
assembly 7130 is in its a "first insertion position" relative to
the lower jaw or more specifically relative to the surgical staple
cartridge 7110 installed in the elongated channel 7102. Thus, to
facilitate insertion of the end effector 7100 through the trocar
port, the cross-sectional area or footprint is sized relative to
the cross-sectional size of the port opening in the trocar port to
permit the end effector 7110 to slidably pass therethrough.
[0359] In at least one implementation, the end effector 7100
employs an active anvil control system 7600 that is configured to
enable the anvil assembly 7130 to move to the first insertion
position to enable the end effector 7100 to be inserted through the
trocar port and then once the end effector 7100 has passed through
the trocar port, enables the anvil assembly 7130 to assume an
operating configuration for stapling tissue. Referring to FIGS. 48
and 51-54, one form of anvil control system 7600 includes a
U-shaped control insert 7602 that is movably supported on the
elongated channel 7102 and is attached to a control bar 7604. The
control bar 7604 extends through the elongated shaft assembly 7050
and is movably supported for axial travel therein. The control bar
7604 may be attached to a movable actuator slide 7606 or other form
of actuator arrangement supported on the handle assembly. See FIG.
47. Movement of the actuator slide 7606 in the distal direction
"DD" will cause the control bar 7604 to move in the distal
direction "DD". Similarly, movement of the actuator slide 7606 in
the proximal direction "PD" will cause the control bar 7604 to move
in the proximal direction "PD".
[0360] As can be seen in FIG. 48, the U-shaped control insert 7602
is formed with two upstanding walls 7608 that each have a somewhat
L-shaped trunnion slot 7610 therein. More specifically, each
trunnion slot 7610 has a vertical slot portion 7612 and a
horizontal slot portion 7614. The trunnion slots 7610 are sized to
movably receive a corresponding anvil trunnion 7138 therein. FIG.
51 illustrates the anvil assembly 7130 in its first insertion
position. As can be seen in that Figure, for example, the anvil
assembly 7130 is being inserted through a distal end portion of a
trocar port 7630. To enable the anvil assembly 7130 to assume that
first insertion position, the clinician moves the control bar 7604
in the distal direction "DD" to cause the movable anvil trunnions
7130 to be retained within the horizontal slot portions 7614 as
shown. When in that position, the anvil mounting portion 7136 is in
is lowest position within the elongated channel 7102.
[0361] The elongated channel 7102 is equipped with an elastic
"biasing means" 7620 that serves to bias the anvil body portion
7132 away from the elongated channel 7102. In various embodiments,
the elastic biasing means 7620 may comprise any form of resilient
member(s) and/or spring(s) that are attached directly to the
elongated channel 7102. For example, in the depicted arrangement,
the biasing means comprises strips of compressible or elastic foam
material 7622 attached along the sides of the elongated channel
7102. When the anvil assembly 7130 is inside the trocar port 7630,
the foam strips 7622 will be compressed as shown in FIG. 51. After
the end effector 7100 has passed through the trocar port 7630, the
clinician may move the control bar 7604 in the proximal direction
"PD" such that the control insert 7602 is also moved proximally to
the position illustrated in FIG. 52. When in that position, the
foam strips 7622 bias the anvil assembly 7130 upward (represented
by arrow "U" in FIG. 52) to a "primary opened position" thereby
causing the anvil trunnions 7138 to move to the upper end of the
vertical trunnion slots 7612 as shown. When the anvil assembly 7130
is in that "primary opened position", the clinician may then
actuate the closure trigger to move the distal closure tube 7280 in
the proximal direction "PD" to cause the anvil assembly 7130 to
move to a "fully open position" as illustrated in FIG. 53. Once the
clinician has positioned the target tissue between the anvil
assembly 7130 and the staple cartridge 7110, the anvil assembly
7130 can be closed using the closure trigger 7202 to move the anvil
assembly 7130 to the closed or fully clamped position illustrated
in FIG. 54.
[0362] FIGS. 55 and 56 illustrates a "passive" anvil control
arrangement 7650 that is configured to enable the anvil assembly
7130 to move to the first insertion position for insertion through
a hollow trocar port 7630 and then, once the end effector 7100 has
passed through the hollow trocar port 7630, to be biased into a
"primary opened position" whereupon further actuation motions may
be applied to the anvil assembly 7130 for acquiring and clamping
the target tissue. In this arrangement, for example, the anvil
control arrangement 7650 includes a U-shaped control insert 7652
that is movably supported on the elongated channel 7102 for
vertical travel therein. One form of control insert 7652 is
depicted in FIG. 57. As can be seen in that Figure, the control
insert includes a pair of vertical side walls 7654 that are spaced
from each other and connected together by an upper bar 7655. Each
vertical side wall has an arcuate trunnion slot 7656 therein.
Referring again to FIGS. 55 and 56, the control insert 7652 is
movable relative to the elongated channel 7102 along an insert axis
"IA-IA" which is transverse to the longitudinal tool axis "LT-LT"
that is defined by the elongated shaft assembly 7050. The control
insert 7652 may movably interface with vertically extending guide
ribs 7660 formed in the elongated channel 7102 to guide the control
insert 7652 as it moves up and down along the insert axis IA-IA
between a first lower position that corresponds to the insert
position of the anvil assembly 7130 and a second upper position
that corresponds to the "primary opened position" wherein actuation
motions may be applied to the anvil assembly 7130. As can be seen
in FIGS. 55 and 56, the anvil trunnions 7138 are received within
the trunnion slots 7656. Control member biasing means 7662 is
provided between the control insert 7652 and the bottom of the
elongated channel 7102 to bias the control insert 7652 in the
upward direction "U" to the second or upper-most position. As shown
in FIG. 55, the control member biasing means 7662 comprises leaf
springs 7664. However, other biasing materials, members, springs,
materials, etc. may be employed.
[0363] FIG. 55 illustrates the end effector 7100 wherein the upper
jaw or anvil assembly 7130 is in the insertion position as it is
being and being inserted through the trocar port 7630. As can be
seen in that Figure, the control insert 7652 is compressed into its
lowest position within the elongated channel 7102 referred to
herein as the first position. After the end effector 7100 has been
inserted through the trocar port 7630, the "biasing means" 7620
serves to bias the anvil body portion 7132 away from the elongated
channel 7102 to the primary opened position as shown in FIG. 56. As
can be seen in that Figure, when the anvil assembly 7130 is in that
position, the springs 7664 bias the control insert 7652 to its
upper-most or second position and the clinician may then operate
the closure system to apply an actuation motion to the anvil
assembly 7130 to move the anvil assembly 7130 relative to the
elongated channel 7102 to a fully opened position for receiving the
target tissue therebetween. The clinician may then again operate
the closure system to move the anvil assembly to the fully clamped
position wherein the end effector is ready for firing.
[0364] FIGS. 58 and 59 illustrate another anvil control
configuration that facilitates initial positioning of the anvil
assembly in a fully compressed, first insertion position wherein
the end effector 7720 can be inserted through the trocar port and
then once the end effector 7100 has passed through the trocar port,
enables the anvil assembly 7730 to assume a primary opened position
whereupon application of an actuation motion to the anvil assembly
7730 may cause the anvil assembly 7730 to move to a fully opened
position. As shown in those Figures, the end effector 7720 is
coupled to a surgical instrument 7710 of the types and construction
disclosed herein. The anvil assembly 7730 may be similar in
construction to other anvil assemblies disclosed herein. For
example, the anvil assembly 7730 may include an anvil body portion
7732 and an anvil mounting portion 7736 that has a pair of
trunnions 7738 protruding therefrom as well as an upstanding anvil
tab 7742. The anvil tab 7742 is configured to interact with the
actuation tab 7290 of the distal closure tube segment 7280 has in
the various manners described herein.
[0365] As can be seen in FIGS. 58 and 59, the end effector 7720
includes an elongated channel 7721 that is similar in construction
and operation to other elongated channel arrangements described
herein. The elongated channel 7721 is configured to operably
support a surgical staple cartridge therein and includes a proximal
mounting portion 7722 that comprises two upstanding wall portions
7723 that each has a trunnion slot 7724 therein. In at least one
implementation, each trunnion slot 7724 has a distal portion 7726
that allows the trunnions to be parked therein during the initial
insertion process. Each trunnion slot 774 further has an arcuate
portion 7727 that facilitates travel of the trunnions 7738 during
opening and closing of the anvil assembly 7730.
[0366] In various implementations, biasing means 7750 are provided
on portions of the underside 7733 of the anvil body portion 7732 as
well as on the sides of the elongated channel 7721 and/or on
portions of the surgical staple cartridge. For example, anvil
biasing member(s) 7752 may be provided on the anvil body portion
7732 in confronting arrangement with anvil biasing member(s) 7756
on the elongated channel 7721. The biasing means 7752, 7754 may
comprise any form of resilient member(s) and/or spring(s). For
example, in the depicted arrangement, the biasing means comprises
strips of compressible or elastic foam material. When the anvil
assembly 7730 is inside the trocar port 7630, the biasing members
7752, 7754 will be compressed as shown in FIG. 58. After the end
effector 7720 has passed through the trocar port 7630, the biasing
members 7752, 7754 bias the anvil assembly 7730 upward to a
"primary opened position" as shown in FIG. 59. When the anvil
assembly 7730 is in that "primary opened position", the clinician
may then actuate the closure trigger to move the distal closure
tube 7280 in the proximal direction "PD" to cause the anvil
assembly 7730 to move to a "fully open position". Once the
clinician has positioned the target tissue between the anvil
assembly 7730 and the staple cartridge, the anvil assembly 7730 can
be moved to the closed or fully clamped position. The amount of
resistance and biasing forces generated by the biasing members may
be altered by employing different biasing members having different
durometers or spring members with different spring compression
characteristics. Another method is to alter the geometry of the
biasing members. FIGS. 60 and 61 depict different biasing member
configurations 7752', 7754' (FIG. 60) and 7752'', 7754'' (FIG.
61).
[0367] FIGS. 62 and 63 illustrate use of the end effector 7720 with
an alternative distal closure tube arrangement 7280' that is
essentially identical as distal closure tube 7280 except that a
biasing member 7292 is mounted on the inwardly extending actuation
tab 7290. In the illustrated embodiment, the biasing member 7292
comprises a leaf-type spring. It will be appreciated however, that
the biasing member could comprise an elastic material that is
attached, for example, to the anvil mounting portion 7736 (distal
from the anvil tab 7742). FIG. 62 illustrates the end effector 7720
the insertion position as it is being inserted through the trocar
port 7630. As can be seen in that Figure, the anvil body portion
7732 is compressed into its lowest position relative to the
elongated channel 7102 by trocar portion 7630 which also places a
biasing force or motion on the biasing member 7292. After the end
effector 7100 has been inserted through the trocar port 7630, the
biasing member 7292 biases the anvil body portion 7132 away from
the elongated channel 7102 to the primary opened position as shown
in FIG. 63. The clinician may then again operate the closure system
to move the anvil assembly 7730 to the fully clamped position
wherein the end effector is ready for firing.
[0368] FIG. 64 illustrates an exemplary surgical instrument 7810
which can include a housing 7820, an elongated shaft assembly 7850
that operably protrudes from the housing 7820 and which is operably
coupled to a surgical end effector 7900. The surgical instrument
7810 depicted in the FIG. 64 comprises a housing 7820 that consists
of a handle 7822 that is configured to be grasped, manipulated and
actuated by a clinician. As the present Detailed Description
proceeds, however, it will be understood that the various unique
and novel arrangements of the various forms of shaft arrangements
and end effector arrangements disclosed herein may also be
effectively employed in connection with robotically-controlled
surgical systems. Thus, the term "housing" may also encompass a
housing or similar portion of a robotic system that houses or
otherwise operably supports at least one drive system that is
configured to generate and apply at least one control motion which
could be used to actuate various forms of surgical end effectors
attached thereto. The term "frame" may refer to a portion of a
handheld surgical instrument. The term "frame" may also represent a
portion of a robotically controlled surgical instrument and/or a
portion of the robotic system that may be used to operably control
a surgical instrument. For example, U.S. patent application Ser.
No. 13/536,323, entitled ROBOTICALLY POWERED SURGICAL DEVICE WITH
MANUALLY ACTUATABLE REVERSING SYSTEM, filed Jun. 28, 2012, the
entire disclosure of which is incorporated by reference herein
discloses various robotic system arrangements that may also be
effectively employed. Furthermore, as will be discussed in further
detail below, the surgical instrument 7810 depicted in at least
some of the accompanying drawings employs a motor for generating
control motions for actuating various components and features of
the surgical end effector. As the present Detailed Description
proceeds, however, those of ordinary skill in the art will
appreciate that certain features and advantages of the present
invention may also be effectively attained in connection with
surgical instruments that are equipped with manually generated
(i.e., non-motor generated) actuation and control motions.
[0369] As illustrated in FIGS. 64 and 66, the handle 7822 may
comprise a pair of interconnectable housing segments 7824, 7826
that may be interconnected by screws, snap features, adhesive, etc.
As used herein, the term "snap feature" includes, but is not
limited to, for example, a tab that has a protrusion thereon that
is configured to retainingly engage a corresponding mating portion
of another component. Such features may be designed to releasably
engage the mating portion or it may not be designed or intended to
be removed. In the illustrated arrangement, the handle housing
segments 7824, 7826 cooperate to form a pistol grip portion 7828
that can be gripped and manipulated by the clinician. As will be
discussed in further detail below, the handle 7822 operably
supports a plurality of drive systems or control systems therein
that are configured to generate and apply various control motions
to corresponding component portions of the elongated shaft assembly
7850 that is operably attached to the surgical end effector 7900.
In the illustrated embodiment, the surgical end effector 7900 is
configured to cut and fasten tissue, for example.
[0370] FIG. 65 illustrates one form of surgical end effector 7900
that may be employed. As can be seen in that Figure, the surgical
end effector 7900 may comprise an elongated channel 7902 that is
configured to receive a surgical fastener cartridge 7910 therein.
The surgical fastener cartridge 7910 may include a cartridge body
7912 that has a centrally disposed elongated slot 7914 therein. The
cartridge body 7912 may further include rows of fastener pockets
7916 that are located on each side of the elongated slot 7914 and
which are configured to support corresponding surgical fasteners
7920 therein. The elongated channel 7902 may further operably
support a tissue-cutting member or knife assembly 7950 therein that
is configured to axially travel in the slot 7914 in the cartridge
body 7912 when installed in the elongate channel 7902. The knife
assembly 7950 may be configured with a tissue cutting edge 7952
that is centrally disposed between a lower foot 7954 and an upper
foot or tab 7956. As will be discussed in further detail below, the
knife assembly 7950 is configured to be axially driven within the
elongated channel 7902 and the surgical fastener cartridge 7910 in
response to motions applied thereto by a firing drive system
8100.
[0371] As can also be seen in FIG. 65, the surgical end effector
7900 may further include an anvil assembly 7930 that is movably
supported on the elongate channel 7902. The anvil assembly 7930 may
be movable relative to the surgical fastener cartridge 7910, for
example, in response to closing and opening motions transferred
thereto from a closure drive system 8000. In other arrangements,
however, the anvil assembly may be fixed and the surgical fastener
cartridge may be configured to move relative to the anvil assembly
upon application of closure motions thereto. In one arrangement,
for example, the anvil assembly 7930 includes an anvil body portion
7932 that has a fastener forming surface 7934 formed on the
underside thereof. The fastener forming surface 7934 may comprise a
series of forming pockets (not shown) that correspond to the
surgical fasteners 7920 supported in the surgical fastener
cartridge 7910. As the legs of the surgical fasteners 7920 are
driven into forming contact with the corresponding forming pockets
in the anvil assembly 7930, they are formed into a desired
tissue-retaining configuration. The anvil assembly 7930 may further
include an anvil mounting portion 7936 that has a pair of trunnions
7938 protruding therefrom that are received within corresponding
arcuate slots 7906 formed in a proximal mounting portion 7904 of
the elongated channel 7902. In various arrangements, the surgical
fasteners 7920 are driven out of their respective fastener pockets
7916 in the surgical fastener cartridge 7910 by corresponding sled
assemblies 7960 and 7970 that are movably supported within the
elongated channel 7902 and are movable in response to firing
motions applied thereto by the firing drive system 8100.
[0372] Referring now to FIG. 66, the handle 7822 may further
include a frame 7830 that operably supports various components of
the closure drive system 8000 and the firing drive system 8100. In
at least one form, the closure drive system 8000 may include an
actuator in the form of a closure trigger 8002 that is pivotally
supported by the frame 7830. The closure trigger 8002 may be
pivotally supported by frame 7830 such that when the clinician
grips the pistol grip portion 7828 of the handle 7822, the closure
trigger 8002 may be easily pivoted from a starting or unactuated
position to an actuated position and more particularly to a fully
compressed or fully actuated position. The closure trigger 8002 may
be biased into the unactuated position by spring or other biasing
arrangement (not shown). Various details regarding the certain
aspects of the construction and operation of the closure drive
system 8000 may be found in U.S. patent application Ser. No.
13/803,097, filed Mar. 14, 2013, and entitled ARTICULATABLE
SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, the entire
disclosure of which is incorporated by reference herein. As
discussed in that reference and as shown in FIG. 66 herein, the
closure trigger 8002 may be configured to cooperate with a closure
release assembly 8020 that is pivotally coupled to the frame 7830.
In at least one form, the closure release assembly 8020 may
comprise a release button assembly 8022 that may be pivoted in a
counterclockwise direction by a release spring (not shown). As the
clinician depresses the closure trigger 8002 from its unactuated
position towards the pistol grip portion 7828 of the handle 7822,
the closure release assembly 8020 serves to lock the closure
trigger 8002 in the fully actuated position. When the clinician
desires to unlock the closure trigger 8002 to permit it to be
biased to the unactuated position, the clinician simply pivots the
closure release button assembly 8020 to cause it to disengage the
closure trigger arrangement and thereby permit the closure trigger
8002 to pivot back to the unactuated position. Other closure
trigger locking and release arrangements may also be employed.
[0373] Referring to FIGS. 66 and 67, the closure drive system 8000
may further comprise a proximal closure tube segment 8010 that has
a proximal end 8012 that is adapted to be rotatably coupled to a
closure tube attachment yoke 8030. The proximal end 8012 of the
proximal closure tube segment 8010 is configured to be received
within a cradle 8032 (FIG. 66) in the closure tube attachment yoke
8030 to permit relative rotation relative thereto. The proximal
closure tube segment 8010 may be rotatably attached to the closure
tube attachment yoke 8030 by a U-shaped connector 8036 that is
configured to be received in an annular slot 8014 in the proximal
end 8012 of the proximal closure tube segment 8010 and be seated in
a slot 8034 (FIG. 66) in the closure tube attachment yoke 8030.
Such arrangement serves to rotatably couple the proximal closure
tube segment 8010 to the closure tube attachment yoke 8030 such
that the proximal closure tube segment 8010 may rotate relative
thereto. More specifically, such arrangement facilitates manual
rotation of the elongated shaft assembly 7850 relative to the
handle 7822 about a longitudinal tool axis "LT-LT" defined by the
elongated shaft assembly 7850 to enable the clinician to rotate the
surgical end effector 7900 in the manner represented by arrow "R"
in FIG. 64.
[0374] In various arrangements, the closure tube attachment yoke
8030 is movably mounted on a proximal articulation tube 8202 of an
articulation system 8200 which will be discussed in further detail
below. Such arrangement permits the closure tube attachment yoke
8030 to move axially on the proximal articulation tube 8202 in
response to actuation of the closure trigger 8002. In particular,
the closure tube attachment yoke 8030 may be pivotally coupled to
the closure trigger 8002 by a closure linkage bar 8040. See FIG.
66. Thus, when the clinician pivots the closure trigger 8002 inward
toward the pistol grip portion 7828 of the handle 7822, the closure
tube attachment yoke 8030 will be advanced in the distal direction
"DD". When the firing trigger 8002 is returned to the unactuated
position, the closure tube attachment yoke 8030 will be advanced
proximally (direction "PD") on the proximal articulation tube 8202
to a starting position.
[0375] The closure drive system 8000 may further include an
intermediate flexible tube segment 8050 that is configured for
attachment to the distal end 8018 of the proximal closure tube
segment 8010. As can be seen in FIG. 68, the intermediate tube
segment 8050 may include a flexible articulation portion 8060 and
an attachment stem portion 8052. The attachment stem portion 8052
may be sized to extend into the open distal end 8018 of the
proximal closure tube segment 8010 in frictional engagement
therewith. The flexible articulation portion 8060 may be integrally
formed with the attachment stem portion 8052 and include an
articulation spine 8062 that includes proximal end portions 8064
(only one can be seen in FIG. 5) that are configured to be received
in corresponding notches 8019 in the distal end 8018 of the
proximal closure tube segment 8010 to prevent relative rotation
between the proximal closure tube segment 8010 and the intermediate
tube segment 8050. The intermediate tube segment 8050 may be
non-rotatably (i.e., attached to prevent relative rotation between
these components) attached to the proximal closure tube segment
8010 by, for example, screws, detents, adhesive, etc.
[0376] The closure drive system 8000 may further include a distal
closure tube segment 8080 that is configured to axially engage and
apply opening and closing motions to the anvil assembly 7930. The
distal closure tube segment 8080 may be attached to the distal end
of intermediate tube segment 8050 for axial travel therewith. The
articulation spine 8062 may further include distal end portions
8066 that are configured to be received in corresponding notches
8084 in the proximal end 8082 of the distal closure tube segment
8080 to prevent relative rotation between the distal closure tube
segment 8080 and the intermediate tube segment 8050. See FIG. 68.
The proximal end 8082 of the distal closure tube segment 8080 may
inwardly extending attachment tabs 8086 that are adapted to be bent
into corresponding notches 8067 in the intermediate tube segment
8050. See FIG. 68. Such arrangement serves to facilitate attachment
of the distal closure tube segment 8080 to the intermediate tube
segment 8050 for axial travel therewith.
[0377] The distal closure tube segment 8080 is configured to apply
opening and closing motions to the anvil assembly 7930. As can be
seen in FIG. 70, one form of the anvil mounting portion 7936 may be
formed with a groove 7940 that defines an anvil tab 7942. As can be
seen in FIGS. 69 and 71, the distal end 8088 of the distal closure
tube segment 8080 has an inwardly extending actuation tab 8090
formed therein that is configured to interact with the anvil tab
7942. For example, when the distal closure tube segment 8080 is in
the open position (FIGS. 69 and 71), the actuation tab 8090 is in
biasing contact with the anvil tab 7942 which serves to pivot the
anvil assembly 7930 to the open position. As shown in FIG. 72, when
the anvil assembly 7930 is in an open position, the trunnions 7938
are located in the bottom of the trunnion slots 7906 in the
proximal mounting portion 7904 of the elongated channel 7902. When
the distal closure tube segment 8080 is advanced distally, the
distal end 8088 contacts an upstanding end wall 7944 on the anvil
body 7932 to cause the anvil assembly 7930 to pivot or otherwise
move toward the surgical fastener cartridge 7910. When assembled,
the trunnions 7938 each extend into a corresponding opening 8092 in
the distal closure tube segment 8080. See FIG. 69.
[0378] Operation of the closure drive system 8000 will now be
described. The anvil assembly 7930 may be moved relative to the
surgical fastener cartridge 7910 by pivoting the closure trigger
toward and away from the pistol grip portion 7828 of the handle
7822. Thus, actuating the closure trigger 8002 causes the proximal
closure tube segment 8010, the intermediate tube segment 8050 and
the distal closure tube segment 8080 to move axially in the distal
direction "DD" to contact the end wall 7944 of the anvil body
portion 7932 to pivot or otherwise move the anvil 7930 toward the
surgical fastener cartridge 7910. The clinician may grasp and
manipulate tissue between the anvil assembly 7930 and the fastener
cartridge 7910 by opening and closing the anvil assembly 7930. Once
the target tissue is captured between the anvil assembly 7930 and
fastener cartridge 7910, the clinician may pivot the closure
trigger 8002 to the fully actuated position wherein it is locked in
place for firing.
[0379] As indicated above, the frame 7830 may also be configured to
operably support the firing drive system 8100 that is configured to
apply firing motions to corresponding portions of the elongated
shaft assembly 7850 and ultimately to the knife assembly 7950 and
the sled assemblies 7960, 7970. As can be seen in FIGS. 64 and 73,
the firing drive system 8100 may employ an electric motor 8102 that
is supported in the pistol grip portion 7828 of the handle 7022. In
various forms, the motor 8102 may be a DC brushed driving motor
having a maximum rotation of, approximately, 25,000 RPM, for
example. In other arrangements, the motor 10302 may include a
brushless motor, a cordless motor, a synchronous motor, a stepper
motor, or any other suitable electric motor. A battery 8104 (or
"power source" or "power pack"), such as a Li ion battery, for
example, may be coupled to the handle 10022 to supply power to a
control circuit board assembly 8106 and ultimately to the motor
8102. FIG. 66 illustrates a battery pack housing 8105 that is
configured to be releasably mounted to the handle 7822 for
supplying control power to the surgical instrument 7810. A number
of battery cells connected in series may be used as the power
source to power the motor 8102. In addition, the power source may
be replaceable and/or rechargeable.
[0380] As outlined above with respect to other various forms, the
electric motor 8102 can include a rotatable shaft 8108 that
operably interfaces with a gear reducer assembly 8110 that is
mounted in meshing engagement with a with a set, or rack, of drive
teeth 8122 on a longitudinally-movable drive member 8120. The gear
reducer assembly 8110 can include, among other things, a housing
8112 and an output pinion gear 8114. See FIG. 10. In certain
embodiments, the output pinion gear 8114 can be directly operably
engaged with the longitudinally-movable drive member 8120 or,
alternatively, operably engaged with the drive member 8120 via one
or more intermediate gears 8116. The intermediate gear, in at least
one such embodiment, can be meshingly engaged with the set, or
rack, of drive teeth 8122 defined in the drive member 8120. In use,
the electric motor 8102 can move the drive member distally,
indicated by an arrow "DD", and/or proximally, indicated by an
arrow "PD", depending on the direction in which the electric motor
8102 rotates the intermediate gear. In use, a voltage polarity
provided by the battery can operate the electric motor 8102 in a
clockwise direction wherein the voltage polarity applied to the
electric motor by the battery can be reversed in order to operate
the electric motor 8102 in a counter-clockwise direction. When the
electric motor 8102 is rotated in one direction, the drive member
8120 will be axially driven in the distal direction "DD". When the
motor 8102 is driven in the opposite rotary direction, the drive
member 8120 will be axially driven in a proximal direction "PD".
The handle 7822 can include a switch which can be configured to
reverse the polarity applied to the electric motor 8102 by the
battery. The handle 7822 can also include a sensor that is
configured to detect the position of the movable drive member 8120
and/or the direction in which the movable drive member 8120 is
being moved.
[0381] Actuation of the motor 8102 can be controlled by a firing
trigger 8130 that is pivotally supported on the handle 7822. The
firing trigger 8130 may be pivoted between an unactuated position
and an actuated position. The firing trigger 8130 may be biased
into the unactuated position by a spring (not shown) or other
biasing arrangement such that when the clinician releases the
firing trigger 8130, it may be pivoted or otherwise returned to the
unactuated position by the spring or biasing arrangement. In at
least one form, the firing trigger 8130 can be positioned
"outboard" of the closure trigger 8002 as discussed in further
detail in U.S. patent application Ser. No. 13/803,097 which has
been previously incorporated by reference in its entirety herein.
In at least one form, a firing trigger safety button 8132 may be
pivotally mounted to the closure trigger 8002. The safety button
8132 may be positioned between the firing trigger 8130 and the
closure trigger 8002 and have a pivot arm (not shown) protruding
therefrom. When the closure trigger 8002 is in the unactuated
position, the safety button 8132 is contained in the handle housing
where the clinician cannot readily access it and move it between a
safety position preventing actuation of the firing trigger 8130 and
a firing position wherein the firing trigger 8130 may be fired. As
the clinician depresses the closure trigger 8002, the safety button
8132 and the firing trigger 8130 pivot down to a position wherein
they can then be manipulated by the clinician.
[0382] As indicated above, in at least one form, the longitudinally
movable drive member 8120 has a rack of teeth 8122 formed thereon
for meshing engagement with a corresponding drive gear of the gear
reducer assembly 8110. At least one form may also include a
manually-actuatable "bailout" assembly that is configured to enable
the clinician to manually retract the longitudinally movable drive
member 8120 should the motor become disabled. U.S. patent
application Ser. No. 13/803,097 contains further details of one
form of bailout assembly that may be employed. U.S. Patent
Application Publication No. US 2010/0089970 also discloses
"bailout" arrangements and other components, arrangements and
systems that may also be employed with the various instruments
disclosed herein. U.S. patent application Ser. No. 12/249,117,
entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH
MANUALLY RETRACTABLE FIRING SYSTEM, and filed on Oct. 10, 2008, now
U.S. Patent Application Publication No. 2010/0089970, is
incorporated by reference in its entirety herein.
[0383] Referring to FIGS. 67 and 68, various forms of the elongated
shaft assembly 7850 may include a firing member assembly 7860 that
is supported for axial travel within an articulation shaft assembly
8230 that is part of the articulation system 8200 and which
essentially functions as shaft frame or spine. The firing member
assembly 7860 may further include a proximal firing shaft 7862 that
has a proximal end portion 7864 that is configured to be rotatably
received in a distal cradle 8126 provided in a distal end 8124 of
the movable drive member 8120. Such arrangement permits the
proximal firing shaft 7862 to rotate relative to the movable drive
member 8120 while also axially moving therewith. The proximal
firing shaft 7862 may further have a slot 7868 formed in its distal
end 7866 for receiving a proximal end 7872 of a flexible distal
firing shaft assembly 7870 therein. See FIG. 68. As can be seen in
that Figure, the proximal end 7872 of the distal firing shaft
assembly 7870 may be received within the slot 7868 in the distal
firing shaft 7862 and may be pinned thereto with a pin 7873.
[0384] The distal firing shaft assembly 7870 may include a central
firing beam 7874 that is located between a right sled pusher beam
7876 and a left sled pusher beam 7878. The central firing beam 7874
and the pusher beams 7876, 7878 may, for example, each be
fabricated from metal that facilitates axial actuation of the sled
assemblies 7960, 7970 in the surgical end effector 7900 while also
facilitating flexing thereof when the end effector 7900 is
articulated as will be discussed in further detail below. In at
least one arrangement, the central pusher beam 7874, the right sled
pusher beam 7876 and the left sled pusher beam 7878 may extend
through a slot 7946 in the anvil mounting portion 7936. The right
sled pusher beam 7876 corresponds to the right sled assembly 7960
and the left sled pusher beam 7878 corresponds to the left sled
assembly 7970 movably supported within the elongated channel 7902.
Axial movement of the right sled pusher beam 7876 and the left sled
pusher beam 7878 will result in the axial advancement of the right
and left sled assemblies 7960, 7970, respectively, within the
elongated channel 7902. As the right sled assembly 7960 is axially
advanced within the elongated channel 7902, it drives the surgical
fasteners 7920 supported in the cartridge body 7912 on the right
side of the slot 7914 out of their respective pockets 7916 and as
the left sled assembly 7970 is axially advanced within the
elongated channel 7902, it drives the surgical fasteners 7920
supported within the cartridge body 7912 on the left side of the
slot 7914 out of their respective pockets 7916.
[0385] The central firing beam 7874 has a distal end 7880 that may
be configured to be received within a slot 7951 provided in the
knife assembly 7954 and retained therein by, for example, a
frictional fit, adhesive, welding, etc. A bottom window 7905 may be
formed in a distal end 7903 of the elongated channel 7902 to enable
the knife assembly 7950 to be inserted therethrough. In at least
one form, the elongated channel 7902 is formed with a right
upstanding wall 7907 and a left upstanding wall 7908 that define a
centrally-disposed channel slot 7909. Once the knife assembly 7950
is inserted into the bottom window 7905 in the elongated channel
7902, the body portion 7951 of the knife assembly 7950 may be
inserted into the channel slot 7909 and advanced proximally in the
elongated channel 7902 to be coupled with the distal end 7980 of
the central firing beam 7874. A lower channel cover 7911 may be
attached to the bottom of the elongated channel 7902 to prevent
tissue, body fluids, etc. from entering into the elongated channel
7902 which might hamper the movement of the knife assembly 7950
therein.
[0386] In one form, the anvil assembly 7930 may be installed onto
the elongate channel 7902 as follows. To commence the installation
process, the anvil assembly 7930 is positioned over the elongated
channel 7902 such that the trunnions 7938 may be inserted into
notches 7913 in the proximal mounting portion 7904 of the elongated
channel 7902 which enable the trunnions 7938 to enter the
corresponding trunnion slots 7906 in the elongated channel 7902.
See FIG. 65. This installation may be performed before the distal
closure tube segment 8080 has been attached to the intermediate
tube segment 8050 or after the distal closure tube segment 8080 has
been moved sufficiently proximally to permit the anvil to be so
positioned. Once the trunnions 8038 are received within their
respective trunnion slots 7906, the distal closure tube segment
8080 may be moved to the position shown in FIGS. 71 and 72 wherein
the distal closure tube segment 8080 retains the trunnions 7938 in
their respective trunnion slots 7906 and the actuation tab 8090 is
in biasing contact with the anvil tab 7942 which serves to pivot
the anvil assembly 7930 to the open position. When in that
position, each trunnion 7938 protrudes into a corresponding opening
8092 in the distal closure tube segment 8080. See FIG. 69. As shown
in FIGS. 65 and 71, when the anvil assembly 7930 is in an open
position, the upper end of the knife assembly 7950 enters a window
7933 in the anvil body portion 7932. Such window 7933 provides
clearance for the anvil assembly 7930 to be moved to the closed
positions while the knife assembly 7950 remains in the unactuated
position. Once the anvil assembly 7930 has been installed with the
knife assembly 7950 in place, an anvil cover 7935 may be attached
to the anvil body 7934 to prevent tissue, body fluids, etc. from
entering into the anvil body 7934 which might hamper the movement
of the knife assembly 7950 therein. As the knife assembly 7950 is
advanced distally in the end effector 7900, the upper tab 7956 of
the knife assembly 7950 engages ledges in the anvil body and the
lower foot 7954 engages portions 7915 of the elongated channel 7902
and serves to retain the anvil assembly 7930 in the closed position
and essentially maintain the spacing between the anvil assembly
7930 and the fastener cartridge 7910.
[0387] FIGS. 70A and 70B illustrate an alternative distal closure
tube arrangement 8080' that may work with an anvil assembly 7930'
that may be substantially identical to anvil assembly 7930 except
that anvil assembly 7930' lacks an anvil tab. In such an
arrangement, for example, each trunnion 7938 extends into a
corresponding opening 8092' in the distal closure tube segment
8080'. The distal closure tube segment 8080' further includes an
inwardly extending gill tab 8094 that protrudes inward for contact
with the corresponding anvil trunnion 7938. When the distal closure
tube segment 8080' is drawn in the proximal direction "PD", each
gill tab 8094 contacts the corresponding trunnion 7938 to cause the
trunnion to move downwardly in its corresponding trunnion slot 7906
in the elongated channel 7902 to pivot or otherwise move the anvil
assembly 7930' into open positions. FIG. 70C illustrates yet
another distal closure tube arrangement 8080'' wherein the
actuation tab is formed by an indentation 8090'' in the distal
closure tube segment 8080'' for interaction with the anvil tab 7942
in the above-described manner.
[0388] FIG. 70D illustrates an alternative anvil assembly 7930''
wherein the anvil tab 7942' is removably attached to the anvil
mounting portion 7936. In one arrangement for example, the anvil
tab 7942' is configured with a snap tab 7943 arranged to
retainingly engage an opening 7941 in the anvil mounting portion
7936. The anvil assembly 7930'' may otherwise be the same as anvil
assembly 7930 described above and be opened and closed in similar
manners by the distal closure tube segment 8080. FIG. 70E
illustrates yet another anvil assembly 7930'' wherein the anvil tab
is formed by a screw 7948 that is removably attachable to the anvil
mounting portion 7936. Such removable anvil tab/screw arrangements
may facilitate ease of installation of the anvil assembly
7930''.
[0389] Referring to FIGS. 67 and 68, one form of articulation
system 8200 includes an articulation shaft assembly 8230 that may
be operably controlled by an articulation control system 8260. In
one form, for example, the articulation shaft assembly 8230 may
include a right articulation shaft segment 8240 and a left
articulation shaft segment 8250. The right articulation shaft
segment 8240 includes a proximal end 8242 that has a right passage
segment 8244 formed therein. Likewise the left articulation shaft
segment 8250 includes a proximal end portion 8252 that has a left
passage segment 8254 formed therein. When the right articulation
shaft segment 8240 and the left articulation shaft segment 8250 are
installed within the proximal closure tube segment 8010, they form
the articulation shaft assembly 8230. The right passage segment
8244 and the left passage segment 8254 cooperate to receive a
portion of the proximal firing shaft 7862 therein. The right
articulation shaft segment 8240 and the left articulation shaft
segment 8250 may be, for example, composed of a plastic, especially
a glass fiber-reinforced amorphous polyamide, sold commercially
under the trade name Grivory GV-6H by EMS-American Grilon.
[0390] In various arrangements, for example, the articulation
control system 8260 may include a nozzle assembly 8262 that is
supported for rotational travel relative to the handle 7822. As can
be seen in FIG. 67, the nozzle assembly 8262 may comprise an upper
nozzle segment 8264 and a lower nozzle segment 8266 that are
attached together by a series of fasteners (e.g., screws) 8268. The
upper nozzle segment 8264 may be configured to rotatably support an
articulation control knob 8270 thereon. In one arrangement, for
example, the articulation control knob 8270 extends through an
opening (not shown) in the upper nozzle segment 8264 and is coupled
to an articulation gear member 8272 by screws 8274. The
articulation gear member 8272 may include articulation spur gear
8276 that extends into an opening 8016 in the proximal end portion
8012 of the proximal closure tube segment 8010. As can be further
seen in FIG. 67, the articulation system 8200 further includes a
right actuation tube adapter 8278 and a left articulation tube
adapter 8280. The right articulation tube adapter 8278 has a right
recess 8279 formed therein that is adapted to receive a right
adapter lug 8246 formed on the proximal end 8242 of the right
articulation shaft segment 8240. Likewise, the left articulation
tube adapter 8280 includes a left recess 8282 that is adapted to
engage a left adapter lug 8256 formed on the proximal end 8252 of
the left articulation shaft segment 8250. The right articulation
tube adapter 8278 further has a series of right articulation drive
gears 8281 that are configured for meshing engagement with the
articulation spur gear 8276. The left articulation tube adapter
8280 has a series of left articulation drive gears 8284 formed
therein that are adapted to intermesh with the articulation spur
gear 8276. Thus, when the articulation control knob 8270 is rotated
about a control axis CA-CA that is transverse to the longitudinal
tool axis LT-LT relative to the handle 7822 (FIG. 64), the left
articulation shaft segment 8250 is, for example, driven axially in
the distal direction "DD" within the proximal closure tube segment
8010 and the right articulation shaft segment 8240 is
simultaneously axially driven in the proximal direction "PD".
[0391] Still referring to FIG. 68, the articulation shaft assembly
8230 may further include a right articulation band 8290 and a left
articulation band 8300. In one form, a proximal end portion 8292 of
the right articulation band 8290 may be attached to a distal
portion 8248 of the right articulation shaft segment such that a
distal portion 8294 of the right articulation band 8290 protrudes
out of a right passage 8249 therein. The proximal end portion 8292
of the right articulation band 8290 may include holes or cavities
8293 that are configured to receive corresponding lugs (not shown)
in the right articulation shaft segment 8240 to facilitate
attachment of the right articulation band 8290 to the right
articulation shaft segment 8240. Likewise, a proximal end portion
8302 of the left articulation band 8300 may have holes or cavities
8303 therein that are configured to receive lugs (not shown) in the
distal portion 8258 of the left articulation shaft segment 8250 to
facilitate attachment of the left articulation band 8300 to the
articulation shaft segment 8250. The articulation bands 8290 and
8300 may be composed of a metal, advantageously full hard 301
stainless steel or its equivalent.
[0392] Referring now to FIGS. 75-78, as was briefly discussed
above, the intermediate tube segment 8050 may have an attachment
stem portion 8052 and a flexible articulation portion 8060. In
various arrangements, the intermediate tube segment 8050 may be
fabricated from, for example, rigid thermoplastic polyurethane sold
commercially as ISOPLAST grade 2510 by the Dow Chemical Company and
include a centrally disposed, vertically-extending articulation
spine 8062. The articulation spine 8062 includes a proximal spine
end 8064 and a distal spine end 8066 that facilitate attachment to
the proximal closure tube segment 8010 and the distal closure tube
segment 8080, respectively as was discussed above. The articulation
spine 8062 further includes a centrally disposed component or knife
slot 8070 for facilitating the passage of various control
components therethrough. In the illustrated arrangement, the slot
8070 movably supports the central firing beam 7874, the right
pusher beam 7876 and the left pusher beam 7878. In various forms,
the centrally disposed slot 8070 is substantially enclosed to
retard or prevent infiltration of body fluids and tissue therein
which might otherwise hamper the movement of the control components
operably passing therethrough.
[0393] As can be most particularly seen in FIG. 78, the flexible
articulation portion 8060 further includes a plurality of right
ribs 8310 and a plurality of left ribs 8320 that may be
integrally-formed with, and laterally protrude from, the
articulation spine 8062. In various forms, for example, each right
rib 8310 may comprise a rib body portion 8312 that is spaced from
the articulation spine 8062 by a corresponding right rib neck
portion 8316. Likewise, each left rib 8320 may comprise a left rib
body portion 8322 that is spaced from the articulation spine 8062
by a left rib neck portion 8326. As can be seen in FIG. 76, the
left and right rib body portions 8312, 8322 have an arcuate shape
to provide the flexible articulation portion 8060 of the
intermediate tube segment 8050 with a substantially-circular
cross-sectional shape. Such shape may facilitate easy passage of
the intermediate tube segment 8050 through a circular passage such
as, for example, an appropriately sized trocar.
[0394] In various arrangements, each of the right rib neck portions
8016 serves to define a right articulation passage 8318 for movably
receiving the right articulation band 8290 therethrough. The right
articulation band 8290 may extend through the right articulation
passage 8318 and be coupled to the proximal mounting portion 7904
of the elongate channel 7902. For example, the distal end 8294 of
the right articulation band 8290 may have a right hook portion 8296
that is adapted to be coupled to a right attachment portion 8297 of
the elongated channel 7902. See FIG. 65. Similarly, each of the
left rib neck portions 8326 serves to define a left articulation
passage 8328 for movably receiving the left articulation band 8300
therethrough. The left articulation band 8300 may extend through
the left articulation passage 8328 and be coupled to the proximal
mounting portion 7904 of the elongated channel 7902. For example,
the distal end 8304 of the left articulation band 8300 may have a
left hook portion 8306 that is adapted to be coupled to a left
attachment portion 8307 of the elongated channel 7902.
[0395] One method of operating the articulation system 8200 will
now be described. When the clinician wishes to articulate the end
effector 7900 to the right relative to the longitudinal tool axis
LT-LT (the right direction is represented by arrow "RD" in FIG.
78), the clinician simply rotates the articulation control knob
8270 in the appropriate direction. For example, turning the control
knob 8270 in a clockwise direction (when viewed from above) causes
the left articulation band to be pushed in the distal direction
"DD" and the right articulation band 8290 is drawn in the proximal
direction "PD" which serve to apply an articulation motion to the
elongated channel 102. As the articulation motion is applied to the
elongated channel 7902, the flexible articulation portion 8060
flexes to accommodate the movement of the surgical end effector
7900 in the "right" direction. Conversely, if the clinician wishes
to articulate the end effector 7900 in the left direction "LD", the
clinician simply rotates the control knob 8270 in a
counterclockwise direction which causes the right articulation band
8290 to be pushed in the distal direction "DD" and the left
articulation band 8300 to be drawn in the proximal "PD" direction
thereby causing the surgical end effector 7900 to move to the left.
The end effector 7900 may also be articulated by a robotic system
(not shown) that is configured to apply control motions to the
articulation bands 8290, 8300.
[0396] Upon application of the above-described articulation motions
to the surgical end effector 7900, it may be desirable to avoid
twisting or torquing the flexible articulation portion 8060 of the
intermediate tube segment 8050. If such torque or twisting were to
occur, the possibility exists for hampering or, in instances of
severe twisting, completely jamming the operation of the central
firing beam 7874 and the right and left sled pusher beams 7876,
7878. To avoid this problem, the right and left ribs 8310, 8320 may
be uniquely configured to prevent twisting between the ribs.
[0397] In at least one arrangement, for example, each rib body 8312
has lateral ends that are arranged in spaced, confronting
relationship with the lateral ends of the rib bodies of adjacent
ribs. Referring again to FIG. 78, for example, the rib body 8312 of
each right rib 8310 has a first right lateral end 8313 and a second
right lateral end 8314. With the exception of the proximal-most
right rib 8310P and the distal-most right rib 8310D, the first
right lateral end 8313 of one right rib 8310 is in confronting
relationship with the second right lateral end 8314 of an adjacent
right rib 8310. When the flexible articulation portion 8060 of the
intermediate tube segment 8050 is unarticulated (e.g., the flexible
articulation portion 8060 is substantially axially aligned on the
longitudinal tool axis LT-LT), the first right lateral end 8313 of
each right ribs 8310 is spaced from the second right lateral end
8314 of the adjacent right rib 8310 by a right rib space 8315. In
the arrangement depicted in FIG. 78, for example, all of the right
rib spaces 8315 have substantially the same space width "SWR".
Likewise, the rib body 8322 of each left rib 8320 has a first left
lateral end 8323 and a second left lateral end 8324. With the
exception of the proximal-most left rib 8320P and the distal most
left rib 8320D, the first left lateral end 8323 of one left rib
8320 is in confronting relationship with the second left lateral
end 8324 of an adjacent left rib 8320. When the flexible
articulation portion 8060 of the intermediate tube segment 8050 is
unarticulated, the first left lateral end 8323 of each left rib
8320 is spaced from the second left lateral end 8324 of the
adjacent left rib 8320 by a left rib space 8325. In the arrangement
depicted in FIG. 78, for example, all of the left rib spaces 8325
have substantially the same space width "SWL". In at least one
form, the right rib space widths SWR are substantially the same as
the left rib space widths SWL. However, the right and left rib
space widths may differ from each other.
[0398] Still referring to FIG. 78, each rib may be provided with a
twist-preventing configuration, generally designated as 8330. In at
least one arrangement, for example, an anti-twist protrusion 8332
may be formed on each of the first right lateral ends 8313 of the
right rib bodies 8312 and on each of the first left lateral ends
8323 of each of the left rib bodies 8322. Each anti-twist
protrusion 8332 corresponds with a substantially
complementary-shaped recces 8334 formed in the rib that is
immediately adjacent and in confronting relationship therewith.
FIG. 77 illustrates this arrangement on the left ribs 8320. In at
least one arrangement, the right ribs 8310 employ an identical
configuration. In at least one form, the protrusions 8332 may be
substantially aligned along a lateral axis. That is, the
protrusions 8332 formed on the right ribs 8310 may be substantially
aligned along a right lateral axis RLA-RLA on the right side of the
articulation spine 8062 and the protrusions 8332 formed on the left
ribs 8320 may be substantially aligned on the left side of the
articulation spine 8062 along a left lateral axis LLA-LLA. When the
flexible portion 8060 is unarticulated, the right lateral axis
RLA-RLA, the left lateral axis LLA-LLA and the longitudinal tool
axis LT-LT may be substantially parallel to each other. As can be
see in FIG. 78, the right lateral axis RLA-RLA and the left lateral
axis LLA-LLA are spaced from the longitudinal tool axis LT-LT.
[0399] As the flexible articulation portion 8060 is articulated in
the right direction "RD", at least some of the protrusions 8332 on
the right ribs 8310 will frictionally engage a portion of a
corresponding recess 8332 in an adjacent right rib 8310 to prevent
the flexible portion 8060 from twisting. Similarly, as the flexible
articulation portion 8060 is articulated in the left direction
"LD", at least some of the protrusions 8332 on the left ribs 8320
will engage a portion of the recess 8332 in an adjacent left rib
8320 in a "twist-preventing orientation" to prevent the flexible
portion 8060 from twisting. This engagement/orientation between the
protrusion 8332 and the bottom of the cavity 8334 in an adjacent
left rib 8320, for example, is illustrated in FIG. 79. As can be
seen in that Figure, in that example, the first left lateral end
8323 of one of the second rib 8320 is in abutting contact with the
second left lateral end 8324 of an adjacent left rib 8320 to
thereby prevent or retard twisting of the flexible portion 8060 of
the intermediate tube segment 8050.
[0400] Various alternative anti-twist arrangements are also
contemplated. For example, the anti-twist features may not provided
on, for example, the proximal-most four ribs. In still other
arrangements, the anti-twist features may be provided in a
plurality of ribs comprising a central area of the flexible
segment, but not in the proximal-most and distal most ribs. In,
other arrangements, the ant-twist features may be employed on every
other pair of ribs along the length of the flexible segment. For
example, the proximal-most pair of adjacent ribs may have
anti-twist features, then the next rib or ribs (distal to those
ribs) may not have anti-twist features and the next ribs (distal
thereto) may have the anti-twist features and so on. These
alternative arrangements may be applied only to the ribs on one
side of the articulation spine or they may be employed on the ribs
on both sides of the articulation spine. By altering the number,
location and/or spacing of the ribs with the anti-twist features,
as well as the space widths between the ribs (with and without
anti-twist features), as well as the geometric shape of the
articulation spine, one can advantageously adjust the overall
flexibility of the flexible segment, its degree of articulation,
its degree of stiffness and its rate of articulation.
[0401] Referring to FIGS. 75 and 76, in the illustrated
arrangement, the articulation spine 8062 is elongated and has a
height, generally designated as "H". In at least one arrangement,
the height "H" is substantially consistent for the length "L" of
the articulation spine 8062. In addition, the articulation spine
8062 may decreasingly taper from the proximal end portion 8064 to
the distal end portion 8066. More specifically, as can be seen in
FIG. 75, the proximal end portion 8064 has a proximal width "PW"
and the distal end portion 266 has a distal width "DW". In the
illustrated embodiment, the "PW" is greater than the distal width
"DW" and the width of the articulation spine 8062 gradually tapers
in width (as opposed to height) from the proximal end 8064 to the
distal end 8066 along length "L". Such tapered articulation spine
arrangement further serves to retard twisting during articulation
of the surgical end effector while facilitating increased
articulation of the distal end of the flexible portion 8060
relative to the proximal end of the flexible portion 8060 and while
facilitating movable passage of various control components (e.g.,
central firing beam 7874, right sled pusher beam 7876, left sled
pusher beam 7878, etc.) therethrough.
[0402] Further, in one arrangement, when the flexible portion 8060
is in an unarticulated or flexed position, all of the right rib
spaces 8315 and left rib spaces 8325 have the same starting width.
Thus, in that configuration, SWR=SWL. FIGS. 80 and 81 illustrate
another intermediate tube segment 8050' that may be substantially
identical to the intermediate tube segment 8050 described above,
except that the right rib spaces 8315 and the left rib spaces 8325
decrease in magnitude going from the proximal end of the flexible
articulation portion 8060' to the distal end of the flexible
articulation portion 8060'. That is, the proximal-most right rib
space 8315P' is the widest right rib space and the distal most
right rib space 8315D' is the narrowest right rib space with the
right rib spaces 8315' getting successively narrower going in the
distal direction "DD". Similarly, the proximal-most left rib space
8325P' is the widest left rib space and the distal-most left rib
space 8325D' is the narrowest left rib space with the left rib
spaces 8325' getting successively narrower going in the distal
direction. In such arrangement, when the articulation motion is
applied to the surgical end effector, the flexible portion 8060
will have a faster rate of flexure at its distal end. That is, a
distal portion of flexible segment 8060' will flex or articulate at
a rate that is greater than a rate at which another portion of
8060' that is proximal to that distal segment will articulate upon
application of an articulation motion to the end effector. Stated
another way, relative movement between the ribs on the distal end
will stop before the relative movement between the more proximal
ribs stops because the spaces between the distal ribs are smaller
than the spaces between the proximal ribs. In the illustrated
arrangement the widths of the right and left rib spaces 8315' and
8325' that are laterally aligned with each other may be equal in
magnitude. Such rib space width arrangements may enable the
flexible articulation portion 8060' to assume a substantial
"U"-shape if desired. See e.g., FIG. 82. It will be understood,
however, that various other slot width arrangements, sizes and
configurations may be employed to achieve a desired amount/range of
articulation while preventing the intermediate tube from
inadvertently twisting about the longitudinal tool axis.
[0403] FIG. 83 depicts another surgical instrument 8410 that is
capable of practicing several unique benefits of the present
invention. The surgical instrument 8410 is designed to manipulate
and/or actuate various forms and sizes of end effectors 8412 that
are operably attached to an elongated shaft assembly 8500 of the
surgical instrument. In the depicted embodiment, for example, the
end effector 8412 comprises a surgical stapling device that has
openable and closable jaws 8413 and 8415. More specifically, the
end effector 8412 includes an elongated channel 8414 that forms a
lower jaw 8413 of the end effector 8412. See FIG. 84. In the
illustrated arrangement, the elongated channel 8414 is configured
to operably support a staple cartridge 8430 and also movably
supports an anvil 8420 that functions as an upper jaw 8415 of the
end effector 8412.
[0404] Referring now to FIGS. 84 and 85, the anvil 8420 may have a
mounting portion 8422 that protrudes from its proximal end 8421.
The mounting portion 8422 may have lateral mounting holes 8424
therethrough that enable the mounting portion 8422 to be pivotally
pinned to an upstanding pivot boss 8417 formed in the elongated
channel 8414 by an anvil pin 8418. The anvil 8420 may be
selectively "moved" towards the surgical staple cartridge 8430
mounted in the elongated channel 8414 by axially advancing a distal
closure tub segment 8590 in the distal direction "DD" as will be
discussed in further detail below. In various implementations, for
example, a first anvil actuation member in the form of an anvil
camming pin 8419 may extend through a camming slot 8423 provided in
the anvil mounting portion 8422. The camming pin 8419 is mounted in
holes 8591 provided in the distal closure tube segment 8590 such
that movement of the distal closure tube segment 8590 in the distal
and proximal directions will result in the movement of the camming
pin 8419 in the camming slot 8423. In addition, the distal closure
tube segment 8590 may further include a second anvil actuation
member in the form of, for example, an actuation pin 8593 that is
positioned to interact with an angled actuation surface 8425 formed
on the proximal end of the anvil mounting portion 8522. FIGS. 89-91
illustrate the anvil 8420 in a first or open position. The anvil
8420 may be moved to a closed position by moving the distal closure
tube segment 8590 in the distal direction "DD". Movement of the
distal closure tube segment 18590 in the distal direction "DD"
causes the first camming pin 8419 to move within the camming slot
8423 in the anvil mounting portion 8422 which thereby causes the
anvil 8420 to pivot about the anvil pin 8418 to the closed position
as illustrated in FIGS. 86-88. To return the anvil 10020 to the
open position (FIGS. 89-91), the distal closure tube segment 8590
is moved in the proximal direction "PD" which causes the first
camming pin 8419 to move in the camming slot 8423 in an opposite
direction and cam the anvil 8420 to the open position. Such closure
tube arrangement differs from prior closure tube arrangements
wherein the distal end of the closure tube segment is configured to
contact the anvil and pivot it to a closed position. Use of the
present camming pin arrangements does not require use of an anvil
that has a more robust portion configured for actuation contact
with the closure tube segment.
[0405] In various arrangements, the end effector 8412 may be
configured to be selectively articulated about a longitudinal tool
axis LT-LT that is defined by the elongated shaft assembly 8500.
For example, the elongated shaft assembly 8500 may include a
flexible neck assembly 8510 that enables the end effector 8412 to
articulate in a first direction "FD" that is essentially the same
direction that the anvil 8420 moves in when the anvil 8420 is moved
from an open position to a closed position (hereinafter referred to
as the anvil closing direction "CD"). See FIGS. 86 and 90. The
flexible neck assembly 8510 will further facilitate articulation of
the end effector 8412 in a second articulation direction "SD" that
is essentially the same as the direction that the anvil moves from
a closed position to an open position (hereinafter referred to the
anvil opening direction "OD"). See FIGS. 86, 89 and 90.
[0406] Various flexible neck assemblies are disclosed in U.S.
Provisional Patent Application Ser. No. 61/386,117, entitled
ARTICULATING SURGICAL DEVICE, and filed Sep. 24, 2010, the entire
disclosure of which is herein incorporated by reference. Other
flexible neck assemblies are disclosed in U.S. Patent Application
Publication No. 2012/0074200, entitled SURGICAL INSTRUMENT WITH
SELECTIVELY ARTICULATABLE END EFFECTOR, and filed Sep. 23, 2011,
the entire disclosure of which is hereby incorporated by reference
herein. The flexible neck assembly 110 may, for example, be
composed of rigid thermoplastic polyurethane sold commercially as
ISOPLAST grade 2510 by the Dow Chemical Company. The flexible neck
assembly 8510 may have a flexible neck segment 8511 that comprises
a first or upper flexible neck portion 8512 and a second or lower
flexible neck portion 8514. These neck portions 8512, 8514 may be
separated by a longitudinal rib portion 8516. The neck portions
8512, 8514 may each have a plurality of neck ribs 8518 that are
configured essentially as semi-circular disks which together
generally form a cylindrical configuration. An upper slot 8520
extends through each of the neck ribs 8518 of the first or upper
flexible neck portion 8512 to form a passage through the first
flexible neck portion 8512 for receiving a first flexible
transmission band assembly 8550 therethrough. Similarly, a lower
slot 8521 extends through each of the neck ribs 8518 in the second
or lower flexible neck portion 8514 to form a passage for receiving
a second flexible transmission band assembly 8570 therethrough.
See, for example, FIG. 86. The flexible neck assembly 8510 may
include guide surfaces 8524 (only one can be seen in FIG. 92) that
extend proximally from the flexible neck segment 8511 for
supporting the reciprocating movement of the flexible transmission
band assemblies 8550, 8570.
[0407] As can be seen in FIG. 92, the first or upper transmission
band assembly 8550 may include a first transmission band 8552 and
the second transmission band assembly 8570 may include a second
transmission band 8572. In addition, the first transmission band
8550 may have a first elongated structural portion 8554 and the
second transmission band 8570 may have a second elongated
structural portion 8574. When the first and second transmission
bands 8550, 8570 are brought into contact with each other during
assembly of the instrument, they form an elongated cylinder which
has a longitudinal cavity 8560 extending concentrically through it
to operably receive a firing rod 10530 therethrough. See FIGS. 93
and 94. The first structural portion 8554 of the first transmission
band 8552 has a first articulation rack 8556 formed thereon and the
second structural portion 8574 of the second transmission band 8572
has a second articulation rack 8576 formed thereon which, as will
be discussed in further detail below, drivingly interface with an
articulation transmission assembly 8600.
[0408] Referring again to FIG. 92, the first transmission band 8552
may have a first exterior reinforcement band portion 8557 that
extends distally from the first structural portion 8554. Likewise,
the second transmission band 8572 may have a second exterior
reinforcement band portion 8577 that extends distally from the
second structural portion 8576. Each exterior reinforcement band
portion 8557, 8577 may have a plurality of attachment lugs 8562 for
securing first and second interior articulation bands 8558, 8578
thereto. For example, the first transmission band 8552 has a first
interior articulation band 8558 attached thereto and the second
transmission band 8572 has a second interior articulation band 8578
attached thereto. The first and second transmission bands 8552,
8572 may be composed of a plastic, especially a glass
fiber-reinforced amorphous polyamide, sold commercially under the
trade name Grivory GV-6H by EMS-American Grilon. In contrast, the
interior articulation bands 8558, 8578 of the transmission band
assembly may be composed of a metal, advantageously full hard 301
stainless steel or its equivalent. The attachment lugs 8562 on the
exterior reinforcement band portions 8557, 8577 of the transmission
bands 8552, 8572, respectively, are received into and secured
within a plurality of lug holes 8564 on the corresponding interior
articulation band 8558, 8578. See FIG. 92.
[0409] In at least one implementation, the proximal end of the
elongated cartridge channel 8414 is provided with a pair of upper
and lower band connector ears 8450. See FIGS. 84 and 86-88. These
band connector ears 8450 are inserted into and through connector
loops 8559, 8579 on the distal end of the interior articulation
bands 8558, 8578, respectively. In this manner, the cartridge
channel 8414 is coupled to the interior articulation bands 8558,
8578 of the flexible neck assembly 8510. Specifically, the
reciprocation of the first and second flexible transmission band
assemblies 8550, 8570 in opposite directions causes the interior
articulation bands 8558, 8578 received in the upper and lower slots
8520, 8521 on the flexible neck segment 8511 to reciprocate in a
like manner. Upon reciprocation of the interior articulation bands
8558, 8578, in particular when the first band 8558 is moved
proximally in tandem with the second band 8578 moving distally, the
first and second flexible neck portions 8514, 8516 bend as the neck
ribs 8518 of the first flexible neck portion 8514 move toward each
other and the neck ribs 8518 of the second flexible neck rib
portion 8516 concurrently move away from each other. The coupling
of the interior articulation bands 8558, 8578 to the exterior
reinforcement band portions 8557, 8577 of the transmission bands
8552, 8572, respectively prevents the interior articulation bands
8558, 8578 from buckling between adjacent neck ribs.
[0410] In various arrangements, the distal closure tube segment
8590 is slid over the channel guide 8528 of the flexible neck
assembly 8510. The proximal end 8591 of the distal closure tube
segment 8590 has a pair of diametrically opposed slots 8592 therein
(only one can be seen in FIGS. 83 and 92) for receiving distally
protruding lugs 8513 protruding from the flexible neck portion 8511
to prevent rotation of the distal closure tube segment 8590
relative to the flexible neck portion 8511. In various embodiments,
the distal closure tube segment 8590 may be retained on the channel
guide 8528 by a retention tab (not shown) that extends into the
fastener hole (not shown) in the channel guide 8528. However, other
fastening arrangements may be employed, for example. Such
arrangement causes the distal closure tube segment 8590 to move
axially with the flexible neck assembly 8510.
[0411] Movement of the first and second transmission bands 8552,
8572 may be controlled by an articulation transmission assembly
8600. The component parts of one form of articulation transmission
assembly 8600 are illustrated in FIG. 92. In one form, the
articulation transmission assembly 8600 may include an actuator
8610, an articulation body 8620 and a nozzle 8650 (FIGS. 83 and
94). Rotational movement of the actuator 8610 causes corresponding
rotation of the articulation body 8620 within the nozzle 8650. The
first and second elongated transmission bands, 8552 and 8572,
consequently reciprocate axially in opposite directions parallel to
the longitudinal tool axis LT-LT of the elongated shaft assembly
10100 to cause the remote articulation of the end effector
8412.
[0412] Still referring to FIG. 92, the articulation body 8620 has a
deck 8622 consisting of first and second spaced-apart, semicircular
deck halves, 8624, 8626. The deck halves are mutually opposed to
each other and essentially represent mirror images of each other.
The first and second deck halves 8624, 8626 have protruding from
their surfaces mutually opposed first and second detents 8625,
8627, respectively. Each deck half 8624, 8626 has a set of deck
teeth 8628 spaced about 180 degrees from the set of deck teeth on
the other deck half. The articulation body 8620 has a pair of
rotation stops 8630 protruding from its surface as well as a pair
of finger recesses 8632. A drive gear 8640 protrudes laterally from
the articulation body 8622. The drive gear 8640 has a flared
opening 8642 through it, and a lateral pivot 8644. Within the
flared opening 8642 of the drive gear 8640, there is a firing rod
orifice (not shown) for receiving a firing rod 8930 therethrough
enabling the application of a firing motion to the end effector
8412. The drive gear 8640 is configured to intermesh with the first
and second drive racks 8556, 8576, respectively to effect the
desired reciprocating movement of the first and second transmission
bands 8552, 8572. See FIG. 94.
[0413] The nozzle 8650 of the articulation transmission assembly
8600 may include a nozzle body 8652. The nozzle body 8652 may have
an axial bore 8654 therethrough that facilitates the passage of the
first transmission band assembly 8550 and the second transmission
band assembly 8570 as well as for the firing rod 8930 and other
operative components of the instrument 8410 including a the
proximal end 8706 of a proximal outer shaft segment 8700. See FIG.
94. The nozzle body 8652 may also have a frame groove 8656 and
flange 8658 to rotatably fasten the nozzle body 8652 to a housing
8800. In various forms, a detent housing 8660 comprises a portion
of the nozzle body 8652. See FIG. 95. An annular array of detent
teeth (not shown) is formed within the detent housing 8660. A
detent housing floor is spaced from the detent teeth. The floor may
have a pair of ledges which interact within the rotation stops 8630
of the articulation body 8620 to limit the degree of rotation. When
the articulation body 8620 is inserted into the detent housing
8660, the base of the articulation body 8620 is supported on the
floor within the detent housing 8660, and the deck teeth 8628 of
the first and second deck halves, 8624, 8626 are aligned for
meshing engagement with the detent teeth of the detent housing
8660. A spring member 8668 is supported within the articulation
body to bias the deck teeth 8628 into meshing engagement with the
detent teeth.
[0414] Referring again to FIG. 92, the actuator 8610 may consist of
a lever arm 8612, a cap 8614 and a pair of retaining fingers 8616.
The lever arm 8612 is mounted on the top of the cap 8614. The pair
of retaining fingers 8616 protrudes laterally from the underside of
the cap 8614. Each of the retaining fingers 8616 has a retaining
clip. The retaining fingers 8616 are received within the finger
recesses 8632 of the articulation body 8620. First and second
detents, 8625, 8627, on the deck halves of the articulation body
are inserted into a slot depression within the underside of the
circular cap 8614. Advantageously, each of the three significant
components of the articulation transmission assembly, namely the
actuator, articulation body and nozzle, may be injection molded
components. Such components, for example, may be fabricated from a
glass fiber-reinforced amorphous polyamide, sold commercially under
the trade name Grivory GV-4H by EMS--American Grilon 150.
[0415] Ratcheting rotation of the actuator 8610 causes articulation
of the end effector 8412 in the first or second directions relative
to the longitudinal tool axis LT-LT. FIG. 86 illustrates the end
effector 8412 in an unarticulated position in solid lines and
exemplary ranges of articulation in broken lines. When the drive
gear 8640 on the articulation body 8620 of the articulation
transmission 8600 is rotated to thereby drive the first
transmission band assembly 150 distally in the "DD" direction and
the second transmission bar assembly 8570 proximally in the
proximal direction "PD", the end effector 8412 will articulate in
the first articulation direction "FD" relative to the longitudinal
tool axis LT-LT. When the drive gear 8640 on the articulation body
8620 of the articulation transmission 8600 has been rotated to
thereby drive the second articulation band assembly 8570 in the
distal direction "DD" and the first articulation band assembly 8550
in the proximal direction "PD", the end effector 8412 will pivot in
a second direction "SD" relative to the longitudinal tool axis
LT-LT.
[0416] As can be seen in FIG. 93, the elongated shaft assembly 8500
further includes a proximal outer shaft segment 8700 that is
attached to the flexible neck assembly 8510. The proximal outer
shaft segment 8700 is substantially rigid and may be attached to
the flexible neck portion 8511 of the flexible neck assembly 8510
by, for example, a press fit, adhesive or other suitable fastener
arrangement. As can be seen in FIG. 94, in at least one embodiment,
the distal end 8702 of the proximal outer shaft segment 8700 has a
pair of opposed notches 8704 therein that are adapted to receive
corresponding lugs 8515 protruding from the flexible neck portion
8511 such that rotation of the proximal outer shaft segment 8700
results in rotation of the flexible neck assembly 8510 and
ultimately of the end effector 8412.
[0417] Still referring to FIG. 92, the proximal outer shaft segment
8700 has a proximal end 8706 that has a slot 8708 for receiving the
drive gear 8640 therethrough such that the proximal outer shaft
segment 8700 may move axially relative thereto. In addition, the
proximal end 8706 of the proximal outer shaft segment 8700 has a
flange 8710 formed thereon that facilitates rotational attachment
to a closure carriage 8820 of an actuation system that is operably
supported within the housing assembly 8800. The closure carriage
and actuation system may be of the same or similar type,
construction and operation as the closure carriage and actuation
system disclosed in U.S. Patent Application Publication No.
2012/0074200 which has been incorporated by reference herein in its
entirety.
[0418] Referring now to FIG. 96, the closure carriage 8820 may
comprise two carriage segments 8822 (only one is illustrated) that
are interconnected together by adhesive, snap features, screws,
etc. As used herein, the term "snap feature" includes, but is not
limited to, for example, a tab that has a protrusion thereon that
is configured to retainingly engage a corresponding mating portion
of another component. Such features may be designed to releasably
engage the mating portion or it may not be designed or intended to
be removed. In at least one form, the closure carriage 8820 has a
distal end 8824 that has a groove arrangement 8826 that is adapted
to receive the flanged end 8710 of the proximal outer shaft segment
8700. Such arrangement serves to attach the proximal end 8706 of
the proximal outer shaft segment 8700 to the closure carriage 8820
while facilitating its selective rotation of the proximal outer
shaft segment 8700 relative to the closure carriage 8820.
Therefore, the elongated shaft assembly 8500 and the end effector
8412 that is operably coupled thereto may be selectively rotated
about the longitudinal tool axis LT-LT relative to the housing
assembly 8800.
[0419] In various implementations, the housing assembly 8800
comprises a pistol-shaped handle housing that may be fabricated in
two or more pieces for assembly purposes. For example, the housing
assembly 8800 as shown comprises a right hand case member 8802 and
a left hand case member 8804 (FIG. 83) that are molded or otherwise
fabricated from a polymer or plastic material and are designed to
mate together. Such case members 8802 and 8804 may be attached
together by snap features, pegs and sockets molded or otherwise
formed therein and/or by adhesive, screws, etc. When assembled, the
housing assembly 8800 movably supports the closure carriage 8820
for selective axial travel therein in response to actuation motions
from a trigger, generally designated as 8830. As the present
Detailed Description proceeds, however, it will be understood that
the various unique and novel aspects and attributes of the various
implementations of the present invention may be effectively
attained when employed with robotically controlled or otherwise
remotely controlled systems. Thus, the term "housing" or "housing
assembly" may also encompass a housing or similar portion of a
robotic system that houses or otherwise operably supports at least
one drive system that is configured to generate and apply at least
one control motion which could be used to actuate various forms of
surgical end effectors attached thereto. For example, various
implementations of the surgical instrument described herein may be
used in connection with those robotic systems and arrangements
disclosed in U.S. patent application Ser. No. 13/536,323, entitled
ROBOTICALLY POWERED SURGICAL DEVICE WITH MANUALLY ACTUATABLE
REVERSING SYSTEM, and filed Jun. 28, 2012, the entire disclosure of
which is incorporated by reference herein.
[0420] The trigger assembly 8830 may, for example, comprise a
primary trigger 8840 and a secondary trigger 8860. The primary and
secondary triggers 8840 and 8860 are pivotally journaled on a pivot
pin assembly 8831 formed in the housing assembly 8800 such that the
triggers 8840 and 8860 may essentially move relative to each other.
Such arrangement permits the trigger assembly 8830 to pivot
relative to the housing assembly 8800 about a pivot axis PA-PA. See
FIG. 96. The primary trigger 8840 has an elongated, grippable
primary trigger paddle 8842 that protrudes from a primary drive
portion 8844 that has a firing rack 8846 formed thereon. In one
embodiment, the secondary trigger 8860 has a secondary trigger
paddle 8862 that protrudes from a secondary drive portion 8864 as
discussed in further detail that is pivotally journaled on the
pivot pin assembly 8831. The primary drive portion 8844 has a slot
8848 that is adapted to receive the secondary drive portion 8864 of
the secondary trigger 8860 therein as the primary trigger paddle
8842 is pivoted towards a pistol grip portion 8806 of the housing
assembly 8800. Such arrangement essentially enables the secondary
trigger 8860 to "nest" within the primary trigger 8840 during
actuation. As will be discussed in detail below, the secondary
trigger 8860 is pivotally actuated by pivoting the primary trigger
8840. Thus, in other embodiments, the secondary trigger 8860 may
lack the secondary trigger paddle 8842. In various forms, the
trigger assembly 8830 may be biased into the unactuated position by
a trigger spring (not shown).
[0421] As can be seen in FIG. 96, the secondary drive portion 8864
of the secondary trigger 8860 may have a closure gear segment 8866
formed thereon that is configured for meshing engagement with a
carriage gear rack 8823 formed on the underside of the closure
carriage 8820. Thus, when the secondary trigger 8860 is pivoted
toward the pistol grip 8806, the closure carriage 8820 is driven in
the distal direction "DD".
[0422] In various implementations, the actuation system 8810 may
further include an actuation bar 8870. The actuation bar 8870 has a
first actuation rack 8872 formed thereon that is configured for
meshing engagement with the primary gear segment 8846 on the
primary trigger 8840. Thus, when the primary gear segment 8846 is
in meshing engagement with the first actuation rack 8872, the
actuation bar 8870 is driven in the distal direction "DD" when the
primary trigger 8840 is pivoted toward the pistol grip 8806. The
actuation bar 8870 has a second actuation rack 8874 formed thereon
configured to meshingly engage clutch teeth 8884 on a clutch shaft
8882 of a clutch assembly 8880. In various embodiments, the clutch
shaft 8882 is rotatably is supported within the housing assembly
8800 and is also laterally movable therein. The clutch shaft 8882
has a hub portion 8886 that has a plurality of spaced teeth 8888
that are configured to drivingly engage teeth openings 8892 in a
drive gear 8890 that is rotatably supported on the clutch shaft
8882. The drive gear 8890 has a segment of drive gears 8894 thereon
that are adapted for meshing engagement with a firing rack 8900
that is movably supported in the housing assembly 8800.
[0423] Various embodiments of the clutch assembly 8880 may further
comprise a clutch plate 8910 that is slidably journaled on a clutch
pin 8849 provided on the primary drive portion 8844 of the primary
trigger 8840. The clutch pin 8849 may be movably received within a
vertical slot 8912 in the clutch plate 8910. The clutch plate 8910
also has a distally-extending clutch arm 8914 that is adapted to
actuatably engage a bevel plate 8889 formed on the clutch shaft
8882. In addition, a clutch spring 8920 is employed to bias the
clutch shaft 8880 laterally such that the teeth 8888 on the clutch
shaft 8882 are brought into meshing engagement with the teeth
openings 8892 in the drive gear 8890.
[0424] As can be seen in FIGS. 92 and 96, the firing rack 8900 is
coupled to a firing rod 8930 that is attached to the proximal end
of the knife bar assembly 8970. In various embodiments, the knife
bar assembly 8970 may comprise an upper bar segment 8971 and a
lower bar segment 8972. Such arrangement may enable the knife bar
assembly 8970 to flex as the end effector 8412 is articulated,
while remaining sufficiently rigid to be driven distally through
the shaft assembly 8500. In the depicted embodiment, the upper and
lower knife bar segments 8971, 8972 are each attached to an
"E-beam" cutting head 8973. In the depicted configuration, the
E-beam cutting head 8973 includes a vertically oriented body
portion 8974 that has an upper portion 8975 and a lower portion
8976. A bottom foot 8977 is formed on or attached to the lower
portion 8976. In alternative embodiments, the bottom foot may
essentially comprise laterally extending lower tabs that protrude
laterally from the lower portion. Similarly, at least one upper tab
8977' is formed on or otherwise attached to the upper portion 8975
of the vertically oriented body portion 8974. In addition, as can
be seen in FIG. 84, the vertically oriented body portion 8974
further includes at least one intermediate tab portion 8978 (only
one is shown) as well as a tissue cutting edge 8979.
[0425] Referring to FIG. 84, the vertically oriented body portion
8974 extends through a longitudinally extending slot 8980 in the
elongated channel 8414 and a longitudinally extending slot 8981 in
the anvil 8420. When assembled, portions of the elongated channel
8414 are received between the bottom foot 8977 and the intermediate
tab portions 8978. The, upper tab portion 8977' is arranged to be
received within the anvil 8420 above portions 8982 of the anvil
8420 that define the anvil slot 8981. To facilitate ease of
assembly, the anvil 8420 may be provided with a movable anvil cover
8983 and the elongated channel 8414 may be provided with a
removable channel cover 8984. Once assembled, the anvil cover 8983
and the channel cover 8984 may be installed to prevent tissue, body
fluids, etc. from entering the anvil 8420 and the elongated channel
8414, respectively which may hamper operation of the cutting head
8973.
[0426] In various arrangements, each staple cartridge 8430 includes
a cartridge body 8431 that has a sled assembly 8985 operably
supported therein. The sled assembly 8985 may have a mounting
portion 8986 that is configured to extend into a sled slot 8987
formed in the vertically oriented body portion 8974 of the cutting
head 8973. See FIGS. 84 and 86. The sled assembly 8985 may be
configured with wedges 8988 that are arranged to contact staple
drivers 8989 that are operably supported within the staple
cartridge 8430. The staple drivers 8989 may support one or more
staples 8990 thereon in a known manner. As the sled assembly 8985
is driven in the distal direction DD through the staple cartridge
8430, the wedges 8988 drive the drivers 8989 upward within the
cartridge 8430 in a known manner. The upwardly moving drivers 8989
drive the staples 8990 into forming contact with a staple forming
undersurface of the anvil 8420. The undersurface may, for example,
include staple-forming pockets that correspond to each staple.
[0427] The end effector 8412 may also employ a cutting head lockout
system, generally designated as 8991 that serves to prevent distal
advancement of the cutting head 8973 when a new staple cartridge
8430 is not present within the elongated channel 8414. In at least
one arrangement, for example, the cutting head lockout system 8991
may comprise a lockout spring 8992 that is mounted to the bottom of
elongated channel 8414. The lockout spring 8992 may be configured
to contact the bottom foot 8977 of the cutting head assembly 8973
when the cutting head assembly 8974 is in the starting position.
See FIGS. 86, 88 and 91. An opening 8993 may be provided through
the bottom of the elongated channel 8414 such that when in that
position, the lockout spring 8992 biases the bottom foot 8977 such
that it interferes with the bottom of the elongated channel 8414.
Thus, when the bottom foot 8977 is in that position, if the
clinician were to try advance the cutting head 8973 distally
through the elongated channel 8414, the bottom foot portion 8977
will contact a portion of the elongated channel 8414 to prevent
such advancement of the cutting head 8973. When a cartridge 8430
has been properly installed with the elongated channel 8414, the
mounting portion 8986 of the sled assembly 8985 extends into the
sled slot 8987 and serves to move the cutting head assembly 8973
into a position whereby the foot portion 8977 is moved out of
interfering contact with the bottom of the elongated channel 8414.
When in that position, the cutting head assembly 8973 is free to be
advanced distally through the elongated channel 8414. Such
arrangement serves to prevent the clinician from inadvertently
firing the end effector when a new cartridge is not present which
could otherwise result in the tissue being cut but not stapled. As
the cutting head 8973 is advanced distally, the bottom foot 8977,
the intermediate tab portions 8978 and the upper tab 8977'
cooperate to orient the anvil 8420 relative to the staple cartridge
deck at a desired spaced relationship relative to each other. A
distally presented tissue-cutting edge 8979, which is between the
upper tab 8977' and intermediate tab portions 8978, severs clamped
tissue while causing the staples 8990 within the staple cartridge
8430 to be formed into the tissue clamped within the end effector
8412.
[0428] As can be seen in FIG. 84, the upper firing bar 8971 is
attached to the upper end portion 8975 and the lower firing bar
8972 is spaced from the upper firing bar 8971 and is attached to
the lower end portion 8976 of the vertically-extending 8974 of the
cutting head 8973. Such arrangement serves to transmit the firing
motions to the upper and lower portions of the cutting head 8973 in
an equivalent manner to facilitate aligned movement of the cutting
head through the anvil 8420, the surgical staple cartridge 8430 and
the elongated channel 8414. In various arrangements, for example,
the upper firing bar 8971 may be attached to the upper end portion
directly behind the upper tabs(s) 8977' such that the upper firing
bar 8971 is essentially axially aligned with point(s) from which
the upper tab(s) 8977' protrude laterally from the upper end
portion 8975. Similarly, the lower firing bar 8972 may be attached
to the bottom end portion 8976 directly behind the bottom foot 8977
or the point(s) from which the laterally protruding bottom tabs
protrude laterally from the bottom end portion 8976 such that the
lower firing bar 8972 is axially aligned therewith. The upper and
lower firing bars 8971, 8972 may be welded to the vertical
extending portion 8974 in those locations. For example, the welds
may be applied to the firing bars from one side or from both
lateral sides of the firing bars. In at least one implementation,
the upper and lower firing bars 8971, 8972 are not directly
attached to each other. The portions of the upper and lower firing
bars 8971, 8972 that extend through the elongated shaft assembly
8500 to be coupled to a distal end portion 8932 of the firing rod
8930 are supported in a contiguous orientation relative to each
other. The proximal ends of the upper and lower firing bars 8971,
8972 may be attached to the distal end portion 8932 of the firing
rod 8930 by a coupler member 8994. See FIG. 92. As will be
discussed in further detail below, the firing rod 8930 facilitates
the application of firing and retraction motions to the knife bar
assembly 10600 by the actuation system 8810. In at least one
implementation, the anvil mounting portion 8422 has a wedge-like
formation 8427 thereon that serves to separate the upper firing bar
8971 and lower firing bar 8972 as the knife bar assembly 8970 is
driven in the distal direction "DD". See, for example, FIG. 91.
[0429] In various arrangements, the firing rod 8930 extends through
a closure bushing 8940 that is mounted within the housing assembly
8800. In at least one form, a pair of mounting studs 8807 protrude
from the handle casings 8802, 8804 and extend through corresponding
slots in the closure carriage 8820 to be received in a retaining
slot in the bushing 8840. A closure spring 8950 that is attached to
a retainer clip 8952 is journaled on the closure bushing 8940. The
closure spring 8950 extends between the nozzle body 8652 and an
internal wall 8825 in the closure carriage 8820. Thus, the closure
spring 8950 serves to bias the closure carriage 8820 in the
proximal direction "PD".
[0430] Various embodiments may also include a releasable closure
locking assembly 8960 that interfaces with the closure carriage
8820 to selectively retain the closure carriage 8820 in its
distal-most closed or clamped position. In at least one form, the
closure locking assembly 8960 includes a locking button 8962 that
is pivotally supported in the housing assembly 8800. The locking
button 8862 has a latch arm 8964 that is configured to abut a
locking ledge 8826 formed on the closure carriage 8820 when the
button 8962 is in the locked position. In addition, the latch arm
8964 has a catch 8966 formed thereon that is configured to
releasably latch with a locking latch 8902 on the proximal end of
the firing rack 8900. A locking spring 8968 serves to bias the
locking button 8962 into the locked position.
[0431] Operation of the surgical instrument 8410 will now be
described. FIGS. 89-91 illustrate the jaws 8413 and 8415 of the end
effector 8412 in an open position. When the end effector 8412 is in
the open position, the latch arm 8964 is located on top of the
locking ledge 8826 formed on the closure carriage 8820 such that
the catch 8966 of the latch arm 894 is in retaining engagement with
the locking latch 8902 on the firing rack 8900. Thus, when in this
initial starting position, the knife bar assembly 8790 cannot be
inadvertently actuated. The clutch plate 8910, as well as the
closure carriage, are each in their proximal-most unactuated
positions. When in those positions, the clutch drive bevel 8889 on
the clutch shaft 8882 is in contact with a portion of the closure
carriage 8820, which prevents the clutch shaft 8882 from laterally
moving into meshing engagement with the drive gear 8890 under the
bias of the clutch spring 8920.
[0432] To initiate the closure process, a first stroke is applied
to the trigger assembly 8830. That is, the trigger assembly 8830 is
initially pivoted toward the pistol grip 8806. Such pivoting action
serves to drive the closure carriage 8820 in the distal direction
"DD" by virtue of the meshing engagement between the closure gear
segment 8866 on the secondary trigger 8860 and the carriage rack
8823 formed on the underside of the closure carriage 8820. Such
distal movement of the closure carriage 8820 also axially advances
the proximal outer shaft segment 8700 and the distal closure tube
segment 8590 in the distal direction "DD". As the distal closure
tube segment 8590 moves distally, the pin 8419 which extends
through the slots 8423 in the anvil mounting portion 8422, travels
from the position illustrated in FIGS. 90 and 91 to the position
illustrated in FIGS. 86-88 to pivot the anvil 8420 to the closed
position. If the surgeon desires to simply grasp and manipulate
tissue prior to clamping it between the anvil 8420 and the surgical
staple cartridge 8430, the trigger assembly 8830 may be pivoted to
open and close the anvil 8420 without fully pivoting the trigger
assembly 8830 to the fully closed position.
[0433] Those of ordinary skill in the art will understand that, as
the trigger assembly 8830 is pivoted toward the pistol grip 8806,
the actuation bar 8870 will necessarily also be driven distally by
virtue of the meshing engagement between the primary gear segment
8846 on the primary trigger 8840 and the first actuation rack 8872
on the actuation bar 8870. The distal movement of the actuation bar
8870 will also result in the an application of a rotary actuation
motion to the clutch shaft 8882 by virtue of the meshing engagement
between the clutch teeth 10484 on the clutch shaft 8882 and the
second actuation rack 8874 on the actuation bar 8870. However, such
rotary motion is not applied to the drive gear 8890 because the
clutch arm 8914 of the clutch plate 8910, in contact with the
clutch drive bevel 8889 on the clutch shaft 8882, prevents the
axial movement of the clutch shaft 8882 into meshing engagement
with the drive gear 8890. Thus, the clutch shaft 8882 freely
rotates relative to the drive gear 8890. Accordingly, the clutch
assembly 8880 automatically prevents the activation of the firing
rack 8900 during the initial actuation of the trigger assembly
8830.
[0434] Once the trigger assembly 8830 has been initially fully
compressed into the closed position, the anvil 8420 will be
retained in the locked or clamped position by the closure locking
assembly 8960 which prevents the proximal movement of the closure
carriage 8820. To drive the knife bar assembly 8970 distally
through the tissue clamped in the end effector 8412, the surgeon
again pivots the primary trigger 8840 toward the pistol grip 8806
of the housing assembly 8800. As the primary trigger 8840 is
pivoted, the firing rack 8900, the firing rod 8930, and the knife
bar assembly 10600 are driven in the distal direction "DD". After
the knife bar assembly 8970 has been driven through the tissue
clamped in the end effector 8412, the surgeon then releases the
primary trigger 8840 to thereby permit the primary trigger 8840 to
pivot to its unactuated position under the bias of the firing
spring 8832. As the primary trigger 8840 pivots back to the
starting position, the firing rack 8900, firing rod 8930, and knife
bar assembly 8970 are drawn proximally back to their respective
starting positions. The end effector 10012 remains in its clamped
position as shown in FIG. 88. As can also be seen in that Figure,
the sled assembly 8985 remains in the distal end of the cartridge
8430 while the knife bar assembly 8970 is returned to the starting
position.
[0435] To unlock the closure carriage 8820 and the secondary
trigger 8860, the surgeon depresses the locking button 8962. As the
locking button 8962 is depressed, the locking arm 8964 is pivoted
out of abutting engagement with the locking ledge 8826 on the
closure carriage 8820. Further details regarding the operation of
the firing and closure systems may be found in U.S. Patent
Application Publication No. US 2012/0074200 which has been herein
incorporated by reference in its entirety. As the closure carriage
8820 moves proximally, the proximal outer shaft segment 8700, the
flexible neck assembly 8510, and the distal closure tube segment
8590 are drawn proximally. As the distal closure tube segment 8590
moves proximally, the shaft 8419 travels proximally within the slot
8423 in the anvil mounting portion 8422 to move the anvil 8420 to
an open position.
[0436] As can be appreciated from the foregoing, the various
surgical instruments disclosed herein afford the clinician with
improved maneuverability and various other advantages that are not
available when using prior surgical instruments that are configured
to cut and fasten tissue. For example, in various implementations
disclosed herein, the end effector is selectively articulatable in
the same directions in which the jaws are movable relative to each
other. Stated another way, the jaws of the surgical end effector
are constrained to move in one plane. In various implementations
disclosed herein, the end effector is also capable of moving in
that same plane. Prior end effectors are commonly constrained to
move in planes that differ from the plane in which the jaws
move.
[0437] Another advantage provided by many of the present
implementations is the use of a firing bar that comprises at least
an upper firing bar and at least a lower firing bar that form a
laminated structure. The upper and lower bars may at some point be
attached to each other or they may be unattached and just be
contiguous with each other. In either arrangement, the upper bar is
attached to an upper end of the cutting head and the lower bar may
be attached to the lower head such that they are spaced from each
other at their points of attachment to the cutting head. Such
arrangement serves to provide for a more stable cutting head
arrangement that may be less likely to twist and/or buckle during
actuation. In addition, the cutting head may be equipped with
laterally protruding upper tab(s) that engage a portion of the
anvil and lower tab(s) that engage the elongated channel. The upper
firing bar may be attached directly behind the point where the
upper tabs are attached such that it is axially aligned therewith.
Likewise the lower firing bar may be attached to the bottom portion
directly behind the points where the bottom tab(s) are attached
such that it is axially aligned therewith. Such axial alignment
facilitates transfer of the driving or actuation motions to the
cutting head at the points where the cutting head engages the anvil
and the elongated channel which may further prevent and buckling
and/or twisting of the cutting head during actuation.
[0438] The various surgical instruments arrangements disclosed
herein that employ tissue cutting and staple firing systems, jaw
opening and closing systems and end effector articulation systems
that essentially employ components that are axially reciprocated
during actuation may be actuated by manually generated actuation
motions, For example, the firing systems may be housed in a handle
that includes trigger arrangements that are configured to generate
actuation motions when the clinician manipulate the triggers. It
will be appreciated, however, that such actuation motions may
likewise be generated by motors that are supported in a handle or
are supported or comprise a portion of a robotic system. Thus, the
various surgical instruments disclosed herein should not be limited
to use solely in connection with hand-held housings and manually
generated actuation motions.
[0439] Powered surgical instruments are disclosed in U.S. Patent
Application Publication No. 2009/0090763, filed on Aug. 12, 2008,
and entitled POWERED SURGICAL STAPLING DEVICE to Zemlok et al.
(hereinafter "Zemlok '763"), the entire disclosure of which is
hereby incorporated by reference herein. Powered surgical
instruments are also disclosed in U.S. Patent Application
Publication No. 2011/0278344, filed on Mar. 9, 2011, and entitled
POWERED SURGICAL INSTRUMENT to Zemlok et al. (hereinafter "Zemlok
'344"), now U.S. Pat. No. 8,201,721, the entire disclosure of which
is hereby incorporated by reference herein. FIG. 97 illustrates a
powered surgical instrument 9010 that, in many ways, may be similar
to those surgical instruments (including various features,
components and subcomponents thereof) disclosed in, for example,
Zemlok '763 and/or Zemlok '344, which have each been incorporated
by reference herein in their respective entireties. Likewise, the
surgical instrument 9010 may be similar to those surgical
instruments disclosed in U.S. patent application Ser. No.
13/974,166, filed Aug. 23, 2013, and entitled FIRING MEMBER
RETRACTION DEVICES FOR POWERED SURGICAL INSTRUMENTS to Shelton et
al. (hereinafter, "Shelton '166") the entire disclosure of which is
hereby incorporated by reference herein. The surgical instrument
9010 depicted in FIG. 97 includes a housing 9012 that has a handle
portion 9014 for facilitating manual manipulation and operation of
the instrument. Thus, the term "housing" as used herein may
encompass a handheld or otherwise hand-manipulatable arrangement.
However, the term "housing" may also encompass portions of an
automated surgical instrument system such as a
robotically-controlled system that is not intended to be handheld
but is otherwise manipulated and actuatable by various components,
portions, and/or actuators of the system. For example, various
implementations of the surgical instrument described herein may be
used in connection with those robotic systems and arrangements
disclosed in U.S. patent application Ser. No. 13/536,323, entitled
ROBOTICALLY POWERED SURGICAL DEVICE WITH MANUALLY ACTUATABLE
REVERSING SYSTEM, and filed Jun. 28, 2012, the entire disclosure of
which is incorporated by reference herein. Furthermore, the
coupling arrangements and end effector arrangement disclosed herein
may also be effectively employed with non-powered hand held
surgical instruments. Thus, the end effector arrangements and
coupling arrangements disclosed herein should not be limited to use
in connection with powered instruments, whether they be hand-held
or otherwise automated.
[0440] An elongated shaft assembly 9116 in the form of an
endoscopic portion protrudes from the housing 9012 and is
configured for operable attachment to a surgical end effector that
is constructed to perform at least one surgical procedure in
response to applications of firing motions thereto. The surgical
end effector may comprise a device configured to cut and staple
tissue such as a "loading unit" 9020 as shown in FIGS. 98-105.
Surgical end effectors, such as loading unit 9020, for example, can
be releasably attached to the elongated shaft assembly 9116 of the
powered surgical instrument 9010, as described in greater detail
herein.
[0441] FIGS. 98-105 illustrate one exemplary form of end effector
or loading unit 9020 that may be employed with the surgical
instrument 9010. As can be seen in FIG. 100, the loading unit 9020
includes an anvil assembly 9220 that is supported for pivotal
travel relative to a carrier 9240 that operably supports a staple
cartridge 9260 therein. The staple cartridge 9260 may comprise a
surgical staple cartridge that is designed to be "implanted" within
the patient. For example, the implantable surgical staple cartridge
9260 may comprise any of the various surgical staple cartridge
arrangements disclosed in U.S. Patent Application Publication No.
2012/0080484, filed Sep. 30, 2010, and entitled SURGICAL STAPLING
INSTRUMENT WITH A VARIABLE STAPLE FORMING SYSTEM, the entire
disclosure of which is hereby incorporated by reference herein. In
at least one implementation for example, the staple cartridge 9260
includes a body portion 9261 that consists of a compressible
hemostat material such as, for example, oxidized regenerated
cellulose ("ORC") or a bio-absorbable foam in which lines of
unformed metal staples are supported. In at least some embodiments,
in order to prevent the staple from being affected and the hemostat
material from being activated during the introduction and
positioning process, the entire cartridge may be coated or wrapped
in a biodegradable film such as a polydioxanon film sold under the
trademark PDS.RTM. or with a Polyglycerol sebacate (PGS) film or
other biodegradable films formed from PGA (Polyglycolic acid,
marketed under the trade mark Vicryl), PCL (Polycaprolactone), PLA
or PLLA (Polylactic acid), PHA (polyhydroxyalkanoate), PGCL
(poliglecaprone 25, sold under the trademark Monocryl) or a
composite of PGA, PCL, PLA, PDS that would be impermeable until
ruptured. The body 9261 of staple cartridge 9260 is sized to be
removably supported within the carrier 9240 as shown such that each
staple therein is aligned with corresponding staple forming pockets
in the anvil assembly 9220.
[0442] The anvil assembly 9220 has a pair of trunnions 9221 formed
thereon that are adapted to be pivotally received within trunnion
slots 9242 in a proximal end 9241 of the carrier 9240 such that the
anvil assembly 9220 may move or pivot between an open position and
a closed position relative to the carrier 9240 about an anvil pivot
axis ANV-ANV. The anvil pivot axis ANV-ANV is transverse to a
longitudinally extending tool axis LA-LA defined by the elongated
shaft assembly 9116. When the anvil assembly 9220 is pivoted from
an open position to a closed position, the anvil assembly 9220 is
moving in a closing direction "CD" about anvil pivot axis ANV-ANV.
Conversely, when the anvil assembly 9220 is moving from a closed
position to an open position, the anvil assembly 9220 is moving in
an opening direction "OD" about anvil pivot axis ANV-ANV.
[0443] The loading unit 9020 employs a unique and novel
articulation joint 9270 that facilitates articulation of the
carrier 9240 and anvil assembly 9220 to pivot about an articulation
axis "AA-AA" that is transverse to a longitudinal tool axis
"LA-LA". For example, the loading unit 9020 may include an end
effector housing 9400 that is configured to be received within an
outer casing 9450. The distal end 9402 of the end effector housing
9400 may have a clevis 9404 formed thereon by two distally
protruding tabs 9406. Each tab 9406 has a pivot hole 9408 formed
therein that is adapted to receive therein a corresponding pivot
pin 9274 formed on an articulation ball assembly 9272. See FIG.
100. The articulation ball assembly 9272 may be rigidly affixed to
the proximal end 9241 of the carrier 9240 by, for example, welding
or other suitable fastening arrangement. As will be discussed in
further detail below, when assembled together, the carrier 9240 and
anvil assembly 9220 can selectively articulate as a unit about the
articulation axis AA-AA in a first direction "FD" which is the same
direction as the anvil closing direction "CD" and in a second
direction "SD" which is the same as the anvil opening direction
"OD". See FIG. 105.
[0444] Still referring to FIG. 100, the end effector housing 9400
may be provided with a channel 9410 for slidably receiving an
articulation link 9420 therein. The articulation link 9420 includes
a proximal end portion 9422 and a distal end 9424. Fixedly attached
to the distal end portion 9424 is an articulation tube 9426. The
articulation tube 9426 may comprise a hollow tube and be attached
to the distal end 9424 by, for example, welding or other suitable
means. As can be seen in FIG. 102, the articulation tube 9426 may
have a series of articulation teeth 9428 formed therein that are
configured to meshingly engage sets of distal articulation teeth
9276 formed on the articulation ball 9272. Thus, movement of the
articulation link 9420 in the distal direction "DD" will cause the
carrier 9240 and anvil assembly 9220 to pivot in the first
direction "FD" about the articulation axis AA-AA. Conversely,
movement of the articulation link 9420 in the proximal direction
"PD" will cause the carrier 9240 and anvil assembly 9220 to pivot
as a unit in the second direction "SD" about the articulation axis
AA-AA. The articulation link 9420 and the articulation tube 9426
may be collectively referred to herein as the articulation link
assembly 9425. See FIG. 100.
[0445] The loading unit 9020 may also be equipped with a drive
assembly 9460 that is configured to axially move through the end
effector housing 9400. In at least one implementation, the drive
assembly 9460 includes a drive beam assembly 9461 that includes an
upper drive beam 9462 and a lower drive beam 9464 that are attached
to a cutting head 9470. The cutting head 9470 may include a body
portion 9471 that has a tissue cutting edge 9472 formed thereon. An
upper portion 9473 of the body portion 9471 has an upper tab 9474
formed thereon. A bottom foot or tab 9476 is formed on a lower
portion 9475 of the body portion 9471. The vertically oriented body
portion 9471 extends through a longitudinally extending slot 9245
in the carrier 9240 and a longitudinally extending slot 9222 in the
anvil assembly 9220. When assembled, the bottom foot 9476 is
configured to slide along the bottom of the carrier 9240. The,
upper tab portion 9474 is arranged to be slidably received within
an elongated channel 9223 formed in the anvil assembly 9220.
[0446] As can be seen in FIG. 100, the upper firing bar 9462 is
attached to the upper end portion 9473 and the lower firing bar
9464 is spaced from the upper firing bar 9462 and is attached to
the lower end portion 9475 of the vertically-extending portion 9471
of the cutting head 9470. Such arrangement serves to transmit the
firing motions to the upper and lower portions of the cutting head
9470 in an equivalent manner to facilitate aligned movement of the
cutting head 9470 through the anvil assembly 9220, the surgical
staple cartridge 9260 and the carrier 9240. In various
arrangements, for example, the upper firing bar 9462 may be
attached to the upper end portion 9473 directly behind the upper
tabs(s) 9474 such that the upper firing bar 9462 is essentially
axially aligned with point(s) from which the upper tab(s) 9474
protrude laterally from the upper end portion 9473. Similarly, the
lower firing bar 9464 may be attached to the bottom end portion
9475 directly behind the bottom foot 9476 or the point(s) from
which the laterally protruding bottom tabs 9476 protrude laterally
from the bottom end portion 9475 such that the lower firing bar
9464 is axially aligned therewith. The upper and lower firing bars
9462, 9464 may be welded to the vertical extending portion 9471 in
those locations. For example, the welds may be applied to the
firing bars from one side or from both lateral sides of the firing
bars. As the cutting head 9470 is driven distally in the distal
direction "DD", the anvil assembly 9220 is pivoted closed between
the upper tabs(s) 9474 and the lower tab(s) or foot 9476. Further
advancement of the cutting head assembly 9470 causes the surgical
staple cartridge 9260 to be crushed between the anvil assembly 9220
and the carrier 9240 thereby causing the surgical staples supported
therein to be formed on both sides of the tissue cut line as they
are brought into contact with the staple forming underside of the
anvil assembly 9220. After the cutting head assembly 9470 has been
advanced to the distal end of the carrier 9240, the user retracts
the cutting head assembly 9470 to the starting position whereupon
the anvil assembly 9220 may be opened to release the staple
cartridge 9260 and stapled tissue. In one implementation, for
example, the upper tab(s) 9474 are configured to interact with the
upper surface of the anvil assembly 9220 to cam or pivot the anvil
assembly 9220 back to the open position. In alternative
arrangements, a spring or other biasing member (not shown) may be
employed to bias the anvil assembly 9220 to the open position when
the cutting head assembly 9470 is in a starting position.
[0447] The drive beam assembly 9460 may further include a proximal
engagement member 9467 that includes a pair of engagement fingers
9468 that are configured to operably engage a distal end 9522 of a
firing rod 9104 as will be discussed in further detail herein. As
can be seen in FIG. 100, for example, the proximal engagement
member 9467 is pivotally coupled to the upper and lower firing bars
9462, 9464 to facilitate articulation and flexing thereof during
articulation of the carrier 9240 about the articulation axis AA-AA
without binding the drive beam assembly 9461. In at least one
implementation, for example, the proximal engagement member 9467 is
pivotally coupled to the upper and lower firing bars 9462, 9464 by
a pair of pivot links 9466. Such links 9466 enable the upper firing
bar 9462 to pivot relative to the proximal engagement member 9467
independent form the lower firing bar 9464 and visa versa.
[0448] As can be seen in FIG. 97, the surgical instrument 9010 may
include a motor 9100 that is configured to generate rotary
actuation motions that may be employed, for example, to apply
firing motions to the loading unit 9020 as will be discussed in
further detail below. In at least one form, for example, the motor
9100 is configured to apply rotary actuation motions to a firing
member assembly, generally designated as 9082. In one arrangement,
for example, the firing member assembly 9082 includes a drive tube
9102 that is rotatably supported within the housing 9012 and has an
internal thread (not shown) formed therein. A proximal threaded
portion of a firing member or firing rod 9104 is supported in
threaded engagement with the drive tube 9102 such that rotation of
the drive tube 9102 results in the axial movement of the firing rod
9104. The firing rod 9104 may interface with the interior of the
drive assembly 9460 in the loading unit 9020. As discussed in
further detail in the aforementioned incorporated Zemlok '763 and
Zemlok '344, rotation of drive tube 9102 in a first direction
(e.g., counter-clockwise) causes the firing rod 9104 to advance the
drive assembly 9460 in the distal direction.
[0449] As can be further seen in FIG. 97, the surgical instrument
9010 may include an articulation system generally designated as
9109. However, surgical instrument 9010 may include various other
articulation system arrangements disclosed in detail herein. In at
least one form, the articulation system 9109 may include an
articulation mechanism 9110 that includes an articulation motor
9112 and a manual articulation knob 9114. The articulation motor
9112 may be actuated by a powered articulation switch 9116 or by
pivoting the manual articulation knob 9114. Actuation of the
articulation motor 9112 serves to rotate an articulation gear 9118
of the articulation mechanism 9110. Actuation of articulation
mechanism 9110 may cause the end effector (e.g., the
cartridge/anvil portion of the loading unit 9020) to move from its
first position, wherein its axis is substantially aligned with
longitudinal tool axis "LA-LA" of the elongated shaft assembly 9116
to a position in which the axis of the end effector is disposed at
an angle relative to the longitudinal tool axis "LA-LA" of the
elongated shaft assembly about, for example, articulation axis
"AA-AA". Further discussion regarding various aspects of the
articulation mechanism 9110 may be found in Zemlok '763 which was
previously incorporated by reference herein in its entirety. In
addition, U.S. Pat. No. 7,431,188, entitled SURGICAL STAPLING
APPARATUS WITH POWERED ARTICULATION, and filed Mar. 15, 2007, the
entire disclosure of which is hereby incorporated by reference
herein, discloses motor-powered articulatable end effectors which
may be employed in connection with surgical instrument 9010. Those
of ordinary skill in the art will understand, however, that the
unique and novel coupling and end effector arrangements disclosed
herein may also be effectively employed with manually-operated
(i.e., non-powered) articulation systems that are known in the
art.
[0450] In various embodiments, the surgical instrument can include
at least one motor, which can apply firing motions to the loading
unit 9020 and/or articulation motions to the articulation system
9109, as described elsewhere in greater detail. The motor 9100 may,
for example, be powered by a power source 9200 of the type
described in further detail in Zemlok '763. For example, the power
source 9200 may comprise a rechargeable battery (e.g., lead-based,
nickel-based, lithium-ion based, etc.). It is also envisioned that
the power source 9200 may include at least one disposable battery.
The disposable battery may, for example, be between about 9 volts
and about 30 volts. However, other power sources may be employed.
FIG. 97 illustrates one example wherein the power source 9200
includes a plurality of battery cells 9202. The number of battery
cells 9202 employed may depend upon the current load requirements
of the instrument 9010.
[0451] Referring to FIG. 97, a power source such as, for example,
the power source 9200 can supply power for operation of the
surgical instrument 9010. For example, the power source 9200 can
supply power for a motor such as, for example, motor 9100 to cause
rotation of the drive tube 9102 in a first direction and ultimately
the axial advancement of the firing rod 9104 which drives the drive
assembly 9460 distally through the loading unit 9020.
Alternatively, the power source 9200 can supply power for the motor
9100 to cause rotation of the drive tube 9102 in a second direction
opposite the first direction and ultimately the axial retraction of
the firing rod 104 which can move the drive beam 9060 proximally to
its starting and/or default position.
[0452] Surgical end effectors, such as a disposable loading unit
9020, for example, can be operably coupled to the elongated shaft
assembly 9116 of the powered surgical instrument 10010 (FIG. 1). In
various embodiments, the surgical instrument 9010 can include an
elongated shaft assembly 9116, which can engage the loading unit
9020, for example. In various embodiments, a coupling assembly 9115
that includes a rotatable coupling collar 9500, for example, can
releasably lock the loading unit 9020 relative to the elongated
shaft assembly 9116. Furthermore, in various embodiments, rotation
of the coupling collar 9500 can facilitate attachment and/or
alignment of a firing assembly and/or an articulation assembly, as
described herein. In various embodiments, the loading unit 9020 can
include a distal attachment portion 9480 and the elongated shaft
assembly 9116 can include an outer tube 9030 and a distal
attachment portion 9032. The distal attachment portion 9480 of the
loading unit 9020 can receive the distal attachment portion 9032 of
the shaft assembly 9116 when the loading unit 9020 is secured to
the elongated shaft assembly 9116 (FIG. 107). Furthermore, the
rotatable coupling collar 9500 can be positioned around the distal
attachment portion 9032 of the shaft assembly 9116, such that the
distal attachment portion 9480 of the loading unit 9020 can also be
positioned within the rotatable coupling collar 9500. The rotatable
coupling collar 9500 can be secured to the elongated shaft assembly
9116 and/or the proximal attachment portion 9480, and, in certain
embodiments, can be rotatably fixed to the distal attachment
portion 9032 of the shaft assembly 9116, for example. In certain
embodiments, a proximal attachment portion of the shaft assembly
9116 can receive a distal attachment portion 9480 of the loading
unit 9020 when the loading unit 9020 is secured to the shaft
assembly 9116. Furthermore, in certain embodiments, a coupling
collar 9500 can be rotatably fixed to the loading unit 9020.
[0453] Referring to FIGS. 106 and 107, as the loading unit 9020
moves between a non-attached position and an attached position
relative to the elongated shaft assembly 9116 of the surgical
instrument 9010, the loading unit 9020 can translate along a
longitudinal tool axis LA-LA as defined by the elongated shaft
assembly 9116. The distal attachment portion 9480 of the loading
unit 9020 can be inserted into the distal attachment portion 9032
of the elongated shaft assembly 9116 as the loading unit 9020 moves
from the non-attached position to the attached position. For
example, the loading unit 9020 can translate in proximal direction
"PD" (FIG. 107) when the loading unit 9020 is moved between the
non-attached position and the attached position. In certain
embodiments, a groove-and-slot engagement between the distal
attachment portion 9480 and the distal attachment portion 9032 can
guide the loading unit 10020 along the longitudinal tool axis LA-LA
defined by the elongated shaft assembly 9116. Referring primarily
to FIG. 110, the distal attachment portion 9480 can include a guide
rail 9482. Furthermore, referring primarily to FIG. 112, the distal
attachment portion 9032 can include a guide slot 9034. The guide
slot 9034 can be dimensioned and structured to receive and guide
the guide rail 9482 as the proximal attachment portion 9480 of the
loading unit 9020 is inserted into the distal attachment portion
9032 of the elongated shaft assembly 9116. For example, the guide
slot 9034 can comprise a longitudinal slot, and the guide rail 9482
can comprise a longitudinal ridge, for example. In certain
embodiments, the guide slot 9034 and guide rail 9482 can prevent
twisting and/or rotating of the loading unit 9020 relative to the
longitudinal tool axis LA-LA.
[0454] Referring primarily to FIG. 106, the distal attachment
portion 9480 can include a first alignment indicia 9484, such as a
first arrow, for example, and the elongated shaft assembly 9116
and/or the coupling collar 9500 can include a second alignment
indicia 9502, such as a second arrow, for example. Alignment of the
first and second alignment indicia 9484, 9502 can align the guide
rail 9482 and the guide slot 9034, which can facilitate attachment
of the distal attachment portion 9480 to the distal attachment
portion 9032. As described herein, translation of the loading unit
9020 along a longitudinal path toward the elongated shaft assembly
9116 can releasably lock the loading unit 9020 relative to the
elongated shaft assembly 9116. In such embodiments, rotation of the
loading unit 9020 relative to the elongated shaft assembly 9116 may
not be required to attach the loading unit 9020 relative to the
elongated shaft assembly 9116. In fact, rotation of the loading
unit 9020 relative to the elongated shaft assembly 9116 can be
restrained and/or prevented by a groove-and-slot engagement between
the distal attachment portion 9032 and the distal attachment
portion 9480, as described herein. In various embodiments, the
coupling collar 9500 can rotate relative to the loading unit 9020
and/or the elongated shaft assembly 9116 to releasably lock the
loading unit 9020 to the elongated shaft assembly 9116. For
example, as described herein, the coupling collar 9500 can rotate
from an initial orientation (FIG. 120) toward a secondary
orientation (FIG. 121) and then return toward the initial
orientation (FIG. 124) to lock the loading unit 9020 to the
elongated shaft assembly 9116.
[0455] Referring primarily to FIGS. 110 and 111, the proximal
portion 9480 of the loading unit 9020 can include a rotation key or
rib 9486. As the loading unit 9020 is moved in the proximal
direction "PD" (FIG. 106) between a non-attached position (FIG.
106) and an attached position (FIG. 107), the rotation key 9486 can
affect rotation of the coupling collar 9500. For example, the
rotation key 9486 can rotate and/or bias the coupling collar 9500
in direction B (FIG. 107) from the initial orientation to the
secondary orientation. The distal attachment portion 9480 can be
inserted into the distal attachment portion 9032 when the coupling
collar 9500 is biased into the secondary orientation. Furthermore,
when the distal attachment portion 9480 is fully inserted into the
distal attachment portion 9032, the rotation key 9486 can permit
the coupling collar 9500 to rotate in direction C (FIG. 107) from
the secondary orientation toward the initial orientation. As used
herein the term "fully inserted" as used with respect to the
coupling of the loading unit 9020 to the elongated shaft assembly
9116 means that the distal attachment portion 9480 of the loading
unit 9020 has been fully inserted in mating or operational
engagement with the distal attachment portion 9032 of the elongated
shaft assembly 9116. Direction C can be opposite to direction B,
for example. As described herein, when the coupling collar 9500
returns to the initial orientation, the coupling collar 9500 can
lock the distal attachment portion 9480 relative to the distal
attachment portion 9032. Referring to FIGS. 110 and 111, the
rotation key 9486 can include a rotation ramp 9488 at the proximal
end thereof. The rotation ramp 9488 can engage an element of the
shaft assembly 9116 to effect rotation of the rotation coupling
collar 9500, for example.
[0456] In various embodiments, the rotation ramp 9488 can affect
rotation of a firing shaft 9104 positioned within the elongated
shaft assembly 9116. For example, referring primarily to FIGS.
115-118, the firing shaft 9104 can include a firing shaft rotator
9600 which can extend radially outward from the firing shaft 9104.
The rotation ramp 9488 of the rotation key 10486 can engage the
firing shaft rotator 9600 when the loading unit 9020 is inserted
into the elongated shaft assembly 9116. In various embodiments, the
rotation ramp 9448 can rotate the firing shaft rotator 9600, which
can rotate the firing shaft 9104. For example, the firing shaft 104
and the firing shaft rotator 9600 can rotate in direction B between
a first orientation (FIG. 121) and a second orientation (FIG. 122).
Referring still to FIGS. 115-118, the firing shaft 9104 can be
engaged with the rotatable coupling collar 9500. For example, the
rotatable coupling collar 9500 can include a rotator groove 9502,
which can be structured and dimensioned to receive and/or hold the
firing shaft rotator 9600. The firing shaft rotator 9600 can be
held by the rotator groove 9600, such that the rotation of the
firing shaft rotator 9600 rotates the rotatable coupling collar
9500. In such embodiments, insertion of the loading unit 9020 into
the elongated shaft assembly 9116, can affect rotation of the
rotatable coupling collar 9500 in direction B (FIG. 122) via
rotation of the firing shaft rotator 9600 in direction B, for
example.
[0457] Referring primarily to FIGS. 112 and 113, the distal
attachment portion 9032 can include a rotation key slot 9510, which
can receive the rotation key 9486 when the distal attachment
portion 9480 is inserted into the distal attachment portion 9032.
In various embodiments, the rotation key slot 9510 can include a
clearance notch 9512 for receiving the firing shaft rotator 9600.
For example, the rotation ramp 9488 at the proximal end of the
rotation key 9486 can rotate the firing shaft rotator 9600 to the
second orientation and into the clearance notch 9512 (FIG. 122).
The rotation key 9486 can continue to move along the rotation key
slot 9510 as the loading unit 9020 is inserted into the elongated
shaft assembly 9116. Furthermore, when the distal end 9490 of the
rotation key 9486 moves past the firing shaft rotator 9600, the
firing shaft rotator 9600 can rotate back toward the first
orientation (FIG. 126), which can corresponding rotate the
rotatable coupling collar 9500 back toward the initial orientation
thereof.
[0458] In various embodiments, the rotatable coupling collar 9500
can be biased into the initial orientation relative to the
elongated shaft assembly 9116 and/or the distal attachment portion
9032. For example, a spring 9514 can bias the coupling collar 9500
into the initial orientation. The spring 9514 can include a
proximal end 9516 that can be secured relative to the elongated
shaft assembly 9116, and a distal end 9550 that can be secured
relative to the coupling collar 9500. For example, the proximal end
9516 of the spring 9514 can be retained in a proximal spring slot
9556 (FIG. 119) of the shaft assembly 9116, and the distal end 9550
of the spring 9514 can be retained in a distal spring slot 9552
(FIG. 114) of the rotatable coupling collar 9500, for example. In
such embodiments, rotation of the coupling collar 9500 can displace
the distal end 9550 of the spring 9514 relative to the proximal end
9516 of the spring 9514, which can generate a torsional force.
Accordingly, the coupling collar 9500 can resist rotation from the
initial orientation to the secondary orientation, and, when the
coupling collar is rotated to the secondary orientation, the spring
9514 can bias the coupling collar 9500 back toward the initial
orientation. Because the firing shaft rotator 9600 is engaged with
the coupling collar 9500, the spring 9514 can also bias the firing
shaft 9104 toward the first orientation thereof.
[0459] In various embodiments, the rotatable coupling collar 9500
can include a locking detent 9518 that releasably locks the loading
unit 9020 to the elongated shaft assembly 9116. Referring primarily
to FIG. 114, the locking detent 9518 can extend radially inward
from the inner perimeter of the rotatable coupling collar 9500. In
various embodiments, the locking detent 9518 can extend into a
detent slot 9520 (FIG. 112) in the distal attachment portion 9032.
Referring primarily to FIG. 112, the detent slot 9520 can form a
notch in the guide slot 9034. In various embodiments, the detent
slot 9520 can extend from the guide slot 9034, and can be
perpendicular or substantially perpendicular to the guide slot
9034, for example. Further, the locking detent 9518 can move along
the detent slot 9520 when the rotatable coupling collar 9500
rotates between the initial orientation and the secondary
orientation relative to the elongated shaft assembly 9116.
[0460] In various embodiments, the locking detent 9518 can engage
the distal attachment portion 9480 of the loading unit 9020 to lock
the loading unit 9020 relative to the elongated shaft assembly
9116. For example, referring again to FIG. 110, the distal
attachment portion 9480 can include the guide rail 9482, which can
have a lock notch 9489 defined therein. The lock notch 9489 can be
structured and dimensioned to receive the locking detent 9518 of
the rotatable coupling collar 9500 when the loading unit 9020 is
fully inserted into the distal attachment portion 9032. For
example, when the distal attachment portion 9480 is fully inserted
into the distal attachment portion 9032, the lock notch 9489 of the
distal attachment portion 9480 can be aligned with the detent slot
9520 of the distal attachment portion 9032. Accordingly, the
locking detent 9518 can slide along the detent slot 9520 in the
distal attachment portion 9032 and into the lock notch 9489 in the
distal attachment portion. Furthermore, the locking detent 9518 can
be biased toward engagement with the lock notch 9489 by the torsion
spring 9514. For example, after the firing shaft rotator 9600
clears the distal end 9490 of the rotation key 9486, the firing
shaft 9104 can be biased back toward the first orientation and the
rotatable coupling collar 9500 can be biased back toward the
initial orientation by the torsion spring 9514. Furthermore, when
the coupling collar 9500 is rotated from the secondary orientation
back to the initial orientation, the locking detent 9518 thereof
can be aligned and engaged with the lock notch 9489 in the guide
rail 9482.
[0461] In various embodiments, rotation of the coupling collar 9500
can facilitate attachment and/or alignment of a firing assembly.
For example, the firing shaft 9104 can extend between a proximal
end 9524 and a distal end 9522. The proximal end 9524 can have a
rotation joint, which can permit rotation of the firing shaft 9104
between the first configuration and the second configuration.
Furthermore, the distal end 9522 can have a coupler for attaching
the proximal engagement member 9467 of the drive beam assembly 9461
to the firing shaft 104. Rotation of the firing shaft 9104 can
facilitate attachment of the proximal engagement member 9467. For
example, as the coupler at the distal end 9522 of the firing shaft
9104 rotates, the distal end 9522 is operably coupled to the
proximal engagement member 9467. In certain embodiments, the
coupler can include a bayonet mount, which can engage a
corresponding bayonet receiver of the cutting element in the
loading unit 9020. Referring primarily to FIGS. 108 and 109, the
firing assembly can further include a sleeve 9526 positioned around
the firing shaft 9104 between the proximal end 9524 and the distal
end 9522, for example.
[0462] In various embodiments, when the firing shaft 9104 rotates
within the elongated shaft assembly 9116, the firing shaft 9104 can
rotate into alignment with a firing shaft slot 528 in the loading
unit 9020. For example, the firing shaft rotator 9600 can be
aligned with the firing shaft slot 9528 when the loading unit 9020
is fully inserted and attached to the elongated shaft assembly
9116. However, in various embodiments, when the loading unit 9020
is only partially inserted into the elongated shaft assembly 9116,
the firing shaft rotator 9600 can be rotated, via the rotation key
9486, out of alignment with the firing shaft slot 9528. In other
words, the firing shaft rotator 9600 can be aligned with the firing
shaft slot 9482 when the firing shaft 9104 is in the first
orientation, and can be misaligned with the firing shaft slot 9482
when the firing shaft 9104 rotates toward the second orientation.
In such embodiments, when the loading unit is only partially
inserted into the elongated shaft assembly 9116 and/or before the
loading unit 9020 is releasably locked to the elongated shaft
assembly 9116 by the rotatable coupling collar 9500, the firing
path of the firing shaft rotator 9600 can be blocked by the distal
attachment portion 9480. Integration of the firing shaft 9104 and
the coupling collar 9500 can ensure the loading unit 9020 is
securely attached to the elongated shaft assembly 9116 before the
firing shaft 9104 can fire and/or advance. For example, the
surgical instrument may be unable to fire until the cutting element
in the loading unit 9020 is coupled to the firing shaft 9104,
and/or until the firing shaft 9104 is properly aligned within the
elongated shaft assembly 9116, for example.
[0463] In certain embodiments, rotation of the coupling collar 9500
can facilitate attachment and/or alignment of an articulation
assembly 9530. Referring primarily to FIGS. 108 and 109, the
articulation assembly 9530 can include a proximal articulation bar
9538, a distal articulation bar 9420, and an articulation connector
9532. Furthermore, the shaft assembly 9116 can include a proximal
articulation bar slot 9534, and the loading unit 9020 can include a
distal articulation bar slot 9410, for example. In certain
embodiments, the proximal articulation bar 9538 can be aligned with
the proximal articulation bar slot 9534, and the distal
articulation bar 9420 can be aligned with the distal articulation
bar slot 10410. Referring now to FIG. 114, the articulation
connector 9532 can be housed in the rotatable coupling collar 9500.
For example, the rotatable coupling collar 9500 can include an
articulation connector slot 9536, and the articulation connector
9532 can be moveably positioned therein.
[0464] In various embodiments, referring again to FIGS. 108 and
109, the proximal articulation bar 9538 can have a proximal notch
9540, and the distal articulation bar 9420 can have a distal notch
9423. Furthermore, the articulation connector 9532 can include a
proximal articulation lug 9533 and a distal articulation lug 9540.
The proximal articulation lug 9533 can be retained in the proximal
notch 9540 of the proximal articulation bar 9538. In certain
embodiments, the distal articulation lug 9535 can operably engage
the distal notch 9423 of the distal articulation bar 9420. As
described herein, the rotatable coupling collar 9500 can rotate
between the initial configuration and the secondary configuration.
As the coupling collar 9500 rotates, the articulation connector
9532 housed therein can also rotate relative to the longitudinal
axis defined by the shaft assembly 9116. In various embodiments,
the proximal articulation lug 9533 of the articulation connector
9532 can remain positioned in the proximal notch 9540 of the
proximal articulation bar 9538 as the articulation connector 9532
rotates. Furthermore, the distal articulation lug 9535 of the
articulation connector 9532 can move into engagement with the
distal notch 9423 of the distal articulation bar 9420 as the
articulation connector 9532 rotates with the coupling collar 9500
from the secondary orientation toward the initial orientation. For
example, when the loading unit 9020 is fully inserted into the
shaft 9488, the distal notch 9423 of the distal articulation bar
9420 can be aligned with the distal articulation lug 9533 of the
articulation connector 9532. In such embodiments, when the
rotatable collar 9500 rotates back to the initial configuration,
the distal articulation lug 9533 can slide into the distal notch
9423 of the distal articulation bar 9420. When the distal
articulation lug 9533 is positioned in the distal notch 9423, the
articulation assembly 9530 can be fully assembled.
[0465] Referring primarily to FIG. 113, in various embodiments, the
proximal articulation bar slot 9534 can include a first clearance
9542 and a second clearance 9544. The proximal and distal
articulation lugs 9533, 9535 of the articulation connector 9532 can
extend into the first and second clearances 942, 9544,
respectively. In certain embodiments, the first and second
clearances 9542, 9544 can provide a space for the proximal and
distal articulation lugs 9533, 9535 to move as the collar 9500
rotates and/or as the articulation assembly 9530 articulates, for
example.
[0466] Referring now to FIGS. 119-126, to connect the loading unit
to the elongated shaft assembly 9116 of the surgical instrument, a
user can align the alignment indicia 9484 of the loading unit 9020
with the alignment indicia 9502 of the elongated shaft assembly
9116 and/or the coupling collar 9500 (FIG. 119). While maintaining
alignment of the alignment indicia 9484, 9502, the user can move
the loading unit 9020 relative to the elongated shaft assembly 9116
along the longitudinal axis LA-LA. The user can move the loading
unit 9020 along a straight or substantially straight path, and, in
various embodiments, need not rotate the loading unit 9020 relative
to the elongated shaft assembly 9116, for example. Referring
primarily to FIG. 121, the loading unit 9020 can continue to
translate relative to the elongated shaft assembly 9116, and the
guide rail 9482 of the distal attachment portion 9480 can fit into
the guide slot 9034 (FIG. 112) in the distal attachment portion
9032 of the elongated shaft assembly 9116. As the distal attachment
portion 9480 moves into the distal attachment portion 9032, the
guide slot 9034 can guide the guide rail 9482, and can maintain
alignment of the alignment indicia 9484, 9502, for example. In
other words, the guide slot 9034 and the guide rail 9482 can
prevent rotation of the loading unit 9020 relative to the
longitudinal axis of the elongated shaft assembly 9116. Referring
primarily to FIG. 120, the proximal articulation lug 9533 of the
articulation connector 9032 can extend into the first clearance
9542 and can be positioned in the proximal notch 9540 of the
proximal articulation bar 9420, and the distal articulation lug
9535 of the articulation connector 9032 can extend through the
second clearance 9544, for example.
[0467] Referring primarily to FIG. 122, as the distal attachment
portion 9480 is inserted into the distal attachment portion 9032,
the rotation key ramp 9488 of the rotation key 9486 can abut the
firing shaft rotator 9600. The rotation key ramp 9488 can guide
and/or direct the firing shaft rotator 9600 into the clearance
notch 9512 extending from the rotation key slot 9510. Furthermore,
as the firing shaft rotator 9600 moves into the clearance notch
9512, the firing shaft 9104 can rotate in the direction B. The
firing shaft 9104 can rotate from the first orientation to the
second orientation. Such rotation of the firing shaft 9104 can
facilitate attachment of the distal end 9522 of the firing shaft
9104 with the proximal engagement member 9467 that is pivotally
coupled to the drive beam assembly 9461. Furthermore, rotation of
the firing shaft rotator 9600 can rotate the coupling collar 9500
in the direction B via the engagement between the firing shaft
rotator 9600 and the firing shaft rotator groove 9600 in the
coupling collar 9500. The coupling collar 9500 can rotate from the
initial orientation to the secondary orientation, for example.
Additionally, the locking detent 9518 can move along the detent
slot 9520 in the shaft assembly 9116 as the coupling collar 9500
rotates. Additionally, rotation of the coupling collar 9500 can
rotate the distal end 9550 of the spring 9514 because the distal
end 9550 of the spring 9514 can be retained in the distal spring
slot 9552 (FIG. 114) in the coupling collar 9500. Displacement of
the distal end 9550 relative to the proximal end 9516 can generate
a torsional springback force, which can bias the coupling collar
9500 from the secondary orientation toward the initial orientation,
for example, and can bias the firing shaft 9104 from the second
orientation toward the first orientation, for example.
[0468] Referring primarily to FIG. 123, as the coupling collar 9500
rotates toward the secondary orientation, the proximal articulation
lug 9533 can remain engaged with the proximal notch 9540 in the
proximal articulation bar 9538. Furthermore, the distal
articulation lug 9535 can rotate such that the distal articulation
lug 9535 provides a clearance for the distal articulation bar 9420
of the loading unit 9020. Referring to FIG. 124, the loading unit
9020 can be fully inserted into the elongated shaft assembly 9116
when the coupling collar 9500 and the articulation connector 9532
positioned therein are rotated to the secondary orientation. In
various embodiments, the distal articulation bar 9420 can clear the
distal articulation lug 9535 of the articulation connector 9532
when the articulation connector 9532 is rotated to the secondary
orientation. Furthermore, the distal articulation lug 9535 can be
rotatably aligned with the distal notch 9423 in the articulation
connector 9532. Referring still to FIG. 124, when the loading unit
9020 is fully inserted into the elongated shaft assembly 9116, the
firing rod rotator 9600 can clear the distal end 9490 of the
rotation key 9486.
[0469] Referring now to the FIG. 125, the firing shaft rotator 9600
can rotate in the direction C when the distal end 9490 of the
rotation key 9486 passes the firing shaft rotator 9600. For
example, the firing shaft rotator 9600 can rotate in direction C
from the second orientation toward the first orientation.
Furthermore, rotation of the firing shaft rotator 9600 can affect
rotation of the coupling collar 9500 in the direction C from the
secondary orientation toward the initial orientation. In various
embodiments, the spring 9514 can bias the firing rod 9104 toward
the first orientation thereof and the collar 9500 toward the
initial orientation thereof. For example, the firing shaft rotator
9600 can be positioned in the firing shaft rotator groove 9602
(FIG. 114) in the coupling collar 9500 such that rotation of the
firing shaft rotator 9600 rotates the coupling collar 9500. Due to
the alignment of the distal articulation lug 9535 of the
articulation connector 9532 and the distal notch 9423 of the distal
articulation bar 9420, the articulation connector 9532 can rotate
as the coupling collar 9500 rotates, and the distal articulation
lug 9535 can rotate into engagement with the distal notch 9423. The
articulation assembly 9530 can be assembled when the distal
articulation lug 9535 engages the distal notch 9423. Furthermore,
as the firing shaft rotator 9600 rotates in direction C, the distal
end 9522 of the firing shaft 9104 can rotate in direction C, which
can facilitate attachment of a the proximal engagement member 9467
of the drive beam assembly 9461 to the distal end 9522 of the
firing shaft 9104.
[0470] Referring now to FIG. 126, rotation of the coupling collar
9500 can also rotate the locking detent 9518 of the collar 9500
into the lock notch 9489 in the guide rail 9482 of the distal
attachment portion 9480. For example, when the loading unit 9020 is
fully inserted into the elongated shaft assembly 9116, the lock
notch 9489 can be aligned with the detent slot 9520 such that the
locking detent 9518 can rotate through the detent slot 9520 and
into the lock notch 9489. As described herein, the spring 9514 can
bias the coupling collar 9500 to rotate in the direction C (FIG.
125) after the firing shaft rotator 9600 clears the distal end 9490
of the rotation key 9486. Referring still to FIG. 126, when the
firing shaft rotator 9600 rotates in direction C, the firing shaft
rotator 9600 can move into alignment with the firing shaft slot
9528 in the loading unit 9020. Alignment of the firing shaft
rotator 9600 with the firing shaft slot 9528 can permit the firing
shaft 9104 to be advanced distally to fire the loading unit 9020,
for example.
[0471] As described herein, the rotatable coupling collar 9500 can
releasably lock the loading unit 9020 relative to the elongated
shaft assembly 9116. Furthermore, rotation of the coupling collar
9500 can facilitate simultaneous attachment and/or alignment of the
articulation assembly 9530, as well as attachment and/or alignment
of the firing shaft 9104 with a cutting head assembly in the
loading unit 9020, for example. Furthermore, rotation of the
coupling collar 9500 can also simultaneously unlock the loading
unit 9020 from the elongated shaft assembly 9116, disconnect the
articulation assembly 9530, and/or disconnect the firing shaft 104
from the cutting element in the loading unit 9020. For example,
when the coupling collar 9500 is again rotated from the initial
orientation toward the secondary orientation, the locking detent
9518 can disengage the lock notch 9489 in the distal attachment
portion 9480. Accordingly, the distal attachment portion 9480 can
be withdrawn from the distal attachment portion 9032 along the
longitudinal axis defined by the elongated shaft assembly 9116, for
example. In various embodiments, the loading unit 9020 can be
unattached from the elongated shaft assembly 9116 without rotating
the loading unit 9020 relative to the elongated shaft assembly
9116. However, the coupling collar 9500 can rotate relative to the
elongated shaft assembly 9116, which can disconnect the distal
articulation bar 9420 from the articulation connector 9532 in the
coupling collar 9500, and can disconnect the firing shaft 9104 from
the cutting element or drive beam assembly in the loading unit
9020, for example.
[0472] Thus, as can be appreciated from the foregoing, at least one
surgical instrument embodiment of the present invention includes a
surgical end effector that comprises a lower jaw and an upper jaw.
In one implementation, the upper jaw comprises a proximal upper jaw
portion that is pivotally coupled to the lower jaw for selective
pivotal travel relative thereto about a pivot axis between open and
closed positions upon application of closing and opening motions to
the proximal upper jaw portion. A distal upper jaw portion may be
movably coupled to the proximal upper jaw portion and is supported
for parallel movement toward and away from the lower jaw when the
proximal upper jaw portion is in the closed position. A firing
member may be operably supported for operable travel within the
surgical end effector relative to the upper and lower jaws when the
proximal upper jaw portion is in the closed position and firing
motions are applied to the firing member.
[0473] In at least one implementation, the surgical instrument may
employ a lockout system that is configured to not only prevent
actuation of the firing system or stated another way, advancement
of the cutting head through the elongated channel when a cartridge
is not present, but also to prevent such firing system actuation
unless a new cartridge has been properly supported within the
elongated channel. In such implementations, each new cartridge has
a sled assembly supported in a starting position. When a cartridge
has been properly installed within the elongated channel, the sled
assembly interfaces with the lockout system to thereby enable the
cutting head to be advanced distally through the cartridge. If,
however, a spent cartridge has been inadvertently installed in the
elongated channel, the lockout system will prevent actuation of the
cutting head, because the sled assembly will be located in the
distal end of the cartridge and thereby unable to interface with
the lockout system. Such system will prevent re-actuation of the
firing system, should the clinician fail to replace a spent
cartridge and attempt to actuate the firing system.
[0474] In at least one other implementation, there is provided a
surgical instrument that comprises an elongated shaft assembly and
a surgical end effector that includes an elongated channel that is
coupled to the elongated shaft assembly. A surgical staple
cartridge may be operably supported in the elongated channel. The
end effector may further comprise an anvil assembly that includes a
proximal anvil portion that is pivotally coupled to the elongated
channel about a pivot axis. The proximal anvil portion is
selectively movable between open and closed positions upon
application of closing and opening motions thereto. The anvil
assembly may further comprise a distal anvil portion that is
slidably coupled to the proximal anvil portion such that when the
proximal anvil portion is in the closed position, the distal anvil
portion is movable relative thereto while remaining parallel to the
elongated channel. A firing member may be operably supported for
operable movement within the surgical end effector upon application
of firing and retraction motions thereto. A firing system may be
configured to selectively apply the firing and retraction motions
to the firing member. The instrument may further include a closure
system for applying the opening and closing motions to the proximal
anvil portion.
[0475] In accordance with at least one other general form, there is
provided a surgical method for treating target tissue within a
patient. In various implementations, the method may comprise
installing a hollow trocar port into a patient and providing a
surgical end effector. The surgical end effector may comprise an
elongated shaft assembly that defines a longitudinal tool axis and
includes a lower jaw that is operably coupled to the elongated
shaft assembly. The lower jaw may include elastic biasing means. An
upper jaw may be supported for movement relative to the lower jaw
upon application of actuation motions thereto. The upper jaw may be
movable between a first insertion position wherein the upper jaw is
compressible against the biasing means on the lower jaw to provide
the surgical end effector with a smallest cross-sectional shape to
facilitate passage of the surgical end effector through the hollow
trocar port into the patient and a primary opened position. When in
the primary open position the upper jaw may be movable into a fully
open position for admitting target tissue between the upper and
lower jaws. Upon application of another actuation motion to the
upper jaw, the upper jaw may be moved to a fully clamped position
wherein a target tissue may be clamped between the upper and lower
jaws. A firing member may be operably supported for selective
operable travel within the surgical end effector upon application
of a firing motion thereto. The surgical method may further
comprise inserting the surgical end effector into the hollow trocar
port such that an inner surface of the hollow trocar port
compresses the upper jaw into the insertion position until the
surgical end effector has exited the distal end of the trocar port
whereupon the biasing means moves the upper jaw into the primary
opened position. The method may also comprise applying the
actuation motion to the upper jaw to move the upper jaw to the
fully opened position and manipulating the end effector such that
the target tissue is positioned between the upper and lower jaws.
The method may further include applying the another actuation
motion to the upper jaw to move the upper jaw into the fully
clamped position and applying the firing motion to the firing
member to cause the firing member to travel from a starting
position to an ending position within the end effector.
[0476] In accordance with another general form, there may be
provided a surgical method for treating target tissue within a
patient. In various implementations, the method may comprise
installing a hollow trocar port into a patient and providing a
surgical end effector. The surgical end effector may comprise an
elongated shaft assembly that has a lower jaw operably coupled
thereto. The lower jaw may include elastic biasing means. An upper
jaw may be supported for movement relative to the lower jaw upon
application of actuation motions thereto. The upper jaw may be
movable between a first insertion position wherein the upper jaw is
compressible against the elastic biasing means to provide the
surgical end effector with a smallest cross-sectional shape to
facilitate passage of the surgical end effector through the trocar
port into the patient and a primary opened position. When in the
primary opened position, an application of an actuation motion to
the upper jaw may move the upper jaw into a fully open position for
admitting target tissue between the upper and lower jaws. Upon
application of another actuation motion to the upper jaw may move
the upper jaw to a fully clamped position wherein the target tissue
is clamped between the upper and lower jaws. A control insert may
operably support a portion of the upper jaw therein and be
selectively movably supported in the lower jaw for travel between a
first position corresponding to the insertion position and a second
position corresponding to the primary opened position. The surgical
end effector may further comprise means for moving the control
insert between the first and second positions and a firing member
that is operably supported for selective operable travel within the
surgical end effector upon application of a firing motion thereto.
The surgical method may further comprise moving the control insert
into the first position and inserting the surgical end effector
through the hollow trocar port into the patient. The method may
also comprise moving the control insert to the second position to
enable the biasing means to move the upper jaw into the primary
opened position and applying the actuation motion to the upper jaw
to move the upper jaw to the fully opened position. The surgical
method may also include manipulating the end effector such that the
target tissue is positioned between the upper and lower jaws and
applying another actuation motion to the upper jaw to move the
upper jaw into the fully clamped position. The surgical method may
include applying the firing motion to the firing member to cause
the firing member to travel from a starting position to an ending
position within the end effector.
[0477] In accordance with another general form, there is provided a
surgical method for treating target tissue within a patient. In
various implementations, the method comprises installing a hollow
trocar port into a patient and providing a surgical end effector.
The surgical end effector may comprise a lower jaw and an upper jaw
that is supported for movement relative to the lower jaw between a
first insertion position wherein the upper jaw is compressible
against the lower jaw to provide the surgical end effector with a
smallest cross-sectional shape to facilitate passage of the
surgical end effector through the hollow trocar port into the
patient and a primary opened position. When in the primary opened
position, upon application of an actuation motion to the upper jaw,
the upper jaw may be movable into a fully open position for
admitting target tissue between the upper and lower jaws. Upon
application of another actuation motion to the upper jaw, the upper
jaw may be moved to a fully clamped position wherein the target
tissue is clamped between the upper and lower jaws. A firing member
may be operably supported for selective operable travel within the
surgical end effector upon application of a firing motion thereto.
The surgical method may further comprise operably coupling an
elongated shaft assembly to the surgical end effector wherein the
elongated shaft assembly defines a longitudinal tool axis and
includes a distal closure tube portion that is supported for axial
travel relative to the upper jaw to apply the actuation motions
thereto. The distal closure tube portion may include biasing means
to automatically bias the upper jaw to the primary opened position
upon exiting of the upper jaw from the trocar port. The surgical
method may also include inserting the surgical end effector into
the hollow trocar port such that an inner surface of the hollow
trocar port compresses the upper jaw into the insertion position
until the surgical end effector has exited the distal end of the
trocar port whereupon the biasing means moves the upper jaw into
the primary opened position. The surgical method may also comprise
applying the actuation motion to the upper jaw to move the upper
jaw to the fully opened position and manipulating the end effector
such that the target tissue is positioned between the upper and
lower jaws. The surgical method may also include applying the
another actuation motion to the upper jaw to move the upper jaw
into the fully clamped position and applying the firing motion to
the firing member to cause the firing member to travel from a
starting position to an ending position within the end
effector.
[0478] Referring to an exemplary embodiment depicted in FIGS.
127-129, 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. 129, 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. 128, 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.
[0479] Referring primarily to FIG. 129, 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. 129,
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. 130 and 131, 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.
[0480] Referring now to FIGS. 132-139, 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. 132-139, 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.
[0481] Referring still to FIGS. 132-139, 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.
[0482] 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. 136, 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. 136).
[0483] Referring still to FIG. 136, 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.
[0484] 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. 130 and 131) as the staple 160 is
fired and/or ejected from the cartridge body 142 (FIGS. 130 and
131), 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. 135),
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.
[0485] 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. 132-139, 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. 133 and 134).
[0486] Referring primarily to FIGS. 133 and 134, 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. 133, 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.
[0487] 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. 136), for example, and the secondary drive surface 182 can
overlap a second plane (see axis B in FIG. 136), 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. 136), and the secondary drive surface 180 can
extend along the second axis B (FIG. 136). In various embodiments,
a lateral gap having a width x (FIGS. 136 and 137) 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. 136) 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.
[0488] Referring still to FIGS. 132-139, 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.
[0489] Referring now to FIGS. 140-143, the sled 190 can drive the
staples 160 from the cavities 144 in the cartridge body 142 (FIG.
129). 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.
[0490] Referring still to FIGS. 140-143, 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. 140-143, 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. 140 and 142).
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.
[0491] Referring primarily to FIGS. 140-143, 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.
[0492] Referring still to FIGS. 140-143, 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. 140 and 141, 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. 142 and 143, 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.
[0493] 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. 130 and 131) and/or can eject the
staple 160 from the cartridge 140 (FIGS. 130 and 131). 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. 133), out of the staple cavity
144.
[0494] Deployment of multiple staples 160 according to an exemplary
application of the present disclosure is depicted in FIGS. 144-147.
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. 129), and multiple rows of staple cavities 144 can
be defined on a second side of the cartridge slot 143. FIGS.
144-147 depict two rows of staples 160 positioned in two rows of
staples cavities 144 in the cartridge body 142. Referring still to
FIGS. 144-147, 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.
[0495] Referring primarily to FIG. 144, as the sled 190 moves
distally, the second lateral portion 191b can contact the first
inner staple 160a. The leading surface 194 (FIGS. 140-143) of the
second lateral portion 191b can begin to lift the first inner
staple 160a, for example. Referring now to FIG. 145, as the sled
190 continues to move distally, the trailing surface 196 (FIGS.
140-143) 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. 140 and 142), 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.
[0496] Referring now to FIG. 146, 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. 147, 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. 140-143), 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. 140 and 142).
[0497] 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. 129), 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.
[0498] An exemplary embodiment of staple deployment is further
illustrated in FIGS. 148-157. 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. 148
and 149, 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.
[0499] Referring primarily to FIGS. 150 and 151, 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.
[0500] Referring now to FIGS. 152 and 153, 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. 153, 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.
144-147) can begin to deform the first inner staples 160a. For
example, staple forming pockets 154 (FIGS. 144-147) 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.
[0501] Referring now to FIGS. 154 and 155, 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.
144-147) 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.
[0502] Referring now to FIGS. 156 and 157, 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. 142 and 143), 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. 144-147)
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. 144-147) can begin to deform the first outer staples 160b
and the second inner staples 160c. For example, staple forming
pockets 154 (FIGS. 144-147) 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.
[0503] Referring now to FIGS. 182-190, 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. 184) on the staple 160 via the
initial drive surface 180 (FIGS. 182-184). The leading surface 194
can lift the staple 160 upward along a plane defined by axis E
(FIG. 183) and axis F (FIG. 184). As indicated in FIGS. 183 and
184, 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.
184) exerted on the initial drive surface 180 in the plane defined
by axes E and F can generate a torque T.sub.1 (FIG. 184). 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. 184) 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.
[0504] Referring now to FIGS. 185-187, 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. 187) 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. 186) and axis J (FIG. 187). As indicated in FIGS. 186 and
187, 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. 187) exerted on the secondary drive surface 182 by
the trailing surface 196 of the sled 190 can generate a torque
T.sub.2 (FIG. 187). Upon comparing FIGS. 184 and 187, 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. 187). 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.
[0505] 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.
[0506] As depicted in FIGS. 184 and 187, 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. 188-190, 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.
[0507] Referring now to FIGS. 171-173, 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. 129). Staples,
such as staples 160, for example, can be ejectably positioned in
the staple cartridge 240. For example, sleds 190 (FIGS. 140-143)
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. 132-139) 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.
[0508] Referring now to FIGS. 158A-158C, 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. 158A, 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.
[0509] In various instances, the staples 160 can be cut, formed
and/or stamped from the bent sheets 130. For example, referring
primarily to FIG. 158B, 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. 158C, 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. 132-139 and 159-162), 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. 158B and
158C, 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.
[0510] For example, referring to FIGS. 158C and 159-162, 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. 158A and 158B) can form the
contoured portions 178 of the staple 160. Moreover, the lateral
flat portions 135a and 135c of the sheet 130 (FIGS. 158A and 158B)
can correspond to the staple legs 164 and 166, and the intermediate
flat portion 135b of the sheet 130 (FIGS. 158A and 158B) can
correspond to the intermediate portion 172 of the base 162, for
example.
[0511] In various instances, the depth D.sub.1(FIGS. 160 and 162)
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. 161), and width
W.sub.1 (FIG. 161) 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.
[0512] Referring primarily to FIGS. 159-162, 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. 129) 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.
[0513] 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. 129) 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.
[0514] Referring now to FIGS. 163-166, a staple outline 232 can be
traced, cut, etched, and/or machined into the sheet of material 130
(FIGS. 158A and 158B), and a staple 260, similar to the staple 160
(FIGS. 159-162), 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. 158A and 158B) 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.
[0515] 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. 163-166, the
height H.sub.2 of the staple base 262 is less than the height
H.sub.1 of the staple base 162 (FIGS. 159-162), 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. 129), for example.
[0516] Referring now to FIGS. 167-170, a staple outline 332 can be
traced, cut, etched, and/or machined into the sheet of material 130
(FIGS. 158A and 158B), and a staple 360, similar to the staples 160
and 260 (FIGS. 159-166), 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. 158A and 158B) 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.
[0517] 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. 167-170,
the height H.sub.3 of the staple base 362 is greater than the
height H.sub.1 of the staple base 162 (FIGS. 159-162) and greater
than the height H.sub.2 of the staple base 262 (FIGS. 163-166), 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. 129), for example.
[0518] Referring now to FIGS. 174-177, a staple, such as a staple
460, for example, can be used in a staple cartridge, such as the
staple cartridge 140 (FIGS. 129-131) and/or the staple cartridge
240 (FIGS. 171-173), 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. 174-177, 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.
[0519] Referring still to FIGS. 174-177, 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. 175) extending between the
first staple leg 464 and the second staple leg 466, and/or relative
to a vertical axis H (FIG. 177) 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.
[0520] Referring now to FIGS. 178-181, a staple, such as a staple
560, for example, can be used in a staple cartridge, such as the
staple cartridge 140 (FIGS. 129-131) and/or the staple cartridge
240 (FIGS. 171-173), 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. 178-181, 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. 179), which can be parallel and/or
substantially parallel to an axis C (FIG. 179) defined between the
first staple leg 564 and the second staple leg 566, for
example.
[0521] 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. 178-181, 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. 179) extending between the first
staple leg 564 and the second staple leg 566.
[0522] 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.
[0523] Further to the above, turning now to FIG. 191, 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. 191, any suitable staple or fastener
could be used with this embodiment, such as staples 160, for
example. Referring generally to FIGS. 199 and 200, 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. 199) and a closed position (FIG. 200). 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. 191, 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.
[0524] Referring primarily to FIGS. 192-195, 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. 192 and
193, 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. 194 and 195, 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. 193, 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.
[0525] 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.
[0526] Referring again to FIG. 191, 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.
[0527] 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.
[0528] 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. 196-198, the sled assembly 790 is movable
between an initial, unfired configuration (FIG. 196) and a second,
extended configuration (FIGS. 197 and 198). In the initial, unfired
configuration of sled assembly 790, referring primarily to FIG.
196, 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. 196, 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. 196 and 197, 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. 197, 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.
[0529] Upon comparing FIGS. 197 and 198, 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. 196-198. FIG. 196 depicts the
sled assembly 790 in a retracted, unfired position; FIG. 197
depicts the sled assembly 790 in an extended, partially-fired
position; and FIG. 198 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. 196-198.
With reference to FIG. 196, 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. 196, 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. 197. 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. 198.
[0530] As discussed above, the end effector 120 can be configured
to staple and transect tissue at the same time. Referring again to
FIG. 191, 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. 196 and 197, 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. 196) and its extended
position (FIG. 197). 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. 200 and 203, 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.
200, 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. 203, 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. 204 and 205, the pusher bars 156 and the knife
bar 159 can be advanced distally together.
[0531] 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.
203, 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.
[0532] 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.
[0533] Turning now to FIGS. 206-208, 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. 203, 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.
[0534] Referring now to FIGS. 211-214, FIG. 211 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. 212. 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. 213, 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. 214. Upon comparing FIGS. 213 and 214, 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.
[0535] After the firing stroke has been completed, referring now to
FIGS. 209 and 210, 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.
[0536] As illustrated in FIGS. 209 and 210, 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.
[0537] 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.
[0538] 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. 218, 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.
215-218, the initial drive surface 895a can contact a staple 160,
for instance, and lift the staple 160 from its unfired position
(FIG. 215) to a partially-fired position (FIG. 216). 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. 218, 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.
[0539] Further to the above, referring again to FIG. 218, 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. 218, 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.
[0540] 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.
[0541] 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.
[0542] 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.
[0543] 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.
[0544] 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.
217-220, 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. 220, 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. 220, 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.
[0545] 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. 219, 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.
[0546] As discussed above, referring primarily to FIGS. 184, 187,
and 190, 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. 148-157, 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. 219 and 220, 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. 129 and
191, 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.
[0547] 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.
[0548] 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.
[0549] 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.
[0550] 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.
[0551] 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.
* * * * *