U.S. patent application number 17/751848 was filed with the patent office on 2022-09-22 for staple cartridge assembly comprising various tissue compression gaps and staple forming gaps.
The applicant listed for this patent is Cilag GmbH International. Invention is credited to Chester O. Baxter, III, Brian F. DiNardo, Disha V. Estera, Jason L. Harris, Jerome R. Morgan, Anil K. Nalagatla, Frederick E. Shelton, IV, Jeffrey S. Swayze.
Application Number | 20220296242 17/751848 |
Document ID | / |
Family ID | 1000006388018 |
Filed Date | 2022-09-22 |
United States Patent
Application |
20220296242 |
Kind Code |
A1 |
Nalagatla; Anil K. ; et
al. |
September 22, 2022 |
STAPLE CARTRIDGE ASSEMBLY COMPRISING VARIOUS TISSUE COMPRESSION
GAPS AND STAPLE FORMING GAPS
Abstract
An end effector including an anvil and a staple cartridge
assembly is disclosed. The staple cartridge assembly comprises a
deck having steps defined thereon for compressing tissue positioned
between the anvil and the staple cartridge assembly to different
pressures. The staple cartridge assembly further comprises staples
having different unformed heights removably stored therein. The
staples are deformed against the anvil to different formed
heights.
Inventors: |
Nalagatla; Anil K.; (Mason,
OH) ; DiNardo; Brian F.; (Loveland, OH) ;
Estera; Disha V.; (Cincinnati, OH) ; Baxter, III;
Chester O.; (Loveland, OH) ; Swayze; Jeffrey S.;
(West Chester, OH) ; Shelton, IV; Frederick E.;
(Hillsboro, OH) ; Morgan; Jerome R.; (Cincinnati,
OH) ; Harris; Jason L.; (Lebanon, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Cilag GmbH International |
Zug |
|
CH |
|
|
Family ID: |
1000006388018 |
Appl. No.: |
17/751848 |
Filed: |
May 24, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
16156161 |
Oct 10, 2018 |
|
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|
17751848 |
|
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|
14836163 |
Aug 26, 2015 |
11058426 |
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16156161 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61B 17/115 20130101;
A61B 17/1155 20130101; A61B 2017/0645 20130101; A61B 17/072
20130101; A61L 31/10 20130101; A61B 2017/07278 20130101; A61B
2090/037 20160201; A61B 17/0644 20130101; A61B 2017/00964 20130101;
A61B 17/07207 20130101; A61B 17/105 20130101; A61B 2017/00893
20130101; A61B 2017/00398 20130101; A61B 2090/038 20160201; A61B
2017/0472 20130101; A61B 17/32 20130101; A61B 2017/06042 20130101;
A61B 2017/07271 20130101; A61B 2090/08021 20160201; A61B 17/0401
20130101; A61B 2017/00526 20130101; A61B 2017/0464 20130101; A61L
31/022 20130101; A61B 2017/07214 20130101; A61B 2017/07264
20130101; A61B 2017/07221 20130101; A61B 2017/2929 20130101; A61B
17/00491 20130101; A61B 17/0469 20130101; A61B 2017/00004 20130101;
A61B 2017/320052 20130101; A61B 17/064 20130101; A61B 2017/07228
20130101; A61B 2017/07235 20130101; A61B 2017/07242 20130101; A61L
31/148 20130101; A61B 2017/00889 20130101; A61B 2017/1142 20130101;
A61B 17/068 20130101; A61B 2017/00831 20130101; A61B 17/07292
20130101 |
International
Class: |
A61B 17/10 20060101
A61B017/10; A61B 17/064 20060101 A61B017/064; A61B 17/072 20060101
A61B017/072; A61B 17/115 20060101 A61B017/115; A61L 31/02 20060101
A61L031/02; A61L 31/10 20060101 A61L031/10; A61L 31/14 20060101
A61L031/14; A61B 17/068 20060101 A61B017/068; A61B 17/32 20060101
A61B017/32; A61B 17/04 20060101 A61B017/04 |
Claims
1-20. (canceled)
21. A surgical staple cartridge, comprising: a cartridge body,
comprising: a deck; and a staple cavity defined in said deck; and a
bioabsorbable staple removably stored in said staple cavity,
wherein said staple comprises a frame, wherein said frame comprises
magnesium, and wherein said frame comprises a treated surface
configured to affect a bioabsorption rate of said frame.
22. The surgical staple cartridge of claim 21, wherein said treated
surface comprises a plasma-treated surface.
23. The surgical staple cartridge of claim 21, wherein said treated
surface comprises a laser-treated surface.
24. The surgical staple cartridge of claim 21, wherein said treated
surface comprises magnesium nitride.
25. The surgical staple cartridge of claim 21, wherein said treated
surface comprises a coating including carbon.
26. The surgical staple cartridge of claim 21, wherein said treated
surface comprises at least one aperture.
27. The surgical staple cartridge of claim 21, wherein said staple
comprises a coating applied to said treated surface.
28. The surgical staple cartridge of claim 27, wherein said coating
is configured to delay the initiation of bioabsorption of said
frame after said staple is implanted into patient tissue.
29. The surgical staple cartridge of claim 28, wherein said coating
comprises sodium stearate.
30. The surgical staple cartridge of claim 29, wherein said coating
comprises an anti-microbial agent.
31. The surgical staple cartridge of claim 30, wherein said
anti-microbial comprises ethyl lauroyl arginate (LAE).
32. A surgical staple cartridge, comprising: a cartridge body,
comprising: a deck; and a staple cavity defined in said deck; and a
bioabsorbable staple removably stored in said staple cavity,
wherein said staple comprises a frame, wherein said frame comprises
magnesium, and wherein a surface of said frame is treated with a
coating configured to delay the initiation of bioabsorption of said
frame after said staple is implanted into patient tissue.
33. The surgical staple cartridge of claim 32, wherein said coating
comprises a bioabsorbable polymer.
34. The surgical staple cartridge of claim 32, wherein said coating
is a first coating, and wherein said staple further comprises a
second coating applied to said first coating.
35. The surgical staple cartridge of claim 34, wherein said second
coating comprises sodium stearate.
36. The surgical staple cartridge of claim 35, wherein said second
coating comprises an anti-microbial agent.
37. The surgical staple cartridge of claim 36, wherein said
anti-microbial comprises ethyl lauroyl arginate (LAE).
38. The surgical staple cartridge of claim 32, wherein said surface
of said frame is treated with a surface treatment configured to
decrease a bioabsorption rate of said frame.
39. The surgical staple cartridge of claim 38, wherein said surface
treatment comprises hardening said surface with a plasma discharge
hardening process.
40. The surgical staple cartridge of claim 38, wherein said surface
treatment comprises hardening said surface with a laser hardening
process.
41. The surgical staple cartridge of claim 38, wherein said surface
treatment comprises hardening said surface by exposing said surface
to a nitrogen-rich environment.
42. The surgical staple cartridge of claim 32, wherein said surface
of said frame is treated with a surface treatment configured to
increase a bioabsorption rate of said frame.
43. The surgical staple cartridge of claim 42, wherein said surface
treatment comprises increasing a surface area of said surface by
creating at least one aperture therein.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application claiming
priority under 35 U.S.C. .sctn. 120 to U.S. patent application Ser.
No. 16/156,161, entitled STAPLE CARTRIDGE ASSEMBLY COMPRISING
VARIOUS TISSUE COMPRESSION GAPS AND STAPLE FORMING GAPS, filed Oct.
10, 2018, now U.S. Patent Application Publication No. 2019/0105047,
which is a continuation application claiming priority under 35
U.S.C. .sctn. 120 to U.S. patent application Ser. No. 14/836,163,
entitled STAPLE CARTRIDGE ASSEMBLY COMPRISING VARIOUS TISSUE
COMPRESSION GAPS AND STAPLE FORMING GAPS, filed Aug. 26, 2015,
which issued on Jul. 13, 2021 as U.S. Pat. No. 11,058,426, the
entire disclosures of which are hereby incorporated by reference
herein.
BACKGROUND
[0002] The present invention relates to surgical instruments and,
in various embodiments, to surgical stapling and cutting
instruments and staple cartridges for use therewith.
[0003] A stapling instrument can include a pair of cooperating
elongate jaw members, wherein each jaw member can be adapted to be
inserted into a patient and positioned relative to tissue that is
to be stapled and/or incised. In various embodiments, one of the
jaw members can support a staple cartridge with at least two
laterally spaced rows of staples contained therein, and the other
jaw member can support an anvil with staple-forming pockets aligned
with the rows of staples in the staple cartridge. Generally, the
stapling instrument can further include a pusher bar and a knife
blade which are slidable relative to the jaw members to
sequentially eject the staples from the staple cartridge via
camming surfaces on the pusher bar and/or camming surfaces on a
wedge sled that is pushed by the pusher bar. In at least one
embodiment, the camming surfaces can be configured to activate a
plurality of staple drivers carried by the cartridge and associated
with the staples in order to push the staples against the anvil and
form laterally spaced rows of deformed staples in the tissue
gripped between the jaw members. In at least one embodiment, the
knife blade can trail the camming surfaces and cut the tissue along
a line between the staple rows.
[0004] The foregoing discussion is intended only to illustrate
various aspects of the related art in the field of the invention at
the time, and should not be taken as a disavowal of claim
scope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Various features of the embodiments described herein are set
forth with particularity in the appended claims. The various
embodiments, however, both as to organization and methods of
operation, together with advantages thereof, may be understood in
accordance with the following description taken in conjunction with
the accompanying drawings as follows:
[0006] FIG. 1 is a perspective view of a staple for use with a
surgical stapling instrument in accordance with at least one
embodiment;
[0007] FIG. 2 is a side elevation view of the staple of FIG. 1;
[0008] FIG. 3 is a top view of the staple of FIG. 1;
[0009] FIG. 4 is a cross-sectional view of the staple of FIG. 1
taken along line 4-4 in FIG. 3;
[0010] FIG. 5 is a perspective view of a staple for use with a
surgical stapling instrument in accordance with at least one
embodiment;
[0011] FIG. 6 is a side elevation view of the staple of FIG. 5;
[0012] FIG. 7 is a side elevation view of a staple for use with
surgical stapling instrument in accordance with at least one
embodiment;
[0013] FIG. 8 is a side elevation view of the staple of FIG. 7 in a
formed configuration;
[0014] FIG. 9 is a top view of the staple of FIG. 7 in the formed
configuration of FIG. 8;
[0015] FIG. 10 is a side elevation view of the staple of FIG. 7 in
a formed configuration and a partial cross-sectional view of an
anvil of a surgical stapling instrument;
[0016] FIG. 11 is a perspective view of a staple for use with a
surgical stapling instrument in accordance with at least one
embodiment;
[0017] FIGS. 11A-11C are cross-sections of portions of the staple
of FIG. 11;
[0018] FIG. 12 is a perspective view of a staple for use with a
surgical stapling instrument in accordance with at least one
embodiment;
[0019] FIG. 13 is a side elevation view of a staple for use with a
surgical stapling instrument in accordance with at least one
embodiment;
[0020] FIG. 14 is a partial top view of a formed staple
configuration comprising a plurality of staples in accordance with
at least one embodiment;
[0021] FIG. 15 is a perspective view of a staple for use with a
surgical stapling instrument in accordance with at least one
embodiment;
[0022] FIG. 16 is a partial cross-sectional view of an anvil
illustrating a portion of the staple of FIG. 15 being formed from
an unformed configuration to a formed configuration;
[0023] FIG. 17 is an elevation view of the staple of FIG. 15 in a
formed configuration;
[0024] FIG. 18 includes side views of multiple staple tips in
accordance with at least one embodiment;
[0025] FIG. 19 is a bottom view of a staple in accordance with at
least one embodiment and forming pockets of an anvil according to a
first arrangement;
[0026] FIG. 20 is partial cross-sectional view of an anvil pocket
of FIG. 19 taken along line 20-20 in FIG. 19;
[0027] FIG. 21 is a bottom view of the staple and the forming
pockets of FIG. 19 according to a second arrangement;
[0028] FIG. 22 is a bottom view of the staple and the forming
pockets of FIG. 19 according to a third arrangement;
[0029] FIG. 23 is a bottom view of the staple of FIG. 19 and
forming pockets in accordance with at least one embodiment;
[0030] FIG. 24 is a partial cross-sectional view of an anvil pocket
of FIG. 23 taken along line 24-24 in FIG. 23;
[0031] FIG. 25 is a bottom view of the staple of FIG. 19 and
forming pockets in accordance with at least one embodiment;
[0032] FIG. 26 is a bottom view of the staple of FIG. 19 and
forming pockets in accordance with at least one embodiment;
[0033] FIG. 27 is a partial perspective view of a staple leg in
accordance with at least one embodiment;
[0034] FIG. 27A is a partial cross-sectional end view of the staple
leg of FIG. 27;
[0035] FIG. 27B is a partial longitudinal cross-section of the
staple leg of FIG. 27;
[0036] FIG. 28 is a perspective view of a portion of a staple strip
manufactured with progressive die stamping;
[0037] FIG. 28A is a partial cross-sectional view of the portion of
the staple strip of FIG. 28 taken along line 28A-28A in FIG.
28;
[0038] FIG. 28B is a partial cross-sectional view of the portion of
the staple strip of FIG. 28 taken along line 28B-28B in FIG.
28;
[0039] FIG. 28C is a partial perspective view of a sled configured
to engage the staple strip of FIG. 28;
[0040] FIG. 29 is a perspective view of a portion of a staple strip
manufactured with progressive die stamping in accordance with at
least one embodiment;
[0041] FIG. 30 is a bottom perspective view of the staple strip of
FIG. 29;
[0042] FIG. 31 is a partial cross-sectional view of a staple
cartridge and staples in accordance with at least one
embodiment;
[0043] FIG. 32 is a perspective view of a staple cartridge assembly
in accordance with at least one embodiment;
[0044] FIG. 33 is a top plan view of the staple cartridge assembly
of FIG. 32;
[0045] FIG. 34 is a detail view of a distal end of the staple
cartridge assembly of FIG. 32;
[0046] FIG. 35 is a partial cross-sectional perspective view of a
staple cartridge assembly in accordance with at least one
embodiment illustrating staples being ejected from the staple
cartridge assembly by a firing member;
[0047] FIG. 36 is a partial exploded view of the staple cartridge
assembly of FIG. 35;
[0048] FIG. 37 is a partial cross-sectional view of the staple
cartridge assembly of FIG. 35 illustrating a staple being deformed
against an anvil by the firing member;
[0049] FIG. 38 is a partial plan view of a staple positioned in a
staple cavity of the staple cartridge assembly of FIG. 35;
[0050] FIG. 39 is a partial perspective view of a staple being
lifted by the firing member of the staple cartridge of FIG. 35;
[0051] FIG. 40 is a bottom perspective view of the staple of FIG.
39;
[0052] FIG. 41 is a diagram illustrating the staple of FIG. 39 in a
level position;
[0053] FIG. 42 is a diagram illustrating the staple of FIG. 39 in a
crooked position;
[0054] FIG. 43 is a cross-sectional plan view of a staple cavity
configured to guide a staple in accordance with at least one
embodiment;
[0055] FIG. 44 is a cross-sectional perspective view of a staple
cartridge assembly positioned in a jaw of a surgical stapling
instrument in accordance with at least one embodiment illustrating
a firing member positioned in a cartridge body of the staple
cartridge assembly;
[0056] FIG. 45 is a partial cross-sectional perspective view of the
staple cartridge assembly of FIG. 44 illustrating a retention
feature configured to hold the firing member in the cartridge body
when the staple cartridge assembly is not positioned in the jaw of
the surgical stapling instrument;
[0057] FIG. 46 is a partial cross-sectional exploded view of the
staple cartridge assembly of FIG. 44;
[0058] FIG. 47 is a partial cross-sectional end view of the staple
cartridge assembly of FIG. 44;
[0059] FIG. 48 is a partial cross-sectional perspective view of the
staple cartridge assembly of FIG. 44 illustrating a retention
feature configured to releasably hold the staple cartridge assembly
in the jaw of the surgical stapling instrument;
[0060] FIG. 49 is a partial plan view of a staple positioned in a
staple cavity of a staple cartridge assembly in accordance with at
least one embodiment;
[0061] FIG. 50 is a detail view of a retention feature configured
to releasably hold the staple in the staple cartridge assembly of
FIG. 49;
[0062] FIG. 51 is a partial cross-sectional elevational view of a
staple cartridge assembly in accordance with at least one
embodiment;
[0063] FIG. 52 is a perspective view of a staple in accordance with
at least one embodiment;
[0064] FIG. 53 is a bottom perspective view of the staple of FIG.
52;
[0065] FIG. 54 is a front elevational view of the staple of FIG.
52;
[0066] FIG. 55 is a side elevational view of the staple of FIG.
52;
[0067] FIG. 56 is a bottom view of the staple of FIG. 52;
[0068] FIG. 57 is a perspective view of a firing member of a staple
cartridge assembly in accordance with at least one embodiment
comprising alignment channels;
[0069] FIG. 58 is a diagram illustrating the firing member of FIG.
57 and a staple positioned in a staple cavity of a staple cartridge
assembly;
[0070] FIG. 59 is a diagram illustrating the firing member of FIG.
57 aligning the staple of FIG. 58 within the staple cavity of FIG.
58;
[0071] FIG. 60 is a perspective view of the firing member of FIG.
57 and staples arranged in two longitudinal rows;
[0072] FIG. 61 is a partial cross-sectional view of an alignment
channel of the firing member of FIG. 57 and a portion of the staple
of FIG. 58;
[0073] FIG. 62 is a partial cross-sectional perspective view of the
staple cartridge assembly of FIG. 58;
[0074] FIG. 63 is a partial exploded view of the staple cartridge
assembly of FIG. 58;
[0075] FIG. 64 is a partial bottom cross-sectional perspective view
of the staple cartridge assembly of FIG. 58;
[0076] FIG. 65 is a partial perspective view of projections
extending from a deck surface of a staple cartridge assembly in
accordance with at least one alternative embodiment;
[0077] FIG. 66 is a partial perspective view of projections
extending from a deck surface of a staple cartridge assembly in
accordance with at least one alternative embodiment;
[0078] FIG. 67 is a bottom perspective view of a cartridge body of
a staple cartridge assembly;
[0079] FIG. 68 is a bottom view of the cartridge body of FIG.
67;
[0080] FIG. 69 is a bottom perspective view of the cartridge body
of the staple cartridge assembly of FIG. 32;
[0081] FIG. 70 is a bottom view of the cartridge body of FIG.
32;
[0082] FIG. 71 is a diagram illustrating the cartridge body of FIG.
67 to an alternative embodiment of a cartridge body;
[0083] FIG. 72 is a partial top plan view of a staple cartridge
assembly in accordance with at least one embodiment;
[0084] FIG. 73 is a partial perspective view of the staple
cartridge of FIG. 32;
[0085] FIG. 74 is a cross-sectional view of the staple cartridge of
FIG. 32 and the anvil of FIG. 37 illustrating certain staples in an
unfired position and certain staples in a fired position;
[0086] FIG. 75 illustrates the staples of the staple cartridge of
FIG. 32 deformed to three different heights;
[0087] FIG. 76 illustrates the staples of the staple cartridge of
FIG. 32 implanted in the tissue of a patient;
[0088] FIG. 77 illustrates a staple of the staple cartridge of FIG.
32 being deformed;
[0089] FIG. 78 is a perspective view of a staple in accordance with
at least one embodiment;
[0090] FIG. 79 is a cross-sectional view of the staple of FIG.
78;
[0091] FIG. 80 is a perspective view of a staple assembly in
accordance with at least one embodiment;
[0092] FIG. 81 is an elevational view of the staple assembly of
FIG. 80;
[0093] FIG. 82 is a perspective view of an implantable staple
adjunct;
[0094] FIG. 83 is a cross-sectional view of the staple adjunct of
FIG. 82;
[0095] FIG. 84 is a partial perspective view of a staple assembly
including the staple adjunct of FIG. 82;
[0096] FIG. 85 illustrates the staple assembly of FIG. 84 implanted
into tissue;
[0097] FIG. 86 is a perspective view of a staple in accordance with
at least one embodiment illustrated in a deformed
configuration;
[0098] FIG. 87 is a plan view of a circular cartridge body
comprising a plurality of the staple assemblies of FIG. 84 in
accordance with at least one embodiment;
[0099] FIG. 88 illustrates the spacing of the staples of FIG. 35 in
unstretched tissue;
[0100] FIG. 89 illustrates the spacing of the staples of FIG. 35 in
stretched tissue;
[0101] FIG. 90 is a perspective view of a staple in accordance with
at least one embodiment;
[0102] FIG. 91 illustrates the staple of FIG. 90 implanted into
tissue;
[0103] FIG. 92 illustrates the staple of FIG. 90 after being
partially dissolved;
[0104] FIG. 93 is a cross-sectional perspective view of a portion
of a circular surgical stapler in accordance with at least one
embodiment;
[0105] FIG. 94 is a partial cross-sectional perspective view of the
circular surgical stapler of FIG. 93;
[0106] FIG. 95 is a partial perspective view of the circular
surgical stapler of FIG. 93;
[0107] FIG. 96 is a partial exploded perspective view of a circular
surgical stapler in accordance with at least one embodiment;
[0108] FIG. 97 is a partial perspective view of the circular
surgical stapler of FIG. 96 illustrating staples in a preloaded
position;
[0109] FIG. 98 is a partial perspective view of the circular
surgical stapler of FIG. 96;
[0110] FIG. 99 is an end view of a circular surgical stapling
configuration in accordance with at least one embodiment;
[0111] FIG. 100 is an end view of a circular surgical stapling
configuration in accordance with at least one embodiment;
[0112] FIG. 101 is partial cross-sectional view of a colon stapled
with a circular stapling instrument disclosed herein;
[0113] FIG. 102 is a partial perspective view of a curved stapler
in accordance with at least one embodiment;
[0114] FIG. 103 is a partial exploded view of the curved stapler of
FIG. 102;
[0115] FIG. 104 is a partial perspective view of the curved stapler
of FIG. 102;
[0116] FIG. 105 is a partial perspective view of a curved stapler
in accordance with at least one embodiment; and
[0117] FIG. 106 is a partial perspective view of the curved stapler
of FIG. 105.
[0118] Corresponding reference characters indicate corresponding
parts throughout the several views. The exemplifications set out
herein illustrate various 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
[0119] The Applicant of the present application owns the following
U.S. patent applications that were filed on Aug. 26, 2015 and which
are each herein incorporated by reference in their respective
entireties: [0120] U.S. patent application Ser. No. 14/836,324,
entitled SURGICAL STAPLES FOR MINIMIZING STAPLE ROLL, now U.S.
Patent Application Publication No. 2017/0056005; [0121] U.S. patent
application Ser. No. 14/836,020, entitled SURGICAL STAPLES
COMPRISING FEATURES FOR IMPROVED FASTENING OF TISSUE, now U.S.
Patent Application Publication No. 2017/0055996; [0122] U.S. patent
application Ser. No. 14/836,411, entitled SURGICAL STAPLES
COMPRISING HARDNESS VARIATIONS FOR IMPROVED FASTENING OF TISSUE,
now U.S. Patent Application Publication No. 2017/0056008; [0123]
U.S. patent application Ser. No. 14/836,058, entitled SURGICAL
STAPLE STRIPS FOR PERMITTING VARYING STAPLE PROPERTIES AND ENABLING
EASY CARTRIDGE LOADING, now U.S. Patent Application Publication No.
2017/0055998; [0124] U.S. patent application Ser. No. 14/836,110,
entitled SURGICAL STAPLING CONFIGURATIONS FOR CURVED AND CIRCULAR
STAPLING INSTRUMENTS, now U.S. Patent Application Publication No.
2017/0056000; [0125] U.S. patent application Ser. No. 14/836,036,
entitled STAPLE CARTRIDGE ASSEMBLY WITHOUT A BOTTOM COVER, now U.S.
Patent Application Publication No. 2017/0055997; [0126] U.S. patent
application Ser. No. 14/836,077, entitled STAPLE CARTRIDGE ASSEMBLY
COMPRISING STAPLE CAVITIES FOR PROVIDING BETTER STAPLE GUIDANCE,
now U.S. Patent Application Publication No. 2017-0055999; [0127]
U.S. patent application Ser. No. 14/836,225, entitled STAPLE
CARTRIDGE ASSEMBLY INCLUDING STAPLE GUIDES, now U.S. Pat. No.
10,028,744; [0128] U.S. patent application Ser. No. 14/836,351,
entitled STAPLE CARTRIDGE ASSEMBLY COMPRISING STAPLE ALIGNMENT
FEATURES ON A FIRING MEMBER, now U.S. Patent Application
Publication No. 2017/0056006; [0129] U.S. patent application Ser.
No. 14/836,294, entitled STAPLES CONFIGURED TO SUPPORT AN
IMPLANTABLE ADJUNCT, now U.S. Patent Application Publication No.
2017/0056004; [0130] U.S. patent application Ser. No. 14/836,375,
entitled STAPLES COMPRISING A COVER, now U.S. Patent Application
Publication No. 2017-0056007; and [0131] U.S. patent application
Ser. No. 14/836,137, entitled STAPLE CARTRIDGE ASSEMBLY INCLUDING
FEATURES FOR CONTROLLING THE ROTATION OF STAPLES WHEN BEING EJECTED
THEREFROM, now U.S. Patent Application Publication No.
2017/0056001.
[0132] Applicant of the present application also owns the following
patent applications that were filed on Dec. 23, 2013 and which are
each incorporated by reference herein in their respective
entireties: [0133] U.S. patent application Ser. No. 14/138,554,
entitled SURGICAL INSTRUMENTS WITH ARTICULATABLE SHAFT
ARRANGEMENTS, now U.S. Patent Application Publication No.
2015/0173789; [0134] U.S. patent application Ser. No. 14/138,465,
entitled SURGICAL STAPLES AND STAPLE CARTRIDGES, now U.S. Patent
Application Publication No. 2015/0173744; [0135] U.S. patent
application Ser. No. 14/138,474, entitled ARTICULATABLE SURGICAL
INSTRUMENTS WITH SEPARATE AND DISTINCT CLOSING AND FIRING SYSTEMS,
now U.S. Pat. No. 9,681,870; [0136] U.S. patent application Ser.
No. 14/138,485 entitled SURGICAL CUTTING AND STAPLING INSTRUMENTS
WITH INDEPENDENT JAW CONTROL FEATURES, now U.S. Pat. No. 9,839,428;
[0137] U.S. patent application Ser. No. 14/138,475, entitled
SURGICAL STAPLES AND STAPLE CARTRIDGES, now U.S. Patent Application
Publication No. 2015/0173749; [0138] U.S. patent application Ser.
No. 14/138,481, entitled SURGICAL STAPLES AND METHODS FOR MAKING
THE SAME, now U.S. Pat. No. 9,968,354; [0139] U.S. patent
application Ser. No. 14/138,489 entitled SURGICAL STAPLES, STAPLE
CARTRIDGES AND SURGICAL END EFFECTORS, now U.S. Pat. No. 9,687,232;
[0140] U.S. Design patent application Ser. No. 29/477,488, entitled
SURGICAL FASTENER, now U.S. Pat. No. D775,336; [0141] U.S. patent
application Ser. No. 14/138,505 entitled FASTENER CARTRIDGE
COMPRISING AN EXTENDABLE FIRING MEMBER, now U.S. Pat. No.
9,585,662; [0142] U.S. patent application Ser. No. 14/138,518
entitled FASTENER CARTRIDGE COMPRISING A FIRING MEMBER CONFIGURED
TO DIRECTLY ENGAGE AND EJECT FASTENERS FROM THE FASTENER CARTRIDGE,
now U.S. Pat. No. 9,763,662; [0143] U.S. patent application Ser.
No. 14/138,530 entitled FASTENER CARTRIDGE COMPRISING A FIRING
MEMBER INCLUDING FASTENER TRANSFER SURFACES, now U.S. Pat. No.
9,549,735; [0144] U.S. patent application Ser. No. 14/138,507,
entitled MODULAR SURGICAL INSTRUMENTS, now U.S. Pat. No. 9,724,092;
[0145] U.S. patent application Ser. No. 14/138,497, entitled
SURGICAL CUTTING AND STAPLING INSTRUMENTS WITH ARTICULATABLE END
EFFECTORS, now U.S. Pat. No. 9,642,620; and [0146] U.S. patent
application Ser. No. 14/138,516, entitled SURGICAL CUTTING AND
STAPLING METHODS, now U.S. Patent Application Publication No.
2015/0173756.
[0147] Numerous specific details are set forth to provide a
thorough understanding of the overall structure, function,
manufacture, and use of the embodiments as described in the
specification and illustrated in the accompanying drawings.
Well-known operations, components, and elements have not been
described in detail so as not to obscure the embodiments described
in the specification. The reader will understand that the
embodiments described and illustrated herein are non-limiting
examples, and thus it can be appreciated that the specific
structural and functional details disclosed herein may be
representative and illustrative. Variations and changes thereto may
be made without departing from the scope of the claims.
[0148] The terms "comprise" (and any form of comprise, such as
"comprises" and "comprising"), "have" (and any form of have, such
as "has" and "having"), "include" (and any form of include, such as
"includes" and "including") and "contain" (and any form of contain,
such as "contains" and "containing") are open-ended linking verbs.
As a result, a surgical system, device, or apparatus that
"comprises," "has," "includes" or "contains" one or more elements
possesses those one or more elements, but is not limited to
possessing only those one or more elements. Likewise, an element of
a system, device, or apparatus that "comprises," "has," "includes"
or "contains" one or more features possesses those one or more
features, but is not limited to possessing only those one or more
features.
[0149] 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.
[0150] Various exemplary devices and methods are provided for
performing laparoscopic and minimally invasive surgical procedures.
However, the reader 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, the reader 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.
[0151] A staple, or fastener, disclosed herein is configured for
use with a surgical stapling instrument. Discussed in greater
detail below, the staple is removably stored in a staple cavity of
a staple cartridge. The staple cartridge comprises a sled
configured to receive a firing actuation from the surgical stapling
instrument which imparts a force on the staple to eject the staple
from the staple cavity. When the staple is ejected, or driven, out
of the staple cavity by the sled, the staple undergoes a
deformation process where the staple forms into a fired
configuration from an unfired configuration. The staple forms into
the fired configuration when the staple contacts corresponding
forming pockets of an anvil of the surgical stapling
instrument.
[0152] Various staples disclosed herein comprise a flat-formed
staple which can be cut and/or stamped from a sheet of material,
for example. The sheet of material can be metallic and can comprise
stainless steel and/or titanium, for example. In at least one
instance, outlines can be traced, etched, and/or cut into the sheet
of material which are machined and/or laser cut to form the staples
into a manufactured shape.
[0153] The staples comprise a pair of staple legs and a staple base
portion, or crown, from which the staple legs extend. Each staple
leg comprises a staple tip, or piercing portion, which is
configured to pierce the tissue and contact a corresponding forming
pocket of the anvil of the surgical stapling instrument. The staple
legs are configured to change shape to achieve a formed
configuration to fasten the tissue. The staple base portion defines
a first plane and the staple legs define a second plane which is
laterally offset from but at least substantially parallel to the
first plane. Embodiments are envisioned where the first and second
planes are not parallel.
[0154] The flat-formed staple 100 depicted in FIGS. 1-4 comprises a
proximal staple leg 110, a distal staple leg 120, and a staple base
portion 130. The staple 100 further comprises vertical transition
portions, or bends, 118, 128 and lateral transition portions, or
bends, 116, 126. The vertical transition portions 118, 128 bend, or
extend, the legs 110, 120 vertically, or upward, from the staple
base portion 130. The lateral transition portions 116, 126 extend
the staple legs 110, 120 laterally outward, or at least
substantially perpendicularly with respect to the staple base
portion 130. The staple legs 110, 120 define a first plane and the
staple base portion 130 defines a second plane. Together, the
vertical transition portions 118, 128 and the lateral transition
portions 116, 126 permit the staple legs 110, 120 to be laterally
offset and parallel with respect to the staple base portion 130.
Stated another way, the first plane is offset from and at least
substantially parallel to the second plane. In FIGS. 1-4, the first
plane is offset in the negative Y direction. Other staples may be
used in conjunction with a plurality of staples 100 where the other
staples comprise a first plane which is offset in the positive Y
direction. The use of both types of staples permits staple rows to
be nested, or interwoven, where staple legs of neighboring rows may
be at least substantially aligned and/or share a common
longitudinal axis. In various instances, the staple rows can be
nested to provide denser staple rows.
[0155] The proximal staple leg 110 and the distal staple leg 120
comprise staple tips 112, 122 and corners 114, 124, respectively.
The tips 112, 122 are configured to pierce tissue and contact a
forming pocket of an anvil of a surgical stapling instrument. The
tips 112, 122 contact the anvil when the staple 100 receives a
driving force to eject the staple 100 from a corresponding staple
cavity in the staple cartridge. The tips 112, 122 and/or legs 110,
120 of the staple 100 will then begin forming from an unfired
configuration to a fired configuration. The proximal staple leg 120
further comprises a leading engagement foot 117 comprising a
chamfered surface, or edge, 119. As the sled contacts the staple
100 upon the sled's distal translation, a feature of the sled can
engage the leading engagement foot 117 to aid in preventing
longitudinal staple roll, or rotation, for example. The engagement
foot 117 can comprise a push point that is configured to be pushed
on to load the staple 100 into a staple cartridge.
[0156] Since the staple 100 is a flat-formed staple, the staple
legs 110, 120, tips 112, 122, and/or other portions of the staple
100 can be further developed, or worked, after being stamped from a
flat, or at least substantially flat, stock. Further developing the
staple 100 can provide specific properties creating and/or altering
preferential bending planes, toughness, and/or elasticity, for
example. Traditional wire-formed staples comprise desirable
properties advantageous for surgical fastening and can be
implemented with the staple 100. Methods for constructing the
corners 114, 124 and/or tips 112, 122, for example, may include any
suitable process including cold working, for example. A specific
process may include coining by working the corners 114, 124 into a
rounded, angled, oblique, and/or parabolic profile, for example.
The staple tips 112, 122 can also be worked using similar methods
to provide an adequate tip configured to pierce tissue and form
against a corresponding forming pocket of the anvil.
[0157] The staple base portion 130 comprises an inclined drive
surface 132, a final drive surface 131, and a distal wall 133. In
various embodiments, the staple 100 is supported in a staple
cartridge by a pan where the final drive surface 131 is configured
to rest on the pan. In various other embodiments where a staple
cartridge is pan-less, the final drive surface does not rest on a
pan, rather, the final drive surface comprises an initial position
residing above a bottom surface of the pan-less staple cartridge.
This would allow a bottom surface of the sled and the bottom
surface of the pan-less staple cartridge to be at least
substantially flush as the sled translates through the cartridge.
The drive surface 132 of each staple base portion 130 is configured
to receive the driving force F.sub.s from the sled of the surgical
stapling instrument. When the sled translates distally through the
staple cartridge, the sled contacts the drive surface 132 to lift
the staple 100 out of the cartridge and, in addition, contact the
final drive surface 131 to form the staple 100 into its fired
configuration.
[0158] The distal wall 133 acts as a distal-most wall of the staple
base portion 130 and is positioned proximal of the distal staple
leg 120 resulting in a lack of any portion of the staple base
portion 130 underneath the distal staple leg 120. Having a greater
amount of mass in the base portion 130 of the staple 100 increases
the ability of the staple 100 to resist rotational motion caused by
the moment M.sub.s applied by the sled. Increasing the moment of
inertia of the staple base portion 130 increases the ability to
resist rotational motion. As a result, a greater torque, or larger
moment, would be required to cause longitudinal staple roll.
[0159] The staple base portion 130 further comprises a top surface,
or compression surface, 136 comprising a proximal surface 139, an
intermediate surface 138, and a distal surface 137. The proximal
surface 139 is angled, or slanted, upward toward the proximal leg
110. The distal surface 137 is angled, or slanted, upward toward
the distal leg 120. The intermediate surface 138 is at least
substantially parallel to the final drive surface 131. This
valley-like configuration limits the stress concentration of tissue
captured near the transition portions 118, 128, 116, 126 where the
legs 110, 120 extend from the staple base portion 130. In various
embodiments, these surfaces 137, 138, 139 can be curved to create a
concave surface. In traditional staples, when formed, the
connections where the legs meet the staple base produce locations
responsible for highly localized tissue stress. This is especially
true in the event that such a traditional staple buckles, or is
crushed, or flattened, rather than formed into a true "B"
configuration.
[0160] In various embodiments, the dynamics of the staple 100 are
predictable when ejected from a staple cartridge. As the staple 100
is ejected from its corresponding staple cavity, a driving force
F.sub.s from the sled generates a moment M.sub.s. One preventive
measure for preventing staple roll includes increasing the moment
of inertia of the staple 100, discussed above, which is configured
to prevent, as illustrated in FIG. 2, longitudinal roll, or
rotation of the staple. In the event that the staple 100 rolls
longitudinally in the distal direction, or, in other words, rotates
counterclockwise about the Y axis, outer, longitudinal staple leg
surfaces 115, 125 of the staple 100 will contact the guide
surfaces, or sidewalls, of the staple cartridge. This contact
produces corresponding reaction forces F.sub.c1 and F.sub.c2. More
particularly, as the staple 100 is driven out of the staple cavity
and rotated about the Y axis, the wall 115 of the proximal staple
leg 110 contacts a proximal sidewall of the staple cartridge
producing a reaction force F.sub.2 which acts upon the staple leg
110 below the center of mass. The wall 125 of the distal staple leg
120 contacts a distal sidewall of the staple cartridge producing a
reaction force F.sub.c1 which acts upon the staple leg 120 above
the center of mass. Both reaction forces, F.sub.c1 and F.sub.c2,
contribute to a reactional moment M.sub.RC to counteract, or
balance, the applied moment M.sub.s acting on the staple 100. The
reaction forces discussed herein may be distributed loads acting
upon a surface area of each of the staple legs 110, 120.
[0161] The moment of inertia of the staple 100 is also configured
to prevent, as illustrated in FIG. 4, lateral roll, or rotation of
the staple 100. The staple base portion 130 comprises a notch 134
defined in the top surface 136 on a side of the staple base portion
130 closest to the legs 110, 120. The notch 134 contributes to the
predictability of the dynamics of the staple 100 before formation
and upon formation when ejected from the staple cartridge. For
example, referring primarily to FIG. 4, the notch 134 is configured
to induce rotation of the staple 100 toward a particular cavity
sidewall. In the event that the staple 100 rolls laterally, or, in
other words, rotates in the direction of the applied moment
M.sub.s, outer, lateral staple leg walls 111, 121 of the staple 100
will contact the guide surfaces, or sidewalls, of the staple
cartridge producing corresponding reaction forces F.sub.c1 and
F.sub.c2. For example, as the staple 100 is driven out of the
staple cavity and rotated in the direction of the applied moment
M.sub.s, the walls 111, 121 of the staple legs 110, 120 contact a
corresponding sidewall of the staple cartridge producing a reaction
force F.sub.c1 which act upon the staple legs 110, 120 above the
center of mass. An outer lateral wall 135 of the staple base
portion 130 contacts another corresponding sidewall of the staple
cartridge producing a reaction force F.sub.c2 which acts upon the
staple base portion 130 below the center of mass. Reaction forces
F.sub.c1 and F.sub.c2 produce a reactional moment M.sub.RC to
counteract, or balance, the applied moment M.sub.s acting on the
staple 100 from the sled. The reaction forces discussed herein may
be distributed loads acting upon a surface area of each of the
staple legs 110, 120 and the staple base portion 130. In various
embodiments, the staple 100 is encouraged to roll laterally in the
direction of the applied moment M.sub.s to control which walls of
the staple cavity are going to be contacted for staple guidance as
the staple 100 is ejected from the staple's 100 corresponding
staple cavity.
[0162] FIGS. 5 and 6 illustrate a wire-formed staple 200 comprising
staple legs 210 and a staple base portion 230. The staple legs 210
are offset and bent at a substantially ninety degree angle from the
staple base portion 230. The staple legs 210 reside in a first
plane which is at least substantially perpendicular to a second
plane defined by the staple base portion 230 and the bend portions
220 of the staple legs 210.
[0163] FIGS. 7-10 illustrate a staple 300 comprising a proximal
staple leg 310, a distal staple leg 320, and a staple base portion,
or crown, 330 having a drive surface 332. The staple legs 310, 320
extend from the staple base portion 330 and each staple leg 310,
320 comprises a laterally outward bend portion and an upward bend
portion. The laterally outward bend portions of the staple legs
bend the staple legs laterally outward with respect to the staple
base portion. The upward bend portions of the staple legs bend the
staple legs vertically with respect to the staple base portion. The
staple 300 comprises a first zone 331 comprising a first hardness,
second zones 311, 321 comprising a second hardness, and third zones
312, 322 comprising a third hardness. Embodiments are envisioned
where the staple 300 comprises more or less zones than depicted.
Varying certain properties, such as the hardness, of different
portions of the staple 300 can provide greater control and
predictability when forming the staple against corresponding
forming pockets such as forming pockets 341 of anvil 340, for
example. The first hardness of the first zone 331 may be greater
than that of the second hardness of the second zones 311, 321. In
many instances, it is desirable to have ductile staple legs 310,
320 capable of permanently changing shape without fracture or, in
other words, having staple legs 310, 320 with a high plasticity,
while having a staple base portion 330 that supports the staple
legs 310, 320 and comprises a hardness greater than the staple legs
310, 320, for example. A greater hardness would increase the staple
base portion's 330 ability to resist deformation upon the
application of an external and/or internal force, such as a force
from the staple legs upon being compressed against the anvil, for
example.
[0164] Metal working different portions of the staples disclosed
herein can comprise several advantages. One of these advantages may
include being able to prevent crushing, or buckling, of the staple
legs during formation and, instead, encourage the staple legs to
deform in a desired configuration as a result of the contact with
the corresponding forming pockets.
[0165] The staple 300 may be formed into any desired formation. In
an unformed configuration, the staple legs 310, 320 define a first
plane P.sub.1 and the staple base portion 330 defines a second
plane P.sub.2. Shown in FIGS. 9 and 10 is an example of a formation
of the staple 300 in which the staple legs 310, 320 are formed
laterally toward the second plane P.sub.2. Variations in hardness
of certain zones and/or portions of the staple 300 can be
responsible for providing directional encouragement when contacting
the forming pockets 341. Embodiments are envisioned where the
staple legs 310, 320 are formed in a direction laterally away from
the second plane P.sub.2.
[0166] FIGS. 11-110 depict a staple 400 comprising staple legs 410
and a staple base portion 430 formed from a flat sheet of material.
The staple base portion 430 comprises a rectangular cross-sectional
profile 431 and the staple legs comprise a round cross-sectional
profile 411. Having round staple legs 410 that extend from a staple
base portion 430 having the rectangular cross-sectional profile 431
can provide a staple base portion and staple legs with no
preferential bending planes. The staple 400 comprises bend portions
420 where the staple legs 410 extend from the staple base portion
430. The bend portions 420 comprise a substantially square
cross-sectional profile 421. The square profile 421 and the
rectangular profile 431 of the bend portions 420 and the staple
base portion 430, respectively, provide a stiff connection and
backbone to the round staple legs 410. The round staple legs 410
eliminate preferential bending planes that staple legs with a
square, rectangular, or any shape with vertices or a non-uniform
shape, cross-sections could have.
[0167] FIG. 12 depicts a staple 500 in accordance with at least one
embodiment comprising a proximal staple leg 510, a distal staple
leg 520, and a staple base portion 530 from which the staple legs
510, 520 extend. The proximal staple leg 510 is bent laterally
outward from the staple base portion 530 in a first direction. The
distal staple leg 520 is bent laterally outward from the staple
base portion in a second direction. The first direction is opposite
the second direction. The staple base portion 530 defines a first
plane and the staple legs 510, 520 define a second plane which
intersects the first plane. One advantage of having the staple legs
510, 520 bent in opposite directions can help prevent lateral roll
by counteracting the applied sled moment on each side of the staple
base portion 530. This results in an S-shaped configuration and
requires complimentary forming pockets.
[0168] A staple 600 is depicted in FIG. 13 comprising a proximal
leg 610, a distal leg 620, and a staple base portion 630 having a
drive surface 632. The distal leg 620 is longer than the proximal
leg 610 resulting in an offset contact timing of the tips 611, 621
of the staple legs 610, 620 against the forming pockets of the
anvil. In various embodiments, the distal leg may comprise a tip
that comprises an initial pre-bent configuration to aid in the
forming process when initially contacting the anvil. This
pre-formed tip 621 would require less compressive force than the
staple tip 611 to begin deformation against the anvil. Having the
longer staple leg, in this case the distal staple leg 620, contact
the anvil before the shorter, or proximal, staple leg, 610 may
require the staple tip 621 of the longer leg 620 to have, to a
certain degree, a pre-formed tip before the tip 611 is
deformed.
[0169] FIG. 14 illustrates an arrangement 700 of formed staples
711, 721. The staples 711 are arranged in a first row 710 and the
staples 721 are arranged in a second row 720 which is adjacent to
the first row 710. The staples 711, 712 may be similar to that of
the staple 600 illustrated in FIG. 13 discussed above. The staples
711 comprise laterally opposing legs 713, 715. The staples 721
comprise laterally opposing legs 723, 725. The laterally opposing
legs 713, 715 each comprise tips configured to contact forming
pockets of an anvil at contact points 713c, 715c, respectively. The
laterally opposing legs 723, 725 also each comprise tips configured
to contact forming pockets of an anvil at contact points 723c,
725c, respectively. The laterally opposing legs 713, 715 each form
inwardly toward the staple base portion from which they extend. The
laterally opposing legs 723, 725 also each form inwardly toward the
staple base portion from which they extend.
[0170] The staple rows 710, 720 are interwoven such that the
contact points 723c, 713c are in substantial alignment. Such an
arrangement allows for a more densely arranged staple row
configuration in a staple cartridge and/or a more densely arranged
forming pocket configuration on an anvil. Also, intersecting
purchase planes may provide for a higher quality purchase and a
larger area of purchase coverage in the tissue. The intersecting
purchase planes may guarantee that anything captured between the
staple rows and the forming pockets is guaranteed to be adequately
fastened. This can help when stapling smaller vessels and/or not
easily visible vessels that, in conventional staple arrangements,
may navigate staple row separations resulting in less than adequate
fastening.
[0171] FIGS. 15-17 depict a staple 800 comprising staple legs 810,
820 and a staple base portion 830 having a drive surface 832. The
staple legs 810, 820 comprise tips 842 configured to contact
forming pockets of an anvil, such as forming pocket 861 of the
anvil 860, for example. The staple tips 842 comprise a piercing
tip, or portion, 842T, a curling surface 842S, and a concave cutout
portion 842C. The piercing tip 842T is configured to pierce the
tissue T upon ejection from the staple cartridge and, once in
contact with the forming pocket 861 of the anvil 860, deform within
the forming pocket 861. Deformation of the staple tip 842 is
encouraged into a certain formation by utilizing the predictable
deformability of the concave cutout portion 842C. The curling
surface 842S of the staple tip 842 is configured to curl, or
deform, from a piercing position 812A, to an intermediate formed
position 812B, and to a non-piercing position 812C. Once the staple
tip 842 has deformed completely, the piercing tip 842T is shielded,
or isolated, from the tissue T by the curling surface 842S. This
prevents further piercing of the tissue T after the tip 842 pierces
the tissue upon ejection. This arrangement also prevents further
injury and/or unwanted irritation that a piercing tip that is
exposed after the initial piercing could possibly inflict.
Preventing further piercing of the tissue T after the legs are
formed also lessens the chance of the staple 800 being pulled
through the tissue T. The curling surface 842S acts as a shield
configured to shield the piercing tip 842T from the tissue T.
[0172] FIG. 18 depicts multiple examples of different types of
staple tips 871, 872, 873, 874, and 875 that can be employed with
any suitable surgical staple such as the staples disclosed herein.
Staple tip 871 comprises a triangular shape with an at least
substantially flat face. Staple tip 872 comprises a face with a
varying contour. Staple tip 873 comprises a rocket-like shape.
Staple tip 874 comprises a nub-like profile. The nub-like profile
may be substantially dull, for example. Staple tip 875 comprises a
pencil-sharpened profile.
[0173] In various embodiments, the staple tips disclosed herein may
comprise a material different than that of the staple to which the
staple tip is connected in order to make deforming in the fashion
desired easier, however, the staple tip material can still be
strong enough to prevent unfolding of the staple tip after
fastening tissue.
[0174] Surgical staples can be encouraged to form into a desired
configuration by changing the shape, size, configuration, and/or
other aspects of the forming pockets configured to form the
staples. FIG. 19 depicts forming pockets 911, 921 configured to
form a staple 900. The staple 900 comprises staple legs 901, 902,
staple tips 910, 920, and a staple base 930, wherein the staples
legs 901, 902 extend from the staple base 930. The staple 900 is
configured to contact and form against the corresponding forming
pockets 911, 921. The forming pocket 911 comprises a forming
channel surface 917 configured to receive a corresponding tip 910
and encourage the tip 910 to form in a direction P1. Shown in FIG.
20, the forming pocket 911 comprises lateral valley-like surfaces
915 and longitudinal valley-like surfaces 913 configured to funnel,
or catch, the tip 910 of the staple in the event of minor
misalignment upon contact. The staple 900, staple leg 901, and/or
staple tip 910 may be driven off target with respect to the forming
channel surface 917 upon ejection from the cartridge. The
valley-like surfaces permit longitudinal and lateral roll of the
staple. Although illustrated as concave surfaces, the valley
surfaces may be convex or flat, for example.
[0175] The forming pocket 921 comprises a forming channel surface
927 configured to receive a corresponding tip 920 of the staple 900
and encourage the tip 920 to form in a direction D1. The direction
D1 is opposite the direction P1 and, as shown in FIG. 19,
illustrates an instance in which the staple legs are formed toward
each other and at least substantially parallel to the staple base
930. Other embodiments are envisioned where the directions D1, P1
direct the corresponding staple legs in opposite directions but
outward with respect to each other. The forming pocket 921 further
comprises lateral valley-like surfaces 925 and longitudinal valley
like surfaces 923 configured to funnel, or catch, the tip 920 of
the staple 900 in the event of minor misalignment upon contact. The
staple 900, staple leg 902, and/or staple tip 920 may be driven off
target with respect to the forming channel surface 927 upon
ejection from the cartridge.
[0176] In various embodiments, the longitudinal valley-like
surfaces may comprise two separate valley surfaces. The two
separate valley surfaces may comprise an initial valley surface
nearest the intended point of contact for the corresponding staple
tip. The initial valley surface may comprise a larger range of
misalignment protection than the other of the separate valley
surfaces. The initial valley surface may comprise a larger width
and/or height than the other of the separate valley surfaces, for
example.
[0177] FIG. 21 depicts another arrangement of the staple pockets
911, 921 discussed above. However, the staple pockets 911, 921 in
the illustrated arrangement are configured to direct the staple
tips inward toward the staple base 130. The leg 901 and tip 910 are
configured to be formed in direction P2. The leg 902 and tip 920
are configured to be formed in direction D2. The directions P2, D2
are transverse. Other embodiments are envisioned where the
directions P2, D2 direct the corresponding staple legs and tips
away from the staple base, or outward.
[0178] FIG. 22 depicts yet another arrangement of the staple
pockets 911, 921 discussed above. The staple pockets 911, 921 in
the illustrated arrangement are configured to form the
corresponding staple legs 901, 902 and tips 910, 920 in opposite
directions where one of the staple legs 902 is directed toward the
staple base 930 and one of the staple legs 901 is directed away
from the staple base 930. The leg 901 and tip 910 are configured to
form in direction P3. The leg 902 and tip 920 are configured to
form in direction D3. The directions P3, D3 are at least
substantially parallel. Other embodiments are envisioned where the
directions P3, D3 are not parallel.
[0179] FIGS. 23 and 24 depict another embodiment of forming pockets
comprising forming pockets 1011, 1021 configured to deform the
staple 900. The forming pockets 1011, 1021 comprise an ear-like
shape providing nested pockets. This type of arrangement can save
space on the staple forming surface of an anvil to allow for more
staple pockets and, as a result, more staples in a staple cartridge
in a lesser amount of space. The forming pocket 1011 comprises a
forming channel surface 1017 configured to receive the
corresponding tip 910 and encourage the tip 910 to form in a curved
direction P4. Shown in FIG. 24, the forming pocket 1011 comprises a
first valley-like, curved surface 1015A and a second valley-like,
curved surface 1015B configured to funnel, or catch, the tip 910 of
the staple in the event of minor misalignment during contact. The
staple 900, staple leg 901, and/or staple tip 910 may be driven off
target with respect to the forming channel surface 917 upon
ejection from its staple cavity. The valley-like surfaces permit
some longitudinal and lateral roll of the staple. Although
illustrated as concave surfaces, the valley surfaces may be convex
or flat, for example.
[0180] The forming pocket 1021 comprises a forming channel surface
1027 configured to receive the corresponding tip 920 of the staple
900 and encourage the tip 920 to form in a direction D4. FIG. 23
illustrates an instance in which the staple legs 901, 902 are
formed toward each other with one staple leg 901 formed away from
the staple base 930 and one staple leg 902 formed toward the staple
base 930. Other embodiments are envisioned where the directions P4,
D4 direct the corresponding staple legs 901, 902 in opposite
directions but outward with respect to each other. The forming
pocket 1021 comprises a first valley-like, curved surface 1025A and
a second valley-like, curved surface 1025B configured to funnel, or
catch, the tip 920 of the staple 900 in the event of minor
misalignment before and/or during contact.
[0181] FIG. 25 depicts yet another embodiment of forming pockets
comprising anvil forming pockets 1111, 1121 configured to deform
corresponding staple legs 901, 902 and tips 910, 920 toward the
staple base 930. The forming pockets 1111, 1121 are trapezoidal in
shape and can be nested with other similar forming pockets using
less space on a forming surface of an anvil. The forming pockets
1111, 1121 are configured to form the staple legs 901, 902 and tips
910, 920 in directions P5, D5, respectively.
[0182] FIG. 26 depicts yet another embodiment of forming pockets
comprising anvil forming pockets 1211, 1221 configured to deform
corresponding staple legs 901, 902 and tips 910, 920 in directions
P6, D6, respectively. The forming pockets 1111, 1121 are triangular
in shape and can be nested with each other comprising an even more
compact forming pocket arrangement on an anvil of a surgical
stapling instrument.
[0183] Referring now to FIGS. 27-27B, a staple leg 1300 is
depicted. The staple leg 1300 comprises a substantially round
staple tip with a substantially square staple leg and a staple leg
body portion 1301. The staple leg 1300 comprises hardened corners
formed using a coining process, for example, where the corners
1303A, 1303B, 1303C, and 1303D were rounded in order to create
preferential bending planes. Stated another way, the staple leg
1300 comprises a cross-sectional profile configured to encourage
the staple leg 1300 to bend in a certain direction due to the
corner hardening upon contact with an anvil. The corners 1303A,
1303B, 1303C, and 1303D may vary in hardness from one corner to the
next, or, may comprise two corners with a first hardness and the
other two corners with a second hardness. The corners 1303A, 1303B,
1303C, and 1303D may be coined to provide different radial profiles
on the same staple leg. For example, the corner 1303A comprises a
radial profile with a radius R.sub.A greater than the radius
R.sub.B of the radial profile of corner 1303B shown in FIG.
27B.
[0184] Portions of the staples disclosed herein may be hardened at
various times of the manufacturing process with any suitable means.
For example, hardening process may include bronzing, chemical vapor
deposition, physical vapor deposition, laser surface treatment,
thermal oxidation, ion nitriding, and/or solid state diffusion, for
example. Other portions of the staples may be prevented from being
hardened by these processes. Other portions of the staples may be
locally annealed, such as the staple tips, for example. Increasing
hardness in certain areas can increase the force required to unform
the staples after the staples have assumed a fired
configuration.
[0185] FIGS. 28-28C depict a staple 1400 and a sled 1460 in
accordance with at least one embodiment. The staple 1400 comprises
staple legs 1410, 1420, a staple base portion 1430 from which the
staple legs 1410, 1420 extend, a drive surface 1432, and a bottom
surface 1431. The staple legs 1410, 1420 extend from the staple
base portion 1430 in a plane which is a parallel and offset with
respect to a plane defined by the staple base portion 1430. The
staple 1400 is made with progressive die stamping utilizing a base
strip 1450 and a connector portion 1451. Although only a single
staple 1400 is shown, a plurality of staples 1400 are attached to
the base strip 1450. The connector portion 1451 connects the staple
1400, specifically the staple base portion 1430, to the base strip
1450. The connector portion 1451 comprises a discontinuity, or
notch, 1453 configured to permit the staples 1400 to detach from
the strip 1450. In at least one instance, the sled 1460 comprises
release portions, or striking portions, 1461. The release portions
1461 of the sled 1460 are configured to engage the discontinuities
1453, or connector portions 1451, to separate, break, and/or shear,
the staples 1400 from the base strip 1450 and permit the staples to
be ejected from their staple cavities by the sled 1460.
[0186] Embodiments are envisioned where the base strip 1450
comprises alignment features such as holes, for example, which
engage corresponding alignment features on a staple cartridge. Such
alignment features may comprise protrusions, for example, that
align with the alignment features of the base strip 1450. In
various instances, a person loading the staples into the cartridge
could align the staples with the staple cavities and/or align the
alignment features before pushing the staples into the staple
cavities. Certain embodiments are envisioned in which the staple
cartridge comprises engagement features configured to engage the
discontinuities 1453 when the strip assemblies are loaded into the
staple cartridge. The engagement features allow the staples 1400 to
be separated from the strip 1450 when the staples 1400 are loaded
into a staple cartridge instead of when the staples 1400 are fired.
Manufacturing staples using progressive die stamping can permit
staples to have different crown sizes, shapes, and/or
configurations as well as staple leg sizes, shapes, and/or
configurations. Another advantage of using progressive die stamping
technology may include the ability to alter the spacing of the rows
of staples in which the staples are aligned.
[0187] FIGS. 29 and 30 depict another embodiment of a strip 1500 of
staples 1501 made with progressive die stamping. The strip 1500 of
staples 1501 comprises a base strip 1550, a connector portion 1551,
and staples 1501. Each staple 1501 comprises, one, a staple base
portion 1530 comprising a bottom surface 1531 and, two, staple legs
1510 extending from the staple base portion 1530. The connector
portion 1551 attaches the bottom surface 1531 of the staple base
portion 1530 to the base strip 1550. The staple legs are bent up
from the staple base portion 1530 such that the legs 1510 reside in
a plane which is offset and at least substantially parallel to a
plane defined by the staple base portion 1530. In the illustrated
embodiment, the staple legs 1510 are bent in a direction opposite
to that of the connector portion 1551. Bending the legs 1510 and
the connector portions 1551 in this manner can permit a more dense
staple row arrangement. The connector portions 1551 can comprise a
discontinuity enabling the staples 1501 to be released from the
base strip 1550 upon loading the staples 1501 into a staple
cartridge and/or firing the staples 1501 from the staple cartridge
as discussed in the previous embodiment.
[0188] FIG. 31 depicts a plurality of staples 1601 and a
cross-sectional view of a portion of a staple cartridge 1650 in
accordance with at least one embodiment. The staples 1601 are
removably stored within corresponding staple cavities 1651 of the
staple cartridge 1650. The staple cartridge 1650 comprises a deck
surface 1653 and staple leg supports 1655. The staples 1601
comprise, one, staple legs 1610 which each comprise a staple tip
1611 and, two, a staple base portion 1630 from which the staple
legs 1610 extend. Each staple 1601 comprises a pre-load
configuration, a loaded configuration, and a fired configuration
where the staple 1601 is ejected from the staple cartridge 1650 and
formed against corresponding forming pockets of an anvil. The
staple legs 1610 are bent outwardly with respect to the staple base
portions 1630 in the pre-load configuration. The staple legs 1610
are biased against sidewalls of the corresponding staple cavity
1651 in the loaded configuration and define a first distance X
between the tips 1611 of the staple legs 1610. In the pre-load
configuration, the distance between the staple tips 1611 of the
staple legs 1610 is greater than X. This biasing force helps
support the staples 1601 in the staple cartridge 1650.
[0189] A staple cartridge 2000 is illustrated in FIGS. 32-34. The
staple cartridge assembly 2000 comprises a cartridge body 2010. The
cartridge body 2010 is positionable in and removable from a jaw of
a surgical stapling instrument. As a result, the staple cartridge
2000 is replaceable; however, other embodiments are envisioned in
which the staple cartridge 2000 is not replaceable. The cartridge
body 2010 comprises a proximal end 2011, a distal end 2012, and a
deck 2014 extending between the proximal end 2011 and the distal
end 2012. The deck 2014 is configured to support the tissue of a
patient when the tissue is compressed against the deck 2014.
[0190] The cartridge body 2010 further comprises a plurality of
staple cavities 2020 defined therein. The staple cavities 2020 are
arranged in six longitudinal rows extending between the proximal
end 2011 and the distal end 2012; however, any suitable arrangement
of staple cavities 2020 can be utilized. A staple, such as staple
2130 (FIG. 40), for example, is removably stored in each staple
cavity 2020. As discussed in greater detail below, the staples are
ejected from the staple cavities 2020 by a firing member when the
firing member is moved from the proximal end 2011 of the cartridge
body 2010 toward the distal end 2012.
[0191] Further to the above, the staples are moved from an unfired
position to a fired position by the firing member. The firing
member lifts the staples toward an anvil, such as anvil 2190 (FIG.
37), for example, to deform the staples between an unfired,
undeformed configuration and a fired, deformed configuration. The
cartridge body 2010 further comprises a longitudinal slot 2013
defined therein. The slot 2013 is configured to receive the staple
firing member and/or a tissue cutting member therein when the
staples are ejected from the staple cavities 2020.
[0192] In various embodiments, further to the above, the staples do
not protrude above the deck 2014 until they are moved toward the
anvil by the firing member. Such embodiments may frequently utilize
small staples. In other embodiments, the legs of the staples
protrude above the deck 2014 when the staples are in their unfired
positions. In at least one such embodiment, the cartridge body 2010
further comprises projections 2050 extending from the deck 2014.
The projections 2050 extend the staple cavities 2020 above the deck
2014 and guide the staples toward the anvil when the staples are
being ejected from the staple cartridge 2000. In such embodiments,
the staples may not extend above the projections 2050 until they
are moved toward the anvil by the firing member.
[0193] Referring primarily to FIG. 34, the projections 2050 do not
extend around the entirety of the staple cavities 2020. A first
projection 2050 is positioned adjacent a first end of each cavity
2020 and a second projection 2050 is positioned adjacent a second
end of each cavity 2020. Each first projection 2050 extends around
a first staple leg guide 2022 of a staple cavity 2020 and each
second projection 2050 extends around a second staple leg guide
2023 of the staple cavity 2020. Each first projection 2050 provides
a proximal bracket which can control and guide the proximal leg of
a staple and each second projection 2050 provides a distal bracket
which can control and guide the distal leg of the staple. The first
projection 2050 of each staple cavity 2020 is not symmetrical with
respect to the first end of the staple cavity 2020 and does not
extend around the entirety of the first end of the cavity 2020.
Similarly, the second projection 2050 of each staple cavity 2020 is
not symmetrical with respect to the second end of the staple cavity
2020 and does not extend around the entirety of the second end of
the cavity 2020. The first projection 2050 and the second
projection 2050 comprise mirror images of one another and are
symmetrically arranged with respect to the center of each staple
cavity 2020; however, any suitable arrangement of projections could
be utilized.
[0194] As illustrated in FIGS. 32-34, the cartridge body 2010
comprises steps 2014' and steps 2014'' which extend upwardly from
the deck 2014. More specifically, the steps 2014' extend upwardly
from the deck 2014 and the steps 2014'' extend upwardly from the
steps 2014'. As a result, the steps 2014'' may apply a larger
compressive pressure to the tissue than the steps 2014' and,
similarly, the steps 2014' may apply a larger compressive pressure
to the tissue than the deck 2014. The steps 2014' and 2014''
comprise staggered longitudinal plateaus; however, the steps 2014'
and 2014'' may comprise any suitable configuration. Moreover,
further to the above, the projections 2050 extending from the steps
2014'' extend above the projections 2050 extending from the steps
2014' and, similarly, the projections 2050 extending from the steps
2014' extend above the projections 2050 extending from the deck
2014. Stated another way, the projections 2050 extending from the
deck 2014, the steps 2014', and the steps 2014'' are staggered.
[0195] A staple cartridge 2100 is illustrated in FIGS. 35-38. The
staple cartridge assembly 2100 comprises a cartridge body 2110 and
is similar to the staple cartridge assembly 2000 and/or the other
staple cartridges disclosed herein in many respects. The cartridge
body 2110 comprises a deck 2114, a plurality of staple cavities
2120a, and a plurality of staple cavities 2120b. The staple
cavities 2120a are similar to the staple cavities 2120b in many
respects. For instance, the staple cavities 2120a and 2120b both
comprise a central slot 2121 having a proximal end and a distal
end, a proximal staple leg guide 2122 extending laterally from the
proximal end of the central slot 2121, and a distal staple leg
guide 2123 extending laterally from the distal end of the central
slot 2121. That said, the staple cavities 2120a and the staple
cavities 2120b are oriented in different directions. More
particularly, the staple leg guides 2122, 2123 of the staple
cavities 2120a extend toward the staple cavities 2120b and,
similarly, the staple leg guides 2122, 2123 of the staple cavities
2120b extend toward the staple cavities 2120a; however, any
suitable arrangement can be utilized.
[0196] A staple 2130a is positioned in each staple cavity 2120a and
a staple 2130b is positioned in each staple cavity 2120b. The
staples 2130a and the staples 2130b are similar in many respects.
For instance, each staple 2130a comprises a base, or crown, 2131, a
proximal leg 2132 extending from a proximal end of the base 2131,
and a distal leg 2133 extending from a distal end of the base 2131.
That said, the staples 2130a, 2130b are adapted in a manner to fit
within the staple cavities 2120a, 2120b, respectively. For example,
when the staples 2130a are positioned in the staple cavities 2120a
and the staples 2130b are positioned in the staple cavities 2120b,
the legs 2132, 2133 of the staples 2130a extend toward the staples
2130b and the legs 2132, 2133 of the staples 2130b extend toward
the staples 2130a; however, other arrangements are possible.
[0197] Further to the above, the proximal legs 2132 of the staples
2130a, 2130b are positioned within the staple leg guides 2122 when
the staples 2130a, 2130b are stored in the staple cavities 2120a,
2120b, respectively. Similarly, the distal legs 2133 of the staples
2130a, 2130b are positioned within the staple leg guides 2123 when
the staples 2130a, 2130b are stored in the staple cavities 2120a,
2120b, respectively. Moreover, the bases 2131 of the staples 2130a,
2130b are positioned in the central slots 2121 of the staple
cavities 2120 when he staples 2130a, 2130b are stored in the staple
cavities 2120a, 2120b, respectively. Referring primarily to FIG.
35, the tips of the staple legs 2132, 2133 extend above the deck
2114 of the cartridge body 2110 when the staples 2130a, 2130b are
in their unfired positions. That said, the tips of the staple legs
2132 are at least partially surrounded by proximal projections 2152
extending from the deck 2114 and the tips of the staple legs 2133
are at least partially surrounded by distal projections 2153
extending from the deck 2114. The proximal projections 2152 extend
around the proximal staple leg guides 2122, but they do not extend
around the proximal ends of the central slots 2121. Similarly, the
distal projections 2153 extend around the distal staple leg guides
2123, but they do not extend around the distal ends of the central
slots 2121.
[0198] Turning now to FIG. 38, each proximal projection 2152
comprises a first portion 2154 which extends around a proximal side
of the proximal guide slot 2122 and a second portion 2155 which
extends around a lateral side of the proximal guide slot 2122. The
proximal projection 2152 does not extend around a distal side of
the proximal guide slot 2122; however, it is envisioned that the
proximal projection 2152 can extend around the distal side of the
proximal guide slot in alternative embodiments. Similarly, each
distal projection 2153 comprises a first portion which extends
around a distal side of the distal guide slot 2123 and a second
portion which extends around a lateral side of the distal guide
slot 2123. The distal projection 2153 does not extend around a
proximal side of the distal guide slot 2123; however, it is
envisioned that the distal projection 2153 can extend around the
proximal side of the distal guide slot in alternative embodiments.
In any event, the arrangement depicted in FIG. 38 protects the
staple legs 2132, 2133 when the staples 2130a, 2130b are in their
unfired positions and, in addition, guide the staples 2130a, 2130b
as the staples are being fired. Such an arrangement also
appropriately controls the flow of tissue relative to the deck 2114
of the cartridge body 2110.
[0199] Referring again to FIG. 38, the staple cavities 2120a and
the staples 2130a are sized and configured such that clearance gaps
are provided between the staples 2130a and the staple cavities
2120a. For example, a clearance gap 2156 is present between the
proximal leg 2132 of a staple 2130b and the proximal sidewall of
the proximal guide slot 2122 and, similarly, a clearance gap 2158
is present between the proximal leg 2132 of the staple 2130b and
the distal sidewall of the proximal guide slot 2122. In addition, a
clearance gap 2157 is present between the lateral side of the
proximal leg 2132 and the lateral sidewall of the proximal guide
slot 2122. Similar gaps can be found between the distal leg 2133
and the distal guide slot 2123. Lateral clearance gaps 2126, 2127
can also be provided between the base 2131 of the staple 2130b and
the lateral sides of the central slot 2121. Such clearance gaps may
be transient and the staple may contact one or more of the
sidewalls nonetheless.
[0200] A staple cartridge 2200 is illustrated in FIG. 43. The
staple cartridge 2200 is similar to the staple cartridges 2000,
2100 and the other staple cartridges disclosed herein in many
respects. The staple cartridge 2200 comprises a cartridge body 2210
including staple cavities 2220 defined therein. Each of the staple
cavities 2220 has a staple, such as staple 2130, for example,
removably stored therein. Each staple cavity 2220 comprises a first
guide slot 2222 configured to guide the leg 2132 of the staple
2130, a second guide slot 2223 configured to guide the leg 2133 of
the staple 2130, and a central slot 2221. The guide slots 2222 and
2223 extend laterally from the central slot 2221 and the central
slot 2221 includes an intermediate guide 2225 configured to guide
the base 2131 of the staple 2130. The first guide slot 2222 is
sized and configured such that the staple leg 2132 is closely
received in a corner of the first guide slot 2222. Similarly, the
second guide slot 2223 is sized and configured such that the staple
leg 2133 is closely received in a corner of the second guide slot
2223. The intermediate guide 2225 is sized and configured to limit
the lateral movement of the staple 2130 within the staple cavity
2220. Moreover, the intermediate guide 2225 is sized and configured
to hold the staple legs 2132 and 2133 in the staple leg guide slots
2222 and 2223, respectively.
[0201] As discussed above, the intermediate guide 2225 is sized and
configured to hold the staple legs 2132 and 2133 against the
sidewalls of the guide slots 2222 and 2223, respectively. Such an
arrangement creates lateral reaction forces, indicated as force
vectors LT in FIG. 43, between the lateral sidewalls of the cavity
2220 and the staple 2130. Such lateral reaction forces generate
friction forces between the sidewalls of the cavity 2220 and the
staple 2130 when the staple 2130 is ejected from the cavity 2220.
It should be understood that friction forces are a function of the
surface area in which they are applied and, as such, the
intermediate guide 2225 does not extend along the entire length of
the central slot 2221. That said, the intermediate guide 2225 has a
longitudinal length which is sufficient to control the orientation
of the staple 2130 within the cavity 2220. Moreover, the
intermediate guide 2225 has a sufficient vertical length sufficient
to control the orientation of the staple 2130 during the firing
stroke of the staple 2130. In at least one instance, the guide 2225
extends along the entire vertical depth of the cavity 2220.
[0202] The intermediate guide 2225 is flat and is configured to
interface with a flat surface defined on the lateral side of the
base 2131 of the staple 2130; however, any suitable arrangement
could be utilized. In certain alternative embodiments, the
intermediate guide 2225 comprises a resilient biasing member
configured to apply a lateral biasing force to the base 2131 of the
staple 2130, for example. In at least one instance, the resilient
biasing member could comprise a cantilever spring, for example.
[0203] The staple cavity 2220 does not include a lateral guide
positioned opposite the lateral intermediate guide 2225. In fact, a
clearance gap 2229 is present between a lateral sidewall 2228 and
the staple 2130.
[0204] Further to the above, referring again to FIG. 43, the staple
2130 is not positioned in the ends of the central slot 2221. More
particularly, the central slot 2221 of the cavity 2220 comprises a
proximal end 2226 and a distal end 2227 and the staple 2130 does
not extend into either the proximal end 2226 or the distal end
2227. Rather, clearance gaps are present between the ends 2226,
2227 and the staple 2130. Such clearance gaps extend between the
ends 2226, 2227 and the intermediate guide 2225. As a result, the
ends 2226, 2227 of the staple cavity 2220 do not control the
longitudinal position of the staple 2130. Instead, the staple leg
guides 2222, 2223 control the longitudinal position of the staple
2130. In fact, the legs 2132 and 2133 of the staple 2130 can be
biased inwardly by the staple leg guides 2222 and 2223,
respectively. Such an arrangement creates longitudinal reaction
forces, indicated as force vectors LG in FIG. 43.
[0205] As a result of the above, the staple cavity 2220 comprises
three control points, or positions, in which the staple cavity 2220
controls the orientation of the staple 2130. These control points
comprise discrete control positions with clearance gaps defined
therebetween. Stated another way, the guides 2222, 2223, and 2225
triangulate the control of the staple 2130. Alternative embodiments
are envisioned which comprise more than three control points. In
any event, the control points provided by the staple leg guides
2222 and 2223 are defined in a first control plane. An intermediate
control point provided by the intermediate guide 2225 is defined in
a second control plane. The first control plane and the second
control plane are parallel; however, alternative embodiments are
envisioned in which the first control plane and the second control
plane are not parallel. Moreover, the first control plane is
aligned with, or adjacent to, the staple legs 2132 and 2133 of the
staple 2130 and the second control plane is aligned with, or
adjacent to, the base 2131 of the staple 2130.
[0206] A staple cartridge 2700 is illustrated in FIG. 65. The
staple cartridge 2700 comprises a cartridge body 2710 which
includes a deck 2714 and a plurality of staple cavities 2220
defined in the deck 2714. Similar to the cartridge body 2110, the
cartridge body 2710 includes projections 2752 and 2753 which extend
above the deck 2714. The projections 2752 at least partially
surround the staple leg guides 2222 of the staple cavities 2220 and
the projections 2753 at least partially surround the staple leg
guides 2223 of the staple cavities 2220. Similar to projections
2152, 2153, the projections 2752, 2753 each include an outside
portion 2754 and a lateral portion 2755. The outside portions 2754
are positioned longitudinally with respect to the staple leg guides
2222 and 2223 while the lateral portions 2755 are positioned
laterally with respect to the staple leg guides 2222 and 2223.
Unlike the projections 2152, 2153, the projections 2752, 2753 each
include an inner portion 2756 which are positioned longitudinally
with respect to the staple leg guides 2222 and 2223. The inner
portions 2756 are connected to the lateral portions 2755 and the
lateral portions 2755 are connected to the outside portions 2754.
Similar to the above, the projections 2752, 2753 extend the staple
cavities 2220 above the deck 2714.
[0207] A staple cartridge 2800 is illustrated in FIG. 66. The
staple cartridge 2800 comprises a cartridge body 2810 which
includes a deck 2814 and a plurality of staple cavities 2220
defined in the deck 2814. Similar to the cartridge body 2110, the
cartridge body 2810 includes projections 2152, 2153 which extend
above the deck 2114. As outlined above, the projections 2152 at
least partially surround the staple leg guides 2222 of the staple
cavities 2220 and the projections 2753 at least partially surround
the staple leg guides 2223 of the staple cavities 2220. Moreover,
the cartridge body 2810 includes inner projections 2856 which are
positioned longitudinally with respect to the staple leg guides
2222 and 2223. The inner projections 2856 are not connected to the
projections 2152, 2153.
[0208] Referring again to FIG. 35, the staples 2130 are driven
between unfired positions and fired positions by a firing member,
such as sled 2140, for example. The sled 2140 comprises wedges 2145
which are configured to directly engage the staples 2130 and lift
the staples 2130 toward an anvil, such as anvil 2190, for example,
as illustrated in FIG. 37. The sled 2140 comprises a wedge 2145 for
each longitudinal row of staples 2130; however, the sled 2140 may
have any suitable number of wedges 2145. Each wedge 2145 comprises
an angled drive surface 2141 which slides under the staples 2130 as
the sled 2140 is advanced from the proximal end of the staple
cartridge 2100 toward the distal end of the staple cartridge 2100.
The base 2131 of each staple 2130 comprises an angled drive surface
2135 which is directly contacted by a drive surface 2141. Stated
another way, each staple 2130 comprises its own integrally-formed
driver having a drive surface 2135. The staples 2130 are comprised
of metal and, as a result, the integrally-formed driver is also
comprised of metal. That said, the staples disclosed herein can be
comprised of any suitable material.
[0209] Further to the above, each drive surface 2141 comprises an
initial, or distal, portion 2142, a second, or intermediate,
portion 2143, and a third, or apex, portion 2144. The initial
portion 2142 extends at a first angle and provides an initial
contact point for the sled 2140 against a staple 2130 as the sled
2140 is moved distally. As the initial portion 2142 slides under
the staple 2130, the staple 2130 is lifted upwardly within the
staple cavity 2120. As the sled 2140 continues to move distally,
the intermediate portion 2143 comes into contact with the staple
2130. The intermediate portion 2143 extends at a second angle which
is different than the first angle. The first angle can be steeper
than the second angle when it is desirable for there to be a quick
initial upward displacement of the staple 2130 whereas the first
angle can be shallower than the second angle when it is desirable
to a provide a gradual initial upward displacement of the staple
2130. In either event, the staple 2130 contacts the anvil 2190
while the staple 2130 is being lifted upwardly by the intermediate
portion 2143, as illustrated in FIG. 37; however, alternative
embodiments are envisioned in which the staple 2130 contacts the
anvil 2190 when the staple 2130 is being lifted upwardly by the
initial portion 2142. In either event, the proximal leg 2132 of the
staple 2130 contacts a proximal forming pocket 2192 defined in the
anvil 2190 and the distal leg 2133 contacts a distal forming pocket
2193 defined in the anvil 2190. The forming pockets 2192 and 2193
are configured to bend the legs 2132 and 2133 inwardly to deform
the staple 2130 and capture the tissue of a patient within the
staple 2130. The apex 2144 of the drive surface 2141 slides under
the staple 2130 to finish the forming process. The apex 2144 can
comprise a peak of the drive surface 2141, a flat surface, and/or a
surface which extends at a third angle which is different than the
first angle and/or the second angle.
[0210] In various instances, each drive surface 2141 can comprise a
portion which trails, or is positioned proximal to, the apex 2144
of the drive surface 2141. Such a trailing portion can be lower
than the apex 2144, for example. Moreover, such a trailing portion
can provide for a gradual decrease in forming pressure in the
staples 2130, for example.
[0211] Turning now to FIG. 39, the staple 2130 further includes a
foot 2134 which extends downwardly from the proximal leg 2132. When
the staple 2130 is in its proper orientation in its staple cavity
2120, as illustrated in FIG. 41, the foot 2134 is not contacted by
the sled 2140. In such instances, an alignment plateau 2146 of the
sled 2140 passes under the foot 2134. When the staple 2130 is not
in its proper orientation in its staple cavity 2120, as illustrated
in FIG. 42, the sled 2140 can contact the staple 2130 and re-orient
the staple 2130. For the purpose of comparison, an improperly
oriented staple 2130 and a properly oriented staple 2130' are both
illustrated in FIG. 42. The sled 2140 comprises an angled alignment
ramp 2148 which is configured to contact the foot 2134 and rotate
the staple 2130 into is proper orientation. After the alignment
ramp 2148 has properly oriented the staple 2130, the alignment
plateau 2146 can slide underneath the foot 2134. As can be
appreciated from FIG. 39, the alignment ramp 2148, the alignment
plateau 2146, and the foot 2134 are arranged in an alignment plane
which is aligned with the forming plane of the legs 2132 and 2133
of the staple 2130. The alignment plane is adjacent to a lifting
plane which includes the forming surface 2141 of the sled 2140 and
the base 2131 of the staple 2130.
[0212] A staple cartridge assembly 2300 is illustrated in FIGS.
44-48. The staple cartridge assembly 2300 is similar to the staple
cartridge 2000, 2100, 2200, and the other staple cartridges
disclosed herein in many respects. The staple cartridge 2300
comprises a cartridge body 2310 and sleds 2340 which are configured
to eject staples removably stored in the cartridge body 2310.
Similar to sled 2140, sleds 2340 comprise staple forming ramps
2145. The ramps 2145 are slidably positioned in longitudinal slots
2115 defined in the cartridge body 2110 which are aligned with the
lifting portions, or planes, of the staples. Notably, as discussed
in greater detail below, the slots 2115 have an open end defined in
the bottom 2316 of the cartridge body 2310.
[0213] Further to the above, the staple cartridge assembly 2300
does not include a cover extending around the bottom 2316 of the
cartridge body 2310. Referring primarily to FIG. 48, the cartridge
body 2310 is directly positioned against the jaw 2180 of the
stapling instrument. In embodiments where a staple cartridge is not
readily removable from the jaw of a stapling instrument and not
readily replaceable with another staple cartridge, the absence of a
bottom cover is not necessarily problematic as the jaw 2180 can
prevent the staples from falling out of the bottom of the staple
cavities 2120 and/or the sleds 2340 from falling out of the bottom
of the longitudinal slots 2115. The staple cartridge assembly 2300
is, however, replaceable and, even though it does not include a
bottom cover, the staple cartridge assembly 2300 includes features
which keep the staples and the sleds 2340 from falling out of the
bottom 2316 of the cartridge body 2310, which are described in
greater detail further below. Such features could be adapted to any
of the staple cartridges disclosed herein.
[0214] Referring primarily to FIGS. 45-47, the cartridge body 2310
includes retention features configured to hold the sleds 2340
therein. For example, the cartridge body 2310 includes proximal
retention features 2317 which are configured to hold the sleds 2340
in the longitudinal slots 2115 when the sleds 2340 are in their
proximal, or unfired, positions. The sleds 2340 are in their
unfired positions when the staple cartridge assembly 2300 is
inserted, or loaded, into the jaw 2180 and, as a result, the
proximal retention features 2317 retain the sleds 2340 in the
cartridge body 2310 when the cartridge assembly 2300 is being
handled by a clinician. Each retention feature 2317 includes an
angled surface 2318 and a shoulder 2319. Each sled 2340 includes a
corresponding recess 2348 configured to receive an angled surface
2318 and, in addition, a corresponding shoulder 2349 which can be
aligned with and/or contact a shoulder 2319 of the retention
feature 2317. When the sleds 2340 are inserted into the slots 2115,
referring to FIG. 46, the ramps 2145 and/or the sidewalls of the
cartridge 2310 can flex to permit the sleds 2340 to slide relative
to the angled surfaces and then resiliently snap back to their
original positions once the shoulders 2349 of the sleds 2340 have
become aligned with the shoulders 2319 of the cartridge body 2310,
as illustrated in FIG. 45. The retention features 2317 are also
configured to prevent the sleds 2340 from sliding proximally out of
the longitudinal slots 2115.
[0215] As a result of the above, the proximal retention features
2317 prevent the sleds 2340 from falling out of the cartridge body
2310 when a clinician is handling the staple cartridge assembly
2300. When the sleds 2340 are advanced distally to fire the
staples, the sleds 2340 are no longer aligned with the proximal
retention features 2317. At such point, however, the staple
cartridge assembly 2300 is already in the jaw 2180 and sled
retention features are no longer needed. That said, the cartridge
body 2310 can include additional retention features which can hold
the sleds 2340 in the cartridge body 2310 regardless of the
position of the sleds 2340. Such retention features could be
configured to hold the sleds 2340 in the cartridge body 2310 when
the sleds 2340 are in their distal, or fully fired, positions, for
example.
[0216] Further to the above, the staples of the staple cartridges
disclosed herein can include one or more features configured to
hold the staples in the staple cavities of the staple cartridge.
Turning now to FIGS. 49 and 50, a staple 2330 includes a base 2331
and one or more staple legs 2332 extending from the base 2331. The
staple 2330 is removably stored in a staple cavity 2320 in the
cartridge body 2310, for example. The base 2331 comprises a
protrusion 2338 extending therefrom which is engaged with a
sidewall of the staple cavity 2320. The interaction between the
protrusion 2338 and the staple cavity sidewall keeps the staple
2330 from falling out of the bottom 2316 of the cartridge body
2310. The interaction between the protrusion 2338 and the staple
cavity sidewall comprises an interference fit; however, such an
interference fit does not prevent the sleds 2340 from ejecting the
staples 2330 from the staple cavities 2320. The protrusion 2338 can
be formed in the base 2331 during a stamping process, for example.
The stamping process can form the protrusion 2338 by creating a
dent 2337 in the opposite side of the base 2331. The staple cavity
2320 includes a vertical groove 2328 which is aligned with the
protrusion 2338. The groove 2328 increases the contact area between
the sidewall of the staple cavity 2320 and the protrusion 2338. In
addition, the groove 2328 can control the orientation of the staple
2330 within the staple cavity 2320. Alternative embodiments are
envisioned which do not comprise the groove 2328.
[0217] In addition to or in lieu of the above, the staples stored
in the staple cartridges disclosed herein can include staple legs
which are resiliently engaged with the sidewalls of their staple
cavities. Turning now to FIG. 51, a staple 2430 can include a base
2431 and staple legs 2432 and 2433 extending from the base 2431.
The staples 2430 are similar to the staples 2130, 2330, and/or the
other staples disclosed herein in many respects. A staple cartridge
body 2410, for example, can include a plurality of staple cavities
2120 defined therein and a staple 2430 positioned in each staple
cavity 2120. FIG. 51 depicts a staple 2430 positioned inside a
cavity 2120 and a staple 2430 positioned outside a staple cavity
2120 of the cartridge body 2430. When the staples 2430 are not
positioned in the staple cavities 2120, the staple legs 2432, 2433
do not extend in parallel directions; rather, they extend outwardly
away from each other. When the staples 2430 are positioned in the
staple cavities 2120, they are flexed inwardly by the sidewalls of
the staple cavities 2120. Stated another way, the staple legs 2432,
2433 are resiliently biased against the sidewalls of the staple
cavities and, owing to this biased engagement, the staples 2430 are
inhibited from falling out of the bottom 2436 of the cartridge body
2410. As illustrated in FIG. 51, the distance between the staple
legs 2432, 2433 when the staples 2130 are positioned in the staple
cavities 2120 is X while the distance between the staple legs 2432,
2433 when the staples 2130 are not positioned in the staple
cavities is larger than X.
[0218] In various embodiments, a cartridge body can include one or
more shoulders which are configured to keep the staples stored
therein from falling out of the bottom of the cartridge body. The
shoulders can at least partially extend underneath the staples.
[0219] In certain embodiments, the cartridge body of a staple
cartridge assembly can be comprised of plastic and can be formed
during an injection molding process, for example. The injection
mold can include two halves which are movable toward and away from
each other. The interface between the injection mold halves is
often called a parting line and it is frequent that flashing, or
seepage of the plastic between the mold halves, can occur at the
parting line. In at least one embodiment, the parting line of an
injection mold can be defined at the interfaces between the deck of
the staple cartridge and the staple cavities defined in the deck.
As a result of the above, plastic flashing can occur around the
perimeter of the staple cavities. Such flashing can releasably hold
the staples in the staple cartridge.
[0220] Referring again to FIG. 48, the cartridge body 2310 is
configured to directly engage the jaw 2180. The jaw 2180 comprises
one or more retention shoulders 2315 defined therein. The cartridge
body 2310 comprises corresponding retention shoulders 2187 which
co-operate with the retention shoulders 2315 to releasably retain
the cartridge body 2310 in the jaw 2180. The cartridge body 2310
and/or the jaw 2180 further comprise ramp surfaces 2314 which are
configured to facilitate the insertion of the cartridge body 2310
into the jaw 2180. As a result of the above, the cartridge body
2310 can have a snap-fit relationship with the jaw 2180. The
snap-fit relationship can be overcome by prying the cartridge body
2310 out of the jaw 2180 such that the staple cartridge assembly
2300 can be replaced.
[0221] A staple 2530 is illustrated in FIGS. 52-56. The staple 2530
is similar to the staples 2130, 2330, 2340, and/or the other
staples disclosed herein in many respects. The staple 2530
comprises a base 2531 and legs 2532 and 2533 extending from the
base 2531. The staple 2530 also includes a projection 2538
extending upwardly from the base 2531. The projection 2538 is
aligned with the staple driving plane which includes the base 2531
and is not aligned with tissue capture plane including the staple
legs 2532 and 2533. The projections 2538 can compress the tissue
outside of the staple capture plane.
[0222] A staple cartridge assembly 2600 is illustrated in FIGS.
57-64. The staple cartridge 2600 comprises a cartridge body 2610
including a plurality of staple cavities 2220 defined therein. The
staple cartridge 2600 further comprises a staple 2530 positioned in
each staple cavity 2220 and sleds 2640 configured to eject the
staples 2530 from the staple cavities 2220. The sleds 2640 are
similar to the sleds 2140 in many respects. Each sled 2640
comprises a plurality of ramps 2645 wherein each ramp 2645
comprises a drive surface 2641 configured to slide under the
staples 2530 and lift the staples 2530 within the staple cavities
2220. Each drive surface 2641 includes an inclined surface 2643
bounded by lateral sidewalls 2649 which define a guide channel that
aligns the staples 2530 with respect to the drive surfaces 2641
and/or the staple cavities 2220. The guide channel is configured to
receive the bases 2531 of the staples 2530 between the sidewalls
2649 and orient the staples 2530 laterally as the sled 2640 is
advanced distally. Such lateral re-alignment is apparent upon
comparing FIGS. 58 and 59. Referring again to FIGS. 52-56, each
staple 2530 comprises a guide feature 2139 defined on the bases
2531 thereof. The guide feature 2139 of each staple 2530 comprises
a curved end, for example, which is configured to interact with the
lateral sidewalls 2649 of the guide channels and adjust the lateral
position of the staples 2530. In various other embodiments, the
guide features 2139 can comprise any suitable configuration.
[0223] In addition to or in lieu of the above, referring primarily
to FIG. 60, the sleds 2640 comprise guide channels 2646 which are
configured to receive the downwardly depending feet 2134 of the
staples 2530 and orient the staples 2530 with respect to the drive
surfaces 2641 and/or the staple cavities 2220. Each guide channel
2646 comprises a ramp portion 2648 and lateral sidewalls. The guide
channels 2646 are configured to receive the bases 2531 of the
staples 2530 between the sidewalls of the channels 2646 and orient
the staples 2530 laterally as the sled 2640 is advanced distally.
Referring primarily to FIG. 61, each foot 2134 comprises lead-in,
or beveled, surfaces 2137 which are configured to interact with the
sidewalls of the channels 2646 to guide the staples 2530 into the
channels 2646. That said, the feet 2134 can comprise any suitable
geometry which facilitates the entry of the staples 2530 into the
channels 2646. The reader should appreciate that, as the staples
2530 are driven upwardly within the staple cavities 2220 by the
drive surfaces 2641, the feet 2134 of the staples 2530 lift out of
the channels 2646. By the time that the staples 2530 are being
formed by the apexes 2644 of the drive surfaces 2641, the feet 2134
are no longer positioned in the channels 2646.
[0224] Referring primarily to FIGS. 58, 59, and 64, the channels
2646 can also align the sleds 2640 with respect to the cartridge
body 2610. More particularly, the cartridge body 2610 further
comprises longitudinal rails 2616 extending downwardly into the
channels 2646. The rails 2616 are closely received in the channels
2646 to limit or prevent lateral movement between the sleds 2640
and the cartridge body 2610 while permit the longitudinal movement
of the sleds 2640 needed to fire the staples 2530 as outlined
above. The foot 2134 of each staple 2530 is configured to properly
orient the staple 2530 within its staple cavity 2220 in the event
that the staple 2530 is misoriented within the staple cavity
2220.
[0225] The arrangements disclosed herein allow for a staple
cartridge to be more compact than previous staple cartridges. Among
other things, the staple cartridges disclosed herein that do not
utilize staple drivers between the firing member and the staples,
i.e., driverless staple cartridges, allow the staple cartridges to
have a shorter overall height. Similarly, the staple cartridges
that do not include a bottom cover also allow the staple cartridges
to have a shorter overall height. Driverless staple cartridges can
also allow smaller staple cavities to be utilized. Turning now to
FIGS. 67 and 68, a cartridge body 2910 includes staple cavities
2920 and a longitudinal slot 2013 defined therein. FIGS. 67 and 68
show the bottom 2916 of the cartridge body 2910 and the bottom
openings of the staple cavities 2920. The reader should appreciate
that the staple cavities 2920 are sized and configured to receive
staple drivers for driving the staples out of the cartridge body
2910. Turning now to FIGS. 69 and 70 which depicts the bottom 2016
of the cartridge body 2010, the staple cavities 2020 of the
cartridge body 2010 are smaller than the staple cavities 2920. As
the reader will recall, drivers are not positioned in the staple
cavities 2020 and, as a result, the size of the staple cavities
2020 can be reduced. FIG. 71 compares the bottom 2916 of the
cartridge body 2910 to the bottom 3016 of an alternative embodiment
of a cartridge body 3010. As can be seen in FIG. 71, the cartridge
body 3010 includes longitudinal rows of staple cavities 3020 which
are much narrower than the longitudinal rows of staple cavities
2920. In various instances, such narrower staple cavities can
permit the center lines of the longitudinal rows of staple cavities
to be closer to one another. Turning now to FIG. 72, a staple
cartridge body 3110 includes longitudinal rows of staple cavities
3120a, 3120b, and 3120c defined in a deck 3114 of the cartridge
body 3110 which are positioned closer together than would be
permitted in embodiments which use staple drivers to lift the
staples within the cartridge body.
[0226] The various embodiments of the staple cartridge assemblies
disclosed herein can have any suitable number of staples and/or any
suitable size of staples. In certain instances, all of the staples
stored in the staple cartridge assembly 2000 (FIG. 73) have the
same, or at least substantially the same, size. Referring to FIG.
77, each staple 2130 in the staple cartridge 2000 comprises an
unformed, or unfired, overall height H1 defined between the bottom
of the base 2131 and the tips of the staple legs 2132, 2133.
Similarly, each staple 2130 comprises a tissue capture area defined
between the top of the base 2131 and the tips of the staple legs
2132, 2133 which has the same height H2 when the staples 2130 are
in their unformed height.
[0227] In contrast to the above, a first group of staples stored in
the staple cartridge 2000 can have a first unformed height H1 and a
second group of staples can have a second unformed height H1 which
is different than the first unformed height H1. Also in contrast to
the above, a first group of staples stored in the staple cartridge
2000 can have a first tissue capture height H2 and a second group
of staples can have a second tissue capture height H2 which is
different than the first tissue capture height H2.
[0228] The first group of staples can be positioned in a first
longitudinal row of staple cavities 2120 while the second group of
staples can be positioned in a second longitudinal row of staple
cavities 2120. In at least one instance, the first row of staple
cavities 2120 can be adjacent the knife slot 2013 in the step
2014'' of the cartridge body 2010 while the second row of staple
cavities 2120 can be adjacent the first row of staple cavities 2120
in the step 2014' of the cartridge body 2010. In at least one such
instance, the first unformed height H1 is shorter than the second
unformed height H1, for example.
[0229] Further to the above, a third group of staples stored in the
staple cartridge 2000 can have a third unformed height H1 which is
different than the first unformed height H1 and/or the second
unformed height H1. The third group of staples can be positioned in
a third longitudinal row of staple cavities 2120. In at least one
instance, the third row of staple cavities 2120 can be adjacent the
second row of staple cavities 2120 in the deck 2014 of the
cartridge body 2010. In at least one such instance, the second
unformed height H1 is shorter than the third unformed height H1,
for example. In addition to or in lieu of the above, the third
group of staples can have a third tissue capture height H2 which is
larger than the second tissue capture height H2.
[0230] In various embodiments, the first group of staples, the
second group of staples, and/or the third group of staples can be
deformed to the same overall formed height. Alternatively, the
first group of staples can be deformed to a first formed height,
the second group of staples can be deformed to a second formed
height, and/or the third group of staples can be deformed to a
third formed height. In such instances, the first group of staples
can apply a larger pressure to the tissue than the second group of
staples and, similarly, the second group of staples can apply a
larger pressure to the tissue than the third group of staples.
[0231] Turning now to FIGS. 74-76, staples having the same unformed
height can be deformed to different formed heights. For example, a
first longitudinal row of staples, represented by staples 2130'',
can be deformed to a first formed height, a second longitudinal row
of staples, represented by staples 2130', can be deformed to a
second formed height, and/or a third row of staples, represented by
staples 2130, can be deformed to a third formed height. The first
formed height is shorter than the second formed height, and the
second formed height is shorter than the third formed height, for
example. In such instances, the first group of staples can apply a
larger pressure to the tissue than the second group of staples and,
similarly, the second group of staples can apply a larger pressure
to the third group of staples.
[0232] A staple 3230 is illustrated in FIGS. 78 and 79. The staple
3230 comprises a base, or crown, 3231, a first leg 3232 extending
from the base 3231, and a second leg 3233 extending from the base
3231. Similar to the base 2131 of the staple 2130, the base 3231 of
the staple 3230 includes an inclined drive surface defined in a
drive plane. Unlike staple 2130, however, the first leg 3232 and
the second leg 3233 define a staple forming plane which is
transverse to, or non-parallel to, the drive plane.
[0233] The staple 3230 further includes a platform 3238 extending
from the base 3231. The platform 3238 is integrally formed with the
base 3231 and has been folded over such that the platform 3238
extends laterally from the base 3231. The platform 3238 is not
directly connected to the legs 3232, 3233. Instead, gaps 3237 are
present between the platform 3238 and the legs 3232, 3233. In
various other embodiments, the platform 3238 is directly connected
to the first leg 3232 and/or the second leg 3233. The platform 3238
extends in a plane, i.e., a support plane, which is transverse to
the drive plane and the staple forming plane; however, the platform
3238 can extend in any suitable direction. The platform 3238 is
flat, or at least substantially flat; however, the platform 3238
can comprise any suitable shape.
[0234] In certain embodiments, the platforms 3238 of the staples
3230 can contact the tissue being stapled when the staples 3230 are
implanted into the tissue. The wider platform 3238 can reduce the
possibility of the staples 3230 tearing through the tissue.
[0235] In various embodiments, a staple cartridge assembly
comprises a cartridge body including a deck and staple cavities
defined in the deck. The staple cartridge assembly further
comprises staples 3230 removably stored in the staple cavities and,
in addition, an implantable layer positioned over the deck. The
implantable layer can comprise any suitable adjunct such as a
tissue thickness compensator and/or a buttress material, for
example. A tissue thickness compensator can compensate for
variations in the thickness of the tissue being stapled. The
implantable layer can be comprised of a woven material and/or a
non-woven material, for example.
[0236] Further to the above, the platforms 3238 of the staples 3230
can abut the layer when the staples 3230 are implanted into the
tissue. In such instances, the platforms 3238 support the layer.
Similar to the above, the platforms 3238 can also reduce the
possibility of the staples 3230 tearing through the layer. The
platforms 3238 of the staples 3230 and the layer can form a
co-operative system which distributes the forces, stresses, and/or
strains being applied to the tissue over a larger area.
[0237] The staple 3230 is formed from a flat sheet of material
utilizing a stamping process. During the stamping process, material
is removed from the sheet to create the general shape of the staple
3230. The first leg 3232 is bent in a first direction and the
second leg 3233 is bent in a second direction; however, both the
first leg 3232 and the second leg 3233 can be bent in any suitable
direction by a die utilizing a single line of action. The platform
3238 is bent in the same direction as the first leg 3232 during the
stamping process, and/or a different stamping process. In certain
instances, the platform 3238 can be created utilizing the same
single line of action that creates the legs 3232 and 3233. In other
instances, the platform 3238 can be created utilizing a second line
of action which is transverse or orthogonal to the first line of
action.
[0238] Turning now to FIG. 86, a staple 3630 comprises a base, or
crown, 3631, and legs 3632 and 3633 extending from the base 3631.
Similar to the staple 3230, the staple 3630 further comprises a
platform 3638 extending from the base 3631. The reader should
appreciate that the platform 3238 of the staple 3230 and the
platform 3638 of the staple 3630 can increase the moment of
inertia, or stiffness, of the staples. The staple 3630 comprises a
relief, or flex, slot 3637 in the base 3631 which decreases the
stiffness of the staple 3630, for example. Additionally, or
alternatively, a relief slot could be provided in the platform
3638. In any event, more than one relief slot could be utilized to
provide the desired stiffness of the staple 3630. Moreover, such
relief slots could be adapted to any of the staples disclosed
herein.
[0239] In addition to or in lieu of the above, turning now to FIGS.
80 and 81, a staple assembly 3330 comprises a staple 3230 and an
implantable adjunct 3370 attached to the staple 3230. The adjunct
3370 comprises a first end including a first aperture 3372
configured to receive the first leg 3232 of the staple 3230 and a
second aperture 3373 configured to receive the second leg 3233. As
a result, the adjunct 3370 is tethered to the staple legs 3232,
3233 and the movement of the adjunct 3370 relative to the staple
3230 is constrained.
[0240] Further to the above, the adjunct 3370 comprises a resilient
portion 3371 which extends over the platform 3238 of the staple
3230. A gap 3377 is present between the resilient portion 3371 of
the adjunct 3370 and the platform 3238 of the staple 3230 when the
staple assembly 3330 is stored in a staple cartridge. When the
staple assembly 3330 is ejected from the staple cartridge, the
staple legs 3232, 3233 of the staples 3230 penetrate the tissue
being stapled and the resilient portion 3371 of the adjunct 3370
comes into contact with the tissue. The resilient portion 3371 is
configured to flex, deflect, and/or displace downwardly toward the
platform 3238 when the adjunct 3370 comes into contact with the
tissue. The resilient portion 3371 can apply a biasing force to the
tissue when the tissue is captured within the staple 3230. The
movement of the resilient portion 3371 is at least partially
constrained by the platform 3238.
[0241] In addition to or in lieu of the above, turning now to FIG.
84, a staple assembly 3430 comprises a staple 3630 and an
implantable adjunct 3470 attached to the staple 3230. The adjunct
3470 comprises a first end including a first aperture 3472
configured to receive the first leg 3632 of the staple 3630 and a
second aperture 3473 configured to receive the second leg 3633. As
a result, the adjunct 3470 is tethered to the staple legs 3632,
3633 and the movement of the adjunct 3470 relative to the staple
3630 is constrained.
[0242] Further to the above, the adjunct 3470 comprises a resilient
portion 3471 which extends over the platform 3638 of the staple
3630. Very little, if any, gap is present between the resilient
portion 3471 of the adjunct 3470 and the platform 3638 of the
staple 3630 when the staple assembly 3430 is stored in a staple
cartridge. When the staple assembly 3430 is ejected from the staple
cartridge, the staple legs 3632, 3633 of the staple 3630 penetrate
the tissue being stapled and the resilient portion 3471 of the
adjunct 3470 comes into contact with the tissue. Referring to FIG.
85, the resilient portion 3471 is configured to flex, deflect,
and/or displace downwardly toward the platform 3638 when the
adjunct 3470 comes into contact with the tissue. The resilient
portion 3471 can apply a biasing force to the tissue when the
tissue is captured within the staple 3630. The movement of the
resilient portion 3471 is at least partially constrained by the
platform 3638.
[0243] Referring primarily to FIGS. 82 and 83, the resilient
portion 3471 of the adjunct 3470 comprises an enclosure. The
enclosure is sealed and includes at least one material therein. In
various instances, the material comprises a medicament. The
medicament is released from the enclosure when the enclosure is
ruptured. The enclosure can rupture when the staple assembly 3430
is implanted in the tissue or after a period of time. The adjunct
3470 is comprised of any suitable biocompatible material and, when
the biocompatible material comprises a bioabsorbable material, the
adjunct 3470 can be absorbed in situ. After a sufficient amount of
the adjunct 3470 has been absorbed, the medicament can be released
from the adjunct 3470. In various alternative embodiments, an
adjunct comprises two separate enclosures. In at least one such
embodiment, a first enclosure can contain a first medicament and a
second enclosure can contain a second medicament. The first
medicament can mix with the second medicament when the enclosures
have been ruptured.
[0244] Further to the above, the material in the chamber of the
resilient portion 3471 can be selected for its mechanical
properties such as its elasticity, for example, and can provide the
resilient portion 3471 with desirable properties to apply a
sufficient biasing force to the tissue. In at least one instance,
it may be desirable for the resilient portion 3471 to have
mechanical properties which closely resemble that of patient
tissue. In other instances, it may be desirable for the resilient
portion 3471 to have a stiffness less than the stiffness of patient
tissue, for example. Such embodiments may provide a suitable
constriction of blood flow within the tissue. In some instances, it
may be desirable for the resilient portion 3471 to have a stiffness
which is less than the stiffness of the base 3631 but greater than
the stiffness of the patient tissue, for example. Such embodiments
may provide strain relief to the tissue.
[0245] The adjuncts 3370, 3470 can be comprised of a woven material
and/or a non-woven material. In at least one instance, the adjuncts
3370, 3470 comprise shells which are comprised of a woven material
and/or a non-woven material. The adjuncts 3370, 3470 can be
comprised of PGA and/or PLA, for example. In at least one instance,
the adjuncts 3370, 3470 comprise shells which are comprised of PGA
and/or PLA, for example.
[0246] The adjuncts 3370, 3470 are configured to be attached to a
single staple. Stated another way, each adjunct 3370, 3470 are only
attached to one staple. Such adjuncts can be referred to as
pledgets. Alternative embodiments are envisioned in which two or
more staples are connected by an adjunct.
[0247] Turning now to FIGS. 88 and 89, the various staples
disclosed herein, such as staples 2130, for example, can be
implanted into the tissue of a patient in longitudinal rows. Two
longitudinal rows of staples 2130 are depicted in FIGS. 88 and 89.
In various instances, the tissue may stretch in various directions,
such as longitudinally, for example. The longitudinal stretch of
tissue T is depicted in FIG. 89. As can be seen in FIG. 89, the
rows of staples 2130 can stretch along with the tissue T. In such
instances, the gaps between the staples 2130 can increase. This gap
increase is readily apparent when comparing the unstretched gap
distance X1 (FIG. 88) to the stretched gap distance X2 (FIG. 89).
The staples 2130 in a third longitudinal row can be positioned and
arranged such that they are aligned with or co-extensive with the
gaps whether or not the gaps are stretched (X2) or unstretched
(X1). Such concepts could be readily adapted to circular and/or
curved staple rows, for example.
[0248] Turning now to FIG. 87, a circular cartridge body 3510, for
example, can utilize the staple assemblies 3430. The cartridge body
3510 comprises a plurality of staple cavities 3520 arranged in
circular, concentric rows. As illustrated in FIG. 87, each staple
cavity includes a staple assembly 3430 positioned therein; however,
any suitable staple could be utilized.
[0249] The staples disclosed herein can be comprised of any
suitable material. In various instances, the staples are comprised
of stainless steel and/or titanium, for example. In certain
instances, the staples disclosed herein are comprised of magnesium.
The entire disclosures of COMPARISON OF THE EFFECTS OF Mg-6Zn AND
Ti-3Al-2.5V ALLOYS ON TGF-.beta./TNF-.alpha./VEGF/b-FGF IN THE
HEALING OF THE INTESTINAL TRACT IN VIVO, Biomed. Mater. 9 (2014)
025011, by Yan et al.; COMPARISON OF THE EFFECTS OF Mg-6Zn AND
TITANIUM ON INTESTINAL TRACT IN VIVO, J. Mater. Sci.: Mater. Med.,
by Yan et al. which published online on Mar. 20, 2013; EVALUATION
OF THE SOFT TISSUE BIOCOMPATIBILITY OF MgCa0.8 AND SURGICAL STEEL
316L IN VIVO: A COMPARATIVE STUDY IN RABBITS, Biomed. Eng. OnLine
2010 9:63, by Erdmann et al.; INVESTIGATION OF THE MECHANICAL AND
DEGRADATION PROPERTIES OF Mg--Sr AND Mg--Zn--Sr ALLOYS FOR USE AS
POTENTIAL BIODEGRADABLE IMPLANT MATERIALS, J. Mech. Behavior of
Biomed. Mat. 7 (2012) 87-95, by Brar et al.; Mg--Zr--Sr ALLOYS AS
BIODEGRADABLE IMPLANT MATERIALS, Acta Biomaterialia 8 (2012)
3177-3188, by Li et al.; ON THE BIODEGRADABILITY, MECHANICAL
BEHAVIOR, AND CYTOCOMPATABILITY OF AMORPHOUS
Mg.sub.72Zn.sub.23Ca.sub.5 AND CRYSTALLINE
Mg.sub.70Zn.sub.23Ca.sub.5Pd.sub.2 ALLOYS AS TEMPORARY IMPLANT
MATERIALS, Soc. Biomat., by Pellicer et al., which published online
on Aug. 28, 2012, are incorporated by reference herein. In at least
one instance, the staples are comprised of a magnesium alloy
including zinc and/or silver, for example. Staples including alloys
of magnesium and zinc increase the healing performance of tissue.
Staples including silver provide anti-microbial benefits. Staples
including all three alloys provide a synergistic dynamic.
[0250] Staples comprised of magnesium, including those comprised of
a magnesium alloy, can be treated to improve the hardness of the
staples. In various instances, a magnesium nitride coating is
applied to the magnesium staples. The magnesium nitride coating is
applied the entirety of the magnesium staples in certain instances
while, in other instances, the magnesium nitride coating is applied
to only portions of the magnesium staples. For instance, it may be
desirable to coat only the staple legs and/or the tips of the
staple legs in magnesium nitride as the staple legs need to have a
sufficient hardness to penetrate the tissue. In at least one such
instance, a mask can be applied to the remainder of the magnesium
staple when the magnesium nitride coating is applied to the staple
legs. The magnesium nitride coating can be created by introducing
the magnesium staples to a nitrogen-rich environment at an elevated
temperature and/or pressure, for example.
[0251] In addition to or in lieu of the above, one or more surfaces
of the magnesium staples can include a coating including
carbon.
[0252] In addition to or in lieu of the above, other surface
hardening techniques could be utilized. For example, the magnesium
staples could be hardened using a laser hardening process and/or a
plasma discharge hardening process. In at least one instance, a
KERONITE ceramic surface treatment, by Keronite International, can
be applied to the staples.
[0253] As discussed above, certain portions of the magnesium
staples may undergo a hardening process while other portions of the
magnesium staples may not undergo a hardening process. In some
instances, certain portions of the magnesium staples can be
hardened to a first hardness while other portions of the magnesium
staples can be hardened to a second hardness which is different
than the first hardness. The portions of the magnesium staples
having a lower hardness will elude magnesium, zinc, and/or silver
ions, for example, faster than the portions of the magnesium
staples having a higher hardness.
[0254] In addition to or in lieu of the above, magnesium staples,
including those comprised of a magnesium alloy, can be at least
partially covered in a coating including silver. In at least one
instance, the silver coating can include ionized silver, for
example. In certain instances, an electroplating process can be
utilized to apply the silver coating to the magnesium staples. In
various instances, the entirety of the magnesium staples are
covered in a silver coating. In at least one instance, a portion,
or portions, of the magnesium staples are masked during the
electroplating process such that the masked portions are not
coated, or at least substantially coated, in silver.
[0255] In addition to or in lieu of the above, the staples
disclosed herein can be coated, or at least partially coated, in an
anti-microbial coating. Such a coating can comprise triclosan, for
example. In at least one instance, the triclosan is mixed in an
absorbable polymer coating. In certain instances, the coating can
comprise LAE intermixed with sodium stearate, for example. The
entire disclosure of WO 2012013577 A1, entitled COMPOSITION FOR
COATING MEDICAL DEVICES CONTAINING LAE AND A POLYCATIONIC
AMPHOTERIC POLYMER, by Gaffar et al., is incorporated by reference
herein.
[0256] Turning now to FIGS. 90-92, a staple 3730 comprises a metal
frame and a coating 3739 on less than the entirety of the metal
frame. The metal frame includes the staple 2130 and is comprised of
magnesium and/or a magnesium alloy, for example. The coating 3739
includes a bioabsorbable polymer; however, the coating 3739 can
comprise any suitable material. The coating 3739 extends around the
legs 2132, 2133 of the metal frame 2130. More specifically, the
coating 3739 spirals around each of the legs 2132, 2133; however,
any suitable arrangement of the coating 3739 could be utilized. The
coating 3739 also covers the transitions, or corners, between the
legs 2132, 2133 and the base, or crown, 2131 of the metal frame
2130. The coating 3739 could also cover a portion of the base 2131.
In various instances, the coating 3739 can be strategically applied
to areas of the metal frame 2130 that are inherently susceptible to
faster bioabsorption, such as the bends, edges, and/or corners of
the metal frame 2130, for example. In any event, a portion of the
metal frame 2130 is covered by the coating 3739 while a portion of
the metal frame 2130 is exposed.
[0257] The magnesium, or magnesium alloy, metal frame 2130 is
bioabsorbable. Referring primarily to FIG. 91, the portions of the
metal frame 2130 that are not covered by the coating 3739 are
directly exposed to the body when implanted, and, thus, immediately
subjected to the body's natural absorption process. The portions of
the metal frame 2130 that are covered by the coating 3739 are not
directly exposed to the body, at least not initially, when
implanted. The coating 3739 protects, or at least somewhat
protects, the portions of the metal frame 2130 that it covers and
delays the bioabsorption of such portions. Over time, referring
primarily to FIG. 92, the unprotected portions of the metal frame
2130 will bioabsorb, leaving behind the portions of the metal frame
2130 that are protected by the coating 3739. The coating 3739 can
substantially encapsulate the portions of the metal frame 2130 that
it covers, at least until the coating 3739 itself is bioabsorbed
and/or until the metal frame 2130 has sufficiently broken apart. At
such point, the portions of the metal frame 2130 that the coating
3739 once protected are exposed and can be bioabsorbed by the
body.
[0258] The bioabsorbable polymer of the coating 3739 can be
comprised of PGA and/or PLA, for example; however, the coating 3739
can be comprised of any suitable material including, but not
limited to, bioabsorbable polymers and non-bioabsorbable polymers.
In certain instances, the coating 3739 comprises a non cross-linked
polymer, for example. Such a polymer can cause the coating 3739 to
swell and encapsulate any sharp edges of the metal frame 2130 that
are created when the metal frame 2130 deteriorates.
[0259] In various embodiments, the coating 3739 can be arranged in
a grid, mesh, and/or lattice arrangement on the metal frame 2130 In
such an embodiment, the metal frame 2130 can be exposed in the
openings in the grid which can allow the metal frame 2130 to be
bioabsorbed in such openings. As the metal frame 2130 begins to
deteriorate, the latticed coating 3739 can act as a net or cage and
hold the fragments of the metal frame 2130 together, for example,
at least until the coating 3739 is bioabsorbed.
[0260] The coating 3739 can be applied to the metal frame 2130 in
any suitable manner. In at least one instance, the coating 3739 can
be sprayed onto the metal frame 2130 such that the coating 3739 is
applied in a random manner which creates random openings through
which the metal frame 2130 can be bioabsorbed. In certain other
instances, the coating 3739 can be applied to the metal frame 2130
in a pattern. In at least one such instance, the pattern can
include a dot-matrix pattern having islands of coating surrounded
by exposed portions of the metal frame 2130.
[0261] In certain alternative embodiments, a staple can include two
or more coatings. In at least one such instance, a first coating
can be bioabsorbed at a first rate and a second coating can be
bioabsorbed at a second rate to expose different portions of the
metal frame 2130 at different times during the healing process, for
example. Such staples can still have uncovered portions; however,
it is contemplated that every portion of a staple could be covered
by at least one or more coatings.
[0262] The therapeutic benefits provided by the materials disclosed
herein are a function of the surface area of the staples that is
exposed to the patient's body. Staples having a larger surface area
may deliver such therapeutic benefits faster than staples having a
smaller surface area. That said, staples having a smaller surface
area may provide such therapeutic benefits over a longer period of
time. Nonetheless, the surface area of the staples disclosed herein
can be increased by introducing apertures into the staples. For
instance, one or more apertures, or through holes, can be created
in the base, or crown, 2131 of the staple 2130, for example. The
through holes can permit tissue to grow through the staple 2130 and
improve the assimilation of the staple 2130 into the body.
[0263] In at least one embodiment, further to the above, the
coating 3739 is not positioned in the apertures as the coating 3739
would reduce the available surface absorption area of the staple
2130. However, if delaying the bioabsorption of these staple
portions is desired, the apertures in the staple 2130 could be
filled, or at least partially filled, with the coating 3739. As
discussed above, the coating 3739 can be configured to delay the
absorption of the underlying metal frame; however, any suitable
coating could be utilized. For example, a coating on the metal
frame could encourage tissue ingrowth into the structure of the
staple. In at least one such instance, the coating comprises small
micropillars that create a porous and/or prickly interaction with
the tissue.
[0264] In various embodiments, further to the above, a suture, or
string, can extend through the apertures defined in the staples.
Such a suture can tether the staples together. In various
instances, the suture is threaded through the apertures while the
staples are positioned in the staple cartridge. In other instances,
the suture is threaded through the apertures after the staples have
been implanted into the tissue. In at least one embodiment, the
suture is positioned in a groove defined in the deck of the staple
cartridge and the staples each comprise a slot or hook defined
therein which is configured to catch the suture as the staples are
being deployed. In any event, the suture can be pulled to gather
the stapled tissue together, such as in a purse-string tissue
gathering technique, for example.
[0265] In various embodiments, the staples disclosed herein can
comprise barbs. In at least one instance, barbs are defined on the
staple leg such that the barbs engage a layer that is implanted
with the tissue. Such barbs can reduce relative movement between
the layer and the staples. In certain embodiments, barbs are
defined on the base of the staple. Such barbs can grip a layer of
tissue positioned adjacent the implanted staples.
[0266] A circular surgical stapler 5000 is depicted in FIGS. 93-95.
The circular surgical stapler 5000 comprises a frame assembly 5020
comprising an attachment portion 5021 configured to operably couple
an anvil to the circular surgical stapler 5000. The circular
surgical stapler 5000 further comprises a knife member 5040
configured to incise tissue captured by the circular surgical
stapler 5000, a surgical staple cartridge 5010 which removably
stores a plurality of staples 5051 therein, and a pusher assembly,
or driver, 5030 configured to eject the staples 5051 out of the
staple cartridge 5010. The surgical staple cartridge 5010 comprises
a cartridge deck 5013 and a plurality of staple cavities 5011
defined in the cartridge deck 5013 which removably store the
staples 5051. The staples 5051 are similar to the staples discussed
in greater detail herein, however, any suitable staple may be used.
The staples 5051 comprise staple legs in a plane which is offset
from a plane defined by the staple base portion.
[0267] Referring primarily to FIG. 95, the staple cavities 5011 of
the staple cartridge 5010 comprise an inner row of staple cavities
5011A, an intermediate row of staple cavities 5011B, and an outer
row of staple cavities 5011C. Staple row spacing can include any
suitable spacing; however, nested rows may be closer together than
non-nested rows. The intermediate row of staple cavities 5011B is
positioned radially outward with respect to the inner row of staple
cavities 5011A. The outer row of staple cavities 5011C is
positioned radially outward with respect to the intermediate row of
staple cavities 5011B. The staple cavities 5011A in the inner row
comprise an orientation which orients the staple legs of the
staples 5051 stored therein such that the staple legs extend
radially outward with respect to the staple base. The intermediate
row of staple cavities 5011B and the outer row of staple cavities
5011C comprise an orientation which orients the staple legs of the
staples 5051 stored therein such that the staple legs extend
radially inward with respect to the staple bases.
[0268] The staple cavities 5011A in the inner row define a
plurality of first gaps therebetween having a distance A. The
intermediate row of staple cavities 5011B define a plurality of
second gaps with a distance B. The outer row of staple cavities
5011C define a plurality of third gaps with a distance C. The
distance A is less than the distances B and C. The distance B is
greater than the distance A but less than the distance C. The
distance C is greater than the distances A and B. The cavities 5011
are arranged such that the first gaps comprise a distance which is
greater than the distances of the second gaps and/or the third
gaps. The cavities 5011 are arranged such that the third gaps
comprise a distance which is less than the distances of the first
gaps and/or the second gaps. Embodiments are envisioned where there
are no gaps associated with one or more rows of staple
cavities.
[0269] The intermediate row of staple cavities 5011B are arranged
such that the cavities 5011B overlap the first gaps defined by the
inner row of staple cavities 5011A in order to compensate for the
lack of tissue ligation in the first gaps. The outer row of staple
cavities 5011C are arranged such that the cavities 5011C overlap
the second gaps defined by the intermediate row of staple cavities
5011B in order to compensate for the lack of tissue ligation in the
second gaps. Overlapping these fastening gaps with such an
arrangement increases the ligation ability of the circular surgical
stapler 5000. This arrangement also permits the fastened tissue to
flex upon fastening. Conventional arrangements utilize greater
quantities of staples in the intermediate and/or outer rows in
order to increase ligation efficiency; however, such conventional
arrangements can limit tissue flexibility after fastening.
[0270] FIGS. 96-98 illustrate a circular surgical stapler 5100 in
accordance with at least one embodiment. The circular surgical
stapler 5100 comprises a frame assembly 5120 comprising an
attachment portion configured to operably couple an anvil to the
circular surgical stapler 5100. The circular surgical stapler 5100
further comprises a knife member 5140 configured to incise tissue
captured by the circular surgical stapler 5100, a surgical staple
cartridge 5110 which removably stores a plurality of staples 5151
therein, and a pusher assembly, or driver, 5130 configured to eject
the staples 5151 out of the staple cartridge 5110. The pusher
assembly 5130 comprises an inner row of staple drivers 5130A, an
intermediate row of staple drivers 5130B, and an outer row of
staple drivers 5130C. The surgical staple cartridge 5110 comprises
a cartridge deck 5113 and a plurality of staple cavities 5111
defined in the cartridge deck 5113 which removably store the
staples 5151 therein. The surgical staple cartridge 5110 further
comprises a plurality of deck features, or staple supports, or
guides, 5115 configured to support, guide, and/or control the
staples 5151 when the staples 5151 are ejected from the staple
cartridge 5110. The deck features, or cavity extenders, 5115 can
have a multitude of purposes such as aiding in the gripping of
tissue intermediate the anvil and the staple cartridge 5110 and/or
storing, releasing, and delivering a medicament to tissue captured
with the stapler 5100, for example.
[0271] The staple cavities 5111 of the staple cartridge 5110 are
similar to the staple cavities 5011 in many respects. The staple
cavities 5111 comprise an inner row of staple cavities 5111A, an
intermediate row of staple cavities 5111B, and an outer row of
staple cavities 5111C. The deck features 5115 comprise a plurality
of first deck features 5115A, a plurality of second deck features
5115B, and a plurality of third deck features 5115C. Each first
deck feature 5115A comprises an intermediate portion 5116 and two
outer portions 5117 to define a T-configuration. The intermediate
portion 5116 sits between two staple cavities 5111A and extends
from the deck 5113 to guide and/or support neighboring staple legs.
The outer portions 5117 branch off of the intermediate portion 5116
in at least substantially opposite directions and extend from the
deck 5113 to guide and/or support a portion of a staple base.
Combining deck features for more than one cavity in such a manner
can save space on the cartridge deck 5113.
[0272] Each second deck feature 5115B and each third deck feature
5115C comprise an intermediate portion 5118 and two outer portions
5119 to define a cavity-surrounding configuration. The intermediate
portion 5118 extends from the deck 5113 to guide and/or support
staple bases of staples removably stored in the intermediate row of
staple cavities 5111B and the outer row of staple cavities 5111C.
The two outer portions 5119 branch off from the intermediate
portion 5118 to support the staple legs that extend from the staple
base that the intermediate portion 5118 is guiding and/or
supporting.
[0273] FIG. 99 illustrates a circular stapling configuration 5200
for use with a circular surgical stapler in accordance with at
least one embodiment. The circular stapling configuration 5200 is
an arrangement of staples employable with a circular staple
cartridge. A circular staple cartridge employing the circular
stapling configuration 5200 comprises corresponding staple cavities
to removably store the staples discussed herein. The circular
stapling configuration 5200 comprises a plurality of staples 5210
comprising an inner row of staples 5213, an intermediate row of
staples 5215, and an outer row of staples 5217. Each staple 5213 is
orientated such that its staple legs face outward toward the outer
row of staples 5217. Each staple 5215 is orientated such that its
staple legs face inward toward the inner row of staples 5113. Each
staple 5217 is orientated such that its staple legs face outward
away from the inner row of staples 5213 and the intermediate row of
staples 5215. Each staple row may reside a certain distance from
each other staple row and/or the cutting member to better control
blood flow and/or predict tissue behavior at certain points within
the stapled tissue.
[0274] The outer row of staples 5217 comprise different
characteristics than the inner and/or intermediate row of staples
5213, 5215. For example, in various instances, the outer row of
staples 5217 are formed into a larger "B" formation resulting in a
greater capture volume and/or taller staple forming height to
alleviate high tissue compression near the outer row of staples
5217. A larger B formation may also improve blood flow toward the
inner rows. In various instances, the outer row of staples 5217
comprise a greater resistance to unfolding by utilizing a larger
staple crown, staple leg widths, and/or staple leg thicknesses.
[0275] The quantity of staples used in each row of staples can vary
in a circular and/or linear surgical staple cartridge. The outer
row of staples 5217 comprise a first quantity, the intermediate row
of staples 5215 comprise a second quantity, and the inner row of
staples 5213 comprise a third quantity. FIG. 99 illustrates a
scenario where the first quantity is equal to the second quantity,
but, greater than the third quantity. In various embodiments, the
first quantity, the second quantity, and the third quantity are
different. In various embodiments, the first quantity is greater
than the second quantity and the second quantity is greater than
the third quantity.
[0276] Varying staple crown widths between staple rows can provide
an effective and/or efficient stapling arrangement. For example,
each outer row staple 5217 comprises a staple crown having a width
that is greater than the crown width of each inner row staple 5213
and each intermediate row staple 5215. The staple crown of each
outer row staple 5217 is bent laterally in order have a larger
crown width staple while maintaining the compact circular stapling
arrangement. Some embodiments are envisioned where the crown of
each outer row staple 5217 is curved. One advantage of bending or
curving the crown of the outer row staples 5217 can include being
able to nest the outer row staples 5217 closer to the intermediate
row staples 5215 and the inner row staples 5213, for example. Each
outer row staple 5217 spans a plurality of gaps defined between the
inner row staples 5213 and/or the intermediate row staples 5215.
Each intermediate row staple 5215 spans, overlaps, or covers each
gap defined between the inner row of staples 5213.
[0277] In various embodiments the gaps defined by the inner row
staples 5213 can be varied based on the radial position of the row
of inner staples. For example, a row of inner staples having a
diameter much less than the diameter of the intestine being stapled
may comprise much larger gaps between the inner row staples to
provide radial flexibility, and/or expansion. A row of inner
staples having a diameter less than, but closer to, the diameter of
the intestine being stapled may comprise smaller gaps between the
inner row staples because, in this instance, vast expansion and/or
flexibility may not be necessary.
[0278] FIG. 100 illustrates a circular stapling configuration 5300
for use with a circular surgical stapler in accordance with at
least one embodiment. The circular stapling configuration 5300 is
an arrangement of staples employable with a circular staple
cartridge. A circular staple cartridge employing the circular
stapling configuration 5300 comprises corresponding staple cavities
to removably store the staples discussed herein. The circular
stapling configuration 5300 comprises a plurality of staples 5310
comprising inner row staples 5313A, 5313B, intermediate row staples
5315C, 5315D, and outer row staples 5317E, 5317F. Each staple
5313A, 5313B is orientated such that the staple legs thereof face
outward toward the outer row staples 5317E, 5317F. Each staple
5315C, 5315D is orientated such that the staple legs thereof face
inward toward the inner row staples 5313A, 5313B. Each staple
5317E, 5317F is orientated such that the staple legs thereof face
outward away from the inner row staples 5313A, 5313B and the
intermediate row staples 5315C, 5315D. Embodiments are envisioned
where various staples within the same row face opposite directions.
Embodiments are envisioned where every staple in every row faces
the same direction. Embodiments are envisioned where the inner row
staples face inward, the intermediate row staples face outward, and
the outer row staples face inward, for example.
[0279] Varying staple crown widths between and within staple rows
can also provide an effective and/or efficient stapling
arrangement. For example, the inner row staples 5313A, 5313B each
comprise a different crown width, the intermediate row staples
5315C, 5315D each comprise a different crown width, and the outer
row staples 5317E, 5317F each comprise a different crown width. In
various embodiments, the crown widths of each staple 5313A, 5313B,
5315C, 5315D, 5317E, and 5317F are all different. Embodiments are
envisioned where crown widths of certain staples in one row are
equal to crown widths of certain staples in another row. The inner
row staples define a stretch zone labeled SZ. The stretch zone SZ
can comprise a gap defined between the staples 5313A, for example.
The stretch zone SZ permits the stapled tissue to flex.
[0280] The circular surgical staplers, circular staple cartridges,
and/or circular stapling configurations may be employed in a
colectomy procedure, for example. FIG. 101 illustrates an example
of a part of a colectomy procedure where two portions of intestine
are joined providing a new pathway, or passage, 5400 for the
digestive system. One portion of intestine T.sub.1 comprises an
inner wall 5410 and a second portion of intestine T.sub.2 comprises
an inner wall 5420. The intestine portions T.sub.1 and T.sub.2 are
stapled with inner staples 5401, intermediate staples 5403, and
outer staples 5405. The intestine portions T.sub.1 and T.sub.2 are
incised creating a new passage P-P for digestive material to pass.
The incision creates cut portions 5411 and 5421 of the intestine
portions T.sub.1 and T.sub.2. The change in diameter between the
inner walls 5410, 5420 of the intestine portions T.sub.1 and
T.sub.2 and the cut portions 5411, 5421 can, in some cases,
constrict, or narrow, the passage P-P making it difficult for
digestive material to pass. It can be desirable to have flexibility
of the staple portion starting with the inner staples 5401. One
method for providing flexibility utilizes staple gaps defined
between staples in the various rows in which the staples are
arranged. Another method for providing flexibility utilizes larger
sized staples with larger staple crowns. In various instances, gaps
between the staples and staple rows permit flexibility of the
stapled portion allowing digestive material to pass more easily. In
various instances, different size staples permit tissue
flexibility.
[0281] FIGS. 102-104 depict a curved stapling instrument 5500 in
accordance with at least one embodiment configured to capture,
incise, and staple tissue. The curved stapling instrument 5500
comprises a frame assembly 5510, a staple cartridge 5520, and an
anvil 5530. Upon receiving a first actuation force, the staple
cartridge 5520 is driven toward the anvil 5530 to capture tissue
therebetween. The curved stapling instrument 5500 further comprises
a knife assembly 5540 comprising a cutting member 5541 configured
to incise the tissue captured between the staple cartridge 5520 and
the anvil 5530. The staple cartridge 5520 comprises a deck 5527
comprising a cutting slot 5521 configured to receive the cutting
member 5541, a plurality of staple cavities 5523A and 5523B, and a
plurality of staples 5560 removably stored within the staple
cavities 5523A, 5523B. The curved stapling instrument 5500 further
comprises a driver assembly 5550 comprising a plurality of staple
drivers 5551 configured to drive the staples 5560 toward the anvil
5530 upon the application of a second actuation force. The second
actuation force is responsible for lifting the driver assembly 5550
and the knife assembly 5540 vertically relative to the curved
stapling instrument 5500 in order to incise and staple the
tissue.
[0282] The staple cartridge 5520 further comprises a plurality of
deck features 5525 extending from the deck 5527. Embodiments are
envisioned where the deck features 5525 are separate portions
configured to be attached to the deck 5527. The deck features 5525
can be extensions of the staple cavities 5523A, 5523B in order to
support, guide, and/or control the staples 5560 while loading the
staples 5560 into the cartridge 5520, while housing, or supporting,
the staples 5560 before ejecting the staples 5560, and/or while
ejecting the staples 5560 from the cartridge 5520. A single deck
feature 5525 supports two different staple legs of neighboring
staples. The deck features 5525 can comprise multiple support walls
configured to support one or more sides, faces, and/or edges of
each staple leg. Embodiments are envisioned where the deck features
5525 on the outer staple rows, rows furthest from the slot, only
correlate with every other staple cavity in each outer row. Staple
features may increase in density the closer to the incision the
staple features are positioned.
[0283] FIGS. 105 and 106 depict a curved stapling instrument 5600
in accordance with at least one embodiment configured to capture,
incise, and staple tissue. The curved stapling instrument 5600
comprises a frame assembly 5610, a staple cartridge 5620, and an
anvil 5630. Upon receiving a first actuation force, the staple
cartridge 5620 is driven toward the anvil 5630 to capture tissue
therebetween. The curved stapling instrument 5600 further comprises
a knife assembly comprising a cutting member configured to incise
the tissue captured between the staple cartridge 5620 and the anvil
5630. The staple cartridge 5620 comprises a deck 5627 comprising a
cutting slot 5621 configured to receive the cutting member, a
plurality of staple cavities 5623, and a plurality of staples 5660
removably stored within the staple cavities 5623. The curved
stapling instrument 5600 further comprises a driver assembly 5650
comprising a plurality of staple drivers 5651 configured to drive
the staples 5660 toward the anvil 5630 upon the application of a
second actuation force. The second actuation force is responsible
for lifting the driver assembly 5650 and the knife assembly
vertically relative to the curved stapling instrument 5600 in order
to incise and staple the tissue.
[0284] The staple cartridge 5620 further comprises a plurality of
deck features 5625 extending from the deck 5627. Embodiments are
envisioned where the deck features 5625 are separate portions
configured to be attached to the deck 5627. The deck features 5625
can be extensions of the staple cavities 5623 in order to support,
guide, and/or control the staples 5660 while loading the staples
5660 into the cartridge 5620, while housing, or supporting, the
staples 5660 before ejecting the staples 5660, and/or while
ejecting the staples 5660 from the cartridge 5620. The deck
features 5625 can comprise multiple support walls configured to
support one or more sides, faces, and/or edges of each staple leg.
The deck features 5625 extend from at least one of the staple leg
walls and at least one of the staple base walls of the staple
cavities.
[0285] The staple drivers 5651 comprise a flat profile which is at
least substantially the same as the bottom profile of the staples
5660. Having similar, or the same, profiles permits an adequate
force distribution by the staple drivers 5651 over the staple base
portions of the staples 5660. When being formed against the anvil
5630, the similar profiles between the drivers 5651 and the staples
5660 prevents the staples 5660 becoming misaligned.
Examples
[0286] Example 1--A staple cartridge assembly for use with a
surgical stapler, wherein the staple cartridge assembly comprises a
cartridge body including a proximal end, a distal end, a deck, a
longitudinal slot defined in the deck extending from the proximal
end toward the distal end and staple cavities, wherein the staple
cavities are arranged in longitudinal rows. Each staple cavity
comprises a top opening defined in the deck, a bottom opening, a
proximal end, a distal end, and a staple cavity sidewall extending
between the proximal end and the distal end. The staple cartridge
assembly further comprises staples removably stored in the staple
cavities, wherein each staple comprises a proximal leg, a distal
leg, a base extending between the proximal leg and the distal leg,
and a retention projection extending from the base, wherein the
retention projections of the staples are engaged with the staple
cavity sidewalls to prevent the staples from falling out of the
bottom openings of the staple cavities. Example 2--The staple
cartridge assembly of Example 1, further comprising a sled movable
from the proximal end toward the distal end to eject the staples
through the top openings of the staple cavities. Example 3--The
staple cartridge assembly of Example 2, wherein the cartridge body
further comprises a bottom surface defined opposite the deck, a
longitudinal channel defined in the bottom surface, wherein at
least a portion of the sled is slidably positioned in the
longitudinal channel, and a retention portion configured to prevent
the sled from falling out of the longitudinal channel through the
bottom surface. Example 4--The staple cartridge assembly of Example
3, wherein the sled is movable between a proximal position and a
distal position during a firing stroke, wherein the retention
portion is engaged with the sled when the sled is in the proximal
position, and wherein the retention portion is not engaged with the
sled when the sled is in the distal position. Example 5--The staple
cartridge assembly of Examples 1, 2, 3, or 4, wherein the staple
cartridge assembly does not comprise a cover extending around the
bottom surface of the cartridge body. Example 6--The staple
cartridge assembly of Examples 1, 2, 3, 4, or 5, wherein the
cartridge body comprises at least one snap-fit feature configured
to directly engage the surgical stapler. Example 7--The staple
cartridge assembly of Examples 3, 4, or 5, wherein the sled
directly engages the staples, and wherein the staple cartridge
assembly does not comprise drivers positioned intermediate the sled
and the staples. Example 8--The staple cartridge assembly of
Examples 1, 2, 3, 4, 5, 6, or 7, wherein each staple is stamped
from a sheet of material, wherein the proximal leg, the distal leg,
and the base of each the staple are formed in a staple plane, and
wherein the retention projection extends laterally from the staple
plane. Example 9--A staple cartridge assembly for use with a
surgical stapler, wherein the staple cartridge assembly comprises a
cartridge body including a proximal end, a distal end, a deck, a
bottom portion, a longitudinal slot defined in the deck extending
from the proximal end toward the distal end, a longitudinal channel
defined in the bottom portion, and staple cavities, wherein each
staple cavity comprises a top opening defined in the deck and a
bottom opening defined in the bottom portion. The staple cartridge
assembly further comprises staples removably stored in the staple
cavities, a sled slidably positioned in the longitudinal channel,
wherein the sled is movable from the proximal end toward the distal
end to eject the staples through the top openings of the staple
cavities, and a retention portion configured to prevent the sled
from falling out of the longitudinal channel through the bottom
portion. Example 10--The staple cartridge assembly of Example 9,
wherein the sled is movable between a proximal position and a
distal position during a firing stroke, wherein the retention
portion is engaged with the sled when the sled is in the proximal
position, and wherein the retention portion is not engaged with the
sled when the sled is in the distal position. Example 11--The
staple cartridge assembly of Examples 9 or 10, wherein the staple
cartridge assembly does not comprise a cover extending around the
bottom portion of the cartridge body. Example 12--The staple
cartridge assembly of Examples 9, 10, or 11, wherein the sled
directly engages the staples, and wherein the staple cartridge
assembly does not comprise drivers positioned intermediate the sled
and the staples. Example 13--A staple cartridge assembly for use
with a surgical stapler, wherein the surgical stapler includes a
jaw configured to receive the staple cartridge assembly, and
wherein the staple cartridge assembly comprises a cartridge body
including a proximal end, a distal end, a deck, a bottom portion,
wherein the staple cartridge assembly does not comprise an
enclosure extending around the bottom portion, a longitudinal slot
defined in the deck extending from the proximal end toward the
distal end, a longitudinal channel defined in the bottom portion,
and staple cavities, wherein each the staple cavity comprises a top
opening defined in the deck and a bottom opening defined in the
bottom portion. The staple cartridge assembly further comprises
staples removably stored in the staple cavities, a sled slidably
positioned in the longitudinal channel, wherein the sled is movable
from the proximal end toward the distal end to eject the staples
through the top openings of the staple cavities during a firing
stroke, and means for preventing the sled from falling out of the
longitudinal channel through the bottom portion. Example 14--The
staple cartridge assembly of Example 13, wherein the sled directly
engages the staples during the firing stroke. Example 15--The
staple cartridge assembly of Examples 13 or 14, further comprising
means for preventing the staples from falling out of the staple
cavities through the bottom openings. Example 16--A staple
cartridge assembly for use with a surgical stapler, wherein the
surgical stapler includes a jaw configured to receive the staple
cartridge assembly, and wherein the staple cartridge assembly
comprises a cartridge body including a proximal end, a distal end,
a deck, a bottom portion, wherein the staple cartridge assembly
does not comprise an enclosure extending around the bottom portion,
and staple cavities, wherein each the staple cavity comprises a top
opening defined in the deck and a bottom opening defined in the
bottom portion. The staple cartridge assembly further comprises
staples removably stored in the staple cavities, wherein the
cartridge body includes shelves integrally formed with the
cartridge body that prevent the staples from falling out of the
staple cavities through the bottom openings. Example 17--A staple
cartridge assembly for use with a surgical stapler, wherein the
staple cartridge assembly comprises a cartridge body including a
proximal end, a distal end, a deck, a longitudinal slot defined in
the deck extending from the proximal end toward the distal end, and
a staple cavity. The staple cavity comprises a top opening defined
in the deck, a bottom opening, a proximal guide, a distal guide, a
sidewall extending between the proximal guide and the distal guide,
and an intermediate guide extending inwardly from the sidewall. The
staple cartridge assembly further comprises a staple removably
stored in the staple cavity including a proximal leg positioned
within the proximal guide, a distal leg positioned within the
distal guide, and a base extending between the proximal leg and the
distal leg, wherein the intermediate guide is positioned to guide
the base and hold the proximal leg in the proximal guide and the
distal leg in the distal guide. Example 18--The staple cartridge
assembly of Example 17, wherein the staple cavity further comprises
a proximal cavity end proximal to the proximal guide and a distal
cavity end distal to the distal guide. Example 19--The staple
cartridge assembly of Example 18, wherein the staple is not
positioned in the proximal cavity end and the distal cavity end.
Example 20--The staple cartridge assembly of Examples 18 or 19,
wherein a first clearance gap is present between the staple base,
the intermediate guide, and the distal cavity end, and wherein a
second clearance gap is present between the staple base, the
intermediate guide, and the proximal cavity end. Example 21--The
staple cartridge assembly of Examples 17, 18, 19, or 20, wherein
the base comprises a flat guide surface interfaced with the
intermediate guide. Example 22--The staple cartridge assembly of
Examples 17, 18, 19, 20, or 21, wherein the cartridge body further
comprises a plurality of the staple cavities, and wherein the
staple cartridge assembly further comprises a plurality of the
staples positioned in the staple cavities. Example 23--The staple
cartridge assembly of Examples 17, 18, 19, 20, 21, or 22, wherein
the proximal guide, the distal guide, and the intermediate guide
triangulate the control of the staple as the staple is ejected from
the staple cavity. Example 24--The staple cartridge assembly of
Examples 17, 18, 19, 20, 21, 22 or 23, wherein the proximal guide
and the distal guide extend above the deck. Example 25--The staple
cartridge assembly of Examples 17, 18, 19, 20, 21, 22, 23, or 24,
wherein the intermediate guide extends above the deck. Example
26--The staple cartridge assembly of Examples 17, 18, 19, 20, 21,
22, 23, 24, or 25, wherein the proximal leg and the distal leg of
the staple define a leg plane, wherein the base comprises a drive
surface in a drive plane, and wherein the drive plane is offset
from the leg plane. Example 27--The staple cartridge assembly of
Examples 17, 18, 19, 20, 21, 22, 23, 24, 25, or 26, wherein the
proximal leg and the distal leg are pinched toward each other by
the proximal guide and the distal guide. Example 28--The staple
cartridge assembly of Examples 17, 18, 19, 20, 21, 22, 23, 24, 25,
26, or 27, wherein the intermediate guide comprises a resilient
biasing member engaged with the base configured to push the
proximal leg into the proximal guide and the distal leg into the
distal guide. Example 29--The staple cartridge assembly of Examples
17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, or 28, wherein the
intermediate guide is positioned closer to the distal guide than
the proximal guide. Example 30--The staple cartridge assembly of
Examples 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, or 28, wherein
the intermediate guide is positioned equidistant between the distal
guide and the proximal guide. Example 31--A staple cartridge
assembly for use with a surgical stapler, wherein the staple
cartridge assembly comprises a cartridge body including a proximal
end, a distal end, a deck, a longitudinal slot defined in the deck
extending from the proximal end toward the distal end, and a staple
cavity. The staple cavity comprises a top opening defined in the
deck, a bottom opening, a proximal guide, a distal guide, and a
sidewall extending between the proximal guide and the distal guide.
The staple cartridge assembly further comprises a staple removably
stored in the staple cavity including a proximal leg positioned
within the proximal guide, a distal leg positioned within the
distal guide, wherein the proximal leg and the distal leg define a
leg plane, and wherein the proximal leg and the distal leg are
pinched toward each other by the proximal guide and the distal
guide, and a base extending between the proximal leg and the distal
leg, wherein the base comprises a drive surface in a drive plane,
and wherein the drive plane is offset from the leg plane. Example
32--The staple cartridge assembly of Example 31, wherein the leg
plane is parallel to the drive plane. Example 33--The staple
cartridge assembly of Examples 31 or 32, wherein the cartridge body
further comprises a plurality of the staple cavities, and wherein
the staple cartridge assembly further comprises a plurality of the
staples positioned in the staple cavities. Example 34--A staple
cartridge assembly for use with a surgical stapler, wherein the
staple cartridge assembly comprises a cartridge body including a
proximal end, a distal end, a deck, a longitudinal slot defined in
the deck extending from the proximal end toward the distal end, and
a staple cavity. The staple cavity comprises a top opening defined
in the deck, a bottom opening, a proximal guide, a distal guide, a
sidewall extending between the proximal guide and the distal end
guide, and an intermediate guide extending inwardly from the staple
cavity sidewall. The staple cartridge assembly further comprises a
staple removably stored in the staple cavity including a proximal
leg positioned within the proximal guide, a distal leg positioned
within the distal guide, and a base extending between the proximal
leg and the distal leg, wherein the proximal guide, the distal
guide, and the intermediate guide triangulate the control of the
staple as the staple is ejected from the staple cavity. Example
35--The staple cartridge assembly of Example 34, wherein the
cartridge body further comprises a plurality of the staple
cavities, and wherein the staple cartridge assembly further
comprises a plurality of the staples positioned in the staple
cavities. Example 36--A staple cartridge assembly for use with a
surgical stapler, wherein the staple cartridge assembly comprises a
cartridge body including a proximal cartridge end, a distal
cartridge end, a deck, a longitudinal knife slot defined in the
deck extending from the proximal cartridge end toward the distal
cartridge end, and a staple cavity. The staple cavity comprises a
top opening defined in the deck, a proximal cavity end, a distal
cavity end, a proximal guide, a distal guide, wherein the proximal
guide and the distal guide extend above the deck, and a cavity slot
extending between the proximal cavity end and the distal cavity
end, wherein the proximal guide and the distal guide extend
laterally with respect to the cavity slot. The staple cartridge
assembly further comprises a staple removably stored in the staple
cavity including a proximal leg positioned within the proximal
guide, a distal leg positioned within the distal guide, and a base
extending between the proximal leg and the distal leg, wherein the
base is positioned in the cavity slot. Example 37--The staple
cartridge assembly of Example 36, wherein the proximal guide and
the distal guide extend toward the knife slot. Example 38--The
staple cartridge assembly of Example 36, wherein the proximal guide
and the distal guide extend away from the knife slot. Example
39--The staple cartridge assembly of Examples 36, 37, or 38,
wherein the proximal guide comprises a proximal bracket. Example
40--The staple cartridge assembly of Example 39, wherein the
proximal bracket does not extend around the proximal cavity end.
Example 41--The staple cartridge assembly of Examples 39 or 40,
wherein the cavity slot is defined by a longitudinal axis, and
wherein the proximal bracket is not aligned with the longitudinal
axis. Example 42--The staple cartridge assembly of Examples 36, 37,
38, 39, 40, or 41, wherein the distal guide comprises a distal
bracket. Example 43--The staple cartridge assembly of Example 42,
wherein the distal bracket does not extend around the distal cavity
end. Example 44--The staple cartridge assembly of Examples 42 or
43, wherein the cavity slot is defined by a longitudinal axis, and
wherein the distal bracket is not aligned with the longitudinal
axis. Example 45--The staple cartridge assembly of Examples 36, 37,
38, 39, 40, 41, 42, 43, or 44, wherein the proximal leg and the
distal leg define a staple leg plane, wherein the base comprises a
drive surface in a drive plane offset from the staple leg plane,
wherein the proximal guide and the distal guide are aligned with
the staple plane, and wherein the proximal guide and the distal
guide are not aligned with the drive plane. Example 46--The staple
cartridge assembly of Examples 36, 37, 38, 39, 40, 41, 42, 43, or
44, wherein the proximal leg and the distal leg define a staple leg
plane, wherein the base comprises a drive surface in a drive plane
offset from the staple leg plane, and wherein the proximal guide
and the distal guide define a bracket plane aligned with the staple
leg plane. Example 47--The staple cartridge assembly of Examples
36, 37, 38, 39, 40, 41, 42, 43, 44, 45, or 46, wherein the
cartridge body further comprises a plurality of the staple
cavities, and wherein the staple cartridge assembly further
comprises a plurality of the staples positioned in the staple
cavities. Example 48--The staple cartridge assembly of Examples 36,
37, 38, 39, 40, 41, 42, 43, 44, 45, 46, or 47, wherein a portion of
the proximal guide that extends above the deck comprises a staple
cavity extender, and wherein a portion of the distal guide that
extends above the deck comprises a staple cavity extender Example
49--A staple cartridge assembly for use with a surgical stapler,
wherein the staple cartridge assembly comprises a cartridge body
including a proximal cartridge end, a distal cartridge end, a deck,
and a staple cavity. The staple cavity includes a proximal cavity
end, a distal cavity end, a proximal guide extending above and
below the deck, a distal guide extending above and below the deck,
and a connecting slot extending between the proximal cavity end and
the distal cavity end, wherein the proximal guide and the distal
guide extend laterally with respect to the connecting slot. The
staple cartridge assembly further comprises a staple removably
stored in the staple cavity comprising a proximal leg
positioned within the proximal guide, a distal leg positioned
within the distal guide, and a base extending between the proximal
leg and the distal leg, wherein the base is positioned in the
cavity slot. Example 50--The staple cartridge assembly of Example
49, wherein the cartridge body further comprises a plurality of the
staple cavities, and wherein the staple cartridge assembly further
comprises a plurality of the staples positioned in the staple
cavities. Example 51--The staple cartridge assembly of Examples 49
or 50, wherein the portion of the proximal guide that extends above
the deck comprises a staple cavity extender, and wherein the
portion of the distal guide that extends above the deck comprises a
staple cavity extender Example 52--A fastener cartridge assembly
for use with a surgical fastening instrument, wherein the fastener
cartridge assembly comprises a cartridge body comprising a proximal
cartridge end, a distal cartridge end, a deck, and a fastener
pocket. The fastener pocket comprises a proximal pocket end, a
distal pocket end, a proximal guide, a distal guide, a proximal
pocket extender, wherein the proximal pocket extender extends above
the deck, a distal pocket extender, wherein the proximal pocket
extender extends above the deck, and a pocket opening extending
between the proximal pocket end and the distal pocket end, wherein
the proximal guide and the distal guide extend laterally with
respect to the pocket opening. The fastener cartridge assembly
further comprises a fastener removably stored in the fastener
pocket comprising a proximal leg positioned within the proximal
guide, a distal leg positioned within the distal guide, and a base
extending between the proximal leg and the distal leg, wherein the
base is positioned in the pocket opening. Example 53--The fastener
cartridge assembly of Example 52, wherein the cartridge body
further comprises a plurality of the fastener pockets, and wherein
the fastener cartridge assembly further comprises a plurality of
the fasteners positioned in the fastener pockets. Example 54--A
staple cartridge assembly for use with a surgical instrument, the
staple cartridge assembly comprising a cartridge body including a
proximal end, a distal end, a deck, and staple cavities defined in
the deck. The staple cartridge assembly further comprises staples
removably positioned in the staple cavities and a firing member
comprising a channel aligned with the staples, wherein the channel
comprises a first lateral sidewall and a second lateral sidewall,
and wherein the channel is configured to receive the staples
between the first lateral sidewall and the second lateral sidewall.
Example 55--The staple cartridge assembly of Example 54, wherein
the channel is defined on an inclined surface of the firing member.
Example 56--The staple cartridge assembly of Examples 54 or 55,
wherein the channel comprises a ramp portion configured to lift the
staples within the staple cavities during a firing stroke of the
firing member and an apex portion configured to form the staples
against an anvil of the surgical instrument to a final formed
height. Example 57--The staple cartridge assembly of Example 56,
wherein the channel comprises a trailing portion positioned
proximally with respect to the apex portion, and wherein the apex
portion is positioned above the trailing portion. Example 58--The
staple cartridge assembly of Examples 54, 55, 56, or 57, wherein
the firing member comprises a sled including a plurality of wedges,
and wherein the channel is defined on one of the wedges. Example
59--The staple cartridge assembly of Examples 54, 55, 56, 57, or
58, wherein the firing member further comprises a ramp configured
to initially lift the staples within the staple cavities and guide
the staples into the channel. Example 60--The staple cartridge
assembly of Examples 54, 55, 56, 57, 58, or 59, wherein the channel
comprises a mouth portion and a longitudinal portion, wherein the
mouth portion provides a lead-in to the longitudinal portion, and
wherein the mouth portion is wider than the longitudinal portion.
Example 61--The staple cartridge assembly of Examples 54, 55, 56,
57, 58, 59, or 60, wherein the staples are received within the
channel without a staple driver positioned between the staples and
the channel. Example 62--The staple cartridge assembly of Examples
54, 55, 56, 57, 58, 59, 60, or 61, wherein the first lateral
sidewall is parallel to the second lateral sidewall. Example
63--The staple cartridge assembly of Examples 54, 55, 56, 57, 58,
59, 60, or 61, wherein the first lateral sidewall is not parallel
to the second lateral sidewall. Example 64--The staple cartridge
assembly of Examples 54, 55, 56, 57, 58, 59, 60, or 61, wherein the
first lateral sidewall and the second lateral are angled with
respect to each other to create a staple entry lead-in. Example
65--The staple cartridge assembly of Examples 54, 55, 56, 57, 58,
59, 60, 61, 62, 63, or 64, wherein the channel comprises a first
channel, and wherein the firing member further comprises a second
channel configured to receive the staples. Example 66--The staple
cartridge assembly of Example 65, wherein each staple comprises a
drive portion configured to enter the first channel, and a forming
portion configured to enter the second channel. Example 67--The
staple cartridge assembly of Examples 65 or 66, wherein the first
channel extends at an angle relative to the second channel. Example
68--The staple cartridge assembly of Examples 65, 66, or 67,
wherein the first channel and the second channel are parallel to
one another in a first region and non-parallel to one another in a
second region. Example 69--The staple cartridge assembly of
Examples 65, 66, 67, or 68, wherein the second channel is
configured to receive the staples before the first channel as the
firing member is advanced toward the distal end. Example 70--A
staple cartridge assembly for use with a surgical instrument, the
staple cartridge assembly comprising a cartridge body comprising a
deck and staple cavities defined in the deck, staples removably
positioned in the staple cavities, and a firing member comprising a
ramp configured to directly engage the staples and a rail extending
from the ramp configured to orient the staples relative to the
ramp. Example 71--The staple cartridge assembly of Example 70,
wherein the rail comprises a first rail, and wherein the firing
member further comprises a second rail extending from the ramp
configured to orient the staples relative to the ramp. Example
72--The staple cartridge assembly of Example 71, wherein the first
rail is parallel to the second rail. Example 73--A staple cartridge
assembly for use with a surgical stapling instrument including an
anvil, wherein the anvil includes forming pockets, and wherein the
staple cartridge assembly comprises a cartridge body comprising a
proximal end, a distal end, a deck, and staple cavities defined in
the deck. The staple cartridge assembly comprises staples removably
positioned in the staple cavities, wherein each staple comprises a
staple driving portion and a staple forming portion, and a firing
member comprising a first guide channel aligned with the staple
driving portions of the staples and a second guide channel aligned
with the staple forming portions of the staples, wherein the first
guide channel and the second guide channel are configured to
co-operatively align the staples with the staple forming pockets of
the anvil when the firing member is moved toward the distal end.
Example 74--A staple cartridge assembly comprising a cartridge body
including a deck, a first longitudinal row of staple cavities, and
a second longitudinal row of staple cavities. The staple cartridge
assembly further comprises a plurality of first staples, wherein
each first staple is removably stored in the first longitudinal row
of staple cavities, and wherein each first staple comprises a
unitary structure including a first base including a first drive
surface and a first staple leg extending from the first base and
including a first tip, wherein a first unformed distance is defined
between the first drive surface and the first tip, a plurality of
second staples, wherein each second staple is removably stored in
the second longitudinal row of staple cavities, and wherein each
second staple comprises a unitary structure including a second base
including a second drive surface and a second staple leg extending
from the second base and including a second tip, wherein a second
unformed distance is defined between the second drive surface and
the second tip which is different than the first unformed distance,
and a firing member configured to directly engage the first staples
and the second staples. Example 75--The staple cartridge assembly
of Example 74, wherein the first staples and the second staples are
formed from a sheet of metal. Example 76--The staple cartridge
assembly of Examples 74 or 75, wherein each first base includes a
first tissue supporting surface, wherein a first tissue capture
distance is defined between the first tissue supporting surface and
the first tip, wherein each second base includes a second tissue
supporting surface, wherein a second tissue capture distance is
defined between the second tissue supporting surface and the second
tip, and wherein the first tissue capture distance is different
than the second tissue capture distance. Example 77--The staple
cartridge assembly of Examples 74, 75, or 76, wherein the deck
comprises a first deck height along the first longitudinal row of
staple cavities and a second deck height along second the
longitudinal row of staple cavities which is different than the
first deck height. Example 78--The staple cartridge assembly of
Example 77, wherein the cartridge body further comprises a
longitudinal slot configured to receive a cutting member, wherein
the first longitudinal row of staple cavities is adjacent the
longitudinal slot, wherein the second longitudinal row of staple
cavities is adjacent the first longitudinal row of staple cavities,
and wherein the second deck height is shorter than the first deck
height. Example 79--The staple cartridge assembly of Examples 74,
75, 76, 77, or 78, wherein the cartridge body further comprises a
longitudinal slot configured to receive a cutting member, wherein
the first longitudinal row of staple cavities is adjacent the
longitudinal slot, and wherein the second longitudinal row of
staple cavities is adjacent the first longitudinal row of staple
cavities. Example 80--The staple cartridge assembly of Examples 74,
75, 76, 77, 78, or 79, wherein the first unformed distance is
shorter than the second unformed distance. Example 81--The staple
cartridge assembly of Examples 74, 75, 76, 77, 78, 79, or 80,
further comprising an anvil configured to deform the staples.
Example 82--The staple cartridge assembly of Example 81, wherein
the anvil is configured to deform the first staples to a first
deformed height and the second staples to a second deformed height
which is different than the first deformed height. Example 83--The
staple cartridge assembly of Examples 81 or 82, wherein the
cartridge body is movable toward the anvil to clamp tissue between
the anvil and the deck of the cartridge body. Example 84--The
staple cartridge assembly of Examples 81, 82, or 83, wherein the
anvil is movable toward the cartridge body to clamp tissue between
the anvil and the deck of the cartridge body. Example 85--The
staple cartridge assembly of Examples 74, 75, 76, 77, 78, 79, 80,
81, 82, 83, or 84, further comprising staple cavity extenders
extending from the deck. Example 86--The staple cartridge assembly
of Examples 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, or 85,
further comprising an implantable layer positioned over the deck.
Example 87--A staple cartridge assembly comprising a cartridge body
comprising a deck, a first longitudinal row of staple cavities, and
a second longitudinal row of staple cavities. The staple cartridge
assembly further comprises a plurality of first staples, wherein
each first staple is removably stored in the first longitudinal row
of staple cavities, and wherein each first staple comprises a
unitary structure including a first base including a first drive
surface and a first tissue supporting surface and a first staple
leg extending from the first base including a first tip, wherein a
first tissue capture distance is defined between the first tissue
supporting surface and the first tip, a plurality of second
staples, wherein each second staple is removably stored in the
second longitudinal row of staple cavities, and wherein each second
staple comprises a unitary structure including a second base
including a second drive surface and a second tissue supporting
surface and a second staple leg extending from the second base
including a second tip, wherein a second tissue capture distance is
defined between the second tissue supporting surface and the second
tip which is different than the first tissue capture distance, and
a firing member configured to directly engage the first staples and
the second staples. Example 88--The staple cartridge assembly of
Example 87, wherein the deck comprises a first deck height along
the first longitudinal row of staple cavities and a second deck
height along second the longitudinal row of staple cavities which
is different than the first deck height. Example 89--The staple
cartridge assembly of Example 88, wherein the cartridge body
further comprises a longitudinal slot configured to receive a
cutting member, wherein the first longitudinal row of staple
cavities is adjacent the longitudinal slot, wherein the second
longitudinal row of staple cavities is adjacent the first
longitudinal row of staple cavities, and wherein the second deck
height is shorter than the first deck height. Example 90--The
staple cartridge assembly of Examples 87, 88, or 89, further
comprising an anvil configured to deform the staples. Example
91--The staple cartridge assembly of Example 90, wherein the anvil
is configured to deform the first staples to a first deformed
height and the second staples to a second deformed height which is
different than the first deformed height. Example 92--The staple
cartridge assembly of Examples 90 or 91, wherein the cartridge body
is movable toward the anvil to clamp tissue between the anvil and
the deck of the cartridge body. Example 93--A staple cartridge
assembly comprising a cartridge body comprising a first
longitudinal row of staple cavities and a second longitudinal row
of staple cavities, a plurality of first staples removably stored
in the first longitudinal row of staple cavities, wherein each
first staple is comprised of stamped metal and includes an
integrally-formed metal driver, a plurality of second staples
removably stored in the second longitudinal row of staple cavities,
wherein each second staple is comprised of stamped metal and
includes an integrally-formed metal driver, and means for forming
the first staples to a first deformed height and the second staples
to a second deformed height, wherein the first deformed height is
different than the second deformed height. Example 94--A staple
cartridge assembly comprising a staple cartridge body including a
deck and staple cavities defined in the deck, staples removable
stored in the staple cavities, wherein each staple comprises a
base, a leg extending from the base, and a platform extending
laterally from the base, and an implantable layer positioned over
the deck, wherein the platforms of the staples are configured to
abut the layer when the staples are implanted into the tissue of a
patient. Example 95--The staple cartridge assembly of Example 94,
wherein each staple is stamped from a sheet of material, wherein
the base defines a base plane, and wherein the platform is folded
out of the base plane. Example 96--The staple cartridge assembly of
Examples 94 or 95, wherein the implantable layer comprises a woven
material. Example 97--The staple cartridge assembly of Examples 94,
95, or 96, wherein the implantable layer comprises a non-woven
material. Example 98--The staple cartridge assembly of Examples 94,
95, 96, or 97, further comprising a retention member extending from
the leg adjacent the base, wherein the retention member is
configured to engage the implantable layer when staples are
implanted into the tissue of a patient. Example 99--The staple
cartridge assembly of Examples 94, 95, 96, 97, or 98, wherein the
platform is flat. Example 100--The staple cartridge assembly of
Examples 94, 95, 96, 97 98, or 99, wherein the platform is not
directly attached to the leg. Example 101--A staple cartridge
assembly comprising a staple cartridge body including a deck and
staple cavities defined in the deck, staples removable stored in
the staple cavities, wherein each staple comprises a crown, a first
leg and a second leg extending from the crown, and a platform
extending laterally from the crown, and an implantable layer
positioned over the deck, wherein the platforms of the staples are
configured to support the layer when the staples are implanted into
the tissue of a patient. Example 102--The staple cartridge assembly
of Example 101, wherein each staple is stamped from a sheet of
material, wherein the crown defines a crown plane, and wherein the
platform is folded out of the crown plane. Example 103--The staple
cartridge assembly of Examples 101 or 102, wherein the implantable
layer comprises a woven material. Example 104--The staple cartridge
assembly of Examples 101, 102, or 103, wherein the implantable
layer comprises a non-woven material. Example 105--The staple
cartridge assembly of Examples 101, 102, 103, or 104, further
comprising a retention member extending from the leg adjacent the
crown, wherein the retention member is configured to engage the
implantable layer when staples are implanted into the tissue of a
patient. Example 106--The staple cartridge assembly of Examples
101, 102, 103, 104, or 105, wherein the platform is flat. Example
107--The staple cartridge assembly of Examples 101, 102, 103, 104,
105, or 106, wherein each staple comprises a compliant adjunct
positioned adjacent the crown. Example 108--The staple cartridge
assembly of Example 107, wherein the compliant adjunct extends
between the first leg and the second leg. Example 109--The staple
cartridge assembly of Examples 107 or 108, wherein the compliant
adjunct is attached to the first leg and the second leg. Example
110--The staple cartridge assembly of Examples 107, 108, or 109,
wherein the compliant adjunct comprises a first aperture and a
second aperture, wherein the first leg extends through the first
aperture, and wherein the second leg extends through the second
aperture. Example 111--The staple cartridge assembly of Examples
107, 108, 109, or 110, wherein the compliant adjunct comprises a
cavity and at least one medicament positioned in the cavity.
Example 112--The staple cartridge assembly of Examples 107, 108,
109,110, or 111, wherein the compliant adjunct comprises a
compressible enclosure. Example 113--A staple cartridge assembly
comprising a staple cartridge body including a deck and staple
cavities defined in the deck, and staples removably stored in the
staple cavities, wherein each staple comprises a crown, a first leg
and a second leg extending from the crown, a platform extending
laterally from the crown, and a compliant adjunct positioned
adjacent the crown. Example 114--The staple cartridge assembly of
Example 113, wherein the compliant adjunct extends between the
first leg and the second leg. Example 115--The staple cartridge
assembly of Examples 113 or 114, wherein the compliant adjunct is
attached to the first leg and the second leg. Example 116--The
staple cartridge assembly of Examples 113, 114, or 115, wherein the
compliant adjunct comprises a first aperture and a second aperture,
wherein the first leg extends through the first aperture, and
wherein the second leg extends through the second aperture. Example
117--The staple cartridge assembly of Examples 113, 114, 115, or
116, wherein the compliant adjunct comprises a cavity and at least
one medicament positioned in the cavity. Example 118--The staple
cartridge assembly of Examples 113, 114, 115, 116, or 117, wherein
the compliant adjunct comprises a compressible enclosure. Example
119--A staple cartridge assembly comprising a cartridge body
including a deck and a plurality of staple cavities defined in the
deck, and a plurality of staples stored in the staple cavities,
wherein each staple comprises a first portion comprised of an alloy
including zinc and magnesium and a second portion comprised of an
absorbable polymer, wherein the second portion is disposed on the
first portion, and wherein the second portion covers less than the
entirety of the first portion. Example 120--The staple cartridge
assembly of Example 119, wherein the first portion comprises a base
and a staple leg extending from the base, and wherein the second
portion extends around the staple leg in a spiral pattern. Example
121--The staple cartridge assembly of Examples 119 or 120, wherein
the second portion is coated on the first portion in a dot-matrix
pattern. Example 122--The staple cartridge assembly of Examples
119, 120, or 121, wherein the first portion comprises a base and a
staple leg extending from the base, wherein a corner is defined
between the base and the staple leg, and wherein the second portion
covers the corner. Example 123--The staple cartridge assembly of
Examples 119, 120, 121, or 122, wherein the absorbable polymer
comprises a non-crosslinked polymer. Example 124--The staple
cartridge assembly of Examples 119, 120, 121, 122, or 123, wherein
the second portion is coated on the first portion in a mesh
pattern. Example 125--The staple cartridge assembly of Examples
119, 120, 121, 122, 123, or 124, wherein the first portion
comprises a base and a staple leg extending from the base, wherein
the staple leg comprises a tissue penetrating tip, and wherein the
staple further comprises magnesium nitride disposed on the tip.
Example 126--The staple cartridge assembly of Examples 119, 120,
121, 122, 123, 124, or 125, wherein the staple further comprises a
coating of ionized silver on at least part of the first portion
that is not coated by the second portion. Example 127--The staple
cartridge assembly of Examples 119, 120, 121, 122, 123, 124, 125,
or 126, further comprising at least one aperture in the first
portion. Example 128--A staple cartridge assembly comprising a
cartridge body including a deck and a plurality of staple cavities
defined in the deck and a plurality of staples stored in the staple
cavities, wherein each staple comprises a metal frame comprised of
a magnesium alloy and an absorbable polymer coated on the metal
frame, wherein the absorbable polymer does not cover every portion
of the metal frame. Example 129--A staple cartridge assembly
comprising a cartridge body including a deck and a plurality of
staple cavities defined in the deck, and a plurality of staples
stored in the staple cavities, wherein each staple comprises a
metal frame comprised of a magnesium alloy, wherein the metal frame
comprises a base and a leg extending from the base, and wherein the
leg comprises a tissue penetrating tip, and a magnesium nitride
coating on the tip. Example 130--The staple cartridge assembly of
Example 129, wherein each staple further comprises an absorbable
polymer coated on the metal frame, and wherein the absorbable
polymer does not cover every portion of the metal frame. Example
131--The staple cartridge assembly of Examples 129 or 130, wherein
each staple further comprises a coating comprising silver on at
least a portion of the metal frame. Example 132--A staple cartridge
assembly comprising a cartridge body including a deck and a
plurality of staple cavities defined in the deck, and a plurality
of staples stored in the staple cavities, wherein each staple
comprises a metal frame comprised of a magnesium alloy, wherein the
metal frame comprises a base and a leg extending from the base, and
wherein the leg comprises a tissue penetrating tip, and a coating
comprising silver on at least a portion of the metal frame. Example
133--The staple cartridge assembly of Example 132, wherein each
staple further comprises an absorbable polymer coated on the metal
frame, and wherein the absorbable polymer does not cover every
portion of the metal frame. Example 134--The staple cartridge
assembly of Examples 132 or 133, further comprising a magnesium
nitride coating on the tip. Example 135--A staple cartridge
assembly comprising a cartridge body including a deck and a
plurality of staple cavities defined in the deck, and a plurality
of staples stored in the staple cavities, wherein each staple
comprises a metal frame comprised of a magnesium alloy, wherein the
metal frame comprises a base and a leg extending from the base, and
wherein the leg comprises tissue penetrating tip, and an aperture
defined in the metal frame. Example 136--The staple cartridge
assembly of Example 135, wherein each staple further comprises an
absorbable polymer coated on the metal frame, and wherein the
absorbable polymer does not cover every portion of the metal frame.
Example 137--The staple cartridge assembly of Example 135, wherein
each staple further comprises an absorbable polymer coated on the
metal frame, and wherein the absorbable polymer is not positioned
in the aperture. Example 138--The staple cartridge assembly of
Example 135, wherein each staple further comprises an absorbable
polymer coated on the metal frame, and wherein the absorbable
polymer is positioned in the aperture. Example 139--The staple
cartridge assembly of Example 135, wherein each staple further
comprises an absorbable polymer coated on the metal frame, and
wherein the aperture is filled with the absorbable polymer. Example
140--A staple cartridge assembly for stapling tissue comprising a
cartridge body including a proximal end, a distal end, and a
plurality of staple cavities, a plurality of staples positioned in
the staple cavities, wherein each staple comprises a base a leg
extending from the base, wherein the leg comprises a tip configured
to penetrate the tissue, and a foot extending from the base, and a
firing member configured to eject the staples from the staple
cavities, wherein the firing member is configured to contact the
foot of any staple that is misoriented within its staple cavity
prior to ejecting the misoriented staple from its staple cavity.
Example 141--The staple cartridge assembly of Example 140, wherein
the firing member comprises a firing ramp configured to contact the
bases of the staples to drive the staples out of the staple
cavities and an alignment ramp configured to contact the feet of
the staples if the staples are misoriented. Example 142--The staple
cartridge assembly of Examples 140 or 141, wherein the firing
member further comprises a firing channel aligned with the firing
ramp, wherein the firing channel is configured to receive the bases
of the staples, and an alignment channel aligned with the alignment
ramp, wherein the alignment channel is configured to receive the
feet of the staples once the staples are properly oriented. Example
143--The staple cartridge assembly of Examples 141 or 142, wherein
the alignment ramp extends distally with respect to the firing ramp
such that the alignment ramp can contact the feet of the staples
before the firing ramp contacts the bases of the staples. Example
144--The staple cartridge assembly of Examples 140, 141, 142, or
143, wherein the foot of the staple is positioned proximally with
respect to the base of the staple. Example 145--The staple
cartridge assembly of Examples 140, 141, 142, 143, or 144, wherein
the firing member is not configured to contact the feet of the
staples if the staples are properly oriented within the staple
cavities. Example 146--A staple cartridge assembly for stapling
tissue comprising a cartridge body comprising a proximal end and a
distal end, and a plurality of staple cavities, wherein each staple
cavity comprises a top opening, a proximal wall, and a distal wall.
The staple cartridge assembly further comprises a firing member and
a plurality of staples positioned in the staple cavities, wherein
each staple comprises a base, a proximal leg extending from the
base, a distal leg extending from the base, and center of mass
defined in the base, wherein the distal wall provides a distal
reaction force to the staple above the center of mass and the
proximal wall provides a proximal reaction force to the staple
below the center of mass wherein the staple is lifted toward the
top opening by the firing member. The staple cartridge assembly
further comprises a firing member configured to eject the staples
from the staple cavities, wherein the firing member is configured
to contact the foot of any staple that is misoriented within its
staple cavity prior to ejecting the misoriented staple from its
staple cavity. Example 147--The staple cartridge assembly of
Example 146, wherein the base defines a drive plane, and wherein
the proximal leg and the distal leg are not in the drive plane.
Example 148--The staple cartridge assembly of Examples 146 or 147,
wherein the proximal leg and the distal leg are offset laterally
from the center of mass of the staple. Example 149--The staple
cartridge assembly of Examples 146, 147, or 148, wherein the distal
wall applies the distal reaction force to the distal leg and the
proximal wall applies the proximal reaction force to the proximal
leg. Example 150--The staple cartridge assembly of Example 147,
wherein the proximal leg extends to a first side of the drive plane
and the distal leg extends to a second side of the drive plane.
Example 151--The staple cartridge assembly of Examples 146, 147,
148, 149, or 150, wherein the base comprises a notch defined
therein configured to shift the center of mass of the staple toward
a side of the staple cavity. Example 152--A staple cartridge
assembly for stapling tissue comprising a cartridge body including
a proximal end, a distal end, and a plurality of staple cavities.
The staple cartridge assembly further comprises a plurality of
staples positioned in the staple cavities, wherein each staple
comprises a base defining a drive plane and a leg extending from
the base, wherein the leg extends to a side of the drive plane, a
firing member configured to eject the staples from the staple
cavities, and means for reducing the rotation of the staples within
the staple cavities when the firing member is driving the staples
out of the staple cavities. Example 153--A surgical staple
cartridge for use with a surgical stapling instrument, the surgical
staple cartridge comprising a cartridge body, a plurality of staple
cavities, and a plurality of staples removably stored in the staple
cavities, wherein each staple comprises a staple base portion which
defines a first plane, a center of mass located within the staple
base portion, a first staple leg extending from the staple base
portion, and a second staple leg extending from the staple base
portion, wherein the first staple leg and the second staple leg
define a second plane which is offset and at least substantially
parallel to the first plane. Example 154--The surgical staple
cartridge of Example 153, wherein the first staple leg and the
second staple leg are configured to form toward the staple base
portion. Example 155--The surgical staple cartridge of Examples 153
or 154, wherein the staple base portion comprises a compression
surface comprising a contour configured to limit tissue
compression. Example 156--The surgical staple cartridge of Examples
153, 154, or 155, wherein the staple base portion comprises a
bottom surface, and wherein the first staple leg further comprises
an engagement foot elevated above the bottom surface. Example
157--The surgical staple cartridge of Examples 153, 154, 155, or
156, wherein the staple base portion comprises an inner wall and a
top surface, wherein the inner wall and the top surface comprise a
cutout configured to cause the staple base portion to lean toward
the staple legs. Example 158--The surgical staple cartridge of
Examples 153, 154, 155, 156, or 157, wherein the first staple leg
extends higher than the second staple leg. Example 159--The
surgical staple cartridge of Examples 153, 154, 155, 156, 157, or
158, wherein the staple base portion comprises a rectangular
cross-sectional profile. Example 160--The surgical staple cartridge
of Examples 153, 154, 155, 156, 157, 158, or 159, wherein the first
staple leg and the second staple leg comprise a substantially round
cross-sectional profile. Example 161--The surgical staple cartridge
of Examples 153, 154, 155, 156, 157, 158, 159, or 160, wherein the
first staple leg and the second staple leg comprise coined corners.
Example 162--The surgical staple cartridge of Examples 153, 154,
155, 156, 157, 158, 159, 160, or 161, wherein the first staple leg
is proximal the second staple leg, wherein the staple base portion
comprises a distal wall, and wherein the distal wall is proximal to
the second staple leg. Example 163--The surgical staple cartridge
of Examples 153, 154, 155, 156, 157, 158, 159, 160, 161, or 162,
wherein the first staple leg comprises a first height and the
second staple leg comprises a second height different than the
first height. Example 164--The surgical staple cartridge of
Examples 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, or 163,
wherein the first staple leg and the second staple leg each
comprise a staple tip configured to form against corresponding
forming pockets of an anvil, wherein the corresponding forming
pockets comprise a valley and a forming surface, and wherein the
valley is configured to funnel the staple tips toward the forming
surface. Example 165--The surgical staple cartridge of Examples
153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, or 164,
wherein the first staple leg and the second staple leg are
configured to form against corresponding forming pockets, wherein
the corresponding forming pockets are configured to form the first
staple leg in a first direction and the second staple leg in a
second direction, and wherein the first direction is opposite and
at least substantially parallel to the second direction. Example
166--The surgical staple cartridge of Example 165, wherein the
first direction points away from the staple base portion, and
wherein the second direction points toward the staple base portion.
Example 167--The surgical staple cartridge of Examples 153, 154,
155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, or 166,
wherein the first staple leg and the second staple leg are
configured to form against corresponding forming pockets, wherein
the corresponding forming pockets are configured to form the first
staple leg in a first curved direction and the second staple leg in
a second curved direction. Example 168--A surgical staple
comprising a staple base portion defining a first plane, a first
staple leg extending at least substantially perpendicular from the
staple base portion, and a second staple leg extending at least
substantially perpendicular from the staple base portion, wherein
the first staple leg and the second staple leg define a second
plane, wherein the first plane
and the second plane intersect. Example 169--A surgical staple
cartridge comprising a plurality of the surgical staple of Examples
152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164,
165, 166, 167, or 168, wherein the surgical staples are arranged in
a plurality of woven rows. Example 170--The surgical staple of
Examples 168 or 169, wherein the staple is configured to form into
an S-shape configuration. Example 171--A surgical staple comprising
a staple base portion comprising a bottom surface which defines a
bottom plane, a center of mass located within the staple base
portion, and a first staple leg and a second staple leg extending
from the staple base portion and defining a staple leg plane which
is offset and at least substantially parallel to the staple base
portion, wherein the first staple leg comprises an engagement foot
elevated above the bottom plane. Example 172--The surgical staple
of Example 171, wherein the engagement foot is laterally offset
with respect to the staple base portion. Example 173--A surgical
staple cartridge for use with a surgical stapler including an anvil
to staple tissue, wherein the anvil comprises a plurality of
forming pockets, the surgical staple cartridge comprising a
cartridge body, a plurality of staple cavities, and a plurality of
staples removably stored within the staple cavities, wherein each
staple comprises a base and a staple leg extending from the base,
wherein the staple leg comprises a staple tip comprising a piercing
portion, wherein the piercing portion is configured to puncture
tissue and deform against the forming pocket of the anvil, and
wherein the piercing portion is configured to deform into a nested
configuration such that the piercing tip is isolated from the
tissue. Example 174--The surgical staple cartridge of Example 173,
wherein the nested configuration comprises a hook configuration
configured to prevent the surgical staple from pulling through the
tissue. Example 175--The surgical staple cartridge of Examples 173
or 174, wherein the staple tip further comprises a cutout portion
configured to receive the piercing portion when the piercing
portion is deformed. Example 176--The surgical staple cartridge of
Example 175, wherein the cutout portion is concave. Example
177--The surgical staple cartridge of Examples 175 or 176, wherein
each staple comprises another staple leg extending from the base,
wherein the another staple leg comprises another staple tip
comprising another cutout portion, and wherein the cutout portion
and the another cutout portion face each other. Example 178--The
surgical staple cartridge of Examples 173, 174, 175, 176, or 177,
wherein the staple tip further comprises a curling surface
configured to ride against a corresponding forming pocket of the
anvil. Example 179--The surgical staple cartridge of Examples 173,
174, 175, 176, 177, or 178, wherein each staple comprises another
staple leg, wherein the staple leg and the another staple leg
define a first plane, wherein the staple base defines a second
plane, and wherein the first plane and the second plane are
laterally offset from each other. Example 180--A surgical staple
for use with a surgical stapler including an anvil, wherein the
anvil comprises a forming pocket, the surgical staple comprising a
staple base portion and a staple leg extending from the staple base
portion, wherein the staple leg comprises a staple tip, and wherein
the staple tip comprises a piercing tip configured to contact the
forming pocket to deform the staple leg and a cutout portion,
wherein the piercing tip is configured to curl in toward the cutout
portion upon contact with the forming pocket such that the staple
tip assumes a non-piercing configuration. Example 181--The surgical
staple of Example 180, wherein the non-piercing configuration
comprises a hook configuration configured to prevent the surgical
staple from pulling through the tissue. Example 182--The surgical
staple of Examples 180 or 181, wherein the cutout portion is
configured to receive the piercing tip when the staple tip is
deformed. Example 183--The surgical staple of Examples 180, 181, or
182, wherein the cutout portion is concave. Example 184--The
surgical staple of Examples 180, 181, 182, or 183, wherein the
staple tip further comprises a deformable surface configured to
form against the forming pocket of the anvil. Example 185--A
surgical staple cartridge for use with a surgical stapler including
an anvil, the surgical staple cartridge comprising a cartridge
body, a plurality of staple cavities, and a plurality of
flat-formed staples removably stored within the staple cavities,
wherein each staple comprises a staple base portion and a staple
leg extending from the base portion, wherein the staple leg
comprises a staple tip comprising a rounded profile and a piercing
portion. Example 186--The surgical staple cartridge of Example 185,
wherein the rounded profile is attained by a cold working process.
Example 187--The surgical staple cartridge of Examples 185 or 186,
wherein the staple tip comprises a coined portion. Example 188--The
surgical staple cartridge of Examples 185, 186, or 187, wherein the
staple tip further comprises a deformable surface configured to
form against a forming pocket of the anvil. Example 189--The
surgical staple cartridge of Examples 185, 186, 187, or 188,
wherein the staple tip comprises a first hardness, and wherein the
staple leg comprises a second hardness different than the first
hardness. Example 190--The surgical staple cartridge of Example
189, wherein the first hardness is greater than the second
hardness. Example 191--A surgical staple cartridge for use with a
surgical stapling instrument, the surgical staple cartridge
comprising a cartridge body, a plurality of staple cavities, and a
plurality of staples removably stored within the staple cavities,
wherein each staple comprises a staple base and a pair of staple
legs extending from the staple base, wherein each staple leg
comprises a staple tip, wherein the staple legs comprise a first
zone comprising a first hardness, and wherein the staple tips
comprise a second zone comprising a second hardness which is
different than the first hardness. Example 192--The surgical staple
cartridge of Example 191, wherein the second hardness is greater
than the first hardness. Example 193--The surgical staple cartridge
of Example 191, wherein the second hardness is less than the first
hardness. Example 194--The surgical staple cartridge of Examples
191, 192, or 193, wherein the staple base comprises a third zone
comprising a third hardness different than the first hardness and
the second hardness. Example 195--The surgical staple cartridge of
Examples 191, 192, 193, or 194, wherein the staple legs comprise
corner portions that are coined to the first hardness. Example
196--The surgical staple cartridge of Example 195, wherein the
corner portions provide a preferential bending plane. Example
197--The surgical staple cartridge of Examples 191, 192, 193, 194,
195, or 196, wherein the first zone comprises a first ductility,
and wherein the second zone comprises a second ductility which is
less than the first ductility. Example 198--A surgical staple
cartridge for use with a surgical stapling instrument, the surgical
staple cartridge comprising a cartridge body, a plurality of staple
cavities, and a plurality of staples removably stored within the
staple cavities, wherein each staple comprises a staple base, a
pair of staple legs extending from the staple base, a first zone
comprising a first hardness, and a second zone comprising a second
hardness which is different that the first hardness. Example
199--The surgical staple cartridge of Example 198, wherein the
first zone is hardened using a first method and the second zone is
hardened using a second method different than the first method.
Example 200--The surgical staple cartridge of Example 198, wherein
only one of the first zone and the second zone is hardened by a
hardening method. Example 201--The surgical staple cartridge of
Examples 198, 199, or 200, wherein each staple further comprises
bend portions intermediate the staple legs and the staple base, and
wherein the bend portions comprise the first zone and the staple
base comprises the second zone. Example 202--The surgical staple
cartridge of Examples 198, 199, 200, or 201, wherein the staple
base comprises the first zone and the staple legs comprise the
second zone. Example 203--The surgical staple cartridge of Examples
198, 199, 200, 201, or 202, wherein the staple legs are not
hardened and the staple base is hardened such that the staple legs
are encouraged to assume a formed configuration and such that the
staple base is configured to avoid plastic deformation. Example
204--The surgical staple cartridge of Examples 198, 199, 200, 201,
202, or 203, wherein each staple leg comprises a transition portion
extending from the staple base and a vertical leg portion extending
from the transition portion, and wherein the staple base comprises
the first zone and the vertical leg portion comprises the second
zone. Example 205--A surgical staple configured to be removably
stored within a surgical staple cartridge in an unfired
configuration, the surgical staple comprising a non-uniform
hardness profile, wherein the staple comprises a first zone having
a first hardness and a second zone having a second hardness,
wherein the first zone is hardened to the first hardness when the
staple is in a pre-load configuration, and wherein the second zone
is hardened to the second hardness when the staple is in the
pre-load configuration. Example 206--A surgical staple cartridge
for use with a surgical stapling instrument, the surgical staple
cartridge comprising a cartridge body, a plurality of staple
cavities, and a plurality of staples removably stored within the
staple cavities, wherein each staple comprises a staple base,
wherein the staple base defines a first zone comprising a first
hardness, a plurality of bend portions extending from the staple
base, wherein the bend portions define a second zone comprising a
second hardness, and staple legs extending from the bend portions,
wherein each staple leg defines a third zone comprising a third
hardness different than the first hardness. Example 207--The
surgical staple cartridge of Example 206, wherein the first
hardness is greater than the third hardness. Example 208--The
surgical staple cartridge of Example 206, wherein the first
hardness is greater than the second hardness and the third
hardness. Example 209--The surgical staple cartridge of Examples
206, 207, or 208, wherein each staple leg comprises a staple tip
defining a fourth zone comprising a fourth hardness which is less
than the third hardness. Example 210--A surgical staple cartridge
for use with a surgical stapling instrument, the surgical staple
cartridge comprising a sled, a cartridge body, a plurality of
staple cavities, and a strip of staples removably stored within the
staple cavities, wherein the strip of staples comprises a plurality
of staples, a strip, and a plurality of connector portions joining
the staples to the strip, wherein the connector portions are
configured to release the staples from the strip. Example 211--The
surgical staple cartridge of Example 210, wherein each connector
portion comprises a discontinuity configured to encourage the
separation of the staples from the strip. Example 212--The surgical
staple cartridge of Example 210, wherein each connector portion
comprises a discontinuity configured to encourage the separation of
the staple from the strip when the strip of staples is loaded into
the cartridge body. Example 213--The surgical staple cartridge of
Examples 210 or 211, wherein the sled is configured to separate the
plurality of staples from the strip by breaking the connector
portions when the sled is translated through the staple cartridge.
Example 214--The surgical staple cartridge of Examples 210, 211,
212, or 213, wherein each staple comprises a pair of outwardly
biasing staple legs configured to engage the cartridge body and
hold the strip of staples in the surgical staple cartridge. Example
215--The surgical staple cartridge of Examples 210, 211, 212, 213,
or 214, wherein the cartridge body comprises a bottom, and wherein
the strip of staples is configured to be loaded into the bottom of
the cartridge body. Example 216--The surgical staple cartridge of
Examples 210, 211, 212, 213, 214, or 215, wherein the plurality of
staples are arranged in a first row and a second row, and wherein
the strip is joined to the staples in the first row and the second
row. Example 217--The surgical staple cartridge of Examples 210,
211, 212, 213, 214, 215, or 216, wherein the plurality of staples
comprises a first group of staples having a first configuration and
a second group of staples having a second configuration different
than the first configuration. Example 218--The surgical staple
cartridge of Examples 210, 211, 212, 213, 214, 215, 216, or 217,
wherein the connector portion comprises a peened portion. Example
219--The surgical staple cartridge of Examples 210, 211, 212, 213,
214, 215, 216, 217, or 218, wherein the sled comprises striking
portions configured to break the connector portions. Example
220--The surgical staple cartridge of Examples 210, 211, 212, 213,
214, 215, 216, 217, 218, or 219, wherein the staples comprise a
chamfered surface configured to engage the sled when the sled is
translated through the cartridge body. Example 221--The surgical
staple cartridge of Examples 210, 211, 212, 213, 214, 215, 216,
217, 218, 219, or 220, wherein the strip comprise alignment
features configured to engage corresponding alignment features on
the cartridge body. Example 222--A surgical staple cartridge for
use with a surgical stapling instrument, the surgical staple
cartridge comprising a cartridge body, a plurality of staple
cavities, and a strip of staples removably stored within the
cartridge body, the strip of staples comprising a plurality of
staples, a strip, and a plurality of connector portions joining the
staples to the strip, wherein the connector portions are engageable
to release the staples from the strip, and wherein the staples, the
strip, and the connector portions are metal. Example 223--The
surgical staple cartridge of Example 222, wherein the plurality of
staples comprises a first plurality of staples comprising a first
crown width and a second plurality of staples comprising a second
crown width which is different than the first crown width. Example
224--The surgical staple cartridge of Examples 222 or 223, wherein
the plurality of staples comprises a first group of staples
comprising staple legs defining a first height and a second group
of staples comprising staple legs defining a second height
different than the first height. Example 225--The surgical staple
cartridge of Example 222, wherein the strip of staples comprises a
uniform composition. Example 226--The surgical staple cartridge of
Examples 222, 223, 224, or 225, wherein the strip comprises
alignment features configured to engage corresponding alignment
features on the cartridge body. Example 227--The surgical staple
cartridge of Example 222, 223, 224, 225, or 226, further comprising
a second strip of staples comprising a plurality of second staples,
a second strip, and a plurality of second connector portions
joining the second staples to the second strip, wherein the
plurality of staples are arranged in a plurality of rows defining a
first row spacing, wherein the plurality of second staples are
arranged in a plurality of second rows defining a second row
spacing, and wherein the first row spacing and the second row
spacing are different. Example 228--A metal strip of surgical
staples configured for use with a surgical staple cartridge, the
metal strip of surgical staples comprising a plurality of staples,
a ribbon, and a plurality of connector portions joining the staples
to the ribbon. Example 229--The metal strip of surgical staples of
Example 228, wherein the connector portions comprise a
discontinuity notch. Example 230--A surgical staple cartridge for
use with a circular stapler, the surgical staple cartridge
comprising a cartridge body, a plurality of staple cavities defined
in the cartridge body, and a plurality of staples removably stored
within the staple cavities, the plurality of staples comprising an
inner row of staples comprising a quantity of first staples,
wherein each first staple comprises a first staple crown defining a
first staple crown width, an intermediate row of staples positioned
radially outward with respect to the inner row of staples, wherein
the intermediate row of staples comprises a quantity of second
staples, and wherein each second staple comprises a second staple
crown defining a second staple crown width, and an outer row of
staples positioned radially outward with respect to the
intermediate row of staples, wherein the outer row of staples
comprises a quantity of third staples, wherein each third staple
comprises a third staple crown defining a third staple crown width,
and wherein one of the first staple crown width, the second staple
crown width, and the third staple crown width is different than
another of the first staple crown width, the second staple crown
width, and the third staple crown width. Example 231--The surgical
staple cartridge of Example 230, wherein the inner row of staples
defines a plurality of first gaps between the first staples, and
wherein the second staples of the intermediate row of staples
overlap the first gaps. Example 232--The surgical staple cartridge
of Example
231, wherein the intermediate row of staples defines a plurality of
second gaps between the second staples, wherein the second gaps are
larger than the first gaps, and wherein the third staples of the
outer row of staples overlap the second gaps. Example 233--The
surgical staple cartridge of Examples 231 or 232, wherein the third
staples of the outer row of staples also overlap the first gaps.
Example 234--The surgical staple cartridge of Example 230, wherein
the inner row of staples defines a plurality of first gaps between
the first staples, wherein the intermediate row of staples defines
a plurality of second gaps between the second staples, wherein the
second staples overlap the first gaps, and wherein the first gaps
and the second gaps are at least substantially equal. Example
235--The surgical staple cartridge of Example 230, wherein the
inner row of staples defines a plurality of first gaps between the
first staples, wherein the intermediate row of staples defines a
plurality of second gaps between the second staples, wherein each
first gap defines a first distance, and wherein each second gap
defines a second distance which is less than the first distance.
Example 236--The surgical staple cartridge of Examples 230, 231,
232, 233, 234, or 235, wherein the first staple crown width is less
than the second staple crown width. Example 237--The surgical
staple cartridge of Examples 230, 231, 232, 233, 234, or 235,
wherein the first staple crown width is at least substantially
equal to the second staple crown width. Example 238--The surgical
staple cartridge of Examples 230, 231, 232, 233, 234, 235, 236, or
237, wherein the third staple crown width is greater than the first
staple crown width and the second staple crown width. Example
239--A surgical staple cartridge for use with a circular stapler,
the surgical staple cartridge comprising a cartridge body, a
plurality of staple cavities defined in the cartridge body, and a
plurality of staples removably stored within the staple cavities,
the plurality of staples comprising an inner row of staples
comprising a first quantity of first staples, wherein each first
staple comprises a first staple crown defining a first staple crown
width, an intermediate row of staples positioned radially outward
with respect to the inner row of staples, wherein the intermediate
row of staples comprises a second quantity of second staples, and
wherein each second staple comprises a second staple crown defining
a second staple crown width, and an outer row of staples positioned
radially outward with respect to the intermediate row of staples,
wherein the outer row of staples comprises a third quantity of
third staples, wherein each third staple comprises a third staple
crown defining a third staple crown width, wherein one of the first
staple crown width, the second staple crown width, and the third
staple crown width is different than another of the first staple
crown width, the second staple crown width, and the third staple
crown width, and wherein one of the first quantity, the second
quantity, and the third quantity is different than another of the
first quantity, the second quantity, and the third quantity.
Example 240--The surgical staple cartridge of Example 239, wherein
the second quantity is less than the first quantity. Example
241--The surgical staple cartridge of Examples 239 or 240, wherein
the second quantity is less than the third quantity. Example
242--The surgical staple cartridge of Examples 239, 240, or 241,
wherein the plurality of staple cavities comprises a plurality of
non-uniform cavity extenders. Example 243--The surgical staple
cartridge of Examples 239, 240, 241, or 242, wherein each first
staple of the inner row of staples comprises a pair of staple legs
extending radially outward from each first staple crown. Example
244--The surgical staple cartridge of Examples 239, 240, 241, 242,
or 243, wherein each second staple of the intermediate row of
staples comprises a pair of staple legs extending radially inward
from each second staple crown. Example 245--The surgical staple
cartridge of Examples 239, 240, 241, 242, 243, or 244, wherein each
third staple of the outer row of staples comprises a pair of staple
legs extending radially inward from each third staple crown.
Example 246--A surgical staple cartridge for use with a surgical
stapler, the surgical staple cartridge comprising a cartridge body,
a plurality of staple cavities defined in the cartridge body, and a
plurality of staples removably stored within the staple cavities,
the plurality of staples comprising an inner row of staples
comprising a first quantity of first staples, wherein each first
staple comprises a first staple crown defining a first staple crown
width, an intermediate row of staples positioned outward with
respect to the inner row of staples, wherein the intermediate row
of staples comprises a second quantity of second staples, and
wherein each second staple comprises a second staple crown defining
a second staple crown width, and an outer row of staples positioned
outward with respect to the intermediate row of staples, wherein
the outer row of staples comprises a third quantity of third
staples, wherein each third staple comprises a third staple crown
defining a third staple crown width, and wherein one of the first
staple crown width, the second staple crown width, and the third
staple crown width is different than another of the first staple
crown width, the second staple crown width, and the third staple
crown width. Example 247--The surgical staple cartridge of Example
246, wherein one of the first quantity, the second quantity, and
the third quantity is different than another of the first quantity,
the second quantity, and the third quantity. Example 248--The
surgical staple cartridge of Example 246, wherein the first
quantity and the second quantity are equal. Example 249--The
surgical staple cartridge of Examples 246, 247, or 248, wherein the
inner row of staples defines a plurality of first gaps between the
first staples, wherein the intermediate row of staples defines a
plurality of second gaps between the second staples, wherein each
first gap defines a first distance, and wherein each second gap
defines a second distance which is less than the first
distance.
[0287] The entire disclosures of: [0288] U.S. Pat. No. 5,403,312,
entitled ELECTROSURGICAL HEMOSTATIC DEVICE, which issued on Apr. 4,
1995; [0289] U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING
INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS,
which issued on Feb. 21, 2006; [0290] U.S. Pat. No. 7,422,139,
entitled MOTOR-DRIVEN SURGICAL CUTTING AND FASTENING INSTRUMENT
WITH TACTILE POSITION FEEDBACK, which issued on Sep. 9, 2008;
[0291] U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL
SURGICAL INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT
COMPONENTS, which issued on Dec. 16, 2008; [0292] U.S. Pat. No.
7,670,334, entitled SURGICAL INSTRUMENT HAVING AN ARTICULATING END
EFFECTOR, which issued on Mar. 2, 2010; [0293] U.S. Pat. No.
7,753,245, entitled SURGICAL STAPLING INSTRUMENTS, which issued on
Jul. 13, 2010; [0294] U.S. Pat. No. 8,393,514, entitled SELECTIVELY
ORIENTABLE IMPLANTABLE FASTENER CARTRIDGE, which issued on Mar. 12,
2013; [0295] U.S. patent application Ser. No. 11/343,803, entitled
SURGICAL INSTRUMENT HAVING RECORDING CAPABILITIES, now U.S. Pat.
No. 7,845,537; [0296] U.S. patent application Ser. No. 12/031,573,
entitled SURGICAL CUTTING AND FASTENING INSTRUMENT HAVING RF
ELECTRODES, filed Feb. 14, 2008; [0297] U.S. patent application
Ser. No. 12/031,873, entitled END EFFECTORS FOR A SURGICAL CUTTING
AND STAPLING INSTRUMENT, filed Feb. 15, 2008, now U.S. Pat. No.
7,980,443; [0298] U.S. patent application Ser. No. 12/235,782,
entitled MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT, now U.S. Pat.
No. 8,210,411; [0299] U.S. patent application Ser. No. 12/249,117,
entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH
MANUALLY RETRACTABLE FIRING SYSTEM, now U.S. Pat. No. 8,608,045;
[0300] U.S. patent application Ser. No. 12/647,100, entitled
MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR
DIRECTIONAL CONTROL ASSEMBLY, filed Dec. 24, 2009, now U.S. Pat.
No. 8,220,688; [0301] U.S. patent application Ser. No. 12/893,461,
entitled STAPLE CARTRIDGE, filed Sep. 29, 2012, now U.S. Pat. No.
8,733,613; [0302] U.S. patent application Ser. No. 13/036,647,
entitled SURGICAL STAPLING INSTRUMENT, filed Feb. 28, 2011, now
U.S. Pat. No. 8,561,870; [0303] U.S. patent application Ser. No.
13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE
STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535; [0304]
U.S. patent application Ser. No. 13/524,049, entitled ARTICULATABLE
SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15,
2012, now U.S. Pat. No. 9,101,358; [0305] U.S. patent application
Ser. No. 13/800,025, entitled STAPLE CARTRIDGE TISSUE THICKNESS
SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. Pat. No. 9,345,481;
[0306] U.S. patent application Ser. No. 13/800,067, entitled STAPLE
CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013,
now U.S. Patent Application Publication No. 2014/0263552; [0307]
U.S. Patent Application Publication No. 2007/0175955, entitled
SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER
LOCKING MECHANISM, filed Jan. 31, 2006; and [0308] U.S. Patent
Application Publication No. 2010/0264194, entitled SURGICAL
STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR, filed Apr.
22, 2010, now U.S. Pat. No. 8,308,040, are hereby incorporated by
reference herein.
[0309] Although the various embodiments of the devices have been
described herein in connection with certain disclosed embodiments,
many modifications and variations to those embodiments may be
implemented. Also, where materials are disclosed for certain
components, other materials may be used. Furthermore, according to
various embodiments, a single component may be replaced by multiple
components, and multiple components may be replaced by a single
component, to perform a given function or functions. The foregoing
description and following claims are intended to cover all such
modification and variations.
[0310] 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.
[0311] By way of example only, aspects described herein may be
processed before surgery. First, a new or used instrument may be
obtained and when necessary cleaned. The instrument may 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 may then be placed in a field of
radiation that can penetrate the container, such as gamma
radiation, x-rays, or high-energy electrons. The radiation may kill
bacteria on the instrument and in the container. The sterilized
instrument may then be stored in the sterile container. The sealed
container may keep the instrument sterile until it is opened in a
medical facility. A device also may be sterilized using any other
technique known in the art, including but not limited to beta or
gamma radiation, ethylene oxide, plasma peroxide, or steam.
[0312] 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.
[0313] 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.
* * * * *