Staple forming pocket arrangement to accommodate different types of staples

• US 10,537,325 B2
• Filed: 12/21/2016
• Issued: 01/21/2020
• Est. Priority Date: 12/21/2016
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Bakos, Gregory J., Shelton, IV, Frederick E., Harris, Jason L., Morgan, Jerome R.
• Primary Examiner(s): Smith, Scott A
• Application Number:
  US15/385,898
• Publication Number:
  US 20180168599A1
• Time in Patent Office: 1,126 Days
• Field of Search: 227 19, 2271752, 2271761, 2271801, 606139, 606153, 606219
• CPC Class Codes: A61B 17/0644 penetrating the tissue, deformable to closed position
• CPC Class Codes: A61B 17/068 Surgical staplers , e.g. containing multiple staples or clampsstaplers containing only one staple A61B17/10; magazines or containers for staples A61B17/105; for performing anastomosis A61B17/115; staplers in general B25C5/00
• CPC Class Codes: A61B 17/0682 for applying U-shaped staples or clamps, e.g. without a forming anvil
• CPC Class Codes: A61B 17/072 for applying a row of staples in a single action , e.g. the staples being applied simultaneously
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00039 Electric or electromagnetic phenomena other than conductivity, e.g. capacity, inductivity, Hall effect
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/0046 with a releasable handle; with handle and operating part separable for prosthetic joint-implanting tools A61F2/4603
• CPC Class Codes: A61B 2017/00473 Distal part, e.g. tip or head A61B2017/00464 takes precedence
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/00991 Telescopic means
• CPC Class Codes: A61B 2017/0641 having at least three legs as part of one single body
• CPC Class Codes: A61B 2017/07214 Stapler heads
• CPC Class Codes: A61B 2017/07221 curved
• CPC Class Codes: A61B 2017/07228 Arrangement of the staples
• CPC Class Codes: A61B 2017/07235 containing different staples, e.g. staples of different shapes, sizes or materials
• CPC Class Codes: A61B 2017/07242 achieving different staple heights during the same shot, e.g. using an anvil anvil having different heights or staples of different sizes
• CPC Class Codes: A61B 2017/0725 with settable gap between anvil and cartridge, e.g. for different staple heights at different shots
• CPC Class Codes: A61B 2017/07264 : characterised by its staple forming cavities, e.g. geometry or material
• CPC Class Codes: A61B 2017/07271 : characterised by its cartridge
• CPC Class Codes: A61B 2017/07278 : characterised by its sled or its staple holder
• CPC Class Codes: A61B 2017/07285 : characterised by its cutter
• CPC Class Codes: A61B 2017/2927 : the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2933 : camming or guiding means
• CPC Class Codes: A61B 2090/032 : pressure limiting, e.g. hydrostatic
• CPC Class Codes: A61B 2090/0808 : for indicating correct assembly of components, e.g. of the surgical apparatus
• CPC Class Codes: A61B 2090/0811 : for the position of a particular part of an instrument with respect to the rest of the instrument, e.g. position of the anvil of a stapling instrument
• CPC Class Codes: A61B 2090/0814 : Preventing re-use
• CPC Class Codes: A61B 34/30 : Surgical robots
• CPC Class Codes: A61B 90/03 : Automatic limiting or abutting means, e.g. for safety

Abstract

A surgical stapling system is disclosed. In various embodiments, the system comprises a staple cartridge attachment portion, a first staple cartridge configured to be operably attached to the cartridge attachment portion, wherein the first cartridge comprises a plurality of first staples comprising first staple legs, and a second staple cartridge configured to be operably attached to the cartridge attachment portion in lieu of the first cartridge, wherein the second cartridge comprises a plurality of second staples comprising second staple legs, and wherein the second staples are different than the first staples. The system further comprises an anvil comprising a tissue-engaging surface and a plurality of forming pockets defined in the surface, wherein each pocket comprises a first landing zone configured to receive a leg of a first staple of the first cartridge and a second landing zone configured to receive a leg of a second staple of the second cartridge.

Claims

1. A surgical stapling system, comprising:

a staple cartridge attachment portion;

a first staple cartridge configured to be operably attached to said staple cartridge attachment portion, wherein said first staple cartridge comprises a plurality of first staples comprising first staple legs;

a second staple cartridge configured to be operably attached to said staple cartridge attachment portion, wherein said second staple cartridge comprises a plurality of second staples comprising second staple legs, and wherein said first staples and said second staples are different; and

an anvil, comprising;

an anvil slot defining an anvil longitudinal axis;

a tissue-engaging surface; and

a longitudinal row of forming pockets defined in said tissue-engaging surface, wherein each said forming pocket comprises;

a first landing zone configured to receive a said leg of a said first staple; and

a second landing zone configured to receive a said leg of a said second staple;

wherein said first staple cartridge further comprises;

a cartridge slot defining a first longitudinal cartridge axis which is aligned with said anvil longitudinal axis when said first staple cartridge is operably attached to said staple cartridge attachment portion; and

a longitudinal row of said first staples aligned with said longitudinal row of forming pockets when said first staple cartridge is operably attached to said staple cartridge attachment portion, wherein each said first staple leg comprises a first staple tip, wherein said first staple tips define a first longitudinal staple axis, wherein said first longitudinal staple axis is a first distance from said first longitudinal cartridge axis; and

wherein said second staple cartridge further comprises;

a cartridge slot defining a second longitudinal cartridge axis which is aligned with said anvil longitudinal axis when said second staple cartridge is operably attached to said staple cartridge attachment portion; and

a longitudinal row of said second staples aligned with said longitudinal row of forming pockets when said second staple cartridge is operably attached to said staple cartridge attachment portion, wherein each said second staple leg comprises a second staple tip, wherein said second staple tips define a second longitudinal staple axis, wherein said second longitudinal staple axis is a second distance from said second longitudinal cartridge axis, and wherein said first distance is different than said second distance.

2. The surgical stapling system of claim 1, wherein said first staples comprise wire staples and wherein said second staples comprise flat formed staples.

3. The surgical stapling system of claim 1, wherein said first staples are configured to be formed into a planar configuration, and wherein said second staples are configured to be formed into a nonplanar configuration.

4. The surgical stapling system of claim 1, wherein said first landing zone of each said forming pocket comprises a first pocket feature configured to take control of forming a said first staple leg into a first configuration.

5. The surgical stapling system of claim 4, wherein said first pocket feature comprises a groove.

6. The surgical stapling system of claim 5, wherein each said first staple comprises a first thickness, and wherein said groove comprises an overall width that is greater than said first thickness.

7. A surgical stapling system, comprising:

a staple cartridge attachment portion;

a first staple cartridge configured to be operably attached to said staple cartridge attachment portion, wherein said first staple cartridge comprises a plurality of first staples comprising first staple legs;

a second staple cartridge configured to be operably attached to said staple cartridge attachment portion, wherein said second staple cartridge comprises a plurality of second staples comprising second staple legs, and wherein said first staples and said second staples are different; and

an anvil, comprising;

a tissue-engaging surface; and

a plurality of forming pockets defined in said tissue-engaging surface, wherein each said forming pocket comprises;

a first landing zone configured to receive a said leg of a said first staple; and

a second landing zone configured to receive a said leg of a said second staple,

wherein said first landing zone of each said forming pocket comprises a first pocket feature configured to take control of forming a said first staple leg into a first configuration,

wherein said first pocket feature comprises a groove,

wherein each said first staple comprises a first thickness, and wherein said groove comprises an overall width that is greater than said first thickness, and

wherein each said second staple comprises a second thickness that is greater than said first thickness, and wherein said second thickness is greater than said overall width of said groove.

8. A surgical stapling system, comprising:

a staple cartridge attachment portion;

a first staple cartridge configured to be operably attached to said staple cartridge attachment portion, wherein said first staple cartridge comprises a plurality of first staples comprising first staple legs;

a second staple cartridge configured to be operably attached to said staple cartridge attachment portion, wherein said second staple cartridge comprises a plurality of second staples comprising second staple legs, and wherein said first staples and said second staples are different; and

an anvil, comprising;

a tissue-engaging surface; and

a plurality of forming pockets defined in said tissue-engaging surface, wherein each said forming pocket comprises;

a first landing zone configured to receive a said leg of a said first staple; and

a second landing zone configured to receive a said leg of a said second staple,

wherein said forming pockets are arranged in a plurality of forming pocket arrangements, wherein said anvil defines a datum plane, wherein said tissue-engaging surface comprises a plurality of tissue-facing surfaces each comprising a said forming pocket arrangement, and wherein said tissue-facing surfaces are individually angled with respect to said datum plane.

9. The surgical stapling system of claim 8, wherein said anvil comprises a proximal end and a distal end, and wherein the angle of each said tissue-facing surface increases progressively from the proximal end to the distal end.

10. A surgical fastening system, comprising:

a fastener cartridge attachment portion;

a first fastener cartridge configured to be installed into said fastener cartridge attachment portion, wherein said first fastener cartridge comprises a plurality of first fasteners comprising first fastener legs;

a second fastener cartridge configured to be installed into to said fastener cartridge attachment portion, wherein said second fastener cartridge comprises a plurality of second fasteners comprising second fastener legs, and wherein said first fasteners and said second fasteners are different; and

an anvil, comprising;

an anvil slot defining an anvil longitudinal axis;

a tissue-engaging surface; and

a longitudinal row of forming pockets defined in said tissue-engaging surface, wherein each said forming pocket comprises;

a first target zone configured to receive a said leg of a said first fastener and form said leg of said first fastener into a first configuration; and

a second target zone configured to receive a said leg of a said second fastener and form said leg of said second fastener into a second configuration, wherein said first configuration and said second configuration are different;

wherein said first fastener cartridge comprises;

a cartridge slot defining a first longitudinal cartridge axis which is aligned with said anvil longitudinal axis when said first fastener cartridge is operably attached to said fastener cartridge attachment portion; and

a longitudinal row of said first fasteners aligned with said longitudinal row of forming pockets when said first fastener cartridge is installed in said fastener cartridge attachment portion, wherein each said first fastener leg comprises a first fastener tip, wherein said first fastener tips define a first longitudinal fastener axis, wherein said first longitudinal fastener axis is a first distance from said first longitudinal cartridge axis;

and wherein said second fastener cartridge comprises;

a cartridge slot defining a second longitudinal cartridge axis which is aligned with said anvil longitudinal axis when said second fastener cartridge is operably attached to said fastener cartridge attachment portion; and

a longitudinal row of said second fasteners aligned with said longitudinal row of forming pockets when said second fastener cartridge is installed in said fastener cartridge attachment portion, wherein each said second fastener leg comprises a second fastener tip, wherein said second fastener tips define a second longitudinal fastener axis, wherein said second longitudinal fastener axis is a second distance from said second longitudinal cartridge axis, and wherein said first distance is different than said second distance.

11. The surgical fastening system of claim 10, wherein said first configuration comprises a planar configuration and said second configuration comprises a nonplanar configuration.

12. The surgical fastening system of claim 10, wherein said first fasteners comprise wire fasteners and wherein said second fasteners comprise flat formed fasteners.

13. The surgical fastening system of claim 10, wherein said first target zone of each said forming pocket comprises a first pocket feature configured to take control of forming a said first fastener leg into said first configuration.

14. The surgical fastening system of claim 13, wherein said first pocket feature comprises a groove.

15. The surgical fastening system of claim 14, wherein each said first fastener comprises a first thickness, and wherein said groove comprises an overall width that is greater than said first thickness.

16. A surgical fastening system, comprising:

a fastener cartridge attachment portion;

a first fastener cartridge configured to be installed into said fastener cartridge attachment portion, wherein said first fastener cartridge comprises a plurality of first fasteners comprising first fastener legs;

a second fastener cartridge configured to be installed into to said fastener cartridge attachment portion, wherein said second fastener cartridge comprises a plurality of second fasteners comprising second fastener legs, and wherein said first fasteners and said second fasteners are different; and

an anvil, comprising;

a tissue-engaging surface; and

a plurality of forming pockets defined in said tissue-engaging surface, wherein each said forming pocket comprises;

a first target zone configured to receive a said leg of a said first fastener and form said leg of said first fastener into a first configuration; and

a second target zone configured to receive a said leg of a said second fastener and form said leg of said second fastener into a second configuration,

wherein said first configuration and said second configuration are different,

wherein said first target zone of each said forming pocket comprises a first pocket feature configured to take control of forming a said first fastener leg into said first configuration,

wherein said first pocket feature comprises a groove,

wherein each said first fastener comprises a first thickness, and wherein said groove comprises an overall width that is greater than said first thickness, and

wherein each said second fastener comprises a second thickness that is greater than said first thickness, and wherein said second thickness is greater than said overall width of said groove.

17. A surgical stapling system, comprising:

a staple cartridge attachment portion;

a first staple cartridge configured to be operably attached to said staple cartridge attachment portion, wherein said first staple cartridge comprises a plurality of first staples comprising first staple legs;

a second staple cartridge configured to be operably attached to said staple cartridge attachment portion, wherein said second staple cartridge comprises a plurality of second staples comprising second staple legs, and wherein said first staples and said second staples are different; and

an anvil, comprising;

an anvil slot defining an anvil longitudinal axis;

a tissue-engaging surface; and

a longitudinal row of forming pockets defined in said tissue-engaging surface, wherein each said forming pocket comprises;

a first landing zone configured to receive a said leg of a said first staple, wherein said first staples are configured to be formed along a first path; and

a second landing zone configured to receive a said leg of a said second staple, wherein said second staples are configured to be formed along a second path, and wherein said first path and said second path are different;

wherein said first staple cartridge comprises;

a cartridge slot defining a first longitudinal cartridge axis which is aligned with said anvil longitudinal axis when said first staple cartridge is operably attached to said staple cartridge attachment portion; and

a longitudinal row of said first staples aligned with said longitudinal row of forming pockets when said first staple cartridge is operably attached to said staple cartridge attachment portion, wherein each said first staple leg comprises a first staple tip, wherein said first staple tips define a first longitudinal staple axis, wherein said first longitudinal staple axis is a first distance from said first longitudinal cartridge axis;

and wherein said second staple cartridge comprises;

a cartridge slot defining a second longitudinal cartridge axis which is aligned with said anvil longitudinal axis when said second staple cartridge is operably attached to said staple cartridge attachment portion; and

a longitudinal row of said second staples aligned with said longitudinal row of forming pockets when said second staple cartridge is operably attached to said staple cartridge attachment portion, wherein each said second staple leg comprises a second staple tip, wherein said second staple tips define a second longitudinal staple axis, wherein said second longitudinal staple axis is a second distance from said second longitudinal cartridge axis, and wherein said first distance is different than said second distance.

18. The surgical stapling system of claim 17, wherein said first staples comprise planar staples.

19. The surgical stapling system of claim 17, wherein said first staples comprise non-planar staples.