Surgical instrument systems comprising an articulatable end effector and means for adjusting the firing stroke of a firing member

• US 10,695,058 B2
• Filed: 11/08/2017
• Issued: 06/30/2020
• Est. Priority Date: 12/18/2014
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Lytle, IV, Thomas W., Shelton, IV, Frederick E., Morgan, Jerome R.
• Primary Examiner(s): Chukwurah, Nathaniel C
• Application Number:
  US15/807,056
• Publication Number:
  US 20180110519A1
• Time in Patent Office: 965 Days
• Field of Search: 2271801, 2271791
• 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 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 2017/00039 Electric or electromagnetic phenomena other than conductivity, e.g. capacity, inductivity, Hall effect
• CPC Class Codes: A61B 2017/00061 spectrum
• CPC Class Codes: A61B 2017/00075 Motion
• CPC Class Codes: A61B 2017/00115 with audible or visual output
• CPC Class Codes: A61B 2017/00132 Setting operation time of a device A61B2017/00123 takes precedence
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• 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 2017/2923 Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/2927 the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2937 with flexible part
• CPC Class Codes: A61B 2090/031 torque limiting
• CPC Class Codes: A61B 2090/034 abutting on parts of the device itself
• CPC Class Codes: A61B 2090/037 with a frangible part, e.g. by reduced diameter
• CPC Class Codes: A61B 2090/067 for measuring angles
• 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 90/03 Automatic limiting or abutting means, e.g. for safety

Abstract

A surgical instrument is disclosed. The surgical instrument can include an end effector, comprising an anvil and a staple cartridge. The surgical instrument can further include a shaft defining a longitudinal axis. The surgical instrument can also include an articulation joint, wherein the end effector is rotatably connected to the shaft about the articulation joint between an unarticulated position and at least one articulated position. The surgical instrument can include means for adjusting the length of a firing stroke as a function of the degree in which the end effector is articulated relative to the longitudinal axis. The surgical instrument can include a sensor configured to defect shifting of lateral portions of a flexible firing bar that extends through the articulation joint. Additionally or alternatively, the surgical instrument can include a relief feature configured to accommodate shifting of lateral portions of a flexible firing bar.

Claims

1. A surgical instrument comprising:

an end effector pivotable between an unarticulated position and an articulated position;

a flexible firing bar movable relative to the end effector;

wherein a length of the flexible firing bar varies between a first length and a second length according to an angular position of the end effector between the unarticulated position and the articulated position; and

a detection system configured to detect the length of the flexible firing bar.

2. The surgical instrument of claim 1, wherein:

the flexible firing bar comprises a first layer and a second layer;

the first layer is configured to shift relative to the second layer based on the angular position between the unarticulated position to the articulated position; and

the length of the flexible firing bar corresponds to a distance between a distal end of the first layer and a proximal end of the second layer.

3. The surgical instrument of claim 1, wherein the detection system comprises:

a plurality of magnets disposed sequentially along the flexible firing bar; and

a sensor configured to determine a relative position of the plurality of magnets corresponding to the length of the flexible firing bar.

4. The surgical instrument of claim 1, wherein the detection system comprises:

a plurality of protrusions disposed sequentially along the flexible firing bar; and

an encoding system configured to determine a relative position of the plurality of protrusions corresponding to the length of the flexible firing bar.

5. The surgical instrument of claim 1, wherein the detection system comprises an electrically conductive material configured to emit a signal indicative of a strain on the flexible firing bar, the strain corresponding to the length of the flexible firing bar.

6. The surgical instrument of claim 1, wherein the detection system comprises:

a magnet disposed on a first side of the flexible firing bar; and

a sensor disposed on a second side of the flexible firing bar, the second side opposing the first side;

wherein the sensor is configured to determine a distance between the magnet and the sensor corresponding to the length of the flexible firing bar.

7. The surgical instrument of claim 1, the flexible firing bar comprising a first layer and a second layer, each of the first layer and the second layer comprising a distal end and a proximal end, wherein the detection system comprises a proximity sensor configured to determine a position of the proximal end of the first layer relative to the proximal end of the second layer corresponding to the length of the flexible firing bar.

8. The surgical instrument of claim 1, the flexible firing bar comprising a first layer and a second layer, wherein the detection system comprises:

a first electrical contact disposed on the first layer;

a second electrical contact disposed on the second layer in a cooperating relationship with the first electrical contact; and

a capacitance defined between the first electrical contact and the second electrical contact, wherein the capacitance corresponds to the length of the flexible firing bar.

9. The surgical instrument of claim 1, the flexible firing bar comprising a first layer and a second layer, wherein the detection system comprises:

a first rotary encoder configured to detect a linear displacement of the first layer; and

a second rotary encoder configured to detect a linear displacement of the second layer;

wherein the linear displacement of the first layer and the linear displacement of the second layer corresponds to the length of the flexible firing bar.

10. The surgical instrument of claim 1, the flexible firing bar comprising a first layer and a second layer, wherein the detection system comprises:

a first set of apertures disposed on the first layer;

a second set of apertures disposed on the second layer;

an emitter configured to transmit a laser signal transverse to the flexible firing bar; and

a receiver configured to detect the laser signal through the first set of apertures and the second set of apertures;

wherein the laser signal detected by the receiver corresponds to the length of the flexible firing bar.

11. A surgical instrument comprising:

an articulation joint;

an end effector pivotably connected at the articulation joint, the end effector pivotable between an unarticulated position and an articulated position;

a flexible firing bar movable through the articulation joint, wherein flexure of the flexible firing bar through the articulation joint causes a length of the flexible firing bar to vary according to an angular position of the end effector between the unarticulated position and the articulated position; and

a sensor configured to detect the length of the flexible firing bar.

12. The surgical instrument of claim 11, wherein:

the flexible firing bar comprises a first layer and a second layer;

the first layer is configured to shift relative to the second layer based on the angular position between the unarticulated position to the articulated position; and

the length of the flexible firing bar corresponds to a distance between a distal end of the first layer and a proximal end of the second layer.

13. The surgical instrument of claim 11, further comprising:

a plurality of magnets disposed sequentially along the flexible firing bar;

wherein the sensor is configured to determine a relative position of the plurality of magnets corresponding to the length of the flexible firing bar.

14. The surgical instrument of claim 11, further comprising:

a plurality of protrusions disposed sequentially along the flexible firing bar;

wherein the sensor is configured to determine a relative position of the plurality of protrusions corresponding to the length of the flexible firing bar.

15. The surgical instrument of claim 11, wherein the sensor comprises an electrically conductive material configured to emit a signal indicative of a strain on the flexible firing bar, the strain corresponding to the length of the flexible firing bar.

16. The surgical instrument of claim 11, further comprising:

a magnet disposed on a first side of the flexible firing bar;

wherein the sensor is disposed on a second side of the flexible firing bar, the second side opposing the first side, and the sensor is configured to determine a distance between the magnet and the sensor corresponding to the length of the flexible firing bar.

17. The surgical instrument of claim 11, the flexible firing bar comprising a first layer and a second layer, each of the first layer and the second layer comprising a distal end and a proximal end, wherein the sensor is configured to determine a position of the proximal end of the first layer relative to the proximal end of the second layer corresponding to the length of the flexible firing bar.

18. The surgical instrument of claim 11, the flexible firing bar comprising a first layer and a second layer, wherein the sensor comprises:

a first electrical contact disposed on the first layer;

a second electrical contact disposed on the second layer in a cooperating relationship with the first electrical contact; and

a capacitance defined between the first electrical contact and the second electrical contact, wherein the capacitance corresponds to the length of the flexible firing bar.

19. The surgical instrument of claim 11, the flexible firing bar comprising a first layer and a second layer, wherein the sensor comprises:

a first rotary encoder configured to detect a linear displacement of the first layer; and

a second rotary encoder configured to detect a linear displacement of the second layer;

wherein the linear displacement of the first layer and the linear displacement of the second layer corresponds to the length of the flexible firing bar.

20. The surgical instrument of claim 11, the flexible firing bar comprising a first layer comprising a first set of apertures and a second layer comprising a second set of apertures, wherein the sensor comprises:

an emitter configured to transmit a laser signal transverse to the flexible firing bar; and

a receiver configured to detect the laser signal through the first set of apertures and the second set of apertures;

wherein the laser signal detected by the receiver corresponds to the length of the flexible firing bar.

21. A surgical instrument comprising:

an end effector pivotable between an unarticulated position and an articulated position;

a firing bar movable relative to the end effector between a proximal position and a distal position;

a motor coupled to the firing bar, the motor configured to drive the firing bar between the proximal position and the distal position;

a first sensor configured to detect an articulation position of the end effector between the unarticulated position and the articulated position; and

a second sensor configured to detect whether the firing bar has stopped;

a controller coupled to the first sensor, the second sensor, and the motor, the controller configured to;

adjust a distance that the firing bar is driven by the motor according to the articulation position of the end effector detected by the first sensor; and

cause the motor to stop driving the firing bar upon determining that the firing bar has stopped via the second sensor.

22. The surgical instrument of claim 21, wherein the second sensor comprises a force sensor configured to detect a force experienced by the firing bar.

23. The surgical instrument of claim 21, wherein the second sensor comprises a current sensor configured to detect a current drawn by the motor.

24. The surgical instrument of claim 21, wherein:

the firing bar comprises a flexible firing bar; and

a flexure of the flexible firing bar varies according to the articulation position of the end effector.

25. The surgical instrument of claim 24, wherein:

the flexible firing bar comprises a plurality of lateral portions that shift relative to each other according to the flexure of the flexible firing bar; and

the first sensor is configured to detect the flexure of the flexible firing bar by detecting a shift of the plurality of lateral portions relative to each other.