Staple drive assembly

• US 20070075115A1
• Filed: 10/04/2005
• Published: 04/05/2007
• Est. Priority Date: 10/04/2005
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Tyco Healthcare Group LP (Medtronic Plc)
• Inventors: Olson, Lee, Stearns, Ralph
• Granted Patent: US 7,641,091 B2
• Time in Patent Office: Days
• US Class Current: 227/175.100
• CPC Class Codes: A61B 17/0644 penetrating the tissue, deformable to closed position
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 2017/0688 Packages or dispensers for surgical staplers
• CPC Class Codes: A61B 2017/07278 characterised by its sled or its staple holder

Abstract

A staple drive assembly includes an actuation sled and at least one staple pusher. The staple drive assembly is adapted to fit within a staple cartridge having a plurality of staples and a corresponding number of retention slots. The at least one staple pusher includes at least one pusher plate for releasably engaging a backspan of a staple. The staple pusher may include a plurality of pusher plates that may be laterally and longitudinally spaced apart. An actuation member has at least one angled camming surface for engaging a complimentary angled surface of the at least one staple pusher. Camming engagement between the actuation member and the at least one staple pusher causes vertical movement of the at least one staple pusher. Lateral and longitudinal offset of the actuation member camming surfaces and the corresponding staple pusher following surfaces improves stability and control of the staple pusher during firing.

Claims

1. A staple drive assembly comprising:

an actuation sled having a base;

at least one camming member disposed on the actuation sled, the at least one camming member including spaced apart first and second cam wedges, each cam wedge including at least first and second drive faces, the at least first and second drive faces being configured to define first and second drive angles with respect to the base wherein the first drive angle is less than the second drive angle;

a staple pusher having spaced apart first and second cam members, each cam member having at least one engagement surface; and

a plurality of pusher plates disposed on the staple pusher.

2. The staple drive assembly of claim 1, wherein first and second cam wedges are spaced apart in at least one of a longitudinal or a lateral direction for engaging the first and second cam members, the first and second cam members being spaced apart in a complementary arrangement.

3. The staple drive assembly of claim 1, wherein first and second cam wedges are longitudinally and laterally spaced apart from one another for engaging the first and second cam members, the first and second cam members being spaced apart in a complementary arrangement.

4. The staple drive assembly of claim 1, wherein each cam member includes first and second engagement surfaces defining respective first and second receiving angles that are complementary to the respective first and second drive angles.

5. The staple drive assembly of claim 4, wherein the first driving angle is in a range of about 15°

to about 25° and

the second driving angle is in a range of about 30°

to about 40°

.

6. The staple drive assembly of claim 1, wherein the actuation sled further includes a guide member.

7. The staple drive assembly of claim 2, wherein movement of the actuation sled along a first axis urges the at least one staple pusher along a second axis, the second axis being transverse to the first axis.

8. The staple drive assembly of claim 4, wherein movement of the actuation sled along a first axis engages first and second cam wedges with respective first and second engagement surfaces thereby urging the staple pusher along a second axis, the second axis being substantially transverse to the first axis.

9. The staple drive assembly of claim 8, wherein movement of the actuation sled along the first axis causes the actuation sled to sequentially engage each first drive face with the corresponding staple pusher engagement surface and each second drive face with the corresponding staple pusher engagement surface.

10. The staple drive assembly of claim 9, wherein each staple pusher cam member has first and second engagement surfaces.

11. The staple drive assembly of claim 10, wherein as the actuation sled transitions from the first drive face contacting the engagement surface to the second drive face contacting the second engagement surface, the staple pusher and the actuation sled contact each other at at least two points.

12. A staple cartridge comprising:

an elongate body member having a number of staple retention slots;

a plurality of staples releasably received in the retention slots;

a plurality of staple pushers disposed along a longitudinal axis of the elongate body member, wherein each staple pusher is movable between a first position and a second position, each staple pusher including a first cam member, a second cam member, and a plurality of pusher plates, each cam member defining a first receiving angle and a second receiving angle; and

an actuation sled disposed in the elongate body member and longitudinally translatable therethrough, the actuation sled including a pair of camming members, each camming member having first and second cam wedges, the first cam wedge being laterally and longitudinally spaced apart from the second cam wedge, wherein each cam wedge is configured to define a first driving angle and a second driving angle, the first and second driving angles being complementary to the respective first and second receiving angles of the respective first and second cam members.

13. The staple cartridge of claim 12, wherein the first drive angles are greater than the second drive angles.

14. The staple cartridge of claim 12, wherein first driving angles are in a range of about 30°

to about 40° and

second driving angles are in a range of about 15°

to about 25°

.

15. The staple cartridge of claim 12, wherein longitudinal movement of the actuation sled sequentially engages each of the staple pushers and urges each of the staple pushers in a direction generally transverse to the longitudinal axis.

16. The staple cartridge of claim 12, wherein longitudinal movement of the actuation sled slidably engages the first and second cam wedges with respective first and second engagement surfaces of each staple pusher thereby urging each staple pusher in a direction generally transverse to the longitudinal axis.

17. The staple cartridge of claim 12, wherein the elongate body member includes a longitudinal guide channel and the actuation sled includes a guide member adapted to be slidably received by the guide channel.

18. The staple cartridge of claim 12, wherein the cam wedges substantially simultaneously engage the corresponding cam members.

19. The staple cartridge of claim 18, wherein the substantially simultaneous engagement of laterally and longitudinally spaced cam wedges and cam members substantially reduces tilting of the staple pushers in a direction not substantially perpendicular to the longitudinal axis during longitudinal movement of the actuation sled.

20. A staple pusher comprising:

a first cam member;

a second cam member laterally spaced from the first cam member, wherein the second cam member is axially offset from the first cam member; and

at least one pusher plate supported by the first and second cam members.

21. The staple pusher of claim 20, wherein each cam member defines a first receiving angle and a second receiving angle.

22. The staple pusher of claim 21, wherein the first receiving angle is greater than the second receiving angle.

23. The staple pusher of claim 22, wherein the first receiving angle is about 35°

and the second receiving angle is about 20°

.

24. The staple pusher of claim 23, wherein the cam members are substantially parallel to each other.

25. The staple pusher of claim 24, wherein each pusher plate is substantially parallel to the cam members.

26. The staple pusher of claim 20, wherein the first cam member is axially offset from the second cam member by about two-thirds of a length of a pusher plate.

27. An actuation sled comprising:

a base;

a first camming member disposed on the base, the first camming member having first and second cam wedges, the first cam wedge being laterally and longitudinally spaced apart from the second cam wedge, each cam wedge configured to define at least one driving angle with respect to the base; and

a second camming member disposed on the base and laterally spaced apart from the first camming member, the second camming member having first and second cam wedges, the first cam wedge being laterally and longitudinally spaced apart from the second cam wedge, each cam wedge configured to define at least one driving angle with respect to the base.

28. The actuation sled of claim 27, wherein each cam wedge is configured to define first and second driving angles, the first driving angles being less than the second driving angles.

29. The actuation sled of claim 28, wherein the first and second driving angles of the first camming member are substantially similar to the first and second driving angles of the second camming member.

30. The actuation sled of claim 28, wherein the first driving angles are in a range of about 15°

to about 25° and

the second driving angles are in a range of about 30°

to about 40°

.

31. The actuation sled of claim 28, wherein the first and second driving angles are complementary to corresponding first and second receiving angles of a staple pusher.

32. The actuation sled of claim 28, further comprising a guide member disposed on the actuation sled, the guide member adapted for slidably engaging a guide channel in a staple cartridge.

33. A staple cartridge comprising:

an elongate body member having a number of staple retention slots;

a plurality of staples releasably received in the retention slots;

at least one staple pusher disposed along a longitudinal axis of the elongate body member, wherein the at least one staple pusher is movable between a first position and a second position, each staple pusher including a first cam member, a second cam member, and a plurality of pusher plates, each cam member defining a first receiving angle and a second receiving angle; and

an actuation sled disposed in the elongate body member and longitudinally translatable therethrough, the actuation sled including a pair of camming members, each camming member having first and second cam wedges, the first cam wedge being laterally and longitudinally spaced apart from the second cam wedge, wherein each cam wedge is configured to define a first driving angle and a second driving angle, the first driving angle being complementary to the respective second receiving angle and the second driving angle being complementary to the first receiving angle of the respective first and second cam members.

34. In a surgical stapler having a staple cartridge with a tissue contacting surface and containing a plurality of surgical staples to be sequentially ejected from the staple cartridge substantially perpendicular to the tissue engaging surface by at least one camming member translating through the staple cartridge to engage a plurality of staple pushers associated with the surgical staples, the improvement comprising a staple pusher having a plurality of camming surfaces defining at least two different angles relative to the tissue engaging surface.

35. In a surgical stapler having a staple cartridge with a tissue contacting surface and containing a plurality of surgical staples to be sequentially ejected from the staple cartridge substantially perpendicular to the tissue engaging surface by at least one camming member translating through the staple cartridge to engage a plurality of staple pushers associated with the surgical staples, the improvement comprising a staple pusher having a plurality of staple pusher camming surfaces defining at least two different angles relative to the tissue engaging surface, and a camming member defining a plurality of camming member camming surfaces corresponding substantially to the staple pusher camming surfaces.

36. A method of firing surgical staples comprising:

providing a surgical stapler having a staple cartridge containing a plurality of surgical staples to be sequentially ejected from the staple cartridge by at least one camming member translating through the staple cartridge to engage a plurality of staple pushers associated with the surgical staples, each staple pusher having first and second staple pusher camming surfaces and the camming member having at least first and second camming member camming surfaces;

translating the camming member through the staple cartridge such that the first camming member camming surface contacts the first staple pusher camming surface and thereafter the second camming member camming surface contacts the second staple pusher camming surface to eject the surgical staples from the staple cartridge.

37. The method of claim 36, wherein the first camming member camming surface defines a first drive angle and the second camming member camming surface defines a second drive angle, the first drive angle being less than the second drive angle.

38. The method of claim 37, wherein the staple pusher contacts the camming member at multiple points as the staple pusher transitions from contacting the first camming member camming surface to contacting the second camming member camming surface.

39. In a surgical stapler having a staple cartridge with a tissue contacting surface and containing a plurality of staples to be sequentially ejected from the staple cartridge substantially perpendicular to the tissue contacting surface by at least one actuation member translating through the staple cartridge to engage a plurality of staple pushers associated with the surgical staples, wherein the improvement comprises at least one actuation member having a plurality of camming surfaces defining at least two different drive angles, the first drive angle being less than the second drive angle.

40. In a surgical stapler having a staple cartridge with a tissue contacting surface and containing a plurality of staples to be sequentially ejected from the staple cartridge substantially perpendicular to the tissue contacting surface by at least one actuation member translating through the staple cartridge to engage a plurality of staple pushers associated with the surgical staples, wherein the improvement comprises at least one actuation member having a plurality of camming surfaces defining at least two different angles relative to the tissue contacting surface and wherein the plurality of camming surfaces are longitudinally spaced apart.

41. A staple drive assembly comprising:

an actuation member having a base and a distal end;

at least one camming member disposed on the distal end, the at least one camming member including spaced apart first and second cam wedges, each cam wedge including at least first and second drive faces, the at least first and second drive faces being configured to define first and second drive angles with respect to the base wherein the first drive angle is less than the second drive angle;

a staple pusher having spaced apart first and second cam members, each cam member having at least one engagement surface; and

a plurality of pusher plates disposed on the staple pusher.

42. The staple drive assembly of claim 41, wherein first and second cam wedges are spaced apart in at least one of a longitudinal or a lateral direction for engaging the first and second cam members, the first and second cam members being spaced apart in a complementary arrangement.

43. The staple drive assembly of claim 41, wherein first and second cam wedges are longitudinally and laterally spaced apart from one another for engaging the first and second cam members, the first and second cam members being spaced apart in a complementary arrangement.

44. The staple drive assembly of claim 41, wherein each cam member includes first and second engagement surfaces defining respective first and second receiving angles that are complementary to the respective first and second drive angles.

45. The staple drive assembly of claim 44, wherein the first driving angle is in a range of about 15°

to about 25°

and the second driving angle is in a range of about 30°

to about 40°

.

46. The staple drive assembly of claim 42, wherein movement of the distal end along a first axis urges the at least one staple pusher along a second axis, the second axis being transverse to the first axis.

47. The staple drive assembly of claim 44, wherein movement of the distal end along a first axis engages first and second cam wedges with respective first and second engagement surfaces thereby urging the staple pusher along a second axis, the second axis being transverse to the first axis.

48. The staple drive assembly of claim 47, wherein as the camming member transitions from the first drive face contacting the first engagement surface to the second drive face contacting the second engagement surface, the staple pusher and the camming member contact each other at at least two points.