ROBOTICALLY-CONTROLLED SURGICAL STAPLING DEVICES THAT PRODUCE FORMED STAPLES HAVING DIFFERENT LENGTHS

• US 20110290851A1
• Filed: 05/27/2011
• Published: 12/01/2011
• Est. Priority Date: 08/31/2005
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery, Inc. (Johnson & Johnson)
• Inventors: Shelton, Frederick E. IV
• Granted Patent: US 9,237,891 B2
• Time in Patent Office: Days
• US Class Current: 227/176.1
• 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 17/115 Staplers for performing anastomosis in a single operation
• CPC Class Codes: A61B 17/32053 Punch like cutting instruments, e.g. using a cylindrical or oval knife A61B17/326 takes precedence; trepans A61B17/1695; for use on the cornea A61F9/007
• CPC Class Codes: A61B 2017/00115 with audible or visual output with imaging means A61B90/37, A61B34/20
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/0023 disposable
• CPC Class Codes: A61B 2017/00327 with actuating members moving in opposite directions
• 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 2017/00685 Archimedes screw
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/0688 Packages or dispensers for surgical staplers
• 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 2017/07264 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 2017/2903 transferring rotary motion
• CPC Class Codes: A61B 2017/2943 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/320052 : Guides for cutting instruments by marking A61B2090/395
• CPC Class Codes: A61B 2017/320069 : for ablating tissue
• CPC Class Codes: A61B 2017/320071 : with articulating means for working tip
• CPC Class Codes: A61B 2017/320093 : additional movable means performing cutting operation
• CPC Class Codes: A61B 2017/320094 : additional movable means performing clamping operation
• CPC Class Codes: A61B 2017/320095 : with sealing or cauterizing means
• CPC Class Codes: A61B 2017/320097 : with stapling means
• 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 34/30 : Surgical robots
• CPC Class Codes: A61B 34/70 : Manipulators specially adapted for use in surgery
• CPC Class Codes: A61B 34/71 : Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 50/30 : Containers specially adapted for packaging, protecting, dispensing, collecting or disposing of surgical or diagnostic appliances or instruments for wound clamps A61B17/10; for ligaturing clips A61B17/122; packages or dispensers for surgical gloves or finger-stalls A61B42/40
• CPC Class Codes: A61B 50/36 : for collecting or disposing of used articles
• CPC Class Codes: B25C 5/0292 : with the objects to be stapled together introduced perpendicularly to the longitudinal axis of the tool in an opening formed by an anvil and a plunger
• CPC Class Codes: F04C 2270/041 : Controlled or regulated

Abstract

A surgical stapling device that comprises an end effector that is configured to receive various control motions from a robotic system.

Claims

1. A staple cartridge for use with a stapling device that has a robotically controlled actuator that is selectively actuatable in an axial direction and an anvil portion that is selectively movable between open and closed positions, said staple cartridge comprising:

a cartridge body supportable within the stapling device for selective confronting relationship with the anvil portion thereof when in a closed position, said cartridge body configured to axially receive a dynamic actuation member therein that is responsive to control motions applied thereto by said robotically controlled actuator;

at least one first staple driver movably supported within said cartridge body for contact by the dynamic actuation member such that, as the dynamic actuation member is axially advanced through said cartridge body when a first control motion is applied thereto by said robotically controlled actuator, said first staple drivers are driven in a direction toward the anvil when the anvil is in the closed position, each said first staple driver defining a first staple support cradle therein for supporting a staple thereon, said first staple support cradle located a first staple forming distance from a corresponding portion of the closed anvil; and

at least one second staple driver movably supported within said cartridge body for contact by the dynamic actuation member such that as the dynamic actuation member is axially advanced through said cartridge body, said second staple drivers are driven in said direction toward the closed anvil, each said second staple driver defining a second staple support cradle therein for supporting another staple thereon, said second staple support cradle located a second staple forming distance from another portion of the closed anvil wherein said second staple forming distance differs from said first staple forming distance.

2. A surgical stapling device, comprising:

a robotic system operable to produce a firing motion and a closing motion;

an implement portion responsive to the firing and closing motions from the robotic system, the implement portion comprising;

an elongate channel coupled to the robotic system and configured to support a staple cartridge therein;

an anvil movably coupled to the elongate channel and having an anvil channel therein, said anvil being movable between open and closed positions in response to said closing motions applied thereto by said robotic system;

a firing device including a distally presented cutting edge longitudinally movable within the elongate channel in response to said firing motion applied thereto by said robotic system;

an upper member on said firing device engageable to the anvil channel and a lower portion longitudinally engaging the elongate channel during distal movement for firing, and wherein said staple cartridge comprises;

a cartridge body supportable within the elongate channel, said cartridge body having a non-planar deck surface configured to confront a staple forming portion of the anvil staple-forming pockets therein when the anvil is in said closed position;

a plurality of first staple drivers movably supported within said cartridge body and being sequentially movable from an unactuated position to an actuated position upon sequential interaction with the firing device, each said first staple driver defining a first staple support cradle therein for supporting a staple thereon, each said first staple support cradle located a first staple forming distance from a corresponding portion of the staple forming portion of the closed anvil; and

a plurality of second staple drivers movably supported within said cartridge body and being laterally spaced from said first staple drivers, each said second staple driver being sequentially movable from another unactuated position to another actuated position upon sequential interaction with the firing device, each said second staple driver defining a second staple support cradle therein for supporting another staple thereon, each said second staple support cradle located a second staple forming distance from another corresponding portion of the staple forming portion of the closed anvil that corresponds to the second staple support cradle and wherein said second staple forming distance differs in magnitude from said first staple forming distance.

3. The surgical stapling device of claim 2 wherein each said first staple driver supports at least two of said staples thereon.

4. The surgical stapling device of claim 3 wherein said first staple support cradle is in a primary driver portion of said first staple driver and wherein each said first staple driver further comprises a secondary driver portion attached to said primary driver portion and defining a secondary staple support cradle located a secondary staple forming distance from another corresponding portion of the anvil when the anvil is in a closed position, said secondary support cradle supporting another one of said staples thereon.

5. The surgical stapling device of claim 4 wherein said secondary staple forming distance is substantially equal to said first staple forming distance.

6. The surgical stapling device of claim 4 wherein said secondary staple forming distance differs in magnitude from said first staple forming distance and said second staple forming distance.

7. The surgical stapling device of claim 2 wherein said plurality of first staple drivers are axially aligned in a first row of first staple drivers and wherein said plurality of second staple driver are aligned in a second row of said second staple drivers.

8. The surgical stapling device of claim 7 wherein said first staple forming distance of one said first staple drivers in said first row of said first staple drivers differs in magnitude from said first staple forming distance of another one of said first staple drivers in said first row of first staple drivers.

9. The surgical stapling device of claim 8 wherein said second staple forming distance of one of said second staple drivers in said second row of said second staple drivers differs in magnitude from said second staple forming distance of another one of said second staple drivers in said second row of said second staple drivers.

10. A surgical stapling device, comprising:

a robotic system operable to produce a firing motion and a closing motion;

an implement portion responsive to the firing and closing motions from the robotic system, the implement portion comprising;

an elongate channel operably coupled to a portion of the robotic system and configured to support a staple cartridge therein;

an anvil movably coupled to the elongate channel and having an anvil channel therein, said anvil being movable from an open position to a closed position upon application of said closing motion thereto from said robotic system;

a firing device including a distally presented cutting edge longitudinally movable within said elongate channel and the anvil from a starting position to an ending position upon application of said firing motion thereto from said robotic system, said firing device having an upper portion for engaging said anvil channel and a lower portion for engaging the elongate channel during distal movement for firing and wherein said staple cartridge comprises;

a cartridge body sized to be supported within the elongate channel, said cartridge body having a longitudinally extending slot therein for receiving the firing device therein, said cartridge body having a non-planar deck surface configured to confront a staple forming portion of the anvil having staple forming pockets therein when the anvil is in said closed position;

a first plurality of inside staple drivers axially aligned in a first row of inside staple drivers in a portion of said cartridge body adjacent a first side of said longitudinally extending slot and a second plurality of inside staple drivers axially aligned in a second row of inside staple drivers in another portion of said cartridge body adjacent a second side of said longitudinally extending slot, said inside staple drivers movably supported within said cartridge body for selective movement toward the anvil when the anvil is in a closed position, each said inside staple driver defining a first staple support cradle for supporting a staple thereon, each said first staple support cradle located a first staple forming distance from a corresponding portion of the anvil when the anvil is in a closed position;

a first plurality of outside staple drivers axially aligned in a first row of outside staple drivers adjacent to said first row of said inside staple drivers and a second plurality of outside staple drivers axially aligned in a second row of outside staple drivers and adjacent to said second row of inside staple drivers, each of said outside staple drivers movably supported within said cartridge body for selective driving movement toward the anvil when the anvil is in the closed position, each of said outside staple drivers defining a second staple support cradle for supporting another staple thereon, each said second staple support cradle located a second staple forming distance from another corresponding portion of the anvil when the anvil is in the closed position, said second staple forming distance differing in magnitude from said first staple forming distance; and

a wedge sled supported within said cartridge body for driving contact by the firing device and actuating contact with said first and second pluralities of said inside staple drivers and said first and second pluralities of said outside staple drivers such that, as said firing device moves within said elongated slot in said cartridge body in a first axial direction in response to said firing motion from said robotic system, said wedge sled drives each of said inside and outside drivers towards the anvil to bring the staples supported thereon into forming contact with the anvil when the anvil is in the closed position.

11. The surgical stapling device of claim 10 wherein each of said inside staple drivers support two of said staples thereon.

12. The surgical stapling device of claim 11 wherein said two staples supported on at least one of said inside staple drivers are longitudinally offset from each other.

13. The surgical stapling device of claim 11 wherein said first staple support cradle is in a primary driver portion of said inside driver and wherein each said inside driver further comprises a secondary driver portion attached to said primary driver portion, said secondary driver portion defining a secondary staple support cradle therein that is located a secondary staple forming distance from another corresponding portion of the anvil when the anvil is in the closed position, each said secondary staple support cradle supporting one of said staples thereon.

14. The surgical stapling device of claim 13 wherein said secondary staple forming distance is substantially equal to said first staple forming distance.

15. The surgical stapling device of claim 13 wherein said secondary staple forming distance differs in magnitude from said first staple forming distance and said second staple forming distance.

16. The surgical stapling device of claim 11 wherein said second staple forming distance of at least one of said outside staple drivers in said first row of said first outside staple drivers differs in magnitude from said second staple forming distance of at least one other said outside staple driver in said first row of said outside staple drivers.

17. The surgical stapling cartridge of claim 16 wherein said second staple forming distance of at least one of said outside staple drivers in said second row of said outside staple drivers differs in magnitude from said second staple forming distance of at least one other said outside staple driver in said second row of said outside staple drivers.

18. The surgical stapling device of claim 10 wherein said first staple forming distance of at least one of said first staple drivers in said first row of said inside staple drivers differs in magnitude from said first staple forming distance of at least one other said inside staple driver in said first row of said inside staple drivers.

19. The surgical stapling device of claim 16 wherein said first staple forming distance of at least one of said inside staple drivers in said second row of said inside staple drivers differs in magnitude from said first staple forming-distance of at least one other said inside staple driver in said second row of said inside staple drivers.

20. A surgical stapling device, comprising:

a robotic system operable to produce a opening and closing motions and a firing and retraction motion;

an elongate channel operably coupled to a portion of the robotic system and configured to support a staple cartridge therein;

an anvil movably coupled to the elongate channel and being movable from an open position to a closed position upon application of said closing motion thereto and movable from said closed position to said open position upon application of said opening motion thereto, said anvil having an anvil channel therein;

a firing device including a distally presented cutting edge longitudinally movable within said elongate channel and the anvil from a starting position to an ending position upon application of said firing motion thereto and from ending position to said starting position upon application of said retraction motion thereto, said firing device having an upper portion engageable to the anvil channel and a lower portion longitudinally engaging the elongate channel during distal movement for firing and wherein said staple cartridge comprises;

a cartridge body sized to be supported within the elongate channel, said cartridge body having a longitudinally extending slot therein for reciprocatingly receiving the firing device therein and a non-planar deck surface configured to confront a staple forming portion of the anvil having staple forming pockets therein when the anvil is in a closed position;

a plurality of first inside staple drivers axially aligned in a first row of first inside staple drivers on a first side of said longitudinally extending slot, each of said first inside staple drivers movably supported within said cartridge body for selective movement toward the anvil when the anvil is in a closed position and supporting at least one staple thereon;

a plurality of first outside staple drivers aligned in a first row of first outside staple drivers on said first side of said longitudinally extending slot and adjacent to said first row of said first inside staple drivers, each of said first outside staple drivers movably supported within said cartridge body for selective driving movement toward the anvil when the anvil is in the closed position and supporting another one of said staples thereon; and

a wedge sled supported within said cartridge body for contact with said firing bar, said wedge sled comprising;

a first inside sled cam having a first maximum sled cam height measured from a bottom-most drive surface of said first inside cam to an upper-most portion of said first inside cam, said first inside sled cam oriented for sequential sliding actuating contact with said first inside staple drivers in said first row of said first inside staple drivers when said firing bar is axially advanced through said elongated slot in a first axial direction such that said first inside staple drivers are driven towards the anvil a first distance equal to said first maximum sled cam height; and

a first outside sled cam having a second maximum sled cam height measured from a bottom-most drive surface of said first outside cam to an upper-most portion of said first outside cam, said second maximum sled cam height differing in magnitude from said first maximum sled cam height, said first outside sled cam oriented for sequential sliding actuating contact with said first outside staple drivers in said first row of said first outside staple drivers when said firing bar is advanced through said elongated slot in the first direction such that said first outside staple drivers are driven towards the anvil a second distance equal to said second maximum sled cam height.

21. The surgical stapling device of claim 20 further comprising:

a plurality of second inside staple drivers aligned in a second row of second inside staple drivers on a second side of said longitudinally extending slot, each of said second inside staple drivers movably supported with said cartridge body for selective driving movement towards the anvil when the anvil is in the closed position and supporting another one of said staples thereon;

a plurality of second outside staple drivers aligned in a second row of second outside staple drivers on said second side of said longitudinally extending slot and adjacent to said second row of said second inside staple drivers, each of said second outside staple drivers movably supported within said cartridge body for driving movement towards the anvil when the anvil is in the closed position and supporting another one of said staples thereon and wherein said wedge sled further comprises;

a second inside sled cam having a primary maximum sled cam height measured from a bottom-most drive surface of said second inside sled cam to an upper-most portion of said second inside sled cam, said second inside sled cam oriented for sequential sliding actuating contact with said second inside staple drivers in said second row of said second inside staple drivers when said firing bar is axially advanced through said elongated slot in the first direction such that said second inside staple drivers are driven towards the anvil a primary distance equal to said primary maximum sled cam height; and

a second outside sled cam having a secondary maximum sled cam height measured from a bottom-most drive surface of said second outside sled cam to an upper-most portion of said second outside sled cam, said second outside sled cam oriented for sequential sliding actuating contact with said second outside staple drivers in said second row of said second outside staple drivers when said firing bar is axially advanced through said elongated slot in the first direction such that said second outside staple drivers are driven towards the anvil a secondary distance equal to said secondary maximum sled cam height.

22. The surgical stapling device of claim 21 wherein said primary maximum sled cam height is substantially equal to said first maximum sled cam height and wherein said secondary maximum sled cam height is substantially equal to said second maximum sled cam height.

23. The surgical stapling device of claim 21 wherein said primary maximum sled cam height is not equal to said first, second, or secondary maximum sled cam heights.

24. A surgical stapling device, comprising:

a robotic system operable to produce opening and closing motions and firing and retraction motions;

an elongate channel operably coupled to a portion of the robotic system and configured to support a staple cartridge therein;

an anvil movably coupled to the elongate channel and being movable from an open position to a closed position upon application of said closing motion thereto and from said closed position to said open position upon application of said opening motion thereto, said anvil having an anvil channel therein;

a firing device including a distally presented cutting edge longitudinally movable in said elongate channel and the anvil, said firing device being movable form a starting position to an ending position upon application of said firing motion thereto and from said ending position to said starting position upon application of said retraction motion thereto, said firing device further having an upper member engageable to the anvil channel and a lower portion longitudinally engaging the elongate channel during distal movement for firing and wherein said staple cartridge comprises;

a cartridge body supportable within the stapling device for selective confronting relationship with the anvil portion thereof when in a closed position, said cartridge body configured to axially receive the distally presented cutting edge of the firing member therein and having a non-planar deck surface configured to confront a staple forming portion of the anvil having staple forming pockets therein when the anvil is in a closed position;

a plurality of first staple drivers movably supported within said cartridge body for sequential contact by the actuator such that, as the actuator is axially advanced through said cartridge body, said first staple drivers are sequentially driven in a direction toward the anvil when the anvil is in the closed position, each said first staple driver defining a first staple support cradle therein for supporting a staple thereon, said first staple support cradle located a first staple forming distance from a corresponding portion of the closed anvil;

a plurality of second staple drivers movably supported within said cartridge body for sequential contact by the actuator such that as the actuator is axially advanced through said cartridge body, said second staple drivers are sequentially driven in said direction toward the closed anvil, each said second staple driver defining a second staple support cradle therein for supporting another staple thereon, said second staple support cradle located a second staple forming distance from another portion of the closed anvil that corresponds to the second staple support cradle and wherein said second staple forming distance differs from said first staple forming distance;

a plurality of third staple drivers movably supported within said cartridge body and being sequentially movable from a third unactuated position to a third actuated position upon sequential interaction with the actuator, each said third staple driver defining a third staple support cradle therein that is located a third maximum staple forming distance from another portion of the closed anvil that corresponds to the third staple support cradle when the anvil is in closed position, and wherein said first maximum staple forming distance differs from said at least one of said second and third maximum staple forming distances;

a first staple disposed in at least one of said first staple support cradles;

a second staple disposed in at least one of said second staple support cradles; and

a third staple in each of said third staple in at least one of said third staple support cradles.