SURGICAL STAPLE AND DRIVER ARRANGEMENTS FOR STAPLE CARTRIDGES

• US 20160089148A1
• Filed: 09/26/2014
• Published: 03/31/2016
• Est. Priority Date: 09/26/2014
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery, Inc. (Johnson & Johnson)
• Inventors: Harris, Jason L., Morgan, Jerome R., Zeiner, Mark S., Shelton, Frederick E. IV
• Granted Patent: US 9,801,628 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 17/0684 having a forming anvil staying above the tissue during stapling
• 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 17/07292 Reinforcements for staple line, e.g. pledgets
• CPC Class Codes: A61B 17/105 Wound clamp magazines for packaging sharps A61B50/3001
• CPC Class Codes: A61B 17/1155 Circular staplers comprising a plurality of staples
• CPC Class Codes: A61B 17/1222 Packages or dispensers therefor clip magazines incorporated in a clip-applying instrument A61B17/128; for surgical articles A61B50/30
• CPC Class Codes: A61B 2017/00004 (bio)absorbable, (bio)resorbable, resorptive for implantable prostheses A61F2210/0004
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/00884 enhancing wound closure
• CPC Class Codes: A61B 2017/00898 expandable upon contact with fluid
• CPC Class Codes: A61B 2017/00942 hydrophilic
• CPC Class Codes: A61B 2017/0688 Packages or dispensers for surgical staplers
• CPC Class Codes: A61B 2017/07214 Stapler heads
• 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 2017/2927 : the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61F 2/4618 : of cartilage

Abstract

An end effector and a staple cartridge are disclosed. The staple cartridge includes an array of staples in which at least one staple is angularly-oriented relative to the longitudinal axis of the staple cartridge. The angled staple(s) provide longitudinal flexibility to the stapled tissue. Additionally, the staple cartridge and/or the end effector are configured to provide variable degrees of compression to tissue. For example, the compression of tissue before, during and/or after stapling can be optimized.

Claims

1. A staple cartridge, comprising:

a cartridge body, wherein a plurality of staple cavities are defined into the cartridge body, and wherein a longitudinal slot is defined at least partially through the cartridge body; and

a plurality of staples removably positioned in the staple cavities, wherein the plurality of staples comprises a first staple and a second staple, wherein each of the staples is oriented at a stretch relief angle relative to the longitudinal slot, and wherein the plurality of staples are arranged to form a longitudinally stretchable array within stapled tissue;

wherein each of the staples is deformable from an unfired configuration to a fired configuration, wherein the first staple comprises a first formed height when in the fired configuration, wherein the second staple comprises a second formed height when in the fired configuration, wherein the first formed height is different than the second formed height, and wherein the first staple is laterally offset from the second staple to provide laterally variable tissue compressible within the longitudinally stretchable array.

2. The staple cartridge of claim 1, wherein the plurality of staples further comprises a third staple, wherein the third staple comprises a third formed height when in the fired configuration, and wherein the third formed height is different than the first formed height and different than the second formed height.

3. The staple cartridge of claim 2, wherein the third formed height is greater than the second formed height, and wherein the second formed height is greater than the first formed height.

4. The staple cartridge of claim 3, wherein the first staple is adjacent to the longitudinal slot, wherein the second staple is laterally outboard relative to the first staple, and wherein the third staple is laterally outboard relative to the second staple.

5. The staple cartridge of claim 1, wherein each of the stretch relief angles comprises an angle between approximately 45 degrees and approximately 135 degrees relative to the longitudinal slot.

6. The staple cartridge of claim 5, wherein the first staple is angularly offset approximately 90 degrees relative to the second staple in the longitudinally stretchable array.

7. The staple cartridge of claim 1, further comprising a plurality of staple-driving surfaces, wherein the staple-driving surfaces are configured to move each of the staples from an unfired position to a fired position, and wherein the staples are deformable from the unfired configurations to the fired configurations when the staple-driving surfaces move the staples from the unfired positions to the fired positions.

8. An end effector, comprising:

a first jaw;

a second jaw comprising a staple cartridge, wherein the staple cartridge comprises;

a cartridge body, wherein a plurality of staple cavities are defined into the cartridge body, and wherein a longitudinal slot extends through at least a portion of the cartridge body; and

an array of staples removably positioned in the staple cavities;

a cutting element movably positioned along the longitudinal slot;

driving means for driving the array of staples from the staple cavities into tissue positioned intermediate the first jaw and the second jaw;

compression control means for providing lateral variations in compression to tissue stapled by the array of staples; and

stretch accommodation means for accommodating longitudinal stretch in tissue stapled by the array of staples.

9. A staple cartridge, comprising:

a cartridge body comprising a deck, wherein a longitudinal slot is defined at least partially through the cartridge body, wherein a plurality of staple cavities are defined into the cartridge body, and wherein the deck comprises;

a first portion having a first elevation configured to affect a first tissue compression; and

a second portion having a second elevation configured to affect a second tissue compression, wherein the second elevation is different than the first elevation and the second tissue compression is different than the first tissue compression, and wherein the second portion is positioned farther from the longitudinal slot than the first portion; and

a staple removably positioned in one of the staple cavities, wherein the staple comprises;

a first leg and a second leg, wherein the second leg is positioned farther from the longitudinal slot than the first leg; and

a base intermediate the first leg and the second leg.

10. The staple cartridge of claim 9, wherein the first leg is aligned with the first portion of the deck, and wherein the second leg is aligned with the second portion of the deck.

11. The staple cartridge of claim 10, wherein the deck further comprises a step intermediate the first portion and the second portion, and wherein at least one of the staple cavities comprises an opening in the deck that traverses the step.

12. The staple cartridge of claim 11, wherein the step extends along an axis substantially parallel to the longitudinal slot.

13. The staple cartridge of claim 9, wherein the plurality of staple cavities comprises a first cavity, wherein the staple is removably positioned in the first cavity, wherein the first cavity comprises an opening in the deck, wherein the opening comprises a first end and a second end, and wherein the first end and the second end are positioned in the first portion of the deck.

14. The staple cartridge of claim 13, wherein the deck further comprises a step intermediate the first portion and the second portion, and wherein the step extends along a contoured path.

15. The staple cartridge of claim 14, wherein the staple cavities are arranged in a plurality of rows on a first side of the longitudinal slot, wherein the plurality of rows comprises a first row and a second row, and wherein the contoured path extends between the first row and the second row.

16. The staple cartridge of claim 9, wherein the base comprises a first end and a second end, wherein the first leg extends from the first end, wherein the second leg extends from the second end, wherein the staple is configured to assume a first formed height at the first end and a second formed height at the second end, and wherein the second formed height is different than the first formed height.

17. The staple cartridge of claim 9, wherein the first leg comprises a first tip and a first length from the first tip to the base when the staple is in an unformed configuration, wherein the second leg comprises a second tip and a second length from the second tip to the base when the staple is in the unformed configuration, and wherein the second length is different than the first length.

18. An end effector, comprising:

clamping means for clamping tissue, wherein the clamping means comprises a longitudinal slot;

an arrangement of staples removably positioned in the clamping means;

cutting means for cutting tissue clamped along the longitudinal slot;

firing means for firing the arrangement of staples into clamped tissue;

tissue flow reduction means for reducing lateral tissue flow in tissue clamped by the clamping means; and

tissue stretch accommodation means for providing longitudinal strain relief to tissue stapled by the arrangement of staples.

19. A surgical end effector, comprising:

a first jaw comprising a staple-forming surface;

a second jaw comprising a staple cartridge, wherein the first jaw and the second jaw are movable between an open configuration and a closed configuration, and wherein the staple cartridge comprises;

a cartridge body comprising a deck, wherein a tissue-compression gap is defined between the deck and the staple-forming surface when the first jaw and the second jaw are in the closed configuration, wherein the deck comprises a first portion and a second portion, and wherein the tissue-compression gap comprises a first gap height intermediate the first portion and the staple-forming surface and a second gap height intermediate the second portion and the staple-forming surface, and wherein the second gap height is different than the first gap height; and

wherein a plurality of staple cavities are defined into the cartridge body, wherein the plurality of staple cavities comprises a first cavity and a second cavity, wherein each of the staple cavities comprises an opening in the deck, and wherein the opening of the first cavity is angularly-oriented relative to the opening of the second cavity; and

a plurality of staples removably positioned in the staple cavities, wherein the plurality of staples comprises a first staple removably positioned in the first cavity and a second staple removably positioned in the second cavity.

20. The surgical end effector of claim 19, wherein each of the staples is movable from an unfired position to a fired position, wherein each of the staples is deformable from an undeformed configuration to a deformed configuration when moved from the unfired position to the fired position, wherein the first staple comprises a first deformed height when in the deformed configuration and wherein the second staple comprises a second deformed height when in the deformed configuration, and wherein the first deformed height is different than the second deformed height.

21. The surgical end effector of claim 19, wherein a longitudinal slot is defined in the cartridge body, and wherein the opening of the first cavity and the opening of the second cavity are positioned on a first side of the longitudinal slot and are angularly-oriented relative to the longitudinal slot.

22. The surgical end effector of claim 19, wherein the plurality of staples are arranged in a plurality of rows, wherein the plurality of rows comprises a first row and a second row, wherein the first cavity is in the first row, and wherein the second cavity is in the second row.

23. The surgical end effector of claim 22, wherein the first row is aligned with the first portion of the deck, and wherein the second row is aligned with the second portion of the deck.

24. The surgical end effector of claim 22, further comprising a driver movably positioned in the staple cartridge, wherein the driver comprises a first trough and a second trough, wherein the second trough is angularly-oriented relative to the first trough, wherein the first staple comprises a first base, wherein the second staple comprises a second base, wherein the first base is aligned with the first trough, and wherein the second base is aligned with the second trough.

25. An end effector, comprising:

a first jaw comprising a plurality of staple-forming pockets, wherein the plurality of staple-forming pockets comprises a first pair of pockets; and

a second jaw comprising a staple cartridge, wherein the first jaw and the second jaw are movable between an open configuration and a closed configuration, and wherein the staple cartridge comprises;

a cartridge body, wherein a plurality of staple cavities are defined into the cartridge body, and wherein the plurality of staple cavities comprises a first cavity; and

a first staple removably positioned in the first cavity, wherein the first staple comprises;

a base comprising a first end and a second end;

a first leg extending from the first end; and

a second leg extending from the second end; and

a first driver, wherein the first staple is positioned intermediate the first driver and the first pair of pockets, wherein the first driver is configured to move the first staple into forming engagement with the first pair of pockets to deform the first staple from an unformed configuration to a formed configuration when the first jaw and the second jaw are in the closed configuration, wherein the first staple comprises a first height at the first end and a second height at the second end when in the formed configuration, and wherein the first height is different than the second height.

26. The end effector of claim 25, wherein the first driver comprises a stepped pushing surface.

27. The end effector of claim 26, wherein the stepped pushing surface comprises:

a first elevation adjacent to the first end of the base;

a second elevation adjacent to the second end of the base; and

a step intermediate the first elevation and the second elevation.

28. The end effector of claim 25, wherein the first pair of pockets comprises a proximal pocket having a first depth and a distal pocket having a second depth, and wherein the first depth is different than the second depth.

29. The end effector of claim 25, wherein the cartridge body further comprises a deck, wherein a longitudinal knife slot extends through at least a portion of the deck, wherein the first cavity comprises a first opening in the deck, wherein the first opening extends along an axis, and wherein the axis traverses the longitudinal knife slot.

30. The end effector of claim 25, wherein the plurality of staple-forming pockets further comprises a second pair of pockets, wherein the plurality of staple cavities further comprises a second cavity, and wherein the staple cartridge further comprises:

a second staple removably positioned in the second cavity, wherein the second staple comprises;

a second base comprising a third end and a fourth end;

a third leg extending from the third end; and

a fourth leg extending from the fourth end; and

a second driver, wherein the second staple is positioned intermediate the second driver and the second pair of pockets, wherein the second driver is configured to move the second staple into forming engagement with the second pair of pockets to deform the second staple from an unformed configuration to a formed configuration when the first jaw and the second jaw are in the closed configuration, wherein the second staple comprises a third height at the third end and a fourth height at the fourth end when in the formed configuration, and wherein the third height is different than the fourth height.

31. The end effector of claim 30, wherein the second leg is further outboard than the first leg, and wherein the fourth leg is further outboard than the third leg.

32. The end effector of claim 31, wherein the second height is greater than the first height, and wherein the fourth height is greater than the third height.

33. The end effector of claim 32, wherein the second leg is further outboard than the third leg.

34. The end effector of claim 36, wherein the second height is greater than the third height.

35. A staple cartridge, comprising:

a cartridge body comprising a deck, wherein a plurality of staple cavities are defined into the cartridge body, wherein each of the staple cavities comprises an opening in the deck;

a plurality of staples removably positioned in the staple cavities, wherein each of the staples comprises;

a base comprising a first end and a second end;

a first leg extending from the first end; and

a second leg extending from the second end; and

a plurality of drivers, wherein at least one of the drivers comprises uneven forming means for purposefully forming the first leg and the second leg of one of the staples to different formed heights relative to the base.