CARTRIDGE ASSEMBLIES FOR SURGICAL STAPLERS

• US 20160120544A1
• Filed: 10/29/2014
• Published: 05/05/2016
• Est. Priority Date: 10/29/2014
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery, Inc. (Johnson & Johnson)
• Inventors: Shelton, Frederick E. IV, Morgan, Jerome R.
• Granted Patent: US 10,517,594 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 17/07207 the staples being applied sequentially
• 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 2017/07257 characterised by its anvil
• 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 2017/320044 Blunt dissectors blunt suture needles A61B2017/06085

Abstract

Surgical stapling devices are disclosed herein that improve on the disclosures of previous surgical stapling devices.

Claims

1. An end effector for a surgical stapling instrument, the end effector comprising:

a staple cartridge, comprising;

a cartridge body including a proximal end portion and a distal end portion;

an elongate slot extending between the proximal end portion and the distal end portion;

a tissue supporting portion, comprising;

a first tissue supporting surface;

a second tissue supporting surface, wherein the second tissue supporting surface is stepped up from the first tissue supporting surface; and

a third tissue supporting surface, wherein the third tissue supporting surface is stepped up from the second tissue supporting surface;

a plurality of first staple cavities arranged in a first row on a lateral side of the elongate slot, wherein the first row extends along the first tissue supporting surface;

a plurality of second staple cavities arranged in a second row on the lateral side of the elongate slot, wherein the second row is closer to the elongate slot than the first row, and wherein the second row extends along the second tissue supporting surface;

a plurality of third staple cavities arranged in a third row on the lateral side of the elongate slot, wherein the third row is closer to the elongate slot than the second row, and wherein the third row extends along the third tissue supporting surface;

a set of staples, comprising;

a first staple removably stored in the first row of staple cavities, wherein the first staple comprises a first unformed height;

a second staple removably stored in the second row of staple cavities, wherein the second staple comprises a second unformed height smaller than the first unformed height; and

a third staple removably stored in the third row of staple cavities, wherein the third staple comprises a third unformed height smaller than the second unformed height, wherein the set of staples are arranged in a first staggered arrangement, wherein the third staple is closer to the distal end portion than the second staple, and wherein the second staple is closer to the distal end portion than the first staple; and

a staple pusher system movable to simultaneously deploy the set of staples, wherein the staple pusher system includes a plurality of independent pusher members, comprising;

a first pusher member configured to lift the first staple;

a second pusher member configured to lift the second staple; and

a third pusher member configured to lift the third staple, wherein the plurality of pusher members are arranged in a second staggered arrangement corresponding to the first staggered arrangement, wherein the third pusher member is closer to the distal end portion than the second pusher member, wherein the second pusher member is closer to the distal end portion than the first pusher member, wherein the first pusher member is coupled to the second pusher member, and wherein the third pusher member is separated from the first pusher member and the second pusher member.

2. The end effector of claim 1, wherein the staple cartridge comprises a firing member movable to drive the plurality of pusher members to deploy the set of staples, and wherein the third pusher member is driven by the firing member faster than the first pusher member and the second pusher member.

3. The end effector of claim 2, wherein the third staple is fully-formed prior to the first staple and the second staple being fully-formed.

4. The end effector of claim 3, wherein the first staple and the second staple are fully-formed simultaneously.

5. The end effector of claim 2, wherein the staple pusher system comprises:

a first camming portion attached to the first pusher member and the second pusher member; and

a second camming portion attached to the third pusher member, wherein the second camming portion is independently movable from the first camming portion.

6. An end effector for a surgical stapling instrument, the end effector comprising:

a staple cartridge, comprising;

a cartridge body including a proximal end portion and a distal end portion;

an elongate slot extending between the proximal end portion and the distal end portion;

a tissue supporting portion, comprising;

a first tissue supporting surface;

a second tissue supporting surface, wherein the second tissue supporting surface is stepped up from the first tissue supporting surface; and

a third tissue supporting surface, wherein the third tissue supporting surface is stepped up from the second tissue supporting surface;

a plurality of first staple cavities arranged in a first row on a lateral side of the elongate slot, wherein the first row extends along the first tissue supporting surface;

a plurality of second staple cavities arranged in a second row on the lateral side of the elongate slot, wherein the second row is closer to the elongate slot than the first row, and wherein the second row extends along the second tissue supporting surface;

a plurality of third staple cavities arranged in a third row on the lateral side of the elongate slot, wherein the third row is closer to the elongate slot than the second row, and wherein the third row extends along the third tissue supporting surface;

a set of staples, comprising;

a first staple removably stored in the first row of staple cavities, wherein the first staple comprises a first unformed height;

a second staple removably stored in the second row of staple cavities, wherein the second staple comprises a second unformed height smaller than the first unformed height; and

a third staple removably stored in the third row of staple cavities, wherein the third staple comprises a third unformed height smaller than the second unformed height, wherein the first staple and the second staple are laterally aligned with each other, wherein the third staple is closer to the distal end portion than the first staple and the second staple, and wherein the set of staples are fully-formed simultaneously; and

a staple pusher system movable to simultaneously deploy the set of staples, wherein the staple pusher system includes a plurality of independent pusher members, comprising;

a first pusher member configured to lift the first staple;

a second pusher member configured to lift the second staple; and

a third pusher member configured to lift the third staple, wherein the first pusher member and the second pusher member are laterally aligned with each other, and wherein the third pusher member is closer to the distal end portion than the first pusher member and the second pusher member.

7. The end effector of claim 6, wherein the staple pusher system comprises:

a first camming portion attached to the first pusher member and the second pusher member; and

a second camming portion attached to the second pusher member and the third pusher member.

8. An end effector for a surgical stapling instrument, the end effector comprising:

a staple cartridge, comprising;

a cartridge body including a proximal end portion and a distal end portion;

an elongate slot extending between the proximal end portion and the distal end portion;

a tissue supporting portion, comprising;

a first tissue supporting surface;

a second tissue supporting surface, wherein the second tissue supporting surface is stepped up from the first tissue supporting surface; and

a third tissue supporting surface, wherein the third tissue supporting surface is stepped up from the second tissue supporting surface;

a plurality of first staple cavities arranged in a first row on a lateral side of the elongate slot, wherein the first row extends along the first tissue supporting surface;

a plurality of second staple cavities arranged in a second row on the lateral side of the elongate slot, wherein the second row is closer to the elongate slot than the first row, and wherein the second row extends along the second tissue supporting surface;

a plurality of third staple cavities arranged in a third row on the lateral side of the elongate slot, wherein the third row is closer to the elongate slot than the second row, and wherein the third row extends along the third tissue supporting surface;

a set of staples, comprising;

a first staple removably stored in the first row of staple cavities, wherein the first staple comprises a first unformed height;

a second staple removably stored in the second row of staple cavities, wherein the second staple comprises a second unformed height smaller than the first unformed height; and

a third staple removably stored in the third row of staple cavities, wherein the third staple comprises a third unformed height smaller than the second unformed height, wherein the second staple and the third staple are laterally aligned with each other, wherein the first staple is further away from the distal end portion than the second staple and the third staple, and wherein the set of staples are fully-formed simultaneously; and

a staple pusher system movable simultaneously to deploy the set of staples, wherein the staple pusher system includes a plurality of independent pusher members, comprising;

a first pusher member configured to lift the first staple;

a second pusher member configured to lift the second staple; and

a third pusher member configured to lift the third staple, wherein the second pusher member and the third pusher member are laterally aligned with each other, and wherein the first pusher member is further away from the distal end portion than the second pusher member and the third pusher member.

9. The end effector of claim 8, wherein the staple pusher system comprises:

a first camming portion attached to the first pusher member and the second pusher member; and

a second camming portion attached to the second pusher member and the third pusher member.

10. An end effector for a surgical stapling instrument, the end effector comprising:

a staple cartridge, comprising;

a cartridge body including a proximal end portion and a distal end portion;

an elongate slot extending between the proximal end portion and the distal end portion;

a tissue supporting portion, comprising;

a first tissue supporting surface;

a second tissue supporting surface, wherein the second tissue supporting surface is stepped up from the first tissue supporting surface; and

a third tissue supporting surface, wherein the third tissue supporting surface is stepped up from the second tissue supporting surface;

a plurality of first staple cavities arranged in a first row on a lateral side of the elongate slot, wherein the first row extends along the first tissue supporting surface;

a plurality of second staple cavities arranged in a second row on the lateral side of the elongate slot, wherein the second row is closer to the elongate slot than the first row, and wherein the second row extends along the second tissue supporting surface;

a plurality of third staple cavities arranged in a third row on the lateral side of the elongate slot, wherein the third row is closer to the elongate slot than the second row, and wherein the third row extends along the third tissue supporting surface;

a plurality of “

U”

shaped staples, comprising;

a first “

U”

shaped staple removably stored in the first row of staple cavities, wherein the first “

U”

shaped staple comprises a first unformed height;

a second “

U”

shaped staple removably stored in the second row of staple cavities, wherein the second “

U”

shaped staple comprises a second unformed height smaller than the first unformed height; and

a third “

U”

shaped staple removably stored in the third row of staple cavities, wherein the third “

U”

shaped staple comprises a third unformed height smaller than the second unformed height, wherein the plurality of “

U”

shaped staples are arranged in a first staggered arrangement, wherein the third “

U”

shaped staple is closer to the distal end portion than the second “

U”

shaped staple, and wherein the second “

U”

shaped staple is closer to the distal end portion than the first “

U”

shaped staple; and

a staple pusher system movable to simultaneously deploy the plurality of “

U”

shaped staples, wherein the staple pusher system includes a plurality of independent pusher members, comprising;

a first pusher member configured to lift the first “

U”

shaped staple, wherein the first pusher member comprises a first retaining feature configured to releasably retain the first “

U”

shaped staple;

a second pusher member configured to lift the second “

U”

shaped staple, wherein the second pusher member comprises a second retaining feature configured to releasably retain the second “

U”

shaped staple; and

a third pusher member configured to lift the third “

U”

shaped staple, wherein the third pusher member comprises a third retaining feature configured to releasably retain the third “

U”

shaped staple, wherein the plurality of independent pusher members are arranged in a second staggered arrangement corresponding to the first staggered arrangement, wherein the third pusher member is closer to the distal end portion than the second pusher member, and wherein the second pusher member is closer to the distal end portion than the first pusher member.

11. The end effector of claim 10, wherein at least one of the first retaining feature, the second retaining feature, and the third retaining feature comprises a retaining hook.

12. The end effector of claim 11, wherein the retaining hook is coupled to a springing member.

13. The end effector of claim 10, wherein at least one of the plurality of first staple cavities, the plurality of second staple cavities, and the plurality of third staple cavities comprises a first narrow end portion and a second narrow end portion.

14. The end effector of claim 13, wherein at least one of the first end portion and the second end portion comprises a bendable seal.

15. The end effector of claim 14, wherein the bendable seal comprises at least one bendable tab.

16. An end effector for a surgical stapling instrument, the end effector comprising:

a frame defining a longitudinal axis;

a first jaw extending fixedly from the frame, wherein the first jaw comprises;

a proximal portion extending along the longitudinal axis; and

a distal portion extending from the proximal portion, the distal portion comprising a hooking region deviating from the longitudinal axis;

a staple cartridge, comprising;

a cartridge body including a proximal end portion and a distal end portion;

an elongate slot extending between the proximal end portion and the distal end portion; and

a tissue supporting portion, comprising;

a first tissue supporting surface on a lateral side of the elongate slot;

a second tissue supporting surface on the lateral side of the elongate slot, wherein the second tissue supporting surface is closer to the elongate slot than the first tissue supporting surface, and wherein the second tissue supporting surface is stepped up from the first tissue supporting surface; and

a third tissue supporting surface on the lateral side of the elongate slot, wherein the third tissue supporting surface is closer to the elongate slot than the second tissue supporting surface, and wherein the third tissue supporting surface is stepped up from the second tissue supporting surface; and

a second jaw extending from the frame, wherein the second jaw comprises an anvil, wherein the second jaw is movable toward the first jaw between an open configuration and an approximated configuration, and wherein the anvil comprises;

a first anvil surface, wherein the first anvil surface and the first tissue contacting surface are separated by a first gap in the approximated configuration;

a second anvil surface, wherein the second tissue anvil surface is stepped up from the first anvil surface, wherein the second anvil surface and the second tissue contacting surface are separated by a second gap in the approximated configuration, and wherein the first gap is greater than the second gap; and

a third anvil surface, wherein the third anvil surface is stepped up from the second anvil surface.

17. The end effector of claim 16, wherein the hooking region comprises a depression configured to capture an anatomical structure.

18. The end effector of claim 17, wherein the distal portion comprises a ramp portion configured to facilitate transition of the anatomical structure from the depression to the tissue supporting portion.

19. The end effector of claim 16, wherein the hooking region comprises a pointed tip.

20. An end effector for a surgical stapling instrument, the end effector comprising:

a staple cartridge, comprising;

a cartridge body including a proximal end portion and a distal end portion;

an elongate slot extending between the proximal end portion and the distal end portion;

a tissue supporting portion, comprising;

a first tissue supporting surface;

a second tissue supporting surface, wherein the second tissue supporting surface is stepped up from the first tissue supporting surface; and

a third tissue supporting surface, wherein the third tissue supporting surface is stepped up from the second tissue supporting surface;

a plurality of first staple cavities arranged in a first row on a lateral side of the elongate slot, wherein the first row extends along the first tissue supporting surface;

a plurality of second staple cavities arranged in a second row on the lateral side of the elongate slot, wherein the second row is closer to the elongate slot than the first row, and wherein the second row extends along the second tissue supporting surface;

a plurality of third staple cavities arranged in a third row on the lateral side of the elongate slot, wherein the third row is closer to the elongate slot than the second row, and wherein the third row extends along the third tissue supporting surface;

a set of staples, comprising;

a first “

U”

shaped staple removably stored in the first row of staple cavities, wherein the first “

U”

shaped staple comprises a first unformed height;

a second “

U”

shaped staple removably stored in the second row of staple cavities, wherein the second “

U”

shaped staple comprises a second unformed height smaller than the first unformed height; and

a “

V”

shaped staple removably stored in the third row of staple cavities, wherein the “

V”

shaped staple comprises a third unformed height smaller than the second unformed height, wherein the set of staples are arranged in a first staggered arrangement, wherein the “

V”

shaped staple is closer to the distal end portion than the second “

U”

shaped staple, and wherein the second “

U”

shaped staple is closer to the distal end portion than the first “

U”

shaped staple; and

a staple pusher system movable to simultaneously deploy the set of staples, wherein the staple pusher system includes a plurality of independent pusher members, comprising;

a first pusher member configured to lift the first “

U”

shaped staple, wherein the first pusher member comprises a first retaining feature configured to releasably retain the first “

U”

shaped staple;

a second pusher member configured to lift the second “

U”

shaped staple, wherein the second pusher member comprises a second retaining feature configured to releasably retain the second “

U”

shaped staple; and

a third pusher member configured to lift the “

V”

shaped staple, wherein the plurality of independent pusher members are arranged in a second staggered arrangement corresponding to the first staggered arrangement, wherein the third pusher member is closer to the distal end portion than the second pusher member, and wherein the second pusher member is closer to the distal end portion than the first pusher member.