SYSTEM FOR DETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A SURGICAL STAPLER

• US 20160256160A1
• Filed: 03/06/2015
• Published: 09/08/2016
• Est. Priority Date: 03/06/2015
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery LLC (Johnson & Johnson)
• Inventors: Shelton, Frederick E. IV, Morgan, Jerome R., Swayze, Jeffrey S., Beckman, Andrew T., Harris, Jason L., Swensgard, Brett E.
• Granted Patent: US 10,617,412 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/0046 with a releasable handle; with handle and operating part separable
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/0608 J-shaped
• CPC Class Codes: A61B 2017/07214 Stapler heads
• CPC Class Codes: A61B 2017/07271 characterised by its cartridge
• CPC Class Codes: A61B 2017/07285 characterised by its cutter
• CPC Class Codes: A61B 2017/2927 the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2929 with a head rotatable about the longitudinal axis of the shaft
• CPC Class Codes: A61B 2090/0808 for indicating correct assembly of components, e.g. of the surgical apparatus
• 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 2090/0812 indicating loosening or shifting of parts of an instrument, signaling maladjustment of parts

Abstract

A surgical instrument system can include an end effector and a staple cartridge which is removably insertable into the end effector. The staple cartridge includes a sled movable from an unfired position to a fired position to eject staples removably stored in the staple cartridge. In various instances, the sled can be inadvertently advanced from its unfired position when the staple cartridge is positioned in the end effector, for example. The surgical instrument system further comprises one or more sensors configured to detect whether the sled is in its unfired position and/or whether the staple cartridge has been mis-inserted into the end effector. The one or more sensors can also determine whether the staple cartridge has been fully seated in the cartridge channel.

Claims

1. A surgical stapling assembly, comprising:

a staple cartridge, comprising;

a cartridge body, comprising;

a proximal end;

a distal end; and

a datum shoulder;

staples removably stored in said cartridge body; and

a sled configured to eject said staples from said cartridge body, wherein said sled is movable between an unfired position in said proximal end of said cartridge body and a fired position in said distal end of said cartridge body; and

an end effector, comprising;

a staple cartridge support configured to receive said cartridge body, wherein said staple cartridge support comprises a datum, wherein said datum shoulder of said cartridge body is configured to contact said datum of said staple cartridge support when said staple cartridge is inserted into said staple cartridge support, and wherein the interaction between said datum shoulder and said datum defines the proper insertion depth of said staple cartridge into said staple cartridge support; and

an insertion depth sensor positioned in said staple cartridge support, wherein said insertion depth sensor is positioned proximally with respect to said proper insertion depth.

2. The surgical stapling assembly of claim 1, wherein said insertion depth sensor is in an open condition when said staple cartridge is not mis-inserted beyond said proper insertion depth, and wherein said staple cartridge closes said insertion depth sensor when said staple cartridge is mis-inserted beyond said proper insertion depth.

3. The surgical stapling assembly of claim 2, further comprising a cutting member configured to move said sled from said unfired position toward said fired position during a firing stroke of said cutting member, wherein said cartridge body comprises a longitudinal slot configured to receive said cutting member, and wherein said sled contacts said cutting member and is prematurely advanced out of said unfired position when said staple cartridge is mis-inserted beyond said proper insertion depth.

4. The surgical stapling assembly of claim 3, wherein said sled comprises a lockout shoulder, wherein said staple cartridge support comprises a lockout aperture including a sidewall, wherein said lockout shoulder is configured to hold said cutting member out of engagement with said lockout aperture sidewall when said sled is in said unfired position, and wherein said surgical stapling assembly further comprises a biasing member configured to bias said cutting member into engagement with said lockout aperture sidewall when said sled has been prematurely advanced from said unfired position.

5. The surgical stapling assembly of claim 1, further comprising an insertion height sensor positioned intermediate said staple cartridge and said staple cartridge support, wherein said insertion height sensor is configured to detect whether said staple cartridge has been fully seated in said staple cartridge support.

6. The surgical stapling assembly of claim 5, wherein said sled is configured to contact said insertion height sensor when said staple cartridge is fully inserted into said staple cartridge support at said proper insertion depth.

7. The surgical stapling assembly of claim 6, wherein said insertion height sensor comprises a first contact and a second contact, and wherein said sled is configured to push said first contact into engagement with said second contact when said staple cartridge is fully seated in said staple cartridge support at said proper insertion depth.

8. The surgical stapling assembly of claim 7, further comprising a sensor circuit including said insertion height sensor and a microprocessor, wherein said insertion height sensor is in communication with said microprocessor, and wherein said sensor circuit is switched between an open condition and a closed condition when said first contact engages said second contact.

9. The surgical stapling assembly of claim 8, further comprising indication means for indicating that said staple cartridge is not fully seated in said staple cartridge support.

10. The surgical stapling assembly of claim 6, wherein said insertion height sensor comprises a first contact, a second contact, and a variable resistance element positioned intermediate said first contact and said second contact, and wherein said sled is configured to push said first contact toward said second contact and compress said resistive element when said staple cartridge is inserted into said staple cartridge support at said proper insertion depth.

11. The surgical stapling assembly of claim 10, further comprising a sensor circuit including said variable resistance element and a microprocessor, wherein said variable resistance element is in communication with said microprocessor, and wherein the resistance of said variable resistance element is a function of the force applied to said variable resistance element by said first contact.

12. The surgical stapling assembly of claim 1, further comprising a sensor circuit comprising including said insertion depth sensor and a microprocessor, and wherein said insertion depth sensor is in communication with said microprocessor.

13. The surgical stapling assembly of claim 12, further comprising indication means for indicating that said staple cartridge has been inserted beyond said proper insertion depth in said staple cartridge support.

14. A surgical stapling assembly, comprising:

a staple cartridge, comprising;

a cartridge body, comprising;

a proximal end; and

a distal end;

staples removably stored in said cartridge body; and

a sled configured to eject said staples from said cartridge body, wherein said sled is movable between an unfired position in said proximal end of said cartridge body and a fired position in said distal end of said cartridge body; and

an end effector, comprising;

a staple cartridge support configured to receive said cartridge body at a proper insertion depth; and

an insertion height sensor positioned in said staple cartridge support, wherein said insertion height sensor is configured to detect whether said staple cartridge has been fully seated in said staple cartridge support, and wherein said sled is configured to contact said insertion height sensor when said staple cartridge is fully inserted into said staple cartridge support at said proper insertion depth.

15. The surgical stapling assembly of claim 14, wherein said insertion height sensor comprises a first contact and a second contact, and wherein said sled is configured to push said first contact into engagement with said second contact when said staple cartridge is fully seated in said staple cartridge support at said proper insertion depth.

16. The surgical stapling assembly of claim 15, further comprising a sensor circuit including said insertion height sensor and a microprocessor, wherein said insertion height sensor is in communication with said microprocessor, and wherein said sensor circuit is switched between an open condition and a closed condition when said first contact engages said second contact.

17. The surgical stapling assembly of claim 16, further comprising indication means for indicating that said staple cartridge is not fully seated in said staple cartridge support.

18. The surgical stapling assembly of claim 15, wherein said insertion height sensor comprises a first contact, a second contact, and a variable resistance element positioned intermediate said first contact and said second contact, and wherein said sled is configured to push said first contact toward said second contact and compress said resistive element when said staple cartridge is inserted into said staple cartridge support at said proper insertion depth.

19. The surgical stapling assembly of claim 18, wherein said variable resistance element is in communication with said microprocessor, and wherein the resistance of said variable resistance element is a function of the force applied to said variable resistance element by said first contact.

20. A surgical stapling assembly, comprising:

a staple cartridge, comprising;

a cartridge body, comprising;

a proximal end; and

a distal end;

staples removably stored in said cartridge body; and

a sled configured to eject said staples from said cartridge body, wherein said sled is movable between an unfired position in said proximal end of said cartridge body and a fired position in said distal end of said cartridge body; and

an end effector, comprising;

a staple cartridge support configured to receive said cartridge body at a proper insertion depth; and

means for detecting whether said staple cartridge is fully inserted into said staple cartridge support at said proper insertion depth.