Surgical staple cartridges supporting non-linearly arranged staples and surgical stapling instruments with common staple-forming pockets

• US 8,899,463 B2
• Filed: 09/30/2010
• Issued: 12/02/2014
• Est. Priority Date: 09/30/2010
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery, Inc. (Johnson & Johnson)
• Inventors: Schall, Christopher J., Shelton, Frederick E. IV
• Primary Examiner(s): Tecco, Andrew M
• Assistant Examiner(s): CHUKWURAH, NATHANIEL C
• Application Number:
  US12/894,340
• Publication Number:
  US 20120080482A1
• Time in Patent Office: 1,524 Days
• Field of Search: 227/175.1, 227/176.1, 227/180.1, 227/179.1, 227/178.1, 227/181.1, 606/219
• US Class Current: 227/176.1
• CPC Class Codes: A61B 1/00064 Constructional details of the endoscope body
• CPC Class Codes: A61B 1/0051 with controlled bending of insertion part
• CPC Class Codes: A61B 1/008 Articulations
• CPC Class Codes: A61B 17/00234 for minimally invasive surgery A61B17/0218, A61B17/0469, A61B17/12013, A61B17/1285, A61B17/29, A61B17/320016 take precedence
• CPC Class Codes: A61B 17/00491 Surgical glue applicators surgical adhesives A61L24/00; two-component delivery syringes A61M5/19
• CPC Class Codes: A61B 17/064 Surgical staples, i.e. penetrating the tissue
• CPC Class Codes: A61B 17/0642 for bones, e.g. for osteosynthesis or connecting tendon to bone
• CPC Class Codes: A61B 17/0643 with separate closing member, e.g. for interlocking with staple
• 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 17/072 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 17/08 Wound clamps or clips, i.e. not or only partly penetrating the tissue suture bridges A61B17/0466; Devices for bringing together the edges of a wound
• CPC Class Codes: A61B 17/1155 Circular staplers comprising a plurality of staples
• CPC Class Codes: A61B 17/29 Forceps for use in minimally invasive surgery
• CPC Class Codes: A61B 17/2909 Handles
• CPC Class Codes: A61B 17/295 combined with cutting implements
• CPC Class Codes: A61B 2017/00004 (bio)absorbable, (bio)resorbable or resorptive
• CPC Class Codes: A61B 2017/003 Steerable
• CPC Class Codes: A61B 2017/00314 : Separate linked members
• CPC Class Codes: A61B 2017/00323 : Cables or rods
• CPC Class Codes: A61B 2017/00327 : with actuating members moving in opposite directions
• CPC Class Codes: A61B 2017/00526 : Methods of manufacturing
• CPC Class Codes: A61B 2017/0053 : Loading magazines or sutures into applying tools
• CPC Class Codes: A61B 2017/00884 : enhancing wound closure
• CPC Class Codes: A61B 2017/00946 : malleable
• CPC Class Codes: A61B 2017/07214 : Stapler heads
• CPC Class Codes: A61B 2017/07221 : curved
• 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 2017/07257 : characterised by its anvil
• 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 2017/07285 : characterised by its cutter
• CPC Class Codes: A61B 2017/2902 : characterized by features of the actuating rod
• CPC Class Codes: A61B 2017/2905 : flexible
• CPC Class Codes: A61B 2017/2908 : Multiple segments connected by articulations
• CPC Class Codes: A61B 2017/291 : the position of the handle being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2919 : details of linkages or pivot points
• CPC Class Codes: A61B 2017/292 : connection of actuating rod to handle, e.g. ball end in recess
• CPC Class Codes: A61B 2017/2923 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/2927 : the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2931 : with releasable head
• CPC Class Codes: A61B 2017/2933 : camming or guiding means
• CPC Class Codes: A61B 2017/2936 : Pins in guiding slots
• CPC Class Codes: A61B 2017/2946 : Locking means
• CPC Class Codes: A61B 90/92 : coded with colour
• CPC Class Codes: Y10T 29/49863 : with prestressing of part

Abstract

A surgical staple cartridge and surgical stapling instruments. In various embodiments, the surgical staple cartridge comprises a cartridge body fabricated from compressible material that supports at least one line of unformed staples therein. The staples may be oriented in linear and/or non-linear arrangements in staple lines. Various forms of staples may be used including staples that have base support members molded or otherwise attached to the base portions of the staples. The surgical stapling instrument has an anvil that is responsive to closing motions to selectively bring the anvil into forming contact with the non-moving staples in the compressible staple cartridge body. The anvil may have a common staple pocket that serves to form all of the staples in a single line of staples.

Claims

1. A surgical staple cartridge for use with an end effector including an anvil, the surgical staple cartridge, comprising:

a cartridge body configured to be operably supported in the end effector such that a cartridge deck thereof is in confronting relationship with a staple-forming undersurface of the anvil; and

at least one line of staples supported in said cartridge body wherein each said staple in said at least one line of staples includes a base and two staple legs protruding therefrom and wherein said base of at least one said staple overlaps and crosses over said base of at least one other adjacent said staple, said at least one staple being oriented relative to said at least one other adjacent said staple and the staple-forming undersurface of the anvil such that when said at least one staple and said at least one other adjacent said staple are driven into forming contact with the staple-forming undersurface of the anvil, the legs of the at least one said staple do not interlock with the legs of the at least one other adjacent said staple.

2. The surgical staple cartridge of claim 1 wherein said base of at least one said staple overlaps said bases of two adjacent said staples.

3. The surgical staple cartridge of claim 1 wherein said staples in said at least one line of said staples are oriented in said cartridge body in a substantially zigzag pattern.

4. The surgical staple cartridge of claim 1 wherein said cartridge body comprises an implantable material.

5. The surgical staple cartridge of claim 4 wherein said cartridge body comprises a substantially-compressible hemostat material.

6. The surgical staple cartridge of claim 1 wherein said cartridge body has an elongated slot therein and wherein said at least one line of staples comprises:

a first line of first staples on one lateral side of said elongated slot, each said first staple having a first staple base and two first staple legs protruding therefrom and wherein said first base of at least one said first staple overlaps said first base of at least one other adjacent said first staple; and

a second line of second staples on another lateral side of said elongated slot, each said second staple having a second staple base and two second staple legs protruding therefrom and wherein said second base of at least one said second staple overlaps said second base of at least one other adjacent said second staple.

7. The surgical staple cartridge of claim 6 wherein said first base of at least one said first staple overlaps said first bases of two adjacent said first staples and wherein said second base of at least one said second staple overlaps said second bases of two adjacent said second staples.

8. The surgical staple cartridge of claim 6 wherein said first staples in said first line of said first staples are oriented in said cartridge body in a first zigzag pattern and wherein said second staples in said second line of said second staples are oriented in said cartridge body in a second zigzag pattern.

9. The surgical staple cartridge of claim 6 wherein said cartridge body comprises an implantable material.

10. The surgical staple cartridge of claim 9 wherein said cartridge body comprises a substantially-compressible hemostat material.

11. An end effector for a surgical instrument, said end effector comprising:

an elongated channel configured to operably support a staple cartridge therein; and

an anvil movably supported relative to said elongated channel, said anvil being selectively movable from an open position wherein a staple-forming surface thereof is spaced away from a staple cartridge supported in said elongated channel to closed positions relative to the staple cartridge within said elongated channel in response to firing motions applied to said anvil, said anvil including at least one anvil pocket configured for forming contact with legs of at least two discrete adjacent staples in a common line of discrete staples in the staple cartridge supported within said elongated channel such that said legs of the at least two discrete adjacent staples are formed in orthogonal non-locking directions.

12. The end effector of claim 11 wherein said anvil has an elongated anvil slot therein configured to accommodate a portion of an axially movable cutting member therethrough and wherein said anvil has at least one common line of said anvil pockets on each side of said elongated anvil slot.

13. The end effector of claim 11 further comprising a staple cartridge supported in said elongated channel, said staple cartridge having a cartridge body supporting said common line discrete of staples therein, wherein each said staple in said common line of discrete staples has a staple base and two staple legs protruding therefrom and wherein said staple base of at least one said staple overlaps said staple base of at least one other adjacent said staple.

14. The end effector of claim 11 further comprising a staple cartridge supported in said elongated channel, said staple cartridge having a cartridge body supporting said common line of discrete staples therein in a substantially zigzag pattern.

15. The end effector of claim 11 further comprising a staple cartridge supported in said elongated channel, said staple cartridge having a cartridge body supporting said common line of discrete staples therein wherein each said staple in said common line of discrete staples has a staple base and two staple legs protruding therefrom and wherein said staple bases of at least two adjacent said staples are coupled together.

16. The end effector of claim 11 further comprising a staple cartridge supported in said elongated channel, said staple cartridge having a cartridge body supporting said common line of discrete staples therein wherein each said staple in said common line of discrete staples has a staple support member molded thereto.

17. The end effector of claim 16 wherein said staple support member is fabricated from a bioabsorbable material.

18. A surgical instrument, comprising:

a handle assembly;

an elongated shaft assembly operably coupled to said handle assembly;

an end effector, comprising;

an elongated channel operably coupled to a portion of said elongated shaft assembly;

a staple cartridge supported in said elongated channel, said staple cartridge supporting at least one line of staples therein, each said staple in said at least one line of staples having a staple base and a pair of staple legs protruding therefrom and wherein said staples in at least one of said at least one line of staples being oriented in a predetermined pattern relative to each other such that an axis of said staple base of one said staple substantially transversely crosses another said staple base of an adjacent said staple in a same said line of staples; and

an anvil movably supported relative to said elongated channel, said anvil being selectively movable from an open position wherein a staple forming surface thereof is spaced away from said staple cartridge to closed positions relative to said staple cartridge in response to firing motions applied to said anvil from said elongated shaft, said anvil having at least one common anvil pocket formed therein corresponding to one of said at least one line of staples in said staple cartridge such that the legs of at least two adjacent staples in said at least one line of staples are formed in orthogonal non-interlocking directions.

19. The surgical instrument of claim 18 further comprising a tissue cutting member operably supported by said elongated shaft assembly and configured to axially travel through an elongated slot in said staple cartridge upon application of cutting motion thereto.

20. The surgical instrument of claim 19 wherein said at least one line of staples comprises:

a first line of first staples on one lateral side of said elongated slot, each said first staple having a first staple base and two first staple legs protruding therefrom and wherein a first base of at least one said first staple substantially transversely crosses over the first base of at least one other adjacent said first staple in said first line of first staples; and

a second line of second staples on another lateral side of said elongated slot, each said second staple having a second staple base and two second staple legs protruding therefrom and wherein a second base of at least one said second staple substantially transversely crosses over a second base of at least one other adjacent said second staple in said second line of first staples.