Surgical staple cartridge with improved staple driver configurations

• US 10,314,587 B2
• Filed: 09/02/2015
• Issued: 06/11/2019
• Est. Priority Date: 09/02/2015
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Harris, Jason L., Shelton, IV, Frederick E.
• Primary Examiner(s): Stinson, Chelsea E
• Application Number:
  US14/843,168
• Publication Number:
  US 20170056011A1
• Time in Patent Office: 1,378 Days
• Field of Search: 2271751
• 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 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/105 Wound clamp magazines for packaging sharps A61B50/3001
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• 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 for prosthetic joint-implanting tools A61F2/4603
• 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 2017/07271 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

Abstract

A surgical staple driver array configured for operable use with a surgical staple cartridge. A distal staple driver is slidably supportable in the surgical staple cartridge and is configured to operably support a distal surgical staple thereon that is oriented in a distal direction. At least one intermediate staple driver is configured to be slidably supported in the surgical staple cartridge adjacent the distal staple driver. Each intermediate staple driver is configured to operably support a first surgical staple that is oriented in a first direction, a second surgical staple that is oriented in a second direction and a third surgical staple that is oriented in a third direction. A proximal staple driver is slidably supported adjacent a proximal most one of the intermediate staple drivers. The proximal staple driver is configured to operably support a proximal surgical staple thereon.

Claims

1. A surgical staple driver array for operable use with a surgical staple cartridge comprising an axially movable sled, wherein the axially movable sled comprises first and second camming members, and wherein said surgical staple driver array comprises:

a distal staple driver slidably supportable in the surgical staple cartridge and configured to operably support a single distal surgical staple thereon that is oriented in a distal direction;

a plurality of intermediate staple drivers configured to be slidably supported in the surgical staple cartridge in series, wherein a distal most one of said intermediate staple drivers is adjacent to said distal staple driver, each of said intermediate staple drivers being configured to operably support a first surgical staple oriented in a first direction, a second surgical staple oriented in a second direction and a third surgical staple oriented in a third direction, wherein the first direction and the third direction are parallel to each other, wherein the second direction is transverse to the first direction and the third direction, wherein each said intermediate staple driver comprises a first camming surface extending transversely under a portion of the first surgical staple and being aligned for camming contact with said first camming member and a second camming surface extending transversely under a portion of the third surgical staple and being aligned for camming contact with the second camming member, and wherein each of said intermediate staple drivers is configured to hookingly engage corresponding portions of the surgical staple cartridge to slidably interlock each said intermediate staple driver to the surgical staple cartridge for slidable operable travel relative thereto in a direction that is transverse to an axis of the surgical staple cartridge; and

a proximal staple driver slidably supported adjacent a proximal most one of said intermediate staple drivers, said proximal staple driver configured to operably support a proximal surgical staple oriented in a proximal direction.

2. The surgical staple driver array of claim 1, wherein said distal direction is parallel to at least one of said first, second and third directions.

3. The surgical staple driver array of claim 1, wherein said proximal direction is parallel to at least one of said first, second and third directions.

4. The surgical staple driver array of claim 1, wherein said distal direction, said first direction, said third direction and said proximal direction are parallel.

5. The surgical staple driver array of claim 1, wherein a distal crown of the distal surgical staple is supported along a distal base axis and a first crown of the first surgical staple is supported along a first base axis that is parallel to said distal base axis.

6. The surgical staple driver array of claim 5, wherein a second staple crown of the second surgical staple is supported along a second base axis that is transverse to said first base axis.

7. The surgical staple driver array of claim 6, wherein a third staple crown of the third surgical staple is supported along a third base axis that is parallel to said first base axis.

8. The surgical staple driver array of claim 7, wherein a proximal staple crown of the proximal surgical staple is supported along a proximal base axis that is parallel to said third base axis of the third surgical staple supported in said proximal most one of said intermediate staple drivers.

9. A surgical staple cartridge, comprising:

an axially movable sled comprising first and second camming members;

a cartridge body comprising a proximal end and a distal end;

a distal staple driver movably supported in said cartridge body and configured to support a distal surgical staple thereon in a distal direction;

a plurality of intermediate staple drivers movably supported in said cartridge body in series, wherein a distal most one of said intermediate staple drivers is adjacent to said distal staple driver, each said intermediate staple driver supporting a first surgical staple in a first direction, a second surgical staple in a second direction and a third surgical staple in a third direction, wherein the first direction and the third direction are parallel to each other, and wherein the second direction is transverse to the first direction and the third direction, wherein each said intermediate staple driver comprises a first camming surface extending transversely under a portion of the first surgical staple and being aligned for camming contact with said first camming member and a second camming surface extending transversely under a portion of the third surgical staple and being aligned for camming contact with the second camming member, and wherein each of said intermediate staple drivers is configured to hookingly engage corresponding portions of the surgical staple cartridge to slidably interlock each said intermediate staple driver to the surgical staple cartridge for slidable operable travel relative thereto in a direction that is transverse to an axis of the surgical staple cartridge; and

a proximal staple driver slidably supported adjacent a proximal most one of said intermediate staple drivers, said proximal staple driver configured to operably support a proximal surgical staple oriented in a proximal direction.

10. The surgical staple cartridge of claim 9, wherein:

a distal crown of the distal surgical staple is supported along a distal base axis and a first crown of the first surgical staple is supported along a first base axis that is parallel to said distal base axis;

a second staple crown of the second surgical staple is supported along a second base axis that is transverse to said first base axis;

a third staple crown of the third surgical staple is supported along a third base axis that is parallel to said first base axis; and

a proximal staple crown of the proximal surgical staple is supported along a proximal base axis that is parallel to said third base axis of the third surgical staple supported in said proximal most intermediate staple driver.

11. The surgical staple cartridge of claim 9, wherein said distal staple driver comprises a distal staple support member comprising:

a distal support column configured to support a distal leg of the distal surgical staple thereon; and

a proximal support column configured to support a proximal leg of the distal surgical staple thereon and wherein one of said distal and proximal support columns is slidably supported in one of a first wall portion and a second wall portion of said cartridge body.

12. The surgical staple cartridge of claim 11, wherein said distal staple driver further comprises a distal camming surface aligned on a first cam axis that extends transversely between said distal and proximal support columns.

13. The surgical staple cartridge of claim 12, wherein at least one of said intermediate staple drivers comprises:

a first staple support member comprising;

a first distal support column configured to support a first distal leg of a corresponding first surgical staple thereon; and

a first proximal support column configured to support a first proximal leg of the corresponding first surgical staple thereon and wherein said at least one of said intermediate staple drivers further comprises;

a second staple support member comprising;

a second distal support column configured to support a second distal leg of a corresponding second surgical staple thereon; and

a second proximal support column configured to support a second proximal leg of the corresponding second surgical staple thereon and wherein said at least one of said intermediate staple drivers further comprises;

a third staple support member comprising;

a third distal support column configured to support a third distal leg of a corresponding third surgical staple thereon; and

a third proximal support column configured to support a third proximal leg of the corresponding third surgical staple thereon and wherein one of said third distal support column and said third proximal support column is slidably supported in one of said first and second wall portions of said cartridge body.

14. The surgical staple cartridge of claim 13, wherein said proximal staple driver comprises:

a proximal staple support member comprising;

another distal support column configured to support another distal leg of the proximal surgical staple thereon; and

another proximal support column configured to support another proximal leg of the proximal surgical staple thereon and wherein one of said another distal and another proximal support columns is slidably supported in one of said first wall portion and said second wall portion of said cartridge body.

15. The surgical staple cartridge of claim 14, further comprising:

at least one distal camming surface on said distal staple support member;

at least one first camming surface on at least one of said first, second and third staple support members; and

at least one proximal camming surface on said proximal staple support member.

16. The surgical staple cartridge of claim 15, wherein said at least one distal camming surface, said at least one first camming surface and said at least one proximal camming surface are aligned on a common camming axis.

17. The surgical staple cartridge of claim 16, wherein said at least one distal camming surface comprises:

a first distal camming surface; and

a second distal camming surface spaced from said first distal camming surface and wherein said at least one first camming surface comprises;

a first camming surface; and

a second camming surface spaced from said first camming surface and wherein said at least one proximal camming surface comprises;

a first proximal camming surface and a second proximal camming surface.

18. The surgical staple cartridge of claim 17, wherein said first distal camming surface, said first camming surface and said first proximal camming surface are aligned on a first camming axis and wherein said second distal camming surface, said second camming surface and said second proximal camming surface are aligned on a second camming axis.

19. The surgical staple cartridge of claim 18, wherein said first camming surface is on said first staple support member and said second camming surface is on said third staple support member.

20. A surgical instrument, comprising:

an axially movable sled comprising first and second camming members;

a surgical staple cartridge;

a distal staple driver movably supported in said surgical staple cartridge, said distal staple driver configured to operably support a corresponding distal surgical staple thereon and comprising a first distal camming surface aligned for camming contact with said first camming member and a second distal camming surface aligned for camming contact with said second camming member;

a plurality of intermediate staple drivers movably supported in said surgical staple cartridge in series, wherein a distal most one of said intermediate staple drivers is adjacent to said distal staple driver, each said intermediate staple driver supporting a corresponding first surgical staple, a corresponding second surgical staple, and a corresponding third surgical staple on staple cradles defined in each intermediate staple driver, each said intermediate staple driver comprising a first camming surface extending transversely under a portion of the first surgical staple and being aligned for camming contact with said first camming member and a second camming surface extending transversely under a portion of the third surgical staple and being aligned for camming contact with the second camming member, and wherein said first surgical staple is oriented parallel to said third surgical staple, and wherein said second surgical staple is oriented transverse to said first surgical staple and said second surgical staple; and

a proximal staple driver slidably supported adjacent a proximal most one of said intermediate staple drivers, said proximal staple driver configured to operably support a corresponding proximal surgical staple thereon and comprising a first proximal camming surface aligned for camming contact with said first camming member and a second proximal camming surface aligned for camming contact with said second camming member.