CN108348234B - Staple cartridge assembly including features for controlling rotation of staples as they are ejected therefrom - Google Patents

Abstract

A staple cartridge includes a cartridge body, staple cavities defined in the cartridge body, and staples removably stored in the staple cavities. The staple cartridge includes features for properly aligning and preventing misalignment of the staples within the staple cavities.

Description

Staple cartridge assembly including features for controlling rotation of staples as they are ejected therefrom

Background

The present invention relates to surgical instruments and, in various embodiments, to surgical stapling and cutting instruments and staple cartridges for use therewith.

The stapling instrument can include a pair of cooperating elongated jaw members, wherein each jaw member can be adapted to be inserted into a patient and positioned relative to tissue to be stapled and/or incised. In various embodiments, one of the jaw members can support a staple cartridge having at least two laterally spaced rows of staples housed therein, and the other jaw member can support an anvil having staple-forming pockets aligned with the rows of staples in the staple cartridge. In general, the stapling instrument can further include a pusher bar and a knife blade that are slidable relative to the jaw members to sequentially eject staples from the staple cartridge via camming surfaces on the pusher bar and/or camming surfaces on a wedge sled that is pushed by the pusher bar. In at least one embodiment, the camming surfaces can be configured to actuate a plurality of staple drivers carried by the cartridge and associated with the staples in order to push the staples against the anvil and form laterally spaced rows of deformed staples in tissue clamped between the jaw members. In at least one embodiment, the blade can follow the cam surface and cut the tissue along the line between the rows of staples.

The above discussion is intended to be merely illustrative of the present aspects of the relevant art in the field of the present invention and should not be taken as negating the scope of the claims.

Drawings

Various features of the embodiments described herein are set forth with particularity in the appended claims. However, various embodiments as to the organization and method of operation, together with advantages thereof, may be understood in accordance with the following description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of a staple for use with a surgical stapling instrument, in accordance with at least one embodiment;

FIG. 2 is a side elevational view of the nail of FIG. 1;

FIG. 3 is a top view of the nail of FIG. 1;

FIG. 4 is a cross-sectional view of the nail of FIG. 1 taken along line 4-4 of FIG. 3;

FIG. 5 is a perspective view of a staple for use with a surgical stapling instrument, in accordance with at least one embodiment;

FIG. 6 is a side elevational view of the nail of FIG. 5;

FIG. 7 is a side elevational view of a staple used with a surgical stapling instrument in accordance with at least one embodiment;

FIG. 8 is a side elevational view of the staple of FIG. 7 in a formed configuration;

FIG. 9 is a top view of the staple of FIG. 7 in the formed configuration of FIG. 8;

FIG. 10 is a side elevational view of the staple of FIG. 7 in a formed configuration and a partial cross-sectional view of an anvil of a surgical stapling instrument;

FIG. 11 is a perspective view of a staple used with a surgical stapling instrument in accordance with at least one embodiment;

11A-11C are cross-sections of portions of the nail of FIG. 11;

FIG. 12 is a perspective view of a staple for use with a surgical stapling instrument, in accordance with at least one embodiment;

FIG. 13 is a side elevational view of a staple used with a surgical stapling instrument in accordance with at least one embodiment;

FIG. 14 is a partial top view of a formed staple configuration including a plurality of staples according to at least one embodiment;

FIG. 15 is a perspective view of a staple for use with a surgical stapling instrument, in accordance with at least one embodiment;

FIG. 16 is a partial cross-sectional view of the anvil showing a portion of the staple of FIG. 15 formed from an unformed configuration to a formed configuration;

FIG. 17 is a front view of the nail of FIG. 15 in a formed configuration;

FIG. 18 includes a side view of a plurality of staple tips in accordance with at least one embodiment;

FIG. 19 is a bottom view of a forming pocket of a staple and anvil according to a first arrangement according to at least one embodiment;

FIG. 20 is a partial cross-sectional view of the anvil pocket of FIG. 19 taken along line 20-20 of FIG. 19;

FIG. 21 is a bottom view of the staple and forming pocket of FIG. 19 according to a second arrangement;

FIG. 22 is a bottom view of the staple and forming pocket of FIG. 19 according to a third arrangement;

FIG. 23 is a bottom view of the staple and forming pocket of FIG. 19 according to at least one embodiment;

FIG. 24 is a partial cross-sectional view of the anvil pocket of FIG. 23 taken along line 24-24 of FIG. 23;

FIG. 25 is a bottom view of the staple and forming pocket of FIG. 19 according to at least one embodiment;

FIG. 26 is a bottom view of the staple and forming pocket of FIG. 19 according to at least one embodiment;

FIG. 27 is a partial perspective view of a staple leg according to at least one embodiment;

FIG. 27A is a partial cross-sectional end view of the staple leg of FIG. 27;

FIG. 27B is a partial longitudinal section of the staple leg of FIG. 27;

FIG. 28 is a perspective view of a portion of a nailing strip made using progressive die stamping;

FIG. 28A is a partial cross-sectional view of the nailing strip portion of FIG. 28 taken along line 28A-28A of FIG. 28;

FIG. 28B is a partial cross-sectional view of the nailing strip portion of FIG. 28 taken along line 28B-28B of FIG. 28;

FIG. 28C is a partial perspective view of a slider configured to engage the nailing strip of FIG. 28;

FIG. 29 is a perspective view of a portion of a nailing strip made using progressive die stamping in accordance with at least one embodiment;

FIG. 30 is a bottom perspective view of the nailing strip of FIG. 29;

FIG. 31 is a partial cross-sectional view of a staple cartridge and staples according to at least one embodiment;

FIG. 32 is a perspective view of a staple cartridge assembly according to at least one embodiment;

FIG. 33 is a top plan view of the staple cartridge assembly of FIG. 32;

FIG. 34 is a detail view of the distal end of the cartridge assembly of FIG. 32;

FIG. 35 is a partial cross-sectional perspective view of the staple cartridge assembly showing staples ejected from the staple cartridge assembly by the firing member in accordance with at least one embodiment;

FIG. 36 is a partially exploded view of the staple cartridge assembly of FIG. 35;

FIG. 37 is a partial cross-sectional view of the staple cartridge assembly of FIG. 35 showing staples deformed against the anvil by the firing member;

FIG. 38 is a partial plan view of staples positioned in the staple cavities of the staple cartridge assembly of FIG. 35;

FIG. 39 is a partial perspective view of staples lifted by a firing member of the staple cartridge of FIG. 35;

FIG. 40 is a bottom perspective view of the nail of FIG. 39;

FIG. 41 is a schematic view showing the staple of FIG. 39 in a horizontal position;

FIG. 42 is a schematic view showing the staple of FIG. 39 in a bent position;

FIG. 43 is a cut-away plan view of a staple cavity configured to guide staples in accordance with at least one embodiment;

FIG. 44 is a cross-sectional perspective view of the staple cartridge assembly positioned in a jaw of a surgical stapling instrument showing a firing member positioned in a cartridge body of the staple cartridge assembly in accordance with at least one embodiment;

FIG. 45 is a partial cross-sectional perspective view of the staple cartridge assembly of FIG. 44 showing a retention feature configured to retain the firing member in the cartridge body when the staple cartridge assembly is not positioned in a jaw of the surgical stapling instrument;

FIG. 46 is a partial cross-sectional exploded view of the staple cartridge assembly of FIG. 44;

FIG. 47 is a partial cross-sectional end view of the staple cartridge assembly of FIG. 44;

FIG. 48 is a partial cutaway perspective view of the cartridge assembly of FIG. 44 illustrating a retention feature configured to releasably retain the cartridge assembly in a jaw of a surgical stapling instrument;

FIG. 49 is a partial plan view of staples positioned in staple cavities of a staple cartridge assembly according to at least one embodiment;

FIG. 50 is a detail view of a retention feature configured to releasably retain staples in the cartridge assembly of FIG. 49;

FIG. 51 is a partial cross-sectional elevation view of a staple cartridge assembly according to at least one embodiment;

FIG. 52 is a perspective view of a staple in accordance with at least one embodiment;

FIG. 53 is a bottom perspective view of the nail of FIG. 52;

FIG. 54 is a front elevational view of the nail of FIG. 52;

FIG. 55 is a side elevational view of the nail of FIG. 52;

FIG. 56 is a bottom view of the nail of FIG. 52;

FIG. 57 is a perspective view of a firing member of a staple cartridge assembly according to at least one embodiment, the firing member including an alignment channel;

FIG. 58 is a schematic view showing the firing member of FIG. 57 and staples positioned in the staple cavities of the staple cartridge assembly;

FIG. 59 is a schematic view of the firing member of FIG. 57 shown aligned with the staples of FIG. 58 within the staple cavities of FIG. 58;

FIG. 60 is a perspective view of the firing member of FIG. 57 and staples arranged in two longitudinal rows;

FIG. 61 is a partial cross-sectional view of the alignment channel of the firing member of FIG. 57 and a portion of the staples of FIG. 58;

FIG. 62 is a perspective view, partially in section, of the staple cartridge assembly of FIG. 58;

FIG. 63 is a partially exploded view of the staple cartridge assembly of FIG. 58;

FIG. 64 is a partial bottom cross-sectional perspective view of the staple cartridge assembly of FIG. 58;

FIG. 65 is a partial perspective view of a protrusion extending from a deck surface of a staple cartridge assembly according to at least one alternative embodiment;

FIG. 66 is a partial perspective view of a protrusion extending from a deck surface of a staple cartridge assembly according to at least one alternative embodiment;

FIG. 67 is a bottom perspective view of the cartridge body of the staple cartridge assembly;

fig. 68 is a bottom view of the cartridge body of fig. 67;

FIG. 69 is a bottom perspective view of the cartridge body of the staple cartridge assembly of FIG. 32;

fig. 70 is a bottom view of the cartridge body of fig. 32;

fig. 71 is a schematic view showing the cartridge body of fig. 67 with an alternative embodiment of the cartridge body;

FIG. 72 is a partial top plan view of a staple cartridge assembly according to at least one embodiment;

FIG. 73 is a partial perspective view of the staple cartridge of FIG. 32;

FIG. 74 is a cross-sectional view of the staple cartridge of FIG. 32 and the anvil of FIG. 37, showing some of the staples in an unfired position and some of the staples in a fired position;

FIG. 75 illustrates the staples of the staple cartridge of FIG. 32 deformed to three different heights;

FIG. 76 shows staples of the staple cartridge of FIG. 32 implanted in tissue of a patient;

FIG. 77 illustrates the staples of the staple cartridge of FIG. 32 being deformed;

FIG. 78 is a perspective view of a staple in accordance with at least one embodiment;

FIG. 79 is a cross-sectional view of the nail of FIG. 78;

FIG. 80 is a perspective view of a staple assembly in accordance with at least one embodiment;

FIG. 81 is a front elevational view of the staple assembly of FIG. 80;

FIG. 82 is a perspective view of an implantable tack assist;

FIG. 83 is a cross-sectional view of the staple aid of FIG. 82;

FIG. 84 is a partial perspective view of the staple assembly including the staple aid of FIG. 82;

FIG. 85 shows the staple assembly of FIG. 84 implanted into tissue;

FIG. 86 is a perspective view of a staple shown in a deformed configuration in accordance with at least one embodiment;

FIG. 87 is a plan view of a circular cartridge body comprising the plurality of staple assemblies of FIG. 84 in accordance with at least one embodiment;

FIG. 88 shows the spacing of the staples of FIG. 35 in unstretched tissue;

FIG. 89 shows the spacing of the staples of FIG. 35 in stretched tissue;

FIG. 90 is a perspective view of a staple in accordance with at least one embodiment;

FIG. 91 shows the staple of FIG. 90 implanted into tissue;

FIG. 92 shows the nail of FIG. 90 after partial dissolution;

FIG. 93 is a cross-sectional perspective view of a portion of a circular surgical stapler according to at least one embodiment;

FIG. 94 is a perspective view, partially in section, of the circular surgical stapler of FIG. 93;

FIG. 95 is a partial perspective view of the circular surgical stapler of FIG. 93;

FIG. 96 is a partially exploded perspective view of a circular surgical stapler in accordance with at least one embodiment;

FIG. 97 is a partial perspective view of the circular surgical stapler of FIG. 96, showing a staple in a preloaded position;

FIG. 98 is a partial perspective view of the circular surgical stapler of FIG. 96;

FIG. 99 is an end view of a circular surgical stapling configuration in accordance with at least one embodiment;

FIG. 100 is an end view of a circular surgical stapling configuration in accordance with at least one embodiment;

FIG. 101 is a partial cross-sectional view of a colon sutured using the circular stapling instrument disclosed herein;

FIG. 102 is a partial perspective view of a curved stapler in accordance with at least one embodiment;

FIG. 103 is a partially exploded view of the curved stapler of FIG. 102;

FIG. 104 is a partial perspective view of the curved stapler of FIG. 102;

FIG. 105 is a partial perspective view of a curved stapler in accordance with at least one embodiment; and is

FIG. 106 is a partial perspective view of the curved stapler of FIG. 105.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate various embodiments of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

Detailed Description

The applicant of the present application owns the following U.S. patent applications filed on even date herewith and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. __________ entitled "SURGICAL STAPLES FOR MINIMIZING STAPLE ROLL"; attorney docket number END7687 USNP/150127;

U.S. patent application Ser. No. __________ entitled "SURGICAL STAPLES COMPRISING FEATURES FOR IMPROVED FASTENING OF TISSUE"; attorney docket number END7678 USNP/150118;

U.S. patent application Ser. No. __________ entitled "SURGICAL STAPLES COMPLEMENTING HARDNESS VARITIONS FOR IMPROVED FASTENING OF TISSUE"; attorney docket number END7727 USNP/150298;

U.S. patent application Ser. No. __________ entitled "SURGICAL STAPLE STRIPS FOR PERMITTING VARYING STAPLE PROPERTIES AND ENABLING EASY CARTRIDGE LOADING"; attorney docket number END7680 USNP/150120;

U.S. patent application Ser. No. __________ entitled "SURGICAL STAPLING CONFIGURATION FOR CURVED AND CIRCULAR STAPLING INSTRUMENTS"; attorney docket number END7682 USNP/150122;

-U.S. patent application serial No. __________ entitled "STAPLE CARTRIDGE ASSEMBLY with a BOTTOM COVER"; attorney docket number END7679 USNP/150119;

-U.S. patent application serial No. __________ entitled "STAPLE CARTRIDGE ASSEMBLY STAPLE CAVITIES FOR PROVIDING bearing platform guide"; attorney docket number END7681 USNP/150121;

-U.S. patent application serial No. __________ entitled "STAPLE CARTRIDGE ASSEMBLY filing stage GUIDES"; attorney docket number END7685 USNP/150125;

-U.S. patent application Ser. No. __________ entitled "STAPLE CARTRIDGE ASSEMBLY COMPRISING STAPLE ALIGNMENT FEATURES ON A FIRING MEMBER"; attorney docket number END7688 USNP/150128;

-U.S. patent application serial No. __________ entitled "STAPLE CARTRIDGE ASSEMBLY variation methods using composition GAPS AND STAPLE FORMING GAPS"; attorney docket number END7684 USNP/150124;

-U.S. patent application serial No. __________ entitled "STAPLES CONFIRED TO SUPPORT AN IMPLANTABLE ADJUNCT"; attorney docket number END7686 USNP/150126; and

-U.S. patent application serial No. __________ entitled "STAPLES COMPRISING A COVER"; attorney docket number END7689 USNP/150129.

The applicant of the present application also owns the following patent applications filed on 23.12.2013 and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/138,554 entitled "SURGICAL INSTRUMENTS WITH ARTICULATABLE SHAFT ARRANGEMENTS";

-U.S. patent application serial No. 14/138,465 entitled "SURGICAL STAPLES AND STAPLE CARTRIDGES";

-U.S. patent application serial No. 14/138,474 entitled "articulable minor impregnation WITH SEPARATE AND DISTINCT CLOSING AND FIRING SYSTEMS";

U.S. patent application Ser. No. 14/138,485 entitled "SURGICAL CUTTING AND STAPLING INSTRUMENTS WITH INDEPENDENT JAW CONTROL FEATURES";

-U.S. patent application serial No. 14/138,475 entitled "SURGICAL STAPLES AND STAPLE CARTRIDGES";

-U.S. patent application serial No. 14/138,481 entitled "SURGICAL STAPLES AND METHODS FOR MAKING THE SAME";

U.S. patent application Ser. No. 14/138,489 entitled "SURGICAL STAPLES, STAPLE CARTRIDGES AND SURGICAL END EFFECTORS";

-U.S. design patent application serial No. 29/477,488 entitled "SURGICAL FASTENER";

-U.S. patent application Ser. No. 14/138,505 entitled "FASTENER CARTRIDGE composition AN EXTENDABLE filing Membrane";

-U.S. patent application Ser. No. 14/138,518 entitled "FASTENER CARTRIDGE composition A dressing MEMBER constructed TO DIRECTLY ENGAGE AND Eject FASTENERS FROM THE FASTENER CARTRIDGE";

-U.S. patent application Ser. No. 14/138,530 entitled "FASTENER CARTRIDGE composition A framing MEMBER INCLUDING FASTENER TRANSFER SURFACES";

-U.S. patent application serial No. 14/138,507 entitled "MODULAR SURGICAL INSTRUMENTS";

U.S. patent application Ser. No. 14/138,497 entitled "SURGICAL CUTTING AND STAPLING INSTRUMENTS WITH ARTICULATABLE END EFFECTORS"; and

U.S. patent application Ser. No. 14/138,516 entitled "SURGICAL CUTTING AND STAPLING METHODS".

Numerous specific details are set forth herein to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments described in the specification and illustrated in the accompanying drawings. Well-known operations, components and elements have not been described in detail so as not to obscure the embodiments described in the specification. The reader will understand that the embodiments described and illustrated herein are non-limiting examples and that specific structural and functional details disclosed herein are representative and illustrative. Variations and changes may be made to these embodiments without departing from the scope of the claims.

The terms "comprises" (and "comprising)" in any form, such as "comprises" and "comprising", "(and" having) "," having "(and" having) ", such as" having "and" having) "," containing "(and" containing) ", such as" comprising "and" containing) ", and" containing "(and" containing) "such as" containing "and" containing "are open-ended verbs. Thus, a surgical system, device, or apparatus that "comprises," "has," "contains," or "contains" one or more elements has those one or more elements, but is not limited to having only those one or more elements. Likewise, an element of a system, apparatus or device that "comprises," "has," "contains," or "contains" one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

The terms "proximal" and "distal" are used herein with respect to a clinician manipulating a handle portion of a surgical instrument. The term "proximal" refers to the portion closest to the clinician and the term "distal" refers to the portion located away from the clinician. It will be further appreciated that for simplicity and clarity, spatial terms such as "vertical," "horizontal," "up," and "down" may be used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily appreciate that the various methods and devices disclosed herein may be used in a variety of surgical procedures and applications, including, for example, in conjunction with open surgery. With continued reference to the present detailed description, the reader will further appreciate that the various instruments disclosed herein may be inserted into the body in any manner, such as through a natural orifice, through an incision or puncture formed in tissue, and the like. The working portion or end effector portion of the instrument may be inserted directly into the patient's body or may be inserted through an access device having a working channel through which the end effector and elongate shaft of the surgical instrument may be advanced.

The staples or fasteners disclosed herein are configured to be used with a surgical stapling instrument. As discussed in more detail below, staples are removably stored in staple cavities of a staple cartridge. The staple cartridge includes a sled configured to receive a firing actuation from the surgical stapling instrument that applies a force to the staples to eject the staples from the staple cavities. As the staples are ejected or driven out of the staple cavities by the sled, the staples undergo a deformation process in which the staples are formed from an unfired configuration to a fired configuration. The staples are formed into a fired configuration when the staples contact corresponding forming pockets of an anvil of the surgical stapling instrument.

The various staples disclosed herein include flat formed staples that may be cut and/or stamped from a sheet of material, for example. For example, the sheet of material may be metallic and may comprise stainless steel and/or titanium. In at least one instance, the contours can be drawn, etched, and/or cut into a sheet of material that is machined and/or laser cut to form the staples into the manufactured shapes.

The staple includes a pair of legs and a staple base portion or crown from which the legs extend. Each staple leg includes a staple tip or piercing portion configured to pierce tissue and contact a corresponding forming pocket of an anvil of a surgical stapling instrument. The staple legs are configured to change shape to achieve a shaped configuration to secure tissue. The staple base portion defines a first plane and the staple legs define a second plane that is laterally offset from, but at least substantially parallel to, the first plane. Embodiments are envisaged in which the first and second planes are non-parallel.

The flat shaped staple 100 shown in fig. 1-4 includes a proximal staple leg 110, a distal staple leg 120, and a staple base portion 130. The nail 100 also includes vertical transitions or bends 118,128 and lateral transitions or bends 116, 126. Vertical transition portions 118,128 bend or extend legs 110,120 vertically or upwardly from a staple base portion 130. The lateral transition portions 116,126 extend the legs 110,120 laterally outward, or at least substantially perpendicular, relative to the base portion 130. The staple legs 110,120 define a first plane and the staple base portion 130 defines a second plane. Together, vertical transition portions 118,128 and lateral transition portions 116,126 allow legs 110,120 to be laterally offset and parallel relative to base portion 130. In other words, the first plane is offset from and at least substantially parallel to the second plane. In fig. 1-4, the first plane is offset in the negative Y-direction. Other staples may be used in conjunction with the plurality of staples 100, wherein the other staples include a first plane that is offset in the positive Y-direction. The use of both types of staples allows for the nesting or interleaving of staple rows wherein the staple legs of adjacent rows may be at least substantially aligned and/or share a common longitudinal axis. In various circumstances, rows of staples can be nested to provide a denser row of staples.

Proximal staple leg 110 and distal staple leg 120 include staple tips 112,122 and corners 114,124, respectively. The tips 112,122 are configured to penetrate tissue and contact a forming pocket of an anvil of a surgical stapling instrument. The tips 112,122 contact the anvil when the staples 100 receive a driving force to eject the staples 100 from the corresponding staple cavities in the staple cartridge. The tips 112,122 and/or legs 110,120 of the staples 100 will then initially be formed from the unfired configuration to the fired configuration. Proximal staple leg 120 also includes a leading engagement foot 117 having a chamfered surface or edge 119. As the sled contacts the staples 100 as the sled translates distally, features of the sled can engage the leading engagement feet 117 to help prevent, for example, longitudinal staple rotation or rotation. The engagement foot 117 may include a push point configured to be pushed to load the staples 100 into the staple cartridge.

Because the staple 100 is a flat formed staple, the legs 110,120, the tips 112,122, and/or other portions of the staple 100 may be further fabricated or machined after stamping from a flat or at least substantially flat stock. Further fabrication of the nail 100 may provide for forming and/or altering specific characteristics such as preferential bending planes, flexibility, and/or elasticity. Conventional wire-formed staples have desirable characteristics that facilitate surgical fastening and can be implemented with the staple 100. The method for constructing the corners 114,124 and/or the tips 112,122 may include, for example, any suitable process including, for example, cold working. Specific processes may include coining by: the corners 114,124 are machined to have, for example, a rounded, angled, sloped, and/or parabolic profile. Staple tips 112,122 can also be processed using similar methods to provide a suitable tip configured to pierce tissue and be formed against a corresponding forming pocket of the anvil.

The staple base portion 130 includes an angled drive surface 132, a final drive surface 131, and a distal wall 133. In various embodiments, the staples 100 are supported in the staple cartridge by a tray, wherein the final drive surface 131 is configured to rest on the tray. In various other embodiments of staple cartridges without a tray, the final drive surface does not rest on the tray, rather, the final drive surface has an initial position above the bottom surface of the discless staple cartridge. This will allow the bottom surface of the sled and the bottom surface of the diskless staple cartridge to be at least substantially flush as the sled translates through the cartridge. The drive surface 132 of each staple base portion 130 is configured to receive a drive force F from a sled of a surgical stapling instrument_s. As the sled translates distally through the staple cartridge, the sled contacts the drive surface 132 to lift the staples 100 out of the cartridge and additionally contacts the final drive surface 131 to shape the staples 100 into their fired configuration.

Distal wall 133 serves as the distal-most wall of staple-based portion 130 and is positioned proximal to distal staple legs 120, thereby lacking any portion of staple-based portion 130 underlying distal staple legs 120. Having a greater amount of mass in the base portion 130 of the staple 100 enhances the resistance of the staple 100 to the moment M applied by the sled_SThe ability to induce rotational motion. Increasing the moment of inertia of the staple base portion 130 enhances the ability to resist rotational movement. Therefore, a greater torque will be requiredOr a greater torque, can cause the longitudinal pin to rotate.

The staple base portion 130 further includes a top or compression surface 136 that includes a proximal surface 139, an intermediate surface 138, and a distal surface 137. Proximal surface 139 is angled or sloped upward toward proximal leg 110. Distal surface 137 angles or slopes upward toward distal leg 120. The intermediate surface 138 is at least substantially parallel to the final drive surface 131. The valley-like configuration limits stress concentrations in tissue captured adjacent to transition portions 118,128,116,126 where legs 110,120 extend from staple base portion 130. In various embodiments, these surfaces 137,138,139 can be curved to form concave surfaces. In conventional staples, the junction where the leg meets the staple base creates a location that causes high local tissue stress when formed. This is particularly true in the case where such conventional staples are twisted, or crushed, or flattened rather than formed into the true "B" configuration.

In various embodiments, the dynamics of the staples 100 are predictable when ejected from the staple cartridge. The driving force F from the sled when the staples 100 are ejected from their corresponding staple cavities_SGenerating a moment M_s. One precautionary measure for preventing staple rotation includes increasing the moment of inertia of the staple 100 discussed above, which is configured to prevent (as shown in FIG. 2) longitudinal rotation or rotation of the staple. If the staple 100 is rotated longitudinally in a distal direction, or in other words, in a counterclockwise direction about the Y-axis, the outer longitudinal staple leg surfaces 115,125 of the staple 100 will contact the guide surfaces or sidewalls of the staple cartridge. The contact generates a corresponding reaction force F_C1And F_C2. More specifically, as the staple 100 is driven out of the staple cavity and rotated about the Y-axis, the wall 115 of the proximal staple leg 110 contacts the proximal sidewall of the staple cartridge, thereby creating a reaction force F acting on the staple leg 110 below the center of mass_C2. The wall 125 of the distal staple leg 120 contacts the distal sidewall of the staple cartridge, thereby creating a reaction force F acting on the staple leg 120 above the center of mass_C1. These two reaction forces F_C1And F_C2Will cause a reaction moment M_RCTo counteract or balance the applied torque M acting on the nail 100_S. The reactive forces discussed herein may be a distributed load acting on the surface area of each of the staple legs 110, 120.

The moment of inertia of the nail 100 is also configured to prevent (as shown in fig. 4) lateral rotation or rotation of the nail 100. The staple base portion 130 includes a notch 134 defined in a top surface 136 on a side of the staple base portion 130 nearest the legs 110, 120. The notches 134 facilitate predictability of the dynamics of the staple 100 before forming and after forming when ejected from the staple cartridge. For example, referring primarily to FIG. 4, the notches 134 are configured to cause rotation of the staple 100 toward a particular cavity sidewall. If the nail 100 is turned laterally, or in other words, at the applied moment M_SWill contact the leading surface or side wall of the staple cartridge, the outer lateral staple leg walls 111,121 of the staple 100 will generate a corresponding reaction force F_C1And F_C2. For example, as the staple 100 is driven out of the staple cavity and under an applied torque M_SIn a direction of the staple cartridge, the walls 111,121 of the staple legs 110,120 contact corresponding side walls of the staple cartridge, thereby creating a reaction force F acting on the staple legs 110,120 above the center of mass_C1. The outer lateral wall 135 of the staple base portion 130 contacts the other corresponding sidewall of the staple cartridge, thereby creating a reaction force F acting on the staple base portion 130 below the center of mass_C2. Reaction force F_C1And F_C2Producing a reaction moment M_RCTo counteract or balance the applied torque M acting on the nail 100 from the slider_S. The reactive forces discussed herein may be a distributed load acting on the surface area of each of the staple legs 110,120 and the staple base portion 130. In various embodiments, the nail 100 is caused to be under an applied moment M_SIn order to control which wall of the staple cavity is to be contacted for staple guidance when the staple 100 is ejected from the corresponding staple cavity of the staple 100.

Fig. 5 and 6 show a wire formed staple 200 including legs 210 and a staple base portion 230. The staple legs 210 are offset and bent from the staple base portion 230 at an angle of substantially ninety degrees. The staple legs 210 lie in a first plane that is at least substantially perpendicular to a second plane defined by the staple base portion 230 and the curved portions 220 of the staple legs 210.

Fig. 7-10 illustrate a staple 300 that includes a proximal staple leg 310, a distal staple leg 320, and a staple base portion or crown 330 having a driving surface 332. The legs 310,320 extend from the staple base portion 330, and each leg 310,320 includes a laterally outward curved portion and an upward curved portion. The laterally outwardly bent portions of the legs laterally outwardly bend the legs relative to the base portion of the staple. The upwardly bent portions of the staple legs vertically bend the staple legs relative to the staple base portion. The staple 300 includes a first zone 331 having a first durometer, a second zone 311,321 having a second durometer, and a third zone 312,322 having a third durometer. Embodiments are contemplated in which the nail 300 includes more or fewer zones than shown. Varying certain characteristics of different portions of the staple 300, such as stiffness, may provide greater control and predictability in forming the staple against a corresponding forming pocket, such as the forming pocket 341 of the anvil 340, for example. The first stiffness of the first region 331 may be greater than the second stiffness of the second regions 311, 321. In many instances, it is desirable to have malleable legs 310,320 that can permanently change shape without breaking, or in other words, to have legs 310,320 that have, for example, high plasticity, while having a staple base portion 330 that supports the legs 310,320 and has a greater stiffness than the legs 310, 320. Greater stiffness will enhance the ability of the staple base portion 330 to resist deformation when external and/or internal forces are applied, such as from the staple legs when compressed against the anvil.

Metalworking the different portions of the staples disclosed herein may have several advantages. One of these advantages may include the ability to prevent the legs of the staple from being crushed or distorted during forming, but instead, to encourage the legs to deform in the desired configuration due to contact with the corresponding forming pockets.

The nail 300 may be formed in any desired configuration. In the unformed configuration, the legs 310,320 define a first plane P₁And the staple base portion 330 defines a second plane P₂. An example of the formation of a staple 300 is shown in fig. 9 and 10, wherein the legs 310,320 are directed towards a second plane P₂Shaped laterally. Variations in the hardness of certain regions and/or portions of the nail 300 may serve to provide directional support when contacting the forming pockets 341. It is contemplated that the legs 310,320 may be inLaterally away from the second plane P₂Is formed in the direction of (a).

Fig. 11-11C show a staple 400 formed from a flat sheet of material that includes staple legs 410 and staple base portions 430. The staple base portion 430 has a rectangular cross-sectional profile 431 and the staple legs have a circular cross-sectional profile 411. Having rounded legs 410 extending from a staple base portion 430 having a rectangular cross-sectional profile 431 can provide a staple base portion and legs that do not have a preferential bending plane. The staple 400 includes a curved portion 420 where the staple legs 410 extend from a staple base portion 430. The curved portion 420 has a substantially square cross-sectional profile 421. The square and rectangular profiles 421 and 431 of the curved and staple base portions 420 and 430, respectively, provide a rigid connection and backbone for the round staple leg 410. The rounded legs 410 eliminate the preferential plane of curvature that legs having a square, rectangular, or any other shape with vertices or non-uniform shapes in cross-section may have.

Fig. 12 illustrates a staple 500 according to at least one embodiment that includes a proximal staple leg 510, a distal staple leg 520, and a staple base portion 530 from which the staple legs 510,520 extend. The proximal staple leg 510 is bent laterally outward from the staple base portion 530 in a first direction. The distal staple legs 520 curve laterally outward from the staple base portion in a second direction. The first direction is opposite to the second direction. The staple base portion 530 defines a first plane and the staple legs 510,520 define a second plane that intersects the first plane. One advantage of bending the legs 510,520 in opposite directions can counteract the slider moment applied on each side of the staple base portion 530, thereby helping to prevent lateral rotation. This results in an S-shaped configuration and requires complementary shaped dimples.

In fig. 13, a staple 600 is shown that includes a proximal leg 610, a distal leg 620, and a staple base portion 630 having a drive surface 632. The distal leg 620 is longer than the proximal leg 610, thereby causing the tips 611,621 of the staple legs 610,620 to deflect in contact time against the forming pockets of the anvil. In various embodiments, the distal leg can include a tip having an initial pre-bent configuration to facilitate the forming process upon initial contact with the anvil. This pre-formed tip 621 will require less compressive force than the staple tip 611 to begin deforming against the anvil. Having the longer leg (in this case distal leg 620) contact the anvil before the shorter or proximal leg 610 may require that the staple tip 621 of the longer leg 620 have a pre-formed tip to some extent before the tip 611 deforms.

Fig. 14 shows an arrangement 700 of forming pegs 711, 721. The staples 711 are arranged in a first row 710 and the staples 721 are arranged in a second row 720 adjacent to the first row 710. The staples 711,712 may be similar to the staple 600 shown in FIG. 13, discussed above. The staple 711 includes laterally opposite leg portions 713,715. The staple 721 includes laterally opposite legs 723,725. The laterally opposed legs 713,715 each include a tip configured to contact the anvil forming pocket at contact points 713c,715c, respectively. The laterally opposite legs 723,725 also each include a tip configured to contact the anvil forming pockets at contact points 723c,725c, respectively. Laterally opposed legs 713,715 are each formed inwardly toward the base portion of the staple from which they extend. Laterally opposed legs 723,725 are also each formed inwardly toward the base portion of the staple from which they extend.

The rows 710,720 of staples are interleaved such that the contact points 723c,713c are substantially aligned. This arrangement allows for a more densely arranged row configuration of staples in the staple cartridge and/or a more densely arranged forming pocket configuration on the anvil. In addition, the intersecting force expansion planes may provide higher quality force expansion and greater area of tissue force expansion coverage. The intersecting force planes ensure that anything trapped between the rows of staples and the forming pockets must be adequately secured. This may be helpful when suturing smaller and/or less visible blood vessels, whereas in conventional staple arrangements the staple row spacing may be manipulated, resulting in less than adequate fastening.

Fig. 15-17 illustrate a staple 800 including staple legs 810,820 and a staple base portion 830 having a drive surface 832. The staple legs 810,820 include tips 842 configured to contact a forming pocket of an anvil, such as forming pocket 861 of anvil 860. Staple tip 842 includes a piercing tip or portion 842T, a curled surface 842S, and a concave cut-out portion 842C. Piercing tip 842T is configured to pierce tissue T upon ejection from the staple cartridge and be deformed within forming pockets 861 of anvil 860 upon contact therewith. The staple tips 842 are urged to deform into a particular configuration by utilizing the predictable deformability of the concave cutout portions 842C. The crimping surface 842S of the staple tip 842 is configured to be crimped or deformed from the piercing location 812A, to the intermediate forming location 812B, and to the non-piercing location 812C. Once the staple tips 842 have been fully deformed, the piercing tips 842T are spaced or isolated from the tissue T by the crimping surfaces 842S. This prevents further penetration of tissue T after tip 842 penetrates tissue while firing. This arrangement also prevents further injury and/or harmful irritation that may be caused by an exposed piercing tip after an initial piercing. Preventing further penetration of the tissue after the legs are formed also reduces the chance that staple 800 will be pulled through tissue T. The curled surface 842S acts as a barrier configured to space the puncture tip 842T from the tissue T.

Fig. 18 illustrates a number of examples of different types of staple tips 871, 872, 873, 874, and 875 that may be used with any suitable surgical staple, such as the staples disclosed herein. The staple tips 871 have a triangular shape with at least substantially flat faces. The staple points 872 include faces having varying profiles. The staple tips 873 have a rocket-like shape. The spike tip 874 has a bump-like profile. The bump-like profile may, for example, be substantially blunt. The nail tip 875 has a pencil-sharpened profile.

In various embodiments, the staple tips disclosed herein can comprise a material different from the staple to which the staple tip is attached so as to be more easily deformed in a desired manner, but the staple tip material can still be strong enough to prevent the staple tips from spreading out after the tissue is fastened.

The surgical staples can be urged into a desired configuration by altering the shape, size, configuration, and/or other aspects of the forming pockets configured to form the staples. FIG. 19 illustrates forming pockets 911,921 configured to enable forming of a staple 900. Staple 900 includes staple legs 901,902, staple tips 910,920, and staple base 930, wherein staple legs 901,902 extend from staple base 930. The staples 900 are configured to contact and be formed against corresponding forming pockets 911, 921. The forming pocket 911 includes a forming channel surface 917 configured to receive a corresponding tip 910 and cause the tip 910 to form in direction P1. As shown in fig. 20, the shaped pockets 911 include lateral valley surfaces 915 and longitudinal valley surfaces 913 that are configured to funnel or capture the tips 910 of the staples with slight misalignment upon contact. Upon ejection from the cartridge, staple 900, staple leg 901 and/or staple tip 910 can be driven off-target relative to forming channel surface 917. The valley surfaces allow longitudinal and lateral rotation of the nail. Although shown as a concave surface, the valley surface may be convex or flat, for example.

The forming pocket 921 includes a forming channel surface 927 configured to receive a corresponding pointed end 920 of the staple 900 and to cause the pointed end 920 to form in the direction D1. Direction D1 is opposite direction P1 and, as shown in fig. 19, illustrates the staple legs being formed toward one another and at least substantially parallel to staple base 930. Other embodiments are contemplated in which the directions D1, P1 direct the corresponding staple legs in opposite directions but outwardly with respect to each other. The forming pocket 921 also includes lateral and longitudinal valley surfaces 925, 923 that are configured to funnel or capture the tip 920 of the nail 900 with slight misalignment upon contact. Upon ejection from the cartridge, the staple 900, staple legs 902, and/or staple tips 920 can be driven off-target relative to the forming channel surface 927.

In various embodiments, the longitudinal valley surface may comprise two separate valley surfaces. The two separate valley surfaces may include an initial valley surface closest to the intended point of contact of the corresponding spike tip. The initial valley surface may have a greater misalignment protection than another of the individual valley surfaces. The initial valley surface may have, for example, a greater width and/or height than another of the individual valley surfaces.

FIG. 21 shows another arrangement of staple pockets 911,921 as discussed above. However, the staple pockets 911,921 in the illustrated arrangement are configured to direct the staple tips inwardly toward the staple base 130. Leg 901 and tip 910 are configured to be shaped in direction P2. The leg 902 and tip 920 are configured to be shaped in a direction D2. The directions P2, D2 are transverse. Other embodiments are contemplated in which the directions P2, D2 direct the corresponding legs and tips away from the staple base or outwardly.

FIG. 22 shows yet another arrangement of the staple pockets 911,921 discussed above. The staple pockets 911,921 in the illustrated arrangement are configured to enable the corresponding staple legs 901,902 and pointed ends 910,920 to be formed in opposite directions, with one of the staple legs 902 directed toward the staple base 930 and one of the staple legs 901 directed away from the staple base 930. Leg 901 and tip 910 are configured to be shaped in direction P3. The leg 902 and tip 920 are configured to be shaped in a direction D3. The directions P3, D3 are at least substantially parallel. Other embodiments are envisaged in which the directions P3, D3 are not parallel.

Fig. 23 and 24 illustrate another embodiment of forming pockets including forming pocket 1011,1021 configured to deform a staple 900. The shaped pockets 1011,1021 have an ear shape that provides nesting pockets. This type of arrangement can save space on the staple forming surface of the anvil, allowing for more staple pockets and, therefore, more staples in the staple cartridge in a smaller amount of space. The forming pocket 1011 includes a forming channel surface 1017 configured to receive a corresponding tip 910 and cause the tip 910 to form in the bending direction P4. As shown in fig. 24, shaped dimple 1011 includes a first valley, curved surface 1015A and a second valley, curved surface 1015B that are configured to funnel or capture spike tip 910 with slight misalignment during contact. Upon ejection from its staple cavity, staple 900, staple leg 901, and/or staple tip 910 can be driven off-target relative to forming channel surface 917. The valley surfaces allow some longitudinal and lateral rotation of the nail. Although shown as a concave surface, the valley surface may be convex or flat, for example.

The forming pocket 1021 includes a forming channel surface 1027 configured to receive a corresponding tip 920 of the staple 900 and to cause the tip 920 to form in direction D4. FIG. 23 illustrates the formation of staple legs 901,902 toward one another, wherein one leg 901 is formed away from staple base 930 and the other leg 902 is formed toward staple base 930. Other embodiments are contemplated in which directions P4, D4 direct corresponding legs 901,902 in opposite directions but outwardly with respect to each other. The forming pocket 1021 includes a first valley, curved surface 1025A and a second valley, curved surface 1025B that are configured to funnel or capture the tip 920 of the staple 900 with slight misalignment before and/or during contact.

FIG. 25 illustrates yet another embodiment of forming pockets comprising anvil forming pockets 1111,1121 configured to deform corresponding staple legs 901,902 and tips 910,920 toward staple base 930. The forming pockets 1111,1121 are trapezoidal in shape and can nest with other similar forming pockets, thereby using less space on the forming surface of the anvil. Forming pockets 1111,1121 are configured to form legs 901,902 and tines 910,920 in directions P5, D5, respectively.

Fig. 26 illustrates yet another embodiment of forming pockets comprising anvil forming pockets 1211,1221 configured to deform corresponding staple legs 901,902 and tips 910,920 in directions P6, D6, respectively. The forming pockets 1111,1121 are triangular in shape and can nest with one another, thereby providing an even more compact arrangement of forming pockets on the anvil of the surgical stapling instrument.

Referring now to fig. 27-27B, staple leg 1300 is shown. Leg 1300 includes a substantially circular spike tip and has a substantially square leg and a leg body portion 1301. The legs 1300 include hardened corners formed using a coining process, for example, in which the corners 1303A, 1303B, 1303C, and 1303D are rounded to form preferential bending planes. In other words, the staple legs 1300 have a cross-sectional profile configured to promote bending of the staple legs 1300 in a particular direction due to corner hardening upon contact with the anvil. The hardness of the corners 1303A, 1303B, 1303C, and 1303D can vary from one corner to the next, or they can include two corners having a first hardness and two other corners having a second hardness. Corners 1303A, 1303B, 1303C, and 1303D can be coined to provide different radial profiles on the same staple leg. For example, corner 1303A includes a radial profile having a radius R_ARadially outward of the corner 1303B shown in FIG. 27BRadius R of the shape_B。

Any suitable device may be used to harden portions of the staples disclosed herein at various times in the manufacturing process. For example, the hardening process may include, for example, gold stamping, chemical vapor deposition, physical vapor deposition, laser surface treatment, thermal oxidation, ion nitriding, and/or solid state diffusion. The other parts of the nail are prevented from hardening by these processes. Other portions of the nail may be locally annealed, such as the nail tip. Increasing the stiffness of certain regions may increase the force required to deform the staples after they have assumed the fired configuration.

FIGS. 28-28C illustrate a staple 1400 and a sled 1460 according to at least one embodiment. Staple 1400 includes legs 1410,1420, a staple base portion 1430 from which legs 1410,1420 extend, a drive surface 1432, and a bottom surface 1431. The staple legs 1410,1420 extend from the staple base portion 1430 in a plane that is parallel and offset relative to a plane defined by the staple base portion 1430. Staples 1400 are stamped from progressive die using base strip 1450 and connector portions 1451. Although only a single staple 1400 is shown, multiple staples 1400 are attached to base strip 1450. Connector portion 1451 connects staples 1400 (specifically, staple base portions 1430) to base strip 1450. Connector portion 1451 includes a break or notch 1453 configured to allow separation of staple 1400 from strip 1450. In at least one instance, the slide 1460 includes a release or strike portion 1461. Release portion 1461 of sled 1460 is configured to engage break-up portion 1453 or connector portion 1451 to separate, break and/or shear staples 1400 from base strip 1450 and allow the staples to be ejected from their staple cavities by sled 1460.

Embodiments are contemplated in which base strip 1450 includes alignment features (such as holes), for example, that engage corresponding alignment features on the staple cartridge. Such alignment features may include, for example, protrusions that align with alignment features of base strip 1450. In various instances, a person loading staples into the cartridge can align the staples with the staple cavities and/or align these alignment features prior to pushing the staples into the staple cavities. Certain embodiments are contemplated in which the staple cartridge includes engagement features configured to engage the break 1453 when the strip assembly is loaded into the staple cartridge. These engagement features allow staples 1400 to be separated from strip 1450 when staples 1400 are loaded into the staple cartridge, rather than when staples 1400 are fired. The use of progressive die stamping to manufacture staples can allow for staples having different crown sizes, shapes, and/or configurations and leg sizes, shapes, and/or configurations. Another advantage of using progressive die stamping techniques may include the ability to vary the pitch of the rows of staples upon which the staples are arranged.

Fig. 29 and 30 show another embodiment of a strip 1500 of staples 1501 stamped using progressive dies. The strip 1500 of staples 1501 includes a base strip 1550, a connector portion 1551, and staples 1501. Each staple 1501 includes, first, a staple base portion 1530 having a bottom surface 1531, and, second, staple legs 1510 extending from the staple base portion 1530. The connector portion 1551 attaches the bottom surface 1531 of the staple base portion 1530 to the base strip 1550. The staple legs are bent upward from the staple base portion 1530 such that the legs 1510 lie in a plane that is offset from and at least substantially parallel to the plane defined by the staple base portion 1530. In the illustrated embodiment, the staple legs 1510 are bent in a direction opposite to the connector portion 1551. Bending the legs 1510 and connector portions 1551 in this manner may allow for a more dense staple line arrangement. The connector portion 1551 may include an interruption portion configured to release the staples 1501 from the base strip 1550 when the staples 1501 are loaded into the staple cartridge and/or the staples 1501 are fired from the staple cartridge, as discussed in previous embodiments.

Fig. 31 illustrates a cross-sectional view of a portion of a plurality of staples 1601 and a staple cartridge 1650 in accordance with at least one embodiment. Staples 1601 are removably stored within corresponding staple cavities 1651 of the staple cartridge 1650. Staple cartridge 1650 includes a deck surface 1653 and staple leg supports 1655. The staple 1601 includes first staple legs 1610 each having a staple tip 1611 and second staple base portions 1630 from which the staple legs 1610 extend. Each staple 1601 has a preloaded configuration, a loaded configuration, and a fired configuration in which the staple 1601 is ejected from the staple cartridge 1650 and formed against a corresponding forming pocket of the anvil. The staple legs 1610 flex outwardly relative to the staple base portion 1630 in the preloaded configuration. The staple legs 1610 are biased against the side walls of the corresponding staple cavities 1651 in the loaded configuration and define a first distance X between the pointed ends 1611 of the staple legs 1610. In the pre-loaded configuration, the distance between the staple tips 1611 of the staple legs 1610 is greater than X. This biasing force helps to support the staples 1601 in the staple cartridge 1650.

The staple cartridge 2000 is shown in FIGS. 32-34. The staple cartridge assembly 2000 comprises a cartridge body 2010. The cartridge body 2010 can be positioned in and removed from the jaws of a surgical stapling instrument. Thus, the staple cartridge 2000 is replaceable; however, other embodiments are contemplated in which the staple cartridge 2000 is not replaceable. The cartridge body 2010 includes a proximal end 2011, a distal end 2012, and a deck 2014 extending between the proximal end 2011 and the distal end 2012. Deck 2014 is configured to support patient tissue as it is pressed against deck 2014.

The cartridge body 2010 also includes a plurality of staple cavities 2020 defined therein. The staple cavities 2020 are arranged in six longitudinal rows extending between the proximal end 2011 and the distal end 2012; however, any suitable arrangement of staple cavities 2020 can be utilized. Staples, such as the staple 2130 (fig. 40), for example, are removably stored in each staple cavity 2020. As discussed in more detail below, the firing member ejects staples from the staple cavities 2020 as the firing member moves from the proximal end 2011 toward the distal end 2012 of the cartridge body 2010.

In addition to the above, a firing member moves staples from an unfired position to a fired position. The firing member lifts the staples toward an anvil, such as anvil 2190 (fig. 37), for example, to deform the staples between an unfired, undeformed configuration and a fired, deformed configuration. The cartridge body 2010 also includes a longitudinal slot 2013 defined therein. The slots 2013 are configured to receive staple firing members and/or tissue cutting members therein as the staples are ejected from the staple cavities 2020.

In various embodiments, in addition to the above, the staples do not protrude above the deck 2014 until the firing member moves the staples toward the anvil. Such embodiments may often utilize smaller staples. In other embodiments, the legs of the staples protrude above the deck 2014 when the staples are in their unfired positions. In at least one such embodiment, the cartridge body 2010 also includes a projection 2050 that extends from the deck 2014. The projections 2050 extend the staple cavities 2020 above the deck 2014 and guide the staples toward the anvil as they are ejected from the staple cartridge 2000. In such embodiments, the staples may not extend over the projections 2050 until the firing member moves the staples toward the anvil.

Referring primarily to fig. 34, the projections 2050 do not extend around the complete staple cavity 2020. A first tab 2050 is positioned adjacent a first end of each cavity 2020, and a second tab 2050 is positioned adjacent a second end of each cavity 2020. Each first protrusion 2050 extends around a first leg guide 2022 of the staple cavity 2020, and each second protrusion 2050 extends around a second leg guide 2023 of the staple cavity 2020. Each first protrusion 2050 provides a proximal cradle that can control and guide the proximal leg of the staple, and each second protrusion 2050 provides a distal cradle that can control and guide the distal leg of the staple. The first tab 2050 of each staple cavity 2020 is not symmetrical with respect to the first end of the staple cavity 2020 and does not extend around the entire first end of the cavity 2020. Similarly, the second projections 2050 of each staple cavity 2020 are not symmetrical with respect to the second end of the staple cavity 2020 and do not extend around the entire second end of the cavity 2020. The first and second projections 2050, 2050 constitute mirror images of each other and are arranged symmetrically with respect to the center of each staple cavity 2020; however, any suitable arrangement of projections may be utilized.

As shown in fig. 32-34, the cartridge body 2010 includes a step 2014' and a step 2014 "extending upwardly from the deck 2014. More specifically, step 2014 'extends upwardly from deck 2014, and step 2014 "extends upwardly from step 2014'. Thus, step 2014 "may apply a greater compressive pressure to tissue than step 2014 ', and similarly, step 2014' may apply a greater compressive pressure to tissue than deck 2014. Steps 2014' and 2014 "comprise staggered longitudinal terraces; however, steps 2014' and 2014 "may have any suitable configuration. Further, in addition to the above, projections 2050 extending from step 2014 "extend above projections 2050 extending from step 2014 ', and similarly, projections 2050 extending from step 2014' extend above projections 2050 extending from deck 2014. In other words, projections 2050 extending from deck 2014, step 2014', and step 2014 "are staggered.

A staple cartridge 2100 is shown in FIGS. 35-38. The staple cartridge assembly 2100 includes a cartridge body 2110 and is similar in many respects to the staple cartridge assembly 2000 and/or other staple cartridges disclosed herein. The cartridge body 2110 includes a deck 2114, a plurality of staple cavities 2120a and a plurality of staple cavities 2120 b. Staple cavity 2120a is similar in many respects to staple cavity 2120 b. For example, staple cavities 2120a and 2120b each include a central slot 2121 having a proximal end and a distal end, a proximal staple leg guide 2122 extending laterally from the proximal end of central slot 2121, and a distal staple leg guide 2123 extending laterally from the distal end of central slot 2121. That is, staple cavities 2120a and staple cavities 2120b are oriented in different directions. More specifically, leg guides 2122,2123 of staple cavity 2120a extend toward staple cavity 2120b, and similarly leg guides 2122,2123 of staple cavity 2120b extend toward staple cavity 2120 a; however, any suitable arrangement may be utilized.

A staple 2130a is positioned in each staple cavity 2120a and a staple 2130b is positioned in each staple cavity 2120 b. The pegs 2130a and 2130b are similar in many respects. For example, each staple 2130a includes a base or crown 2131, a proximal leg 2132 extending from a proximal end of the base 2131, and a distal leg 2133 extending from a distal end of the base 2131. That is, the staples 2130a,2130b can fit within the staple cavities 2120a,2120b, respectively, in a manner. For example, when staple 2130a is positioned in staple cavity 2120a and staple 2130b is positioned in staple cavity 2120b, legs 2132,2133 of staple 2130a extend toward staple 2130b and legs 2132,2133 of staple 2130b extend toward staple 2130 a; however, other arrangements are possible.

In addition to the above, when staples 2130a,2130b are stored in staple cavities 2120a,2120b, respectively, proximal leg portions 2132 of staples 2130a,2130b are positioned within staple leg guides 2122. Similarly, when staples 2130a,2130b are stored in staple cavities 2120a,2120b, respectively, distal legs 2133 of staples 2130a,2130b are positioned within staple leg guides 2123. Further, when staples 2130a,2130b are stored in staple cavities 2120a,2120b, respectively, bases 2131 of staples 2130a,2130b are positioned in central slot 2121 of staple cavity 2120. Referring primarily to fig. 35, when the staples 2130a,2130b are in their unfired positions, the tips of the staple legs 2132,2133 extend above the deck 2114 of the cartridge body 2110. That is, the tips of the staple legs 2132 are at least partially surrounded by a proximal protrusion 2152 extending from the deck 2114, and the tips of the staple legs 2133 are at least partially surrounded by a distal protrusion 2153 extending from the deck 2114. The proximal tabs 2152 extend around the proximal leg guide 2122, but they do not extend around the proximal end of the central slot 2121. Similarly, the distal tabs 2153 extend around the distal leg guide 2123, but they do not extend around the distal end of the central slot 2121.

Turning now to fig. 38, each proximal tab 2152 includes a first portion 2154 that extends around the proximal side of the proximal guide slot 2122 and a second portion 2155 that extends around the side of the proximal guide slot 2122. The proximal protrusion 2152 does not extend around the distal side of the proximal guide slot 2122; however, it is contemplated that in alternative embodiments, the proximal tab 2152 can extend around the distal side of the proximal guide slot. Similarly, each distal tab 2153 includes a first portion that extends around the distal side of the distal guide slot 2123 and a second portion that extends around the side of the distal guide slot 2123. The distal protrusion 2153 does not extend around the proximal side of the distal guide slot 2123; however, it is contemplated that in alternative embodiments, the distal tab 2153 can extend around the proximal side of the distal guide slot. In any event, the arrangement shown in fig. 38 protects the staple legs 2132,2133 when the staples 2130a,2130b are in their unfired positions, and additionally guides the staples 2130a,2130b as they are fired. This arrangement also suitably controls the flow of tissue relative to the deck 2114 of the cartridge body 2110.

Referring again to fig. 38, staple cavities 2120a and staples 2130a are sized and configured to provide clearance gaps between staples 2130a and staple cavities 2120 a. For example, there is a clearance gap 2156 between the proximal leg 2132 of the staple 2130b and the proximal side wall of the proximal guide slot 2122, and similarly, a clearance gap 2158 between the proximal leg 2132 of the staple 2130b and the distal side wall of the proximal guide slot 2122. In addition, a clearance gap 2157 exists between the sides of the proximal leg 2132 and the lateral side walls of the proximal guide slot 2122. A similar gap can be found between the distal leg 2133 and the distal guide slot 2123. A lateral clearance gap 2126,2127 may also be provided between the base 2131 of the peg 2130b and the side of the central slot 2121. Nonetheless, such clearance gaps may be short and staples may contact one or more of the sidewalls.

A staple cartridge 2200 is shown in fig. 43. Staple cartridge 2200 is similar in many respects to staple cartridge 2000,2100 and other staple cartridges disclosed herein. The staple cartridge 2200 includes a cartridge body 2210 that includes staple cavities 2220 defined therein. Each staple cavity 2220 has, for example, staples, such as staples 2130, removably stored therein. Each staple cavity 2220 includes a first guide slot 2222 configured to guide the legs 2132 of a staple 2130, a second guide slot 2223 configured to guide the legs 2133 of a staple 2130, and a central slot 2221. The guide slots 2222 and 2223 extend laterally from the central slot 2221, and the central slot 2221 includes a medial guide 2225 configured to guide the base 2131 of the staple 2130. The first guide slot 2222 is sized and configured such that the staple leg 2132 is closely received in a corner of the first guide slot 2222. Similarly, the second guide slots 2223 are sized and configured such that the staple legs 2133 are closely received in the corners of the second guide slots 2223. The mid-guide 2225 is sized and configured to limit lateral movement of the staples 2130 within the staple cavities 2220. In addition, the mid guide 2225 is sized and configured to retain the staple legs 2132 and 2133 in the leg guide slots 2222 and 2223, respectively.

As discussed above, the mid guide 2225 is sized and configured to seat the staple legs 2132 and 2133 against the side walls of the guide slots 2222 and 2223, respectively. This arrangement creates a lateral reaction force (indicated in fig. 43 as force vector LT) between the lateral sidewalls of the cavity 2220 and the staple 2130. Such lateral reaction forces create friction between the sidewalls of the cavity 2220 and the staples 2130 when the staples 2130 are ejected from the cavity 2220. It should be appreciated that the frictional force varies with the surface area over which the frictional force is applied, and therefore, the intermediate guide 2225 does not extend along the entire length of the central slot 2221. That is, the mid guide 2225 has a longitudinal length that is sufficient to control the orientation of the staples 2130 within the cavities 2220. In addition, the mid guide 2225 has a vertical length sufficient to control the orientation of the staples 2130 during the firing stroke of the staples 2130. In at least one instance, the guide 2225 extends along the entire vertical depth of the cavity 2220.

The mid guide 2225 is flat and is configured to interface with flat surfaces defined on the sides of the base 2131 of the staples 2130; however, any suitable arrangement may be utilized. In certain alternative embodiments, the middle guide 2225 includes a resilient biasing member configured to apply a lateral biasing force, for example, to the base 2131 of the staples 2130. In at least one instance, the resilient biasing member can comprise, for example, a cantilever spring.

The staple cavities 2220 do not include lateral guides positioned opposite the lateral medial guides 2225. In fact, there is a clearance gap 2229 between the lateral side walls 2228 and the staples 2130.

In addition to the above, referring again to fig. 43, the staples 2130 are not positioned in the ends of the central slot 2221. More specifically, the central slot 2221 of the cavity 2220 includes a proximal end 2226 and a distal end 2227, and the staples 2130 do not extend into the proximal end 2226 or the distal end 2227. Instead, there is a clearance gap between the end 2226,2227 and the peg 2130. Such clearance gap extends between end 2226,2227 and intermediate guide 2225. Thus, the ends 2226,2227 of the staple cavities 2220 do not control the longitudinal position of the staples 2130. Instead, the leg guides 2222,2223 control the longitudinal position of the staples 2130. In fact, the leg portions 2132 and 2133 of the staple 2130 can be biased inwardly by the leg guides 2222 and 2223, respectively. This arrangement generates a longitudinal reaction force (indicated as force vector LG in fig. 43).

As a result of the above, the staple cavities 2220 include three control points or positions in which the staple cavities 2220 control the orientation of the staples 2130. The control points include discrete control positions defining a clearance gap therebetween. In other words, the guides 2222,2223, and 2225 triangulate the control of the staples 2130. Alternative embodiments including more than three control points are contemplated. In any event, the control points provided by the leg guides 2222 and 2223 are defined in a first control plane. The intermediate control points provided by the intermediate guide 2225 are defined in a second control plane. The first control plane is parallel to the second control plane; however, alternative embodiments are envisaged in which the first control plane is not parallel to the second control plane. Further, the first control plane is aligned with or adjacent to the staple legs 2132 and 2133 of the staple 2130 and the second control plane is aligned with or adjacent to the base 2131 of the staple 2130.

A staple cartridge 2700 is shown in fig. 65. The staple cartridge 2700 includes a cartridge body 2710 that includes a deck 2714 and a plurality of staple cavities 2220 defined in the deck 2714. Similar to the cartridge body 2110, the cartridge body 2710 includes tabs 2752 and 2753 which extend above the deck 2714. The projections 2752 at least partially surround the leg guide 2222 of the staple cavity 2220, and the projections 2753 at least partially surround the leg guide 2223 of the staple cavity 2220. Similar to tabs 2152,2153, tabs 2752,2753 each include an outer portion 2754 and a lateral portion 2755. The outer portion 2754 is longitudinally positioned relative to the leg guides 2222 and 2223, while the lateral portion 2755 is laterally positioned relative to the leg guides 2222 and 2223. Unlike the tabs 2152,2153, the tabs 2752,2753 each include an inner portion 2756 that is longitudinally positioned relative to the leg guides 2222 and 2223. The inner portion 2756 is connected to the lateral portion 2755, and the lateral portion 2755 is connected to the outer portion 2754. Similar to the above, the tabs 2752,2753 extend the staple cavities 2220 above the deck 2714.

A staple cartridge 2800 is shown in FIG. 66. The staple cartridge 2800 includes a cartridge body 2810 that includes a deck 2814 and a plurality of staple cavities 2220 defined in the deck 2814. Similar to the cartridge body 2110, the cartridge body 2810 includes a tab 2152,2153 extending above the deck 2114. As outlined above, the projections 2152 at least partially surround the leg guide 2222 of the staple cavity 2220, and the projections 2753 at least partially surround the leg guide 2223 of the staple cavity 2220. In addition, the cartridge body 2810 includes internal projections 2856 that are positioned longitudinally relative to the leg guides 2222 and 2223. The inner protrusion 2856 is not connected to the protrusion 2152,2153.

Referring again to fig. 35, the staples 2130 are driven between an unfired position and a fired position by a firing member, such as sled 2140. The sled 2140 includes wedges 2145 configured to directly engage the staples 2130 and lift the staples 2130 toward an anvil, such as anvil 2190, as shown, for example, in fig. 37. The slide 2140 includes a wedge 2145 for each longitudinal row of staples 2130; however, the slide 2140 may have any suitable number of wedges 2145. Each wedge 2145 includes an angled drive surface 2141 that slides under the staples 2130 as the sled 2140 advances from the proximal end of the staple cartridge 2100 toward the distal end of the staple cartridge 2100. The base portion 2131 of each staple 2130 includes an angled drive surface 2135 that is in direct contact with the drive surface 2141. In other words, each staple 2130 includes its own integrally formed driver with a drive surface 2135. The nail 2130 is made of metal, and therefore the driver formed integrally is also made of metal. That is, the staples disclosed herein may be constructed of any suitable material.

In addition to the above, each drive surface 2141 includes an initial or distal portion 2142, a second or intermediate portion 2143, and a third or apex portion 2144. The initiation portion 2142 extends at a first angle and provides an initial contact point for the sled 2140 against the staple 2130 as the sled 2140 moves distally. As the initial portion 2142 slides under the staples 2130, the staples 2130 lift upward within the staple cavities 2120. As the sled 2140 continues to move distally, the middle portion 2143 comes into contact with the peg 2130. The middle portion 2143 extends at a second angle different from the first angle. The first angle may be steeper than the second angle when rapid initial upward displacement of the nail 2130 is desired, and the first angle may be shallower than the second angle when it is desired to provide gradual initial upward displacement of the nail 2130. In either case, as the staples 2130 are lifted upward by the middle portion 2143, the staples 2130 contact the anvil 2190, as shown in fig. 37; however, alternative embodiments are contemplated in which the staples 2130 contact the anvil 2190 as the staples 2130 are lifted upward by the initiator portions 2142. In either case, the proximal legs 2132 of the staples 2130 contact proximal forming pockets 2192 defined in the anvil 2190 and the distal legs 2133 contact distal forming pockets 2193 defined in the anvil 2190. The shaped pockets 2192 and 2193 are configured to bend the legs 2132 and 2133 inward, thereby deforming the staples 2130 and capturing the patient's tissue within the staples 2130. The apex 2144 of the drive surface 2141 slides under the staple 2130 to complete the forming process. The apex 2144 may include a highest point of the drive surface 2141, a flat surface, and/or a surface extending at a third angle different from the first angle and/or the second angle.

In various instances, each drive surface 2141 may include an apex 2144 trailing the drive surface 2141 or a portion positioned proximal to the apex. This trailing portion may be, for example, below vertex 2144. Further, this trailing portion can provide a gradual reduction in forming pressure in, for example, the nail 2130.

Turning now to fig. 39, the staple 2130 also includes a foot 2134 that extends downwardly from the proximal leg 2132. When the staple 2130 is in its proper orientation in its staple cavity 2120, as shown in fig. 41, the foot 2134 is not in contact with the slider 2140. In such cases, the alignment plateau 2146 of the slide 2140 passes under the foot 2134. When the staples 2130 are not in their proper orientation in their staple cavities 2120, as shown in fig. 42, the gliders 2140 may contact the staples 2130 and reorient the staples 2130. For purposes of comparison, an incorrectly oriented staple 2130 and a correctly oriented staple 2130' are shown in fig. 42. The slide 2140 includes an angled alignment slide 2148 configured to contact the foot 2134 and rotate the staple 2130 into a correct orientation. After the alignment runners 2148 have properly oriented the pins 2130, the alignment platform 2146 may be slid under the feet 2134. As can be appreciated from fig. 39, the alignment runners 2148, the alignment lands 2146, and the feet 2134 are arranged in an alignment plane that is aligned with the forming plane of the legs 2132 and 2133 of the staple 2130. The alignment plane is adjacent to the lifting plane, which includes the forming surface 2141 of the slide 2140 and the base 2131 of the nail 2130.

A staple cartridge assembly 2300 is illustrated in FIGS. 44-48. The staple cartridge assembly 2300 is similar in many respects to staple cartridge 2000,2100,2200 and other staple cartridges disclosed herein. The staple cartridge 2300 includes a cartridge body 2310 and a sled 2340 configured to eject the staples removably stored in the cartridge body 2310. Similar to slide 2140, slide 2340 includes a staple forming slide 2145. The runners 2145 are slidably positioned in longitudinal slots 2115 defined in the cartridge body 2110 that are aligned with the lift portions or planes of the staples. Notably, as discussed in greater detail below, the slots 2115 have open ends defined in the bottom 2316 of the cartridge body 2310.

In addition to the above, the staple cartridge assembly 2300 does not include a cover that extends around the bottom 2316 of the cartridge body 2310. Referring primarily to fig. 48, the cartridge body 2310 rests directly against the jaws 2180 of the stapling instrument. In embodiments where the staple cartridge is not easily removable from the jaws of the stapling instrument and not easily replaceable with another staple cartridge, the lack of bottom cover is not necessarily problematic because jaw 2180 can prevent staples from falling out of the bottom of staple cavities 2120 and/or can prevent sled 2340 from falling out of the bottom of longitudinal slot 2115. However, the staple cartridge assembly 2300 is replaceable, and even if it does not include a bottom cover, the staple cartridge assembly 2300 includes features that prevent the staples and sled 2340 from falling out of the bottom 2316 of the cartridge body 2310, as will be described in more detail further below. Such features may be suitable for any of the staple cartridges disclosed herein.

45-47, the cartridge body 2310 includes retention features configured to retain the slider 2340 therein. For example, the cartridge body 2310 includes proximal retention features 2317 that are configured to retain the sled 2340 in the longitudinal slot 2115 when the sled 2340 is in its proximal or unfired position. The sled 2340 is in its unfired position when the staple cartridge assembly 2300 is inserted or loaded into the jaws 2180, and thus the proximal retention feature 2317 retains the sled 2340 in the cartridge body 2310 when the clinician is operating the cartridge assembly 2300. Each retention feature 2317 includes an angled surface 2318 and a shoulder 2319. Each slider 2340 includes a corresponding recess 2348 configured to receive angled surface 2318, and additionally includes a corresponding shoulder 2349 that may align with and/or contact shoulder 2319 of retention feature 2317. When the slider 2340 is inserted into the slot 2115, see fig. 46, the runners 2145 and/or the side walls of the cartridge 2310 can flex to allow the slider 2340 to slide relative to the angled surfaces and then resiliently snap back to its original position, as shown in fig. 45, once the shoulders 2349 of the slider 2340 have become aligned with the shoulders 2319 of the cartridge body 2310. The retention feature 2317 is also configured to prevent the slider 2340 from sliding proximally out of the longitudinal slot 2115.

As a result of the above, the proximal retention feature 2317 prevents the sled 2340 from falling out of the cartridge body 2310 while the clinician is operating the staple cartridge assembly 2300. When the sled 2340 is advanced distally to fire the staples, the sled 2340 is no longer aligned with the proximal retention feature 2317. However, at this point, cartridge assembly 2300 is already in jaw 2180 and the sled retention feature is no longer required. That is, the cartridge body 2310 can include additional retention features that can retain the slider 2340 in the cartridge body 2310 regardless of the position of the slider 2340. Such retention features can be configured to retain the sled 2340 in the cartridge body 2310, for example, when the sled 2340 is in its distal or fully fired position.

In addition to the above, the staples of the staple cartridges disclosed herein can comprise one or more features configured to retain the staples in the staple cavities of the staple cartridge. Turning now to fig. 49 and 50, the staple 2330 includes a base 2331 and one or more staple legs 2332 extending from the base 2331. For example, the staples 2330 are removably stored in staple cavities 2320 in the cartridge body 2310. The base 2331 includes a protrusion 2338 extending therefrom that engages a sidewall of the staple cavity 2320. The interaction between the protrusions 2338 and the staple cavity sidewalls prevents the staples 2330 from falling out of the bottom 2316 of the cartridge body 2310. The interaction between the protrusions 2338 and the staple cavity sidewalls includes an interference fit; however, such an interference fit does not prevent the slider 2340 from ejecting the nail 2330 from the nail cavity 2320. The protrusions 2338 can be formed in the base 2331, for example, during a stamping process. The stamping process can form the protrusions 2338 by creating indentations 2337 on opposite sides of the base 2331. The staple cavity 2320 includes a vertical groove 2328 that aligns with the protrusion 2338. The channel 2328 increases the contact area between the sidewall of the staple cavity 2320 and the protrusion 2338. Additionally, the channel 2328 can control the orientation of the staple 2330 within the staple cavity 2320. Alternative embodiments that do not include the trench 2328 are contemplated.

In addition to or in lieu of the foregoing, staples stored in the staple cartridges disclosed herein may include staple legs that resiliently engage the sidewalls of their staple cavities. Turning now to fig. 51, the staple 2430 can include a base 2431 and staple legs 2432 and 2433 extending from the base 2431. Staple 2430 is similar in many respects to staple 2130,2330 and/or other staples disclosed herein. Staple cartridge body 2410 can, for example, include a plurality of staple cavities 2120 defined therein and a staple 2430 positioned in each staple cavity 2120. Fig. 51 shows staples 2430 positioned inside cavities 2120 and staples 2430 positioned outside staple cavities 2120 of cartridge body 2430. When staples 2430 are not positioned in staple cavities 2120, staple legs 2432,2433 do not extend in a parallel direction; rather, they extend outwardly away from each other. When staples 2430 are positioned in staple cavities 2120, they flex inward under the action of the sidewalls of staple cavities 2120. In other words, the staple legs 2432,2433 are resiliently biased against the sidewalls of the staple cavities and, as a result of this biasing engagement, the staples 2430 are prevented from falling out of the bottom 2436 of the cartridge body 2410. As shown in fig. 51, the distance between staple legs 2432,2433 is X when staple 2130 is positioned in staple cavity 2120, and the distance between staple legs 2432,2433 is greater than X when staple 2130 is not positioned in a staple cavity.

In various embodiments, the cartridge body can comprise one or more shoulders configured to inhibit staples stored therein from falling out of the bottom of the cartridge body. These shoulders may extend at least partially underneath the nail.

In certain embodiments, the cartridge body of the staple cartridge assembly can be comprised of plastic and can be formed, for example, during an injection molding process. The injection mold may comprise two halves movable towards and away from each other. The joint between injection mold halves is commonly referred to as a parting line, and flash or seepage of plastic between the mold halves can often occur at the parting line. In at least one embodiment, a parting line of an injection mold can be defined at a junction between a deck of a staple cartridge and a staple cavity defined in the deck. As a result of the above, plastic flash can occur around the periphery of the nail cavity. Such flashing may releasably retain the staples in the staple cartridge.

Referring again to fig. 48, the cartridge body 2310 is configured to directly engage the jaws 2180. The jaws 2180 include one or more retaining shoulders 2315 defined therein. The cartridge body 2310 includes corresponding retention shoulders 2187 that cooperate with the retention shoulders 2315 to releasably retain the cartridge body 2310 in the jaws 2180. The cartridge body 2310 and/or the jaws 2180 further comprise ramp surfaces 2314 that are configured to facilitate insertion of the cartridge body 2310 into the jaws 2180. As a result of the above, the cartridge body 2310 can have a snap-fit relationship with the jaws 2180. This snap fit relationship can be overcome by prying the cartridge body 2310 out of the jaws 2180 such that the cartridge assembly 2300 can be replaced.

In fig. 52-56, a peg 2530 is shown. Staple 2530 is similar in many respects to staple 2130,2330,2340 and/or other staples disclosed herein. The peg 2530 includes a base 2531 and legs 2532 and 2533 extending from the base 2531. The peg 2530 also includes a projection 2538 extending upwardly from the base 2531. The projections 2538 are aligned with the staple driving plane comprising the base 2531 and are not aligned with the tissue capture plane comprising the staple legs 2532 and 2533. The projections 2538 can compress tissue outside of the staple capture plane.

A staple cartridge assembly 2600 is illustrated in FIGS. 57-64. The staple cartridge 2600 comprises a cartridge body 2610 that includes a plurality of staple cavities 2220 defined therein. The staple cartridge 2600 further includes staples 2530 positioned within each staple cavity 2220 and a sled 2640 configured to eject the staples 2530 from the staple cavities 2220. Slider 2640 is similar in many respects to slider 2140. Each slide 2640 includes a plurality of ramps 2645, wherein each ramp 2645 includes a drive surface 2641 configured to slide under the staples 2530 and lift the staples 2530 within the staple cavities 2220. Each drive surface 2641 includes a ramped surface 2643 bounded by lateral sidewalls 2649 that define guide channels that align the staples 2530 relative to the drive surfaces 2641 and/or the staple cavities 2220. The guide channels are configured to receive the bases 2531 of the staples 2530 between the sidewalls 2649 and orient the staples 2530 laterally as the slider 2640 is advanced distally. This lateral realignment is apparent when comparing fig. 58 and 59. Referring again to fig. 52-56, each staple 2530 includes a guide feature 2139 defined on its base 2531. The guide features 2139 of each staple 2530 include, for example, curved ends configured to interact with the lateral sidewalls 2649 of the guide channel and adjust the lateral position of the staple 2530. In various other embodiments, the guide features 2139 can comprise any suitable configuration.

In addition to or in lieu of the above, referring primarily to fig. 60, the slides 2640 include guide channels 2646 that are configured to receive the downwardly depending feet 2134 of the staples 2530 and orient the staples 2530 relative to the drive surface 2641 and/or the staple cavities 2220. Each guide channel 2646 includes a slide portion 2648 and lateral sidewalls. The guide channels 2646 are configured to receive the bases 2531 of the staples 2530 between the sidewalls of the channels 2646 and orient the staples 2530 laterally as the slider 2640 is advanced distally. Referring primarily to fig. 61, each foot 2134 includes a lead-in or chamfered surface 2137 configured to interact with the sidewalls of the channel 2646 to guide the staple 2530 into the channel 2646. That is, the foot 2134 may have any suitable geometry that facilitates entry of the staple 2530 into the channel 2646. The reader should appreciate that as the drive surfaces 2641 drive the staples 2530 downward within the staple cavities 2220, the feet 2134 of the staples 2530 are lifted out of the channels 2646. By the time the apex 2644 of the drive surface 2641 forms the staple 2530, the foot 2134 is no longer positioned in the channel 2646.

Referring primarily to fig. 58, 59, and 64, the channel 2646 can also align the slider 2640 relative to the cartridge body 2610. More specifically, the cartridge body 2610 also includes longitudinal rails 2616 that extend downwardly into the channel 2646. The guide rail 2616 is closely received in the channel 2646 to limit or prevent lateral movement between the slider 2640 and the cartridge body 2610 while allowing the longitudinal movement of the slider 2640 required to fire the staples 2530 as outlined above. The foot 2134 of each staple 2530 is configured to properly orient the staple 2530 within its staple cavity 2220 in the event that the staple 2530 is improperly oriented within the staple cavity 2220.

The arrangement disclosed herein allows for a more compact staple cartridge than previous staple cartridges. Among other things, the staple cartridges disclosed herein that do not utilize staple drivers between the firing member and the staples (i.e., driverless staple cartridges) allow the staple cartridges to have a shorter overall height. Similarly, staple cartridges that do not include a bottom cover also allow the staple cartridge to have a lower overall height. A driverless staple cartridge may also allow for the use of smaller staple cavities. Turning now to fig. 67 and 68, the cartridge body 2910 includes staple cavities 2920 and longitudinal slots 2013 defined therein. Fig. 67 and 68 illustrate the bottom 2916 of the cartridge body 2910 and the bottom openings of the staple cavities 2920. The reader will appreciate that the staple cavities 2920 are sized and configured to receive staple drivers to drive staples out of the cartridge body 2910. Turning now to fig. 69 and 70, which illustrate the bottom 2016 of the cartridge body 2010, the staple cavities 2020 of the cartridge body 2010 are smaller than the staple cavities 2920. The reader will recall that the driver is not positioned in the staple cavity 2020, and thus the size of the staple cavity 2020 may be reduced. Fig. 71 compares the bottom 2916 of the cartridge body 2910 with the bottom 3016 of the alternative embodiment of the cartridge body 3010. As can be seen in fig. 71, the cartridge body 3010 comprises a substantially narrower longitudinal row of staple cavities 3020 than the longitudinal row of staple cavities 2920. In various circumstances, such narrower staple cavities may allow the centerlines of the longitudinal rows of staple cavities to be closer to one another. Turning now to fig. 72, the staple cartridge body 3110 includes longitudinal rows of staple cavities 3120a, 3120b, and 3120c defined in the deck 3114 of the cartridge body 3110 that are positioned closer together than would be permitted in embodiments where the staples within the cartridge body are lifted using staple drivers.

Various embodiments of the staple cartridge assemblies disclosed herein can have any suitable number of staples and/or any suitable size of staples. In some instances, all of the staples stored in the cartridge assembly 2000 (fig. 73) have the same, or at least substantially the same, dimensions. Referring to fig. 77, each staple 2130 in the staple cartridge 2000 includes an overall unformed or unfired height H1 defined between the bottom of the base 2131 and the tips of the staple legs 2132, 2133. Similarly, each staple 2130 includes a tissue capture area defined between the top of the base 2131 and the tips of the staple legs 2132,2133 that has the same height H2 when the staple 2130 is in its unformed height.

In contrast to the above, a first group of staples stored in the staple cartridge 2000 can have a first unformed height H1 and a second group of staples can have a second unformed height H1 that is different from the first unformed height H1. Also in contrast to the above, a first set of staples stored in the staple cartridge 2000 can have a first tissue capture height H2 and a second set of staples can have a second tissue capture height H2 that is different than the first tissue capture height H2.

A first set of staples can be positioned in first longitudinal row staple cavities 2120 and a second set of staples can be positioned in second longitudinal row staple cavities 2120. In at least one instance, the first row of staple cavities 2120 can be adjacent to the knife slot 2013 in the step 2014 "of the cartridge body 2010, while the second row of staple cavities 2120 can be adjacent to the first row of staple cavities 2120 in the step 2014' of the cartridge body 2010. In at least one such case, the first unformed height H1 is shorter than the second unformed height H1, for example.

In addition to the above, a third group of staples stored in the staple cartridge 2000 can have a third unformed height H1 that is different from the first unformed height H1 and/or the second unformed height H1. A third set of staples can be positioned in a third longitudinal row of staple cavities 2120. In at least one instance, the third row of staple cavities 2120 can be adjacent to the second row of staple cavities 2120 in the deck 2014 of the cartridge body 2010. In at least one such case, the second unformed height H1 is shorter than the third unformed height H1, for example. In addition to or in lieu of the above, a third set of staples can have a third tissue capture height H2 that is greater than the second tissue capture height H2.

In various embodiments, the first set of staples, the second set of staples, and/or the third set of staples can be deformed to the same overall formed height. Alternatively, a first set of staples may be deformed to a first formed height, a second set of staples may be deformed to a second formed height, and/or a third set of staples may be deformed to a third formed height. In such cases, the first group of staples may exert a greater pressure on the tissue than the second group of staples, and similarly, the second group of staples may exert a greater pressure on the tissue than the third group of staples.

Turning now to fig. 74-76, staples having the same unformed height can be deformed to different formed heights. For example, a first longitudinal row of staples (represented by staples 2130 ") may be deformed to a first formed height, a second longitudinal row of staples (represented by staples 2130') may be deformed to a second formed height, and/or a third row of staples (represented by staples 2130) may be deformed to a third formed height. For example, the first forming height is shorter than the second forming height, and the second forming height is shorter than the third forming height. In such cases, the first set of staples may exert a greater pressure on the tissue than the second set of staples, and similarly, the second set of staples may exert a greater pressure than the third set of staples.

A staple 3230 is shown in fig. 78 and 79. The staple 3230 includes a base or crown 3231, a first leg 3232 extending from the base 3231, and a second leg 3233 extending from the base 3231. Similar to the base 2131 of the staple 2130, the base 3231 of the staple 3230 includes an angled drive surface defined in a drive plane. Unlike the staple 2130, however, the first leg 3232 and the second leg 3233 define a staple forming plane that is transverse or non-parallel to the drive plane.

The staple 3230 also includes a platform 3238 extending from the base 3231. The platform 3238 is integrally formed with the base 3231 and folded such that the platform 3238 extends laterally from the base 3231. The platform 3238 is not directly connected to the leg 3232,3233. In contrast, there is a gap 3237 between the platform 3238 and the leg 3232,3233. In various other embodiments, the platform 3238 is directly connected to the first leg 3232 and/or the second leg 3233. The platform 3238 extends in a plane transverse to the drive plane and staple forming plane (i.e., the support plane); however, the platform 3238 may extend in any suitable direction. The platform 3238 is flat or at least substantially flat; however, the platform 3238 may have any suitable shape.

In certain embodiments, the platform 3238 of the staple 3230 can contact the stapled tissue when the staple 3230 is implanted in the tissue. A wider platform 3238 may reduce the likelihood of staples 3230 tearing in the tissue.

In various embodiments, a staple cartridge assembly comprises a cartridge body comprising a deck and staple cavities defined in the deck. The staple cartridge assembly further includes staples 3230 removably stored in the staple cavities, in addition to an implantable layer positioned over the deck. The implantable layer may include any suitable adjunct, such as a tissue thickness compensator and/or a buttress material. The tissue thickness compensator can compensate for variations in the thickness of the stapled tissue. The implantable layer can be constructed of, for example, a woven material and/or a nonwoven material.

In addition to the above, the platforms 3238 of the staples 3230 can abut the layer when the staples 3230 are implanted in tissue. In such cases, the platform 3238 supports the layer. Similar to the above, the platform 3238 can also reduce the likelihood of the peg 3230 tearing in the layer. The platform 3238 of the staples 3230 and the layer can form a cooperative system that distributes forces, stresses and/or strains applied to tissue over a larger area.

The pins 3230 are formed from a flat piece of material using a stamping process. During the stamping process, material is removed from the sheet to form the general shape of the staples 3230. The first leg 3232 is curved in a first direction and the second leg 3233 is curved in a second direction; however, both the first leg portion 3232 and the second leg portion 3233 can be bent in any suitable direction with a single line of action by a die. During this and/or a different stamping process, the platform 3238 is bent in the same direction as the first leg 3232. In some cases, the platform 3238 can be formed using the same single line of action that forms the legs 3232 and 3233. In other instances, the platform 3238 can be formed with a second line of action that is transverse or orthogonal to the first line of action.

Turning now to fig. 86, the staple 3630 includes a base or crown 3631 and legs 3632 and 3633 extending from the base 3631. Similar to the staple 3230, the staple 3630 also includes a platform 3638 that extends from a base 3631. The reader should appreciate that the platform 3238 of the staple 3230 and the platform 3638 of the staple 3630 can increase the moment of inertia or stiffness of the staple. The staples 3630 include pressure relief or flex slots 3637 in the base 3631 that, for example, reduce the stiffness of the staples 3630. Additionally or alternatively, pressure relief slots may be provided in the platform 3638. In any event, more than one pressure relief slot can be utilized to provide the desired stiffness of the staple 3630. Further, such relief slots may be suitable for any of the staples disclosed herein.

Additionally or alternatively to the above, turning now to fig. 80 and 81, a staple assembly 3330 includes a staple 3230 and an implantable adjunct 3370 attached to the staple 3230. The auxiliary 3370 includes a first end portion including a first aperture 3372 configured to receive the first leg 3232 of the staple 3230 and a second aperture 3373 configured to receive the second leg 3233. Thus, the adjunct 3370 is tethered to the staple leg 3232,3233 and the motion of the adjunct 3370 relative to the staple 3230 is constrained.

In addition to the above, the auxiliary 3370 includes a resilient portion 3371 that extends above the platform 3238 of the nail 3230. When the staple assembly 3330 is stored in the staple cartridge, a gap 3377 exists between the flexible portion 3371 of the adjunct 3370 and the platform 3238 of the staple 3230. When the staple assembly 3330 is ejected from the staple cartridge, the staple legs 3232,3233 of the staples 3230 penetrate the stapled tissue and the resilient portion 3371 of the adjunct 3370 comes into contact with the tissue. The resilient portion 3371 is configured to flex, deflect and/or displace downward toward the platform 3238 when the adjunct 3370 comes into contact with tissue. The resilient portion 3371 can apply a biasing force to tissue as it is captured within the staple 3230. The movement of the resilient portion 3371 is at least partially constrained by the platform 3238.

In addition to or in lieu of the foregoing, turning now to fig. 84, a staple assembly 3430 includes staples 3630 and implantable adjuncts 3470 attached to the staples 3230. The auxiliary piece 3470 includes a first end portion that includes first apertures 3472 configured to receive the first legs 3632 of the staples 3630 and second apertures 3473 configured to receive the second legs 3633. Thus, the accessory 3470 is tethered to the staple leg 3632,3633 and movement of the accessory 3470 relative to the staples 3630 is constrained.

In addition to the above, the auxiliary objects 3470 include elastic portions 3471 that extend above the platforms 3638 of the staples 3630. When the staple assembly 3430 is stored in the staple cartridge, there is little, if any, clearance between the resilient portions 3471 of the adjuncts 3470 and the platforms 3638 of the staples 3630. When the staple assembly 3430 is ejected from the staple cartridge, the staple legs 3632,3633 of the staples 3630 penetrate the stapled tissue and the resilient portions 3471 of the adjuncts 3470 come into contact with the tissue. Referring to fig. 85, resilient portion 3471 is configured to flex, deflect and/or displace downward toward platform 3638 when auxiliary component 3470 is brought into contact with tissue. The resilient portion 3471 can apply a biasing force to tissue as the tissue is captured within the staples 3630. The movement of the resilient portion 3471 is at least partially constrained by the platform 3638.

Referring primarily to fig. 82 and 83, the resilient portion 3471 of the auxiliary component 3470 comprises an enclosure. The package is sealed and includes at least one material therein. In each case, the material includes a drug. When the package is ruptured, the drug is released from the package. The enclosure can rupture when the staple assembly 3430 is implanted in tissue or after a period of time. Auxiliary element 3470 is constructed of any suitable biocompatible material, and when the biocompatible material comprises a bioabsorbable material, auxiliary element 3470 can be absorbed in situ. After a sufficient amount of auxiliary element 3470 has been absorbed, the drug may be released from auxiliary element 3470. In various alternative embodiments, the auxiliary element comprises two separate packages. In at least one such embodiment, the first enclosure can contain a first medicament and the second enclosure can contain a second medicament. The first medicament may be mixed with the second medicament when the package has been ruptured.

In addition to the above, the material in the chamber of the resilient portion 3471 may be selected for its mechanical properties, such as its elasticity, and may provide the resilient portion 3471 with desired properties to apply a sufficient biasing force to the tissue. In at least one instance, it may be desirable for the flexible portion 3471 to have mechanical properties that closely resemble those of the patient's tissue. In other cases, it may be desirable for the resilient portion 3471 to have a stiffness that is less than the stiffness of the patient's tissue, for example. Such embodiments may provide for proper constriction of blood flow within the tissue. In some cases, it may be desirable for the resilient portion 3471 to have a stiffness that is less than the stiffness of the base 3631, but greater than the stiffness of the patient's tissue, for example. Such embodiments may provide strain relief to tissue.

The auxiliary pieces 3370,3470 may be constructed of a woven and/or nonwoven material. In at least one instance, the accessory 3370,3470 includes a shell constructed of a woven and/or nonwoven material. The auxiliary piece 3370,3470 may be constructed of, for example, PGA and/or PLA. In at least one instance, the accessory 3370,3470 includes a housing constructed from, for example, PGA and/or PLA.

The accessory 3370,3470 is configured to be attachable to a single staple. In other words, each accessory 3370,3470 is attached to only one peg. Such an aid may be referred to as absorbent cotton. Alternative embodiments are envisaged in which two or more spikes are connected by an accessory.

Turning now to fig. 88 and 89, the individual staples disclosed herein (such as staple 2130) can be implanted in longitudinal rows into the tissue of a patient. Two longitudinal rows of staples 2130 are shown in fig. 88 and 89. In various instances, the tissue may be stretched in various directions (such as longitudinally). Longitudinal stretching of the tissue T is shown in fig. 89. As can be seen in fig. 89, the staples 2130 may be stretched along with the tissue T. In such cases, the gap between the spikes 2130 can increase. This increase in gap is apparent when comparing the unstretched gap distance X1 (fig. 88) to the stretched gap distance X2 (fig. 89). The staples 2130 in the third longitudinal row can be positioned and arranged such that they are aligned with or coextensive with the gap, regardless of whether the gap is stretched (X2) or unstretched (X1). Such concepts may be readily adapted to, for example, round and/or curved rows of staples.

Turning now to fig. 87, the circular cartridge body 3510 can utilize, for example, a staple assembly 3430. The cartridge body 3510 comprises a plurality of staple cavities 3520 arranged in circular concentric rows. As shown in fig. 87, each staple cavity includes a staple assembly 3430 positioned therein; however, any suitable staple may be utilized.

The staples disclosed herein may be constructed of any suitable material. In each case, the nail is constructed of, for example, stainless steel and/or titanium. In some cases, the staples disclosed herein are comprised of magnesium. The entire disclosures of the following documents are incorporated herein by reference: COMPARISON OF THE EFFECTS OF Mg-6Zn AND Ti-3Al-2.5V ALLOYS ON TGF- β/TNF- α/VEGF/b-FGF IN THE HEALING OF THE INTESTINAL TRACT IN VIVO, published by Yan et Al, biomed. Mater.9(2014) 025011; yan et al, COMPARISON OF THE EFFECTS OF Mg-6Zn AND TITANIUM ON INTESTINAL TRACT IN VIVO published online ON 20.3.3.2013, J.Mater.Sci: Mater.Med.; EVALUATION OF THE SOFT TISSUE BIOCOMPATITITY OF MgCa0.8AND SURGICAL STEEL 316L IN VIVO, published by Erdmann et al, A COMPARATIVE STUDY IN RABBITS, biomed.Eng.OnLine 20109: 63; INVESTATION OF THE MECHANICAL AND GRADATION PROPERTIES OF Mg-Sr AND Mg-Zn-Sr ALLOYS FOR USE AS POLYTEIAL BIODEGRADABLE IMPLANT MATERIALS, J.Mech.Behavior OF biomed. Mat.7(2012)87-95 by Brar et al; Mg-Zr-Sr ALLOYS AS BIODEGRADABLE IMPLANT MATERIALS, Acta Biomaterialia 8(2012)3177-3188 published by Li et al; ON THE bie bioodegmability, MECH, published by Pellicer et al ON-line at 8/28/2012ANICAL BEHAVIOR,AND CYTOCOMPATABILITY OF AMORPHOUS Mg₇₂Zn₂₃Ca₅AND CRYSTALLINE Mg₇₀Zn₂₃Ca₅Pd₂ALLOYS AS TEMPORARY IMPLANT MATERIALS, Soc.Biomat.. In at least one instance, the nail is constructed of, for example, a magnesium alloy containing zinc and/or silver. Staples comprising magnesium and zinc alloys enhance the healing properties of tissue. The peg comprising silver provides antimicrobial benefits. Nails comprising all three alloys provide synergistic kinetics.

Nails composed of magnesium, including those composed of magnesium alloys, may be treated to improve the hardness of the nail. In each case, a magnesium nitride coating was applied to the magnesium nail. In some cases, the magnesium nitride coating was applied to all of the magnesium nails, while in other cases, the magnesium nitride coating was applied to only portions of the magnesium nails. For example, when the legs require sufficient hardness to penetrate tissue, it may be desirable to coat only the legs and/or the tips of the legs in magnesium nitride. In at least one such case, a mask can be applied to the remainder of the magnesium nail when the magnesium nitride coating is applied to the nail legs. The magnesium nitride coating may be formed, for example, by introducing the magnesium nail into a nitrogen-rich environment at elevated temperature and/or pressure.

Additionally or alternatively to the above, one or more surfaces of the magnesium nail may include a coating comprising carbon.

In addition to or in lieu of the foregoing, other hardfacing techniques may be utilized. For example, the magnesium nail may be hardened using a laser hardening process and/or a plasma discharge hardening process. In at least one instance, a Keronite ceramic surface treatment by Keronite International can be applied to the nail.

As discussed above, certain portions of the magnesium nail may be subjected to a hardening process, while other portions of the magnesium nail may not be subjected to a hardening process. In some cases, some portions of the magnesium nail may be hardened to a first hardness, while other portions of the magnesium nail may be hardened to a second hardness different from the first hardness. Magnesium spike portions with lower hardness will, for example, precipitate magnesium, zinc and/or silver ions faster than magnesium spike portions with higher hardness.

In addition to or in lieu of the foregoing, magnesium nails (including those composed of magnesium alloys) may be at least partially covered in a coating comprising silver. In at least one instance, the silver coating can comprise, for example, ionized silver. In some cases, a silver coating may be applied to the magnesium nail using an electroplating process. In each case, the entire magnesium nail was covered in a silver coating. In at least one instance, one or more portions of the magnesium nail are masked during the electroplating process such that the masked portions are not coated, or at least substantially coated, in the silver.

In addition to or in lieu of the foregoing, the staples disclosed herein may be coated or at least partially coated in an antimicrobial coating. Such a coating may comprise, for example, triclosan. In at least one instance, triclosan is mixed in the absorbable polymer coating. In some cases, the coating may comprise LAE intermixed with sodium stearate, for example. The entire disclosure of WO 2012013577A1, entitled "COMPOSITIONS FOR COATING MEDICAL DEVICES CONTAINING LAE AND A POLYCATIONIC AMPHOTERIC POLYMER" by Gaffar et al is incorporated herein by reference.

Turning now to fig. 90-92, the peg 3730 includes a metal frame and a coating 3739 over less than all of the metal frame. The metal frame includes pins 2130 and is constructed of, for example, magnesium and/or a magnesium alloy. Coating 3739 comprises a bioabsorbable polymer; however, the coating 3739 may comprise any suitable material. The coating 3739 extends around the legs 2132,2133 of the metal frame 2130. More specifically, coating 3739 spirals around each of legs 2132, 2133; however, any suitable arrangement of coating 3739 may be utilized. The coating 3739 also covers the transitions or corners between the legs 2132,2133 and the base or crown 2131 of the metal frame 2130. The coating 3739 can also cover a portion of the base 2131. In various instances, the coating 3739 can be strategically applied to areas of the metal frame 2130 that are inherently more readily bioabsorbed, such as bends, edges, and/or corners of the metal frame 2130. In any case, a portion of the metal frame 2130 is covered by the coating 3739, while another portion of the metal frame 2130 is exposed.

The magnesium or magnesium alloy metal framework 2130 is bioabsorbable. Referring primarily to fig. 91, the portion of the metal frame 2130 not covered by the coating 3739 is directly exposed to the body upon implantation and is thus immediately subjected to the body's natural absorption processes. The portion of the metal frame 2130 that is covered by the coating 3739 is not directly exposed to the body at the time of implantation, or at least is not initially directly exposed to the body. The coating 3739 protects, or at least to some extent protects, the portions of the metal frame 2130 covered thereby and delays the bioabsorption of these portions. Over time, referring primarily to fig. 92, the unprotected portions of the metal frame 2130 will be bioabsorbed, leaving the portions of the metal frame 2130 protected by the coating 3739. The coating 3739 can substantially encapsulate the portion of the metal frame 2130 covered thereby, at least until the coating 3739 itself is bioabsorbed and/or until the metal frame 2130 has sufficiently disintegrated. At this point, the portion of the metal frame 2130 that was protected by the coating 3739 is exposed and can be bioabsorbed by the body.

The bioabsorbable polymer of coating 3739 can be comprised of, for example, PGA and/or PLA; however, the coating 3739 may be constructed of any suitable material, including but not limited to bioabsorbable and non-bioabsorbable polymers. In some cases, coating 3739 comprises, for example, a non-crosslinked polymer. Such polymers may swell the coating 3739 and encapsulate any sharp edges of the metal frame 2130 that form when the metal frame 2130 deteriorates.

In various embodiments, the coating 3739 can be disposed on the metal frame 2130 in a grid, mesh, and/or lattice arrangement. In such embodiments, the metal frame 2130 may be exposed in the openings of the mesh, thereby allowing the metal frame 2130 to be bioabsorbed in these openings. When the metal frame 2130 begins to degrade, the lattice-like coating 3739 can act as a mesh or cage and hold the pieces of the metal frame 2130 together, e.g., at least until the coating 3739 is bioabsorbed.

The coating 3739 may be applied to the metal frame 2130 in any suitable manner. In at least one instance, the coating 3739 can be sprayed onto the metal frame 2130 such that the coating 3739 is applied in a random manner, thereby creating random openings through which the metal frame 2130 can be bioabsorbed. In certain other cases, the coating 3739 can be applied to the metal frame 2130 in a pattern. In at least one such case, the pattern can comprise a dot matrix pattern having coating islands surrounded by exposed portions of the metal frame 2130.

In certain alternative embodiments, the staple may include two or more coatings. In at least one such instance, the first coating can be bioabsorbable at a first rate and the second coating can be bioabsorbable at a second rate, exposing different portions of the metal frame 2130 at different times, e.g., in a healing process. Such staples may still have an uncovered portion; however, it is contemplated that each portion of the staple may be covered by at least one or more coatings.

The therapeutic benefit provided by the materials disclosed herein varies with the surface area of the peg exposed to the patient's body. Staples having a larger surface area may deliver such therapeutic benefits more quickly than staples having a smaller surface area. That is, staples having a smaller surface area may provide such therapeutic benefits over a longer period of time. Nonetheless, the surface area of the staples disclosed herein can be increased by introducing apertures into the staples. For example, one or more apertures or through-holes may be formed, e.g., in the base or crown portion 2131 of the spike 2130. These through holes can allow tissue to grow out of the staple 2130 and improve the assimilation of the staple 2130 into the body.

In at least one embodiment, in addition to the above, the coating 3739 is not positioned in the aperture as the coating 3739 can reduce the available surface absorption area of the peg 2130. However, if it is desired to delay the bio-absorption of these staple portions, the coating 3739 can be filled or at least partially filled in the apertures of the staples 2130. As discussed above, the coating 3739 can be configured to delay absorption by the underlying metal frame; however, any suitable coating may be utilized. For example, a coating on the metal frame may promote tissue ingrowth into the staple structure. In at least one such case, the coating comprises smaller micropillars that create porous and/or multi-spinous interactions with the tissue.

In various embodiments, in addition to the above, a suture or thread may extend through an aperture defined in the staple. Such sutures may tether the staples together. In various instances, sutures are threaded through the apertures when the staples are positioned in the staple cartridge. In other cases, the suture is threaded through the aperture after the staple has been implanted into the tissue. In at least one embodiment, the sutures are positioned in channels defined in a deck of the staple cartridge, and the staples each include a slot or hook defined therein configured to grasp the sutures as the staples are deployed. In any event, the suture may be pulled to gather the sutured tissues together, such as with a purse string tissue gathering technique.

In various embodiments, the staples disclosed herein can comprise barbs. In at least one instance, barbs are defined on the staple legs such that the barbs engage the implanted layer with tissue. Such barbs may reduce relative movement between the layer and the staple. In certain embodiments, barbs are defined on the base of the staple. Such barbs can grip a layer of tissue positioned adjacent to an implanted staple.

A circular surgical stapler 5000 is shown in FIGS. 93-95. The circular surgical stapler 5000 includes a frame assembly 5020 that includes an attachment portion 5021 that is configured to operably couple an anvil to the circular surgical stapler 5000. The circular surgical stapler 5000 further includes a knife member 5040 configured to cut into tissue captured by the circular surgical stapler 5000, a surgical staple cartridge 5010 having a plurality of staples 5051 removably stored therein, and a pusher assembly or driver 5030 configured to eject the staples 5051 from the staple cartridge 5010. The surgical staple cartridge 5010 includes a cartridge deck 5013 and a plurality of staple cavities 5011 defined in the cartridge deck 5013 and removably storing staples 5051. The staples 5051 are similar to the staples discussed in greater detail herein, but any suitable staples may be used. The staple 5051 includes staple legs in a plane that is offset from a plane defined by the staple base portion.

Referring primarily to FIG. 95, the staple cavities 5011 of the staple cartridge 5010 include inner rows of staple cavities 5011A, middle rows of staple cavities 5011B, and outer rows of staple cavities 5011C. The staple row spacing may include any suitable spacing; however, nested rows may be closer together than non-nested rows. The middle row of staple cavities 5011B are positioned radially outward relative to the inner row of staple cavities 5011A. The outer row of staple cavities 5011C are positioned radially outward relative to the middle row of staple cavities 5011B. The staple cavities 5011A in the inner row have an orientation that orients the legs of the staples 5051 stored in the staple cavities such that the legs extend radially outward relative to the staple base. The middle and outer rows of staple cavities 5011B and 5011C have an orientation that orients the legs of the staples 5051 stored in the staple cavities such that the legs extend radially inward relative to the staple base.

The staple cavities 5011A in the inner row define a plurality of first gaps therebetween having a distance a. The middle row of staple cavities 5011B defines a plurality of second gaps having a distance B. The outer row of staple cavities 5011C defines a plurality of third gaps having a distance C. Distance a is less than distances B and C. Distance B is greater than distance a but less than distance C. Distance C is greater than distances a and B. The cavity 5011 is arranged such that the distance of the first gap is greater than the distance of the second gap and/or the third gap. The cavity 5011 is arranged such that the distance of the third gap is smaller than the distance of the first gap and/or the second gap. Embodiments are contemplated in which there are no gaps associated with one or more rows of staple cavities.

The middle row of staple cavities 5011B is arranged such that the cavity 5011B overlaps the first gap defined by the inner row of staple cavities 5011A in order to compensate for the lack of tissue ligation in the first gap. The outer row of staple cavities 5011C is arranged such that the cavities 5011C overlap a second gap defined by the middle row of staple cavities 5011B in order to compensate for the lack of tissue ligation in the second gap. Overlapping these fastening gaps with this arrangement enhances the ligation capabilities of the circular surgical stapler 5000. This arrangement also allows the fastened tissue to flex when fastened. Conventional arrangements utilize a greater number of staples in the middle and/or outer rows in order to increase ligation efficiency; however, such conventional arrangements may limit tissue flexibility after fastening.

Fig. 96-98 illustrate a circular surgical stapler 5100 in accordance with at least one embodiment. The circular surgical stapler 5100 includes a frame assembly 5120 that includes an attachment portion configured to operably couple an anvil to the circular surgical stapler 5100. The circular surgical stapler 5100 further includes a knife member 5140 configured to cut through tissue captured by the circular surgical stapler 5100, a surgical staple cartridge 5110 that removably stores a plurality of staples 5151 therein, and a pusher assembly or driver 5130 configured to eject the staples 5151 from the staple cartridge 5110. The pusher assembly 5130 includes an inner row of staple drivers 5130A, an intermediate row of staple drivers 5130B, and an outer row of staple drivers 5130C. The surgical staple cartridge 5110 includes a cartridge deck 5113 and a plurality of staple cavities 5111 defined in the cartridge deck 5113 and in which the staples 5151 are removably stored. The surgical staple cartridge 5110 further includes a plurality of deck features or staple supports or guides 5115 configured to support, guide, and/or control the staples 5151 as the staples 5151 are ejected from the staple cartridge 5110. The deck features or cavity extensions 5115 can have a variety of uses, such as to help clamp tissue between the anvil and staple cartridge 5110, and/or to store, release, and deliver drugs to tissue captured with the stapler 5100.

The staple cavities 5111 of the staple cartridge 5110 are similar in many respects to the staple cavities 5011. The staple cavities 5111 include an inner row of staple cavities 5111A, an intermediate row of staple cavities 5111B, and an outer row of staple cavities 5111C. The deck features 5115 include a plurality of first deck features 5115A, a plurality of second deck features 5115B, and a plurality of third deck features 5115C. Each first deck feature 5115A includes a middle portion 5116 and two outer portions 5117 to define a T-configuration. The intermediate portion 5116 is located between the two staple cavities 5111A and extends from the deck 5113 to guide and/or support the adjacent staple legs. The outer portions 5117 branch off from the intermediate portion 5116 in at least substantially opposite directions and extend from the deck 5113 to guide and/or support a portion of the staple base. Combining deck features with more than one cavity in this manner can save space on the bin deck 5113.

Each second plate feature 5115B and each third plate feature 5115C includes a middle portion 5118 and two outer portions 5119 to define a configuration around the cavity. The middle portion 5118 extends from the deck 5113 to guide and/or support the staple bases of staples removably stored in the middle row of staple cavities 5111B and the outer row of staple cavities 5111C. The two outer portions 5119 branch off of the middle portion 5118 to support the legs extending from the base of the staple, with the middle portion 5118 guiding and/or supporting the base of the staple.

Figure 99 illustrates a circular stapling configuration 5200 for use with a circular surgical stapler, in accordance with at least one embodiment. The circular stapling configuration 5200 is an arrangement of staples that can be employed with a circular staple cartridge. A circular staple cartridge in a circular stapling configuration 5200 includes corresponding staple cavities to removably store staples as discussed herein. The circular stitching configuration 5200 includes a plurality of staples 5210 having inner rows of staples 5213, intermediate rows of staples 5215, and outer rows of staples 5217. Each staple 5213 is oriented such that its legs face outwardly toward the outer rows of staples 5217. Each staple 5215 is oriented such that its legs face inwardly toward the inner rows of staples 5113. Each staple 5217 is oriented such that its legs face outwardly away from the inner and middle rows of staples 5213, 5215. Each staple row may be located at a distance from each other staple row and/or the cutting member in order to better control blood flow and/or predict tissue behavior at certain points within the stapled tissue.

The outer row of staples 5217 have different characteristics than the inner row of staples and/or the middle row of staples 5213,5215. For example, in various instances, the outer rows of staples 5217 are formed into a larger "B" configuration, thereby creating a larger capture volume and/or a higher staple forming height to mitigate high tissue compression near the outer rows of staples 5217. Larger B shapes may also improve blood flow toward these inner rows. In each case, the outer row of staples 5217 can have greater resistance to deployment by utilizing a greater crown, leg width, and/or leg thickness.

The number of staples used in each row of staples may vary in circular and/or linear surgical staple cartridges. The outer rows of staples 5217 have a first number, the middle rows of staples 5215 have a second number, and the inner rows of staples 5213 have a third number. Fig. 99 shows a case where the first number is equal to the second number but greater than the third number. In various embodiments, the first number, the second number, and the third number are different. In various embodiments, the first number is greater than the second number, and the second number is greater than the third number.

Differing crown widths between rows of staples can provide an efficient and/or effective stapling arrangement. For example, each outer row of staples 5217 comprises crowns with a width greater than the width of the crowns of each inner row of staples 5213 and each intermediate row of staples 5215. The crown of each outer row of staples 5217 is laterally curved in order to have staples with a greater crown width while maintaining a compact circular stapling arrangement. Some embodiments are contemplated in which the crown of each outer row of spikes 5217 is curved. One advantage of bending or bending the crowns of the outer row of spikes 5217 can include the ability to nest, for example, outer row of spikes 5217 closer to the middle row of spikes 5215 and inner row of spikes 5213. Each outer row of staples 5217 spans a plurality of gaps defined between inner rows of staples 5213 and/or intermediate rows of staples 5215. Each intermediate row of staples 5215 spans, overlaps or covers each gap defined between inner rows of staples 5213.

In various embodiments, the gap defined by the inner row of staples 5213 can be varied based on the radial position of the inner row of staples. For example, a row of inner staples having a diameter much smaller than the diameter of the bowel being stapled may include a much larger gap between the inner rows of staples to provide radial flexibility and/or stretching. A row of inside staples having a diameter smaller than but closer to the diameter of the stapled intestine may comprise smaller gaps between the inner rows of staples, since in this case no significant stretching and/or flexibility may be required.

Figure 100 illustrates a circular stapling configuration 5300 for use with a circular surgical stapler, in accordance with at least one embodiment. The circular stapling configuration 5300 is an arrangement of staples that can be employed with a circular staple cartridge. The circular staple cartridge employing the circular stapling configuration 5300 includes corresponding staple cavities to removably store staples as discussed herein. Circular stitching configuration 5300 includes a plurality of staples 5310 having inner rows of staples 5313A,5313B, intermediate rows of staples 5315C,5315D, and outer rows of staples 5317E, 5317F. Each staple 5313A,5313B is oriented such that its staple legs face outwardly toward these outer rows of staples 5317E, 5317F. Each staple 5315C,5315D is oriented such that its staple legs face inwardly toward these inner rows of staples 5313A, 5313B. Each staple 5317E,5317F is oriented such that its staple legs face outwardly away from inner row of staples 5313A,5313B and middle row of staples 5315C, 5315D. Embodiments are contemplated in which the staples in the same row face in opposite directions. Embodiments are contemplated in which each staple in each row faces in the same direction. Embodiments are contemplated in which, for example, the inner rows of staples face inwardly, the middle rows of staples face outwardly, and the outer rows of staples face inwardly.

The different crown widths between and within rows of staples can also provide an efficient and/or effective stapling arrangement. For example, inner rows of staples 5313A,5313B each have different crown widths, intermediate rows of staples 5315C,5315D each have different crown widths, and outer rows of staples 5317E,5317F each have different crown widths. In various embodiments, the crown width of each nail 5313A,5313B, 5315C,5315D, 5317E, and 5317F all differ. Embodiments are contemplated in which the crown width of some of the staples in one row is equal to the crown width of some of the staples in the other row. The inner row of staples defines a stretch zone marked SZ. The stretch zone SZ may include, for example, a gap defined between the staples 5313A. The stretching zone SZ allows the sutured tissue to flex.

Circular surgical staplers, circular staple cartridges, and/or circular stapling configurations may be used, for example, in colectomies. Fig. 101 shows an example of a portion of a colectomy in which two portions of the intestine are joined, providing a new pathway or channel 5400 for the digestive system. Intestine T₁Includes an inner wall 5410, and the intestine T₂Includes an inner wall 5420. Intestinal portion T is stapled using medial staples 5401, medial staples 5403 and lateral staples 5405₁And T₂. Incising the intestinal part T₁And T₂Thereby forming a new pathway P-P for the passage of digestive substances. The incision forms a part of the intestine T₁And T₂And cutout portions 5411 and 5421. Intestinal part T₁And T₂The change in diameter between inner wall 5410,5420 and cut- out portion 5411,5421 may in some cases constrict or narrow the passageway P-P, making it difficult for digestive substances to pass through. It may be desirable to have flexibility in the staple portions starting from inner staples 5401. One method for providing flexibility utilizes staple gaps defined between the staples in each row of deployed staples. Another method for providing flexibility utilizes larger size staples with larger crowns. In each case, the gap between the staples and the staple rows allows flexibility of the stapled section, thereby allowing easier passage of digestive substances. In each case, staples of different sizes allow for tissue flexibility.

Fig. 102-104 illustrate a curved stapling instrument 5500 configured to capture, incise and staple tissue in accordance with at least one embodiment. The curved stapling instrument 5500 includes a frame assembly 5510, a staple cartridge 5520, and an anvil 5530. Upon receiving the first actuation force, the staple cartridge 5520 is driven toward the anvil 5530 capturing tissue therebetween. The curved stapling instrument 5500 further comprises a knife assembly 5540 that includes a cutting member 5541 configured to incise tissue captured between the staple cartridge 5520 and the anvil 5530. The staple cartridge 5520 includes a deck 5527 that includes a cutting slot 5521 configured to receive a cutting member 5541, a plurality of staple cavities 5523A and 5523B, and a plurality of staples 5560 removably stored within the staple cavities 5523A, 5523B. The bending stapling instrument 5500 further includes a driver assembly 5550 that includes a plurality of staple drivers 5551 configured to drive the staples 5560 toward the anvil 5530 upon application of a second actuation force. The second actuation force acts to vertically lift the driver assembly 5550 and knife assembly 5540 relative to the curved stapling instrument 5500 in order to incise and staple tissue.

The staple cartridge 5520 also includes a plurality of deck features 5525 extending from the deck 5527. Embodiments are contemplated in which deck feature 5525 is a separate portion configured to be attachable to deck 5527. The deck features 5525 may be extensions of the nail cavities 5523A,5523B to support, guide, and/or control the nails 5560 as the nails 5560 are loaded into the magazine 5520, as the nails 5560 are received or supported prior to ejection of the nails 5560, and/or as the nails 5560 are ejected from the magazine 5520. A single deck feature 5525 supports two different staple legs adjacent to a staple. The deck feature 5525 can include a plurality of support walls configured to support one or more sides, faces, and/or edges of each staple leg. Embodiments are contemplated in which the deck features 5525 on the outer rows of staples (the rows furthest from the slot) are associated with only every other staple cavity in each outer row. The closer the staple features are located from the cut, the greater the density of the staple features may follow.

Fig. 105 and 106 illustrate a curved stapling instrument 5600 configured to capture, incise, and staple tissue according to at least one embodiment. The curved stapling instrument 5600 includes a frame assembly 5610, a staple cartridge 5620, and an anvil 5630. Upon receiving a first actuation force, the staple cartridge 5620 is driven toward the anvil 5630 capturing tissue therebetween. The curved stapling instrument 5600 also includes a knife assembly that includes a cutting member configured to incise tissue captured between the staple cartridge 5620 and the anvil 5630. The staple cartridge 5620 includes a deck 5627 that includes a cutting slot 5621 configured to receive a cutting member, a plurality of staple cavities 5623, and a plurality of staples 5660 removably stored within the staple cavities 5623. The curved stapling instrument 5600 also includes a driver assembly 5650 that includes a plurality of staple drivers 5651 configured to drive the staples 5660 toward the anvil 5630 upon application of a second actuation force. The second actuation force acts to vertically lift the driver assembly 5650 and knife assembly relative to the curved stapling instrument 5600 in order to incise and staple tissue.

The staple cartridge 5620 further includes a plurality of deck features 5625 extending from the deck 5627. Embodiments are contemplated in which deck feature 5625 is a separate part configured to be attachable to deck 5627. The deck features 5625 may be extensions of the staple cavities 5623 to support, guide, and/or control the staples 5660 as the staples 5660 are loaded into the cartridge 5620, as the staples 5660 are received or supported prior to ejection of the staples 5660, and/or as the staples 5660 are ejected from the cartridge 5620. The deck features 5625 may include a plurality of support walls configured to support one or more sides, faces, and/or edges of each staple leg. A deck feature 5625 extends from at least one of the staple leg walls and at least one of the staple base walls of the staple cavity.

The staple drivers 5651 have a flat profile that is at least substantially identical to the bottom profile of the staples 5660. Having similar or identical profiles allows for a desirable force distribution of the staple drivers 5651 within the staple base portion of the staples 5660. The similar profile between the driver 5651 and the staples 5660 prevents the staples 5660 from becoming misaligned when formed against the anvil 5630.

Examples

Example 1: a staple cartridge assembly for use with a surgical stapler, wherein said staple cartridge assembly comprises a cartridge body comprising a proximal end, a distal end, a deck, a longitudinal slot defined in said deck and extending from said proximal end toward said distal end, and staple cavities, wherein said staple cavities are arranged in a longitudinal row. Each staple cavity includes a top opening, a bottom opening, a proximal end, a distal end, and a staple cavity sidewall extending between the proximal and distal ends defined in the deck. The staple cartridge assembly further comprises staples removably stored in the staple cavities, wherein each staple comprises a proximal leg, a distal leg, a base extending between the proximal and distal legs, and a retention tab extending from the base, wherein the retention tab of the staple engages the staple cavity sidewall to prevent the staple from falling out of the bottom opening of the staple cavity.

Example 2: the staple cartridge assembly of embodiment 1, further comprising a sled movable from said proximal end toward said distal end to eject said staples through said top openings of said staple cavities.

Example 3: the staple cartridge assembly of embodiment 2, wherein said cartridge body further comprises a bottom surface defined opposite said deck; a longitudinal channel defined in the bottom surface, wherein at least a portion of the slider is slidably positioned in the longitudinal channel; and a retaining portion configured to prevent the slider from falling out of the longitudinal channel through the bottom surface.

Example 4: the staple cartridge assembly of embodiment 3, wherein said sled is movable between a proximal position and a distal position during a firing stroke, wherein said retention portion is engaged with said sled when said sled is in said proximal position, and wherein said retention portion is not engaged with said sled when said sled is in said distal position.

Example 5: the staple cartridge assembly of embodiments 1, 2,3, or 4, wherein said staple cartridge assembly does not comprise a cover extending around said bottom surface of said cartridge body.

Example 6: the staple cartridge assembly of embodiments 1, 2,3, 4, or 5, wherein said cartridge body comprises at least one snap-fit feature configured to directly engage said surgical stapler.

Example 7: the staple cartridge assembly of embodiments 3,4, or 5, wherein the sled directly engages the staples, and wherein the staple cartridge assembly does not include a driver positioned intermediate the sled and the staples.

Example 8: the staple cartridge assembly of embodiments 1, 2,3, 4, 5, 6, or 7, wherein each staple is stamped from a sheet of material, wherein the proximal leg, the distal leg, and the base of each staple are formed in a staple plane, and wherein the retention tabs extend laterally from the staple plane.

Example 9: a staple cartridge assembly for use with a surgical stapler, wherein said staple cartridge assembly comprises a cartridge body comprising a proximal end, a distal end, a deck, a bottom portion, a longitudinal slot defined in said deck and extending from said proximal end toward said distal end, a longitudinal channel defined in said bottom portion, and staple cavities, wherein each staple cavity comprises a top opening defined in said deck and a bottom opening defined in said bottom portion. The staple cartridge assembly further comprises staples removably stored in the staple cavities; a sled slidably positioned in the longitudinal channel, wherein the sled is movable from the proximal end toward the distal end to eject the staples through the top openings of the staple cavities; and a retaining portion configured to prevent the slider from falling out of the longitudinal channel through the bottom portion.

Example 10: the staple cartridge assembly of embodiment 9, wherein said sled is movable between a proximal position and a distal position during a firing stroke, wherein said retention portion is engaged with said sled when said sled is in said proximal position, and wherein said retention portion is not engaged with said sled when said sled is in said distal position.

Example 11: the staple cartridge assembly of embodiments 9 or 10, wherein said staple cartridge assembly does not comprise a cover extending around said bottom portion of said cartridge body.

Example 12: the staple cartridge assembly of embodiments 9,10, or 11, wherein the sled directly engages the staples, and wherein the staple cartridge assembly does not include a driver positioned intermediate the sled and the staples.

Example 13: a staple cartridge assembly for use with a surgical stapler, wherein the surgical stapler comprises jaws configured to receive the staple cartridge assembly, and wherein the staple cartridge assembly comprises a cartridge body comprising a proximal end; a distal end; a deck; a bottom portion, wherein the staple cartridge assembly does not include an enclosure extending around the bottom portion; a longitudinal slot defined in the deck and extending from the proximal end toward the distal end; a longitudinal channel defined in the bottom portion; and a nail cavity, wherein each of the nail cavities includes a top opening defined in the deck and a bottom opening defined in the bottom portion. The staple cartridge assembly further comprises staples removably stored in the staple cavities; a sled slidably positioned in the longitudinal channel, wherein the sled is movable from the proximal end toward the distal end to eject the staples through the top openings of the staple cavities during a firing stroke; and means for preventing the slide from falling out of the longitudinal channel through the bottom portion.

Example 14: the staple cartridge assembly of embodiment 13, wherein said sled directly engages said staples during said firing stroke.

Example 15: the staple cartridge assembly of embodiments 13 or 14, further comprising means for preventing said staples from falling out of said staple cavities through said bottom openings.

Example 16: a staple cartridge assembly for use with a surgical stapler, wherein the surgical stapler comprises jaws configured to receive the staple cartridge assembly, and wherein the staple cartridge assembly comprises a cartridge body comprising a proximal end; a distal end; a deck; a bottom portion, wherein the staple cartridge assembly does not include an enclosure extending around the bottom portion; and a nail cavity, wherein each of the nail cavities includes a top opening defined in the deck and a bottom opening defined in the bottom portion. The staple cartridge assembly further comprises staples removably stored in the staple cavities, wherein the cartridge body comprises a shelf integrally formed with the cartridge body that prevents the staples from falling out of the staple cavities through the bottom openings.

Example 17: a staple cartridge assembly for use with a surgical stapler, wherein said staple cartridge assembly comprises a cartridge body comprising a proximal end, a distal end, a deck, a longitudinal slot defined in said deck and extending from said proximal end toward said distal end, and staple cavities. The staple cavity includes a top opening, a bottom opening, a proximal guide, a distal guide, a sidewall extending between the proximal guide and the distal guide, and a middle guide extending inwardly from the sidewall defined in the deck. The staple cartridge assembly further includes staples removably stored in the staple cavities, the staples including a proximal leg positioned within the proximal guide, a distal leg positioned within the distal guide, and a base extending between the proximal and distal legs, wherein the intermediate guide is positioned to guide the base and retain the proximal leg in the proximal guide and the distal leg in the distal guide.

Example 18: the staple cartridge assembly of embodiment 17, wherein said staple cavities further comprise a proximal cavity end proximal to said proximal guide and a distal cavity end distal to said distal guide.

Example 19: the staple cartridge assembly of embodiment 18, wherein said staples are not positioned in said proximal cavity end and said distal cavity end.

Example 20: the staple cartridge assembly of embodiments 18 or 19, wherein a first clearance gap exists between said staple base, said middle guide, and said distal cavity end, and wherein a second clearance gap exists between said staple base, said middle guide, and said proximal cavity end.

Example 21: the staple cartridge assembly of embodiments 17, 18, 19, or 20, wherein the base comprises a flat guide surface that interfaces with the middle guide.

Example 22: the staple cartridge assembly of embodiments 17, 18, 19, 20, or 21, wherein said cartridge body further comprises a plurality of said staple cavities, and wherein said staple cartridge assembly further comprises a plurality of said staples positioned in said staple cavities.

Example 23: the staple cartridge assembly of embodiments 17, 18, 19, 20, 21, or 22, wherein said proximal guide, said distal guide, and said middle guide triangulate control of said staples as said staples are ejected from said staple cavities.

Example 24: the staple cartridge assembly of embodiments 17, 18, 19, 20, 21, 22, or 23, wherein said proximal guide and said distal guide extend above said deck.

Example 25: the staple cartridge assembly of embodiments 17, 18, 19, 20, 21, 22, 23, or 24, wherein the intermediate guide extends above the deck.

Example 26: the staple cartridge assembly of embodiments 17, 18, 19, 20, 21, 22, 23, 24, or 25, wherein said proximal and distal legs of said staples define a leg plane, wherein said base comprises a drive surface in a drive plane, and wherein said drive plane is offset from said leg plane.

Example 27: the staple cartridge assembly of embodiments 17, 18, 19, 20, 21, 22, 23, 24, 25, or 26, wherein said proximal and distal legs are clamped toward each other by said proximal and distal guides.

Example 28: the staple cartridge assembly of embodiments 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, or 27, wherein the intermediate guide comprises a resilient biasing member engaged with the base, the resilient biasing member configured to urge the proximal leg into the proximal guide and the distal leg into the distal guide.

Example 29: the staple cartridge assembly of embodiments 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, or 28, wherein the middle guide is positioned closer to the distal guide than the proximal guide.

Example 30: the staple cartridge assembly of embodiments 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, or 28, wherein the middle guide is positioned at an equal distance between the distal guide and the proximal guide.

Example 31: a staple cartridge assembly for use with a surgical stapler, wherein said staple cartridge assembly comprises a cartridge body comprising a proximal end, a distal end, a deck, a longitudinal slot defined in said deck and extending from said proximal end toward said distal end, and staple cavities. The staple cavity includes a top opening, a bottom opening, a proximal guide, a distal guide, and a sidewall extending between the proximal guide and the distal guide defined in the deck. The staple cartridge assembly further comprises staples removably stored in the staple cavities, the staples comprising proximal legs positioned within the proximal guide; a distal leg positioned within the distal guide, wherein the proximal leg and the distal leg define a leg plane, and wherein the proximal leg and the distal leg are clamped toward each other by the proximal guide and the distal guide; and a base extending between the proximal leg and the distal leg, wherein the base comprises a drive surface in a drive plane, and wherein the drive plane is offset from the leg plane.

Example 32: the staple cartridge assembly of embodiment 31, wherein said leg plane is parallel to said drive plane.

Example 33: the staple cartridge assembly of embodiments 31 or 32, wherein said cartridge body further comprises a plurality of said staple cavities, and wherein said staple cartridge assembly further comprises a plurality of said staples positioned in said staple cavities.

Example 34: a staple cartridge assembly for use with a surgical stapler, wherein said staple cartridge assembly comprises a cartridge body comprising a proximal end, a distal end, a deck, a longitudinal slot defined in said deck and extending from said proximal end toward said distal end, and staple cavities. The staple cavity includes a top opening, a bottom opening, a proximal guide, a distal guide, a sidewall extending between the proximal and distal guides, and an intermediate guide extending inwardly from the staple cavity sidewall defined in the deck. The staple cartridge assembly further comprises staples removably stored in the staple cavities, the staples comprising a proximal leg positioned within the proximal guide, a distal leg positioned within the distal guide, and a base extending between the proximal leg and the distal leg, wherein the proximal guide, the distal guide, and the middle guide triangulate control of the staples as the staples are ejected from the staple cavities.

Example 35: the staple cartridge assembly of embodiment 34, wherein said cartridge body further comprises a plurality of said staple cavities, and wherein said staple cartridge assembly further comprises a plurality of said staples positioned in said staple cavities.

Example 36: a staple cartridge assembly for use with a surgical stapler, wherein said staple cartridge assembly comprises a cartridge body comprising a proximal cartridge end, a distal cartridge end, a deck, a longitudinal knife slot defined in said deck and extending from said proximal cartridge end toward said distal cartridge end, and staple cavities. The nail cavity includes a top opening defined in the deck; a proximal lumen end; a distal lumen end; a proximal guide; a distal guide, wherein the proximal guide and the distal guide extend above the deck; and a lumen slot extending between the proximal and distal lumen ends, wherein the proximal and distal guides extend laterally relative to the lumen slot. The staple cartridge assembly further comprises staples removably stored in the staple cavities, the staples comprising a proximal leg positioned within the proximal guide, a distal leg positioned within the distal guide, and a base extending between the proximal leg and the distal leg, wherein the base is positioned in the cavity slot.

Example 37: the staple cartridge assembly of embodiment 36, wherein said proximal guide and said distal guide extend toward said knife slot.

Example 38: the staple cartridge assembly of embodiment 36, wherein said proximal guide and said distal guide extend away from said knife slot.

Example 39: the staple cartridge assembly of embodiments 36, 37, or 38, wherein said proximal guide comprises a proximal carriage.

Example 40: the staple cartridge assembly of embodiment 39, wherein said proximal bracket does not extend around said proximal cavity end.

Example 41: the staple cartridge assembly of embodiments 39 or 40, wherein said cavity slot is defined by a longitudinal axis, and wherein said proximal bracket is not aligned with said longitudinal axis.

Example 42: the staple cartridge assembly of embodiments 36, 37, 38, 39, 40, or 41, wherein said distal guide comprises a distal carriage.

Example 43: the staple cartridge assembly of embodiment 42, wherein said distal carriage does not extend around said distal cavity end.

Example 44: the staple cartridge assembly of embodiments 42 or 43, wherein said cavity slot is defined by a longitudinal axis, and wherein said distal carriage is not aligned with said longitudinal axis.

Example 45: the staple cartridge assembly of examples 36, 37, 38, 39, 40, 41, 42, 43, or 44, wherein the proximal leg and the distal leg define a staple leg plane, wherein the base comprises a drive surface in a drive plane offset from the staple leg plane, wherein the proximal guide and the distal guide are aligned with the staple plane, and wherein the proximal guide and the distal guide are not aligned with the drive plane.

Example 46: the staple cartridge assembly of examples 36, 37, 38, 39, 40, 41, 42, 43, or 44, wherein the proximal leg and the distal leg define a staple leg plane, wherein the base comprises a drive surface in a drive plane offset from the staple leg plane, and wherein the proximal guide and the distal guide define a carriage plane aligned with the staple leg plane.

Example 47: the staple cartridge assembly of embodiments 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, or 46, wherein said cartridge body further comprises a plurality of said staple cavities, and wherein said staple cartridge assembly further comprises a plurality of said staples positioned in said staple cavities.

Example 48: the staple cartridge assembly of embodiments 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, or 47, wherein the portion of the proximal guide that extends above the deck comprises a staple cavity extension, and wherein the portion of the distal guide that extends above the deck comprises a staple cavity extension

Example 49: a staple cartridge assembly for use with a surgical stapler, wherein said staple cartridge assembly comprises a cartridge body comprising a proximal cartridge end, a distal cartridge end, a deck, and staple cavities. The staple cavity includes a proximal cavity end, a distal cavity end, proximal guides extending above and below the deck, distal guides extending above and below the deck, and a connecting slot extending between the proximal and distal cavity ends, wherein the proximal and distal guides extend laterally relative to the connecting slot. The staple cartridge assembly further comprises staples removably stored in the staple cavities, the staples comprising a proximal leg positioned within the proximal guide, a distal leg positioned within the distal guide, and a base extending between the proximal leg and the distal leg, wherein the base is positioned in the cavity slot.

Example 50: the staple cartridge assembly of embodiment 49, wherein said cartridge body further comprises a plurality of said staple cavities, and wherein said staple cartridge assembly further comprises a plurality of said staples positioned in said staple cavities.

Example 51: the staple cartridge assembly of embodiments 49 or 50, wherein the portion of the proximal guide that extends above the deck comprises a staple cavity extension, and wherein the portion of the distal guide that extends above the deck comprises a staple cavity extension

Example 52: a fastener cartridge assembly for use with a surgical fastening instrument, wherein the fastener cartridge assembly comprises a cartridge body comprising a proximal cartridge end, a distal cartridge end, a deck, and fastener pockets. The fastener pocket includes a proximal pocket end; a distal pocket end; a proximal guide; a distal guide; a proximal dimple extension, wherein the proximal dimple extension extends above the deck; a distal pocket extension, wherein the proximal pocket extension extends above the deck; and a pocket opening extending between the proximal pocket end and the distal pocket end, wherein the proximal guide and the distal guide extend laterally relative to the pocket opening. The fastener cartridge assembly further comprises a fastener removably stored in the fastener pocket, the fastener comprising a proximal leg positioned within the proximal guide, a distal leg positioned within the distal guide, and a base extending between the proximal leg and the distal leg, wherein the base is positioned in the pocket opening.

Example 53: the fastener cartridge assembly of embodiment 52, wherein said cartridge body further comprises a plurality of said fastener pockets, and wherein said fastener cartridge assembly further comprises a plurality of said fasteners positioned in said fastener pockets.

Example 54: a staple cartridge assembly for use with a surgical instrument includes a cartridge body including a proximal end, a distal end, a deck, and staple cavities defined in the deck. The staple cartridge assembly further comprises staples removably positioned in the staple cavities and a firing member having channels aligned with the staples, wherein the channels comprise first and second lateral sidewalls, and wherein the channels are configured to receive the staples between the first and second lateral sidewalls.

Example 55: the staple cartridge assembly of embodiment 54, wherein said channel is defined on an inclined surface of said firing member.

Example 56: the staple cartridge assembly of embodiments 54 or 55, wherein the channel comprises a ramp portion configured to lift the staples within the staple cavities during a firing stroke of the firing member and an apex portion configured to form the staples against an anvil of the surgical instrument to a final formed height.

Example 57: the staple cartridge assembly of embodiment 56, wherein said channel comprises a trailing portion positioned proximally relative to said apex portion, and wherein said apex portion is positioned above said trailing portion.

Example 58: the staple cartridge assembly of embodiments 54, 55, 56, or 57, wherein the firing member comprises a sled comprising a plurality of wedges, and wherein the channel is defined on one of the wedges.

Example 59: the staple cartridge assembly of embodiments 54, 55, 56, 57, or 58, wherein the firing member further comprises a ramp configured to initially lift the staples within the staple cavities and guide the staples into the channel.

Example 60: the staple cartridge assembly of embodiments 54, 55, 56, 57, 58, or 59, wherein the channel comprises a mouth portion and a longitudinal portion, wherein the mouth portion provides a lead-in to the longitudinal portion, and wherein the mouth portion is wider than the longitudinal portion.

Example 61: the staple cartridge assembly of embodiments 54, 55, 56, 57, 58, 59, or 60, wherein the staples are received within the channel without staple drivers positioned between the staples and the channel.

Example 62: the staple cartridge assembly of embodiments 54, 55, 56, 57, 58, 59, 60, or 61, wherein said first lateral sidewall is parallel to said second lateral sidewall.

Example 63: the staple cartridge assembly of embodiments 54, 55, 56, 57, 58, 59, 60, or 61, wherein said first lateral sidewall is not parallel to said second lateral sidewall.

Example 64: the staple cartridge assembly of embodiments 54, 55, 56, 57, 58, 59, 60, or 61, wherein the first and second lateral sidewalls are angled relative to each other to form a staple entry lead-in.

Example 65: the staple cartridge assembly of embodiments 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, or 64, wherein the channel comprises a first channel, and wherein the firing member further comprises a second channel configured to receive the staples.

Example 66: the staple cartridge assembly of embodiment 65, wherein each staple comprises a drive portion configured to enter the first channel and a forming portion configured to enter the second channel.

Example 67: the staple cartridge assembly of embodiments 65 or 66, wherein said first channel extends at an angle relative to said second channel.

Example 68: the staple cartridge assembly of embodiments 65, 66, or 67, wherein the first channel and the second channel are parallel to each other in a first region and non-parallel to each other in a second region.

Example 69: the staple cartridge assembly of embodiments 65, 66, 67, or 68, wherein said second channel is configured to receive said staples before said first channel as said firing member is advanced toward said distal end.

Example 70: a staple cartridge assembly for use with a surgical instrument, said staple cartridge assembly comprising: a cartridge body comprising a deck and staple cavities defined therein; a staple removably positioned in the staple cavity; and a firing member comprising a ramp configured to directly engage the staples and a rail extending from the ramp and configured to orient the staples relative to the ramp.

Example 71: the staple cartridge assembly of embodiment 70, wherein said rail comprises a first rail, and wherein said firing member further comprises a second rail extending from said sled and configured to orient said staples relative to said sled.

Example 72: the staple cartridge assembly of embodiment 71, wherein said first rail is parallel to said second rail.

Example 73: a staple cartridge assembly for use with a surgical stapling instrument comprising an anvil, wherein the anvil comprises a forming pocket, and wherein the staple cartridge assembly comprises a cartridge body comprising a proximal end, a distal end, a deck, and staple cavities defined in the deck. The staple cartridge assembly comprises: staples removably positioned in the staple cavities, wherein each staple comprises a staple driving portion and a staple forming portion; and a firing member comprising first guide channels aligned with the staple driving portions of the staples and second guide channels aligned with the staple forming portions of the staples, wherein the first guide channels and the second guide channels are configured to cooperatively align the staples with the staple forming pockets of the anvil as the firing member is moved toward the distal end.

Example 74: a nail bin assembly comprises a bin body, wherein the bin body comprises a deck, a first longitudinal nail row cavity and a second longitudinal nail row cavity. The staple cartridge assembly further comprises a plurality of first staples, wherein each first staple is removably stored in the first longitudinal row of staple cavities, and wherein each first staple has a unitary structure comprising a first base having a first drive surface and a first staple leg extending from the first base and having a first tip, wherein a first unformed distance is defined between the first drive surface and the first tip; a plurality of second staples, wherein each second staple is removably stored in the second longitudinal row of staple cavities, and wherein each second staple has a unitary structure comprising a second base having a second drive surface and a second staple leg extending from the second base and having a second tip, wherein a second unformed distance is defined between the second drive surface and the second tip, the second unformed distance being different than the first unformed distance; and a firing member configured to directly engage the first and second staples.

Example 75: the staple cartridge assembly of embodiment 74, wherein said first staple and said second staple are formed from sheet metal.

Example 76: the staple cartridge assembly of embodiments 74 or 75, wherein each first base comprises a first tissue supporting surface, wherein a first tissue capturing distance is defined between the first tissue supporting surface and the first tip, wherein each second base comprises a second tissue supporting surface, wherein a second tissue capturing distance is defined between the second tissue supporting surface and the second tip, and wherein the first tissue capturing distance is different than the second tissue capturing distance.

Example 77: the staple cartridge assembly of embodiments 74, 75, or 76, wherein the deck has a first deck height along the first longitudinal row of staple cavities and a second deck height along the second longitudinal row of staple cavities that is different than the first deck height.

Example 78: the staple cartridge assembly of embodiment 77, wherein said cartridge body further comprises a longitudinal slot configured to receive a cutting member, wherein said first longitudinal row of staple cavities is adjacent to said longitudinal slot, wherein said second longitudinal row of staple cavities is adjacent to said first longitudinal row of staple cavities, and wherein said second deck height is shorter than said first deck height.

Example 79: the staple cartridge assembly of embodiments 74, 75, 76, 77, or 78, wherein the cartridge body further comprises a longitudinal slot configured to receive a cutting member, wherein the first longitudinal row of staple cavities is adjacent to the longitudinal slot, and wherein the second longitudinal row of staple cavities is adjacent to the first longitudinal row of staple cavities.

Example 80: the staple cartridge assembly of embodiments 74, 75, 76, 77, 78, or 79, wherein the first unformed distance is shorter than the second unformed distance.

Example 81: the staple cartridge assembly of embodiments 74, 75, 76, 77, 78, 79, or 80, further comprising an anvil configured to deform the staples.

Example 82: the staple cartridge assembly of embodiment 81, wherein the anvil is configured to deform the first staples to a first deformed height and the second staples to a second deformed height, the second deformed height being different than the first deformed height.

Example 83: the staple cartridge assembly of embodiments 81 or 82, wherein the cartridge body is movable toward the anvil to clamp tissue between the anvil and the deck of the cartridge body.

Example 84: the staple cartridge assembly of embodiments 81, 82, or 83, wherein the anvil is movable toward the cartridge body to clamp tissue between the anvil and the deck of the cartridge body.

Example 85: the staple cartridge assembly of embodiments 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, or 84, further comprising staple cavity extensions extending from the deck.

Example 86: the staple cartridge assembly of embodiments 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, or 85, further comprising an implantable layer positioned over the deck.

Example 87: a nail bin assembly comprises a bin body, wherein the bin body comprises a deck, a first longitudinal nail row cavity and a second longitudinal nail row cavity. The staple cartridge assembly further comprises a plurality of first staples, wherein each first staple is removably stored in the first longitudinal row of staple cavities, and wherein each first staple has a unitary structure comprising a first base having a first drive surface and a first tissue support surface, and a first staple leg extending from the first base and having a first pointed end, wherein a first tissue capture distance is defined between the first tissue support surface and the first pointed end; a plurality of second staples, wherein each second staple is removably stored in the second longitudinal row of staple cavities, and wherein each second staple has a unitary structure comprising a second base having a second drive surface and a second tissue-supporting surface, and a second staple leg extending from the second base and having a second pointed end, wherein a second tissue-capturing distance is defined between the second tissue-supporting surface and the second pointed end, the second tissue-capturing distance being different than the first tissue-capturing distance; and a firing member configured to directly engage the first and second staples.

Example 88: the staple cartridge assembly of embodiment 87, wherein said deck has a first deck height along said first longitudinal row of staple cavities and a second deck height along said second longitudinal row of staple cavities, said second deck height being different than said first deck height.

Example 89: the staple cartridge assembly of embodiment 88, wherein the cartridge body further comprises a longitudinal slot configured to receive a cutting member, wherein the first longitudinal row of staple cavities is adjacent to the longitudinal slot, wherein the second longitudinal row of staple cavities is adjacent to the first longitudinal row of staple cavities, and wherein the second deck height is shorter than the first deck height.

Example 90: the staple cartridge assembly of embodiments 87, 88, or 89, further comprising an anvil configured to deform said staples.

Example 91: the staple cartridge assembly of embodiment 90, wherein the anvil is configured to deform the first staples to a first deformed height and the second staples to a second deformed height, the second deformed height being different than the first deformed height.

Example 92: the staple cartridge assembly of embodiment 90 or 91, wherein said cartridge body is movable toward the anvil to clamp tissue between the anvil and the deck of the cartridge body.

Example 93: a staple cartridge assembly, comprising: the nail magazine comprises a magazine body, a first clamping device and a second clamping device, wherein the magazine body comprises a first longitudinal nail row cavity and a second longitudinal nail row cavity; a plurality of first staples removably stored in said first longitudinal row of staple cavities, wherein each first staple is comprised of stamped metal and comprises an integrally formed metal driver; a plurality of second staples removably stored in said second longitudinal row of staple cavities, wherein each second staple is comprised of stamped metal and comprises an integrally formed metal driver; and means for forming the first staple to a first deformed height and the second staple to a second deformed height, wherein the first deformed height is different from the second deformed height.

Example 94: a staple cartridge assembly, comprising: a staple cartridge body comprising a deck and staple cavities defined in the deck; staples removably stored in the staple cavities, wherein each staple comprises a base, a leg extending from the base, and a platform extending laterally from the base; and an implantable layer positioned above the deck, wherein the deck of the staple is configured to abut the layer when the staple is implanted into tissue of a patient.

Example 95: the staple cartridge assembly of embodiment 94, wherein each staple is stamped from a sheet of material, wherein said base defines a base plane, and wherein said deck is folded out of said base plane.

Example 96: the staple cartridge assembly of embodiments 94 or 95, wherein the implantable layer comprises a woven material.

Example 97: the staple cartridge assembly of embodiments 94, 95, or 96, wherein the implantable layer comprises a nonwoven material.

Example 98: the staple cartridge assembly of embodiments 94, 95, 96, or 97 further comprising a retaining member extending from said leg adjacent to said base, wherein said retaining member is configured to engage said implantable layer when staples are implanted into said tissue of a patient.

Example 99: the staple cartridge assembly of embodiments 94, 95, 96, 97, or 98, wherein said deck is flat.

Example 100: the staple cartridge assembly of embodiments 94, 95, 96, 97, 98, or 99, wherein the deck is not directly attached to the legs.

Example 101: a staple cartridge assembly, comprising: a staple cartridge body comprising a deck and staple cavities defined in the deck; staples removably stored in said staple cavities, wherein each staple comprises a crown, first and second legs extending from said crown, and a deck extending laterally from said crown; and an implantable layer positioned above the deck, wherein the deck of the staples is configured to support the layer when the staples are implanted into tissue of a patient.

Example 102: the staple cartridge assembly of embodiment 101, wherein each staple is stamped from a sheet of material, wherein the crowns define a crown plane, and wherein the deck is folded out of the crown plane.

Example 103: the staple cartridge assembly of embodiments 101 or 102, wherein the implantable layer comprises a woven material.

Example 104: the staple cartridge assembly of embodiments 101, 102, or 103, wherein the implantable layer comprises a nonwoven material.

Example 105: the staple cartridge assembly of embodiments 101, 102, 103, or 104, further comprising a retention member extending from said leg and adjacent to said crown, wherein said retention member is configured to engage said implantable layer when staples are implanted into said tissue of a patient.

Example 106: the staple cartridge assembly of embodiments 101, 102, 103, 104, or 105, wherein the deck is planar.

Example 107: the staple cartridge assembly of embodiments 101, 102, 103, 104, 105, or 106, wherein each staple comprises a compliant adjunct positioned adjacent to the crown.

Example 108: the staple cartridge assembly of embodiment 107, wherein said compliant adjunct extends between said first leg and said second leg.

Example 109: the staple cartridge assembly of embodiments 107 or 108, wherein the compliant adjunct is attached to the first leg and the second leg.

Example 110: the staple cartridge assembly of embodiments 107, 108, or 109, wherein the compliant adjunct comprises a first aperture and a second aperture, wherein the first leg extends through the first aperture, and wherein the second leg extends through the second aperture.

Example 111: the staple cartridge assembly of embodiments 107, 108, 109, or 110, wherein the compliant adjunct comprises a cavity and at least one medicament positioned in the cavity.

Example 112: the staple cartridge assembly of embodiments 107, 108, 109, 110, or 111, wherein the compliant adjunct comprises a compressible enclosure.

Example 113: a staple cartridge assembly, comprising: a staple cartridge body comprising a deck and staple cavities defined in the deck; and staples removably stored in the staple cavities, wherein each staple comprises a crown, first and second legs extending from the crown, a platform extending laterally from the crown, and a compliant adjunct positioned adjacent to the crown.

Example 114: the staple cartridge assembly of embodiment 113, wherein said compliant adjunct extends between said first leg and said second leg.

Example 115: the staple cartridge assembly of embodiments 113 or 114, wherein said compliant adjunct is attached to said first leg and said second leg.

Example 116: the staple cartridge assembly of embodiments 113, 114, or 115, wherein said compliant adjunct comprises a first aperture and a second aperture, wherein said first leg extends through said first aperture, and wherein said second leg extends through said second aperture.

Example 117: the staple cartridge assembly of embodiments 113, 114, 115, or 116, wherein said compliant adjunct comprises a cavity and at least one medicament positioned in said cavity.

Example 118: the staple cartridge assembly of embodiments 113, 114, 115, 116, or 117, wherein said compliant adjunct comprises a compressible enclosure.

Example 119: a staple cartridge assembly, comprising: a cartridge body comprising a deck and a plurality of staple cavities defined in the deck; and a plurality of staples stored in the staple cavities, wherein each staple comprises a first portion comprised of an alloy comprising zinc and magnesium and a second portion comprised of a resorbable polymer, wherein the second portion is disposed on the first portion, and wherein the second portion covers less than all of the first portion.

Example 120: the staple cartridge assembly of embodiment 119, wherein said first portion comprises a base and staple legs extending from said base, and wherein said second portion extends in a helical pattern around said staple legs.

Example 121: the staple cartridge assembly of embodiments 119 or 120, wherein the second portion is coated on the first portion in a dot matrix pattern.

Example 122: the staple cartridge assembly of embodiments 119, 120, or 121, wherein the first portion comprises a base and staple legs extending from the base, wherein a corner is defined between the base and the staple legs, and wherein the second portion covers the corner.

Example 123: the staple cartridge assembly of embodiments 119, 120, 121, or 122, wherein the absorbable polymer comprises a non-crosslinked polymer.

Example 124: the staple cartridge assembly of embodiments 119, 120, 121, 122, or 123, wherein the second portion is coated on the first portion in a mesh pattern.

Example 125: the staple cartridge assembly of embodiments 119, 120, 121, 122, 123, or 124, wherein said first portion comprises a base and staple legs extending from said base, wherein said staple legs comprise tissue penetrating tips, and wherein said staples further comprise magnesium nitride disposed on said tips.

Example 126: the staple cartridge assembly of embodiments 119, 120, 121, 122, 123, 124, or 125, wherein the staples further comprise a coating of ionized silver on at least a portion of the first portion not coated by the second portion.

Example 127: the staple cartridge assembly of embodiments 119, 120, 121, 122, 123, 124, 125, or 126, further comprising at least one aperture in the first portion.

Example 128: a staple cartridge assembly, comprising: a cartridge body comprising a deck and a plurality of staple cavities defined in the deck; and a plurality of staples stored in the staple cavities, wherein each staple comprises a metal frame comprised of a magnesium alloy and an absorbable polymer coated on the metal frame, wherein the absorbable polymer does not cover every portion of the metal frame.

Example 129: a staple cartridge assembly, comprising: a cartridge body comprising a deck and a plurality of staple cavities defined in the deck; and a plurality of staples stored in the staple cavities, wherein each staple comprises a metal frame comprised of a magnesium alloy, wherein the metal frame comprises a base and a leg extending from the base, and wherein the leg comprises a tissue penetrating tip and a magnesium nitride coating on the tip.

Example 130: the staple cartridge assembly of embodiment 129, wherein each staple further comprises an absorbable polymer coated on the metal frame, and wherein the absorbable polymer does not cover every portion of the metal frame.

Example 131: the staple cartridge assembly of embodiments 129 or 130, wherein each staple further comprises a coating comprising silver on at least a portion of the metal frame.

Example 132: a staple cartridge assembly, comprising: a cartridge body comprising a deck and a plurality of staple cavities defined in the deck; and a plurality of staples stored in the staple cavities, wherein each staple comprises a metal frame comprised of a magnesium alloy and a coating comprising silver on at least a portion of the metal frame, wherein the metal frame comprises a base and a leg extending from the base, and wherein the leg comprises a tissue penetrating tip.

Example 133: the staple cartridge assembly of embodiment 132, wherein each staple further comprises an absorbable polymer coated on the metal frame, and wherein the absorbable polymer does not cover every portion of the metal frame.

Example 134: the staple cartridge assembly of embodiment 132 or 133, further comprising a magnesium nitride coating on the tip.

Example 135: a staple cartridge assembly, comprising: a cartridge body comprising a deck and a plurality of staple cavities defined in the deck; and a plurality of staples stored in the staple cavities, wherein each staple comprises a metal frame comprised of a magnesium alloy and an aperture defined in the metal frame, wherein the metal frame comprises a base and a leg extending from the base, and wherein the leg comprises a tissue penetrating tip.

Example 136: the staple cartridge assembly of embodiment 135, wherein each staple further comprises an absorbable polymer coated on the metal frame, and wherein the absorbable polymer does not cover every portion of the metal frame.

Example 137: the staple cartridge assembly of embodiment 135, wherein each staple further comprises an absorbable polymer coated on the metal frame, and wherein the absorbable polymer is not positioned in the aperture.

Example 138: the staple cartridge assembly of embodiment 135, wherein each staple further comprises an absorbable polymer coated on the metal frame, and wherein the absorbable polymer is positioned in the aperture.

Example 139: the staple cartridge assembly of embodiment 135, wherein each staple further comprises an absorbable polymer coated on said metal frame, and wherein said apertures are filled with said absorbable polymer.

Example 140: a staple cartridge assembly for stapling tissue, said staple cartridge assembly comprising: a cartridge body comprising a proximal end, a distal end, and a plurality of staple cavities; a plurality of staples positioned in the staple cavities, wherein each staple comprises a base, a leg extending from the base, and a foot extending from the base, wherein the leg comprises a tip configured to penetrate the tissue; and a firing member configured to eject the staples from the staple cavities, wherein the firing member is configured to contact the foot portions of any misoriented staples within its staple cavities prior to ejecting them from their staple cavities.

Example 141: the staple cartridge assembly of embodiment 140, wherein said firing member comprises a firing ramp and an alignment ramp, said firing ramp configured to contact said bases of said staples to drive said staples out of said staple cavities, and said alignment ramp configured to contact said feet of said staples in the event said staples are misoriented.

Example 142: the staple cartridge assembly of embodiment 140 or 141, wherein said firing member further comprises a firing channel aligned with said firing ramp, wherein said firing channel is configured to receive said bases of said staples; and an alignment channel aligned with the alignment ramp, wherein the alignment channel is configured to receive the foot of the staple once the staple is properly oriented.

Example 143: the staple cartridge assembly of embodiments 141 or 142, wherein the alignment sled extends distally relative to the firing sled such that the alignment sled is configured to contact the feet of the staples before the firing sled contacts the bases of the staples.

Example 144: the staple cartridge assembly of embodiments 140, 141, 142, or 143, wherein said feet of said staples are positioned proximally relative to said bases of said staples.

Example 145: the staple cartridge assembly of examples 140, 141, 142, 143, or 144, wherein said firing member is configured to not contact said feet of said staples if said staples are properly oriented within said staple cavities.

Example 146: a staple cartridge assembly for stapling tissue, said staple cartridge assembly comprising: a cartridge body comprising a proximal end and a distal end; and a plurality of staple cavities, wherein each staple cavity comprises a top opening, a proximal wall, and a distal wall. The staple cartridge assembly further comprises a firing member and a plurality of staples positioned in the staple cavities, wherein each staple comprises a base, a proximal leg extending from the base, a distal leg extending from the base, and a centroid defined in the base, wherein the distal wall provides a distal reaction force to the staple above the centroid and the proximal wall provides a proximal reaction force to the staple below the centroid, wherein the staples are lifted by the firing member toward the top opening. The staple cartridge assembly further comprises a firing member configured to eject the staples from the staple cavities, wherein the firing member is configured to contact the feet of any misoriented staples within its staple cavities prior to ejecting them from their staple cavities.

Example 147: the staple cartridge assembly of embodiment 146, wherein said base defines a drive plane, and wherein said proximal leg and said distal leg are not in said drive plane.

Example 148: the staple cartridge assembly of embodiment 146 or 147, wherein said proximal leg and said distal leg are laterally offset from the centroid of the staple.

Example 149: the staple cartridge assembly of embodiments 146, 147, or 148, wherein the distal wall applies the distal reaction force to the distal leg and the proximal wall applies the proximal reaction force to the proximal leg.

Example 150: the staple cartridge assembly of embodiment 147, wherein said proximal leg extends to a first side of said drive plane and said distal leg extends to a second side of said drive plane.

Example 151: the staple cartridge assembly of embodiments 146, 147, 148, 149, or 150, wherein the base comprises a notch defined therein configured to shift the center of mass of the staple toward a side of the staple cavity.

Example 152: a staple cartridge assembly for stapling tissue, said staple cartridge assembly comprising a cartridge body comprising a proximal end, a distal end, and a plurality of staple cavities. The staple cartridge assembly further comprises a plurality of staples positioned in the staple cavities, wherein each staple comprises a base defining a drive plane and a leg extending from the base, wherein the leg extends to one side of the drive plane; a firing member configured to eject said staples from said staple cavities; and means for reducing rotation of the staples within the staple cavities as the firing member drives the staples out of the staple cavities.

Example 153: a surgical staple cartridge for use with a surgical stapling instrument, the surgical staple cartridge comprising a cartridge body, a plurality of staple cavities, and a plurality of staples removably stored in the staple cavities, wherein each staple comprises a staple base portion defining a first plane, a center of mass located within the staple base portion, a first staple leg extending from the staple base portion, and a second staple leg extending from the staple base portion, wherein the first staple leg and the second staple leg define a second plane that is offset from and at least substantially parallel to the first plane.

Example 154: the surgical staple cartridge of embodiment 153, wherein said first staple leg and said second staple leg are configured to be formed toward said staple base portion.

Example 155: the surgical staple cartridge of embodiments 153 or 154, wherein said staple base portion comprises a compression surface comprising a profile configured to limit tissue compression.

Example 156: the surgical staple cartridge of embodiments 153, 154, or 155, wherein said staple base portion comprises a bottom surface, and wherein said first staple leg further comprises an engagement foot that is raised above said bottom surface.

Example 157: the surgical staple cartridge of embodiments 153, 154, 155, or 156, wherein the staple base portion comprises an inner wall and a top surface, wherein the inner wall and the top surface comprise a cutout configured to bias the staple base portion toward the staple legs.

Example 158: the surgical staple cartridge of embodiments 153, 154, 155, 156, or 157 wherein said first staple leg extends higher than said second staple leg.

Example 159: the surgical staple cartridge of embodiments 153, 154, 155, 156, 157, or 158 wherein the staple base portion has a rectangular cross-sectional profile.

Example 160: the surgical staple cartridge of embodiments 153, 154, 155, 156, 157, 158, or 159, wherein the first staple leg and the second staple leg have a substantially circular cross-sectional profile.

Example 161: the surgical staple cartridge of embodiments 153, 154, 155, 156, 157, 158, 159, or 160, wherein said first staple leg and said second staple leg comprise coined corners.

Example 162: the surgical staple cartridge of embodiments 153, 154, 155, 156, 157, 158, 159, 160, or 161, wherein said first staple leg is proximal to said second staple leg, wherein said staple base portion comprises a distal wall, and wherein said distal wall is proximal to said second staple leg.

Example 163: the surgical staple cartridge of embodiments 153, 154, 155, 156, 157, 158, 159, 160, 161, or 162, wherein said first staple leg has a first height and said second staple leg has a second height different from said first height.

Example 164: the surgical staple cartridge of embodiments 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, or 163, wherein the first staple leg and the second staple leg each comprise a staple tip configured to form against a corresponding forming pocket of an anvil, wherein the corresponding forming pocket comprises a valley and a forming surface, and wherein the valley is configured to funnel the staple tips toward the forming surface.

Example 165: the surgical staple cartridge of embodiments 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, or 164, wherein the first staple leg and the second staple leg are configured to be formed against corresponding forming pockets, wherein the corresponding forming pockets are configured to form the first staple leg in a first direction and the second staple leg in a second direction, and wherein the first direction is opposite and at least substantially parallel to the second direction.

Example 166: the surgical staple cartridge of embodiment 165, wherein said first direction faces away from said staple base portion, and wherein said second direction points toward said staple base portion.

Example 167: the surgical staple cartridge of embodiments 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, or 166, wherein the first staple leg and the second staple leg are configured to be formed against corresponding forming pockets, wherein the corresponding forming pockets are configured to form the first staple leg in a first bending direction and the second staple leg in a second bending direction.

Example 168: a surgical staple comprising a staple base portion defining a first plane, a first staple leg extending at least substantially perpendicularly from the staple base portion, and a second staple leg extending at least substantially perpendicularly from the staple base portion, wherein the first staple leg and the second staple leg define a second plane, wherein the first plane and the second plane intersect.

Example 169: a surgical staple cartridge comprising a plurality of surgical staples of embodiments 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, or 168, wherein said surgical staples are arranged in a plurality of woven rows.

Example 170: the surgical staple of embodiments 168 or 169, wherein said staple is configured to be formed into an S-shaped configuration.

Example 171: a surgical staple comprising a staple base portion having a bottom surface defining a bottom plane, a center of mass located within the staple base portion, and first and second staple legs extending from the staple base portion and defining a staple leg plane that is offset from and at least substantially parallel to the staple base portion, wherein the first staple leg comprises an engagement foot that is elevated above the bottom plane.

Example 172: the surgical staple of embodiment 171, wherein said engagement foot is laterally offset from said staple base portion.

Example 173: a surgical staple cartridge for use with a surgical stapler comprising an anvil to staple tissue, wherein the anvil comprises a plurality of forming pockets, the surgical staple cartridge comprising a cartridge body, a plurality of staple cavities, and a plurality of staples removably stored within the staple cavities, wherein each staple comprises a base and a staple leg extending from the base, wherein the staple leg comprises a staple tip having a piercing portion, wherein the piercing portion is configured to pierce tissue and deform against the forming pockets of the anvil, and wherein the piercing portion is configured to deform into a nested configuration such that the piercing tip is isolated from the tissue.

Example 174: the surgical staple cartridge of embodiment 173, wherein said nested configuration comprises a hook configuration configured to prevent said surgical staples from pulling through said tissue.

Example 175: the surgical staple cartridge of embodiments 173 or 174, wherein the staple tip further comprises a cutout portion configured to receive the piercing portion when the piercing portion is deformed.

Example 176: the surgical staple cartridge of embodiment 175, wherein said cut-out portion is concave.

Example 177: the surgical staple cartridge of embodiments 175 or 176, wherein each staple comprises another staple leg extending from the base, wherein the other staple leg comprises another staple tip having another cut-out portion, and wherein the cut-out portion and the other cut-out portion face each other.

Example 178: the surgical staple cartridge of embodiments 173, 174, 175, 176, or 177 wherein the staple tip further comprises a crimping surface configured to ride over a corresponding forming pocket of the anvil.

Example 179: the surgical staple cartridge of embodiments 173, 174, 175, 176, 177, or 178, wherein each staple comprises another staple leg, wherein the staple leg and the another staple leg define a first plane, wherein the staple base defines a second plane, and wherein the first plane and the second plane are laterally offset from one another.

Example 180: a surgical staple for use with a surgical stapler comprising an anvil, wherein the anvil comprises a forming pocket, the surgical staple comprising a staple base portion and staple legs extending from the staple base portion, wherein the staple legs comprise staple tips, and wherein the staple tips comprise a piercing tip configured to contact the forming pocket to deform the staple legs and a cut-out portion, wherein the piercing tip is configured to crimp toward the cut-out portion upon contact with the forming pocket such that the staple tips assume a non-piercing configuration.

Example 181: the surgical staple of embodiment 180, wherein said non-piercing configuration comprises a hook configuration configured to prevent said surgical staple from pulling through said tissue.

Example 182: the surgical staple of embodiments 180 or 181, wherein the cut portion is configured to receive the piercing tip when the staple tip is deformed.

Example 183: the surgical staple of embodiments 180, 181, or 182, wherein said cut out portion is concave.

Example 184: the surgical staple of embodiments 180, 181, 182, or 183, wherein the staple tip further comprises a deformable surface configured to be formed against the forming pockets of the anvil.

Example 185: a surgical staple cartridge for use with a surgical stapler including an anvil, said surgical staple cartridge comprising a cartridge body, a plurality of staple cavities, and a plurality of flat formed staples removably stored within said staple cavities, wherein each staple comprises a staple base portion and a staple leg extending from said base portion, wherein said staple leg comprises a staple tip having a rounded profile and a piercing portion.

Example 186: the surgical staple cartridge of embodiment 185, wherein said rounded profile is achieved by a cold working process.

Example 187: the surgical staple cartridge of embodiments 185 or 186, wherein the staple tip comprises a coined portion.

Example 188: the surgical staple cartridge of embodiments 185, 186, or 187 wherein the staple tip further comprises a deformable surface configured to be formed against a forming pocket of the anvil.

Example 189: the surgical staple cartridge of embodiments 185, 186, 187, or 188, wherein said staple tips have a first hardness, and wherein said staple legs have a second hardness different from said first hardness.

Example 190: the surgical staple cartridge of embodiment 189, wherein said first durometer is greater than said second durometer.

Example 191: a surgical staple cartridge for use with a surgical stapling instrument, said surgical staple cartridge comprising a cartridge body, a plurality of staple cavities, and a plurality of staples removably stored within said staple cavities, wherein each staple comprises a staple base and a pair of staple legs extending from said staple base, wherein each staple leg comprises a staple tip, wherein said staple leg comprises a first region having a first hardness, and wherein said staple tip comprises a second region having a second hardness, said second hardness being different from said first hardness.

Example 192: the surgical staple cartridge of embodiment 191, wherein said second hardness is greater than said first hardness.

Example 193: the surgical staple cartridge of embodiment 191, wherein said second hardness is less than said first hardness.

Example 194: the surgical staple cartridge of embodiments 191, 192, or 193, wherein the staple base comprises a third region having a third hardness that is different from the first hardness and the second hardness.

Example 195: the surgical staple cartridge of embodiments 191, 192, 193, or 194, wherein said staple legs comprise corner portions coined to said first stiffness.

Example 196: the surgical staple cartridge of embodiment 195, wherein said corner portion provides a preferentially curved plane.

Example 197: the surgical staple cartridge of embodiments 191, 192, 193, 194, 195, or 196, wherein the first zone has a first malleability, and wherein the second zone has a second malleability that is less than the first malleability.

Example 198: a surgical staple cartridge for use with a surgical stapling instrument, said surgical staple cartridge comprising a cartridge body, a plurality of staple cavities, and

a plurality of staples removably stored within the staple cavities, wherein each staple comprises a staple base, a pair of staple legs extending from the staple base, a first region having a first durometer, and a second region having a second durometer different from the first durometer.

Example 199: the surgical staple cartridge of embodiment 198, wherein said first zone is hardened using a first method and said second zone is hardened using a second method, said second method being different than said first method.

Example 200: the surgical staple cartridge of embodiment 198, wherein only one of said first zone and said second zone is hardened by a hardening process.

Example 201: the surgical staple cartridge of embodiments 198, 199, or 200, wherein each staple further comprises a curved portion intermediate said staple legs and said staple base, and wherein said curved portion comprises said first zone and said staple base comprises said second zone.

Example 202: the surgical staple cartridge of embodiments 198, 199, 200, or 201, wherein said staple base comprises said first zone and said staple legs comprise said second zone.

Example 203: the surgical staple cartridge of embodiments 198, 199, 200, 201, or 202, wherein the staple legs are unhardened and the staple base is hardened such that the staple legs are urged to assume a formed configuration and such that the staple base is configured to avoid plastic deformation.

Example 204: the surgical staple cartridge of embodiments 198, 199, 200, 201, 202, or 203, wherein each staple leg comprises a transition portion extending from the staple base and a vertical leg portion extending from the transition portion, and wherein the staple base comprises the first zone and the vertical leg portion comprises the second zone.

Example 205: a surgical staple configured to be removably stored in an unfired configuration within a surgical staple cartridge, said surgical staple having a non-uniform hardness distribution, wherein said staple comprises a first region having a first hardness and a second region having a second hardness, wherein said first region is hardened to said first hardness when said staple is in a preloaded configuration, and wherein said second region is hardened to said second hardness when said staple is in said preloaded configuration.

Example 206: a surgical staple cartridge for use with a surgical stapling instrument, said surgical staple cartridge comprising a cartridge body, a plurality of staple cavities, and a plurality of staples removably stored within said staple cavities, wherein each staple comprises a staple base, wherein said staple base defines a first zone having a first hardness; a plurality of curved portions extending from the staple base, wherein the curved portions define a second zone having a second hardness; and staple legs extending from the bent portion, wherein each staple leg defines a third region having a third hardness, the third hardness being different from the first hardness.

Example 207: the surgical staple cartridge of embodiment 206, wherein said first hardness is greater than said third hardness.

Example 208: the surgical staple cartridge of embodiment 206, wherein said first hardness is greater than said second hardness and said third hardness.

Example 209: the surgical staple cartridge of embodiments 206, 207, or 208, wherein each staple leg comprises a staple tip defining a fourth zone having a fourth hardness that is less than the third hardness.

Example 210: a surgical staple cartridge for use with a surgical stapling instrument, said surgical staple cartridge comprising a sled, a cartridge body, a plurality of staple cavities, and a strip of staples removably stored within said staple cavities, wherein said strip of staples comprises a plurality of staples, a strip, and a plurality of connector portions connecting said staples to said strip, wherein said connector portions are configured to release said staples from said strip.

Example 211: the surgical staple cartridge of embodiment 210, wherein each connector portion comprises an interruption configured to urge the staples away from the strip.

Example 212: the surgical staple cartridge of embodiment 210, wherein each connector portion comprises an interruption configured to urge the staples from the strip as the strip of staples are loaded into the cartridge body.

Example 213: the surgical staple cartridge of embodiments 210 or 211, wherein said sled is configured to separate said plurality of staples from said strip by breaking said connector portion as said sled translates through said staple cartridge.

Example 214: the surgical staple cartridge of embodiments 210, 211, 212, or 213, wherein each staple comprises a pair of outwardly biased staple legs configured to engage the cartridge body and retain the strip of staples in the surgical staple cartridge.

Example 215: the surgical staple cartridge of embodiments 210, 211, 212, 213, or 214, wherein said cartridge body comprises a bottom, and wherein said strip staples are configured to be loaded into said bottom of said cartridge body.

Example 216: the surgical staple cartridge of embodiments 210, 211, 212, 213, 214, or 215, wherein said plurality of staples are arranged in a first row and a second row, and wherein said strip is connected to said staples in said first row and said second row.

Example 217: the surgical staple cartridge of embodiments 210, 211, 212, 213, 214, 215, or 216, wherein the plurality of staples comprises a first group of staples having a first configuration and a second group of staples having a second configuration, the second configuration different than the first configuration.

Example 218: the surgical staple cartridge of embodiments 210, 211, 212, 213, 214, 215, 216, or 217, wherein the connector portion comprises a peened portion.

Example 219: the surgical staple cartridge of embodiments 210, 211, 212, 213, 214, 215, 216, 217, or 218, wherein the sled comprises a striking portion configured to break the connector portion.

Example 220: the surgical staple cartridge of embodiments 210, 211, 212, 213, 214, 215, 216, 217, 218, or 219, wherein said staples comprise chamfered surfaces configured to engage said sled when said sled translates through said cartridge body.

Example 221: the surgical staple cartridge of embodiments 210, 211, 212, 213, 214, 215, 216, 217, 218, 219, or 220, wherein said strip comprises an alignment feature configured to engage a corresponding alignment feature on said cartridge body.

Example 222: a surgical staple cartridge for use with a surgical stapling instrument, said surgical staple cartridge comprising a cartridge body, a plurality of staple cavities, and a strip of staples removably stored within said cartridge body, said strip of staples comprising a plurality of staples, a strip, and a plurality of connector portions connecting said staples to said strip, wherein said connector portions are engageable to release said staples from said strip, and wherein said staples, said strip, and said connector portions are metal.

Example 223: the surgical staple cartridge of embodiment 222, wherein said plurality of staples comprises a first plurality of staples having a first crown width and a second plurality of staples having a second crown width, said second crown width different than said first crown width.

Example 224: the surgical staple cartridge of embodiments 222 or 223, wherein the plurality of staples comprises a first group of staples having staple legs defining a first height and a second group of staples having staple legs defining a second height, the second height being different than the first height.

Example 225: the surgical staple cartridge of embodiment 222, wherein said strip staples comprise a uniform composition.

Example 226: the surgical staple cartridge of embodiments 222, 223, 224, or 225 wherein said strip comprises an alignment feature configured to engage a corresponding alignment feature on said cartridge body.

Example 227: the surgical staple cartridge of embodiments 222, 223, 224, 225, or 226, further comprising a second strip of staples comprising a plurality of second staples, a second strip, and a plurality of second connector portions connecting the second staples to the second strip, wherein the plurality of staples are arranged in a plurality of rows defining a first row spacing, wherein the plurality of second staples are arranged in a plurality of second rows defining a second row spacing, and wherein the first row spacing and the second row spacing are different.

Example 228: a metal strip surgical staple configured for use with a surgical staple cartridge, said metal strip surgical staple comprising a plurality of staples, a band, and a plurality of connector portions connecting said staples to said band.

Example 229: the metal strip surgical staple of embodiment 228, wherein said connector portion comprises an interruption notch.

Example 230: a surgical staple cartridge for use with a circular stapler, said surgical staple cartridge comprising a cartridge body, a plurality of staple cavities defined in said cartridge body, and a plurality of staples removably stored within said staple cavities, said plurality of staples comprising an inner row of staples having a number of first staples, wherein each first staple comprises a first crown defining a first crown width; a middle row of staples positioned radially outward relative to the inner row of staples, wherein the middle row of staples comprises a number of second staples, and wherein each second staple comprises a second crown defining a second crown width; and an outer row of staples positioned radially outward relative to the middle row of staples, wherein the outer row of staples comprises a number of third staples, wherein each third staple comprises a third crown defining a third crown width, and wherein one of the first, second, and third crown widths is different than the other of the first, second, and third crown widths.

Example 231: the surgical staple cartridge of embodiment 230, wherein said inner row of staples defines a plurality of first gaps between said first staples, and wherein said second staples of said middle row of staples overlaps said first gaps.

Example 232: the surgical staple cartridge of embodiment 231, wherein said middle row of staples defines a plurality of second gaps between said second staples, wherein said second gaps are greater than said first gaps, and wherein said third staples of said outer row of staples overlap said second gaps.

Example 233: the surgical staple cartridge of embodiments 231 or 232, wherein said third staple of said outer row of staples also overlaps said first gap.

Example 234: the surgical staple cartridge of embodiment 230, wherein said inner row of staples defines a plurality of first gaps between said first staples, wherein said middle row of staples defines a plurality of second gaps between said second staples, wherein said second staples overlap said first gaps, and wherein said first gaps and said second gaps are at least substantially equal.

Example 235: the surgical staple cartridge of embodiment 230, wherein said inner row of staples defines a plurality of first gaps between said first staples, wherein said middle row of staples defines a plurality of second gaps between said second staples, wherein each first gap defines a first distance, and wherein each second gap defines a second distance less than said first distance.

Example 236: the surgical staple cartridge of embodiments 230, 231, 232, 233, 234, or 235 wherein said first crown width is less than said second crown width.

Example 237: the surgical staple cartridge of embodiments 230, 231, 232, 233, 234, or 235 wherein said first crown width is at least substantially equal to said second crown width.

Example 238: the surgical staple cartridge of embodiments 230, 231, 232, 233, 234, 235, 236, or 237 wherein said third crown width is greater than said first crown width and said second crown width.

Example 239: a surgical staple cartridge for use with a circular stapler, said surgical staple cartridge comprising a cartridge body, a plurality of staple cavities defined in said cartridge body, and a plurality of staples removably stored within said staple cavities, said plurality of staples comprising an inner row of staples having a first number of first staples, wherein each first staple comprises a first crown defining a first crown width; a middle row of staples positioned radially outward relative to the inner row of staples, wherein the middle row of staples comprises a second number of second staples, and wherein each second staple comprises a second crown defining a second crown width; and an outer row of staples positioned radially outward relative to the middle row of staples, wherein the outer row of staples comprises a third number of third staples, wherein each third staple comprises a third crown defining a third crown width, wherein one of the first, second, and third crown widths is different than the other of the first, second, and third crown widths, and wherein one of the first, second, and third numbers is different than the other of the first, second, and third numbers.

Example 240: the surgical staple cartridge of embodiment 239, wherein said second number is less than said first number.

Example 241: the surgical staple cartridge of embodiments 239 or 240, wherein said second number is less than said third number.

Example 242: the surgical staple cartridge of embodiments 239, 240, or 241, wherein said plurality of staple cavities comprises a plurality of non-uniform cavity extensions.

Example 243: the surgical staple cartridge of embodiments 239, 240, 241, or 242 wherein each first staple of the inner row of staples comprises a pair of staple legs extending radially outward from each first crown.

Example 244: the surgical staple cartridge of embodiments 239, 240, 241, 242, or 243 wherein each second staple of said intermediate row of staples comprises a pair of staple legs extending radially inward from each second crown.

Example 245: the surgical staple cartridge of embodiments 239, 240, 241, 242, 243, or 244 wherein each third staple of the outer row of staples comprises a pair of staple legs extending radially inward from each third crown.

Example 246: a surgical staple cartridge for use with a surgical stapler, said surgical staple cartridge comprising a cartridge body, a plurality of staple cavities defined in said cartridge body, and a plurality of staples removably stored within said staple cavities, said plurality of staples comprising an inner row of staples having a first number of first staples, wherein each first staple comprises a first crown defining a first crown width; a middle row of staples positioned outwardly relative to the inner row of staples, wherein the middle row of staples comprises a second number of second staples, and wherein each second staple comprises a second crown defining a second crown width; and an outer row of staples positioned outwardly relative to the middle row of staples, wherein the outer row of staples comprises a third number of third staples, wherein each third staple comprises a third crown defining a third crown width, and wherein one of the first, second, and third crown widths is different than the other of the first, second, and third crown widths.

Example 247: the surgical staple cartridge of embodiment 246 wherein one of said first number, said second number, and said third number is different from the other of said first number, said second number, and said third number.

Example 248: the surgical staple cartridge of embodiment 246, wherein said first number and said second number are equal.

Example 249: the surgical staple cartridge of embodiments 246, 247, or 248, wherein the inner row of staples defines a plurality of first gaps between the first staples, wherein the middle row of staples defines a plurality of second gaps between the second staples, wherein each first gap defines a first distance, and wherein each second gap defines a second distance that is less than the first distance.

The entire disclosures of the following patents are hereby incorporated by reference:

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U.S. patent 7,000,818 entitled "SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS" published on 21.2.2006;

U.S. Pat. No. 7,422,139 entitled "MOTOR-DRIVEN SURGICAL CUTTING AND FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK" published on 9.9.2008;

U.S. patent 7,464,849 entitled "ELECTRO-MECHANICAL SURGICAL INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS" published on 16.12.2008;

U.S. patent 7,670,334 entitled "SURGICAL INSTRUMENT HAVATING AN ARTICULATING END EFFECTOR" published on 3, 2/2010;

U.S. patent 7,753,245 entitled "SURGICAL STAPLING INSTRUMENTS" published on 13.7.2010;

U.S. patent 8,393,514 entitled "SELECTIVELY ORIENTABLE IMPLANTABLE FASTENER CARTRIDGE" published on 12.3.2013;

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U.S. patent application Ser. No. 12/031,873, filed on 15.2.2008, entitled "END EFFECTORS FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT," now U.S. patent 7,980,443;

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U.S. patent application Ser. No. 12/249,117 entitled "POWER SURGICAL CUTTING AND STAPLING APPATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM", now U.S. patent 8,608,045;

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U.S. patent application serial No. 13/800,025 entitled "STAPLE CARTRIDGE TISSUE thickingsenser SYSTEM" filed on 13/3/2013, now U.S. patent application publication 2014/0263551;

U.S. patent application serial No. 13/800,067 entitled "STAPLE CARTRIDGE TISSUE thickingsenser SYSTEM" filed on 13/3/2013, now U.S. patent application publication 2014/0263552;

U.S. patent application publication 2007/0175955 entitled "SURGICAL CUTTING AND FASTENING INSTRUMENTT WITH CLOSURE TRIGGER LOCKING MECHANISM" filed on 31.1.2006; and

U.S. patent application publication 2010/0264194 entitled "SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR" filed on 22.4.2010, now U.S. Pat. No. 8,308,040.

While various embodiments of the device have been described herein in connection with certain disclosed embodiments, many modifications and variations to these embodiments may be implemented. In addition, where materials for certain components are disclosed, other materials may also be used. Further, according to various embodiments, a single component may be replaced with multiple components, and multiple components may also be replaced with a single component, to perform a given function or functions. It is intended that the above description and the following claims cover all such modifications and variations.

The device disclosed herein may be designed to be disposed of after a single use, or it may be designed to be capable of multiple uses. In either case, however, the device may be reconditioned for reuse after at least one use. Refurbishment may include any combination of disassembly of the device, followed by cleaning or replacement of particular parts, and subsequent reassembly steps. In particular, the device may be disassembled, and any number of the particular pieces or parts of the device may be selectively replaced or removed in any combination. After cleaning and/or replacement of particular components, the device may be reassembled for subsequent use either at a reconditioning facility, or by a surgical team immediately prior to a surgical procedure. Those skilled in the art will appreciate that the finishing assembly may be disassembled, cleaned/replaced, and reassembled using a variety of techniques. The use of such techniques and the resulting conditioning apparatus are within the scope of the present application.

By way of example only, aspects described herein may be processed prior to surgery. First, a new or used instrument can be obtained and cleaned as needed. The instrument may then be sterilized. In one sterilization technique, the instrument is placed in a closed and sealed container (such as a plastic or TYVEK bag). The container and instrument may then be placed in a field of radiation that can penetrate the container, such as gamma radiation, X-rays, or high-energy electrons. The radiation may kill bacteria on the instrument and in the container. The sterilized instrument can then be stored in a sterile container. The sealed container may keep the instrument sterile until the container is opened in a medical facility. The device may also be sterilized using any other technique known in the art, including but not limited to beta or gamma radiation, ethylene oxide, plasma peroxide, or steam.

While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.

Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. Thus, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

Claims (10)

1. A staple cartridge assembly for stapling tissue, comprising:

a cartridge body, said cartridge body comprising:

a proximal end;

a distal end; and

a plurality of staple cavities;

a plurality of staples positioned in the staple cavities, wherein the staples comprise:

a base;

a leg extending from the base, wherein the leg comprises a tip configured to penetrate the tissue; and

a foot extending from the base; and

a firing member configured to eject said staples from said staple cavities, wherein said firing member is configured to contact said feet of any misoriented staples within its staple cavities prior to ejecting said misoriented staples from its staple cavities; a firing ramp configured to contact the base of the staples to drive the staples out of the staple cavities; and

an alignment ramp configured to contact the foot of the staple if the staple is misoriented;

wherein the firing member further comprises:

a firing channel aligned with the firing ramp, wherein the firing channel is configured to receive the bases of the staples; and

an alignment channel aligned with the alignment ramp, wherein the alignment channel is configured to receive the foot of the staple once the staple is properly oriented.

2. The staple cartridge assembly of claim 1, wherein said alignment sled extends distally relative to said firing sled such that said alignment sled is configured to contact said feet of said staples before said firing sled contacts said bases of said staples.

3. The staple cartridge assembly of claim 1, wherein said feet of said staples are positioned proximally relative to said bases of said staples.

4. The staple cartridge assembly of claim 1, wherein said firing member is configured to not contact said feet of said staples if said staples are properly oriented within said staple cavities.

5. The staple cartridge assembly of claim 1, wherein each said staple cavity comprises:

the top is open;

a proximal wall; and

a distal wall;

wherein each of the staples further comprises:

a proximal leg extending from the base;

a distal leg extending from the base; and

a center of mass defined in the base, wherein the distal wall is configured to provide a distal reaction force to the staple above the center of mass when the staple is rotated to contact the distal wall, and the proximal wall is configured to provide a proximal reaction force to the staple below the center of mass when the staple is rotated to contact the proximal wall, wherein the staple is lifted by the firing member toward the top opening.

6. The staple cartridge assembly of claim 5, wherein said base defines a drive plane, and wherein said proximal leg and said distal leg are not in said drive plane.

7. The staple cartridge assembly of claim 6, wherein said proximal leg and said distal leg are laterally offset from said center of mass of said staple.

8. The staple cartridge assembly of claim 6, wherein said distal wall applies said distal reaction force to said distal leg and said proximal wall applies said proximal reaction force to said proximal leg.

9. The staple cartridge assembly of claim 6, wherein said proximal leg extends to a first side of said drive plane and said distal leg extends to a second side of said drive plane.

10. The staple cartridge assembly of claim 5, wherein said base comprises a notch defined therein configured to shift said center of mass of said staples toward a side of said staple cavities.

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