CN109310414B - Circular stapling system including rotary firing system - Google Patents

Abstract

An end effector for use with a surgical stapler includes a cartridge body having a longitudinal axis and a plurality of staple cavities defined in the cartridge body. The staple cavities include a first annular row of staple cavities extending about the longitudinal axis and a second annular row of staple cavities extending about the longitudinal axis. The end effector also includes staples removably stored in the staple cavities and a ramp rotatable about a longitudinal axis to sequentially eject the staples from the staple cavities.

Description

Circular stapling system including rotary firing system

Background

The present invention relates to surgical instruments and, in various arrangements, to surgical stapling and cutting instruments designed to staple and cut tissue and staple cartridges for use therewith.

Drawings

Various features of the embodiments described herein, along with their advantages, may be understood from the following description in conjunction with the following drawings:

FIG. 1 is a perspective view of a surgical instrument including an interchangeable surgical tool assembly according to at least one embodiment;

FIG. 2 is another perspective view of the handle assembly of the surgical instrument of FIG. 1 with a portion of the handle housing omitted to expose the components housed therein;

FIG. 3 is an exploded assembly view of portions of the handle assembly of the surgical instrument of FIGS. 1 and 2;

FIG. 4 is a cut-away perspective view of the handle assembly of FIGS. 2 and 3;

fig. 5 is a partial cross-sectional side view of the handle assembly of fig. 2-4, with the gripping portion of the handle assembly shown in solid lines in one position relative to the main housing portion of the handle assembly and the gripping portion of the handle assembly shown in dashed lines in another position relative to the main housing portion of the handle assembly;

FIG. 6 is an end cross-sectional view of the handle assembly of FIGS. 2-5 taken along line 6-6 of FIG. 5;

FIG. 7 is another end sectional view of the handle assembly of FIGS. 2-6, taken along line 7-7 of FIG. 5;

FIG. 8 is another end cross-sectional view of the handle assembly of FIGS. 2-7 showing the shifter gear in meshing engagement with the drive gear on the rotary drive socket;

FIG. 9 is another end cross-sectional view of the handle assembly of FIGS. 2-8 showing the position of the shifter solenoid when the shifter gear is in meshing engagement with the drive gear on the rotary drive socket;

fig. 10 is another perspective view of the handle assembly of fig. 2-9 with portions thereof shown in cross-section and access panel portions thereof shown in phantom;

Fig. 11 is a top view of the handle assembly of fig. 2-11 with the bailout system shown in an actuatable position;

fig. 12 is a perspective view of the bailout handle of the bailout system shown in fig. 2-11;

fig. 13 is an exploded assembly view of portions of the panic handle of fig. 12, with portions thereof shown in cross-section;

FIG. 14 is a cross-sectional elevation view of the handle assembly of FIG. 11;

FIG. 15 illustrates an exploded view of an interchangeable tool assembly in accordance with at least one embodiment;

FIG. 16 is a perspective view of the interchangeable tool assembly of FIG. 15;

FIG. 17 is a cutaway perspective view of the interchangeable tool assembly of FIG. 15;

FIG. 18 is a cross-sectional exploded view of the interchangeable tool assembly of FIG. 15;

FIG. 19 is a perspective view of the articulation block of the interchangeable tool assembly of FIG. 15;

FIG. 20 is a cross-sectional perspective view of the articulation joint of the interchangeable tool assembly of FIG. 15 including the articulation block of FIG. 19;

FIG. 21 is another cross-sectional perspective view of the articulation joint of FIG. 20;

FIG. 22 is a partially exploded view of the interchangeable tool assembly of FIG. 15;

FIG. 23 is another partially exploded view of the interchangeable tool assembly of FIG. 15;

FIG. 24 is a partially exploded view of the articulation joint of FIG. 20;

FIG. 25 is a cutaway perspective view of the proximal end of the interchangeable tool assembly of FIG. 15;

FIG. 26 is an end view of the interchangeable tool assembly of FIG. 15;

FIG. 27 is a cross-sectional view of the end effector of the interchangeable tool assembly of FIG. 15 taken along line 27-27 of FIG. 26, showing the end effector in a clamped but unfired state;

FIG. 28 is a cross-sectional view of the end effector of the interchangeable tool assembly of FIG. 15 taken along line 28-28 of FIG. 26, showing the end effector in a clamped but unfired state;

FIG. 29 is a cross-sectional view of the end effector of the interchangeable tool assembly of FIG. 15 taken along line 29-29 of FIG. 26 showing the end effector in a clamped but unfired state;

FIG. 30 is a cross-sectional view of the end effector of the interchangeable tool assembly of FIG. 15 shown in a disassembled state;

FIG. 31 shows the end effector of the interchangeable tool assembly of FIG. 15 articulated in a first direction;

FIG. 32 shows the end effector of the interchangeable tool assembly of FIG. 15 articulated in a second direction;

FIG. 33 is a perspective view of the cartridge body of the interchangeable tool assembly of FIG. 15;

fig. 34 is a perspective view of a cartridge body according to at least one alternative embodiment;

FIG. 35 is an exploded view of an end effector of an interchangeable tool assembly according to at least one alternative embodiment;

FIG. 36 is an exploded view of the end effector of FIG. 35;

FIG. 37 is an exploded view of an end effector of an interchangeable tool assembly according to at least one alternative embodiment;

FIG. 38 is an exploded view of an end effector of an interchangeable tool assembly according to at least one alternative embodiment;

FIG. 39 is a perspective view showing a staple cartridge and shaft of a surgical stapling instrument in accordance with at least one embodiment;

FIG. 40 is a partial cross-sectional view of a staple cartridge assembled to the stapling instrument of FIG. 39;

FIG. 41 is a partial cross-sectional view of a surgical stapling instrument including a closure drive, an anvil, and a lockout configured to prevent the anvil from fitting to the closure drive when the closure drive is not in a fully extended position;

FIG. 42 is a partial cross-sectional view of the surgical stapling instrument of FIG. 41 showing an anvil attached to the closure drive assembly;

FIG. 43 is a partial perspective view of a surgical stapling instrument including a staple cartridge and a closure drive configured to move an anvil relative to the staple cartridge;

FIG. 44 is a partial cross-sectional view of the stapling instrument of FIG. 43 showing a lockout configured to prevent retraction of the closure drive when the anvil is not attached to the closure drive;

FIG. 45 is a partial cross-sectional view of the stapling instrument of FIG. 44 showing an anvil attached to the closure drive and a latch disengaged from the closure drive;

FIG. 46 is a partial cross-sectional view of a surgical stapling instrument including a staple cartridge having staples removably stored therein, an anvil, a closure drive configured to move the anvil relative to the staple cartridge, and a firing drive configured to eject the staples from the staple cartridge;

FIG. 47 is a detail view of a lockout configured to prevent actuation of the firing drive prior to movement of the anvil to the closed position;

FIG. 48 is a detail view of the lockout of FIG. 47 disengaged from the firing drive;

FIG. 49 is a partial perspective view of a surgical stapling instrument including a staple cartridge having staples removably stored therein, an anvil, a closure drive configured to move the anvil relative to the staple cartridge, and a firing drive configured to eject the staples from the staple cartridge;

FIG. 50 is a detail view of a lockout of the surgical stapling instrument of FIG. 49 configured to prevent actuation of the firing drive prior to the anvil applying sufficient pressure to tissue captured between the anvil and the staple cartridge;

FIG. 51 is a detail view of the lockout of FIG. 50 disengaged from the firing drive;

FIG. 52 is a partial perspective view of a surgical stapling instrument including a staple cartridge having staples removably stored therein, an anvil, a closure drive configured to move the anvil relative to the staple cartridge, and a firing drive configured to eject the staples from the staple cartridge;

FIG. 53 is a detail view of a lockout of the surgical stapling instrument of FIG. 52 configured to prevent separation of the anvil from the closure drive when a cutting member of the firing drive is exposed above the staple cartridge;

FIG. 54 is a detail view of the lockout of FIG. 53 disengaged from the anvil after the firing drive has been fully retracted following the firing stroke;

FIG. 55 is a partial cross-sectional view of a surgical stapling instrument including a staple cartridge having staples removably stored therein, an anvil, a closure drive configured to move the anvil relative to the staple cartridge, and a firing drive configured to eject the staples from the staple cartridge;

FIG. 56 is a partial cross-sectional view of the surgical stapling instrument of FIG. 55 showing the closure drive in a clamped configuration and the firing drive in an unfired configuration, wherein the firing drive maintains the lockout in an unreleased configuration;

FIG. 57 is a partial cross-sectional view of the surgical stapling instrument of FIG. 55 showing the firing drive in an at least partially fired configuration and the lockout of FIG. 56 in a released configuration;

FIG. 58 is a partial cross-sectional view of the surgical stapling instrument of FIG. 55 showing the closure drive in an extended or open configuration and the lockout of FIG. 56 engaged with the closure drive to prevent the closure drive from being reclamped;

FIG. 59 is a cross-sectional view of a surgical stapling instrument including a staple cartridge having staples removably stored therein, an anvil, a closure drive configured to move the anvil relative to the staple cartridge, and a firing drive configured to eject the staples from the staple cartridge shown in a deactivated or latched configuration;

FIG. 59A is a cross-sectional end view of the surgical stapling instrument of FIG. 59 taken along line 59A-59A of FIG. 59;

FIG. 60 is a cross-sectional view of the surgical stapling instrument of FIG. 59 shown in a clamped configuration with the firing drive activated;

FIG. 60A is a cross-sectional end view of the surgical stapling instrument of FIG. 59 taken along line 60A-60A of FIG. 60;

FIG. 61 is a partial cross-sectional view of a surgical stapling instrument including a staple cartridge having staples removably stored therein, an anvil, a closure drive configured to move the anvil relative to the staple cartridge, and a firing drive configured to eject the staples from the staple cartridge, wherein the closure drive is shown in an undamped configuration and the firing drive is shown in an inoperable configuration;

FIG. 62 is a partial cross-sectional view of the surgical stapling instrument of FIG. 61, with the closure drive shown in a clamped configuration and the firing drive shown in an operable configuration;

FIG. 63 is a perspective view of a rotatable intermediate drive member of the firing drive of the surgical instrument of FIG. 61;

FIG. 64 is a partial perspective view of a rotatable firing shaft of a firing drive of the surgical instrument of FIG. 61;

FIG. 65 is an elevational view of a spring system configured to bias the firing shaft of FIG. 64 out of engagement with the intermediate drive member of FIG. 63;

FIG. 66 is an exploded view of an end effector of a surgical stapling instrument including a staple cartridge in accordance with at least one embodiment;

FIG. 67 is a partial cross-sectional view of the end effector of FIG. 66 showing a lockout configured to prevent the end effector from being operated when the staple cartridge is not fully assembled to the stapling instrument;

FIG. 68 is a partial cross-sectional view of the end effector of FIG. 66 showing the latch in an unlocked configuration;

FIG. 69 is an exploded view of an end effector of a surgical stapling instrument including a staple cartridge in accordance with at least one embodiment;

FIG. 70 is a partial cross-sectional view of the end effector of FIG. 69 showing a lock configured to releasably retain a staple cartridge to the stapling instrument;

FIG. 71 is a partial cross-sectional view of the end effector of FIG. 69 showing the lock in an unlocked configuration;

FIG. 72 illustrates a shaft of a surgical stapling instrument configured for use with a staple cartridge selected from a plurality of circular staple cartridges;

FIG. 73 is a cross-sectional view of the distal end of the suturing apparatus of FIG. 72;

FIG. 74 is a partial cross-sectional view of a surgical stapling instrument including an unfired staple cartridge and a lockout system configured to prevent the staple cartridge from being re-fired after having been previously fired by a firing drive of the surgical instrument;

FIG. 75 is a partial cross-sectional view of the stapling instrument of FIG. 74 shown in a clamped configuration with a firing drive in a firing configuration;

FIG. 76 is a partial cross-sectional view of the stapling instrument of FIG. 74 shown in an undamped configuration with the firing drive in a retracted configuration;

FIG. 77 is an end view of the firing drive and frame of the stapling instrument of FIG. 74, showing the firing drive in an unfired configuration;

FIG. 78 is an end view of the firing drive and frame of the stapling instrument of FIG. 74, showing the firing drive in a retracted configuration;

FIG. 79 is an end view of an alternative staple cartridge design that may be used with the stapling instrument of FIG. 74;

FIG. 80 is an end view of an alternative staple cartridge design that may be used with the stapling instrument of FIG. 74;

FIG. 81 is a perspective view of a surgical stapling instrument including a flexible shaft in accordance with at least one embodiment;

FIG. 82 is a schematic view of a surgical instrument kit including a plurality of end effectors in accordance with at least one embodiment;

fig. 82A is a schematic view of a robotic surgical instrument system including a plurality of attachable end effectors, according to at least one embodiment;

FIG. 83 is a perspective view of several of the end effectors shown in FIG. 82;

FIG. 84 is a perspective view of an anvil according to at least one embodiment;

FIG. 85 is a cross-sectional view of the anvil of FIG. 84;

FIG. 86 is a partial cross-sectional view of the end effector including an anvil of FIG. 84 shown in a firing configuration;

FIG. 87 is a perspective view of an anvil according to at least one embodiment;

FIG. 88 is a plan view of the anvil of FIG. 87;

FIG. 89 is a cross-sectional view of an end effector, according to at least one embodiment, shown in a clamped, unfired configuration;

FIG. 90 is a cross-sectional view of the end effector of FIG. 89 shown in a fired configuration;

FIG. 91 is a cross-sectional view of an end effector according to at least one alternative embodiment, shown in a clamped, unfired configuration;

FIG. 92 is a cross-sectional view of the end effector of FIG. 91 shown in a firing configuration;

FIG. 93 is a cross-sectional view of an end effector according to at least one alternative embodiment, shown in a clamped, unfired configuration;

FIG. 94 is a cross-sectional view of the end effector of FIG. 91 shown in a firing configuration;

FIG. 95 is a perspective view of a staple forming pocket according to at least one embodiment;

FIG. 96 is a cross-sectional view of the staple forming pockets of FIG. 95;

FIG. 97 is an exploded view of an end effector configured to sequentially deploy a first annular row of staples and a second annular row of staples, according to at least one embodiment;

FIG. 98 is a partial cross-sectional view of the end effector of FIG. 97 showing a firing drive that deploys staples in a first row of staples;

FIG. 99 is a partial cross-sectional view of the end effector of FIG. 97 showing the firing drive of FIG. 98 deploying staples in a second row of staples;

FIG. 100 is a partial perspective view of a firing drive configured to sequentially drive a first driver for firing a first row of staples, a second driver for firing a second row of staples, and then a third driver for driving a cutting member;

FIG. 101 is a partial perspective view of the firing drive of FIG. 100 showing the first driver in a firing position;

FIG. 102 is a partial perspective view of the firing drive of FIG. 100 showing the second driver in a firing position;

FIG. 103 is a partial perspective view of the firing drive of FIG. 100 showing the third driver in a firing position;

FIG. 104 is an exploded view of the firing drive of FIG. 100;

FIG. 105 is a partial perspective view of the firing drive of FIG. 100 in the configuration of FIG. 103;

FIG. 106 is an exploded view of a firing drive according to at least one alternative embodiment;

FIG. 107 is a perspective view of a portion of a surgical staple cartridge for use with a circular surgical stapling instrument in accordance with at least one embodiment;

FIG. 108 shows a pair of staples in unformed and formed configurations in accordance with at least one embodiment;

FIG. 109 is a cross-sectional view of a portion of an anvil relative to a portion of the surgical staple cartridge of FIG. 107 prior to actuation of the staple forming process;

FIG. 110 is another cross-sectional view of the anvil of FIG. 109 and the staple cartridge of FIG. 107 after formation of the staples;

FIG. 111 is a perspective view of a portion of a surgical staple cartridge for use with a circular surgical stapling instrument in accordance with at least one embodiment;

FIG. 112 is a cross-sectional view of a portion of an anvil relative to a portion of the surgical staple cartridge of FIG. 111 prior to actuation of the staple forming process;

FIG. 113 is another cross-sectional view of the anvil and staple cartridge of FIG. 112 after formation of the staples;

FIG. 114 is a top view of a staple cartridge according to at least one embodiment;

FIG. 115 is a bottom view of an anvil according to at least one embodiment;

FIG. 116 is a cross-sectional view of a portion of an anvil relative to a portion of a surgical staple cartridge;

FIG. 117 shows three unformed surgical staples;

FIG. 118 shows a partial cross-sectional view of a staple cartridge of a circular stapler according to at least one embodiment; and is

FIG. 119 illustrates a partial perspective view of a staple cartridge of a circular stapler in accordance with at least one embodiment.

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 patent applications, filed on even date herewith and each incorporated herein by reference in its entirety:

-U.S. patent application Ser. No. ________ entitled "METHOD FOR OPERATING A SURGICAL STAPLING SYSTEM"; attorney docket number END7821 USNP/150535;

-U.S. patent application Ser. No. _______ entitled "MODULAR SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY"; attorney docket number END7822 USNP/150536;

-U.S. patent application serial No. _______ entitled "SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE DISPLAY FIELD"; attorney docket number END7822USNP 1/150536-1;

-U.S. patent application serial No. _______ entitled "minor entering HANDLE association WITH robust GRIP support"; attorney docket number END7823 USNP/150537;

-U.S. patent application serial No. _______ entitled "rolling POWERED minor inserting WITH manual active ballout SYSTEM"; attorney docket number END7824 USNP/150538;

U.S. patent application Ser. No. _______ entitled "SURGICAL CUTTING AND STAPLING END EFFECTOR WITH ANVIL CONCENTRIC DRIVE MEMBER"; attorney docket number END7825 USNP/150539;

-U.S. patent application serial No. _______ entitled "close SYSTEM ARRANGEMENTS FOR SURGICAL curing AND STAPLING DEVICES WITH SEPARATE AND DISTINCT FIRING SHAFTS"; attorney docket number END7826 USNP/150540;

-U.S. patent application Ser. No. _______ entitled "INTERCHANGEABLE SURGICAL TOOL ASSEMBLY WITH A SURGICAL END EFFECTOR THAT IS SELECTIVELY ROTATABLE ABOUT A SHAFT AXIS"; attorney docket number END7827 USNP/150541;

-U.S. patent application serial No. _______ entitled "SURGICAL STAPLING SYSTEM COMPRISING A SHIFTABLE TRANSMISSION"; attorney docket number END7829 USNP/150543;

U.S. patent application Ser. No. _______ entitled "SURGICAL STAPLING SYSTEM CONFIGURED TO PROVIDE selection OF recording OF TISSUE"; attorney docket number END7830 USNP/150544;

-U.S. patent application Ser. No. _______ entitled "SURGICAL STAPLING SYSTEM COMPRISING A CONTOURABLE SHAFT"; attorney docket number END7831 USNP/150545;

-U.S. patent application Ser. No. _______ entitled "SURGICAL STAPLING SYSTEM COMPRISING A TISSUE COMPRESSION LOCKOUT"; agent's case number END7832 USNP/150546;

-U.S. patent application Ser. No. _______ entitled "SURGICAL STAPLING SYSTEM COMPRISING AN UNCLAMPING LOCKOUT"; attorney docket number END7833 USNP/150547;

-U.S. patent application Ser. No. _______ entitled "SURGICAL STAPLING SYSTEM COMPRISING A JAW CLOSURE LOCKOUT"; agent case number END7834 USNP/150548;

-U.S. patent application Ser. No. _______ entitled "SURGICAL STAPLING SYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT"; attorney docket number END7835 USNP/150549;

-U.S. patent application serial No. _______ entitled "SURGICAL STAPLING SYSTEM COMPRISING A SPENT CARTRIDGE LOCKOUT"; attorney docket number END7836 USNP/150550;

-U.S. patent application serial No. _______ entitled "SURGICAL INSTRUMENT COMPRISING A SHIFTING MECHANISM"; attorney docket number END7837 USNP/150551;

-U.S. patent application Ser. No. _______ entitled "SURGICAL STAPLING INSTRUMENTS COMPLEMENTING MULTIPLE LOCKOUTS"; attorney docket number END7838 USNP/150552;

-U.S. patent application serial No. _______ entitled "SURGICAL STAPLING INSTRUMENT"; agent case number END7839 USNP/150553;

-U.S. patent application serial No. _______ entitled "SURGICAL STAPLING SYSTEM CONFIGURED TO applied annual ROWS OF STAPLES HAVING DIFFERENT HEIGHTS"; attorney docket number END7840 USNP/150554;

U.S. patent application Ser. No. _______ entitled "SURGICAL STAPLING SYSTEM COMPRISING A GROOVED FORMING POCKET"; attorney docket number END7841 USNP/150555;

-U.S. patent application serial No. _______ entitled "artificial MODIFICATION machinery FOR minor platform"; attorney docket number END7842 USNP/150556;

-U.S. patent application serial No. _______ entitled "STAPLE CARTRIDGES WITH atraumatc featurs"; attorney docket number END7843 USNP/150557;

-U.S. patent application Ser. No. _______ entitled "CIRCULAR STAPLING SYSTEM COMPRISING AN INCISABLE TISSUE SUPPORT"; agent case number END7844 USNP/150558; and

-U.S. patent application serial No. _______ entitled "CIRCULAR STAPLING SYSTEM comprisingload CONTROL"; attorney docket number END7845USNP 1/150559-1.

The applicant of the present application also owns the following U.S. patent applications filed on 31/12/2015 and each of which is incorporated herein by reference in its entirety:

-U.S. patent application serial No. 14/984,488 entitled "MECHANISMS FOR COMPENSATING FOR BATTERY PACK FAILURE IN POWERED SURGICAL INSTRUMENTS";

-U.S. patent application serial No. 14/984,525 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS"; and

U.S. patent application Ser. No. 14/984,552 entitled "SURGICAL INSTRUMENTS WITH SEPARABLE MOTORS AND MOTOR CONTROL CICUITS".

The applicant of the present application also owns the following U.S. patent applications filed on 9/2/2016 and each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 15/019,220 entitled "SURGICAL INSTRUMENT WITH ARTICULATING AND AXIALLY TRANSLATABLE END EFFECTOR";

U.S. patent application Ser. No. 15/019,228 entitled "SURGICAL INSTRUMENTS WITH MULTIPLE LINK ARTICULATION ARRANGEMENTS";

-U.S. patent application Ser. No. 15/019,196 entitled "SURGICAL INSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY CONSTRAINT";

-U.S. patent application Ser. No. 15/019,206 entitled "SURGICAL INSTRUMENTS WITH AN END EFFECTOR THAT IS HIGHLY ARTICULATABLE RELATIVE TO AN ELONGATE SHAFT ASSEMBLY";

U.S. patent application Ser. No. 15/019,215 entitled "SURGICAL INSTRUMENTS WITH NON-SYMMETRICAL ARTICULATION ARRANGEMENTS";

-U.S. patent application serial No. 15/019,227 entitled "article minor filing WITH SINGLE article LINK ARRANGEMENTS";

U.S. patent application Ser. No. 15/019,235 entitled "SURGICAL INSTRUMENTS WITH TESTIONING ARRANGEMENTS FOR CABLE DRIVEN ARTICULATION SYSTEMS";

U.S. patent application Ser. No. 15/019,230 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH OFF-AXIS FIRING BEAM ARRANGEMENTS"; and

U.S. patent application Ser. No. 15/019,245 entitled "SURGICAL INSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS".

The applicant of the present application also owns the following U.S. patent applications filed on 12.2.2016 and each of which is incorporated herein by reference in its entirety:

-U.S. patent application serial No. 15/043,254 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS";

-U.S. patent application serial No. 15/043,259 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS";

-U.S. patent application serial No. 15/043,275 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS"; and

U.S. patent application Ser. No. 15/043,289 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS".

The applicant of the present application owns the following patent applications filed on day 18/6/2015 and each of which is incorporated herein by reference in its entirety:

-U.S. patent application Ser. No. 14/742,925 entitled "SURGICAL END EFFECTORS WITH POSITIVE JAW OPENING ARRANGEMENTS";

U.S. patent application Ser. No. 14/742,941 entitled "SURGICAL END EFFECTORS WITH DUAL CAM ACTUATED JAW CLOSING FEATURES";

-U.S. patent application serial No. 14/742,914 entitled "MOVABLE filing bed SUPPORT FOR easy maintenance letters";

U.S. patent application Ser. No. 14/742,900 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH COMPOSITE FIRING BEAM STRUCTURES WITH CENTER FIRING SUPPORT MEMBER FOR ARTICULATION SUPPORT";

U.S. patent application Ser. No. 14/742,885 entitled "DUAL ARTICULATION DRIVE SYSTEM ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS"; and

U.S. patent application Ser. No. 14/742,876 entitled "PUSH/PULL ARTICULATION DRIVE SYSTEMS FOR ARTICULATABLE SURGICAL INSTRUMENTS".

The applicant of the present application owns the following patent applications filed 3/6/2015 and each of which is incorporated herein by reference in its entirety:

-U.S. patent application serial No. 14/640,746 entitled "POWERED minor instroment";

U.S. patent application Ser. No. 14/640,795 entitled "MULTIPLE LEVEL THRESHOLDS TO MODIFY OPERATION OF POWER SURGICAL INSTRUMENTS";

-U.S. patent application Ser. No. 14/640,832 entitled "ADAPTIVE TISSUE COMPRESSION TECHNIQUES TO ADAJUST CLOSURE RATES FOR MULTIPLE TISSUE TYPE"; attorney docket number END7557 USNP/140482;

U.S. patent application Ser. No. 14/640,935 entitled "OVERAID MULTI SENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE TISSUE COMPRESSION";

U.S. patent application Ser. No. 14/640,831 entitled "MONITORING SPEED CONTROL AND PRECISION INCREASING OF MOTOR FOR POWER SURGICAL INSTRUMENTS";

-U.S. patent application Ser. No. 14/640,859 entitled "TIME DEPENDENT EVALTION OF SENSOR DATA TO DETERMINE STATIONITY, CREPE, AND VISCELATIC ELEMENTS OF MEASURES";

-U.S. patent application serial No. 14/640,817 entitled "INTERACTIVE FEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS";

U.S. patent application Ser. No. 14/640,844 entitled "CONTROL TECHNIQUES AND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH SELECT CONTROL PROCESSING FROM HANDLE";

-U.S. patent application serial No. 14/640,837 entitled "SMART SENSORS WITH LOCAL SIGNAL PROCESSING";

-U.S. patent application Ser. No. 14/640,765 entitled "SYSTEM FOR DETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A SURGICAL STAPLER";

-U.S. patent application Ser. No. 14/640,799 entitled "SIGNAL AND Power COMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT"; and

U.S. patent application Ser. No. 14/640,780 entitled "SURGICAL INSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING".

The applicant of the present application owns the following patent applications filed 2015 on day 2, 27 and each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/633,576 entitled "SURGICAL INSTRUMENT SYSTEM COMPLISING AN INSPECTION STATION";

-U.S. patent application serial No. 14/633,546 entitled "minor applied configuration TO ASSESS WHETHER A minor PARAMETER OF THE minor applied PARAMETER IS WITHIN AN ACCEPTABLE minor PARAMETER BAND";

U.S. patent application Ser. No. 14/633,576 entitled "SURGICAL CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE BATTERIES";

-U.S. patent application serial No. 14/633,566 entitled "CHARGING SYSTEM THAT energy EMERGENCY resolution FOR CHARGING A BATTERY";

-U.S. patent application Ser. No. 14/633,555 entitled "SYSTEM FOR MONITORING WHETHER A SURGICAL INSTRUMENTS NEEDS TO BE SERVICED";

-U.S. patent application serial No. 14/633,542 entitled "related BATTERY FOR a SURGICAL INSTRUMENT";

-U.S. patent application serial No. 14/633,548 entitled "POWER ADAPTER FOR a SURGICAL insert";

-U.S. patent application serial No. 14/633,526 entitled "adaptive minor insert HANDLE";

-U.S. patent application serial No. 14/633,541 entitled "MODULAR station association"; and

-U.S. patent application serial No. 14/633,562 entitled "SURGICAL APPATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER";

the applicant of the present application owns the following patent applications filed 2014, 12, 18 and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/574,478 entitled "SURGICAL INSTRUMENT SYSTEM COMPLEMENTS A ARTICULATED END EFFECTOR AND MEANS FOR ADJUSE THE FIRING STROKE OF A FIRING";

U.S. patent application Ser. No. 14/574,483 entitled "SURGICAL INSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS";

-U.S. patent application Ser. No. 14/575,139 entitled "DRIVE ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS";

-U.S. patent application serial No. 14/575,148 entitled "LOCKING argemenets FOR DETACHABLE SHAFT association WITH article END effects";

-U.S. patent application Ser. No. 14/575,130 entitled "SURGICAL INSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A DISCRETE NON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE";

U.S. patent application Ser. No. 14/575,143 entitled "SURGICAL INSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS";

U.S. patent application Ser. No. 14/575,117 entitled "SURGICAL INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FILING BEAM SUPPORT ARRANGEMENTS";

U.S. patent application Ser. No. 14/575,154 entitled "SURGICAL INSTRUMENTS WITH ARTICULATED END EFFECTORS AND IMPROVED FIRING BEAM SUPPORT ARRANGEMENTS";

-U.S. patent application Ser. No. 14/574,493 entitled "SURGICAL INSTRUMENT ASSEMBLY COMPLEMENTING A FLEXIBLE ARTICULATION SYSTEM"; and

U.S. patent application Ser. No. 14/574,500 entitled "SURGICAL INSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM".

The applicant of the present application owns the following patent applications filed 2013 on 3/1 and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 13/782,295 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH reduced Pathways For Signal Communication," now U.S. patent application publication 2014/0246471;

U.S. patent application Ser. No. 13/782,323 entitled "Rotary Power engineering Joints For scientific Instruments," now U.S. patent application publication 2014/0246472;

U.S. patent application Ser. No. 13/782,338 entitled "thumb Switch arrays For Surgical Instruments," now U.S. patent application publication 2014/0249557;

U.S. patent application Ser. No. 13/782,499 entitled "Electrical scientific Device with Signal Relay Arrangement", now U.S. patent application publication 2014/0246474;

U.S. patent application Ser. No. 13/782,460 entitled "Multiple Processor Motor Control for Modular Surgical Instruments," now U.S. patent application publication 2014/0246478;

U.S. patent application Ser. No. 13/782,358 entitled "journal Switch Assemblies For Surgical Instruments," now U.S. patent application publication 2014/0246477;

U.S. patent application Ser. No. 13/782,481 entitled "Sensor straight End Effect During Removal Through Trocar", now U.S. patent application publication 2014/0246479;

U.S. patent application Ser. No. 13/782,518 entitled "Control Methods for scientific Instruments with Removable implementation procedures", now U.S. patent application publication 2014/0246475;

U.S. patent application Ser. No. 13/782,375 entitled "road Power Surgical Instruments With Multiple details of Freedom", now U.S. patent application publication 2014/0246473; and

U.S. patent application Ser. No. 13/782,536 entitled "SURGICAL INSTRUMENT SOFT STOP," now U.S. patent application publication 2014/0246476.

The applicant of the present application also owns the following patent applications filed 2013, month 3, day 14 and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 13/803,097 entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE," now U.S. patent application publication 2014/0263542;

U.S. patent application Ser. No. 13/803,193 entitled "CONTROL ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT", now U.S. patent application publication 2014/0263537;

U.S. patent application Ser. No. 13/803,053 entitled "INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT," now U.S. patent application publication 2014/0263564;

U.S. patent application Ser. No. 13/803,086 entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPLISING AN ARTICULATION LOCK," now U.S. patent application publication 2014/0263541;

U.S. patent application Ser. No. 13/803,210 entitled "SENSOR ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0263538;

U.S. patent application Ser. No. 13/803,148 entitled "Multi-functional Motor FOR A SURGICAL INSTRUMENT," now U.S. patent application publication 2014/0263554;

U.S. patent application Ser. No. 13/803,066 entitled "DRIVE SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0263565;

U.S. patent application Ser. No. 13/803,117 entitled "ARTICULATION CONTROL FOR ARTICULATE SURGICAL INSTRUMENTS," now U.S. patent application publication 2014/0263553;

U.S. patent application Ser. No. 13/803,130 entitled "DRIVE TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0263543; and

U.S. patent application Ser. No. 13/803,159 entitled "METHOD AND SYSTEM FOR OPERATING A SURGICAL INSTRUMENT," now U.S. patent application publication 2014/0277017.

The applicant of the present application also owns the following patent applications filed 3/7 2014 and incorporated herein by reference in their entirety:

U.S. patent application Ser. No. 14/200,111 entitled "CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0263539.

The applicant of the present application also owns the following patent applications filed 3/26 2014 and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/226,106 entitled "POWER MANAGEMENT CONTROL SYSTEM FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2015/0272582;

-U.S. patent application serial No. 14/226,099 entitled "serilization version CIRCUIT", now U.S. patent application publication 2015/0272581;

-U.S. patent application Ser. No. 14/226,094 entitled "VERIFICATION OF NUMBER OF Battery improvements/Process COUNT", now U.S. patent application publication 2015/0272580;

U.S. patent application Ser. No. 14/226,117 entitled "POWER MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP CONTROL", now U.S. patent application publication 2015/0272574;

U.S. patent application Ser. No. 14/226,075 entitled "MODULAR POWER SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES", now U.S. patent application publication 2015/0272579;

U.S. patent application Ser. No. 14/226,093 entitled "FEEDBACK ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2015/0272569;

U.S. patent application Ser. No. 14/226,116 entitled "SURGICAL INSTRUMENT UTILIZING SENSOR ADAPTATION", now U.S. patent application publication 2015/0272571;

U.S. patent application Ser. No. 14/226,071 entitled "SURGICAL INSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR," now U.S. patent application publication 2015/0272578;

U.S. patent application Ser. No. 14/226,097 entitled "SURGICAL INSTRUMENT COMPRISING INTERACTIVE SYSTEMS," now U.S. patent application publication 2015/0272570;

U.S. patent application Ser. No. 14/226,126 entitled "INTERFACE SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS", now U.S. patent application publication 2015/0272572;

U.S. patent application Ser. No. 14/226,133 entitled "MODULAR SURGICAL INSTRUMENTS SYSTEM," now U.S. patent application publication 2015/0272557;

-U.S. patent application serial No. 14/226,081 entitled "SYSTEMS AND METHODS FOR CONTROLLING A SEGMENTED circui", now U.S. patent application publication 2015/0277471;

U.S. patent application Ser. No. 14/226,076 entitled "POWER MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE PROTECTION," now U.S. patent application publication 2015/0280424;

U.S. patent application Ser. No. 14/226,111 entitled "SURGICAL STAPLING INSTRUMENTT SYSTEM," now U.S. patent application publication 2015/0272583; and

U.S. patent application Ser. No. 14/226,125 entitled "SURGICAL INSTRUMENT COMPRISING A ROTATABLE SHAFT," now U.S. patent application publication 2015/0280384.

The applicant of the present application also owns the following patent applications filed 2014, 9, 5 and each incorporated herein by reference in its entirety:

-U.S. patent application serial No. 14/479,103 entitled "CIRCUITRY AND SENSORS FOR POWERED MEDICAL DEVICE," now U.S. patent application publication 2016/0066912;

U.S. patent application Ser. No. 14/479,119 entitled "ADJUNCT WITH INTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION," now U.S. patent application publication 2016/0066914;

U.S. patent application Ser. No. 14/478,908 entitled "MONITORING DEVICE DEGRADATION BASED ON COMPONENT EVALUATION," now U.S. patent application publication 2016/0066910;

-U.S. patent application Ser. No. 14/478,895 entitled "MULTIPLE SENSOR WITH ONE SENSOR AFFECTING A SECOND SENSOR' S OUTPUT OR INTERPRETATION", now U.S. patent application publication 2016/0066909;

U.S. patent application Ser. No. 14/479,110 entitled "USE OF POLARITY OF HALL MAGNET DETECTION TO DETECTION MISLOADED CARTRIDGE", now U.S. patent application publication 2016/0066915;

U.S. patent application Ser. No. 14/479,098 entitled "SMART CARTRIDGE WAKE UP OPERATION AND DATA RETENTION," now U.S. patent application publication 2016/0066911;

U.S. patent application Ser. No. 14/479,115 entitled "MULTIPLE MOTOR CONTROL FOR POWER MEDICAL DEVICE", now U.S. patent application publication 2016/0066916; and

U.S. patent application Ser. No. 14/479,108 entitled "LOCAL DISPLAY OF TIMSSUE PARAMETER STABILIZATION", now U.S. patent application publication 2016/0066913.

The applicant of the present application also owns the following patent applications filed 2014 on 4/9 and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/248,590 entitled "MOTOR DRIVEN SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS", now U.S. patent application publication 2014/0305987;

U.S. patent application Ser. No. 14/248,581 entitled "SURGICAL INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE OPERATED FROM THE SAME ROTATABLE OUTPUT", now U.S. patent application publication 2014/0305989;

U.S. patent application Ser. No. 14/248,595 entitled "SURGICAL INSTRUMENT SHAFT INCLUDING SWITCH FOR CONTROLLING THE OPERATION OF THE SURGICAL INSTRUMENT", now U.S. patent application publication 2014/0305988;

U.S. patent application serial No. 14/248,588 entitled "POWERED LINEAR minor stable", now U.S. patent application publication 2014/0309666;

U.S. patent application Ser. No. 14/248,591 entitled "TRANSMISSION ARRANGEMENT FOR A SURGICAL INSTRUMENT", now U.S. patent application publication 2014/0305991;

-U.S. patent application Ser. No. 14/248,584 entitled "MODULAR MOTOR DRIN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR ALIGNING ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS", now U.S. patent application publication 2014/0305994;

U.S. patent application serial No. 14/248,587 entitled "POWERED minor platform," now U.S. patent application publication 2014/0309665;

U.S. patent application Ser. No. 14/248,586 entitled "DRIVE SYSTEM DECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT", now U.S. patent application publication 2014/0305990; and

U.S. patent application Ser. No. 14/248,607 entitled "MODULAR MOTOR DRIN SURGICAL INSTRUMENTS WITH STATUS INDICATION ARRANGEMENTS," now U.S. patent application publication 2014/0305992.

The applicant of the present application also owns the following patent applications filed 2013 on 16.4.2013 and each incorporated herein by reference in its entirety:

U.S. provisional patent application serial No. 61/812,365 entitled "minor entering WITH MULTIPLE functional electronic BY a SINGLE MOTOR";

-U.S. provisional patent application serial No. 61/812,376 entitled "LINEAR CUTTER WITH POWER";

-U.S. provisional patent application serial No. 61/812,382 entitled "LINEAR CUTTER WITH MOTOR AND piston GRIP";

U.S. provisional patent application Ser. No. 61/812,385 entitled "SURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTION MOTORS AND MOTOR CONTROL"; and

U.S. provisional patent application serial No. 61/812,372 entitled "minor entering WITH MULTIPLE functional PERFORMED BY A SINGLE MOTOR".

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 term "comprises" (and any form of "comprising", such as "comprises" and "comprising)", "has" (and "has)", such as "has" and "has)", "contains" (and any form of "containing", such as "comprises" and "containing)", and "containing" (and any form of "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 possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, a system, apparatus, or device that "comprises," "has," "includes," 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 this detailed description, the reader will further appreciate that the various instruments disclosed herein can 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 a patient 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.

A surgical stapling system may include a shaft and an end effector extending from the shaft. The end effector includes a first jaw and a second jaw. The first jaw includes a staple cartridge. A staple cartridge is insertable into and removable from the first jaw; however, other embodiments are contemplated in which the staple cartridge is not removable or at least easily replaceable from the first jaw. The second jaw includes an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closure axis; however, other embodiments are envisioned in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises an articulation joint configured to allow rotation or articulation of the end effector relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments are contemplated that do not include an articulation joint.

The staple cartridge includes a cartridge body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal end and the distal end. In use, the staple cartridge is positioned on a first side of tissue to be stapled and the anvil is positioned on a second side of the tissue. The anvil is moved toward the staple cartridge to compress and clamp the tissue against the deck. Staples removably stored in the cartridge body can then be deployed into tissue. The cartridge body includes staple cavities defined therein, wherein the staples are removably stored in the staple cavities. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of the longitudinal slot and three rows of staple cavities are positioned on a second side of the longitudinal slot. Other configurations of the staple cavities and staples are possible.

The staples are supported by staple drivers in the cartridge body. The driver is movable between a first, unfired position and a second, fired position to eject the staples from the staple cartridge. The driver is retained in the cartridge body by a retainer that extends around a bottom of the cartridge body and includes a resilient member configured to grip the cartridge body and retain the retainer to the cartridge body. The driver is movable between its unfired position and its fired position by the sled. The slider is movable between a proximal position adjacent the proximal end and a distal position adjacent the distal end. The sled includes a plurality of ramp surfaces configured to slide under and lift the drivers toward the anvil, and the staples are supported on the drivers.

In addition to the above, the sled can be moved distally by the firing member. The firing member is configured to contact the sled and urge the sled toward the distal end. A longitudinal slot defined in the cartridge body is configured to receive a firing member. The anvil also includes a slot configured to receive the firing member. The firing member also includes a first cam that engages the first jaw and a second cam that engages the second jaw. The first and second cams can control a distance or tissue gap between a deck of the staple cartridge and the anvil as the firing member is advanced distally. The firing member also includes a knife configured to incise tissue captured intermediate the staple cartridge and the anvil. It is desirable that the knife be positioned at least partially adjacent to the ramp surface so that the staples are ejected prior to the knife.

Fig. 1 illustrates a motor-driven surgical system 10 that may be used to perform a variety of different surgical procedures. In the illustrated embodiment, the motor driven surgical system 10 includes a selectively reconfigurable housing or handle assembly 20 that is attached to one form of interchangeable surgical tool assembly 1000. For example, the system 10 shown in FIG. 1 includes an interchangeable surgical tool assembly 1000 that includes a surgical cutting and fastening instrument, which may be referred to as a endocutter. As will be discussed in further detail below, the interchangeable surgical tool assemblies may include end effectors that are adapted to support different sizes and types of staple cartridges and that have different shaft lengths, sizes, types, and the like. For example, such a configuration may utilize any suitable fastener or fasteners to fasten tissue. For example, a fastener cartridge including a plurality of fasteners removably stored therein can be removably inserted into and/or attached to an end effector of a surgical tool assembly. Other surgical tool assemblies can be used interchangeably with the handle assembly 20. For example, the interchangeable surgical tool assembly 1000 may be separate from the handle assembly 20 and replaced with a different surgical tool assembly configured to perform other surgical procedures. In other configurations, the surgical tool assembly may not be interchangeable with other surgical tool assemblies and, for example, substantially comprise a dedicated shaft that is non-removably attached or coupled to the handle assembly 20. The surgical tool assembly may also be referred to as an elongate shaft assembly. The surgical tool assembly may be reusable, or in other configurations, the surgical tool assembly may be designed to be discarded after a single use.

With continued reference to the present detailed description, it should be understood that the various forms of interchangeable surgical tool assemblies disclosed herein may also be effectively used in conjunction with robotically controlled surgical systems. Thus, the terms "housing" and "housing assembly" may also encompass a housing or similar portion of a robotic system that houses or otherwise operably supports at least one drive system configured to generate and apply at least one control action that may be used to actuate the elongated shaft assemblies disclosed herein and their respective equivalents. The term "frame" may refer to a portion of a hand-held surgical instrument. The term "frame" may also refer to a portion of a robotically-controlled surgical instrument and/or a portion of a robotic system that may be used to operably control a surgical instrument. For example, the SURGICAL tool assemblies disclosed herein may be used WITH various robotic systems, INSTRUMENTS, components, and methods, such as, but not limited to, those disclosed in U.S. patent application serial No. 13/118,241 (now U.S. patent application publication 2012/0298719) entitled "SURGICAL station instrumentation WITH rotable station product depolyment mechanisms," which is hereby incorporated by reference in its entirety.

Referring now to fig. 1 and 2, the housing assembly or handle assembly 20 includes a main housing portion 30 that may be formed from a pair of housing segments 40, 70 that may be made of plastic, polymeric material, metal, or the like and joined together by suitable fastener configurations (e.g., adhesives, screws, press-fit features, snap-fit features, latches, or the like). As will be discussed in further detail below, the main housing portion 30 operably supports a plurality of drive systems therein that are configured to generate and apply various control motions to corresponding portions of interchangeable surgical tool assemblies operably attached thereto. The handle assembly 20 further includes a grip portion 100 that is movably coupled to the main housing portion 30 and is configured to be grasped and manipulated by a clinician at various locations relative to the main housing portion 30. Grip portion 100 may be made of a pair of grip segments 110, 120, which may be made of plastic, polymeric material, metal, etc. and joined together by suitable fastener configurations (e.g., adhesive, screws, press-fit features, snap-fit features, latches, etc.) for assembly and maintenance purposes.

As can be seen in fig. 2, the grip portion 100 includes a grip housing 130 defining a hollow cavity 132 configured to operably support a drive motor and a gear box as will be discussed in further detail below. The upper portion 134 of the grip housing 130 is configured to extend through the opening 80 in the main housing portion 30 and is pivotally journaled on a pivot shaft 180. The pivot axis 180 defines a pivot axis labeled "PA". See fig. 3. For reference purposes, the handle assembly 20 defines a handle axis labeled "HA" which may be parallel to the shaft axis "SA" of the elongated shaft assembly of the interchangeable surgical tool operably attached to the handle assembly 20. The pivot axis PA is transverse to the handle axis HA. See fig. 1. This configuration enables the grip portion 100 to pivot about the pivot axis PA relative to the main housing portion 30 to a position that is most suitable for the type of interchangeable surgical tool assembly coupled to the handle assembly 20. The grip housing 130 defines a grip axis, generally designated "GA". See fig. 2. When the interchangeable surgical tool assembly coupled to the handle assembly 20 comprises, for example, a endocutter, the clinician may wish to position the grip portion 100 relative to the main housing portion 30 such that the grip axis GA is perpendicular or substantially perpendicular (angle "H1") to the handle axis HA (referred to herein as the "first grip position"). See fig. 5. However, if the handle assembly 20 is used to control an interchangeable surgical tool assembly including, for example, a circular stapler, the clinician may wish to pivot the grip portion 100 relative to the main housing portion 30 to a position in which the grip axis GA is at a forty-five degree or about a forty-five degree angle or other suitable acute angle (angle "H2") relative to the handle axis HA. This position is referred to herein as the "second gripping position". Fig. 5 shows the grip portion 100 in a second grip position in dashed lines.

Referring now to fig. 3-5, the handle assembly 20 further includes a grip locking system, generally designated 150, to selectively lock the grip portion 100 in a desired orientation relative to the main housing portion 30. In one configuration, the grip locking system 150 includes an arcuate sequence 152 of tines 154. The teeth 154 are spaced apart from one another and form a locking groove 156 therebetween. Each locking groove 156 corresponds to a particular angular locking position of the grip portion 100. For example, in at least one configuration, the teeth 154 and locking groove or "locking position" 156 are arranged to allow the grip portion 100 to be locked at 10-15 degree intervals between a first grip position and a second grip position. This configuration may employ two stop positions that are modulated for the type of instrument (shaft configuration) employed. For example, for a endocutter shaft configuration, it may be approximately about ninety degrees from the shaft, and for a circular stapler configuration, the angle may be about forty-five degrees from the shaft while sweeping forward toward the surgeon. The grip locking system 150 further includes a locking button 160 having a locking portion configured to lockingly engage the locking groove 156. For example, the locking buttons 160 are pivotally mounted in the main handle section 30 on pivot pins 131 to allow the locking buttons 160 to pivot into engagement with the corresponding locking grooves 156. The locking spring 164 serves to bias the locking button 160 into an engaged or locked position with the corresponding locking groove 156. The locking portion and tooth configuration is used to enable the teeth 154 to slide past the locking portion when the clinician presses the lock button 160. Thus, to adjust the angular position of the grip portion 100 relative to the main housing portion 30, the clinician depresses the lock button 160 and then pivots the grip portion 100 to the desired angular position. Once the grip portion 100 is moved to the desired position, the clinician releases the lock button 160. The locking spring 164 then biases the locking button 160 toward the sequence of teeth 154 so that the locking portion enters the corresponding locking groove 156 to hold the grip portion 100 in that position during use.

The handle assembly 20 operably supports a first rotary drive system 300, a second rotary drive system 320, and a third axial drive system 400. The rotary drive systems 300, 320 are each powered by a motor 200 operably supported in the grip portion 100. As seen in fig. 2, for example, a motor 200 is supported within the cavity 132 in the grip portion 100 and has a gearbox assembly 202 with an output drive shaft 204 projecting therefrom. In various forms, the motor 200 may be, for example, a DC brushed driving motor having a maximum rotation of about 25,000 RPM. In other constructions, the motor may include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The motor 200 may be powered by a power source 210, which in one form may include a removable power pack 212. The power source 210 may comprise any of a variety of power source configurations, for example, as disclosed in further detail in U.S. patent application publication 2015/0272575 entitled "SURGICAL INSTRUMENTS COMPLISING A SENSOR SYSTEM," the entire disclosure of which is hereby incorporated by reference herein. In the illustrated construction, for example, the power pack 212 may include a proximal housing portion 214 configured for attachment to a distal housing portion 216. The proximal housing portion 214 and the distal housing portion 216 are configured to operably support a plurality of batteries 218 therein. The batteries 218 may each include, for example, a lithium ion ("LI") or other suitable battery. The distal housing portion 216 is configured for removable operable attachment to a handle circuit board assembly 220 that is also operably coupled to the motor 200. The handle circuit board assembly 220 may also be generally referred to herein as a "control system or CPU 224". A plurality of batteries 218 connected in series may be used as a power source for the handle assembly 20. Further, the power source 210 may be replaceable and/or rechargeable. In other embodiments, the surgical instrument 10 may be powered by, for example, Alternating Current (AC). The motor 200 may be controlled by a rocker switch 206 mounted to the grip portion 100.

As described above, the motor 200 is operably coupled to a gearbox assembly 202 that includes an output drive shaft 204. A drive bevel gear 230 is attached to the output drive shaft 204. The motor 200, gearbox assembly 202, output drive shaft 204, and drive bevel gear 230 may also be collectively referred to herein as a "motor assembly 231". The drive bevel gear 230 interfaces with a driven bevel gear 234 attached to a system drive shaft 232 and a pivot bevel gear 238 journaled on a pivot shaft 180. The driven bevel gear 234 is axially movable on the system drive shaft 232 between an engaged position, in which the driven bevel gear 234 is in meshing engagement with the drive bevel gear 230 (fig. 5), and a disengaged position, in which the driven bevel gear 234 is out of meshing engagement with the drive bevel gear 230 (fig. 14). A drive system spring 235 is journaled between the driven bevel gear 234 and a proximal end flange 236 formed on a proximal portion of the system drive shaft 232. See fig. 4 and 14. The drive system spring 235 is used to bias the driven bevel gear 234 out of meshing engagement with the drive bevel gear 230, as will be discussed in further detail below. The pivoting bevel gear 238 facilitates pivotal travel of the output drive shaft 204 and the drive bevel gear 230 with the grip section 100 relative to the main handle section 30.

In the illustrated example, the system drive shaft 232 interfaces with a rotary drive selector system, generally designated 240. For example, in at least one form, the rotary drive selector system 240 includes a shifter gear 250 that is selectively movable between the first rotary drive system 300 and the second rotary drive system 320. As seen in fig. 6-9, for example, the drive selector system 240 includes a shifter mounting plate 242 that is non-movably mounted within the main handle portion 30. For example, the shifter mounting plates 242 may be frictionally retained between mounting lugs (not shown) formed in the housing segments 40, 70 or otherwise retained therein by screws, adhesives, or the like. Still referring to fig. 6-9, the system drive shaft 232 extends through an aperture in the shifter mounting plate 242 and has a central or system drive gear 237 non-rotatably attached thereto. For example, the center drive gear 237 may be attached to the system drive shaft 232 by a keyway configuration 233. See fig. 6-9. In other constructions, the system drive shaft 232 may be rotatably supported in the shifter mounting plate 242 by corresponding bearings (not shown) mounted thereto. In any event, rotation of the system drive shaft 232 will result in rotation of the center drive gear 234.

As seen in fig. 3, the first drive system 300 includes a first drive socket 302 rotatably supported in the distal wall 32 formed in the main handle section 30. The first drive socket 302 may include a first body portion 304 having a splined socket formed therein. A first driven gear 306 is formed on or non-movably attached to the first body portion 304. The first body portion 304 can be rotatably supported in a corresponding hole or channel provided in the distal wall 32, or it can be rotatably supported in a corresponding bearing (not shown) mounted in the distal wall 32. Similarly, the second rotary drive system 320 includes a second drive socket 322 also rotatably supported in the distal wall 32 of the main handle section 30. The second drive socket 322 may include a second body portion 324 having a splined socket formed therein. The second driven gear 326 is formed on or non-rotatably mounted to the second body portion 324. The second body portion 324 can be rotatably supported in a corresponding hole or channel provided in the distal wall 32, or it can be rotatably supported in a corresponding bearing (not shown) mounted in the distal wall 32. The first and second drive sockets 302, 322 are spaced apart from one another on each side of the handle axis HA. See, for example, fig. 4.

As noted above, in the illustrated example, the rotary drive selector system 240 includes the shifter gear 250. As can be seen in fig. 6-9, the shifter gear 250 is rotatably mounted on an idler shaft 252 that is movably supported in an arcuate slot 244 in the shifter mounting plate 242. The shifter gear 250 is mounted for free rotation on an idler shaft 252 and is held in meshing engagement with the center drive gear 234. The idler shaft 252 is coupled to the end of the shaft 262 of the displacer solenoid 260. The shifter solenoid 260 is pinned or otherwise mounted with the main handle housing 30 such that when the shifter solenoid 260 is actuated, the shifter gear 250 moves into meshing engagement with one of the first driven gear 306 or the second driven gear 326. For example, in one configuration, when the solenoid shaft 262 is retracted (fig. 6 and 7), the shifter gear 250 is in meshing engagement with the center drive gear 234 and the first driven gear 306 such that actuation of the motor 200 will result in rotation of the first drive socket 302. As seen in fig. 6 and 7, a shifter spring 266 may be employed to bias the shifter gear 250 to the first actuated position. Thus, if power is lost to the surgical instrument 10, the shifter spring 266 will automatically bias the shifter gear 250 to the first position. When the shifter gear 250 is in this position, subsequent actuation of the motor 200 will result in rotation of the first drive socket 302 of the first rotary drive system 300. When the shifter solenoid is actuated, the shifter gear 250 moves into meshing engagement with the second driven gear 326 on the second drive socket 322. Thereafter, actuation of the motor 200 will result in actuation or rotation of the second drive socket 322 of the second rotary drive system 320.

As will be discussed in further detail below, the first and second rotary drive systems 300, 320 may be used to power various components of the interchangeable surgical tool assembly coupled thereto. As described above, in at least one configuration, the shifter spring 266 will bias the shifter gear 250 to the first position if power from the motor is lost during actuation of the interchangeable surgical tool assembly. Depending on the component of the interchangeable surgical tool assembly that is manipulated, it may be necessary to reverse the application of the rotary drive motion to the first drive system 300 to enable the interchangeable surgical tool assembly to be removed from the patient. The handle assembly 20 of the illustrated example employs a manually actuatable "panic" system, generally designated 330, for example to manually apply a rotary drive motion to the first rotary drive system 300 in the above-described circumstances.

Referring now to fig. 3, 10 and 11, the illustrated emergency system 330 includes an emergency drive train 332 that includes a planetary gear assembly 334. In at least one form, the planetary gear assembly 334 includes a planetary gear housing 336 that houses a planetary gear arrangement (not shown) including a planetary bevel gear 338. The planetary gear assembly 334 includes an emergency drive shaft 340 that is operatively coupled to the planetary gear arrangement within the planetary gear housing 336. Rotation of the planetary bevel gear 338 rotates the planetary gear configuration which ultimately rotates the emergency drive shaft 340. The emergency drive gear 342 is journaled on the emergency drive shaft 340 such that the emergency drive gear 342 is axially movable on the emergency drive shaft 340 and also rotates therewith. Emergency drive gear 342 is movable between a spring stop flange 344 formed on emergency drive shaft 340 and a shaft end stop 346 formed on the distal end of emergency drive shaft 340. An emergency shaft spring 348 is journaled on the emergency drive shaft 340 between the emergency drive gear 342 and the spring stop flange 344. An emergency drive gear 342 is biased distally on the emergency drive shaft 340 by an emergency shaft spring 348. When the emergency drive gear 342 is in its distal-most position on the emergency drive shaft 340, it is in meshing engagement with an emergency driven gear 350 non-rotatably mounted to the system drive shaft 232. See fig. 14.

Referring now to fig. 12 and 13, the bailout system 330 includes a bailout actuator assembly or bailout handle assembly 360 that facilitates manual application of a bailout drive motion to the bailout drive train 332. As can be seen in these figures, the emergency handle assembly 360 includes an emergency bevel gear assembly 362 including an emergency bevel gear 364 and a ratchet gear 366. The bailout handle assembly 360 further includes a bailout handle 370 that is movably coupled to the bailout bevel gear assembly 362 by a pivoting yoke 372 pivotally mounted on the ratchet gear 366. The emergency handle 370 is pivotally coupled to the pivoting yoke 372 by a pin 374 for selective pivotal travel between the storage position "SP" and the actuation position "AP". See fig. 12. The handle spring 376 is used to bias the emergency handle 370 to the actuated position AP. In at least one configuration, for example, the angle between the axis SP representing the storage position and the axis AP representing the actuation position may be about thirty degrees. See fig. 13. As also seen in fig. 13, the emergency handle assembly 360 further includes a ratchet pawl 378 rotatably mounted in a cavity or bore 377 in the pivot yoke 372. Ratchet pawl 378 is configured to meshingly engage ratchet gear 366 when rotated in actuation direction "AD" and then rotate out of meshing engagement when rotated in the opposite direction. The ratchet spring 384 and the spherical member 386 are movably supported in a cavity 379 in the pivot yoke 372 and serve to lockingly engage detents 380, 382 in the ratchet pawl 378 when the emergency handle 370 is actuated (ratcheted).

Referring now to fig. 3 and 10, the emergency system 330 further includes an emergency access panel 390 that is manipulable between an open position and a closed position. In the illustrated construction, the emergency access panel 390 is configured to be removably coupled to the housing segment 70 of the main housing portion 30. Thus, in at least this embodiment, the emergency access panel 390 is considered to be in the "open" position when removed from or separated from the main housing portion 30, and is considered to be in the "closed" position when the emergency access panel 390 is attached to the main housing portion 30 as shown. However, other embodiments are contemplated in which the access panel is movably coupled to the main housing portion such that it remains attached thereto when the access panel is in the open position. For example, in such embodiments, the access panel is pivotally or slidably attached to the main housing portion and is manipulable between an open position and a closed position. In the example shown, emergency access panel 390 is configured to snapably engage a corresponding portion of housing segment 70 to removably retain it in a "closed" position. Other forms of mechanical fasteners, such as screws, pins, etc., may also be used.

Regardless of whether the emergency access panel 390 is separable from the main housing portion 30 or remains movably attached to the main housing portion 30, the emergency access panel 390 includes a drive system locking member or yoke 392 and an emergency locking member or yoke 396, each projecting from or otherwise formed on a rear surface thereof. The drive system locking yoke 392 includes a drive shaft notch 394 that is configured to receive a portion of the system drive shaft 232 therein when the emergency access panel 390 is installed in the main housing portion 30 (i.e., the emergency access panel is in the "closed" position). The drive system lock yoke 392 serves to bias the driven bevel gear 234 into meshing engagement with the drive bevel gear 230 (as opposed to the bias of the drive system spring 235) when the emergency access panel 390 is positioned or installed in the closed position. Further, emergency locking yoke 396 includes an emergency drive shaft notch 397 configured to receive a portion of emergency drive shaft 340 therein when emergency access panel 390 is installed or positioned in the closed position. As seen in fig. 5 and 10, emergency lock yoke 396 also serves to bias emergency drive gear 342 out of meshing engagement with emergency driven gear 350 (as opposed to the bias of emergency shaft spring 348). Thus, when emergency access panel 390 is installed or in a closed position, emergency locking yoke 396 prevents emergency drive gear 342 from interfering with the rotation of system drive shaft 232. Further, the emergency locking yoke 396 includes a handle recess 398 to engage and retain the emergency handle 370 in the storage position SP.

Fig. 4, 5 and 10 illustrate the configuration of the drive system components and emergency system components when the emergency access panel 390 is installed or in a closed position. As can be seen in these figures, the drive system locking member 392 biases the driven bevel gear 234 into meshing engagement with the drive bevel gear 230. Thus, when the emergency access panel 390 is installed or in a closed position, actuation of the motor 200 will result in rotation of the drive bevel gear 230 and ultimately the system drive shaft 232. Additionally, when in this position, emergency locking yoke 396 is used to bias emergency drive gear 342 out of meshing engagement with emergency driven gear 350 on system drive shaft 232. Thus, when the emergency access panel 390 is installed or in the closed position, the drive system may be actuated by the motor 200 and disconnect or prevent the emergency system 330 from applying any actuation motion to the system drive shaft 232. To activate the emergency system 330, the clinician first removes the emergency access panel 390 or otherwise moves the emergency access panel 390 to the open position. This action disengages the drive system locking member 392 from engaging the driven bevel gear 234, allowing the drive system spring 235 to bias the driven bevel gear 234 out of meshing engagement with the drive bevel gear 230. Additionally, removal of emergency access panel 390 or movement of emergency access panel to an open position may also cause emergency lock yoke 396 to disengage from emergency drive gear 342, allowing emergency shaft spring 348 to bias emergency drive gear 342 into meshing engagement with emergency driven gear 350 on system drive shaft 232. Rotation of the emergency drive gear 342 will result in rotation of the emergency driven gear 350 and the system drive shaft 232. Removing the emergency access panel 390 or otherwise moving the emergency access panel 390 to the open position also allows the handle spring 376 to bias the emergency handle 370 to the actuated position shown in fig. 11 and 14. When in this position, the clinician may manually ratchet the emergency handle 370 in a ratchet direction RD, which may result in rotation of the ratchet bevel gear 364 (e.g., in a clockwise direction in fig. 14), ultimately resulting in application of a retraction rotational motion to the system drive shaft 232 via the emergency drive train 332. The clinician may ratchet the emergency handle 370 multiple times until the system drive shaft 232 is rotated multiple times sufficiently to retract the components of the surgical end effector portion of the surgical tool assembly that are attached to the handle assembly 20. Once the emergency system 330 is sufficiently manually actuated, the clinician may then reposition the emergency access panel 390 (i.e., return the emergency access panel 390 to the closed position), thereby causing the drive system locking member 392 to bias the driven bevel gear 234 out of meshing engagement with the drive bevel gear 230 and the emergency locking yoke 396 to bias the emergency drive gear 342 out of meshing engagement with the emergency driven gear 350. As described above, the shifter spring 266 will bias the shifter solenoid 260 to the first actuated position if power is lost or interrupted. In this manner, actuation of the bailout system 330 will result in a reverse or retraction motion being applied to the first rotary drive system 300.

As described above, for example, the surgical stapling instrument can include a manually actuated bailout system configured to retract the staple firing drive. In many instances, the bailout system may require the operation and/or cranking of more than one time to fully retract the staple firing drive. In such instances, users of the stapling instrument may forget how many times they have cranked the bailout device and/or otherwise not know the distance the firing drive needs to be retracted. Various embodiments are contemplated wherein the stapling instrument includes a system configured to detect the position of a firing member of a firing drive, determine the distance that the firing member needs to be retracted, and display that distance to a user of the surgical instrument.

In at least one embodiment, a surgical stapling instrument comprises one or more sensors configured to detect a position of a firing member. In at least one example, the sensor comprises, for example, a hall effect sensor, and can be positioned in the shaft and/or end effector of the stapling instrument. The sensor is in signal communication with a controller of the surgical stapling instrument, which in turn is in signal communication with a display on the surgical stapling instrument. The controller includes a microprocessor configured to compare the actual position of the firing member to a reference or reference position (which includes the fully retracted position of the firing member) and calculate a distance between the actual position of the firing member and the reference position, i.e., a remaining distance.

In addition to the above, the display includes, for example, an electronic display, and the controller is configured to display the remaining distance on the electronic display in any suitable manner. In at least one example, the controller displays a progress bar on the display. In such instances, for example, an empty progress bar may indicate that the firing member is at the end of its firing stroke, and a full progress bar may indicate that the firing member has been fully retracted. In at least one example, for example, 0% can indicate that the firing member is at the end of its firing stroke, and 100% can indicate that the firing member has been fully retracted. In certain examples, the controller is configured to display on the display how many times the panic mechanism needs to be actuated to retract the firing member to its fully retracted position.

In addition to the above, actuation of the arming mechanism can operably disconnect a battery or power source of the surgical stapling instrument from an electric motor of the firing drive. In at least one embodiment, actuation of the emergency mechanism will toggle a switch that electrically decouples the battery from the electric motor. Such a system would prevent manual retraction of the electric motor against the firing member.

The illustrated handle assembly 20 also supports a third axial drive system, generally designated 400. As seen in fig. 3 and 4, in at least one form, the third axial drive system 400 includes a solenoid 402 having a third drive actuator member or rod 410 protruding therefrom. The distal end 412 of the third drive actuator member 410 has a third drive bracket or socket 414 formed therein to receive a corresponding portion of a drive system component of an interchangeable surgical tool assembly operably attached thereto. Solenoid 402 is wired to or otherwise in communication with handle circuit board assembly 220 and control system or CPU 224. In at least one configuration, the solenoid 402 is "spring-loaded" such that when the solenoid 402 is unactuated, its spring member biases the third drive actuator 410 back to the unactuated, starting position.

As noted above, the reconfigurable handle assembly 20 can be advantageously used to actuate a variety of different interchangeable surgical tool assemblies. To this end, the handle assembly 20 includes a tool mounting portion, generally designated 500, for operably coupling an interchangeable surgical tool assembly thereto. In the illustrated example, the tool mounting portion 500 includes two inward facing dovetail receiving slots 502 configured to engage corresponding portions of the tool attachment module portion of the interchangeable surgical tool assembly. Each dovetail receiving slot 502 may be tapered or, in other words, may be slightly V-shaped. Dovetail receiving slot 502 is configured to releasably receive a corresponding tapered attachment or lug portion formed on a portion of a tool attachment nozzle portion of an interchangeable surgical tool assembly. Each interchangeable surgical tool assembly may also be equipped with a latch system configured to releasably engage a corresponding retention pocket 504 formed in the tool mounting portion 500 of the handle assembly 20.

Various interchangeable surgical tool assemblies may have a "primary" rotary drive system configured to operably couple to or interface with the first rotary drive system 310, and a "secondary" rotary drive system configured to operably couple to or interface with the second rotary drive system 320. The primary and secondary rotary drive systems can be configured to provide various rotary motions to portions of a particular type of surgical end effector that form part of an interchangeable surgical tool assembly. To facilitate operably coupling the primary rotary drive system to the first rotary drive system and the secondary rotary drive system to the second rotary drive system 320, the tool mounting portion 500 of the handle assembly 20 further includes a pair of insertion ramps 506 configured to distally bias portions of the primary and secondary rotary drive systems of the interchangeable surgical tool assembly during the coupling process to facilitate aligning and operably coupling the primary rotary drive system to the first rotary drive system 300 on the handle assembly 20 and to align and operably couple the secondary rotary drive system to the second rotary drive system 320 on the handle assembly 20.

The interchangeable surgical tool assembly may further include a "tertiary" axial drive system for imparting axial motion to a corresponding portion of the surgical end effector of the interchangeable surgical tool assembly. To facilitate operably coupling the three-stage axial drive system to the third axial drive system 400 on the handle assembly 20, the third drive actuator member 410 is provided with a socket 414 configured to operably receive therein a lug or other portion of the three-stage axial drive system.

An interchangeable tool assembly 2000 is shown in fig. 15. Interchangeable tool assembly 2000 is similar in many respects to interchangeable tool assembly 1000, but differs in some other respects from interchangeable tool assembly 1000. For example, the interchangeable component 2000 is a circular stitching component. Referring primarily to fig. 15 and 16, circular stapling assembly 2000 includes a shaft portion 2100 and an end effector 2200. The shaft portion 2100 includes a proximal portion that is releasably attached to the handle assembly 20, for example. The end effector 2200 includes a first portion 2210 rotatably attached to the shaft portion 2100 about an articulation joint 2300. The end effector 2200 also includes a second portion 2220 releasably attached to the first portion 2210. The second portion 2220 includes a cartridge portion 2222 that includes an annular array of staple cavities 2224 defined therein and the staples stored in each staple cavity 2224. The second portion 2220 further comprises an anvil 2230 comprising a tissue compression surface 2232 and annular arrays of forming pockets 2234 (fig. 27) aligned with the staple cavities 2224 that are configured to deform the staples as they are ejected from the staple cavities 2224.

In addition to the above, referring again to fig. 15 and 16, the second portion 2220 of the end effector 2200 can be selectively attached to and detached from the first portion 2210 of the end effector 2200. The second portion 2220 includes an outer housing 2227 that includes a proximal connector 2229 configured to be received within an aperture or chamber 2218 defined in the housing 2217 of the first portion 2210. The fit between the connector 2229 of the housing 2227 and the housing 2217 of the first part 2210 is tight. The compression fit between the connector 2229 and the housing 2217 may prevent the second portion 2220 from being accidentally displaced longitudinally and/or rotationally relative to the first portion 2210. In various examples, a detent member can be used to releasably secure the second portion 2220 to the first portion 2210 of the end effector 2200.

Referring to fig. 15 and 35-38, the second portion 2220 of the end effector 2200 may be interchanged with other second portions, such as the second portion 2220 ', the second portion 2220 ", the second portion 2220'", and/or the other second portion 2220. The second portions 2220 ', 2220 ", and 2220'" are similar in many respects to the second portion 2220. For example, each of the second portions 2220, 2220 ', 2220 ", and 2220"' includes a central aperture 2226 defined therein. That is, the second portions 2220 ', 2220 ", and 2220'" are otherwise different from the second portion 2220. For example, the second portion 2220' has a larger diameter than the second portion 2220. In addition, the annular array of staple cavities 2224 defined in the second portion 2220' has a larger circumference than the annular array of staple cavities 2224 defined in the second portion 2220. Similarly, the second portion 2220 "has a larger diameter than the second portion 2220 ', and the annular array of staple cavities 2224 defined in the second portion 2220" has a larger circumference than the annular array of staple cavities 2224 defined in the second portion 2220'. Likewise, the second portion 2220 "'has a larger diameter than the second portion 2220", and the annular array of staple cavities 2224 defined in the second portion 2220 "' has a larger circumference than the annular array of staple cavities 2224 defined in the second portion 2220".

In addition to the above, the anvil 2230 can be interchangeable with other anvils such as the anvil 2230 ', the anvil 2230 "', and/or another anvil 2230. The anvils 2230 ', 2230 "' are similar in many respects to the anvil 2230. For example, each anvil 2230, 2230 ', 2230 "' includes a longitudinal shaft 2236 that includes a connecting flange 2238. That is, the anvils 2230 ', 2230 "' are otherwise different from the anvil 2230. For example, the anvil 2230' has a larger diameter than the anvil 2230. Further, the annular array of forming pockets 2234 defined in the anvil 2230 'has a larger circumference than the annular array of forming pockets 2234 defined in the anvil 2230 such that the forming pockets 2234 remain aligned with the staple cavities 2224 defined in the second portion 2220'. Similarly, the anvil 2230 "has a larger diameter than the anvil 2230 ', and the annular array of forming pockets 2234 defined in the anvil 2230" has a larger circumference than the annular array of forming pockets 2234 defined in the anvil 2230', such that the forming pockets 2234 remain aligned with the staple cavities 2224 defined in the second portion 2220 ". Likewise, the anvil 2230 "' has a larger diameter than the anvil 2230" and the annular array of forming pockets 2234 defined in the second portion 2220 "' has a larger circumference than the annular array of forming pockets 2234 defined in the anvil 2230" such that the forming pockets 2234 remain aligned with the staple cavities 2224 defined in the second portion 2220 "'.

Referring primarily to fig. 17, the shaft portion 2100 includes a proximal connector 2120 and an elongate shaft portion 2110 extending distally from the proximal connector 2120. Proximal connector 2120 includes a first input 2318 and a second input 2418. The first input 2318 is operably connected to an end effector articulation system and the second input 2418 is operably connected to an end effector clamping and staple firing system. The first input 2318 and the second input 2418 may operate in any suitable order. For example, the first input 2318 can be rotated in a first direction to articulate the end effector 2200 in the first direction and correspondingly rotated in a second direction to articulate the end effector 2200 in the second direction. Once the end effector 2200 has been properly articulated, the second input 2428 can be rotated to close the anvil 2230 and clamp tissue against the cartridge portion 2222 of the end effector 2200. As discussed in more detail further below, the second input 2428 can then be operated to fire staples from the staple cavities 2224 and incise tissue captured within the end effector 2200. In various alternative embodiments, the first input 2318 and the second input 2328 may operate in any suitable order and/or simultaneously.

The first input 2318 is mounted to a proximal end of an articulation shaft 2310 that is rotatably mounted in a shaft portion 2010. Referring primarily to fig. 20 and 21, the rotatable articulation shaft 2310 includes a distal end and a worm gear 2312 mounted to the distal end. The worm gear 2312 is threadedly engaged with the articulation slide 2320. More specifically, the articulation slide 2320 includes a threaded bore 2322 defined therein, and the worm gear 2312 is threadedly engaged with the threaded bore 2322. When the articulation shaft 2310 is rotated in a first direction, the worm gear 2312 pushes the articulation slide 2320 distally (fig. 32). When the articulation shaft 2310 is rotated in a second or opposite direction, the worm gear 2312 pulls the articulation slide 2320 proximally (fig. 31). The articulation slide 2320 is slidably supported by an articulation block 2112 fixedly mounted in the distal end of the elongate shaft portion 2110. Movement of the articulation slide 2320 is limited to proximal and distal movement of the articulation block 2112 by a guide slot 2315 defined in the articulation block 2112. The articulation slide 2320 also includes a longitudinal key 2326 extending therefrom that is closely received in a longitudinal keyway 2116 defined in the bottom of the guide slot 2315, which limits relative movement between the articulation slide 2320 and the articulation block 2112 to a longitudinal path.

Referring again to fig. 20, 21, and 24, the articulation slide 2320 is coupled to the articulation link 2330. The articulation sled 2320 includes a drive pin 2324 extending therefrom that is positioned within a proximal bore 2334 defined in the articulation link 2330. The drive pin 2324 is closely received within the aperture 2334 such that the drive pin 2324 and the side wall of the aperture 2334 cooperate to define an axis of rotation between the articulation slide 2320 and the articulation link 2330. Articulation link 2330 is also coupled to housing 2217 of end effector 2200. More specifically, articulation link 2330 further includes a distal aperture 2335 positioned therein, and outer housing 2217 includes a pin 2215 positioned in distal aperture 2335. The pin 2215 is closely received within the hole 2335 such that the pin 2215 and the sidewalls of the hole 2335 cooperate to define an axis of rotation between the articulation link 2330 and the housing 2217.

In addition to the above, referring to fig. 18-21 and 24, end effector 2200 is rotatably coupled to articulation block 2112 of shaft 2100 about articulation joint 2300. The housing 2217 of the end effector 2200 includes apertures 2213 defined in opposing sides thereof, and the articulation block 2112 includes projections 2113 extending from opposing sides thereof that are positioned in the apertures 2213. Protrusion 2113 is closely received within aperture 2213 such that protrusion 2113 and the sidewall of aperture 2213 cooperate to define an articulation axis about which end effector 2200 may be articulated. As the articulation shaft 2310 is rotated to drive the articulation slide 2320 distally, the articulation slide 2320 drives the proximal end of the articulation link 2330 distally. In response to distal movement of the proximal end of the articulation link 2330, the articulation link 2330 rotates about the drive pin 2324 which rotates the end effector 2200 about the articulation joint 2300. When the articulation input device 2310 is rotated to drive the articulation slide 2320 proximally, similar to the above, the articulation slide 2320 pulls the proximal end of the articulation link 2330 proximally. In response to proximal movement of the proximal end of the articulation link 2330, the articulation link 2330 rotates about the drive pin 2324 which rotates the end effector 2200 about the articulation joint 2300. The articulation link 2330 provides at least one degree of freedom between the articulation slide 2320 and the housing 2217. Thus, the articulation linkage 2330 allows the end effector 2200 to articulate through a wide range of articulation angles.

As described above, referring to fig. 17 and 25, the proximal connector 2120 of the interchangeable tool assembly 2000 includes the second input 2418. The second input 2418 includes a drive gear 2417 that meshingly engages with a drive gear 2416 mounted on a proximal end of the drive shaft 2410. A drive shaft 2410 extends through the shaft portion 2110 and a hole 2114 defined in the articulation block 2112, as shown in fig. 19. The bore 2114 includes a bearing and rotatably supports the drive shaft 2410. Alternatively, the holes 2114 may comprise clearance holes. In either case, referring primarily to fig. 22, the drive shaft 2410 extends through the articulation joint 2300 and into a chamber 2218 defined in the end effector housing 2217. Drive shaft 2410 is rotatably supported by a bearing 2414 mounted to drive shaft 2410, which is captured within a recess 2214 defined in a housing 2217 of end effector 2200. The drive shaft 2410 also includes an output gear 2412 mounted to a distal end thereof such that rotation of the drive shaft 2410 is transmitted to the output gear 2412.

Referring primarily to fig. 18, 22, and 23, the output gear 2412 of the drive shaft 2410 is operably engaged with the transmission 2420. As discussed in greater detail below, the transmission 2420 is configured to displace the end effector 2200 between a first mode of operation wherein the drive shaft 2410 moves the anvil 2230 relative to the cartridge body 2222 and a second mode of operation wherein the drive shaft 2410 fires the staples from the staple cavities 2224 and cuts into tissue captured between the anvil 2230 and the cartridge body 2222. The transmission 2420 includes an orbital drive that includes a planetary plate 2421 and four planetary gears 2424 rotatably mounted to the planetary plate 2421. The planet plate 2421 includes a clearance hole extending through its center, and the drive shaft 2410 extends through the clearance hole. The planet plate 2421 and planet gears 2424 are positioned in a chamber 2219 defined in the end effector housing 2217. Each planet gear 2424 is rotatable about a gear pin 2423 extending from planet plate 2421. Gear pin 2423 is positioned along a circumference about the clearance hole. Output gear 2412 is meshingly engaged with planet gears 2424, and as described in more detail below, drive shaft 2410 drives planet gears 2424.

In addition to the above, a drive shaft 2410 extends through the articulation joint 2300. In order to maintain the output gear 2412 in proper engagement with the planetary gear 2424 when the end effector 2200 is articulated, the drive shaft 2410 is flexible. In at least one example, the drive shaft 2410 is constructed of, for example, plastic.

As described above, the transmission device 2420 includes a first mode of operation and a second mode of operation. Referring primarily to fig. 23 and 28, the interchangeable tool assembly 2000 further includes a shifter 2600 movable between a first position and a second position to switch the transmission 2420 between its first and second modes of operation. When the shifter 2600 is in its first position, as shown in fig. 28-30, the shifter 2600 is not engaged with the planet plates 2421 of the transmission 2420, and thus, the planet plates 2421 and the planet gears 2424 are rotated by the drive shaft 2410. More specifically, drive shaft 2410 rotates planet gears 2424 about their respective gear pins 2423, and planet gears 2424 rotate planet plates 2421 due to reaction forces between planet gears 2424 and annular ring gear 2534 extending about planet gears 2424, as described in more detail further below. The planet plates 2421 are operably coupled with the output coupling 2430 such that rotation of the planet plates 2421 is transmitted to the output coupling 2430. Referring primarily to fig. 23, the output coupling 2430 includes an array of holes 2433 extending around its outer periphery, with gear pins 2423 extending from the planet plate 2421 extending to and closely received by the holes 2433 defined in the output coupling 2430 such that there is little relative movement between the planet plate 2421 and the output coupling 2430.

Referring primarily to fig. 18 and 23, the output coupling 2430 includes a drive socket 2432. The drive socket 2432 comprises a bore, for example, generally hexagonal; however, any suitable configuration may be utilized. The drive socket 2432 is configured to receive a closure shaft 2440 that extends through the second portion 2220 of the end effector 2200. The closure shaft 2440 includes a proximal drive end 2442 having a generally hexagonal shape that is closely received within the drive socket 2432 such that rotation of the drive shaft 2410 can be transmitted to the closure shaft 2440. The closing shaft 2440 is rotatably supported within the housing 2227 of the second portion 2220 by a bearing 2444. The bearing 2444 includes, for example, a thrust bearing; however, the bearing 2444 may comprise any suitable bearing.

Referring primarily to fig. 23 and 28-30, the closure shaft 2440 includes a threaded portion 2446 that is threadably engaged with a threaded bore 2456 defined in the trocar 2450. As discussed in greater detail further below, the anvil 2230 can be attached to a trocar 2450 that can be translated to move the anvil 2230 toward and/or away from the cartridge body 2222. Referring again to fig. 18, the trocar 2450 includes at least one longitudinal keyway 2459 defined therein that is configured to cooperate with at least one longitudinal key extending from the inner surface 2546 of the drive sleeve 2540. The drive sleeve 2540 is part of a staple firing system, as discussed further below, and the reader should appreciate that the trocar 2450 and the drive sleeve 2540 slide relative to one another in one aspect, and cooperatively inhibit relative rotational movement therebetween in another aspect. Due to the threaded engagement between the closure shaft 2440 and the trocar 2450, the closure shaft 2440 can displace or translate the trocar 2450 distally when the closure shaft 2440 is rotated in a first direction and, correspondingly, displace or translate the trocar 2450 proximally when the closure shaft 2440 is rotated in a second or opposite direction.

As described above, the anvil 2230 can be attached to the trocar 2450. The anvil 2230 includes an attachment flange 2238 configured to engage and grip the trocar 2450. The attachment flange 2238 includes a cantilevered beam that is attached to the shaft portion 2236 of the anvil 2230. Referring primarily to fig. 23, the trocar 2450 includes a retention notch or recess 2458 that is configured to releasably receive the attachment flange 2238 when the anvil 2230 is assembled to the trocar 2450. The retention notch 2458 and the attachment flange 2238 are configured to resist inadvertent disengagement of the anvil 2230 from the trocar 2450. The attachment flanges 2238 are spaced apart by longitudinal slots 2237. The longitudinal slot 2237 is configured to receive a longitudinal rib 2457 extending from the trocar 2450 when the anvil 2230 is assembled to the trocar 2450. The ribs 2457 are closely received within the slots 2237 and, thus, inhibit rotation of the anvil 2230 relative to the trocar 2450.

Once the anvil 2230 has been properly positioned relative to the cartridge portion 2222, the tool assembly 2000 can be displaced into its second mode of operation, as described above. The shifter 2600 comprises, for example, an electrically actuated motor for shifting the transmission 2420 of the end effector 2200. In various other embodiments, the displacer 2600 may include any suitable device that is actuated electrically and/or manually. The shifter 2600 is in signal communication with a processor of the surgical stapling instrument and is in power communication with a battery of the surgical stapling instrument. In various examples, an insulated wire extends, for example, between the shifter 2600 and a handle of a surgical instrument such that the processor can communicate with the shifter 2600 and the battery can provide power to the shifter 2600. In various other examples, shifter 2600 may comprise a wireless signal receiver and the processor may be in wireless communication with shifter 2600. In certain examples, power can be provided wirelessly to the shifter 2600, e.g., through inductive circuitry. In various examples, shifter 2600 may include its own power supply.

Distractor 2600 comprises a housing that is mounted in a chamber 2218 defined in a proximal end of end effector 2200. The shifter 2600 includes a clutch key or toggle 2602 and an output shaft 2604 that is movable between a first position and a second position relative to the shifter housing. The clutch key 2602 includes a first lock tooth 2608 and a second lock tooth 2609, and when the clutch key 2602 is in its first position, the first lock tooth 2608 is engaged with the firing tube 2530 of the staple firing system and, at the same time, the second lock tooth 2609 is disengaged from the planet plate 2421 of the transmission 2420. More specifically, the first lock tooth 2608 is positioned in a hole 2538 that is part of an annular array of holes 2538 defined about the firing tube 2530, and the second lock tooth 2609 is not positioned in a hole 2429 that is part of an annular array of holes 2429 defined about the planet plate 2421. For the reasons described above, the shifter 2600 prevents the firing tube 2530 from rotating and, thus, locks the staple firing system when the clutch key 2602 is in its first position. While the staple firing system is locked by the shifter 2600 when the clutch key 2602 is in its first position, the drive shaft 2410 may rotate the planet plate 2421 and operate the anvil closure system, as described above.

As shown in FIG. 23, the firing tube 2530 includes an inner annular gear rack 2534 defined in an inner sidewall 2532 thereof. Planetary gears 2424 operably intermesh with rack 2534. When the shifter 2600 is in its first position, as shown in fig. 28, the firing tube 2530 is held in place by the shifter 2600 and the planet gear 2424 can be rotated relative to the firing tube 2530 and the rack 2534 by the drive shaft 2410. In the example, the planet gears 2424 rotate about longitudinal drive axes defined by the drive shafts 2410 and, simultaneously, about axes defined by their respective gears 2423. The reader will appreciate that planet gears 2424 are driven directly by the drive shaft 2410 and that planet gears 2424 drive and rotate planet plates 2421 due to the reaction forces generated between planet gears 2424 and the firing tube 2530. When the shifter 2600 is actuated to move the clutch key 2602 to its second position, the first lock tooth 2608 is disengaged from the firing tube 2530 and, at the same time, the second lock tooth 2609 is engaged with the planet plate 2421. When the clutch key 2602 is in its second position, the planet plates 2421 are held in place by the shifter 2600 and, thus, the closure drive is locked and inoperable to move the anvil 2230. As the drive shaft 2410 rotates in the example, the output gear 2412 drives and rotates the planet gears 2424 about their respective gear pins 2423 relative to the planet plates 2421. The planet gear 2424 drives the firing tube 2530 via the rack 2534 and rotates the firing tube 2530 about its longitudinal axis.

In addition to the above, and referring again to FIG. 23, the firing tube 2530 is operably coupled to a drive sleeve 2540 of the staple firing system. More specifically, the inner sidewall 2532 of the firing tube 2530 includes a longitudinal slot 2535 defined therein that is configured to closely receive a longitudinal rib 2545 defined on the drive sleeve 2540 such that the drive sleeve 2540 rotates with the firing tube 2530. The drive sleeve 2540 also includes a threaded distal end 2542 that is threadedly engaged with the drive collar 2550. More specifically, the drive collar 2550 includes a threaded bore 2552 that is threadedly engaged with the threaded distal end 2542. The drive collar 2550 is positioned in a bore 2228 defined in the housing of the end effector 2200 and is prevented from rotating within the bore 2228, for example by a longitudinal rib and groove arrangement. For the reasons described above, rotation of the drive sleeve 2540 longitudinally translates the drive collar 2550. For example, the drive collar 2550 is distally advanced when the drive sleeve 2540 is rotated in a first direction and proximally retracted when the drive sleeve 2540 is rotated in a second or opposite direction.

When the drive collar 2550 is pushed distally, as described above, the drive collar 2550 pushes the staple drive block 2560 and cutting member 2570, such as a knife, distally, for example, during the firing stroke of the staple firing system. More particularly, the drive collar 2550 urges the staple drive block 2560 and cutting member 2570 between a proximal unfired position, wherein the staples are positioned in the staple cavities 2224 defined in the cartridge body portion 2222 and the cutting member 2570 is recessed below the deck surface of the cartridge body portion 2222, and a distal fired position, wherein the staples are deformed against the anvil 2230 and tissue captured between the anvil 2230 and the cartridge body portion 2222 is transected by the cutting member 2570. The drive collar 2550 includes a drive recess 2554 configured to abut the staple drive block 2560 and the cutting member 2570 as the drive collar 2550 is advanced distally. The staple drive block 2560 comprises a plurality of staple supports defined therein, wherein each staple support is configured to support a base of a staple. The staple supports are aligned with the staple cavities 2224 defined in the cartridge body portion 2222 and are arranged in at least two concentric rows.

The staple drive block 2560 and cutting member 2570 are attached to the drive collar 2550 such that when the drive collar 2550 is moved proximally away from the anvil 2230, the staple drive block 2560 and cutting member 2570 are pulled proximally by the drive collar 2550. In at least one example, the staple drive block 2560 and the cutting member 2570 comprise one or more hooks that extend into holes 2557 defined in the drive collar 2550. In various examples, the staple drive block 2560 and the cutting member 2570 can be retracted such that they are fully retracted below the deck surface of the cartridge body portion 2222.

In addition to the above, the end effector 2200 can be operable in a third operating mode wherein the clutch key 2602 of the shifter 2600 is simultaneously operably engaged with the anvil closure system and the staple firing system. In this mode of operation, the first lock tooth 2608 is engaged with a firing tube 2530 of the staple firing system and the second lock tooth 2609 is engaged with the planet plates 2421 of the transmission 2420. In the example, the first lock tooth 2608 is positioned in a hole 2538 defined in the firing tube 2530 and the second lock tooth 2609 is positioned in a hole 2429 defined in the planet plate 2421. For the reasons described above, the drive shaft 2410 simultaneously moves the anvil 2230, staple drive block 2560 and cutting member 2570 relative to the cartridge body 2222.

Referring again to fig. 15, a user of the interchangeable tool assembly 2000 can select from a set of second portions 2220, 2220 ', 2220 ", 2220'", and/or any other suitable second portions, and assemble the selected second portions to the first portion 2210 of the end effector 2200. Referring primarily to fig. 18, when the second parts are assembled to the first part 2210, each second part includes a housing connector 2229 that engages a housing 2217 of the first part 2210. In addition, when the second parts are assembled to the first part 2210, each second part includes a closure shaft 2440 that operably engages a drive socket 2432 of the first part 2210. In addition, when the second portions are assembled to the first portion 2210, each second portion includes a drive sleeve 2540 that operably engages the firing tube 2530 of the first portion 2210.

In addition to the above, referring to fig. 35 and 36, tool assembly 2000' is interchangeable with tool assembly 2000. The tool assembly 2000 is similar in many respects to the tool assembly 2000; however, tool assembly 2000' is configured to apply a circular staple line having a larger diameter than the circular staple line applied by tool assembly 2000. The tool assembly 2000 'includes, among other things, a wider second portion 2220', staple drivers 2560 ', a knife assembly 2570', a cartridge body 2222 ', and an anvil 2230'. Referring to fig. 37, the tool assembly 2000 "is interchangeable with the tool assembly 2000. Tool assembly 2000 "is similar in many respects to tool assemblies 2000 and 2000'; however, tool assembly 2000 "is configured to apply a circular staple line having a larger diameter than the circular staple line applied by tool assembly 2000'. The tool assembly 2000 "includes, among other things, a wider second portion 2220", staple drivers 2560 ", a knife assembly 2570", a cartridge body 2222 ", and an anvil 2230". Referring to fig. 38, tool assembly 2000 "' is interchangeable with tool assembly 2000. Tool assembly 2000 '"is similar in many respects to tool assemblies 2000, 2000', and 2000"; however, tool assembly 2000' "is configured to apply a circular staple line having a larger diameter than the circular staple line applied by tool assembly 2000". The tool assembly 2000 "'includes, among other things, a wider second portion 2220"', a staple driver 2560 "', a knife assembly 2570"', a cartridge body 2222 "', and an anvil 2230"'.

In various embodiments, the surgical instrument can have any suitable number of operating modes other than those described above. In at least one embodiment, a surgical stapling instrument includes a transmission including a first mode of operation for firing staples, a second mode of operation for deploying a cutting member, and a third mode of operation for simultaneously firing staples and deploying a cutting member. In the first mode of operation, the cutting member is not deployed. Further, the processor of such a surgical instrument may be programmed such that the instrument cannot be placed in the second mode of operation without first completing the first mode of operation. For the reasons described above, a user of the surgical instrument may decide whether to cut tissue after firing the staples.

An alternative embodiment of a staple cartridge body for use with a surgical stapler is shown in FIG. 34. The cartridge body 2222 'includes an outer annular row of staple cavities 2224 and an inner annular row of staple cavities 2224'. The staple cavities 2224 are defined in a first step of the cartridge body deck and the staple cavities 2224' are defined in a second step of the cartridge body deck. The second step extends above the first step. In other words, the first step has a first landing height and the second step has a second landing height, which is higher than the first landing height. A platform wall separates the first step and the second step. In various embodiments, the platform wall is sloped. In certain embodiments, the platform wall is orthogonal to the first step and/or the second step.

The cartridge body 2222 'also includes a cavity extension 2229' that extends from the first step of the deck. The cavity extensions 2229' surround the ends of the staple cavities 2224 and extend the staple cavities 2224 above the first step. The cavity extension 2229' can at least partially control the staples above the first step when ejecting the staples from the staple cavities 2224. The cavity extensions 2229 'are also configured to contact the captured tissue and compress the tissue against the cartridge body 2222'. The cavity extensions 2229 'can also control the flow of tissue relative to the cartridge body 2222'. For example, the cavity extension 2229' may limit radial flow of tissue. Cavity extension 2229' may have any suitable configuration and may extend from the first step any suitable height. In at least one example, the top surface of cavity extension 2229' is aligned with or has the same height as the second step, for example. In other examples, cavity extension 2229' may extend above or below the second step.

In addition to the above, the staple cavities 2224 each include a first staple positioned therein that has a first unformed height. The staple cavities 2224' each include a second staple positioned therein that has a second unformed height that is different than the first unformed height. For example, the first unformed height is higher than the second unformed height; however, the second unformed height may be higher than the first unformed height. In an alternative embodiment, the first unformed staple height and the second unformed staple height are the same.

The first staples are deformed to a first deformed height and the second staples are deformed to a second deformed height different from the first deformed height. For example, the first deformation height is higher than the second deformation height. This configuration may improve blood flow into the stapled tissue. Alternatively, the second deformation height may be higher than the first deformation height. This configuration may improve the flexibility of the tissue along the inner transverse line. In certain alternative embodiments, the first deformed height and the second deformed height are the same.

As noted above, the interchangeable tool assembly may include, among other things, a shaft, an end effector, and a replaceable staple cartridge. The replaceable staple cartridge comprises: a closure drive configured to move to open and close the end effector to capture tissue within the end effector, and a firing drive configured to staple and sever tissue captured within the end effector. When the replaceable staple cartridge is assembled to the shaft, the closure drive and firing drive of the end effector are operably coupled with the corresponding closure drive and firing drive of the shaft. In the event that the replaceable staple cartridge is not properly assembled to the shaft, the replaceable staple cartridge may not operate in its intended manner. As described in more detail below, the replaceable staple cartridge and/or the shaft may include a lockout that prevents the replaceable staple cartridge from operating unless the replaceable staple cartridge is properly attached to the shaft.

Turning now to fig. 39, an interchangeable tool assembly 3000 includes a shaft 3010 and a replaceable staple cartridge 3020. Similar to the above, the replaceable staple cartridge 3020 comprises a closure drive input and a firing drive input that are operably coupled to the closure drive output and the firing drive output, respectively, when the staple cartridge 3020 is fully seated on the shaft 3010. For the sake of brevity, the operation of such closure and firing systems is not repeated herein.

Interchangeable tool assembly 3000 also includes lockout circuit 3090. Latch circuit 3090 includes conductors 3096 and contacts 3092. First contact 3092 is electrically coupled to first conductor 3096, and second contact 3092 is electrically coupled to second conductor 3096. Prior to fully seating the staple cartridge 3020 onto the shaft 3010, the first contacts 3092 are not electrically coupled to the second contacts 3092. The staple cartridge 3020 includes a contact bridge 3094 that incorporates electrical coupling contacts 3092 when the staple cartridge 3020 is fully seated on the shaft 3010. Contacts 3092 and contact bridge 3094 are constructed and arranged such that when staple cartridge 3020 is only partially seated on shaft 3010, contact bridge 3094 does not electrically couple contact 3092.

The interchangeable tool assembly 3000 may be used with a surgical instrument system including, for example, a manually operable handle and/or a robotic system. In various embodiments, the surgical instrument system comprises an electric motor configured to drive the staple firing system of the tool assembly 3000, and further comprises a controller configured to operate the electric motor. The latching circuit of the tool assembly 3000 communicates with the controller. When the controller detects that the contact bridge 3094 is not engaged with the contacts 3092, or the lockout circuit is in an open state, the controller prevents the electric motor from operating the staple firing system. In various examples, the controller is configured such that it does not provide power to the electric motor when the lockout circuit is in the open state. In certain other examples, the controller is configured to provide power to the electric motor such that it operates the closure system rather than the firing system when the lockout circuit is in the open state. In at least one such example, the controller operates a transmission coupled to the electric motor such that the output of the electric motor is directed only to the closed system. When the controller detects that the contact bridge 3094 is engaged with the contacts 3092, or that the lockout circuit is in a closed state, the controller allows the electric motor to operate the staple firing system.

When the surgical instrument system includes a handle, in addition to the above, the controller can actuate a trigger lock that prevents a firing trigger of the handle from being actuated when the controller detects that the lockout circuit is in the open configuration. When the staple cartridge 3020 is fully seated on the shaft 3010 and the lockout circuit is closed, the controller may retract the trigger lock and allow the firing trigger to be actuated. Such systems may be used with motorized and/or non-motorized firing drives. For example, the non-motorized firing drive may be driven by a hand crank.

As described above, the anvil 2230 may be fitted to the trocar shaft 2450 of the closure drive of the tool assembly 2000. The attachment flange 2238 of the anvil 2230 is configured to engage a recess 2458 defined in the trocar shaft 2450 to attach the anvil 2230 thereto. Once the anvil 2230 is assembled to the trocar shaft 2450, the trocar shaft 2450 and anvil 2230 can be retracted or pulled toward the staple cartridge 2222 by closing the drive to compress the tissue against the staple cartridge 2222. However, in some instances, the anvil 2230 may not fit properly to the trocar shaft 2450. When the clinician attempts to assemble the anvil 2230 to the trocar shaft 2450, misassembly of the anvil 2230 and trocar shaft 2450 can often occur if the trocar shaft 2450 does not extend sufficiently above the deck of the staple cartridge 2222. Generally, in the example, the anvil 2230 is sufficiently attached to the trocar shaft 2450 such that the trocar shaft 2450 can move the anvil 2230 toward the staple cartridge 2222, but when the anvil 2230 begins to compress tissue against the staple cartridge 2222, the anvil 2230 can separate from the trocar shaft 2450.

Turning now to fig. 39 and 40, there is shown an interchangeable tool assembly 3100 that is similar in many respects to interchangeable tool assembly 2000 discussed above. The tool assembly 2000 comprises a cartridge body 3120 that includes a deck 3121 configured to support tissue as the tissue is compressed against the cartridge body 3120 by the anvil 2130. The tool assembly 3100 further comprises a closure drive configured to move the anvil 2130 relative to the cartridge body 3120. The closure drive includes a trocar shaft 3150 that includes a recess defined therein, similar to that described above. The recess includes a distal shoulder 3158 configured to retain the anvil 2130 to the trocar shaft 3150. In addition, the tool assembly 3100 also includes a firing drive configured to eject the staples from the cartridge body 3120. The firing drive includes a rotatable shaft 3162 and a translatable collar 3160 threadably engaged with the rotatable shaft 3162, the translatable collar being configured to eject staples from the cartridge body 3120. The rotatable shaft 3162 includes a longitudinal bore 3164 defined therein, and the trocar shaft 3150 extends through the bore 3164.

In addition to the above, the closure drive also includes a clamp 3190 mounted to the trocar shaft 3150. Clamp 3190 includes a base 3192 that fits within a slot defined in trocar shaft 3150. The clamp 3190 also includes compliant arms or appendages 3198 extending from the base 3192. The arm 3198 is movable between an extended position (fig. 39) and a flexed position (fig. 40). When the arm 3198 is in its flexed position, as shown in fig. 40, the anvil 2130 may be locked to the trocar shaft 3150. When the trocar shaft 3150 extends sufficiently above the platform 3121 of the cartridge body 3120, as shown in fig. 40, the arm 3198 is held in its flexed position by the translatable collar 3160 of the firing drive. Translatable collar 3160 includes an annular shoulder 3168 configured to resiliently bias arms 3198 inwardly when arms 3198 contact shoulder 3168.

When the trocar shaft 3150 is not in a sufficiently extended position above the cartridge platform 3121, the arms 3198 are not biased inwardly by the shoulders 3168. In the example, the arm 3198 is in its extended position, as shown in fig. 39. When arm 3198 is in its extended position, arm 3198 prevents attachment of anvil 2130 to trocar shaft 3150. More specifically, the arm 3198 prevents the connecting flange 2138 of the anvil 2130 from being seated behind the shoulder 3158 defined in the trocar shaft 3150. In the example, the arm 3198 prevents the anvil 2130 from partially attaching to the trocar shaft 3150 and, as a result, a clinician attempting to assemble the anvil 2130 to the trocar shaft 3150 cannot partially assemble the anvil 2130 to the trocar shaft 3150 and the above-described problems can be avoided. The reader will appreciate that the anvil 2130 is typically fitted onto the trocar shaft 3150 in situ or within the patient, and that proper fitting of the anvil 2130 onto the trocar shaft 3150 will accelerate the completion of the surgical technique employed. The above-described system provides a latch that prevents a partially assembled anvil from being compressed against tissue.

Turning now to fig. 41-43, interchangeable tool assembly 3200 includes a latch configured to prevent retraction of the closure drive when no anvil is attached thereto, as discussed in more detail below. The tool assembly 3200 includes a shaft 3210 and an end effector 3220. The end effector 3220 includes an outer housing 3227, a cartridge body 3222, and a longitudinal bore 3226 defined therethrough. The tool assembly 3200 also includes a closure drive comprising a trocar shaft 3250 and an anvil 3230 attachable to the trocar shaft 3250. Similar to the above, the closure drive can be configured to move the anvil 3230 toward and away from the cartridge body 3222. Trocar shaft 3250 is movable between an extended position and a retracted position. Both fig. 42 and 43 show the trocar shaft 3250 in its extended position.

In addition to the above, tool assembly 3200 also includes a retraction lock 3290 configured to prevent movement of trocar shaft 3250 from its extended position (fig. 42 and 43) toward its retracted position when anvil 3230 is not assembled to trocar shaft 3250. Retraction lock 3290 includes a lock arm 3292 rotatably mounted to housing 3227 about a projection or pin 3294. The retraction lock 3290 also includes a spring 3296 engaged with the lock arm 3292 and configured to bias the lock arm 3292 toward the trocar shaft 3250. Trocar shaft 3250 includes a lock shoulder 3258 and, when anvil 3230 is not assembled to trocar shaft 3250, as shown in fig. 42, lock arm 3292 is configured to capture lock shoulder 3258 and prevent proximal movement of trocar shaft 3250. More specifically, lock arm 3292 includes a catch 3298 configured to slide under lock shoulder 3258. When anvil 3230 is assembled to trocar shaft 3250, anvil 3230 contacts lock arm 3292 and displaces lock arm 3292 away from lock shoulder 3258, as shown in fig. 43. At this point, the trocar shaft 3250 has been unlocked and can be moved toward the cartridge body 3222 to its retracted position.

Turning now to fig. 44-46, the interchangeable tool assembly 3300 includes a closure drive, a staple firing drive, and a latch configured to prevent the staple firing drive from being operated until the closure-driven anvil is set to the correct tissue gap, as discussed in more detail below. The tool assembly 3300 includes a shaft 3310 and an end effector 3320. The end effector 3320 comprises an inner frame 3329, an outer housing 3327, and a cartridge body 3322. Similar to the above, the closure drive device includes a trocar shaft 3350 and an anvil 2230 attachable to the trocar shaft 3350. Also similar to the above, the trocar shaft 3350 can be movable between an extended position (fig. 45) and a retracted position (fig. 46) to move the anvil 2230 toward and away from the cartridge body 3322. The firing drive includes a rotatable shaft 3360 that is configured to distally displace the firing drive to eject the staples stored in the cartridge body 3322.

In addition to the above, the end effector 3320 includes a firing drive lock 3390 movably mounted to the internal frame 3329. Firing drive lock 3390 includes a lock pin 3394 and a lock spring 3398 positioned around lock pin 3394. Locking pin 3394 includes a head 3392 and a stop 3396. A locking spring 3398 is positioned intermediate the stop 3396 and the side wall of the cavity 3328 defined in the internal frame 3329. When the trocar shaft 3350 is in the extended position, as shown in FIG. 45, a lock spring 3398 biases a lock pin 3394 into a lock aperture 3364 defined in the rotatable shaft 3360 of the staple firing drive assembly. In such an example, the interaction between the lock pin 3394 and the side walls of the lock hole 3364 prevents the shaft 3360 from being rotated to fire the staples from the cartridge body 3322. When the trocar shaft 3350 is fully retracted, the trocar shaft 3350 engages the head 3392 of the locking pin 3394. The head 3392 includes a cam surface defined thereon that is configured to be engaged by the trocar shaft 3350 to move the firing drive lock 3390 between a locked configuration (fig. 45) and an unlocked configuration (fig. 46). When the drive lock 3390 is in its unlocked configuration, the shaft 3360 of the firing drive may be rotated.

Firing drive lockout of the tool assembly 3300 requires the anvil 2230 to move to or within a predetermined position before the staples can be fired. In addition, the firing drive lockout of the tool assembly 3300 requires that the tissue gap between the anvil 2230 and the cartridge body 3322 be less than a certain distance before the staples can be fired. Thus, the position of the anvil 2230 and/or the closure system will deactivate the staple firing lockout. Such a configuration may help prevent malformation of the staples and/or under compression of the tissue, among other things.

Turning now to fig. 47-49, the interchangeable tool assembly 3400 includes a closure drive configured to clamp tissue, a staple firing drive, and a firing drive lockout 3490 configured to prevent the staple firing drive from operating until the closure drive applies sufficient clamping pressure to the tissue. The closure drive includes a trocar shaft 3450 and an anvil, such as anvil 2230, attached to trocar shaft 3450. Similar to the above, the trocar shaft 3450 can be moved from the extended position (fig. 48) to the retracted position (fig. 49) to compress tissue against the cartridge body of the tool assembly 3400. The firing drive arrangement includes a rotatable shaft 3460 that is configured to distally displace the staple drivers and eject the staples from the cartridge body.

A firing drive lockout 3490 is positioned intermediate the trocar shaft 3450 of the closure drive and the rotatable shaft 3460 of the firing drive. The firing drive lockout 3490 includes a distal plate 3492, a proximal plate 3494, and a spring 3493 positioned intermediate the distal plate 3492 and the proximal plate 3494. The firing drive lockout 3490 also includes a lock pin 3498 movable between a locked configuration (fig. 48) in which the lock pin 3498 is engaged with the shaft 3460 and an unlocked configuration (fig. 49) in which the lock pin 3498 is disengaged from the shaft 3460. The locking pins 3498 are positioned in a pin chamber 3496 defined between the distal plate 3492 and the proximal plate 3494. More specifically, the latch 3498 includes an angled head positioned intermediate a cam 3495 defined on the distal plate 3492 and a cam 3495 defined on the proximal plate 3494. As the trocar shaft 3450 is retracted proximally, the trocar shaft 3450 pushes the distal plate 3492 proximally and the cam 3495 defined on the distal plate 3492 engages the heads of the detents 3498. In the example, a cam 3495 defined on the distal plate 3492 cooperates with a cam 3495 defined on the proximal plate 3494 to displace the latch 3498 to its unlatched configuration, as shown in fig. 49.

As described above, as the distal plate 3492 is moved by the trocar shaft 3450 toward the proximal plate 3494, the cam 3495 of the firing drive latch 3490 compresses the heads of the detents 3498. More specifically, the cam 3495 drives the detents 3498 inward and out of engagement with the rotatable shaft 3460. When the lock-pin 3498 is in its locked configuration, the lock-pin 3498 is positioned in a lock aperture 3468 defined in the shaft 3460, and the lock-pin 3498 prevents the shaft 3460 from rotating due to the interaction between the lock-pin 3498 and the sidewall of the lock aperture 3468. Thus, the staples cannot be fired from the cartridge body by the firing drive. When the lock-pin 3498 is moved to the unlocked configuration, the lock-pin 3498 is moved out of the lock-hole, as described above, and the shaft 3460 can be rotated by the firing drive to fire the staples from the cartridge body. In various embodiments, the shaft 3460 can include a circumferential array of lock apertures 3468 defined in the shaft 3460, each configured to receive a lock pin 3498 and lock the firing drive. 49-51, the firing drive lockout 3490 also includes a biasing member, such as a spring 3499, configured to bias the lock pin 3498 into the lock hole 3468.

In addition to the above, the spring 3493 of the firing drive latch 3490 is configured to resist proximal movement of the trocar shaft 3450. The spring 3493 is a linear coil spring; however, any suitable spring may be used. Further, more than one spring may be used. In any event, the spring 3493 or spring system has a stiffness that applies a spring force to the distal plate 3492 of the firing drive latch 3490 when the trocar shaft 3450 is retracted. In other words, the force applied to distal plate 3492 by spring 3493 increases in proportion to the distance that trocar shaft 3450 is displaced proximally. The spring force generated by the spring 3493 opposes the clamping force applied to the tissue by the anvil 2230. Thus, the clamping force must overcome some or a predetermined spring force generated by the spring 3493 in order to sufficiently displace the distal plate 3492 and unlock the firing drive. In such instances, the tissue clamping force must reach a predetermined threshold before the firing drive lockout 3490 may be deactivated and the staple firing drive may be actuated.

As discussed in connection with the various embodiments disclosed herein, a staple firing drive drives staples against an anvil to deform the staples to a desired formed height. In various examples, the staple firing drive is further configured to push a cutting member, such as a knife, distally to cut tissue captured between the cartridge body and the anvil. In such instances, the knife is exposed above the deck of the cartridge body. That is, when the anvil is in its closed or clamped position, the anvil is closely positioned relative to the cartridge body and the knife is largely covered by the anvil even though the knife is exposed above the cartridge body. The knife will be exposed and exposed when the anvil is to be moved to its open position and/or separated from the closure drive before the knife is retracted below the deck of the cartridge body. Tool assembly 3500 is shown in fig. 52-54 and includes a latch 3590 configured to prevent the anvil from moving to its open position when the knife is exposed above the cartridge deck.

The tool assembly 3500 includes a closure drive and a firing drive. The closure drive includes a trocar shaft 3550 and an anvil 3530 releasably attached to the trocar shaft 3550. Similar to the above, the trocar shaft 3550 can be translated proximally and distally by a rotatable closure shaft 2440 threadably engaged with the trocar shaft 3550. The firing drive includes a rotatable shaft 3562 and a translatable collar 3560 threadably engaged with the rotatable shaft 3562. Similar to the above, the collar 3560 can translate proximally and distally when the shaft 3562 rotates in the first and second directions, respectively. Also similar to the above, the collar 3560 of the firing drive is configured to advance and retract the staple driver array and knife assembly 2570 toward and away from the anvil 3530.

In addition to the above, the lockout 3590 includes a lock arm 3592 rotatably mounted to the firing drive shaft 3562 about a pivot 3594. The latch 3590 further includes a biasing member or spring 3599 engaged with the lock arm 3592 and configured to bias the lock arm 3592 into contact with the anvil 3530. In use, the anvil 3530 is assembled to the trocar shaft 3550 and the trocar shaft 3550 is then retracted to position the anvil 3530 in its closed or clamped position relative to the cartridge body. As the anvil 3530 is retracted, the lock arms 3592 of the latches 3590 slide against an outer surface of the anvil 3530 until the lock arms 3592 are aligned with the lock recesses 3532 defined in the anvil 3530. At this time, spring 3599 biases lock arm 3592 into lock recess 3532, as shown in fig. 53. More specifically, lock arms 3592 are positioned behind the lock shoulders that define lock recesses 3532. The firing drive can then be operated to fire the staples and cut the tissue. In the example, the cutting edge of knife assembly 2570 is exposed above the cartridge body, and due to the latch 3590, the closure drive is locked or prevented from opening until the cutting edge of knife assembly 2570 is no longer exposed.

Referring primarily to FIG. 52, the lock arms 3592 further include a reset tab 3593 extending therefrom. The collar 3560 of the firing drive further includes a cam 3563 that is configured to engage the reset tab 3593 when the collar 3560 and knife assembly 2570 are retracted proximally by the firing drive. The cam 3563 is configured to rotate the lock arm 3592 downward out of engagement with a lock shoulder defined in the lock recess 3532 and unlock the closure drive. The cam 3563 is configured to unlock the closure drive when the cutting edge of the knife assembly 2570 has been retracted below the cartridge platform; however, in other embodiments, the cam 3563 can unlock the closure drive when the cutting edge is flush, or at least substantially flush, with the cartridge deck. In some embodiments, the closure drive may not unlock before the knife assembly 2570 is fully retracted. Once the closure drive is unlocked, the closure drive can be operated to again move the anvil 3530 to the open or undamped position.

Once the staples of the interchangeable tool assembly are fired, the tool assembly may no longer be used according to various embodiments. As discussed in more detail below, the tool assembly may include a latch configured to prevent the tool assembly from being re-clamped to tissue after it is used to staple the tissue.

Referring now to fig. 53-56, in at least one embodiment, an interchangeable tool assembly 3600 includes: a closure drive configured to position an anvil, such as anvil 2230, for example, relative to the staple cartridge; and a firing drive configured to drive staples from the staple cartridge. Similar to the above, the anvil 2230 may be attached to a translatable trocar shaft 3650 of the closure drive device. Also similar to the above, the firing drive includes a rotatable shaft 3660, a translatable collar 2550 threadably engaged with the rotatable shaft 3660, and a staple firing drive 2560 displaceable by the rotatable shaft 3660. In use, the closure drive is operable to position the anvil 2230 in a clamped position relative to the staple cartridge, and the firing drive is then operable to fire the staples into the tissue captured between the anvil 2230 and the staple cartridge. The closure drive is then operated to open the anvil 2230 and release the tissue.

In addition to the above, the tool assembly 3600 includes a latch 3690 configured to prevent the anvil 2230 from reclamping to tissue. The lockout 3690 includes a lock arm 3692 rotatably mounted to the rotatable shaft 3660 and held in an unlocked configuration by the firing drive as the closure drive moves the anvil 2230 between the open, undamped position (FIG. 53) and the closed, clamped position (FIG. 54). As the trocar shaft 3650 and the anvil 2230 move relative to the firing drive to position the anvil 2230 relative to the staple cartridge, the lock arm 3692 is retained in its unlocked configuration between the rotatable shaft 3660 and the translatable collar 2550. The arm 3692 remains in its unlocked configuration until the firing drive is operated, as shown in FIG. 55. As the shaft 3460 rotates in a first direction, the collar 2550 is displaced distally and the springs 3699 of the latches 3690 may bias the lock arms 3692 against the trocar shaft 3650. As the collar 2550 is displaced distally to fire the staples and then retracted proximally, the trocar shaft 3650 rotates relative to the lock arm 3692. The closure drive can then be operated to reopen the anvil 2230, thereby loosening the tissue and/or separating the anvil 2230 from the trocar shaft 3650. Upon reopening of the anvil 2230, spring 3699 biases lock arm 3692 into a lock recess 3652 defined in the trocar shaft 3650 and/or the anvil 2230. Once lock arm 3692 is positioned in lock recess 3652, lock arm 3692 prevents proximal retraction of trocar shaft 3650. In the event that the closure drive is operated in an attempt to retract the trocar shaft 3650, the lock arms 3692 will abut the lock shoulders defined in the lock recesses 3652 and prevent retraction of the trocar shaft 3650 and the anvil 2230. Thus, the lockout 3690 prevents the anvil 2230 from being re-clamped to the tissue after the tool assembly 3600 has undergone, or at least partially undergone, a firing cycle, and the tool assembly 3600 cannot be used again. In addition, the latch 3690 may function as a used cartridge latch.

Turning now to fig. 59 and 60, tool assembly 3700 includes staple cartridge 3720 and anvil 3730. The tool assembly 3700 also includes a closure system configured to move the anvil 3730 toward the staple cartridge 3720 and a firing system configured to eject or fire staples removably stored in the staple cartridge 3720. The anvil 3730 includes a longitudinal shaft portion 3736 and attachment arms 3738 extending from the shaft portion 3736 configured to resiliently grip a closure actuator or trocar 3734 of the closure system. The closure actuator 3734 can be retracted proximally by a closure drive to move the trocar 3734 between an open, undamped position (fig. 59) and a closed, clamped position (fig. 60). When the closure system is in its open configuration, as shown in fig. 59, the staple firing system is disabled and cannot be actuated to fire staples stored in the staple cartridge 3720, as described in more detail below.

In addition to the above, the staple firing system includes a rotatable firing shaft 3750 having a threaded distal end, and further includes a translatable firing nut 2550 including a threaded bore configured to receive the threaded distal end of the firing shaft 3750. Notably, referring to fig. 59, when the anvil 3730 is in its open position, there is a gap between the threaded distal end of the firing shaft 3750 and the threaded bore defined in the firing nut 2550. Thus, the firing shaft 3750 cannot distally displace the firing nut 2550 until the firing shaft 3750 is threadably engaged with the firing nut 2550.

As shown in fig. 60, the attachment arms 3738 of the anvil 3730 are configured to engage the firing shaft 3750 and deflect the firing shaft 3750 outward as the anvil 3730 is moved to its closed position. Referring primarily to fig. 59A and 60A, attachment arms 3738 are configured to engage inwardly extending protrusions 3758 defined on firing shaft 3750 and push the periphery of protrusions 3758 and firing shaft 3750 outward. In the illustrated example, the threaded distal end of the firing shaft 3750 is pushed into operative engagement with the threaded bore of the firing nut 2550 at the threaded interface 3790, and at this point, the firing shaft 3750 can displace the firing nut 2550 distally to eject staples from the staple cartridge 3720 as the firing shaft 3750 is rotated by the firing drive. When the anvil 3730 is reopened, the firing shaft 3750 will return to its original configuration and operably disengage the firing nut 2550.

For the reasons described above, tool assembly 3700 includes a lockout that prevents staples from being fired when anvil 3730 is not attached to the closure system, when anvil 3730 is improperly attached to the closure system, and/or when anvil 3730 is not fully closed.

Turning now to fig. 61 and 62, tool assembly 3800 includes: a replaceable staple cartridge comprising staples removably stored therein; an anvil configured to deform the staples; a closure drive system configured to move the anvil relative to the staple cartridge; and a firing system configured to eject the staples from the staple cartridge. As described below, tool assembly 3800 also includes a lockout configured to prevent the firing system from being operated unless the staple cartridge is fully seated on tool assembly 3800.

The staple cartridge includes a cartridge frame 3820 configured to engage the shaft frame 3810 of the tool assembly 3800. The staple cartridge also includes a drive shaft 3830 that is inserted into the shaft frame 3810 when the staple cartridge is assembled to the tool assembly 3800. More particularly, referring primarily to fig. 64, the drive shaft 3830 includes a proximal end 3832 that includes a ring gear portion 3833 that is configured to engage and compress a transmission 3860 of the firing system when a staple cartridge is mounted to the tool assembly 3800. Referring primarily to fig. 62, the transmission 3860 includes a first portion 3862, a second portion 3864, and a third portion 3868 that are capable of transmitting rotational input motion to the drive shaft 3830 when pushed into operative engagement with one another.

Referring primarily to fig. 63 and 64, the ring gear portion 3833 of the drive shaft 3830 is configured to engage a corresponding gear portion 3863 defined on a distal side of the first transmission portion 3862, and the first transmission portion 3862 may operably engage the second transmission portion 3864 when the first transmission portion 3862 is urged proximally by the drive shaft 3830. More specifically, the first transmission portion 3862 includes a proximal gear portion 3865 that engages a distal gear portion 3866 of the second transmission portion 3864 and urges the second transmission portion 3864 proximally as the first transmission portion 3862 is urged proximally by the drive shaft 3830. When the second transmission portion 3864 is pushed proximally by the first transmission portion 3862, the second transmission portion 3864 may operably engage the third transmission portion 3868, similar to as described above. More specifically, the second transmission portion 3862 includes a proximal gear portion 3867 that engages the distal gear portion 3869 of the third transmission portion 3864 as the first and second transmission portions 3862, 3864 are urged proximally by the drive shaft 3830. The third transmission portion 3868 is operatively coupled to the input shaft and is supported by the input shaft and/or the shaft housing 3810 for proximal displacement.

Referring primarily to fig. 61, the transfer device 3860 further includes at least one spring member 3870 positioned intermediate the first transfer portion 3862 and the second transfer portion 3864. In at least one example, the spring member 3870 can comprise one or more wave springs, for example. The spring member 3870 is configured to bias the first transfer portion 3862 and the second transfer portion 3864 away from each other. Additionally or alternatively, the transfer device 3860 includes at least one spring member 3870 positioned intermediate the second transfer portion 3864 and the third transfer portion 3868, the spring member configured to bias the second transfer portion 3864 and the third transfer portion 3868 apart from one another, similar to the above. Referring primarily to fig. 65, each spring member 3870 includes two belleville springs 3872 configured to deflect when a compressive force is applied thereto; however, the spring member 3870 may comprise any suitable configuration.

In addition to the above, and referring again to fig. 61, the input shaft of the tool assembly 3800 can rotate the third transmission portion 3868; however, unless the spring member 3870 positioned intermediate the second and third transmission portions 3864, 3868 has been sufficiently compressed to connect the proximal gear portion 3867 of the second transmission portion 3864 with the distal gear portion 3869 of the third transmission portion 3868, the rotation of the third transmission portion 3868 cannot be transmitted to the second transmission portion 3864. Similarly, the second transmission portion 3864 cannot transmit rotational motion to the first transmission portion 3862 unless the spring member 3870 positioned intermediate the first transmission portion 3862 and the second transmission portion 3864 has been sufficiently compressed to connect the proximal gear portion 3865 of the first transmission portion 3862 with the distal gear portion 3866 of the second transmission portion 3864. As described above, when the staple cartridge is fully seated on the shaft frame 3810, the drive shaft 3830 engages the first transmission portion 3862 with the second transmission portion 3864 and engages the second transmission portion 3864 with the third transmission portion 3868, as shown in fig. 62. In the example, rotation of the input shaft may be transmitted to the drive shaft 3830. However, if the staple cartridge is not fully seated on the shaft frame 3810, one or more of the transmission portions 3862, 3864, and 3868 cannot be operably engaged with one another, and rotation of the input shaft cannot be transmitted to the drive shaft 3830. Thus, tool assembly 3800 ensures that staples stored within the staple cartridge cannot be ejected from the staple cartridge unless the staple cartridge is fully seated on shaft frame 3810.

Turning now to fig. 66-68, tool assembly 3900 includes a shaft 3910 and a replaceable staple cartridge 3920. The replaceable staple cartridge 3920 includes a closure drive configured to move the anvil relative to the staple cartridge 3920 and also includes a firing drive including a rotatable firing shaft 3930 configured to eject staples removably stored in the staple cartridge 3920. Similar to the above, the tool assembly 3900 includes a lockout configured to prevent the firing drive from ejecting staples from the staple cartridge 3920 unless the staple cartridge 3920 is fully or fully seated on the shaft 3910. More specifically, the lockout prevents the firing shaft 3930 from rotating within the staple cartridge 3920 unless the staple cartridge 3920 is fully or fully seated onto the shaft 3910. In various examples, referring to fig. 67, the firing shaft 3930 includes an annular array of locking apertures 3939 defined in an outer periphery thereof, and the staple cartridge 3920 includes at least one lock 3929 configured to releasably engage the locking apertures 3939 defined in the shaft 3930. Lock 3929 includes a proximally extending cantilever beam; however, any suitable configuration may be utilized. The lock 3929 also includes a lock protrusion that extends into the lock aperture 3939 and prevents the firing shaft 3930 from rotating, or at least substantially rotating, relative to the body of the staple cartridge 3920. The lock 3929 is configured such that it is biased into engagement with a lock aperture 3939 defined in the firing shaft 3930 until the lock aperture 3929 is lifted out of the lock aperture 3939 when the staple cartridge 3920 is fully or fully assembled to the shaft 3910, as shown in fig. 68. Referring to fig. 68, the outer housing of the shaft 3910 includes a wedge 3919 configured to lift the lock 3929 away from the firing shaft 3930 and disengage the lock 3929 from the locking aperture 3939. The wedge 3919 is configured such that it does not disengage the lock 3929 from the firing shaft 3930 unless the staple cartridge 3920 has been fully or sufficiently seated on the shaft 3910, as shown in fig. 68. Fig. 67 shows a scenario in which the staple cartridge 3920 is not fully or fully seated on the shaft 3910.

Turning now to fig. 69-71, tool assembly 4000 includes a shaft 4010 and a replaceable staple cartridge 4020. The replaceable staple cartridge 4020 comprises a closure drive configured to move an anvil relative to the staple cartridge 4020 and further comprises a firing drive comprising a rotatable firing shaft 3930 configured to eject staples removably stored in the staple cartridge 4020. The staple cartridge 4020 includes a lock 4029 configured to releasably connect the staple cartridge 4020 to the shaft 4010. The lock 4029 includes a proximally extending cantilever arm and a lock shoulder 4028 extending therefrom. The locks 4029 are configured to flex inwardly within the shaft 4010 when the staple cartridge 4020 is assembled to the shaft 4010 and then resiliently return to or at least toward their undeflected state when the lock shoulders 4028 of the locks 4029 are aligned with the windows 4019 defined in the outer housing of the shaft 4010. In such an example, when the staple cartridge 4020 has been fully or fully seated on the shaft 4010, the lock shoulder 4028 enters the window 4019, as shown in fig. 70. To unlock the staple cartridge 4020, the clinician may, for example, insert a tool or a finger thereof into the window and press the lock 4029 away from the window 4019. At this point, the staple cartridge 4020 may be removed from the shaft 4010, and a new staple cartridge may be attached to the shaft 4010 if so desired by the clinician.

Additionally or alternatively, the surgical stapling system can include an electrical lockout configured to prevent a closure drive of the stapling system from clamping the anvil to the tissue and/or to prevent a firing drive from performing its firing stroke when the staple cartridge has not been fully or sufficiently seated on the shaft of the stapling system. In various examples, the stapling system can include a sensor configured to detect whether the staple cartridge has been fully or sufficiently seated on the shaft, and further include an electric motor configured to operate the firing drive. In the event that the sensor detects that the staple cartridge is not fully or sufficiently attached to the shaft, the motor may be electrically deactivated. In various examples, the suturing system includes a controller, such as a microprocessor, in communication with the sensor and the electric motor. In at least one example, the controller is configured to perform the following operations: firstly, allowing the electric motor to be operated when the sensor detects a correctly seated cartridge on the shaft, and secondly, preventing the electric motor from being operated when the sensor detects an incorrectly seated cartridge on the shaft.

Turning now to fig. 72, a tool assembly kit 4100 includes a shaft 4110 and a plurality of staple cartridges, e.g., 4120 ', 4120 ", and 4120"'. Each staple cartridge 4120, 4120 ', 4120 "and 4120'" is configured to apply circular rows of staples having different diameters. For example, staple cartridge 4120 "' is configured to apply staples in a pattern having a larger diameter, while staple cartridge 4120 is configured to apply staples in a pattern having a smaller diameter. In various examples, different staple cartridges can deploy staples having different unformed heights. In at least one example, a staple cartridge in which staples are applied in a larger pattern deploys staples having a larger undeformed height, while a staple cartridge in which staples are applied in a smaller pattern deploys staples having a smaller undeformed height. In some examples, a staple cartridge can deploy staples having two or more unformed heights. In any case, a staple cartridge selected from a plurality of staple cartridges may be fitted to shaft 4110.

Referring to fig. 72 and 73, the tool assembly 4100 includes a detection circuit 4190 configured to detect whether a staple cartridge is fully or sufficiently attached to the shaft 4110. The detection circuit 4190 is not completely housed within the shaft 4110; instead, the staple cartridge must be properly assembled to shaft 4110 to complete detection circuit 4190. The detection circuit 4190 includes a conductor 4193 that extends through a channel 4192 defined in a frame defined the shaft 4110 and/or along an outer housing of the shaft 4110. Referring primarily to fig. 73, each conductor 4193 is electrically coupled to an electrical contact 4194 defined in the distal end of the housing. The staple cartridge 4120, for example, includes corresponding electrical contacts 4195 positioned and arranged on the body 4122 of the staple cartridge 4120 such that the contacts 4195 engage the contacts 4194 on the shaft 4110. The staple cartridge 4120 further comprises conductors 4196 that extend through and/or along the cartridge body 4122. Each conductor 4196 is electrically coupled with a contact 4195. In certain examples, the conductors 4196 are directly coupled to each other and, in such examples, the detection circuit 4190 is closed once the staple cartridge 4120 is properly assembled to the shaft 4110.

In certain examples, in addition to the above, the detection circuit 4190 of the tool assembly 4100 extends through the platform portion 4124 of the staple cartridge 4120. In at least one example, the platform portion 4124 is movably attached to the cartridge body 4122. More specifically, in at least one such example, the spring members 4198 are positioned intermediate the cartridge body 4122 and the platform portion 4124 and are configured to allow the platform portion 4124 to move or float relative to the cartridge body 4122 as the tissue is compressed against the platform portion 4124. In at least one example, the spring member 4198 comprises one or more wave springs, for example. The spring members 4198 also form an electrically conductive path between the cartridge body 4122 and the platform portion 4124. More particularly, the spring members 4198 are positioned intermediate the electrical contacts 4197 and 4199 defined on the cartridge body 4122 and the platform portion 4124, respectively. The conductors 4196 are electrically coupled to electrical contacts 4197 defined on the distal end of the cartridge body 4122, and the electrical contacts 4199 are electrically coupled to one another by the conductors in the platform portion 4125. As described above, once the staple cartridge 4120 is properly assembled to the shaft 4110, the detection circuit 4190 is closed.

Turning now to fig. 74-76, tool assembly 4200 includes a lockout configured to prevent a replaceable circular staple cartridge from being fired more than once, as described in further detail below. In use, the replaceable circular staple cartridge 4220 is assembled to the shaft 4210 of the tool assembly 4200. The tool assembly 4200 is then positioned in the surgical site and the anvil 2230 is fitted to the trocar 2450 of the closure drive. The anvil 2230 is then moved toward the staple cartridge 4220 using the closure drive to clamp the patient's tissue against the staple cartridge 4220 until the anvil 2230 reaches the closed or clamped position. This position of the anvil 2230 is shown in fig. 74. At this point, the firing drive may be operated to deploy staples removably stored in the staple cartridge 4220. The firing drive includes, among other things, a rotatable drive shaft 4230 threadedly engaged with the drive collar 4240 and also includes a staple firing driver 2560. The drive collar 4240 and firing drive 2560 comprise separate components; however, in alternative embodiments, the drive collar 4240 and the firing driver 2560 can be integrally formed. The firing drive is configured to rotate in a first direction during a firing stroke to push the drive collar 4240 and staple firing driver 2560 distally between an unfired position (fig. 74) and a fired position (fig. 75) to eject staples from the staple cartridge 4220. The drive collar 4240 and the staple drivers 2560 are prevented from rotating within the staple cartridge 4220 and, as a result, the drive shaft 4230 rotates relative to the drive collar 4240 and the staple drivers 2560.

In addition to the above, the drive collar 4240 includes one or more latches 4290 extending proximally therefrom. Each latch 4290 comprises a locking pin 4292 slidably positioned within a pin hole 4293 defined in the drive collar 4240. Each latch 4290 further includes a biasing member, such as a spring 4294, configured to bias the pin 4292 proximally. When the firing drive is in its unfired configuration, as shown in fig. 74, the latches 4290 are not engaged with the rotatable drive shaft 4230 and/or the frame 4222 of the staple cartridge 4220. When the drive collar 4240 and the staple driver 2560 are pushed distally by the drive shaft 4230, the locking pin 4292 moves away from the drive shaft 4230, as shown in fig. 75. After the firing stroke has been completed and the staples have been sufficiently deformed against the anvil 2230, the drive shaft 4230 is rotated in the opposite direction to draw the drive collar 4240 and staple drivers 4260 proximally during the retraction stroke. In the example, the latch 4290 moves toward the drive shaft 4230. Notably, the retraction stroke is longer than the firing stroke, and thus, the drive collar 4240 moves proximally relative to its initial unfired position to a retracted position, as shown in fig. 76. In this retracted position of the drive collar 4240, the latch 4290 has engaged the drive shaft 4230 and the frame 4222 of the staple cartridge 4220. More specifically, each latch 4290 has entered a locking aperture defined between the drive shaft 4230 and the cartridge frame 4222. Referring now to fig. 78, each locking aperture is defined by an aperture wall 4295 in the drive shaft 4230 and an aperture wall 4296 in the frame 4222. Once the locking pin 4292 enters the locking hole, the drive collar 4240 cannot be rotated by the drive shaft 4230 and the firing system of the staple cartridge 4220 has been locked. Thus, a particular staple cartridge 4220 cannot be reused and must be replaced with a new staple cartridge in order to reuse the tool assembly 4200.

The reader will appreciate that in addition to the above, the lockout pin 4292 may or may not be partially positioned in the lockout hole when the firing drive is in its unfired configuration, as shown in fig. 74. However, to the extent the locking pin 4292 is partially positioned in the locking hole, in the example, the pin 4292 can be distally displaced within a pin hole 4293 defined in the drive collar 4240 when the firing drive shaft 4230 is rotated. The reader will also appreciate that when the drive collar 4240 is moved to its retracted position, the locking pins 4292 seat deep enough into locking holes defined in the drive shaft 4230 to prevent the pins 4292 from moving distally out of the locking holes when the firing drive shaft 4230 is rotated again in its first direction.

Referring again to fig. 78, when the drive collar 4240 is in its retracted position, the side walls 4295 and 4296 of the locking apertures are aligned with each other. However, as the drive shaft 4230 is rotated, the side walls 4295 defined in the drive shaft 4230 will rotate out of alignment with the side walls 4296 defined in the cartridge body 4222. In some examples, the side wall 4295 may temporarily rotate to realign with the side wall 4296 as the firing drive 4230 rotates. In any event, referring now to fig. 77, when the firing system is in its unfired configuration, the side wall 4295 is not aligned with the side wall 4296. Thus, when the firing system is in its unfired configuration and the staple cartridge 4220 cannot be inadvertently locked, the lockout pin 4292 cannot enter the lockout hole.

Referring now to fig. 80, in at least one alternative embodiment, the one or more locking apertures 4295 "can be defined solely in the drive shaft 4230" of the tool assembly 4200 ". In such embodiments, once the locking pin 4292 enters the locking hole 4295 ", the drive collar 4240 will not be able to rotate relative to the drive shaft 4230". Indeed, the drive collar 4240 and the drive shaft 4230 "will be synchronously locked together, but not necessarily into the frame of the tool assembly 4200", which will prevent the drive shaft 4230 "from rotating relative to the drive collar 2440 and distally displacing the drive collar 2440.

Referring now to fig. 79, in at least one alternative embodiment, each firing drive lockout has a different configuration such that each locking pin uniquely mates with its corresponding locking hole. For example, tool assembly 4200 ' includes a first locking pin configured to enter a first locking hole defined by sidewalls 4295 and 4296, and a second locking pin configured to enter a second locking hole defined by sidewalls 4295 ' and 4296 '. However, the first locking pin of the tool assembly 4200' is sized and configured such that it cannot enter the second locking hole, and correspondingly, the second locking pin is sized and configured such that it cannot enter the first locking hole. Further, neither the first locking pin nor the second locking pin can enter the hole formed by the combination of side walls 4295 and 4296 'or the hole formed by the combination of side walls 4295' and 4296.

As described above, a stapling instrument configured to deploy a circular row of staples can include an articulation joint. The articulation joint is configured to allow an end effector of the stapling instrument to articulate relative to a shaft of the stapling instrument. Such stapling instruments can assist a surgeon in positioning the end effector within the rectum and/or colon of a patient. In various embodiments, referring to fig. 81, a stapling instrument configured to deploy circular rows of staples, such as a stapling instrument 9000, for example, can comprise a contoured or adjustable frame 9010. The frame 9010 may be configured to be permanently deformed during use. For example, in at least one such embodiment, frame 9010 is constructed from a ductile metal such as silver, platinum, palladium, nickel, gold, and/or copper. For example, in certain embodiments, frame 9010 is constructed of a malleable plastic. For example, in at least one embodiment, the frame is comprised of a polymer comprising metal ions bonded to polymer chains, such as an ionic polymer-metal composite (IPMC). A voltage potential or electric potential may be applied to the IPMC material in order to deflect the shaft in a desired manner. In some examples, the shaft may be contoured along one radius of curvature, while in other examples, the shaft may be contoured along more than one radius of curvature. For example, when the shaft is within the patient, the voltage potential or potentials may be modified to contour the shaft. In certain embodiments, the contoured portion of the frame comprises a plurality of pivotable links. In at least one embodiment, the contoured portion of the frame is comprised of a viscoelastic material.

In addition to the above, the stapling instrument can further comprise a lock configured to releasably retain the contoured portion of the frame of the stapling instrument in its contoured configuration. In at least one example, the suturing apparatus frame includes an articulatable frame link and one or more longitudinal tension cables that can pull the frame link proximally and lock the frame link together. In certain examples, each frame connector can include a longitudinal bore extending therethrough configured to receive a distally movable rod. The rod is flexible enough to pass through the longitudinal holes, which may not be perfectly aligned with each other when the contoured portion has been contoured yet rigid enough to hold the stapling instrument in its contoured configuration.

As described herein, a surgical instrument may be made up of multiple modules that fit together with one another. For example, in at least one embodiment, a surgical instrument includes a first module having a handle and a second module having a shaft assembly. The shaft assembly includes an end effector configured to staple and/or incise tissue of a patient; however, the shaft assembly can include any suitable end effector. In various examples, the end effector includes a third module attachable to the shaft assembly. Referring now to fig. 82 and 83, a handle, such as handle 20, for example, includes a controller and a display 10000 in communication with the controller. The controller is configured to display data regarding the operation of the surgical instrument on the display 10000. The data displayed on display 10000 associates information about at least one operating parameter of the first module and/or at least one operating parameter of the second module to the surgeon. For example, the controller may display data on the progress of the staple firing stroke on display 10000.

In addition to the above, the shaft assembly further includes a second display. For example, shaft assembly 2000 includes a display 10100; however, any of the shaft assemblies disclosed herein can include a display, such as display 10100. The second module includes its own controller configured to display data regarding the operation of the surgical instrument on the display 10100. Similar to the above, the data displayed on the display 10100 relates to information regarding at least one operating parameter of the first module and/or at least one operating parameter of the second module. The controller of the second module is in signal communication with the controller of the first module; however, in other embodiments, the second module controller may operate independently of the first module controller. In certain alternative embodiments, the second module does not include a controller. In such embodiments, the controller of the first module is in signal communication with the first display 10000 and the second display 10100 and controls the data displayed on the first display 10000 and the second display 10100.

As described above, tool assembly 2000 includes an anvil and a staple cartridge. The handle 20 includes an actuation system configured to move the anvil relative to the staple cartridge. The anvil can be positioned within a range of positions relative to the staple cartridge to control the distance or gap between the anvil and the staple cartridge, thereby controlling the formed height of the staples as they are ejected from the staple cartridge. For example, the anvil is positioned closer to the staple cartridge to deform the staples to a smaller formed height and is positioned further away from the staple cartridge to deform the staples to a larger formed height. In any event, the second display 10100 of the tool assembly 2000 is configured to display the position of the anvil relative to the staple cartridge and/or to display the height at which the staples will be or have been formed. In various embodiments, the shaft assembly can include an actuator configured to control a function of the end effector, and a display that displays data regarding the end effector function adjacent the actuator.

Referring to FIG. 1, a tool assembly 1500 includes a shaft and an end effector extending from the shaft. The shaft includes a shaft frame and a longitudinal shaft axis. The end effector includes an end effector frame and a longitudinal end effector axis. The end effector further includes a distal head and a rotational joint that allows the distal head to rotate relative to the end effector frame about a longitudinal end effector axis. The distal head includes a first jaw and a second jaw. The first jaw includes a staple cartridge having staples removably stored therein or a channel configured to receive such a staple cartridge, and the second jaw includes an anvil configured to deform the staples. The second jaw is movable relative to the first jaw between an open position and a closed position; however, other embodiments are also contemplated in which the first jaw is movable relative to the second jaw, and/or both the first and second jaws are movable relative to each other.

In certain embodiments, the tool assembly may include an articulation joint in addition to the rotary joint. In at least one such embodiment, the rotational joint is distal with respect to the articulation joint. In such embodiments, rotation of the distal head does not affect the angle at which the end effector has been articulated. That is, other embodiments are contemplated in which the articulation joint is located distally relative to the rotational joint. Such embodiments may provide a wide sweep of the distal head. In either case, the longitudinal end effector axis is movable relative to the longitudinal shaft axis. In at least one example, the longitudinal end effector axis is movable between a position in which it is collinear with the longitudinal shaft axis and a position in which it is transverse to the longitudinal shaft axis.

In addition to the above, the distal head of the tool assembly 1500 is rotatable between an initial position and a rotated position. In at least one example, the distal head is rotatable between a zero or top dead center position and a second position. In certain examples, the distal head is rotatable through a range of motion of at least 360 degrees. In other examples, the distal head is rotatable through a range of rotation of less than 360 degrees. In either case, the tool assembly 1500 and/or the handle 20 are configured to track the rotational position of the distal head. In various examples, the tool assembly 1500 and/or the handle 20 includes an electric motor operably coupled with the distal head of the end effector, and further includes an encoder configured to directly track the rotation of the distal head and/or indirectly track the rotation of the distal head, such as by evaluating the rotational position of a shaft of the electric motor. The controller of the handle 20 is in signal communication with the encoder and is configured to display the rotational position of the distal head, for example on the display 10000.

In at least one embodiment, the orientation and arrangement of the data displayed on display 10000 is static as the distal head of the end effector rotates. Of course, in such embodiments, the data displayed on display 10000 would be updated by the surgical instrument controller; however, the data display is not reoriented and/or rearranged as the distal head rotates. Such an embodiment may provide the surgeon with the information necessary to properly utilize the surgical instrument in the static field. In at least one alternative embodiment, the data fields on display 10000 are dynamic. In this context, the term dynamic does not only mean that data is updated on the display 10000; the term dynamic also means that the data is reoriented and/or rearranged on the display 10000 as the distal head rotates. In at least one example, the orientation of the data tracks the orientation of the distal head. For example, if the distal head is rotated 30 degrees, the data field on display 10000 is also rotated 30 degrees. In various instances, the distal head can be rotated 360 degrees and the data field can be rotated 360 degrees.

In addition to the above, the data field may be oriented in any orientation that matches the orientation of the distal head. Such an embodiment may provide the surgeon with an accurate and intuitive sense of the orientation of the distal head. In certain embodiments, the controller orients the data field to an orientation selected from the array of independent locations that most closely matches the orientation of the distal head. For example, if the distal head has been rotated 27 degrees and the selectable independent data field positions are 15 degrees apart, the controller may reorient the data fields to be 30 degrees from the reference orientation. Similarly, for example, if the distal head has been rotated 17 degrees and the selectable independent data field positions are 5 degrees apart, the controller may reorient the data fields to be 15 degrees from the reference orientation. In at least one embodiment, the reference orientation is aligned with a feature of the surgical instrument itself. For example, the reference orientation of the handle 20 is aligned with an axis of the grip extending through the handle 20. In such embodiments, the controller may ignore the orientation of the handle 20 relative to its environment. However, for example, in at least one alternative embodiment, the reference orientation is aligned relative to the gravitational axis.

In addition to the above, the controller is configured to be able to reorient the entire data field displayed on the display 10000 relative to the orientation of the distal head. In other embodiments, the controller is configured to reorient only a portion of the data fields shifted on the display 10000 relative to the orientation of the distal head. In such embodiments, a portion of the data field remains static with respect to the reference orientation while another portion of the data field rotates with respect to the reference orientation. In certain embodiments, the first portion of the data field is rotated by a first rotation angle and the second portion of the data field is rotated in the same direction by a second rotation angle. For example, the second portion may be rotated through a smaller angle than the first portion. In various embodiments, the first portion of the data field is rotated in a first direction and the second portion of the data field is rotated in a second or opposite direction.

In addition to the above, the data fields are reoriented and/or rearranged in real time or at least substantially in real time with the rotation of the distal head. Such embodiments provide extremely responsive data displays. In other embodiments, reorientation and/or rearrangement of data fields may delay rotation of the distal head. Such implementations may provide a data display with less jitter. In various embodiments, a first portion of the data field is redirected and/or rearranged at a first speed and a second portion of the data field is redirected and/or rearranged at a second or different speed. For example, the second portion may be rotated at a slower speed.

As described above, the data fields on display 10000 rotate as the distal head of the end effector rotates. However, in other embodiments, the data field or a portion of the data field translates as the distal head rotates. Also as described above, the controller of the surgical instrument is configured to reorient and/or rearrange the data fields on the handle display 10000. However, the controller of the surgical instrument may reorient and/or rearrange the data fields on a second display, such as a shaft display.

Referring again to fig. 15 and 83, the tool assembly 2000 includes an actuator 10200 configured to actuate the articulation drive system of the tool assembly 2000. The actuator 10200 is rotatable about a longitudinal axis, which is, for example, parallel or at least substantially parallel to the longitudinal axis of the shaft 2100. The actuator 10200 is operably coupled to a rheostat in signal communication with the controller of the handle 20, for example. When the actuator 10200 is rotated in a first direction about its longitudinal axis, the rheostat detects the rotation of the actuator 10200 and the controller operates the electric motor to articulate the end effector 2200 in the first direction. Similarly, when the actuator 10200 is rotated about its longitudinal axis in a second or opposite direction, the rheostat detects the rotation of the actuator 10200 and the controller operates the electric motor to articulate the end effector 2200 in the second or opposite direction. In various examples, the end effector 2200 can be articulated about 30 degrees from the longitudinal axis in a first direction, and/or about 30 degrees from the longitudinal axis in a second or opposite direction, for example.

As the reader will appreciate, in addition to the above, the tool assembly 2000 does not have an on-board electric motor configured to operate the articulation drive system; rather, the electric motor of the articulation drive system is located in a handle, such as handle 20, to which tool assembly 2000 is attached. Thus, an actuator on the detachable shaft assembly controls the operation of the handle. In other embodiments, the electric motor of the articulation drive system may be located in the tool assembly 2000. In either case, the display 10100 is configured to display articulation of the end effector 2200 in at least some manner. As the reader will appreciate, the display 10100 is adjacent to the actuator 10200, and thus, the surgeon can easily view the input and output of the articulation drive system simultaneously.

In addition to the above, for example, a surgical tool assembly comprising a contoured shaft may be advantageously shaped to fit within the rectum or colon of a patient. However, such a contoured shaft cannot withstand significant amounts of tensile and/or compressive loads. To compensate for this, in various embodiments, only the rotatable drive system may extend through the contouring formable portion of the shaft. In such examples, the shaft need only resist the rotational reaction force generated by the rotatable drive system. In such embodiments, the rotational motion of the drive system can be converted to linear motion distally relative to the contoured shaft portion, if desired. Such longitudinal movement may generate tensile and/or compressive forces; however, such forces may be resolved or balanced within the end effector, i.e., distally relative to the contoured shaft portion. Such embodiments may also utilize an articulation joint positioned distally relative to the contoured shaft portion. In such embodiments, the tool assembly may not utilize a push-pull drive system that traverses the contoured shaft portion.

The anvil 6020 of the circular stapling instrument is illustrated in fig. 84 and 85. The anvil 6020 includes a tissue compression surface 6022 and an annular array of staple forming pockets 6024 defined in the tissue compression surface 6022. The anvil 6020 also includes a frame 6028, an attachment mount 6026, and a shaft extending from the attachment mount 6026. The shaft is configured to be releasably attachable to a closure drive of a circular stapling instrument such that the anvil 6020 is movable toward and away from a staple cartridge of the circular stapling instrument. Compression surface 6022, attachment mount 6026, and frame 6028 are constructed of, for example, stainless steel; however, any suitable material or materials may be used.

In addition to the above, the anvil 6020 also includes a tissue support 6030. The tissue support 6030 is positioned within an annular bore defined within the tissue support surface 6022. The tissue support 6030 is tightly secured within the anvil 6020 such that there is little, if any, relative motion therebetween. The tissue support 6030 includes an annular tissue support surface 6032 that is adjacent to the annular tissue compression surface 6022 of the anvil 6020. The tissue support 6030 also includes an inner annular wall 6036 defined therein and also includes a bottom wall 6038 that is positioned adjacent the anvil frame 6028 of the anvil 6020.

Referring now to FIG. 86, a circular stapling instrument includes a staple cartridge 6040 that includes a first annular row of staples 6070, a second annular row of staples 6080, and a firing drive configured to eject the staples 6070 and 6080 from the staple cartridge 6040 during a firing stroke of the firing drive. As shown in fig. 86, staples 6070 and 6080 are deformed by forming pockets 6024 as they are ejected from staple cartridge 6040. In various examples, staples 6070 and 6080 are deformed to the same height, while in other examples staples 6070 and 6080 are deformed to different heights. For example, the staples 6070 may be deformed to a smaller deformed height than the staples 6080. In other examples, the staples 6080 are deformed to a smaller height than the staples 6070.

Additionally or alternatively, the staples 6070 and 6080 can have different unformed heights. For example, the staples 6070 may have a smaller unformed height than the staples 6080. In other examples, the staples 6080 have a smaller unformed height than the staples 6070. In some examples, staples 6070 and 6080 have the same unformed height.

In addition to the above, the stapling instrument can be cut into tissue T as staples 6070 and 6080 are deformed against the anvil 6020 to staple the tissue T captured between the anvil 6020 and the staple cartridge 6040. The firing drive, which ejects the staples from their staple cavities, drives the cutting member 6050 toward the tissue T and anvil 6020. The distal edge of the cutting member 6050 transects the tissue T and then slides along the inner sidewall 6036 of the tissue support 6030 without transecting the inner sidewall 6036. The cutting edge of the cutting member 6050 is annular and it is aligned with the annular inner wall 6036 of the tissue support 6030. The cutting member 6050 is advanced into the anvil 6020 until the cutting member 6050 transects the bottom wall 6038, as shown in fig. 86.

The firing drive arrangement experiences various loads as the staples 6070 and 6080 are driven against the anvil 6020 and/or cut tissue. For example, the firing drive can experience increased loads when transecting tissue that has previously been stapled, e.g., with staples 6090 (fig. 86). However, transecting the bottom wall 6038 by the cutting member 6050 can produce a sudden change or pulse in the force transmitted by the firing drive. The clinician may sense this sudden change in force using the surgical stapler and/or an electronic sensor system configured to detect a change in load of the firing drive. The tissue support 6030 can be constructed of a material that is capable of gripping when the cutting member 6050 applies a load to the bottom wall 6038. In at least one example, the tissue support 6030 is comprised of, for example, plastic. In any case, transection of the bottom wall 6038 can be detected, and once detected, the clinician and/or electronic sensor system can determine that the cutting process has been completed.

The firing drive deforms the staples 6070, 6080 and simultaneously cuts into tissue using the cutting member 6050; however, it is contemplated that the staple forming step and the tissue cutting step may be staggered. In at least one example, the tissue cutting step does not begin until the staple forming step is complete.

It should be appreciated from fig. 86 that when the surface 6032 can partially support tissue T, the cutting member 6050 can push the tissue T into the cavity defined between the inner wall 6036 of the tissue support 6030 and the attachment mount 6026 as the cutting member 6050 is moved toward the bottom wall 6038. In other words, the cutting member 6050 can drag the tissue T along the wall 6036 before the tissue T is finally cut. In the example, the cut made by the cutting member 6050 may not be precise. The following discusses a modification of the embodiment disclosed in fig. 86.

Turning now to fig. 87 and 88, the tissue support 6030 of the anvil 6020 has been replaced with a tissue support 6130. The tissue support 6130 includes a first or outer annular wall 6131 and a second or inner annular wall 6133. The inner wall 6133 defines a hole 6136 configured to closely receive the attachment mount 6026. The outer wall 6131 and the inner wall 6133 are connected by a lateral wall 6132. The lateral wall 6132 extends radially around the center of the tissue support 6130 between the inner wall 6133 and the outer wall 6131. The lateral walls 6132 are evenly spaced from each other; however, alternative embodiments are contemplated in which the lateral walls 6132 are unevenly spaced from one another. In either case, the lateral wall 6132 defines an annular array of cavities 6134 in the tissue support 6130. In various instances, each cavity 6134 can be closed on each side other than the side facing the tissue, for example. In other examples, the tissue-facing side of the cavity may be closed.

The outer wall 6131 and the inner wall 6133 of the tissue support 6130 are configured to support tissue as the tissue is transected by the cutting member 6050. The lateral wall 6132 also supports tissue and, in addition, resists or resists tissue sliding relative to the outer wall 6131 and inner wall 6133 as the tissue is transected. It will be appreciated that when the tissue is transected, the tissue can enter the cavity 6134; however, relative motion between the tissue and the sidewall can be greatly reduced. Depending on the amount of support desired, the composition and arrangement of the lateral wall 6132 can be selected to provide more support to the tissue or less support to the tissue. For example, a thicker lateral wall 6132 may provide more tissue support than a thinner lateral wall 6132. Similarly, more lateral walls 6132 can provide more tissue support than thinner lateral walls 6132.

As the cutting member 6050 moves through its cutting stroke, the cutting member 6050 cuts the tissue and transects the lateral wall 6132. The cutting member 6050 is annular and traverses the lateral wall 6132 adjacent to the outer wall 6131; however, the cutting member can transect the wall 6132 at any suitable location. In any event, the lateral walls 6132 support the tissue before, during, and after it is cut and prevent or at least reduce the likelihood of dragging the tissue along the outer wall 6131 and/or inner wall 6133. Similar to the tissue support 6030, the tissue support 6130 includes a bottom wall 6138 that is transected at the end of the cutting stroke.

A surgical stapler including a staple cartridge 6240 and an anvil 6220 is disclosed in fig. 89 and 90. Staple cartridge 6240 is similar in many respects to staple cartridge 6040. The anvil 6220 is similar in many respects to the anvil 6020 and anvil 6120. The anvil 6220 includes an attachment stem 6226 and a looped tissue buttress 6230 positioned about the attachment stem 6226. The tissue support 6230 includes a central bore configured to closely receive the shaft 6226. The tissue buttress 6230 further comprises an annular outer wall 6231 positioned adjacent to the tissue compression surface of the anvil 6220 and further comprises a lateral wall 6232 extending radially from the outer wall 6231. The tissue bolster 6230 does not include an inner annular wall, and the inner ends of the lateral walls 6232 are free to flex. The tissue support 6230 also includes a bottom wall 6238 that is incised by the cutting member 6050, similar to that described above.

A surgical stapler including a staple cartridge 6240 and an anvil 6220 is illustrated in fig. 91 and 92. However, the reader will appreciate that the tissue bolster 6230 of the anvil 6220 has been replaced with a tissue bolster 6330. The tissue strut 6330 includes an annular central bore configured to closely receive the shaft 6226. The tissue support 6330 further includes a top wall 6332, a bottom wall 6338, and side walls 6336 extending between the top and bottom walls 6332, 6338. The top wall 6332 is parallel, or at least substantially parallel, to the bottom wall 6338; however, embodiments are also contemplated in which the walls 6332 and 6338 are not parallel. Sidewalls 6336 are parallel or at least substantially parallel; however, embodiments are also contemplated in which the sidewalls 6336 are not parallel.

Walls 6332, 6336 and 6338 define an annular cavity 6334 therebetween. The cavity 6334 is enclosed, or at least substantially enclosed, on all sides. The cavity 6334 extends uninterrupted around the shaft 6226; however, other embodiments are also contemplated in which the cavity 6334 is interrupted by sidewalls and/or varies in geometry, for example.

Similar to the above, the tissue support 6330 is configured to support tissue as it is transected by the cutting member 6050. The tissue buttresses 6330 are closely received within the anvil 6220 such that the tissue buttresses 6330 do not move, or at least substantially do not move, relative to the anvil 6220. In addition, the tissue support 6330 comprises a rigid box-like profile such that the deflection of the tissue support 6330 is minimized or insignificant as the cutting member 6050 transects tissue. As shown in fig. 91, a gap exists between the bottom wall 6338 and the inner side wall 6336. Such gaps may provide some flexibility in the tissue support 6330; however, other embodiments are also contemplated in which such gaps are not present. Tissue support 6330 is constructed of, for example, plastic; however, in various embodiments, the tissue support 6330 may be constructed of flexible and/or elastomeric plastic, for example.

The cutting member 6050 transects the tissue support 6330 during its cutting stroke. As shown in fig. 92, the cutting member 6050 transects the top wall 6332 after transecting the tissue, and then into the cavity 6334. The top wall 6332 includes an annular notch 6333 defined therein that is aligned with the annular cutting edge of the cutting member 6050. The notch 6333 reduces the profile of the top wall 6332 and facilitates cutting into the top wall 6332. The cutting member 6050 may also transect the bottom wall 6338 during its cutting stroke. As the reader will appreciate, the transection of the top and bottom walls 6332, 6338 of the tissue supports 6330 may generate a force pulse in the firing drive of the stapling instrument. The top and bottom walls 6332, 6338 may be structurally configured to provide different pulses so that the clinician and/or the electronic sensor system of the surgical instrument may discern the difference between the pulses and not misinterpret the lancing of the top wall 6332 as the end of the firing/cutting stroke.

Referring again to fig. 91 and 92, the top wall 6332 of the tissue bolster 6330 is aligned, or at least substantially aligned, with the tissue compression surface 6022 of the anvil 6220. Additionally or alternatively, the top wall 6332 may be recessed relative to the tissue compression surface 6022 and/or extend over the tissue compression surface 6022. The top wall 6332 of the tissue buttress extends above the forming surface 6024 of the anvil 6220. Additionally or alternatively, the top wall 6332 may be recessed relative to the shaped surface 6024 and/or aligned with the shaped surface 6024.

A surgical stapler including a staple cartridge 6240 and an anvil 6220 is illustrated in fig. 93 and 94. However, the reader will appreciate that the tissue buttress 6230 of the anvil 6220 has been replaced with a tissue buttress 6430. The tissue support 6430 includes an annular central bore configured to closely receive the shaft 6226. The tissue support 6430 also includes a top wall 6432, a bottom wall 6438, and a side wall 6436 extending between the top wall 6432 and the bottom wall 6438. The walls 6432, 6436, and 6438 define an annular cavity 6434 therebetween. The cavity 6434 is closed or at least substantially closed on all sides. The cavity 6434 extends uninterrupted around the shaft 6226; however, other embodiments are also contemplated in which the cavity 6434 is interrupted by sidewalls and/or varies in geometry, for example.

Similar to the above, the tissue support 6430 is configured to support tissue as it is transected by the cutting member 6050. The tissue buttress 6430 is closely received within the anvil 6220 such that the tissue buttress 6430 does not move, or at least substantially does not move, relative to the anvil 6220. Further, the tissue support 6430 comprises a rigid polygonal cross-section such that the flexing of the tissue support 6430 is minimized or insignificant as the cutting member 6050 transects tissue. As shown in fig. 93, a gap exists between the bottom wall 6438 and the inner side wall 6436. Such gaps may provide some flexibility in the tissue support 6430; however, other embodiments are also contemplated in which such gaps are not present. The tissue support 6430 is constructed of, for example, plastic; however, in various embodiments, the tissue support 6430 may be constructed of, for example, a flexible and/or elastomeric plastic.

As shown in fig. 93 and 94, inner sidewall 6436 is shorter than outer sidewall 3436; however, other embodiments are also contemplated in which the outer sidewall 6436 is shorter than the inner sidewall 6436. Further, the top wall 6432 is not parallel to the bottom wall 6438. More specifically, the top wall 6432 includes a sloped portion that extends transversely to the bottom wall 6438 and/or other portions of the top wall 6432.

The cutting member 6050 transects the tissue support 6430 during its cutting stroke. As shown in fig. 94, the cutting member 6050 transects the top wall 6432 after transecting tissue, and then into the cavity 6434. The cutting member 6050 may also transect the bottom wall 6438 during its cutting stroke.

As described above, the tissue supports disclosed herein are configured to support tissue as the cutting member cuts through the tissue. For example, typically, the tissue incised by the cutting member has been previously stapled, i.e., stapled during a previous step in the surgical procedure. In various examples, such staples may also be incised by the cutting member even if they are composed of metals such as titanium and/or stainless steel. In other examples, such staples may not be incised by the cutting member; rather, they can be pushed into the material comprising the tissue bolster. Whether or not the staples are incised by the cutting member, the tissue supports disclosed herein in various examples have sufficient strength and/or stiffness to prevent staples captured by the cutting member against the tissue support from generating deformations in the tissue support that exceed local plasticity. In at least one such example, the localized plastic deformation is limited to less than a Characteristic Length (CL) of the staple in any direction relative to the staple. In at least one example, the material of the tissue support can be selected such that staples captured against the tissue support can, for example, only form a plastically deformed region in the tissue support having a diameter of less than 2 x CL. In other examples, the material of the tissue support may be selected such that staples captured against the tissue support may, for example, only form a plastically deformed region in the tissue support having a diameter of less than 1.5 × CL. The characteristic length of the staple may be, for example, the width or the backspan of the crown, and/or the formed height of the legs in their deformed configuration. Further, the tissue supports disclosed herein can be constructed of a material that is sufficiently stiff to support the staples as they are incised by the cutting member. In at least one example, the hardness of the material comprising the tissue bolster is equal to or greater than the hardness of the material comprising the staples incised against the tissue bolster. In some instances, the hardness of the material comprising the tissue bolster is less than the hardness of the material comprising the incised staples; however, the structural design of the tissue bolster is sufficient to prevent the tissue bolster from being plastically stretched beyond an acceptable plastic deformation zone. In some instances, the energy required to cut into the tissue and the formed staples in the tissue is less than the energy required to cut into the tissue buttress. In various examples, the material comprising the tissue bolster may resist the staple chisel. In at least one example, a biocompatible lubricant can be placed on and/or impregnated within the tissue buttress to prevent staples from being captured on the tissue buttress.

In various examples, the tissue compression surface of the anvil and the tissue contacting surface of the tissue buttress are flat or at least substantially flat. This configuration may distribute the force applied by the anvil over a large area of tissue. Other embodiments are envisioned in which the tissue compression surface of the anvil and/or the tissue contacting surface of the tissue buttress are not flat. In certain examples, the tissue compression surface of the anvil and/or the tissue contacting surface of the tissue buttress include tissue gripping members or spikes extending therefrom that are configured to engage and grip tissue. Such tissue gripping members may, for example, reduce relative movement or slippage between the tissue and the anvil. In at least one example, the tissue clamping member density on the tissue compression surface of the anvil and the tissue contacting surface of the tissue buttress are the same. In other examples, the tissue gripping member density on the tissue contacting surface of the tissue buttress is higher than the tissue gripping member density on the compression surface of the anvil. In such instances, the tissue gripping members can prevent the tissue from flowing or sliding radially inward when the tissue buttress is positioned radially inward relative to the compression surface of the anvil.

The anvil 6520 is disclosed in fig. 95. The anvil 6520 comprises a tissue compression surface 6522 and further comprises forming pockets defined in the tissue compression surface 6522 that are configured to deform the staples into a desired configuration as the staples are ejected from their staple cartridges. Each forming pocket comprises a pair of cups, wherein each pair of cups is configured to deform a leg of a staple. For example, the pair of forming cups may include a first forming cup 6530a configured to deform a first leg of a staple and a second forming cup 6530b configured to deform a second leg of a staple. The first and second forming cups 6530a, 6530b are mirror images of each other with respect to an axis 6531 extending between the first and second forming cups 6530a, 6530 b; however, other configurations may be utilized.

The first forming cup 6530a includes a first or outer end 6532 and a second or inner end 6534. The first forming cup 6530a also includes a bottom or bathtub surface 6536 extending between an outer end 6532 and an inner end 6534. The first end 6532 is configured to receive the leg of the staple and begin the leg forming process. The first end 6532 includes a curved surface configured to flex the staple legs toward the second end 6534. The bottom surface 6536 comprises a curved or concave surface configured to at least partially rotate the staple legs back toward the staple cartridge. The second end 6534 includes a curved surface configured to guide the staple legs out of the forming cup 6530 a.

The second forming cup 6530b comprises a similar configuration to that of the first forming cup 6530a and is configured to deform the second leg of the peg. For the reasons described above, the first forming cup 6530a guides the first leg of the staple toward the second leg, and the second forming cup 6530b guides the second leg of the staple toward the first leg. In various examples, for example, the first forming cup 6530a and the second forming cup 6530B cooperate to deform the staple into a B-shaped configuration; however, the forming cup can be configured to deform the staples into any suitable configuration.

Referring primarily to fig. 96, each forming cup 6530(6530a and 6530b) includes a first lateral sidewall 6537 and a second lateral sidewall 6539 extending between a first end 6532 and a second end 6534. In various examples, the first lateral sidewall 6537 and the second lateral sidewall 6539 are mirror images of each other relative to a longitudinal axis 6533 extending through the center of the forming cup 6530. In other examples, the first lateral sidewall 6537 and the second lateral sidewall 6539 are not mirror images of each other. In either case, for example, the side walls 6537, 6539 are sloped or beveled to guide the staple legs toward the center of the forming cup, i.e., toward the axis 6533.

Each forming cup 6530 includes a groove or channel 6538 defined in a bottom surface 6536 thereof. The channel 6538 extends longitudinally between the first end 6532 and the second end 6534 of the forming cup 6530. The grooves 6538 extend parallel to and are laterally offset relative to a central longitudinal axis 6535 of the forming cup 6530. The grooves 6538 are wider than the legs of the staple deformed by the forming cup 6530; however, other embodiments are also contemplated in which the grooves 6538 are narrower than the legs of the staple. In either case, the channels 6538 are configured to guide the staple legs along a predetermined path within the forming cup 6530.

In various examples, the grooves of the forming cup 6530 are configured to twist the legs of the nail as they are deformed. In at least one example, the staple is planar or at least substantially planar prior to deformation. In at least one such example, the legs and bases of the staples lie in the same plane aligned with the longitudinal axis 6535 as the staples are ejected from the staple cartridge. As the staple legs enter the forming cup 6530, the first end 6532 and the bottom surface 6536 are sloped and/or otherwise configured to guide the legs toward the channel 6538. Once the staple legs enter the grooves 6538, the grooves 6538 will twist the staple legs out of plane with the staple base. For the reasons described above, the unformed staple configuration is planar, but the formed staple configuration is non-planar. However, other embodiments are also contemplated in which the staples have a non-planar configuration before and after their deformation.

The grooves 6538 of the forming cups 6530 (for a given set of forming cups 6530) are positioned on the same side of the longitudinal axis 6535 and are configured to be able to twist both staple legs to the same side of the staple base. However, other embodiments are also contemplated in which the first staple leg is twisted to one side of the staple base and the second staple leg is twisted to the other side of the staple base. In at least one such embodiment, the first groove 6538 is positioned on a first side of the longitudinal axis 6535 that is configured to twist the first staple leg to a first side of the staple base, while the second groove 6538 is positioned on a second side of the longitudinal axis 6535 that is configured to twist the second staple leg to a second side of the staple base.

For a given set of forming cups 6530, the channels 6538 of the forming cups 6530 are collinear, or at least substantially collinear. However, other embodiments are also contemplated in which the grooves 6538 are positioned on the same side of the longitudinal axis 6535, but are not collinear with each other. In at least one such example, the grooves 6538 are parallel to one another, while in other such examples, the grooves 6538 are not parallel to one another.

Referring primarily to fig. 96, the grooves 6538 are deeper than the bottom surface 6536 of the forming cup 6530. However, other embodiments are also contemplated in which the grooves and the bottom surface of the forming cup have the same depth.

In various examples, the forming cups 6530 are arranged in longitudinal rows when the anvil 6520 is part of a longitudinal end effector configured to apply longitudinal rows of staples. In at least one such example, the grooves 6538 of the forming cup are arranged such that all of the staples deployed by the end effector are bent out of plane in the same direction. In other examples, the channels 6538 are arranged in a first longitudinal row of the forming cups 6530 to bend the staple legs in a first direction, and in a second longitudinal row of the forming cups 6530 to bend the staple legs in a second or different direction. In some examples, the grooves 6538 are arranged to bend the legs of a first staple in the row in a first direction and to bend the legs of a second staple in the row in a second or opposite direction.

In various examples, the forming cups 6530 are arranged in an annular row when the anvil 6520 is part of an annular end effector configured to apply an annular row of staples. In at least one such example, the grooves 6538 are positioned radially outward relative to a central longitudinal axis 6535 of the forming cup 6530. In other examples, the grooves 6538 are located radially inward relative to the central longitudinal axis 6535 of the forming cup 6530. In certain examples, the grooves 6538 are positioned radially outward in a first annular row of forming cups 6530 and radially inward in a second annular row of forming cups 6530.

In addition to the above, the forming pockets of the anvil can comprise any suitable configuration. In at least one example, the forming pocket can include two forming cups that are mirror images of each other with respect to the central axis. Each forming cup includes a triangular configuration having an outer end and an inner end. The inner ends of a pair of shaped cups are adjacent to each other. The outer end of the forming cup is wider than the inner end and is configured to receive the leg of the staple. Each forming cup further includes a bottom or bathtub surface extending between an outer end and an inner end, and further includes a longitudinal channel defined in the bottom surface configured to guide the staple legs within the forming cup. In at least one example, the longitudinal groove is centered in the bottom surface of the forming cup.

An end effector 7000 of the circular stapling assembly is disclosed in fig. 97-99. The end effector 7000 includes a staple cartridge which includes a deck 7030 and a cartridge body 7040. The platform 7030 includes a tissue compression surface 7031 and staple cavities 7032 defined in the compression surface 7031. The staple cavities 7032 are arranged in a first or inner annular row and a second or outer annular row. Each staple cavity 7032 in the inner row includes a first staple 7070a removably stored therein, and each staple cavity 7032 in the outer row includes a second staple 7070b removably stored therein.

The end effector 7000 further includes staple drivers configured to push the staples out of the staple cartridge. For example, the staple cartridge comprises a first annular row of staple drivers 7060a that is configured to eject a first row of staples 7070a, and a second annular row of staple drivers 7060b that is configured to eject a second row of staples 7070b from the cartridge body 7040. The staple drivers 7060a and 7060b are positioned within and/or aligned with staple cavities 7032 defined in the platform 7030. The staple drivers 7060a and 7060b can slide within the staple cavities 7032 to eject the staples 7070a and 7070b, respectively, from the staple cavities 7032.

The end effector 7000 further includes an anvil 7020. The anvil 7020 comprises a tissue compression surface 7021 and staple forming pockets 7022 defined in the compression surface 7021. The staple forming pockets 7022 are arranged in a first or inner annular row and a second or outer annular row. The staple forming pockets 7022 are aligned with the staple cavities 7032 such that the staples 7070a, 7070b are in contact with the staple forming pockets 7022 when the staples 7070a, 7070b are ejected from the staple cavities 7032.

The end effector 7000 further includes a firing member 7056 that is configured to lift the staple drivers 7060a and 7060b into the staple cavities 7032 to eject the staples 7070a and 7070b, respectively, from the staple cavities 7032. The firing member 7056 includes a base 7054 and a ramp 7055. The base portion 7054 is slidably positioned within a recess 7052 defined in the firing drive 7050. The ramp 7055 is slidably positioned within a slot 7041 defined in the cartridge body 7040. As will be described in greater detail below, the ramps 7055 are configured to slide within the slots 7041 and progressively contact the staple drivers 7060a, 7060b to eject the staples 7070a, 7070b from the staple cavities 7032.

In addition to the above, the firing member 7056 can be moved through a firing stroke to eject the staples 7070a, 7070b from the staple cavities 7032. During the firing stroke, the firing member 7056 moves along a curved or arcuate path defined by the slot 7041. Referring primarily to fig. 97, the slot 7041 includes a first end 7042 and a second end 7049 and a continuous path therebetween. The ramp 7055 of the firing member 7056 is positioned in the first end 7042 at the beginning of the firing stroke and in the second end 7049 at the end of the firing stroke. The first ends 7042 of the slots 7041 are aligned with the inner row of staple cavities 7032 and the second ends 7049 of the slots 7041 are aligned with the outer row of staple cavities 7032. The slot 7041 also includes a first peripheral portion 7043 that extends about a central longitudinal axis 7090 that extends through the end effector 7000. The first peripheral portion 7043 of the slot 7041 is aligned with and extends below the staple drivers 7060a in the inner row of staple cavities 7032. The ramps 7055 of the firing member sequentially engage the staple drivers 7060a to sequentially fire the staples 7070a as the firing member 7056 moves through the first peripheral portion 7043 of the slot 7041.

The first peripheral portion 7043 is defined by a uniform, or at least substantially uniform, radius of curvature about the longitudinal axis 7090; however, other embodiments are also contemplated in which the radius of curvature of the first peripheral portion 7043 is not uniform. In at least one such example, the first peripheral portion 7043 comprises a spiral. In other words, in the example, the first peripheral portion 7043 recedes away from the longitudinal axis 7090 as it extends about the longitudinal axis 7090.

The second peripheral portions 7045 of the slots 7041 are aligned with and extend below the staple drivers 7060b in the outer row of staple cavities 7032. The ramps 7055 of the firing member sequentially engage the staple drivers 7060b to sequentially fire the staples 7070b as the firing member 7056 is moved through the second peripheral portion 7045 of the slot 7041. The second peripheral portion 7045 is defined by a uniform or at least substantially uniform radius of curvature about the longitudinal axis 7090; however, other embodiments are also contemplated in which the radius of curvature of the second peripheral portion 7045 is not uniform. In at least one such example, the second peripheral portion 7045 includes a spiral. In other words, in the example, the second peripheral portion 7045 recedes away from the longitudinal axis 7090 as it extends about the longitudinal axis 7090.

In addition to the above, the slot 7041 includes a transition portion 7044 intermediate a first peripheral portion 7043 and a second peripheral portion 7045. During the firing stroke, the ramp 7055 sequentially slides through the first peripheral portion 7043, the transition portion 7044, and then the second peripheral portion 7045. The transition portion 7044 allows the firing member 7056 to shift between a first radius of curvature for a first row of staples and a second radius of curvature for a second row of staples. In certain embodiments, a transition portion 7044 between the first peripheral portion 7043 and the second peripheral portion 7045 may not be necessary. In at least one such example, the first peripheral portion 7043 can comprise a first helical configuration and the second peripheral portion 7045 can comprise a second helical configuration, e.g., aligned such that an end of the first helical configuration is aligned with a start of the second helical configuration.

The firing member 7056 is driven along its firing path by a firing drive 7050. For example, the firing drive 7050 is driven about the longitudinal axis 7090 by a hand crank and/or an electric motor. The firing drive 7050 includes a drive recess 7052 defined therein. The base 7054 of the firing member 7056 is positioned in the drive recess 7052. The drive recess 7052 is larger than the base 7054 of the firing member 7056 such that the base 7054 can move or float within the drive recess 7052. The driving recess 7052 is defined by sidewalls that limit movement of the base 7054 within the recess 7052. As the firing drive 7050 rotates about the longitudinal axis 7090, the side walls of the drive recess 7052 contact the base 7054 and push the drive member 7056 through the slot 7051. As described above, the radius of curvature of the slot 7051 has one or more changes, and the base 7054 of the firing member 7056 can slide within the drive recess as the firing member 7056 moves through such changes.

As noted above, staples in the first or inner staple row are deployed sequentially before staples in the second or outer staple row are deployed sequentially. Such embodiments may control the inner circumference of the colon, for example, prior to suturing outward. In other embodiments, the staples in the outer staple row are sequentially deployed before the staples in the inner staple row are sequentially deployed. Such embodiments may, for example, form a boundary in colon tissue prior to suturing inwardly.

In various examples, in addition to the above, the first staples 7070a and the second staples 7070b have the same unformed height. In at least one such example, the first staples 7070a and the second staples 7070b are formed to the same formed height. In other such examples, the first staples 7070a can be formed at a first formed height and the second staples 7070b can be formed at a second formed height that is different than the first formed height. In at least one such example, the first formed height of the inner row of staples is shorter than the second formed height of the outer row of staples. For example, such a configuration may provide a more gradual transition between stapled and unstitched tissue. In other examples, the first formed heights of the inner rows of staples are higher than the second formed heights of the outer rows of staples. For example, such a configuration may make the innermost tissue of the resulting bowel, for example, more flexible.

In some examples, in addition to the above, the first staples 7070a have a first unformed height and the second staples 7070b have a second unformed height that is different than the first unformed height. In at least one such example, the first staples 7070a and the second staples 7070b are formed to the same formed height. In other such examples, the first staples 7070a are formed to a first formed height and the second staples 7070b are formed to a second formed height that is different than the first formed height.

The end effector 7000 has two annular rows of staples; however, the end effector can have any suitable number of annular rows of staples. For example, the end effector may have three annular rows of staples. In at least one such example, the staples in the first annular row can have a first unformed staple height, the staples in the second annular row can have a second unformed staple height, and the third staples in the third annular row can have a third unformed staple height. Further, in at least one such example, the staples in the first annular row can have a first deformed staple height, the staples in the second annular row can have a second deformed staple height, and the third staples in the third annular row can have a third deformed staple height.

Firing drive 7150 is shown in fig. 100-105. The firing drive 7150 includes a rotatable drive shaft 7152 that may rotate about a longitudinal axis. Firing drive 7150 also includes a three stage sequential driver assembly including a first or inner driver 7154a, a second or intermediate driver 7154b, and a third or outer driver 7154 c. The drive shaft 7152 includes a drive pin 7151 extending therefrom. A drive pin 7151 extends through the drive slot in each of the drivers 7154a, 7154b, and 7154 c. For example, first driver 7154a includes a first drive slot 7153a defined therein, second driver 7154b includes a second drive slot 7153b defined therein, and third driver 7154c includes a third drive slot 7153c defined therein. Drive slots 7153a, 7153b, and 7153c do not have the same configuration; however, drive slots 7153a, 7153b, and 7153c have an overlapping configuration that are aligned, or at least substantially aligned, with one another at drive pin 7151. For example, the drive pin 7151 is in the unfired position of fig. 100, and the drive slots 7153a, 7153b, and 7153c are aligned with the drive pin 7151.

In addition to the above, fig. 100 shows drivers 7154a, 7154b, and 7154c in an unfired position. As the drive shaft 7152 rotates through the first portion of its firing stroke, referring now to fig. 101, the drive pin 7151 rotates through a peripheral path in which the drive pin 7151 engages the side wall of the drive slot 7153a and pushes or cams distally the first driver 7154 a. Notably, the drive pins 7151 do not drive the drivers 7154b and 7154c distally during the first portion of the firing stroke. As can be seen in fig. 100, the drive slots 7153b and 7153c are aligned with the peripheral path of the drive pin 7151 throughout the first portion of the firing stroke. The first driver 7154a is configured to fire a first annular row of staples as the first driver 7154a is distally displaced.

As the drive shaft 7152 rotates through the second portion of its firing stroke, referring now to fig. 102, the drive pin 7151 rotates through a peripheral path in which the drive pin 7151 engages the side wall of the drive slot 7153b and pushes or cams the second driver 7154b distally. Notably, the drive pin 7151 does not drive the driver 7154c distally during the second portion of the firing stroke. Similar to the above, the drive slots 7153a and 7153c are aligned with the peripheral path of the drive pin 7151 throughout the second portion of the firing stroke. The second driver 7154b is configured to fire a second annular row of staples as the second driver 7154b is distally displaced.

As the drive shaft 7152 rotates through the third portion of its firing stroke, referring now to fig. 103, the drive pin 7151 rotates through a peripheral path in which the drive pin 7151 engages the side wall of the drive slot 7153c and pushes or cams distally the third driver 7154 c. Similar to the above, the drive slots 7153a and 7153b are aligned with the peripheral path of the drive pin 7151 throughout the third portion of the firing stroke. The third driver 7154c is configured to deploy the cutting member when the third driver 7154c is distally displaced; however, in certain embodiments, the third driver 7154c may deploy a third row of staples, for example.

For the reasons set forth above, there is no overlap between the first staple firing stage, the second staple firing stage, and the tissue cutting stage. They are timed in sequence. Thus, the force required to deform the staples and cut the tissue is spread out over the firing stroke. In addition, the firing drive 7150 may not be capable of cutting tissue prior to tissue stapling. Various alternative embodiments are envisioned in which there is some overlap between the first staple firing stage, the second staple firing stage, and/or the tissue cutting stage. In at least one such embodiment, the configuration of drive slots 7153a, 7153b, and 7153c can be adapted such that there is partial overlap in the motion of first drive 7154a and second drive 7154b and/or partial overlap in the motion of second drive 7154b and third drive 7154 c.

Referring primarily to fig. 103 and 104, drivers 7154a, 7154b, and 7154c include mating features that prevent, or at least inhibit, rotation of drivers 7154a, 7154b, and 7154c relative to one another. For example, first driver 7154a includes a longitudinal key 7155a that is positioned in a longitudinal slot 7156b defined in second driver 7154 b. Keys 7155a and slots 7156b are configured to allow first driver 7154a to slide longitudinally relative to second driver 7154b, but to block rotational movement between first driver 7154a and second driver 7154 b. Similarly, second drive 7154b includes a longitudinal key 7155b that is positioned in a longitudinal slot 7156c defined in third drive 7154 c. Keys 7155b and slots 7156c are configured to allow second driver 7154b to slide longitudinally relative to third driver 7154c, but to block rotational movement between second driver 7154b and third driver 7154 c.

To retract drives 7154a, 7154b, and 7154c, drive shaft 7152 is rotated in the opposite direction. In the example, drive shaft 7152 sequentially engages the side walls of drive slot 7153c, the side walls of drive slot 7153b, and then the side walls of drive slot 7153a to return third driver 7154c, second driver 7154b, and first driver 7154a to their unfired positions (fig. 100).

The firing drive 7250 is as shown in FIG. 106. The firing drive 7250 operates in a similar manner to the firing drive 7150. The firing drive 7250 includes a drive shaft 7252 that is rotatable about a longitudinal axis. The drive shaft 7252 includes a cam surface or ramp 7256 that rotates through several stages of the firing stroke. The firing drive 7250 also includes a first, second, and third driver 7254a, 7254b, 7254c that are engaged by the cams 7256 of the drive shaft 7252 as the firing drive 7250 rotates. In a first stage of the firing stroke, the cam 7256 engages a cam surface 7255a defined on the first driver 7254a and drives the first driver 7254a distally. In a second stage of the firing stroke, the cam 7256 engages a cam surface 7255b defined on the second driver 7254b and drives the second driver 7254b distally, and in a third stage of the firing stroke, the cam 7256 engages a cam surface 7255c defined on the third driver 7254c and drives the third driver 7254c distally.

The first cam surface 7255a is shorter than the second cam surface 7255b and, therefore, the first driver 7254a has a shorter firing stroke than the second driver 7254 b. Similarly, the second cam surface 7255b is shorter than the third cam surface 7255c and, therefore, the second driver 7254b has a shorter firing stroke than the third driver 7254 c. For example, such a configuration may be used to form different rows of staples to different forming heights. In other embodiments, the drivers 7254a, 7254b, and 7254c can have any suitable firing stroke. In at least one embodiment, the drivers 7254a, 7254b, and 7254c have, for example, the same firing stroke. For example, such a configuration may be used to form different rows of staples to the same formed height.

FIG. 107 is a perspective view of a portion of a staple cartridge 4410 that can be used with a circular surgical stapling instrument in accordance with at least one embodiment. Various circular surgical stapling instruments are known. FOR example, U.S. patent application serial No. 14/836,110 entitled "SURGICAL STAPLING devices FOR CIRCULAR SURGICAL INSTRUMENTS AND CIRCULAR SURGICAL INSTRUMENTS" filed on 26.8.2015, which is hereby incorporated by reference in its entirety. U.S. patent application serial No. 14/498,070 entitled "CIRCULAR surgical stapler construction," filed on 26.9.2014. FASTENER CARTRIDGES FOR APPLYING RADIALLY EXPANDING FASTENER LINES, "the entire disclosure of which is hereby incorporated by reference herein. As described in these references, circular surgical staplers typically include a frame assembly including an attachment portion configured to operably couple an anvil to the circular surgical stapler.

Generally, the anvil includes an anvil head that supports one or more annular lines of staple forming pockets. An anvil shaft or trocar portion is attached to the anvil head and is configured to be removably coupled to an anvil attachment portion of a circular stapling instrument. Various circular surgical stapling instruments include means for selectively moving the anvil toward and away from the surgical staple cartridge so that the target tissue can be clamped between the anvil and the deck of the surgical staple cartridge. The surgical staple cartridge removably stores therein a plurality of surgical staples arranged in one or more annular arrays corresponding to the configuration of staple forming pockets provided in the anvil. Staples are removably stored within corresponding staple cavities formed in the staple cartridge and are supported on corresponding portions of a selectively movable pusher assembly that is operably received within the circular stapler. The circular stapler also includes an annular knife or cutting member configured to incise tissue clamped between the anvil and the staple cartridge.

Referring again to fig. 107, the staple cartridge 4410 comprises a cartridge body 4411 which defines an annular cartridge deck surface 4412. The cartridge body 4411 comprises an inner annular row 4420 of spaced apart inner staple cavities 4422 and an outer annular row 4440 of spaced apart outer staple cavities 4442. The inner staple cavities 4422 are staggered relative to the spaced apart outer staple cavities 4442 as can be seen in fig. 107. A medial surgical staple 4430 is supported within each inner staple cavity 4422 and a lateral surgical staple 4450 is supported within each outer staple cavity 4442. The outer staples 4450 in the outer annular row 4440 may have different characteristics than the inner staples 4430 in the inner annular row 4420. For example, as shown in the embodiment of fig. 108, outer staples 4450 have an unformed "gull-wing" configuration. Specifically, each outer staple 4450 bag Including a pair of leg portions 4454, 4464 extending from crown 4452. Each leg 4454, 4464 includes a vertical portion 4456, 4466, respectively, extending from crown 4452. In one embodiment, the vertical portions 4456, 4466 may be parallel to each other. However, in the illustrated construction, the vertical portions 4456, 4466 are not parallel to each other. For example, the angle A between the crown 4452 and the vertical portions 4456, 4466 in the illustrated construction₁Greater than ninety degrees. See fig. 108. Additional details regarding nail configuration can be found in U.S. patent application serial No. 14/319,008, now U.S. patent application publication No.2015/0297232, entitled "FASTENER CARTRIDGE constituent NON-UNIFORM FASTENERS," filed on 30/6/2014, the entire disclosure of which is hereby incorporated by reference herein. However, other upright portions 4456, 4466 may be arranged at other angles relative to crown 4452. One advantage of orienting vertical legs 4456, 4466 at an angle of greater than ninety degrees relative to crown 4452 is that such a configuration can help temporarily retain staples within their corresponding staple cavities.

At least one leg 4454, 4464 includes an inwardly extending end portion. For example, in the embodiment shown in fig. 108, each leg 4454, 4464 comprises an inwardly extending leg portion. In the illustrated construction, leg portion 4458 extends inwardly from vertical leg portion 4456, and leg portion 4468 extends inwardly from vertical leg portion 4466. As can be seen in fig. 108, leg portion 4458 is shorter than leg portion 4468. In other words, distance H between crown 4452 and the point at which leg portion 4458 is angled inwardly from vertical leg portion 4456 _AGreater than the distance H between crown 4452 and the point at which leg portion 4468 is angled inwardly from vertical leg portion 4466_C. Thus, in at least one embodiment, distance H_BLess than length H_D. Angle a at which leg portion 4458 is inclined relative to vertical leg portion 4556₂May be equal to the angle a at which leg portion 4468 is inclined relative to vertical leg portion 4466₃Or angle A₂And A₃May be different from each other. Additional details regarding staple configuration can be found in U.S. patent application Ser. No. 14/319,008 entitled "FASTENER CARTRIDGE COMPRISING NON-UNIFORM FASTENERS," filed on 30/6/2014, now designated asU.S. patent application publication No.2015/0297232, which is incorporated herein by reference.

In at least one embodiment, each of the medial surgical staples 4430 can have the configuration shown in fig. 108. As seen in fig. 108, a medial surgical staple 4430 has a crown 4432 and two vertical legs 4434, 4436 extending therefrom. Vertical legs 4434, 4436 may extend relatively perpendicularly from crown 4432, or they may be at an angle A which may be greater than ninety degrees₄And (4) extending. Such a configuration can facilitate temporary retention of the staples 4430 within their corresponding staple cavities 4422. However, vertical legs 4434, 4436 extend from crown 4432 at different angles. In some embodiments, angle a ₄Are equal to each other. In other embodiments, angle A₄Are different from each other. In the illustrated embodiment, inner staple 4430 and outer staple 4450 each have the same unformed height UFH. The inner and outer staples 4430 and 4450 were formed from conventional surgical staple lines. In at least one embodiment, the staple lines used to form the outer staples 4450 have a larger diameter than the staple lines used to form the inner staples 4430. In other embodiments, the medial and lateral staples may have the same diameter and may be formed from wire having other diameters. In some configurations, the medial and lateral staples may be formed from the same type of staple line. Thus, in such a configuration, the wire diameters of the medial and lateral staples would be the same. However, in another embodiment, the medial and lateral staples may have the same unformed shape/configuration, but be formed from two different staple lines having different wire diameters. Also, in at least one configuration, the crown width CW of each of the outer staples 4450_OGreater than crown width CW of each inside staple 4430_I. Additional details regarding nail configuration can be found in U.S. patent application serial No. 14/319,008, now U.S. patent application publication No.2015/0297232, entitled "FASTENER CARTRIDGE constituent NON-UNIFORM FASTENERS," filed on 30/6/2014, which is incorporated herein by reference.

Returning to FIG. 107, the staple cartridge 4410 comprises an outer edge 4414 that extends above the deck surface 4412. During surgery, the clinician can adjust the position of the anvil relative to the cartridge of the circular stapler. In at least one such embodiment, the staple cartridge 4410 further comprises deck features 4416 and 4418 which extend from a deck surface 4412. As can be seen in fig. 107, a series of inner platform features 4416 are disposed between an inner row 4420 of staple cavities 4422 and a centrally disposed knife opening 4413 through which a knife or cutting member will pass during the firing process. The platform features 4416 can be shaped and positioned relative to the inner staple cavities and openings 4413 as shown in fig. 107, 109, and 110. For example, each inner platform feature 4416 may have a flat wall portion 4415 that is coextensive with the wall of knife opening 4413 and a tapered or sloped body portion 4417 adjacent to the row of inner staple cavities 4422. See fig. 109 and 110. In the embodiment shown in fig. 107, the platform features 4416 are oriented in the gap between two adjacent inner staple cavities 4422 and are staggered between pairs of staple cavities 4422 as shown. The cavity extension configuration or platform feature in the system can be used for the lower pressures often encountered in flat platform silos. The disclosed configuration may also help to reduce tissue movement and slippage. Since slippage of tissue is generally undesirable, the outer diameter retention features may be larger and more numerous. The inner diameter feature may be used to increase tissue tension/shear as the blade passes alongside the inner diameter, which may allow the system to cut better. However, the platform features 4416 may have different shapes and configurations and may be located at different locations on the platform surface 4412.

As can also be seen in fig. 107, 109, and 110, each of the other outer staple cavities 4442 includes an outer platform feature 4418 associated with each end thereof. As the staples 4450 are ejected from the staple cartridge 4410, the outer deck features 4418 extend above the deck surface 4412 and guide the outer staples 4450 toward the anvil. In such embodiments, the outer staples may not extend over the outer deck features 4418 until the firing member moves the outer staples 4450 toward the anvil. Referring primarily to fig. 107, in at least one embodiment, the outer platform features 4418 do not extend around the entire corresponding outer staple cavity 4442. The first outer platform feature 4418 is positioned adjacent a first end of the corresponding outer cavity 4442 and the second outer platform feature 4418 is positioned adjacent a second end of the outer cavity 4442. As can be seen in fig. 107, an outer platform feature 4418 is associated with every other outer staple cavity 4442. Such a configuration may be used to reduce overall pressure and minimize tissue stretching and movement. However, in other embodiments, first and second outer platform features 4418 may be associated with each outer staple cavity 4442. In other embodiments, the outer platform feature may extend around the entire perimeter of the corresponding outer cavity. As can be seen in fig. 109, inner platform feature 4416 is shorter than outer platform feature 4418. In other words, each inner platform feature protrudes above platform surface 4412 a distance that is less than the distance that each outer platform feature 4418 protrudes above platform surface 4412. Each outer platform feature may protrude above the platform surface 4412 the same distance that the outer edge 4414 protrudes above the platform surface 4412. Furthermore, as can also be seen in fig. 109, each outer platform feature 4418 has a generally tapered or tapered outer profile, which can help prevent tissue from hanging up on the platform features during insertion of the stapler head into the patient's colon and rectum.

The platform feature configuration described above may provide one or more advantages. For example, the upstanding outer edge can help prevent tissue from sliding on the cartridge deck. The upstanding edge may also include a repeating pattern of high and low points rather than forming a continuous lip. The internal upstanding features may also help to hold tissue adjacent the blade and result in improved cutting. Internal platform features may be located between each cavity or in an alternative configuration, the platform features may comprise one continuous upstanding lip. It may be desirable to balance the number of platform features to minimize the number of high force/compression zones while achieving a desired amount of tissue fixation. The cavity concentric features can serve the additional purpose of minimizing tissue flow in the area from which the staple legs protrude. Such a configuration also facilitates formation of the desired staples as the staple legs are ejected and transition to the receiving anvil pockets, which may consist of corresponding forming pockets. Such localized dimple features increase the area of low compression while facilitating support of the legs from the cartridge as the staples exit the cartridge. This configuration thus minimizes the distance the staple must "jump" before encountering the anvil pocket. Tissue flow tends to increase radially outward from the center of the cartridge. Referring to fig. 118, the improved upright lateral row extension has a tendency to catch on tissue as it is tubular when inserted up into the colon.

Fig. 109 and 110 illustrate the use of a surgical staple cartridge 4410 in conjunction with an anvil 4480. The anvil 4480 comprises an anvil head portion 4482 which operably supports a staple forming insert or portion 4484 and a knife pad ring 4490. Knife washer 4490 is supported in facing relationship with knife 4492 which is supported in the head of the stapler. In the illustrated embodiment, the staple forming inserts 4484 are made of, for example, steel, stainless steel, or the like, and comprise an inner row of inner staple forming pockets 4486 and an outer row of outer staple forming pockets 4488. Each inside staple forming pocket 4486 corresponds to one of the inner staple cavities 4422 and each outside staple forming pocket 4488 corresponds to one of the outer staple cavities 4442. In the illustrated construction, when the anvil 4480 is moved to its fired position relative to the cartridge deck surface 4412, the inner staple forming pockets 4486 are closer to the cartridge deck surface 4412 than the outer staple forming pockets 4488. In other words, a first gap g between the first staple forming portion 4485 and the cartridge deck surface 4412₁Or the first staple forming distance is less than the second gap g between the second staple forming portion 4487 and the cartridge deck surface 4412₂Or a second staple forming distance.

As can be further seen in fig. 109 and 110, the inside staples 4430 are each supported within their corresponding inner staple cavities 4422 on a corresponding inner driver portion 4502 of the pusher assembly 4500, and each outside staple 4450 is supported within its corresponding outer staple cavity 4442 on a corresponding outer driver portion 4504. Advancing the pusher assembly 4500 toward the anvil 4480 will cause the inner and outer staples 4430, 4450 to be driven into forming contact with their respective corresponding staple forming pockets 4486, 4488 as illustrated in fig. 110. Further, the knife 4492 is advanced distally through the tissue clamped between the anvil 4480 and the deck surface 4412 and through the frangible bottom 4491 of the knife washer 4490. Such a configuration is used to provide a formed height FH for lateral staples 4450 _OThe forming height is greater than the forming height FH of the inside nail 4430_I. In other words, outer row 4440 of outer staples 4450 was shaped into a larger "B" configuration, resulting in a larger capture volume and/or higher staple lengthStaple forming height to mitigate high tissue compression near the outer staple row 4440. Larger B shapes may also improve blood flow toward these inner rows. In various examples, outer row 4440 of outer staples 4450 has 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 can vary. In one embodiment, for example, there are more outer staples 4450 than inner staples 4430. Another embodiment employs more medial staples 4430 than lateral staples 4450. In various examples, the wire diameter of the outer staples 4450 is greater than the wire diameter of the inner staples 4430. Medial staple 4430 and lateral staple 4450 can have the same unformed height UFH. Crown width CW in outer row 4440 of outer staples 4450_OCrown width CW greater than inner row 4420 of inside staples 4430_I. The gull-wing configuration of outside spikes 4450 employs bends located at different distances from their respective crowns. Using a stepped anvil configuration with a flat (non-stepped) cartridge deck surface 4412, staples of different formed heights are produced with a uniform driver or pusher stroke.

FIG. 111 illustrates another staple cartridge embodiment 4610. As can be seen in fig. 111, the staple cartridge 4610 comprises a cartridge platform 4612 that includes an inner annular row 4620 of spaced apart inner staple cavities 4622 and an outer annular row 4640 of spaced apart outer staple cavities 4642. The inner staple cavities 4622 are staggered relative to the spaced apart outer staple cavities 4642, as can be seen in fig. 111. A medial surgical staple 4630 is supported within each inner staple cavity 4622 and a lateral surgical staple 4650 is supported within each outer staple cavity 4642. Further, outer edge 4614 extends above platform surface 4612. In various embodiments, in addition to the above, the staples do not protrude above the deck surface 4612 until the firing member moves the staples 4630, 4650 toward the anvil. Such embodiments may often utilize small staples relative to the depth of their respective staple cavities in which the staples are stored. In other embodiments, the legs of the staples protrude above the deck surface 4612 when the staples are in their unfired positions. In at least one such embodiment, the staple cartridge 4610 further includes platform features 4616 and 4618 extending from the platform surface 4612.

As also seen in fig. 111, each of the other inner staple cavities 4622 includes an inner platform feature 4616 associated with each end thereof. When the corresponding inner staples 4630 are ejected from the staple cartridge 4610, the inner platform features 4616 extend above the platform surface 4612 and guide the corresponding inner staples 4630 toward the anvil. In such embodiments, the inner staples may not extend above the inner platform feature 4616 until the firing member moves the inner staples 4630 toward the anvil. In the example shown, the inner platform features 4616 do not extend around the entire corresponding inner staple cavity 4622. The first inner platform feature 4616 is positioned adjacent a first end of the corresponding inner lumen 4622 and the second inner platform feature 4616 is positioned adjacent a second end of the inner lumen 4622. However, in other embodiments, an inner platform feature 4416 may be associated with each inner staple cavity 4622. In other embodiments, the inner platform feature may extend around the entire perimeter of the corresponding inner staple cavity. By employing land features having different heights in a concentric pattern, where they are associated with every other cavity, lower pressure tissue gap regions can be provided while balancing them to guide as many staple legs as possible for as long as possible. In other words, such a configuration may minimize the amount of tissue flow, reducing the overall amount of pressure applied to the target tissue.

Still referring to fig. 111, each outer staple cavity 4642 includes an outer platform feature 4618 associated with each of their ends. When the staples 4650 are ejected from the staple cartridge 4610, the outer platform features 4618 extend above the platform surface 4612 and guide the outer staples 4650 toward the anvil. In such embodiments, the lateral staples may not extend above the outer platform feature 4618 until the firing member moves the lateral staples 4650 toward the anvil. As can be seen in fig. 111, in the example shown, the outer platform features 4618 do not extend around the entire corresponding outer staple cavity 4642. The first outer platform feature 4618 is positioned adjacent a first end of a corresponding outer chamber 4642 and the second outer platform feature 4618 is positioned adjacent a second end of the outer chamber 4642. As can be seen in fig. 111, an outer platform feature 4618 is associated with each outer staple cavity 4642. However, in other embodiments, the first and second outer platform features 4618 may be associated with every other outer staple cavity 4642. In other embodiments, the outer platform feature may extend around the entire perimeter of the corresponding outer cavity. As can be seen in fig. 112 and 113, inner platform feature 4616 and outer platform feature 4618 extend the same distance above platform surface 4612. In other words, they have the same height. Furthermore, as can also be seen in fig. 112 and 113, each inner platform feature 4416 and each outer platform feature 4618 has a generally tapered or tapered outer profile, which may help prevent tissue from hanging up on the platform features during insertion of the stapler head into the colon and rectum of a patient.

Fig. 112 and 113 illustrate the use of a surgical staple cartridge 4610 in connection with an anvil 4680. The anvil 4680 includes an anvil head portion 4682 that operably supports a staple forming insert or portion 4684 and a knife washer 4690. The knife pad 4690 is supported in facing relationship with a knife 4692 supported in the stapler head. In the illustrated embodiment, the staple forming inserts 4684 are made of, for example, steel, stainless steel, or the like, and comprise an inner row of inner staple forming pockets 4686 and an outer row of outer staple forming pockets 4688. Each of the inner staple forming pockets 4686 corresponds to one of the inner staple cavities 4622 and each of the outer staple forming pockets 4688 corresponds to one of the outer staple cavities 4642. In the illustrated configuration, the distance g of the inner staple forming pockets 4686 from the platform surface 4612₁As are the outer staple forming pockets 4688.

As further seen in fig. 112 and 113, the inner staples 4630 are supported within corresponding inner staple cavities 4622 on the corresponding inner driver portion 4702 of the pusher assembly 4700. The outer staples 4650 are supported within corresponding outer staple cavities 4642 on the corresponding outer driver portions 4704. Advancing the pusher assembly 4700 toward the anvil 4680 will cause the inner staples 4630 and the outer staples 4650 to be driven into forming contact with their respective corresponding staple forming pockets 4686, 4688, as shown in fig. 113. Further, the knife 4692 is advanced distally through the tissue clamped between the anvil 4680 and the platform surface 4612 and through the frangible bottom 4691 of the knife washer 4690. In the example shown in fig. 112 and 113, each inner staple 4630 is formed from a first wire diameter D ₁And has a first unformed height L₁Is formed. For example, the first wire diameter D₁May be about 0.0079"-0.015"(increments typically 0.0089", 0.0094 "and 0.00145"), and a first unformed height L₁May be about 0.198 "-0.250". Each of the lateral staples 4650 is formed of a material having a second wire diameter D₂And has a second unformed height L₂Is formed. In the embodiment shown in FIGS. 112 and 113, D₁<D₂And L is₁<L₂. However, as can be seen in fig. 113, the inner staple 4630 and the outer staple 4650 are formed to have the same formed height FH. Thicker wire staples on the outside tend to provide high tear and burst strength compared to the inner row of smaller diameter staples, which tend to better maintain hemostasis. In other words, the tighter the inner row of staples, the better the hemostasis is maintained, while the less compression of the outer row of staples promotes better healing and blood flow. Further, staples with longer legs may ensure more B bending even if formed to the same height as staples with shorter legs, which may make the longer leg staples stronger and more likely to be properly shaped enough to remain in high load conditions. The number of staples used in each row of staples can vary. In one embodiment, for example, the inner row 4620 has the same number of inner staples 4630 as the outer rows 4640 of outer staples 4650. In various configurations, the crown width of the staples 4650 is greater than the crown width of the inner staples 4630. In other embodiments, the staples 4630, 4650 may have the same crown width. In other constructions, the pins 4630, 4650 may have the gull-wing design described above. For example, at least one leg of the staple may include an inwardly bent end portion, or both legs may include end portions that are inwardly bent toward each other. Such staples may be used in either an inner annular row or an outer annular row or both an inner annular row and an outer annular row.

FIG. 114 illustrates another circular staple cartridge embodiment 4810 that includes a cartridge deck 4812 that includes three annular rows of staple cavities 4820, 4840, 4860 that are spaced apart. Inner or first row 4820 contains a first plurality of inner or first staple cavities 4822, each arranged at a first angle. Each inner staple cavity 4822 operably supports a corresponding inner or first staple 4830 therein. The internal cavity 4822 orients the first spike 4830 at the same uniform angle relative to the tangential direction. In the example shownEach of the inner staples 4830 is formed by a staple having a first staple diameter D₁Is formed. In one example, the first staple line diameter D₁And may be about 0.0079"-0.015" (increments typically 0.0089", 0.0094", and 0.00145 "). Referring to FIG. 117, each inner staple 4830 includes a first crown 4832 and two first leg portions 4834. The first crown has a first crown width C₁And each first leg portion 4834 has a first unformed leg length L₁. In one example, the first crown width C₁May be about 0.100"-0.300" and the first unformed leg length L₁May be about 0.198 "-0.250". First leg portions 4834 can each be at an angle A relative to first crown 4832₁And (4) arranging. Angle A₁Which may be about 90 deg., or it may be slightly greater than 90 deg., such that first leg portion 4834 flares slightly outward to help retain first staple 4830 in its corresponding first staple cavity 4822.

Turning to fig. 115 and 116, the staple cartridge 4810 is intended to be used in conjunction with an anvil 4900 that includes two inner or first rows 4902 of a first pair 4903 of staggered or angled first staple forming pockets 4904. Each first pair 4903 of first staple forming pockets 4904 corresponds to a first staple 4830. One first staple forming pocket 4904 corresponds to one first staple leg 4834 and the other first staple forming pocket 4904 of the pair 4903 corresponds to the other first staple leg 4834. Such a configuration is used to establish a formed staple configuration in which first leg 4834 of first staple 4830 is formed out of plane with first crown 4832 of that particular first staple 4830 such that one first leg 4834 is formed on one side of first crown 4832 and the other first leg 4834 is formed on the other side of first crown 4832. This "three-dimensional" formed staple configuration is shown in fig. 115 relative to some of the first staple forming pockets 4904.

As can be seen most particularly in fig. 116, the cartridge deck 4812 has a "stepped" configuration. The cartridge deck 4812 includes an inner or first cartridge deck portion 4814 corresponding to an inner or first annular row 4820 of inner or first staple cavities 4822. As can be further seen in fig. 116, when the anvil 4900 is moved to the closed or clamped position, the anvil 4900 containing the first staple forming pockets 4904 The portion is spaced apart from the platform portion 4814 by a first gap distance g₁。

Referring again to fig. 114, 116, and 117, intermediate or second row 4840 contains a second plurality of intermediate or second staple cavities 4842, each arranged at a second angle. Each intermediate staple cavity 4842 operably supports a corresponding intermediate or second staple 4850 therein. The middle lumen 4842 orients the middle or second spike 4850 at the same uniform second angle relative to the tangential direction. However, the second angle is different from the first angle. In other words, when first and second staples are supported in their respective first and second cavities, the axis of the first crown of each first staple 4830 will eventually intersect the axis of extension of the second crown of the adjacent second staple 4850 when extended. As seen in fig. 116 and 117, each second or intermediate staple 4850 includes a second crown or base 4852 and two second legs 4854. Staple base 4852 can have a somewhat rectangular cross-sectional shape and be formed from a flat piece of material. Second leg 4854 can have, for example, a circular cross-sectional profile. The second or middle nail may include various nail CONFIGURATIONS disclosed in U.S. patent application serial No. 14/836,110 entitled "SURGICAL STAPLING CONFIGURATIONS FOR CURVED AND CIRCULAR STAPLING INSTRUMENTS," filed on, FOR example, 8/26/2015, which is incorporated herein by reference in its entirety. Having round legs extending from a staple base portion having a rectangular cross-sectional profile can provide a staple base portion and legs that are free of preferential bending planes. Second staple 4850 includes curved portions 4856 where staple legs 4854 extend from staple base portion 4852. The curved portion 4856 can have a generally square cross-sectional profile. The square and rectangular profiles of the curved portion 4856 and staple base portion 4852 provide a rigid connection and brace, respectively, to the round staple leg 4854. Rounded legs 4854 eliminate the preferential bending plane that legs having a cross-section that is square, rectangular, or any shape with vertices or non-uniform shapes may have. Each second leg 4854 has a second diameter D ₂. In at least one embodiment, D₂>D₁. Second base or crown 4852 has a second crown width C₂. In one configuration, C₂>C₁. Second legs 4854 can each be at an angle A relative to second base or crown 4852₂And (4) arranging. Angle A₂Which may be about 90 deg., or it may be slightly larger than 90 deg., such that second legs 4854 flare slightly outward to help retain second staples 4850 in their corresponding second staple cavities 4842.

Turning to fig. 115 and 116, the anvil 4900 further includes two intermediate or second rows 4912 of a staggered or angled second pair 4913 of second staple forming pockets 4914. Each second pair 4913 of second staple forming pockets 4914 corresponds to a second staple 4850. One second staple forming pocket 4914 corresponds to one second staple leg 4854 and the other second staple forming pocket 4914 of the pair 4913 corresponds to the other second staple leg 4854. Such a configuration is used to establish a formed staple configuration in which second leg 4854 is formed out of plane with second base 4852 of a particular second staple 4850. This "three-dimensional" formed staple configuration is shown in fig. 115 relative to some of the second staple forming pockets 4914.

As can be seen most particularly in fig. 116, the cartridge deck 4812 also includes a second cartridge deck portion 4816 corresponding to the middle or second annular row 4840 of middle or second staple cavities 4842. As further seen in fig. 116, when the anvil 4900 is moved to the closed or clamped position, the portion of the anvil 4900 containing the second staple forming pockets 4914 is spaced from the land portion 4816 by a second gap distance g ₂. In the example shown, g₂>g₁。

Referring again to fig. 114, 116, and 117, the outer or third row 4860 includes a third plurality of outer or third staple cavities 4862 sized relative to second staple cavities 4842 such that each outer or third staple cavity 4862 spans a distance between two adjacent second cavities 4842. Each outer staple cavity 4862 operably supports a corresponding outer or third staple 4870 therein. The outer lumen 4862 orients the outer or third spike 4870 tangentially to the circumferential direction. As can be seen in fig. 116 and 117, each third or outer staple 4870 comprises a third crown or base 4872 and two third legs 4874. The staple base 4872 may have a somewhat rectangular cross-sectional shape and be formed from a flat piece of material. Third leg 4874 can have a circular cross-section, for exampleA face profile. Third or lateral nail 4870 may include various nail CONFIGURATIONS disclosed in U.S. patent application serial No. 14/836,110 entitled "SURGICAL STAPLING CONGURATIONS FOR CURVED AND CIRCULAR STAPLING INSTRUMENTS," filed on, FOR example, 8/26/2015, which is incorporated by reference herein in its entirety. Having round legs extending from a staple base portion having a rectangular cross-sectional profile can provide a staple base portion and legs that are free of preferential bending planes. Third staple 4870 includes a curved portion 4876 where staple legs 4874 extend from staple base portion 4872. The loop 4876 can have a generally square cross-sectional profile. The square and rectangular profiles of curved portion 4876 and staple base portion 4872 provide a rigid connection and a strut, respectively, to circular staple leg 4874. Rounded legs 4874 eliminate the preferential plane of curvature that legs having a square, rectangular, or any pointed or non-uniform shape in cross-section may have. In at least one embodiment, D ₃>D₂. Third base or crown 4872 has a third crown width C₃And each third leg 4874 has a third unformed leg length L₃. In one configuration, C₃>C₂And L is₃>L₂. Third legs 4874 can each be at an angle a relative to third base or crown 4872₃And (4) arranging. Angle A₃Which may be about 90 deg., or it may be slightly greater than 90 deg., such that third legs 4874 flare slightly outward to help retain third staples 4870 in their corresponding third staple cavities 4862.

Turning to fig. 115 and 116, the anvil 4900 further includes an outer row 4916 of outer or third staple forming pockets 4918. Each third staple forming pocket 4918 corresponds to a third staple 4870. As can be seen most particularly in FIG. 116, the cartridge deck 4812 also includes a third cartridge deck portion 4818 corresponding to the outer or third row 4860 of outer or third staple cavities 4862. As further seen in fig. 116, when the anvil 4900 is moved to the closed or clamped position, the portion of the anvil 4900 containing the third staple forming pockets 4918 is spaced a third gap distance g from the land portion 4818₃. In the example shown, g₃>g₂. As seen further in fig. 116It can be seen that in at least one embodiment, a tissue thickness compensator 4920 is used in conjunction with each of the outer or third staples 4870. The tissue thickness compensator can comprise a woven material embedded with Oxidized Regenerated Cellulose (ORC) to promote hemostasis. The tissue thickness compensator 4920 may comprise any of the various tissue thickness compensator configurations disclosed in U.S. patent application serial No. 14/187,389 (U.S. patent application publication No.2015/0238187), entitled "improved tissue LAYER ASSEMBLIES," filed 24/2/2014, the entire disclosure of which is hereby incorporated by reference herein. As can be seen in fig. 116, the tissue thickness compensator 4920 has a thickness labeled "a". In one embodiment, the tissue thickness compensator has a thickness of about 0.015 "-0.045". However, other thicknesses may be employed.

Thus, in at least one embodiment shown in fig. 114-117, the staple cartridge 4810 can employ a different number of staples in each of the three rows of staples. In one configuration, the inner staple row comprises conventional staples having a minimum wire diameter and a minimum unformed leg length. Each first staple has the shortest crown width and each first staple is oriented at a uniform angle with respect to the tangential direction. The configuration of the intermediate staples is different from the first staple configuration. Each leg of the middle peg has a moderate wire diameter and an unformed leg length. Each intermediate staple has a crown width slightly greater than that of the inside staple and each intermediate staple is oriented at a uniform angle relative to the tangential direction but at a different angle relative to the inner row of inside staples. The configuration of each of the outer staples is similar to the configuration of the middle staple. Each of the third legs of each of the outer staples has a maximum wire diameter compared to the wire diameter of the legs of the inner and middle staples. The crown width of each of the outer staples is significantly greater than the crown widths of the inner and middle staples. Each outside staple is oriented tangentially to the circumferential direction of the cartridge. The outer rows of staples employ woven tissue thickness compensators (spacer fabrics) embedded with ORC to promote hemostasis. The stepped anvil and stepped cartridge deck create different formed staple heights, with the staples having the shortest formed heights being in the inner row and the staples having the longest formed heights being in the outer row. The anvil pockets corresponding to the inner and middle rows of staples are "slanted" to form three-dimensional staples in the inner and middle rows. The "bathtub" anvil pockets correspond to the outer rows of staples. In at least one embodiment, the staples can be fired sequentially. For example, the staples in the inner and middle rows can be fired first, and the staples in the outer row subsequently fired. The annular knife cuts clamped tissue during the firing process.

As described in various embodiments of the present disclosure, a circular stapling instrument includes an anvil and a staple cartridge. One or both of the anvil and the staple cartridge are movable relative to the other between an open configuration and a closed configuration to capture tissue therebetween. The staple cartridge receives staples within, or at least partially within, the row of circular staple cavities. Staples are deployed from their respective staple cavities into the captured tissue in circular rows and are formed against corresponding circular rows of forming pockets in the anvil. The firing drive is configured to eject staples from the staple cartridge during a firing stroke of the firing drive.

The anvil of a circular stapling instrument typically includes a tissue compression surface and an annular array of staple forming pockets defined in the tissue compression surface. The anvil further includes an attachment mount and a shaft extending from the attachment mount. The shaft is configured to be releasably attachable to a closure drive of a circular stapling instrument such that the anvil is movable toward and away from a staple cartridge of the circular stapling instrument.

The staple cartridge and anvil may be advanced separately within the patient and combined at the surgical site. In various examples, a staple cartridge is advanced through a narrow tubular body of a patient, such as the colon, for example. The staple cartridge can include several tissue contacting features, such as stepped lands and pocket extensions. To avoid inadvertently injuring the patient as the staple cartridge is advanced toward the target tissue, the present disclosure proposes, among other things, various modifications to several tissue contacting features.

Referring to fig. 118, a partial cross-sectional view illustrates a staple cartridge 15500 of a circular surgical instrument pressed against tissue (T) as the staple cartridge 15500 is advanced within a patient's body. The various structural features of the staple cartridge 15500 are modified to form a specially contoured outer frame 15502 to protect the tissue. Staple cartridge 15500 includes a plurality of annular rows of staple cavities. In at least one example, an outer row 15504 of staple cavities 15510 at least partially surrounds an inner row 15506 of staple cavities 15512, as shown in fig. 118. Staple cavities 15510 and 15512 are configured to receive staples 15530 and 15531, respectively.

The terms inner and outer depict a relationship relative to the central axis 15533. For example, the inner tissue contacting surface 15518 is closer to the central axis 15533 than the outer tissue contacting surface 15516.

As shown in fig. 119, the staple cartridge 15500 includes a stepped cartridge deck 15508. The outer row 15504 is defined in the outer tissue contacting surface 15516 of the stepped cartridge deck 15508, while the inner row 15506 is defined in the inner tissue contacting surface 15518 of the stepped cartridge deck 15508. The outer tissue contacting surface 15516 is stepped down from the inner tissue contacting surface 15518, which creates a gradient that reduces friction when the staple cartridge 15500 is pressed against tissue.

In certain examples, the outer tissue-contacting surface 15516 is parallel, or at least substantially parallel, to the inner tissue-contacting surface 15518. In other examples, outer tissue contacting surface 15516 is angled such that a first plane defined by outer tissue contacting surface 15516 is transverse to a second plane defined by inner tissue contacting surface 15518. An angle is defined between the first plane and the second plane. The angle may be acute. In at least one example, the angle can be any angle selected from a range greater than about 0 ° and less than or equal to about 30 °, for example. In at least one example, the angle can be any angle selected from a range greater than about 5 ° and less than or equal to about 25 °, for example. In at least one example, the angle can be any angle selected from a range greater than about 10 ° and less than or equal to about 20 °, for example. The angled outer tissue contacting surface 15516 can reduce friction or snagging on tissue as the staple cartridge 15500 is moved relative to the tissue. In at least one example, the angled outer tissue contacting surface 15516 also steps down from the inner tissue contacting surface 15518.

In at least one example, an inner portion of the outer tissue contacting surface 15516 is flat or at least substantially flat, while an outer edge 15548 of the outer tissue contacting surface 15516 is beveled, curved, and/or chamfered to reduce friction or snagging on tissue as the staple cartridge 15500 is moved relative to the tissue. For example, staple cavities 15510 reside in a flat interior portion of outer tissue-contacting surface 15516. The outer edges 15550 of the inner tissue-contacting surface 15518 may also be beveled, and/or curved to reduce friction or snagging on tissue as the staple cartridge 15500 is moved relative to the tissue.

In order to accommodate staples having the same, or at least substantially the same, unformed height in the staple cavities 15510 of the outer row 15504 and the staple cavities 15512 of the inner row 15504, the staple cavities 15510 of the outer row 15504 include dimple extensions 15514. Dimple extensions 15514 are configured to control and guide staples 15530 as they are ejected from their respective staple cavities 15510. In certain instances, for example, the dimple extensions 15514 can be configured to accommodate staples having a larger unformed height than staples of the inner tissue-contacting surface 15518.

As shown in fig. 119, the staple cavities 15510 in the outer row 15504 are laterally aligned, or at least substantially aligned, with the gaps 15520 between two adjacent staple cavities 15512 in the inner row 15506. The staple cavity 15510 includes a first end 15522 and a second end 15524. Second end 15524 overlaps first end 15526 of one of two consecutive staple cavities 15512 such that staple leg 15530a positioned at second end 15524 is radially aligned, or at least substantially aligned, with staple leg 15531a positioned at first end 15526, as shown in fig. 118. Likewise, the first end 15522 of a staple cavity 15510 overlaps the second end 15528 of another of two consecutive staple cavities 15512.

Dimple extensions 15514 include a first collet 15532 that protrudes from outer tissue contacting surface 15516 to conceal the pointed ends 15536 of staple legs 15530a that extend beyond outer tissue contacting surface 15516. The first collet 15532 includes an end 15538 protruding from the first end 15522, an inner sidewall 15540 and an outer sidewall 15542 extending away from the end 15538 to form the first collet 15532. In at least one example, the first collet 15532 defines, or at least substantially defines, a "C" shaped wall extending over a portion of the perimeter 15535 of the staple cavity 15510 including the first end 15522.

To reduce friction against tissue, inner sidewall 15540 protrudes from outer tissue-contacting surface 15516 to a greater height than outer sidewall 15542. In other words, the outer sidewall 15542 is at a lower elevation than the inner sidewall 15540. This configuration creates a gradient for a smooth transition from inner sidewall 15540 to outer sidewall 15542 to outer tissue-contacting surface 15516. In at least one example, the inner sidewall 15540 and the inner tissue-contacting surface 15518 have the same, or at least substantially the same, height relative to the outer tissue-contacting surface 15516. Alternatively, the inner sidewall 15540 and the inner tissue-contacting surface 15518 have different heights relative to the outer tissue-contacting surface 15516. In some examples, the height of the inner sidewall 15540 relative to the inner tissue-contacting surface 15518 is lower with reference to the outer tissue-contacting surface 15516. This configuration creates a gradient for a smooth transition from inner tissue contacting surface 15518 to inner sidewall 15540 to outer sidewall 15542 to outer tissue contacting surface 15516.

Inner tissue-contacting surface 15518, inner sidewall 15540, outer sidewall 15542, and/or outer tissue-contacting surface 15516 define separate portions of outer frame 15502 that form a contour; however, as shown in fig. 118, such portions remain close enough to each other such that tissue cannot be captured therebetween when staple cartridge 15500 is pressed against the tissue. Further, one or more of the portions may include a beveled, contoured, curved, arcuate, and/or chamfered outer surface to reduce friction against tissue. As shown in fig. 118, the upper surface 15544 of the outer sidewall 15542 and the upper surface 15546 of the inner sidewall 15540 are sloped, contoured, curved, arced, and/or chamfered to define a contoured outer frame 15502.

In at least one example, upper surface 15544 and upper surface 15546 define a tilted plane that is transverse to a first plane defined by outer tissue-contacting surface 15516 and a second plane defined by inner tissue-contacting surface 15518. In at least one example, a first angle is defined between the inclined plane and the first plane. A second angle may also be defined between the inclined plane and the second plane. The first angle and the second angle may have the same or at least substantially the same value. Alternatively, the value of the first angle may be different from the second angle. In at least one example, the first angle and/or the second angle is an acute angle. In at least one example, the first angle is any angle selected from a range greater than about 0 ° and less than or equal to about 30 °, for example. In at least one example, the first angle is any angle selected from a range greater than about 5 ° and less than or equal to about 25 °, for example. In at least one example, the first angle is any angle selected from a range greater than about 10 ° and less than or equal to about 20 °, for example. In at least one example, for example, the second angle is any angle selected from a range greater than about 0 ° and less than or equal to about 30 °. In at least one example, for example, the second angle is any angle selected from a range greater than about 5 ° and less than or equal to about 25 °. In at least one example, for example, the second angle is any angle selected from a range greater than about 10 ° and less than or equal to about 20 °.

In addition to the above, dimple extension 15514 includes a second jacket 15534 that is similar in many respects to first jacket 15532. Similar to first collet 15532, second collet 15534 protrudes from outer tissue contacting surface 15516 to conceal the tips of the staple legs extending beyond outer tissue contacting surface 15516. The second collet 15534 includes an end 15538 protruding from the second end 15524, an inner sidewall 15540 and an outer sidewall 15542 extending from the end 15538 to form the second collet 15534.

While one dimple extension 15514 is shown in fig. 119, it should be understood that one or more other dimple extensions 15514 can protrude from outer tissue contacting surface 15516, for example. In at least one example, the first and second jackets 15532, 15534 are connected via sidewalls to define dimple extensions that completely surround the staple cavities, for example.

Many of the surgical instrument systems described herein are actuated by an electric motor; however, the surgical instrument systems described herein may be actuated in any suitable manner. In various circumstances, for example, the surgical instrument systems described herein can be actuated by a manually operated trigger. In various instances, the motors disclosed herein may comprise one or more portions of a robotic control system. Further, any of the end effectors and/or tool assemblies disclosed herein may be used with a robotic surgical instrument system. Fig. 82A schematically illustrates a robotic surgical instrument system 20'; however, U.S. patent application serial No. 13/118,241 (now U.S. patent application publication No.2012/0298719), entitled "SURGICAL INSTRUMENTS WITH robotic SURGICAL INSTRUMENTS," discloses several examples of robotic SURGICAL instrument systems, for example, in greater detail.

The surgical instrument systems described herein have been described in connection with the deployment and deformation of staples; however, the embodiments described herein are not so limited. For example, various embodiments are contemplated in which fasteners other than staples, such as clamps or tacks, are deployed. Moreover, various embodiments are also contemplated that utilize any suitable means for sealing tissue. For example, an end effector according to various embodiments may include an electrode configured to heat and seal tissue. In addition, for example, an end effector according to certain embodiments may apply vibrational energy to seal tissue.

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

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U.S. patent No.7,464,849 entitled "ELECTRO-MECHANICAL SURGICAL INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS" published 16.12.2008;

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U.S. patent No.7,753,245 entitled "SURGICAL STAPLING INSTRUMENTS" published on 13.7.2010;

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While various devices have been described herein in connection with certain embodiments, modifications and variations to these embodiments may also 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. The foregoing detailed description and the following claims are intended to 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 used multiple times. In either case, however, the device may be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular pieces of the device, and subsequent reassembly of the device. In particular, the reconditioning facility and/or surgical team can remove the device, and after cleaning and/or replacement of particular components of the device, the device can be reassembled for subsequent use. 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 prosthetic devices are within the scope of the present application.

The devices disclosed herein may be processed prior to surgery. First, new or used instruments may 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, and/or high energy electrons. The radiation may kill bacteria on the instrument and in the container. The sterilized instrument may then be stored in a sterile container. Sealing the container may maintain the instrument in a sterile state 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 radiation, gamma radiation, ethylene oxide, plasma peroxide, and/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 (8)

1. An end effector for use with a surgical stapler, wherein the end effector comprises:

a cartridge body comprising a longitudinal axis;

a plurality of staple cavities defined in said cartridge body, said plurality of staple cavities comprising:

a first annular strip nail cavity extending around the longitudinal axis; and

a second annular staple bank cavity extending about the longitudinal axis;

a staple removably stored in the staple cavity; and

a ramp rotatable about the longitudinal axis along a helical firing path to eject the staples from the staple cavities,

wherein the end effector further comprises staple drivers, and wherein the ramps are configured to sequentially engage the staple drivers to sequentially eject the staples from the staple cavities.

2. The end effector of claim 1, wherein the ramp sequentially ejects the staples stored in the first annular row of staple cavities before sequentially ejecting the staples stored in the second annular row of staple cavities.

3. The end effector of claim 1, wherein the cartridge body comprises a helical slot configured to guide the ramp, and wherein the helical slot extends about the longitudinal axis while continuously approaching the longitudinal axis.

4. The end effector of claim 1, wherein the cartridge body comprises a helical slot configured to guide the ramp, and wherein the helical slot extends about the longitudinal axis while continuously receding from the longitudinal axis.

5. The end effector of claim 1, wherein the cartridge body comprises a curved slot configured to receive the ramp, and wherein the curved slot extends about the longitudinal axis while proximal to the longitudinal axis.

6. The end effector of claim 1, wherein the cartridge body comprises a curved slot configured to receive the ramp, and wherein the curved slot extends about the longitudinal axis while continuously receding from the longitudinal axis.

7. The end effector of claim 1, wherein the staple comprises:

a plurality of first staples, wherein each said first staple is positioned in said first annular row of staple cavities, and wherein each said first staple is defined by a first unformed height; and

a plurality of second staples, wherein each said second staple is positioned in said second annular row of staple cavities, and wherein each said second staple is defined by a second unformed height that is different than said first unformed height.

8. The end effector of claim 7, further comprising an anvil configured to deform said staples, wherein said anvil is configured to deform said first staples to a first formed height and said second staples to a second formed height, and wherein said first formed height is different than said second formed height.

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