CN109963516B - Surgical instrument including primary and secondary firing latches - Google Patents

Abstract

The invention discloses a surgical suturing system. The system includes a distal end, an unused staple cartridge including a plurality of staples removably stored therein, a channel configured to receive the unused staple cartridge, and an anvil configured to deform the staples. The system also includes a firing drive configured to move through a firing stroke and a primary lockout configured to prevent movement of the firing member through the firing stroke when an unused staple cartridge is not positioned in the channel. The system also includes a secondary lockout actuatable to prevent movement of the firing drive through a firing stroke, wherein the secondary lockout is actuated in response to the firing stroke being blocked by the primary lockout.

Description

Surgical instrument including primary and secondary firing latches

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 system according to at least one embodiment;

FIG. 2 is a perspective view of a portion of a rotary drive firing assembly and a sled of a surgical staple cartridge according to at least one embodiment, wherein the sled is in a starting position and the firing assembly is in a first "unlocked" position;

FIG. 3 is another perspective view of a portion of the rotary drive firing assembly embodiment of FIG. 2 in a second "lockout" position, wherein the sled is not in the starting position;

FIG. 4 is a side elevational view of a surgical staple cartridge initially installed in a surgical end effector configured to cut and staple tissue in accordance with at least one embodiment;

FIG. 5 is another side elevational view of a surgical staple cartridge disposed in the channel of the surgical end effector of FIG. 4 with the sled of the surgical staple cartridge in a starting position and engaged with the firing member of the surgical instrument;

FIG. 6 is another side elevational view of a partially used surgical staple cartridge disposed in the channel of the surgical end effector of FIG. 4, with the sled of the surgical staple cartridge not in the starting position;

FIG. 7 is a perspective view of a portion of a rotary drive firing assembly and a channel of a surgical cutting and stapling end effector with the firing assembly in a "lockout" position in accordance with at least one embodiment;

FIG. 8 is another perspective view of a portion of the rotary drive firing assembly of FIG. 7 and a sled of a surgical staple cartridge with the sled in a starting position and the firing assembly in an "unlocked" position;

FIG. 9 is a perspective view of a threaded nut portion in accordance with at least one embodiment;

FIG. 10 is a perspective view of the threaded nut portion of FIG. 9 installed into a corresponding channel embodiment shown in cross-section;

FIG. 11 is a cross-sectional elevation view of the channel and threaded nut portion of FIG. 10, with the threaded nut portion in a locked position;

FIG. 12 is another cross-sectional elevation view of the channel and threaded nut portion of FIGS. 10 and 11 with the nut portion in an unlocked position;

FIG. 13 is another cross-sectional elevation view of the channel and threaded nut portion of FIGS. 10-12 with the threaded nut portion in the locked position and showing the initial installation of the sled of the surgical staple cartridge into the channel and with the cartridge body omitted for clarity;

FIG. 14 is another cross-sectional elevation view of the channel, threaded nut portion and slider of FIG. 13 with the slider installed to move the nut portion to an unlocked position;

FIG. 15 is a cross-sectional side elevational view of a surgical cutting and stapling end effector in accordance with at least one embodiment;

FIG. 16 is an exploded assembly perspective view of an anvil assembly of the surgical end effector of FIG. 15;

FIG. 17 is a cross-sectional view of the anvil assembly of FIG. 16;

FIG. 18 is a cross-sectional view of the surgical end effector of FIG. 15 with its firing members in a locked position;

FIG. 19 is another cross-sectional view of the surgical end effector of FIG. 18 taken at its proximal end with the firing member assembly in an unlocked position;

FIG. 20 is another cross-sectional view of the surgical end effector of FIG. 18 taken at a location distal of the view of FIG. 19;

FIG. 21 is a perspective view of a surgical stapling instrument including a handle and a replaceable loading unit in accordance with at least one embodiment;

FIG. 22 is a perspective view of the loading unit of FIG. 21 shown with the cartridge jaw disengaged from the loading unit;

FIG. 23 is a perspective view of a surgical stapling instrument including a handle and a replaceable loading unit in accordance with at least one embodiment;

FIG. 24 is a perspective view of the loading unit of FIG. 23;

FIG. 25 shows the attachment portion of the handle and loading unit of FIG. 23;

FIG. 26 is a cross-sectional view of an end effector of the loading unit of FIG. 21;

FIG. 27 is a detail view of an attachment between the cartridge jaw of FIG. 21 and a frame of the staple loading unit;

FIG. 28 is a cross-sectional view of an end effector of a loading unit according to at least one embodiment;

FIG. 29 is a detail view of an attachment between the cartridge jaw of FIG. 28 and a frame of the loading unit;

FIG. 30 is a perspective view of a frame of the loading unit of FIG. 28;

FIG. 31 is a detail view of the proximal end of the cartridge jaw of FIG. 28;

FIG. 32 is a detail view showing the connection between the frame of FIG. 28 and the cartridge jaw;

FIG. 33 is an exploded view of a staple cartridge jaw according to at least one embodiment;

FIG. 34 is a partial perspective view of a loading unit according to at least one embodiment;

FIG. 35 is a partial front view of a frame of a loading unit according to at least one embodiment shown without a staple cartridge clamp attached thereto;

FIG. 36 is a partial front view of a cartridge jaw attached to a frame of the loading unit of FIG. 35;

FIG. 37 is a partial front view of the loading unit of FIG. 35 shown in a clamped configuration;

FIG. 38 is a partial front view of the loading unit of FIG. 35 shown in a partially fired configuration;

FIG. 39 is a partial front view of a frame of a loading unit according to at least one embodiment shown without a staple cartridge clamp attached thereto;

FIG. 40 is a partial front view of a cartridge jaw attached to a frame of the loading unit of FIG. 39;

FIG. 41 is a partial front view of the loading unit of FIG. 39 shown in a clamped configuration;

FIG. 42 is a partial front view of the loading unit of FIG. 39 shown in a partially fired configuration;

FIG. 43 is a partial perspective view of the loading unit of FIG. 39 shown with the cartridge jaw attached to the frame;

FIG. 44 is a partial perspective view of a cartridge jaw attached to a frame of a loading unit according to at least one embodiment;

FIG. 45 is a partial front view of an attempt to attach the cartridge jaw of FIG. 44 to a loading unit configured to receive a different cartridge jaw;

FIG. 46 is a partial front view of the cartridge jaw of FIG. 44 attached to the frame of the loading unit of FIG. 44;

FIG. 47 is a partial front view of a connection between a cartridge jaw and a frame of a loading unit according to at least one embodiment;

FIG. 48 is a partial front view of the loading unit of FIG. 47;

FIG. 49 is a partial elevational view of a cartridge jaw attached to the loading unit of FIG. 47, the cartridge jaw being configured to be used with a different loading unit other than the loading unit of FIG. 47;

FIG. 50 is a partial front view of a surgical instrument system including a deflectable locking arrangement shown in a locked configuration;

FIG. 51 is a partial front view of the surgical instrument system of FIG. 50 with the locking arrangement shown in an unlocked configuration;

FIG. 52 is a partial front view of a surgical instrument system including a magnetic locking arrangement shown in a locked configuration;

FIG. 53 is a partial front view of the surgical instrument system of FIG. 52 with the magnetic locking arrangement shown in an unlocked configuration;

FIG. 54 is a partial front elevational view of the surgical instrument system of FIG. 52 shown in a partially fired configuration;

FIG. 55 is a partial perspective view of a staple cartridge of the surgical instrument system, wherein the staple cartridge includes a drive arrangement configured to control a locking arrangement of the surgical instrument system;

FIG. 56 is a perspective view of a slider for use with the cartridge body of FIG. 55;

FIG. 57 is a perspective view of the false drive device of the staple cartridge of FIG. 55;

FIG. 58 is a partial front view of a surgical instrument system employing the staple cartridge of FIG. 55, wherein the surgical instrument system includes a lockout arrangement configured to limit movement of the firing member until the staple cartridge is loaded into the surgical instrument system;

FIG. 59 is a partial front view of the surgical instrument system of FIG. 58 with the locking arrangement shown in an unlocked configuration;

FIG. 60 is a partial front elevational view of the surgical instrument system of FIG. 58 shown in a partially fired configuration;

FIG. 61 is a partial perspective view of a staple cartridge used with the surgical instrument system including a lockout circuit including a severable member;

FIG. 62 is a cross-sectional plan view of the surgical instrument system of FIG. 61, wherein the surgical instrument system further includes an electromagnet and a lockout member, wherein the lockout member is shown in an unlocked position, and wherein the lockout circuit is in a closed configuration;

FIG. 63 is a cross-sectional plan view of the surgical instrument system of FIG. 61, with the lockout member shown in a locked position, and with the lockout circuit in an open configuration;

FIG. 64 is a perspective view of a surgical instrument system including a circuit lockout arrangement including electrical contacts positioned on a sled for use with a staple cartridge;

FIG. 65 is a partial front view of the surgical instrument system of FIG. 64;

FIG. 66 is a partial cross-sectional view of the firing member lockout showing the firing member lockout in a locked configuration;

FIG. 67 is a cross-sectional view of the firing member lockout of FIG. 66 taken along line 67-67 of FIG. 66;

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

FIG. 69 is a cross-sectional view of the firing member latch of FIG. 66 taken along line 69-69 of FIG. 68;

FIG. 70 is a cross-sectional plan view of the firing member latch of FIG. 66 taken along line 70-70 of FIG. 68;

FIG. 71 is a partial front view of a stapling assembly including an unused staple cartridge in accordance with at least one embodiment;

FIG. 72 is a partial plan view of the suturing assembly of FIG. 71;

FIG. 73 is a partial front view of the suturing assembly of FIG. 71 shown in a used condition;

FIG. 74 is a partial plan view of the suturing assembly of FIG. 71 shown in the condition of FIG. 73;

FIG. 75 is a partial perspective view of a stapling assembly including an unused staple cartridge in accordance with at least one embodiment;

FIG. 76 is a partial perspective view of the suturing assembly of FIG. 75 shown in a used condition;

FIG. 77 is a partial perspective view of the seaming assembly shown with parts removed for ease of illustration;

FIG. 78 illustrates a pin of the stapling assembly of FIG. 77 configured to affect a detection circuit of the stapling assembly;

FIG. 79 is a partial perspective view of certain components of the suturing assembly of FIG. 77;

FIG. 80 is a partial perspective view of a shaft housing of the suturing assembly of FIG. 77;

FIG. 81 is a partial plan view of a staple cartridge according to at least one embodiment;

FIG. 81A illustrates a firing force profile experienced when firing a staple cartridge in at least one embodiment;

FIG. 82 is a partial cross-sectional view of a suturing assembly including a latch according to at least one embodiment;

FIG. 83 is a partial cross-sectional view of the suturing assembly of FIG. 82 shown in a locked configuration;

FIG. 84 is a partial cross-sectional view of a suturing assembly including a latch according to at least one embodiment;

FIG. 85 is a partial cross-sectional view of a suturing assembly including a latch according to at least one embodiment;

FIG. 86 is a partial cross-sectional view of a stapling assembly including a braking component in accordance with at least one embodiment;

FIG. 87 is a partial cross-sectional view of a suturing assembly including a damping system in accordance with at least one embodiment;

FIG. 88 is a schematic view illustrating a stapling assembly including an electromagnetic brake, in accordance with at least one embodiment;

FIG. 89 is a partial cross-sectional view of a suturing assembly including a damping system in accordance with at least one embodiment;

FIG. 90 is a circuit configured to detect the position and progression of the staple firing member, showing the staple firing member in a fully fired position;

FIG. 91 illustrates the staple firing member of FIG. 90 in a fully retracted position;

FIG. 92 is a cross-sectional view of a suturing assembly including a latch, shown in an unlocked configuration in accordance with at least one embodiment;

FIG. 93 is a cross-sectional end view of the suturing assembly of FIG. 92 shown in an unlocked configuration;

FIG. 94 is a cross-sectional view of the suturing assembly of FIG. 92 shown in a locked configuration; and is

FIG. 95 is a cross-sectional end view of the suturing assembly of FIG. 92 shown in its locked configuration.

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

Detailed Description

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

-U.S. patent application Ser. No. ________ entitled "SURGICAL INSTRUMENT COMPRISING A LOCKOUT"; attorney docket number END7828 USNP/150542;

-U.S. patent application Ser. No. ________ entitled "SURGICAL INSTRUMENT SYSTEM COMPRISING A MAGNETIC LOCKOUT"; attorney docket number END7789 USNP/150503;

-U.S. patent application Ser. No. ________ entitled "SURGICAL INSTRUMENT COMPRISING A REPLACEABLE CARTRIDGE JAW"; attorney docket number END7790 USNP/150504; and

-U.S. patent application serial No. ________ entitled "CARTRIDGE LOCKOUT ARRANGEMENTS FOR ROTARY POWERED SURGICAL CUTTING AND STAPLING INSTRUMENTS"; attorney docket number END7791 USNP/150505.

The applicant of the present application owns the following patent applications filed 2016, 4, 15 and each of which is incorporated herein by reference in its entirety:

-U.S. patent application serial No. 15/130,575 entitled "stable FORMATION DETECTION mechanism mechasms";

U.S. patent application Ser. No. 15/130,582 entitled "SURGICAL INSTRUMENT WITH DETECTIONION SENSOR";

U.S. patent application Ser. No. 15/130,588 entitled "SURGICAL INSTRUMENT WITH IMPROVED STOP/START CONTROL DURING A FINING MOTION";

-U.S. patent application serial No. 15/130,595 entitled "minor entering WITH ADJUSTABLE STOP/START CONTROL duration a dressing movement";

U.S. patent application Ser. No. 15/130,566 entitled "SURGICAL INSTRUMENT WITH MULTI PROGRAM RESPONSES DURING A FIRING MOTION";

U.S. patent application Ser. No. 15/130,571 entitled "SURGICAL INSTRUMENT WITH MULTI PROGRAM RESPONSES DURING A FIRING MOTION";

U.S. patent application Ser. No. 15/130,581 entitled "MODULAR SURGICAL INSTRUMENT WITH CONFIGURABLE OPERATING MODE";

-U.S. patent application Ser. No. 15/130,590 entitled "SYSTEMS AND METHODS FOR CONTROLLING A SURGICAL STAPLING AND CUTTING INSTRUMENT"; and

U.S. patent application Ser. No. 15/130,596 entitled "SYSTEMS AND METHODS FOR CONTROLLING A SURGICAL STAPLING AND CUTTING INSTRUMENT".

The applicant of the present application owns the following U.S. patent applications filed 2016, month 4, day 1 and each of which is incorporated herein by reference in its entirety:

-U.S. patent application Ser. No. 15/089,325 entitled "METHOD FOR OPERATING A SURGICAL STAPLING SYSTEM";

-U.S. patent application Ser. No. 15/089,321 entitled "MODULAR SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY";

-U.S. patent application serial No. 15/089,326 entitled "SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE DISPLAY FIELD";

-U.S. patent application serial No. 15/089,263 entitled "minor entering HANDLE association WITH robust GRIP support";

-U.S. patent application serial No. 15/089,262 entitled "rolling POWERED minor inserting WITH manual active ballout SYSTEM";

U.S. patent application Ser. No. 15/089,277 entitled "SURGICAL CUTTING AND STAPLING END EFFECTOR WITH ANVIL CONCENTRIC DRIVE MEMBER";

-U.S. patent application serial No. 15/089,283 entitled "close SYSTEM ARRANGEMENTS FOR SURGICAL curing AND STAPLING DEVICES WITH SEPARATE AND DISTINCT FIRING SHAFTS";

-U.S. patent application Ser. No. 15/089,296 entitled "INTERCHANGEABLE SURGICAL TOOL ASSEMBLY WITH A SURGICAL END EFFECTOR THAT IS SELECTIVELY ROTATABLE ABOUT A SHAFT AXIS";

-U.S. patent application serial No. 15/089,258 entitled "SURGICAL STAPLING SYSTEM COMPRISING A SHIFTABLE TRANSMISSION";

U.S. patent application Ser. No. 15/089,278 entitled "SURGICAL STAPLING SYSTEM CONFIGURED TO PROVIDE selection OF recording OF TISSUE";

-U.S. patent application Ser. No. 15/089,284 entitled "SURGICAL STAPLING SYSTEM COMPRISING A CONTOURABLE SHAFT";

-U.S. patent application Ser. No. 15/089,295 entitled "SURGICAL STAPLING SYSTEM COMPRISING A TISSUE COMPRESSION LOCKOUT";

-U.S. patent application Ser. No. 15/089,300 entitled "SURGICAL STAPLING SYSTEM COMPRISING AN UNCLAMPING LOCKOUT";

-U.S. patent application Ser. No. 15/089,196 entitled "SURGICAL STAPLING SYSTEM COMPRISING A JAW CLOSURE LOCKOUT";

-U.S. patent application Ser. No. 15/089,203 entitled "SURGICAL STAPLING SYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT";

-U.S. patent application serial No. 15/089,210 entitled "SURGICAL STAPLING SYSTEM COMPRISING A SPENT CARTRIDGE LOCKOUT";

-U.S. patent application serial No. 15/089,324 entitled "SURGICAL INSTRUMENT COMPRISING A SHIFTING MECHANISM";

-U.S. patent application Ser. No. 15/089,335 entitled "SURGICAL STAPLING INSTRUMENTS COMPLEMENTING MULTIPLE LOCKOUTS";

-U.S. patent application serial No. 15/089,339 entitled "SURGICAL STAPLING INSTRUMENT";

-U.S. patent application serial No. 15/089,253 entitled "SURGICAL STAPLING SYSTEM CONFIGURED TO applied annual ROWS OF STAPLES HAVING DIFFERENT HEIGHTS";

U.S. patent application Ser. No. 15/089,304 entitled "SURGICAL STAPLING SYSTEM COMPRISING A GROOVED FORMING POCKET";

-U.S. patent application serial No. 15/089,331 entitled "artificial MODIFICATION machinery FOR minor platform";

-U.S. patent application serial No. 15/089,336 entitled "STAPLE CARTRIDGES WITH atraumatc featurs";

-U.S. patent application Ser. No. 15/089,312 entitled "CIRCULAR STAPLING SYSTEM COMPRISING AN INCISABLE TISSUE SUPPORT";

-U.S. patent application serial No. 15/089,309 entitled "CIRCULAR STAPLING SYSTEM comprisingrotary FIRING SYSTEM"; and

U.S. patent application Ser. No. 15/089,349 entitled "CIRCULAR STAPLING SYSTEM COMPRISING LOAD CONTROL".

The applicant of the present application also has the following U.S. patent applications filed on 31/12/2015, each of which is hereby incorporated 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 has the following U.S. patent applications filed on 9/2/2016, each of which is hereby incorporated 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 has the following U.S. patent applications filed on 12.2.2016, each of which is hereby incorporated 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 ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0246472;

U.S. patent application Ser. No. 13/782,338 entitled "THUMBWHEEL SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS," now U.S. patent application publication 2014/0249557;

-U.S. patent application Ser. No. 13/782,499 entitled "ELECTROMECHANICAL SURGICAL 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 MOTORS CONTROL FOR MODULAR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0246478;

U.S. patent application Ser. No. 13/782,358 entitled "JOYSTICK SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0246477;

-U.S. patent application Ser. No. 13/782,481 entitled "SENSOR STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR", now U.S. patent application publication 2014/0246479;

U.S. patent application Ser. No. 13/782,518 entitled "CONTROL METHOD FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS", now U.S. patent application publication 2014/0246475;

U.S. patent application Ser. No. 13/782,375 entitled "Rolling Power weighted accumulation INSTRUMENTS WITH MULTIPLE layers 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 of which is 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 of which is 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 2013 on month 4 and 9 and each of which is 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 of which is 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 arrangements of the staple cavities and staples are possible.

The staples are supported by a staple driving device in the cartridge body. The drive device is movable between a first, or unfired position and a second, or fired position to eject the staples from the staple cartridge. The drive is retained in the cartridge body by a retainer that extends around the bottom of the cartridge body and includes an elastic member configured to grip the cartridge body and retain the retainer to the cartridge body. The drive device 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 the drive device toward the anvil and lift the drive device, and the staples are supported on the drive device.

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.

Certain surgical stapling and cutting end effectors described herein include an elongate channel that is configured to removably receive a staple cartridge having surgical staples stored therein. The staple cartridge includes an ejection device or drive device movably supported within a cartridge body of the staple cartridge, each of which is configured to support one or more staples thereon. The staple support drivers are arranged in longitudinal rows within the cartridge body on each side of a longitudinally extending slot defined in the cartridge body. The slot is configured to movably receive a firing member that may have a tissue cutting edge thereon for cutting tissue that has been clamped between the anvil and the staple cartridge. The driving means are pushed upwards in the cartridge body, i.e. towards the deck of the cartridge body, upon contact by a slider configured to be driven longitudinally through the cartridge body by the firing member. The sled is movably supported within the cartridge and includes a plurality of angled or wedge-shaped cams corresponding to rows of staple driving devices within the cartridge. In an unfired or "new" staple cartridge, the sled is positioned at a starting position that is adjacent to the first or most proximal staple drive of each row. The sled is advanced distally by the firing member during a firing stroke to eject the staples from the cartridge body. Once the staple cartridge is at least partially fired, i.e., ejected from the cartridge body, the firing member is retracted back to the starting or unfired position and the sled remains at the distal end of the now used staple cartridge. Once the firing member has returned to the starting or unfired position, the used staple cartridge can be removed from the channel of the end effector.

In addition to the above, a surgical instrument system 10 is shown in fig. 1. The surgical instrument system 10 includes a handle 14 and a shaft assembly 200 that is removably attachable to the handle 14. The shaft assembly 200 includes an end effector 300 that includes a cartridge channel 302 and an anvil 306 that is movable relative to the cartridge channel 302. The staple cartridge 304 is removably positioned in the cartridge channel 302.

Such cutting and stapling end effectors are mounted to the distal end of an elongate shaft assembly that operably supports a variety of drive shafts and components that are configured to apply various control motions to the end effector. In various instances, the shaft assembly can include an articulation joint or can otherwise be configured to facilitate articulation of the end effector relative to a portion of the elongate shaft when articulation motions are applied to the end effector. The shaft assembly is coupled to a housing that supports various drive systems that are operably connected with various components in the elongate shaft assembly. In some arrangements, the housing may comprise a hand-held housing or handle. In other arrangements, the housing may comprise a portion of a robotic or automated surgical system. The various drive systems of the housing may be configured to impart axial drive device motions, rotational drive motions, and/or combinations of axial and rotational drive motions to the elongate shaft assembly. In a hand-held arrangement, the axial movement may be generated by one or more manually actuated hand cranks and/or by one or more electric motors. Robotic systems may employ electric motors and/or other automated drive arrangements configured to generate and implement the necessary control motions to the elongate shaft assembly, and in some cases, ultimately to the firing member in the end effector.

For surgical end effectors requiring rotational control motions, the elongate shaft assembly may include a "proximal" rotary drive shaft portion that is rotated by a corresponding motor or other source of rotational motion supported in the housing. The proximal rotary drive shaft is configured to apply rotary control motions to an end effector drive shaft supported in the end effector. In such arrangements, the firing member interfaces with the end effector drive shaft such that the firing member can be longitudinally advanced through the end effector and then returned to an unfired position.

When using a surgical instrument configured to cut and staple tissue, measures should be taken to ensure that an unused surgical staple cartridge has been properly installed in the end effector of the surgical instrument prior to actuation of the firing drive system of the surgical instrument. If the clinician inadvertently actuates the tissue cutting member of the firing drive system without first installing an unused staple cartridge in the end effector, for example, the tissue cutting member may sever tissue without stapling the tissue. Similar problems can occur if the clinician inadvertently installs a partially used staple cartridge into the end effector. When a staple cartridge is used in a previous procedure or a step prior to the procedure, and then removed from the end effector prior to ejection of all staples therefrom, a partially used staple cartridge is formed. If such a partially used cartridge is reused in a surgical instrument, the tissue cutting member may create a cut in the tissue that is longer than the staple line applied to the tissue. Thus, when using a surgical end effector configured to cut and staple tissue, it is desirable that the surgical end effector be configured to prevent actuation of the tissue cutting member unless an unused "new" staple cartridge is properly installed in the end effector.

Fig. 2 and 3 illustrate portions of a surgical cutting and stapling end effector 20000 that may address such issues. As can be seen in fig. 2 and 3, the end effector 20000 includes a rotating end effector drive shaft 20010. Although not shown, the rotary end effector drive shaft 20010 is rotatably supported within an elongate channel that is configured to removably support a surgical staple cartridge therein. The rotary end effector drive shaft 20010 is configured to receive rotary drive motion from a proximal rotary drive shaft that is attached to a channel or otherwise operably interfaces with the rotary end effector drive shaft 20010. The rotary control motion may be applied to the proximal rotary drive shaft by a corresponding drive arrangement, which may include one or more motors that are manually actuated or controlled by a robotic control system or other source of rotary control motion. In an alternative arrangement, the rotary control motion may be generated manually. Still referring to fig. 2 and 3, the surgical end effector 20000 includes a firing assembly 20020 configured for longitudinal travel within the channel. In the exemplified embodiment, the firing assembly 20020 comprises an upper firing body 20022 having a distal firing ear 20024 and a proximal firing ear 20026. The distal firing ear 20024 has a non-threaded bore (not shown) therein configured to receive a rotary end effector drive shaft 20010 therethrough. The proximal firing ear 20026 is spaced apart from the distal firing ear 20024 to define a nut cavity 20028 therebetween. The proximal firing ear 20026 has a non-threaded bore 20027 therethrough configured to receive a rotary end effector drive shaft 20010 therethrough.

As can be seen in fig. 2 and 3, the rotary end effector drive shaft 20010 is threaded. The firing assembly 20020 includes a travel nut 20030 that is threadably journaled on the rotary end effector drive shaft 20010 and is located within a nut cavity 20028 between a distal firing ear 20026 and a proximal firing ear 20027. The traveling nut 20040 is movable within the nut cavity 20028 between a first position (fig. 2) and a second position (fig. 3). The traveling nut 20040 includes an upper notch portion 20042 having a distally extending retainer tab 20044 protruding therefrom. When the travel nut 20040 is in the first position, the notch upper portion 20042 is vertically aligned with the upper firing body 20022 of the firing assembly 20020. As further seen in fig. 2 and 3, the distal firing ear 20024 can include a pair of laterally projecting distal fins 20025 (only one of which is visible in the figures) and the proximal firing ear 20026 can include a pair of laterally projecting proximal fins 20027. Likewise, the traveling nut 20040 can include a pair of nut fins 20046 configured to align with the distal and proximal fins 20025, 20027 when the traveling nut 20040 is in the first position. See fig. 2. When in this aligned position, fins 20025, 20027 and 20046 pass freely within channels provided in the body of the staple cartridge. Additionally, in the illustrated arrangement, the upper body portion 20022 of the firing assembly 20020 includes a pair of lateral projection upper fins 20030 that are configured to be slidably received in corresponding channels in the anvil or otherwise slidably engage the anvil as the firing assembly is driven distally through the end effector. Thus, the fins 20025, 20027, 20046 and the upper fin 20030 serve to maintain the anvil at a desired distance from the staple cartridge during the firing process. The firing assembly 20020 also includes a tissue cutting surface or tissue cutting blade 20032 for cutting tissue that has been clamped between the anvil and the staple cartridge.

The channel of the surgical end effector 20000 is configured to operably and removably support a surgical staple cartridge including a sled 20050 therein. The sled 20050 is movable from a starting position at the proximal end of the staple cartridge to an ending position within the cartridge. The slider 20050 includes a central slider body 20052 having a collection of camming wedges 20054 formed therein. In the illustrated embodiment, the slide 20050 includes four camming wedges 20054, with two camming wedges 20054 located on each side of the central slide body 20052. Each camming wedge 20054 will correspond to a line of staple support drivers located in the cartridge body. As the sled 20050 is driven distally through the cartridge body, the camming wedges 20054 will drive the staple driving devices upwardly in sequence in corresponding lines within the cartridge body, thereby driving the staples into contact with the underside of the anvil.

In the exemplified embodiment, the sled 20050 includes a retention cavity 20056 formed in the central sled body 20052 that is configured to retentively engage a distally extending retainer tab 20044 of a traveling nut 20040 when the traveling nut is in the first position and the sled 20050 is in the starting (pre-firing) position. See fig. 2. In certain arrangements, one or more biasing members 20060 can be provided in the firing assembly 20020 to bias the travel nut 20040 into the first position. For example, a torsion spring may be supported in one or both of the proximal firing ear 20024 and the distal firing ear 20026 to bias the travel nut 20040 into the first position (direction D) when the threaded end effector drive shaft 20020 is not actuated₁). However, when the threaded end effector drives the shaft 20020 in the firing direction (D)₂) Upon rotation, the rotary drive shaft 20020 overcomes the bias of the biasing member 20060 and moves the traveling nut 20030 to the second position shown in fig. 3. When the traveling nut 20030 is in the second position, the retention tabs 20044 are misaligned with the slots in the cartridge body that slidably receive the central sled body 20052, and the nut fins 20046 are misaligned with the channels in the cartridge body. Thus, further rotation of the rotary end effector drive bar 20010 will not drive the firing assembly 20020 distally due to such misalignment of the tabs 20044 and fins 20046 with the corresponding portions of the cartridge body. However, if the cartridge is unused (never fired), the cartridge will have a sled 20050 in the home position. When the cartridge is properly seated in the end effector channel, the retainer tab 20044 will be received in the slideA retention cavity 20056 in the piece 20050 will retain the travel nut 20030 in the first position when the rotary end effector drive shaft 20010 is rotated in the firing direction. Thus, such an arrangement will prevent the clinician from inadvertently advancing the firing assembly 20020 (and tissue cutting surface 20044) when an unused cartridge is not properly seated in the channel. If a used or even partially used cartridge is placed in the channel, the sled will not be in the starting position and the clinician will not be able to fire the firing assembly. If an unused cartridge is present in the channel, but is not properly seated therein, such that the retention tab is received within the retention cavity in the sled, the clinician will be unable to advance the firing assembly.

Turning next to fig. 4-6, portions of another surgical cutting and stapling end effector 20100 are shown. For example, the end effector 20100 includes a channel 20110 configured to removably receive a surgical staple cartridge 20200 therein. In at least one embodiment, the end effector 20100 includes a rotary end effector drive shaft 20120 that is selectively movable or deflectable between a first "locked" position and a second "driven" position. The rotary end effector drive shaft 20120 is configured to receive rotary drive motion from a proximal rotary drive shaft (not shown). The rotational control motion may be applied to the proximal rotational drive shaft by a corresponding drive arrangement, which may include one or more motors that are manually actuated or controlled by a robotic control system. In an alternative arrangement, the rotary control motion may be generated manually. The rotary end effector drive shaft 20120 may be rotatably supported on its proximal and distal ends by corresponding rotary bearing arrangements or mounts that facilitate operative rotation of the rotary end effector drive shaft 20120 while deflecting a portion of the rotary end effector drive shaft between a first position and a second position upon rotational operative engagement with the proximal rotary drive shaft or other source of rotary motion.

As seen in fig. 4-8, the surgical end effector 20100 includes a firing assembly 20130 configured for longitudinal travel within a channel 20110. In the illustrated embodiment, the firing assembly 20130 includes a firing body 20132 that is threadably journaled on the rotary end effector drive shaft 20120. The firing body 20132 includes a pair of laterally projecting fins 20134 configured to pass within a channel 20112 in the channel 20110. The channel 20112 may be defined by two inwardly extending spaced channel tabs 20114 (only one tab is visible in fig. 7 and 8) with a slot 20116 therebetween to accommodate passage of the rotary end effector drive shaft 20120 and the firing body 20132 therebetween. See fig. 7 and 8. Additionally, in the illustrated arrangement, the upper body portion 20136 of the firing assembly 20130 includes a pair of laterally projecting upper fins 20138 that are configured to be slidably received in corresponding channels 20152 in the anvil 20150 as the firing assembly 20130 is driven distally through the end effector 20100. Thus, the fins 20134 and 20138 serve to maintain the anvil 20150 at a desired distance from the staple cartridge 20200 during the firing process. The firing assembly 20130 also includes a tissue cutting surface or tissue cutting blade 20139 that is configured to cut tissue that has been clamped between the anvil and the staple cartridge.

FIG. 4 illustrates installation of an unused staple cartridge 20200 into a surgical end effector 20100. As can be seen in fig. 4, the unused staple cartridge 20200 comprises a sled 20210 in a starting position. The sled 20210 is movable from a starting position at the proximal end of the staple cartridge 20200 to an ending position within the cartridge 20200. As can be seen in fig. 8, the slider 20210 includes a central slider body 20212 having a collection of cam wedges 20214 formed therein. In the illustrated embodiment, the slider 20210 includes four camming wedges 20214, with two camming wedges 20214 located on each side of the central slider body 20212. Each camming wedge 20214 corresponds to a wire of a staple support drive supported in the magazine 20200. As the sled 20210 is driven distally through the cartridge 20200, the camming wedges 20214 sequentially drive the staple driving devices upward in corresponding lines within the cartridge 20200, driving the staples into contact with the underside of the anvil 2015. Prior to placement of the unused staple cartridge 20200 in the channel 20110, the rotary drive shaft 20120 is in a first or up position (represented by arrow "U"). FIG. 7 illustrates the position of the rotary drive shaft 20120 and firing assembly 20130 in a locked position prior to installation of a staple cartridge in the end effector. As can be seen in fig. 7, the fins 20134 are aligned with the channel tabs 20144 of the channel 20110 such that if the clinician were to actuate the rotary drive shaft 20120, driving the firing assembly distally through the channel 20110, the firing assembly 20130 is prevented from moving distally due to contact between the fins 20134 and the channel tabs 20114. The distance that the rotary drive shaft 20120 and the firing assembly 20130 can deflect downward is shown in FIG. 7 as distance Df.

In the exemplified embodiment, a firing assembly engagement notch 20216 is provided in the sled body 20212 that is configured to engage a corresponding engagement notch 20137 in the upper body portion 20136 of the firing assembly 20130. When the firing assembly engagement notch 20216 of the sled 20210 initially engages the engagement notch 20137 in the upper body portion 20136 of the firing assembly 20130, the sled 20120 biases or deflects the firing assembly 20130 and the end effector rotation drive shaft 20120 downward into the channel 20110 (represented by arrow "D" in fig. 8). This movement aligns the fins 20134 of the firing assembly 20130 with the channel 20112 in the channel 20110. The surgical staple cartridge 20220 can be configured to snap into the channel 20100 and be retained therein in a properly installed orientation. Fig. 5 and 8 illustrate the rotary drive shaft 20120 in a "drive position" or "second position" wherein, when the rotary drive shaft 20120 is rotated in a firing direction, the firing assembly 20130 is vertically aligned with the channel 20110 so as to allow the firing assembly 20130 to be driven distally through the staple cartridge 20200.

FIG. 6 illustrates installation of an unused or partially used staple cartridge 20200 into a surgical end effector 20100. As can be seen in fig. 6, the sled 20210 has been moved distally from a starting position within the staple cartridge 20200'. Thus, when the staple cartridge 20200' is properly installed within the channel 20110, the sled 20210, and more specifically the firing assembly engagement notches 20126 in the sled 20210, are disengaged from the engagement notches 20137 in the firing assembly 20130. Thus, the firing assembly 20130 remains in the first or locked position. Thus, if the clinician inadvertently actuates the rotary end effector drive shaft 20120, the firing assembly 20130 will not be advanced distally into the cartridge 20200'.

9-14 illustrate portions of another lockable firing assembly 20300 that are prevented from being advanced distally unless an unused surgical staple cartridge has been properly seated within the end effector channel 20400. FIG. 9 illustrates a threaded nut portion 20302 of the firing assembly 20300 that is threadably journaled on the rotary end effector drive shaft in the manner described herein. The rotary end effector drive shaft has been omitted from fig. 9-14 for clarity. In the illustrated embodiment, the locking ears 20304 and the actuator ears 20306 project laterally from the threaded nut portion 20302. Although not shown, the firing assembly 20300 includes an upper firing body having a tissue cutting edge, which may be similar to those disclosed herein. Fig. 10-14 illustrate the threaded nut portion 20302 of the connecting channel 20400. It should be appreciated that channel 20400 is configured to operably and removably support a surgical staple cartridge therein. Referring first to fig. 10, the channel 20400 includes a centrally disposed longitudinal slot 20402 configured to operably support a rotary end effector drive shaft and to allow the threaded nut 20302 to travel longitudinally through the channel 20400. Further, a first longitudinal protrusion 20404 and a second longitudinal protrusion 20406 are provided on each side of the longitudinal slot 20402. Flanges 20404, 20406 serve to define a longitudinal channel 20408 that allows ears 20304 and 20306 to pass therethrough when firing assembly 20300 distally through channel 20400. In addition, channel 20400 comprises a longitudinal cavity 20410 for receiving the cartridge body therein. It should be understood that the cartridge body can be configured to be snapably and removably retained within the cavity 20410.

In the illustrated embodiment, the latching recess 20412 is disposed in the flange 20404. When the firing assembly 20300 is in a first or starting position prior to firing, the lock recess 20412 is sized to receive at least a portion of the lock ear 20304 therein. A locking spring or biasing member 20414 is disposed on the flange 20406 and is configured to engage and bias the actuator ear 20306 in the locking direction "L". Such rotation of the actuator ears 20306 causes the lock ears 20304 to enter the lock notches 20412. When in this position, the firing assembly 20300 cannot be advanced distally when the rotary end effector drive shaft is rotated in the firing direction.

FIG. 12 illustrates the position of the threaded nut portion 20302 of the firing assembly 20300 when the firing assembly has been moved to a second or unlocked position. FIG. 13 illustrates what happens when a surgical staple cartridge is initially introduced into channel 20400. In fig. 13 and 14, the cartridge body has been omitted for the sake of clarity. However, it should be understood that the surgical staple cartridge includes a sled 20500. The sled 20500 is movable from a starting position at the proximal end of the staple cartridge to an ending position within the cartridge. As seen in fig. 13 and 14, slide 20500 includes a central slide body 20502 having a collection of camming wedges 20504 formed therein. In the illustrated embodiment, slide 20500 includes four camming wedges 20504 with two camming wedges 20504 located on each side of central slide body 20502. Each camming wedge 20504 corresponds to a line of staple supporting drivers located in magazine 20500. As the sled 20500 is driven distally through the cartridge, the camming wedges 20504 sequentially drive the staple driving devices upward in corresponding lines within the cartridge, ejecting the staples into contact with the underside of the anvil.

Still referring to fig. 13, the slide 20500 is configured to contact the actuator ears 20306 when the cartridge is properly installed in the channel 20400 and the slide is in the home position. For example, in the illustrated embodiment, the downwardly extending actuator member 20506 is formed on or otherwise attached to the slide 20500. When the cartridge is installed in channel 20400, an actuator member 20506 on slide 20500 contacts actuator ears 20306 and biases the firing assembly in an unlocking direction "UL" (fig. 13) to the position shown in fig. 14. As can be seen in fig. 14, the lock ears 20304 are clear of the lock notches 20412 and the firing assembly 20300 can now be advanced longitudinally through the channel and staple cartridge. Thus, such an arrangement will prevent the clinician from inadvertently advancing the firing assembly unless the cartridge with the sled in the starting position has been properly installed in the channel. As used in this context, the term "properly installed" means that the staple cartridge has been retentively disposed into the channel in an intended manner, allowing the sled and other portions thereof to interact with the firing assembly in the manner described herein.

Fig. 15-17 illustrate a portion of an end effector 20500 configured to cut and staple tissue. The end effector 20500 includes an elongate channel 20510 that is configured to operably support a surgical staple cartridge 20600 therein. The end effector includes an anvil assembly 20700 that operably supports an anvil concentric drive member 20710 for operably driving a firing member 20720 through the end effector 20500. Anvil concentric drive member 20710 may, for example, be centrally disposed within anvil frame 20712 and extend substantially the length thereof. In the illustrated embodiment, the anvil concentric drive member 20710 comprises an anvil drive shaft including a distal bearing ear 20714 and a proximal bearing ear 20716. The distal bearing ears 20714 are rotatably received in a distal bearing housing 20718, which is supported within bearing sleeves in the anvil frame 20712. The proximal bearing ears 20716 are rotatably supported in the anvil assembly 20700 by a floating bearing casing 20720 that is movably supported in a bearing casing 20722 formed in the proximal anvil portion 20724. See fig. 16. The proximal and distal bearing housing arrangements may serve to prevent or at least minimize the generation of compressive forces on the anvil drive shaft 20710, which may otherwise cause the anvil drive shaft 20710 to bend under high force conditions. The anvil drive shaft 20710 also includes a drive firing gear 20726, a proximal threaded or helical portion 20728 and a distal threaded or helical portion 20730. In the illustrated arrangement, the proximal threaded portion 20728 has a first length and the distal threaded portion 20730 has a distal length greater than the first length. In the arrangement shown, the pitch of the distal threaded portion 20730 is greater than the pitch of the proximal threaded portion 20728. In another manner, it can be stated that the lead of distal threaded portion 20730 is greater than the lead of proximal threaded portion 20728. In one arrangement, the lead of distal threaded portion 20730 may be about twice the lead of proximal threaded portion 20728. Further, a dead space 20731 may be disposed between the proximal and distal threaded portions 20728, 20730. In at least one example, the anvil drive shaft 20710 may be integrally formed from an extruded gear blank.

To facilitate assembly of the various anvil components, the anvil assembly 20700 includes an anvil cap 20740 that may be attached to the anvil frame 20712 by welding, snap features, or the like. Further, the anvil assembly 20700 includes a pair of anvil plates or staple forming plates 20742 which may include a pattern of various staple forming pockets on a bottom surface thereof corresponding to the arrangement of staples in the surgical staple cartridge 20600 supported in the elongate channel 20510. The staple forming plates 20742 may be made of metal or a similar material and welded or otherwise attached to the anvil frame 20712. In other arrangements, a single anvil having a slot therein to receive a firing member may also be employed. Such an anvil plate or combination of plates may be used to improve the overall stiffness of the anvil assembly. For example, the anvil can be flat and have staple forming pockets "cast" therein.

As seen in fig. 15 and 18-20, the surgical end effector 20500 includes a firing member 20800 having a body portion 20802 with a knife nut portion 20804 formed thereon or otherwise attached thereto. The knife nut portion 20804 is configured to be received on the anvil drive shaft 20710. Distal threaded knot 20806 and proximal threaded knot 20808 are configured to engage proximal threaded portion 20728, and distal threaded portion 20730 is formed in knife nut portion 20804. Distal threaded nodule 20806 is spaced apart from proximal threaded nodule 20808 relative to the length of dead space 20731, such that when knife nut portion 20804 spans dead space 20731, distal threaded nodule 20806 is in threaded engagement with distal threaded portion 20730 and proximal threaded nodule 20808 is in threaded engagement with proximal threaded portion 20728. Further, anvil engagement tabs 20810 project laterally from opposing lateral portions of the knife nut 20804 and are each oriented to engage a corresponding staple forming plate 20742, which is attached to the anvil frame 20712. Firing member 20800 also includes channel engagement tabs 20820 protruding from each lateral side of body portion 20800. Firing member 20800 also includes a tissue cutting surface 20822.

Rotation of anvil drive shaft 20710 in a first rotational direction will result in axial movement of firing member 20800 from a first position to a second position. Similarly, rotation of anvil drive shaft 20710 in a second rotational direction will result in axial retraction of firing member 20800 from the second position back to the first position. The anvil drive shaft 20710 ultimately obtains rotational motion from a proximal drive shaft (not shown) operably interfacing with the distal power shaft 20830. In the illustrated arrangement, the distal power shaft 20830 has a distal drive gear 20832 configured to be in meshing engagement with a drive firing gear 20726 on the anvil drive shaft 20710 when the anvil assembly 20710 is in the closed position. Anvil drive shaft 20710 is said to be "separate and distinct" from distal power shaft 20830. That is, for example, in at least the arrangement shown, anvil drive shaft 20710 is not coaxially aligned with distal power shaft 20830 and does not form a portion of distal power shaft 20830. Further, anvil drive shaft 20710 is movable relative to distal power shaft 20830, e.g., as anvil assembly 20700 is moved between open and closed positions. The proximal drive shaft can ultimately be rotated by a motor supported in the housing that is attached to a shaft assembly coupled to the surgical end effector 20500. The housing may comprise a hand-held component or a part of a robotically controlled system.

In the illustrated arrangement, the anvil assembly 20700 is closed by distally advancing the closure tube 20900. As seen in fig. 15, closure tube 20900 includes an internally threaded closure nut 20902 configured to threadingly engage a closure thread segment 20834 formed on distal power shaft 20830. Initial rotation of the distal power shaft 20830 will drive the closure tube 20900 distally to the cam, driving the anvil assembly 20700 to the closed position. Rotation of the distal power shaft 20830 in an opposite direction will drive the closure tube 20900 in a proximal direction to allow the anvil assembly 20700 to move to the open position.

Turning to fig. 18-20, the channel includes a pair of inwardly extending longitudinal retention tabs 20512 having a slot space 20514 therebetween to accommodate longitudinal movement of the firing member 20800. In addition, the channel 20510 includes a proximal locking cavity 20516 adjacent to the retention tab 20512. The lock cavity 20516 transitions into a distal firing cavity coextensive with the tab 20512 and a space 20514 therebetween. The lock cavity 20516 is larger than the distal firing cavity to allow the firing member 20800 to pivot to the position shown in fig. 18. When in this position, the firing member body 20802 is misaligned with the slot space and the tabs 20820 are misaligned with the distal firing cavity 20518. When in this position, one of tabs 20820 protruding from firing member 20800 is aligned with one of retention tabs 20512, thereby preventing firing member 20800 from being longitudinally advanced through channel 20510. When the anvil shaft 20710 is initially rotated and a surgical staple cartridge with the sled in the starting position is not installed in the channel 20510, the firing member 20800 will pivot to this "locked" position. However, when a cartridge having a sled in the home position has been installed in channel 20510, the sled will help contact or otherwise interface with firing member 20800 to position firing member 20800 and maintain it in alignment with space 20514 between retention tabs 20512. See fig. 19. Thus, continued rotation of anvil drive shaft 20710 will drive firing member 20800 distally through channel 20510, as shown in fig. 20. Accordingly, such an arrangement will prevent the clinician from inadvertently actuating anvil drive shaft 20710 to drive firing member 20800 distally through channel 20510 unless an unused surgical staple cartridge having a sled in a starting position has been installed therein.

In other arrangements, detection of the sled in the correct position within an unused staple cartridge that has been properly seated in the channel of the surgical cutting and stapling end effector may be determined electrically. This can be achieved, for example, by contacts on the slider which complete the circuit when the slider is in a starting position in a cartridge which has been correctly placed in the channel. After firing, the circuit is open and no further firing is allowed until the circuit is closed again.

As mentioned above, stapling assemblies for first grasping, clamping, stapling and/or cutting tissue are known in the art. Previous stapling assemblies, such as those disclosed in U.S. patent No. 5,865,361, for example, have included a loading unit operably connected to a handle assembly. The disclosure of U.S. Pat. No. 5,865,361, entitled "SURGICAL STAPLING APPATUS," published on 2.2.1999, is hereby incorporated by reference in its entirety. While the handle assembly of these previous stapling assemblies was configured for multiple uses, the loading unit was configured for a single use. After each loading unit has been used, or at least partially used, the loading unit is removed from the handle assembly and then replaced with a new or unused loading unit, if desired. The configuration of these previous loading units does not allow for the bin portion of the loading unit to be replaced so that the used loading unit can be reused.

U.S. patent application publication 2012/0286021 discloses an alternative stapling assembly that includes a first jaw with an anvil and a second jaw with a staple cartridge. The entire disclosure of U.S. patent application publication 2012/0286021 entitled "REPLACEABLE STAPLE CARTRIDGE," published 11/15/2012 is incorporated herein by reference. Unlike previous loading units, the second jaw of these stapling assemblies may be completely removed from the loading unit and then replaced with another second jaw, assuming the previous second jaw has been used. Notably, the entire second jaw of these STAPLING assemblies is replaced-not only is a portion of the second jaw disclosed in U.S. patent 6,988,649 entitled "SURGICAL STAPLING INSTRUMENT HAVING A SPENT CARTRIDGE LOCKOUT," published 24.1.2006, the entire disclosure of which is incorporated herein by reference.

However, the seaming assembly disclosed in U.S. patent application publication 2012/0286021 has drawbacks. For example, the stapling assembly disclosed in U.S. patent application publication 2012/0286021 includes a cutting member that is capable of being advanced distally even if the second jaw is not attached to the stapling assembly. Thus, the cutting member may be unintentionally exposed to the tissue of the patient. Various modifications to these seaming assemblies, and the like, are discussed further below.

Turning now to fig. 21, the surgical instrument system 21000 includes a handle 21010 and a stapling assembly or loading unit 21030 attached to a shaft 21020 of the handle 21010. Referring primarily to fig. 22, the loading unit 21030 includes a proximal end or bayonet connector 21032 configured to releasably attach the loading unit 21030 to the shaft 21020. Similar to the stapling assembly disclosed in U.S. patent application publication 2012/0286021, the loading unit 21030 includes an anvil 21040 and an attachable cartridge jaw 21050. Once attached to the loading unit 21030, the cartridge jaw 21050 can be pivoted between an open position (fig. 21) and a closed or clamped position.

The handle 21010 includes an actuator or trigger 21014 that can be rotated toward the pistol grip 21012 of the handle 21010 to distally drive the firing bar of the loading unit 21030. During the first stroke of the trigger 21014, the firing bar engages the cartridge jaw 21050 and moves the cartridge jaw 21050 to its closed position. During one or more subsequent strokes of the trigger 21014, the firing bar is advanced through the cartridge jaw 21050. The cartridge jaw 21050 includes a plurality of staples removably stored therein that are ejected from the cartridge jaw 21050 as the firing bar is advanced distally through the cartridge jaw 21050. More specifically, as discussed in more detail elsewhere herein, the firing bar enters the cartridge jaw 21050 and pushes a sled stored in the cartridge jaw 21060 distally, which in turn drives staples out of the cartridge jaw 21050.

Referring primarily to fig. 22, the loading unit 21030 also includes an articulation joint 21036 about which the anvil 21040 and the cartridge jaw 21050 can be articulated. The loading unit 21030 includes an articulation drive configured to articulate the anvil 21040 and the cartridge jaw 21050 about the articulation joint 21036. The articulation drive is operably coupled to an articulation actuator 21016 that can be rotated to push or pull the articulation drive depending on the direction of rotation of the articulation actuator 21016.

An alternative surgical instrument system 21100 is illustrated in fig. 23 and 24. System 21100 includes a handle 21110 and an attachable loading unit 21130. Similar to the above, the loading unit 21130 includes an anvil jaw 21040 and a removably attached cartridge jaw 21050. The loading unit 21130 further includes an articulation joint 21138 and a flexible joint 21136 configured to allow the end effector to articulate relative to the shaft portion 21120 of the loading unit 21130. The shaft portion 21120 includes a proximal connector 21122 configured to attach the loading unit 21130 to the handle 21110. Referring primarily to fig. 25, the proximal connector 21122 includes rotatable inputs 21128 that are operably engageable with the rotatable output 21118 of the handle 21110. Each rotatable input 21128 is part of a drive system that articulates the loading unit 21130 about the flexible joint 21136 and/or articulation joint 21128, closing the cartridge jaws 21050, and/or firing staples, for example, from the cartridge jaws 21050. The handle 21110 includes controls 21114 and 21116, which may be used to operate the drive system of the loading unit 21130. U.S. patent application publication 2013/0282052 entitled "APPATUS FOR ENDOSCOPIC PROCEDURES" published at 24/10/2013 is incorporated herein by reference in its entirety.

In addition to the above, the cartridge jaw 21050 is removably attached to the anvil jaw 21040 of the loading unit 21030. Referring primarily to fig. 26 and 27, the proximal end of the anvil jaw 21040 includes attachment tabs 21042 extending from opposite sides thereof. The proximal end of the cartridge jaw 21050 includes a recess 21052 defined therein that is configured to receive the attachment protrusion 21042. Anvil jaw 21040 is fixedly attached to the frame of loading unit 21030, and attachment tab 21042 fixedly extends from anvil jaw 21040. In at least one instance, anvil jaw 21040 and/or attachment tab 21042 is integrally formed with the frame of anvil portion 21030.

The cartridge jaw 21050 also includes clamps 21056 that are configured to engage and grasp the attachment protrusions 21042. Each clip 21056 is positioned within a slot 21055 defined in the cartridge jaw 21050. When the cartridge jaw 21050 is attached to the loading unit 21030, the clamp 21056 bends around the attachment tab 21042. When the cartridge jaw 21050 is fully attached to the loading unit 21030, the clamp 21056 resiliently snaps or returns to its unbent configuration and retains the attachment projection 21042 in the recess 21052.

In addition to the above, when the clamp 21056 is engaged with the attachment tab 21042, the cartridge jaw 21050 is properly attached to the loading unit 21030 and the attachment tab 21042 is fully seated in the recess 21052. That is, the loading unit 21030 does not include a sensing system configured to detect whether the cartridge jaw 21050 is properly attached to the loading unit 21030. 28-32, the loading unit 21130 includes a system configured to detect whether the cartridge jaw 21150 is properly attached to the anvil jaw 21140 of the loading unit 21130, as described in more detail below.

The loading unit 21130 includes circuitry that is turned on or closed when the cartridge jaw 21150 is properly attached to the loading unit 21130. The circuit is in communication with a microprocessor or controller of the surgical instrument system. The controller is located in a handle of the surgical instrument system; however, the controller may be in any suitable portion of the surgical instrument system, such as the loading unit 21130. Alternatively, the controller may be in a housing of the surgical instrument assembly that is attached to the robotic surgical system and/or in the robotic surgical system itself. In any event, the controller is in communication with an electric motor that drives a staple firing system of the surgical instrument system.

When the controller detects that a staple cartridge is not properly attached to the loading unit 21130, the controller can prevent the electric motor from driving the staple firing system through the staple firing stroke, in addition to the above. In at least one such case, the controller may open a switch between a power source (e.g., a battery) and the electric motor to prevent power from being supplied to the electric motor. When the controller detects that the staple cartridge 21150 is properly attached to the loading unit 21130, the controller can allow the electric motor to receive power from the battery and drive the staple firing system through a staple firing stroke when actuated by a user of the surgical instrument system. In at least one such case, the controller may close a switch, for example, between the battery and the electric motor.

The circuitry of the loading unit 21130 includes a conductor 21147 (fig. 30 and 32) that extends through the shaft portion of the loading unit 21130, and further includes a contact 21146 positioned around each of the attachment protrusions 21142. Each of the conductors 21147 is electrically coupled to a microprocessor and contact 21146. The staple cartridge 21150 includes a portion of an electrical circuit that completes the electrical circuit when the staple cartridge 21150 is fully engaged with the attachment protrusion 21142. Referring to fig. 31, the portion of the circuitry in the staple cartridge 21150 includes contacts 21159 positioned in each of the recesses 21052 and conductors or traces 21157 extending between or electrically coupled to the contacts 21159. The clamp 21056 is configured to retain contacts 21159 of the cartridge jaw 21150 against contacts 21146 extending around the attachment portion 21142. In at least one instance, the clamp 21056 is constructed of an electrically conductive material and is in communication with the trace 21157. In such cases, the clamp 21056 is part of the circuitry in the staple cartridge 21150. In any event, when the cartridge jaw 21150 is separated from the loading unit 21130, the circuit is broken or open and the microprocessor can detect that the cartridge jaw 21150 is no longer attached to the loading unit 21130.

In addition to the above, if only one of the contact members 21159 is engaged with its corresponding contact member 21146, the controller can determine that the cartridge jaw 21150 is not properly connected to the loading unit 21130. In such instances, the electrical circuit will be in an open circuit state and, as a result, the microprocessor will treat the improperly assembled staple cartridge jaw 21150 as a missing cartridge jaw 21150 and prevent the electric motor from being actuated to perform a staple firing stroke. In various instances, the surgical instrument system can include an indicator light and/or a feedback system that informs a user of the surgical instrument system that a jaw detection circuit of the staple cartridge is not closed. In response thereto, the user can investigate the condition and properly position the cartridge jaw 21150 to close the detection circuit.

As shown in fig. 31, the conductor 21157 extends laterally across the cartridge jaw 21150. As the firing member is advanced distally through the cartridge jaw 21150, the firing member can transect and/or break the conductor 21157 and open the jaw detection circuit. At this point, the controller may allow the electric motor to be operated to advance the firing member distally until the firing member is retracted to its unfired position. After the firing member has been retracted to its unfired position, the controller can then prevent re-operation of the electric motor until the unused cartridge jaw 21150 is properly attached to the loading unit 21130. Thus, the circuitry of loading unit 21130 can serve as a missing cartridge latch, an improperly attached cartridge latch, and a used cartridge latch.

In addition to or in lieu of the foregoing, the sled 21170 can include a conductive portion that electrically connects the lateral jaw contacts 21159 and/or the conductive clips 21056 when the sled 21170 is in its unfired position. In at least one instance, the glider 21170 comprises a conductor and/or trace that extends from one side of the glider 21170 to the other. When the sled 21170 is advanced distally, the conductive portion of the sled 21170 no longer electrically communicates with the contact 21159 and/or the clip 21056, and the jaw detection circuit is open. To the extent that the jaw assembly also includes conductor 21157, conductor 21157 can be cut or broken to open the jaw detection circuit as described above. In various circumstances, the sled 21170 can be displaced from the jaw detection circuit while, for example, cutting or breaking the conductor 21157. In any event, the conductive sled 21170 can provide a used cartridge latch.

In various alternative embodiments, the circuit latch of the loading unit is not transected as the firing member is advanced distally. Turning now to fig. 34, the staple cartridge jaw 21250 of the loading unit 21230 comprises a cartridge body 21251, a plurality of staple cavities 21258 defined in the cartridge body 21251, and a longitudinal slot 21259 defined in the cartridge body 21251 that is configured to receive a portion of the firing member. Similar to cartridge jaw 21150, cartridge jaw 21250 includes a portion of the loading unit circuitry. The portion of the electrical circuit in cartridge jaw 21250 includes electrical contacts, such as contacts 21159 defined in recess 21052, and compliant electrical contacts 21257 disposed on opposite sides of longitudinal slot 21251. Each compliant contact 21257 is in electrical communication with the contact 21052 via, for example, a conductor or trace extending through the cartridge body 21251.

Compliant contacts 21257 are configured to engage anvil jaw 21240 of loading unit 21230 when cartridge jaw 21250 is assembled to loading unit 21250. More specifically, the compliant contacts 21257 engage conductive pathways 21247 defined in the anvil jaw 21240 that are electrically connected to the compliant contacts 21257 and at which point the circuit has been closed. The compliant contacts 21257 remain in constant engagement with the conductive pathways 21247, i.e., when the cartridge jaw 21250 is in the open position, when the cartridge jaw 21250 is in the closed position, and when the cartridge jaw 21250 is moved between its open and closed positions. When the firing member is advanced distally, it passes through the gap defined between the contacts 21257 and, therefore, does not transect the electrical jaw detection circuit. Such an arrangement may provide for a missing cartridge jaw latch and/or a improperly attached cartridge jaw latch.

In addition to the above, compliant contacts 21257 can comprise springs configured to bias cartridge jaw 21250 into an open position. When cartridge jaw 21250 is moved to its closed position, compliant contacts 21257 are compressed between cartridge jaw 21250 and anvil 21240. Compliant contacts 21257, along with other portions of the electrical clamp detection circuitry, are electrically isolated from metallic or conductive portions of the stapling assembly to maintain the integrity of the jaw detection circuitry and prevent shorting of the jaw detection circuitry.

In addition to or in lieu of an electrical or electronic lockout, such as the lockout described above, the loading unit may include a mechanical lockout that prevents the firing system from performing a staple firing stroke if the cartridge jaw is not properly attached to the loading unit. Turning now to fig. 33, as the firing member 21160 is advanced distally during a staple firing stroke, the cartridge jaw 21150 includes a sled 21170 that is advanced distally by the firing member 21160 (fig. 30). The cartridge jaw 21150 further comprises lockout members 21172 that are pivotally engaged with the cartridge body 21151 of the cartridge jaw 21150. As described in U.S. patent application publication 2012/0286021, the lockout members 21172 are biased inwardly to a lockout position when the sled 21170 is advanced at least partially distally during a firing stroke, thereby preventing the cartridge jaw 21150 from being re-fired.

Although the lockout member 21172 may prevent distal advancement of the firing member 21160, as described above, the firing member 21160 may be configured to push and slide between the lockout members 21172 under certain circumstances. As an improvement, one or both of the lockout members 21172 may include a latch or hook extending inwardly toward the firing member 21160. When the lockout members 21172 are biased inward after the sled 21170 is advanced distally, the latches or hooks can engage apertures defined in the firing member 21160 when the firing member 21160 is retracted back to its unfired position. Once the latches or hooks are positioned in the firing member apertures, they can prevent the firing member 21160 from advancing distally through a used cartridge. At this point, the staple cartridge must be replaced to unlock the firing member 21160.

As described above, the attachable staple cartridge jaw is movable between an open position and a closed position to clamp tissue therebetween. Other embodiments are contemplated in which the cartridge jaw is removably attachable to the stapling instrument, but the anvil jaw is movable between an open position and a closed position. Turning now to fig. 35-38, the stapling assembly 21530 includes an attachable staple cartridge jaw 21550 that includes a cartridge body 21551 and an additional pivotable anvil jaw 21540. The stapling assembly 21530 further comprises a firing member, such as firing member 21160, that is configured to move distally to engage the anvil jaw 21540 and move the anvil jaw 21540 to a closed position. More specifically, the firing member 21160 includes a first cam member 21162 configured to engage the cartridge jaw 21550 and a second cam member 21164 configured to engage the anvil jaw 21540 and move the anvil jaw 21540 toward the cartridge jaw 21550.

The suturing assembly 21530 also includes a mechanical latch 21572. Latch 21572 is mounted to the frame of stitching assembly 21530 on frame pivot 21232. The latch 21572 extends distally and is supported by the frame pin 21533. The latches 21572 comprise wires; however, the latches 21572 may be constructed of any suitable material. The latch 21572 also includes an elongate recess track 21576 defined therein that is configured to receive a latch pin 21166 extending from the firing member 21160. Referring primarily to fig. 35, when the latch 21572 is in its locked position, the elongate recess rail 21276 restrains or limits longitudinal displacement of the firing member 21160. More specifically, the recess track 21576 is configured to allow distal advancement of the firing member 21160 to move the anvil jaw 21540 between its open and closed positions, but prevent distal advancement of the firing member 21160 to perform a firing stroke unless the lockout 21572 is moved to its unlocked position, as discussed below.

When the cartridge jaw 21550 is attached to the stapling assembly 21530, as shown in fig. 36, the sled 21270 of the cartridge jaw 21550 contacts the distal arm 21574 of the latch 21572 and deflects the latch 21572 downward to its unlocked position. At this point, the lockout 21572 has been displaced below the lockout pin 21166 of the firing member 21160, and thus, the firing member 21160 may be advanced distally to perform a staple firing stroke, as shown in fig. 37. During the staple firing stroke, the firing member 21160 pushes the sled 21270 distally from the lock arm 21574, and the latch 21572 can return to its unbent or locked configuration. When the firing member 21160 is retracted as shown in fig. 38, the lockout pin 21166 can engage the lockout 21572 and flex the lockout 21572 downward to allow the firing member 21160 to return to its unfired position. Notably, the sled 21270 does not retract with the firing member 21160, and thus, even though the firing member 21160 has been retracted, the lockout 21572 cannot be re-unlocked. As a result of the above, the latch 21572 can function as both a missing cartridge latch and a used cartridge latch.

Turning now to fig. 39-43, stapling assembly 21330 comprises an attachable staple cartridge jaw 21350 that includes a cartridge body 21351 and an additional anvil jaw 21340. The stapling assembly 21330 further comprises a firing member, such as firing member 21160, that is configured to move distally to engage the anvil jaw 21340 and the cartridge jaw 21350. More specifically, the firing member 21160 includes a first cam member 21162 configured to engage the cartridge jaw 21350 and a second cam member 21164 configured to engage the anvil jaw 21340, which closes the jaws 21340 and 21350 as the firing member 21160 is advanced distally.

Stitching assembly 21330 also includes a mechanical latch 21372. Latch 21372 is mounted to the frame of stitching assembly 21330 at frame pivot 21232. Latch 21372 extends distally and is constrained by frame pin 21333. Latch 21372 comprises a wire; however, the latch 21372 may be constructed of any suitable material. The lockout 21372 further includes an elongate recess track 21376 defined therein that is configured to receive a lockout pin 21166 extending from the firing member 21160. Referring primarily to fig. 39, when the lockout 21372 is in its locked position, the elongate recess track 21376 restrains or limits longitudinal movement of the firing member 21160. More specifically, the recess track 21376 is configured to allow distal advancement of the firing member 21160 to close the stapling assembly 21330 but prevent distal advancement of the firing member 21160 to perform a firing stroke.

When the cartridge jaw 21550 is attached to the stapling assembly 21530, as shown in fig. 40, the sled 21370 of the cartridge jaw 21350 contacts the distal arm 21374 of the latch 21372 and deflects the latch 21372 upward to an unlocked position. At this point, the lockout 21372 has been displaced over the lockout pin 21166 of the firing member 21160, and thus, the firing member 21160 can be advanced distally to perform a staple firing stroke, as shown in fig. 41. During a staple firing stroke, the firing member 21160 pushes the sled 21370 distally out from under the lock arm 21374, and the lockout 21372 can return to its unbent or locked configuration. When the firing member 21160 is retracted as shown in fig. 42, lockout pin 21166 can engage lockout 21372 and flex lockout 21372 upward to allow the firing member 21160 to return to its unfired position. Notably, the sled 21370 does not return with the firing member 21160. As a result of the above, latch 21372 can function as both a missing cartridge latch and a used cartridge latch.

Referring to fig. 43, the arms 21374 of the lockout 21372 are laterally spaced apart on opposite sides of the longitudinal slot 21359 such that the firing member 21160 can slide between the arms 21374. In this case, the arm is not transected by the firing member 21160.

During a surgical procedure, several loading units may be used with the handle of a surgical stapling system. In at least one instance, a first loading unit configured to apply 30mm staple lines, for example, may be used; a second loading unit may be used, configured to apply 45mm staple lines; and a third loading unit configured to apply 60mm staple lines may be used. In case each of these loading units comprises a replaceable cartridge jaw, the wrong cartridge jaw may be attached to the loading unit. For example, a clinician may attempt to attach a 60mm staple cartridge jaw to a loading unit configured to apply a 30mm staple line. Thus, some staples ejected from a 60mm staple cartridge jaw may not be deformed by the anvil, and/or the tissue cut line may be longer than the staple line. The stapling assemblies and/or loading units disclosed herein may include means for preventing attachment of an incorrect staple cartridge jaw thereto, as discussed in more detail below.

Referring to fig. 44 and 46, in addition to the above, the recess 21052 defined in the cartridge jaw 21250 is configured to closely receive the attachment protrusion 21142 of the loading unit 21130 such that a close fit exists therebetween. In at least one instance, the attachment protrusion 21242 ' (fig. 45) of the second loading unit 21130' is smaller than the attachment protrusion 21142, and correspondingly, the recess of the second cartridge jaw with which the second loading unit 21130' is used is smaller than the recess 21052. To provide a form of error proofing, the recess of the second cartridge jaw is too small to receive the attachment protrusion 21142 of the loading unit 21130, and thus, the second cartridge jaw cannot be attached to the loading unit 21130. Similarly, turning now to fig. 45, the recess 21052 of the cartridge jaw 21250 is larger than the attachment protrusion 21242 'of the second loading unit 21130', such that the clip 21056 of the cartridge jaw 21250 cannot retain the attachment protrusion 21242 'in the recess 21052, and thus, cannot retain the cartridge jaw 21250 to the loading unit 21130'. In such instances, the interconnection between the cartridge jaw 21250 and the loading unit 21130 'would be too loose for the cartridge jaw 21250 to be used with the loading unit 21130'.

In the above case, the attachment projection of the loading unit, the recess of the cartridge jaw and the spring clip holding the cartridge jaw to the loading unit have the same configuration on both sides of the stapling assembly. In other cases, the attachment projections, recesses, and/or spring clips on one side of the stapling assembly are different than the attachment projections, recesses, and/or spring clips on the other side of the stapling assembly. For example, the larger attachment projections, recesses, and spring clips are disposed on one side of the stapling assembly, while the smaller attachment projections, recesses, and spring clips are disposed on the other side. Such an arrangement may increase the alignment available to prevent improper attachment of the cartridge jaw to the loading unit.

In the above case, the attachment projection of the loading unit, the recess of the cartridge jaw and the spring clip are aligned with respect to a common lateral axis. In other cases, the attachment protrusions, recesses, and/or spring clips on one side of the stapling assembly are misaligned with the attachment protrusions, recesses, and/or spring clips on the other side. In other words, one side is offset from the other side. Such an arrangement may also increase the alignment that may be used to prevent improper attachment of the cartridge jaw to the loading unit.

In addition to the above, it is envisaged that a set of loading units may be provided, wherein each loading unit of the set can be configured such that only cartridge jaws intended for use with the loading unit can be correctly attached to the loading unit.

Turning now to fig. 47 and 48, the cartridge jaw 21050 includes a proximal shoulder 21058 that is positioned proximate to the loading unit 21030 when the cartridge jaw 21050 is attached to the frame of the loading unit 21030. Due to the close fit between the protrusions 21042, the recess 21052, as well as the clip 21056 and cartridge jaw 21050, are held in place so that the shoulder 21058 of the cartridge jaw 21050 does not interfere with, for example, the distal progression of the firing member 21160. More specifically, the shoulder 21058 does not interfere with the first cam member 21162 of the firing member 21160. With an incorrect staple cartridge attached to the cartridge jaw 21050, in certain circumstances, a proximal shoulder of the incorrect cartridge jaw can interfere with the distal progression of the first cam member and thus prevent the firing member 21160 from performing a firing stroke with the incorrect staple cartridge. Turning now to FIG. 49, the cartridge jaw 21450 is an incorrect cartridge jaw for use with the loading unit 21030. While the staple cartridge jaw 21450 has been attached to the loading unit 21030, the proximal shoulder 21458 prevents the firing member 21060 from advancing distally.

In addition to the above, the proximal shoulder of the staple cartridge jaw can comprise a sharp or abrupt corner. In at least one such case, for example, the proximal shoulder does not include a chamfer or lead-in.

In various circumstances, if the tissue clamped between the cartridge jaw and the opposing anvil jaw is too thick, the proximal shoulder of the cartridge jaw can be configured to prevent distal advancement of the staple firing member. In such a case, the cartridge jaw will not be fully closed and a proximal shoulder of the cartridge jaw will be positioned forward of the staple firing member. Such an arrangement would include a tissue thickness latch; however, such an arrangement may also be used as a tissue clamping lockout in the event that the cartridge jaw has not been moved to its clamped position.

In addition to or in lieu of the foregoing, an electronic or software lockout of the surgical instrument system may be utilized to prevent the firing drive from executing a staple firing stroke in the event an incorrect staple cartridge jaw is attached to the surgical instrument system. In various instances, as described above, a portion of the jaw detection circuit can extend through the staple cartridge jaw, and in at least one instance, a controller of the surgical instrument system can be configured to evaluate the portion of the jaw detection circuit extending through the staple cartridge jaw to determine whether a staple cartridge attached to the jaw of the surgical instrument system is a staple cartridge jaw suitable for use with the surgical instrument system. In at least one instance, the clamp 21056 of the first staple cartridge jaw has an electrical property, such as resistance or impedance, that is detectably different than the clamp 21056 of the second staple cartridge jaw.

Referring again to fig. 22, 26 and 28, a cartridge jaw removal tool 21090 can be used to separate the cartridge jaw from the loading unit. U.S. patent application publication 2012/0286021 discusses the cartridge removal tool in more detail.

It is desirable to use the lockout system with a surgical stapling instrument having a replaceable cartridge assembly. For example, in the event that a user forgets to install a staple cartridge into the instrument without such a lockout system, the firing member of the surgical instrument may be used to cut tissue of the patient without stapling it. Such a case is not preferable. In another example, where a user mounts a used or partially used staple cartridge to the instrument and there is no lockout system, the firing member of the surgical instrument will similarly cut but not staple or only partially staple the tissue of the patient. Such a case is also not preferable. Accordingly, a surgical instrument that can automatically lockout the firing member to prevent advancement of the firing member within the end effector is desired.

Turning now to fig. 50 and 51, a surgical instrument system 25100 is shown that includes a missing cartridge and a used cartridge lockout system. The system 25100 includes a firing member 25110, a staple cartridge assembly 25120, and an anvil jaw 25130. The firing member 25110 includes a distally presented cutting portion 25111 that is configured to cut tissue as it is advanced through the end effector portion of the surgical instrument system 25100. The firing member 25110 is configured to deploy a plurality of staples from the cartridge assembly 25120 to the anvil jaw 25130 by longitudinally advancing the sled 25121 through the cartridge assembly 25120. During a staple firing stroke, sled 25121 can be moved from a proximal unfired position to a distal fully fired position. After the staple firing stroke is completed, the firing member 25110 is retracted. The sled 25121 is not retracted with the firing member 25110. However, embodiments are contemplated in which slider 25121 is at least partially retracted.

The surgical instrument system 25100 also includes a latching member 25140. The lockout member 25140 is configured to prevent the firing member 25110 from advancing through the staple firing stroke when a cartridge is not present in the surgical instrument system 25100 or has been used, or is partially used, is stored in the surgical instrument system 25100. The latching member 25140 includes a proximal portion 25141 of a spine pin 25101 that is pivotally mounted to a frame portion of the system 25100. The lockout member 25140 also includes a lockout face or shoulder 25142 configured to latch the firing member 25110, and a deflectable portion 25143. The latch 25140 is movable, or deflectable, between a locked position (FIG. 50) and an unlocked position (FIG. 51) when the cartridge assembly is installed in the system 25100. When the cartridge assembly is not installed in system 25100, latching member 25140 is spring biased to a locked position, as discussed in more detail below. When a used or partially used staple cartridge assembly is installed in system 25100, latching member 25140 is also spring biased into a locked position, as also discussed in more detail below.

When the lockout member 25140 is in its locked position as shown in fig. 50, a firing member pin 25113 mounted on the firing member 25110 is configured to abut a lockout face 25142 of the lockout member 25140, which prevents distal advancement of the firing member 25110. To move the lockout member 25140 from the locked position to the unlocked position, an unused, ready to fire cartridge assembly must be properly installed within the system 25100. More specifically, sled 25121 of an unused, cocked cartridge assembly is in its proximal, unfired position, and when such cartridge assembly is installed in system 25100, sled 25121 deflects or bends, deflectable portion 25143 down into its unlatched position. Referring to fig. 51, when lockout member 25140 is in its unlocked position, firing member pin 25113 is advanced significantly beyond lock face 25142, allowing firing member 25110 to advance distally to deploy staples and cut tissue during a firing stroke.

As can be seen in fig. 50 and 51, when the lock member 25140 is in its locked position, some longitudinal movement of the firing member 25110 is permitted. This freedom of longitudinal movement when the lockout member 25140 is in its locked position allows the firing member 25110 to advance distally to close the jaws of the system 25100 and move proximally to prevent the jaws from reopening. The jaws of the manipulation system 25100 can be necessary, for example, to load and/or unload a staple cartridge.

As described above, when the firing member 25110 is retracted after a firing stroke, the sled 25121 does not return with the firing member 25110. When the firing member 25110 is retracted, the firing member pins 25113 will deflect or bend the deflectable portion 25143 to its unlocked position, allowing the pins 25113 to pass the catch surfaces 25142 and return to the home position. Once pins 25113 retract past lock faces 25142, lockout member 25140 springs back or returns to its locked position to prevent repeated firing through a used staple cartridge installed in system 25100. Firing member 25110 can be further retracted such that the jaws of system 25100 can then be released from the stapled tissue.

Referring now to fig. 52-54, another surgical instrument system 25200 is shown. The system 25200 includes another type of missing cartridge and used cartridge latch arrangement. The system 25200 includes a firing member 25210 and a staple cartridge assembly 25220. The firing member 25210 includes a distally presented cutting portion 25211 configured to cut tissue as it is advanced through the system 25200. The firing member is configured to deploy a plurality of staples from the cartridge assembly 25220 by longitudinally advancing a sled 25221 through the cartridge assembly 25220. During a staple firing stroke, the sled 25221 can be moved from a proximal unfired position to a distal fully fired position. The sled 25221 is not retracted with the firing member 25210; however, embodiments are contemplated in which slider 25221 is at least partially retracted.

The surgical instrument system 25200 further includes a lockout member 25240. The lockout member 25240 is configured to prevent the firing member 25210 from advancing through its staple firing stroke when a cartridge is not present in the system 25200 or has been used, or is partially used, stored in the system 25200. The lockout member 25240 includes a first or proximal portion 25241 rotatably mounted to a first spine pin 25201 of the system 25200. For example, a spine pin 25201 may extend from an axle frame or spine of the system 25200. The latching member 25240 also includes a second portion 25242, a third or catch portion 25243, and a fourth or distal portion 25245. The latch member 25240 is movable between a locked position (fig. 52 and 54) and an unlocked position (fig. 53). When the cartridge assembly is not properly installed within system 25200, lockout member 25240 is spring biased to a locked position. When a used or partially used staple cartridge assembly is installed within system 25200, lockout member 25240 is also biased to the locked position.

When the lockout member 25240 is in its locked position as shown in fig. 52, a firing member pin 25213 mounted on the firing member 25210 is configured to abut a locking face or shoulder 25244 of the lockout member 25240. Due to lock face 25244, distal advancement of firing member 25210 is prevented beyond this position. To move the lockout member 25240 from its locked position to its unlocked position, an unused, ready to fire cartridge assembly must be installed within the system 25200. The unused, ready to fire cartridge assembly includes a sled 25221 in a proximal unfired position.

The slider 25221 includes a magnet 25226 oriented with one of its poles "P1" facing the distal portion 25245 of the latch member 25240 and the other pole "P2" facing away from the distal portion 25245 of the latch member 25240. The distal portion 25245 of the latching member 25240 includes a magnet 25246 disposed thereon. The magnet 25246 is oriented with the pole "P1" facing a similar pole "P1" of the slider magnet 25226, and the other pole "P2" away from the slider magnet 25226. The pole P1 of magnet 25226 and the pole P1 of magnet 25246 repel each other. This relationship creates a floating effect 25221 when the sled is in its proximal unfired position (fig. 53), which pushes or repels latch 25240 upward into its unlocked position, lifting lock face 25244 away from pin 25213 of firing member 25210 to allow pin 25213 to advance beyond lock face 25142. The firing member 25210 can then be advanced distally to deploy staples and cut tissue during a firing stroke.

When firing member 25210 is retracted after its firing stroke, pin 25213 is configured to contact the angled face of distal portion 25245 to push distal portion 25245 and, thus, latch member 25240 pushes the pin toward its unlatched position, allowing pin 25213 to pass through lock face 25244 when returning to its home position. Once pin 25213 passes lock face 25244, lockout member 25240 recoils or returns to its locked position to prevent repetitive firing strokes through a used or partially used staple cartridge installed in system 25100.

Similar to the system 25100 shown in fig. 50 and 51, the lockout member 25240 is configured to allow the firing member 25210 to move within a distance "y" to allow the jaws to be clamped and unclamped while relying on the firing member 25210 for the clamping and unclamping functions. The pin 25213 and firing member 25210 can therefore move within the latch portion 25243 of latch member 25240 even if a missing staple cartridge and/or a used staple cartridge is positioned in the system 25100.

Another surgical instrument system 25300 is shown in FIGS. 55-60. The system 25300 comprises another type of lockout arrangement, wherein the system 25300 is configured to be locked out when a cartridge is not installed in the system 25300. The system is also configured to be latched when a used or partially used cartridge is installed in the system 25300. The system 25300 includes a firing member 25310 and a cartridge assembly 25320. The firing member 25310 includes a distally presented cutting portion 25311 that is configured to cut tissue as it is advanced through the system 25300. The firing member 25310 is configured to deploy a plurality of staples from the staple cartridge assembly 25320 by longitudinally advancing a sled 25330 (fig. 56) through the staple cartridge assembly 25320. During the firing stroke, sled 25330 can be moved from a proximal unfired position to a distal fully fired position. In various circumstances, the sled 25230 is not retracted with the firing member 25310; however, embodiments are contemplated in which slider 25230 is at least partially retracted.

The surgical instrument system 25300 also includes a lockout member 25340. The lockout member 25340 is configured to prevent the firing member 25310 from being advanced through the staple firing stroke when a cartridge is not present in the system 25300 or has been used, or a partially used cartridge is present in the system 25300. The latching member 25340 is similar in many respects to the latching members 25140, 25240. Referring to fig. 58-60, the latching member 25340 includes a first or proximal portion 25341 rotatably mounted to a first spine pin 25301 of the system 25300. Alternatively, the proximal portion 25341 may be fixedly mounted to the spine 25301 of the system 25300. The latching member 25340 further includes a second portion 25342, a third or catch portion 25343, and a fourth or distal portion 25345. The latching member 25340 is movable between a locked position (fig. 58 and 60) and an unlocked position (fig. 59). When the cartridge assembly is not installed in the system 25300, the lockout member 25340 is spring biased to its locked position. When a used or partially used cartridge assembly is installed in the system 25300, the lockout member 25340 is also biased to its locked position.

Staple cartridge assembly 25320 comprises sled 25330 and a plurality of drive devices 25328 configured to eject staples as they are driven by ramps 25330a, 25330B, 25330C and 25330D of sled 25330. The staple cartridge assembly 25320 further comprises a control member that is movable between an unused position and a used position by the sled 25330 as the sled 25330 is advanced distally during its staple firing stroke. The control member is in its unused position when the staple cartridge 25320 is loaded into the surgical instrument system 25300 and is configured to move the lockout member 25340 from its locked position to its unlocked position when the unused staple cartridge assembly 25320 is loaded into the surgical instrument system 25300. A first configuration of the proximal drive means 25325 is shown in fig. 55 and 57. The proximal driver 25325 includes a driver wedge portion 25326 and a magnetic portion 25327. When the proximal drive 25325 is in its unused position and the sled 25330 is in its unfired position (fig. 59), the drive wedge portion 25326 is positioned within the sled notch 25331 and the magnetic portion 25327 is sufficiently close to the distal portion 25327 to cause the distal portion 25327 to move or lift the lockout member 25340 to its unlocked position.

A similar proximal drive configuration is shown in fig. 59 and 60. The proximal driver 25325' includes a driver wedge portion 25326' and a magnetic portion 25327 '. The wedge portion 25326' of the proximal driver 25325' is positioned on the proximal driver 25325' side. When the proximal drive 25325 is in its unused position and the sled 25330 is in its unfired position (fig. 59), the drive wedge portion 25326 is positioned within the sled notch 25331 and the magnetic portion 25327 is sufficiently close to the distal portion 25327 to cause the distal portion 25327 to move the locking member 25340 into its unlocked position. When the driver wedge portion 25326 'is positioned within the slider notch 25331, the magnetic portion 25327' is configured to hold the latch member 25340 in its unlocked position. When the sled 25330 is advanced distally from its unfired position, the sled 25330 drives the proximal driver 25325 'such that the driver wedge portion 25326' is driven out of the sled notch 25331. Thus, magnetic portion 25327' is no longer close enough to the latch member 25340 to hold the latch member in its unlocked position, and the latch member is therefore spring biased to its locked position (fig. 60). Reference "D" is defined as the top surface of slider 25330, and when the bottom of wedge portion 25326 'is aligned with or above reference D, the magnetic relationship between distal portion 25345 and magnetic portion 25327' is insufficient to hold latch member 25340 in its unlocked position, thus releasing latch member 25340.

Once the lockout member 25340 has been released to its locked position (fig. 60) and the mounted cartridge assembly 25320 has been at least partially used (fig. 60), the system 25300 is prevented from re-firing the same cartridge assembly 25320. When the firing member 25310 is retracted, the lockout pin 25312 overlies the distal portion to temporarily move the lockout member 25340 away until the lockout pin 25312 reaches the catch portion 25343. When the latching pin 25312 reaches the catch portion 25343, the latching member 25340 springs back or returns to its locked position. When in its used position, magnetic portion 25327' does not pull locking member 25340 into its unlocked position. In various circumstances, the proximal drive device 25325' can engage the cartridge assembly 25320 in a press-fit manner when the proximal drive device 25325' is moved to its used position by the sled 25330 to prevent the proximal drive device 25325' from falling toward its unused position. This arrangement may prevent the latching member 25340 from being mistakenly unlocked. In addition to the used cartridge assembly, in the event that a cartridge is not installed in the system 25300, the latching member is forced into its locked position. Only the absence of the proximal drive means may completely prevent the blocking member 25340 from moving to its unlocked position.

The control members 25325, 25325' are driven by the slider 25330 and may be referred to as a drive; however, they do not drive the staples. In this manner, the control members 25325, 25325' comprise "dummy" drives. That is, it is contemplated that the proximal-most staple driving device of the staple cartridge assembly may be used as the control member.

Another surgical instrument system is shown in fig. 61-63. The system 25400 includes a cartridge assembly 25410, lockout circuitry 25420, and a lockout member 25430. The latching member 25440 is fixedly attached to the ridge 25401 of the system 25400. The latch member 25430 also includes a spring member and is biased, for example, toward its locked position (fig. 63). When the lockout member 25430 is in its locked position, the hook portion 25431 of the lockout member 25430 is configured to latch the firing member when a surgical instrument or clinician attempts to advance the firing member beyond the lockout member 25440 without an unused cartridge assembly installed in the system 25400.

To move the lockout member 25440 to its unlocked position so that the firing member may be advanced through the cartridge module 25410 during a staple firing stroke, the electromagnet 25421 is employed. The electromagnet 25421 is disposed on the spine portion 25401 of the system 25400, but may be disposed at any suitable location within the system 25400. Conductors are positioned in the system 25400 along the spine portion 25401, for example, to power the electromagnets 25421. Lockout circuitry 25420, including electromagnet 25421 and its power supply, extends through the cartridge assembly 25410. As discussed below, when the circuit 25420 is on or closed, power is supplied to the electromagnet 25421. When the circuit is not on or open, the electromagnet 25421 is not energized. Also as discussed below, there are scenarios in the system 25400 where a used or partially used bin is an open circuit for the circuit 25420. The absence of bins in system 25400 is another scenario in which circuit 25420 is an open circuit.

The latching circuitry 25420 includes conductors 25422 extending from an electromagnet 25421 to a pair of electrical contacts 25423 positioned within the system 25400. The electrical contacts 25423 are positioned within the jaws of the system 25400, such as to receive a channel portion of the cartridge assembly 25410. The cartridge assembly 25410 further comprises a conductor leg 25425 configured to engage the contact 25423 when the cartridge assembly 25410 is fully seated in the channel portion of the jaws. The conductor leg 25425 is part of an electrical trace 25424 defined within the cartridge assembly 25410. Conductor legs 25425 are disposed on a proximal face 25412 of the cartridge assembly 25410. Also disposed on the proximal face 25412 is a severable portion 25426 of an electrical trace 25424 that extends across the slot 25411 of the cartridge assembly 25410. The cutting edge of the firing member is configured to sever or incise the severable portion 25426 during a staple firing stroke of the firing member.

When the cartridge assembly is installed and not in use, in addition to the above, the severable portion 25426 is not severed and the lockout circuit 25420 is on or closed. When the lockout circuit 25420 (fig. 62) is on, the electromagnet 25421 receives power urging the lockout member 25430 to its unlocked position, allowing the firing member to pass through. After the severable portion 25426 is severed or cut, the surgical instrument detects an unaccessed circuit during the firing stroke of the firing member. An open or not completed circuit indicates that the cartridge assembly 25410 is in the wrong configuration. This may be due to the installation of a used or partially used cartridge or the absence of a cartridge installed in the system 25400. When the circuit 25420 is not on (fig. 63), e.g., in the wrong configuration, the electromagnet 25421 is de-energized and releases the latching member 25430 to its locked position (fig. 63).

When the used cartridge assembly 25410 is removed from the surgical instrument system 25400, the lockout circuit 25420 remains in the open state and the electromagnet 25421 remains unpowered. When the unused cartridge assembly 25410 is fully seated in the system 25400, the lockout circuit 25420 is again closed and the electromagnet 25421 is re-energized to unlock the lockout member 25430. Notably, if the cartridge assembly 25410 is not fully seated in the system 25400, the legs 25425 will not engage the contacts 25423 and the lockout circuit 25420 will remain in an open, unenergized state.

Another surgical instrument system 25500 is shown in fig. 64 and 65. The system 25500 includes a staple cartridge 25501 that includes a sled 25510 that is movable between an unfired position and a fired position. The firing member 25503 is configured to move the sled 25510 from its unfired position to its fired position to deploy a plurality of staples (not shown) stored within the cartridge 25501 via the ramp 25511. The system 25500 further comprises a circuit 25520 configured to indicate to a user of the surgical instrument and/or the system 25500 whether a cartridge installed within the system 25500 is used or partially used, or whether a cartridge installed within the system 25500 is unused and ready to fire. When the sled 25510 is in its unfired position, the sled 25510 completes the electrical circuit 25520, and when the sled 25510 is in its fired or partially fired position, the sled 25510 does not complete the electrical circuit 25520 and the electrical circuit 25520 is an open circuit.

The lockout circuit 25520 includes, for example, a pair of conductors 25521 in electrical communication with the handle of the surgical instrument, and a pair of electrical contacts 25522 positioned within the jaw portion of the surgical instrument system 25500, which is configured to support the staple cartridge 25501. The electrical contacts 25522 are positioned such that corresponding pads or contacts 25523 disposed on the proximal face 25512 of the sled 25510 contact the electrical contacts 25522 when the staple cartridge 25501 is fully seated in the system 25500 and the sled 25510 is in its unfired position (fig. 65). The tether portion or conductor 25524 connects or electrically couples the contact 25523 and is attached to the proximal medial face 25513 of the slider 25510. Contact 25522 extends to the bottom surface of the slider beyond proximal face 25512. When the sled 25510 is in its unfired position, the contact 25523 is engaged with the lockout circuit 25520 and the closure circuit 25520 is completed indicating an unfired, ready to fire staple cartridge. When the lockout circuit 25520 is not closed, software and/or mechanical features, such as those disclosed herein, may be used to lockout the surgical instrument. In at least one instance, the lockout circuit 25520 is in signal communication with a controller of the surgical instrument system 255500 that powers the electric motor of the firing drive when the lockout circuit 25520 is in the closed state and prevents power from being supplied to the electric motor when the lockout circuit 25520 is open.

The firing member lockout arrangement of the system 25600 is shown in fig. 66-70. The system 25600 includes a firing member 25610, a latch 25620, and a shaft spine 25601. The shaft spine 25601 houses the latch 25620 and the firing member 25610. The firing member 25610 includes a distally presented cutting edge 25611 that is configured to incise tissue during a staple firing stroke of the firing member 25610. The latch 25620 is configured to latch the firing member 25610 when the latch 25620 is activated and allow the firing member 25610 to pass through. In addition to the above, the latch 25620 may be activated by a controller of the system 25600 when an unused staple cartridge is not positioned in the system 25600.

The latch 25620 includes a solenoid 25621 and a mechanical linkage that includes a first link 25623 and a second link 25624. The links 25623, 25624 are attached at pivot 25622. The solenoid 25621 is positioned within 25601 so that the solenoid 25621 can apply a force to the link near the pivot 25622. The latch 25620 is shown in a biased, locked position in fig. 66 and 67. Latch 25620 also includes a lock body or cam plate 25625 that is pivotally coupled to the end of second link 25624. The cam plate 25625 is biased to the knife strip window 25612 to latch the firing member 25610 when the solenoid 25621 is in its unactuated configuration, as shown in fig. 66 and 67.

In various circumstances, a plurality of windows are provided in the firing member 25610. Another window, such as window 25614, may include another proximal surface. The window 25614 may serve as an intermediate lockout to lock the firing member 25610 in operation. An event such as a knife stick may trigger the solenoid 25621 to release the latch 25620 to its locked position, preventing further actuation of the firing member 25610. In various circumstances, a distal surface of a window in the firing member 25610 can be configured such that when the firing member 25610 is retracted proximally, the cam plate 25625 can ride over the distal surface to prevent locking of the firing member 25610 as the firing member 25610 is moved proximally. In other instances, it may be desirable to lock the firing member 25610 as it moves proximally.

In some cases, the latch may be configured to allow movement in one direction, but prevent movement in another direction. For example, a slight retraction of the firing member 25610 may be desirable when the distal movement of the firing member 25610 has been blocked. In such instances, when proximally retracted, the tissue within the area surrounded by the firing member 25610 may naturally decompress and after waiting a defined period of tissue decompression, the solenoid 25621 may be activated to move the latch 25620 to its unlocked position (fig. 68 and 69), thus allowing the firing member 25610 to be advanced distally again.

Fig. 68-70 show the latch 25620 in an unlocked position. After comparing fig. 66 and 67 with fig. 68-70, it can be seen that upon actuation, the solenoid 25621 moves the mechanical link into a collinear configuration to slide or force the cam plate 25625 out of the window 25612, unlocking the firing member 25610. A slider support 25603 is provided within the ridge 25601 to guide the cam plate 25625 as the solenoid valve 25621 moves the mechanical link. In at least one instance, the slider support 25603 controls the movement of the cam plate 25625 to, for example, a linear path.

Various embodiments disclosed herein include a lockout configured to prevent distal advancement of a firing member under certain conditions. In many cases, the lockout is sufficient to prevent distal advancement of the firing member. In some instances, it may be desirable to have more than one lockout configured to prevent distal advancement of the firing member. In such instances, the primary and secondary latches may prevent distal advancement of the firing member. As described in more detail below, the secondary latch may be actuated as a result of actuating the primary latch. For example, the primary lockout may prevent distal advancement of the firing member due to the loading unit lacking a cartridge jaw, the cartridge jaw not being properly attached to the loading unit, and/or the jaw of the cartridge having been at least partially fired before, and the secondary lockout may be actuated to assist the primary lockout in preventing distal advancement of the firing member when distal displacement of the firing member is impeded by the primary lockout.

Turning now to fig. 82 and 83, the loading unit includes a shaft 21730 and a firing member system extending through the shaft 21730. The firing member system includes a first or proximal firing member 21760 and a second or distal firing member 21762. During the staple firing stroke of the firing member system, the proximal firing member 21760 is pushed distally by, for example, an electric motor and/or a hand crank. Likewise, the distal firing member 21762 is pushed distally by the proximal firing member 21760. The firing member system also includes a lockout 21780 positioned intermediate the proximal and distal firing members 21760, 21762. The latch 21780 is configured to transmit a firing force from the proximal firing member 21760 to the distal firing member 21762 during a staple firing stroke. In the event that the force transmitted through the lockout 21780 exceeds the expected firing force during the staple firing stroke, and/or exceeds a predetermined threshold force, the lockout 21780 enters a locked configuration, as shown in fig. 83, and described in more detail below.

The lockout 21780 includes a lock arm 21782 pivotally mounted to the proximal firing member 21760 at pivot 21784. The lock arm 21782 is configured to abut a drive surface 21768 defined on a proximal end of the firing member 21762 and to push the firing member 21762 distally. In at least one instance, the drive surface 21768 forms a tapered surface, for example. The latch 21780 also includes a biasing member or spring 21785 configured to bias the lock arms 21782 inward against the drive surface 21768 toward an unlocked configuration, as shown in fig. 82. Each locking arm 21782 includes a pin 21783 extending therefrom that is configured to mount an end of a spring 21785 thereto. When the latch 21780 enters the locked configuration, in addition to the above, the lock arms 21782 slide relative to the drive surface 21768 and expand or rotate outward into engagement with the shaft 21730. The shaft 21730 includes racks 21781 defined therein that are engaged by the lock arm 21782 and prevent distal advancement of the proximal firing member 21760.

In addition to the above, when the lock arm 21782 is displaced outward, the spring 21785 is elastically stretched. The stiffness of the spring 21785 is selected such that when the force transmitted from the proximal firing member 21760 to the distal firing member 21762 is below a threshold force, the spring 21785 can retain the lock arm 21782 against the drive surface 21768 in its unlocked configuration, also allowing the lock arm 21782 to move outward when the force transmitted from the proximal firing member 21760 to the distal firing member 21762 exceeds the threshold force. The force transmitted between the proximal firing member 21760 and the distal firing member 21762 is below a threshold force when the proximal firing system fires staples from the staple cartridge and above the threshold force when the distal firing member 21760 is arrested by, for example, a missing cartridge and/or a used cartridge lockout. In such instances, the latch 21780 is deployed in response to the other latch, thereby preventing advancement of the staple firing system. In other words, the latch 21780 may include a secondary latch that cooperates with the primary latch to prevent advancement of the staple firing system.

In various circumstances, in addition to the above, the latch 21780 can provide overload protection to the staple firing system. For example, the staple firing system can jam during the firing stroke and the lockout 21780 can be deployed to stop the staple firing stroke. In such a case, latch 21780 may transmit the firing force or at least a portion of the firing force to shaft 21730 instead of the staple cartridge. Thus, the lockout 21780 may prevent the firing system and/or staple cartridge from being damaged or at least damaged further. In such cases, the latch 21780 is deployed in response to a condition of the stapling assembly outside of the predetermined latch. Referring again to fig. 82 and 83, the rack 21781 is the same length or longer than the first stroke of the staple firing system such that the latch 21780 can engage the rack 21781 at any point during the firing stroke.

When the force transmitted from the proximal firing member 21760 to the distal firing member 21762 falls below a force threshold, the spring 21785 can resiliently return the lock arm 21782 to its unlocked configuration and into engagement with the drive surface 21768 of the distal firing member 21762. At this point, if the conditions that caused actuation of the secondary latch 21780 have subsided, the firing stroke may be completed. Otherwise, the proximal firing member 21760 may be retracted.

Turning now to fig. 92-95, the loading unit includes a shaft 246530 and a staple firing system extending through the shaft 246530. The staple firing system includes a proximal firing member 2460 and a distal firing member 24562. During a staple firing stroke of the staple firing system, the proximal firing member 2460 is pushed distally by, for example, an electric motor and/or a hand crank. Likewise, the distal firing member 24562 is pushed distally by the proximal firing member 24560. The staple firing system also includes a lockout 245480 positioned intermediate the proximal and distal firing members 245760, 24562. The lockout 24522 is configured to transmit firing forces from the proximal firing member 2460 to the distal firing member 24562 during a staple firing stroke. In the event that the force transmitted through the latch 24560 during the staple firing stroke exceeds the expected firing force, and/or exceeds a predetermined threshold force, the latch 245780 enters a locked configuration, as shown in fig. 94 and 95.

Referring primarily to fig. 93 and 95, the latch 245780 includes, for example, a substantially C-shaped configuration that extends around a portion of the distal firing member 24562. The latch 24409 includes lock arms 24584 that grip the distal firing member 24562 when the latch 24409 is in its unactuated or unlocked configuration, as shown in fig. 92 and 93. The lockout 245780 also includes a drive tab 24526 that is contacted by the proximal firing member 2460 as the proximal firing member 2460 is driven distally during the staple firing stroke of the staple firing system. When the latches 24284 are pushed distally by the proximal firing member 24560, the latches 24284 abut a drive surface 24562 defined on the distal firing member 24562 and push the distal firing member 24562 distally. Thus, the latch 245780 transmits a pushing force from the proximal firing member 24560 into the drive surface 24562 through the lock arm 24584.

Referring primarily to FIG. 92, drive tab 2482 is not coplanar with locking arm 24584; instead, drive tab 24526 extends laterally from the plane defined by lock arm 24584. More specifically, at least when the latch 245780 is in its unactuated configuration, the drive tab 24526 includes an elevated portion that flips from the lock arm 24584. The latch 24522 is configured to remain in its unactuated configuration as long as the thrust force transmitted through the latch 24522 is below a threshold force. The impulse force required to complete the firing stroke is below the threshold force. When the urging force through the transmission latch 245780 exceeds a threshold force, the latch 245780 contracts to its actuated configuration, as shown in fig. 94 and 95. For example, the urging force can exceed a threshold force when the distal firing member 24562 abuts a missing staple cartridge, such as in a staple cartridge, and/or a staple cartridge lockout has been used.

Referring again to fig. 94 and 95, when latch 24would move to its actuated configuration, locking arms 24584 expand radially outward to engage shaft 245730. In at least one instance, shaft 245730 can include a recess 24576 defined therein that is configured to receive locking arm 24584. A recess 24576 is defined in shaft 245730 such that lock arm 24584 aligns with recess 24576 when distal advancement of the firing system is prevented by an absent cartridge and/or a used cartridge lockout. Once lock arm 24584 is in recess 245634, latch 245480 can prevent distal advancement of the firing system. In various circumstances, the recess 245734 is positioned and arranged to stop the firing member 24560 before a cutting member of the firing drive incises tissue. When the proximal firing member 2460 is retracted and the pushing load applied to the latches 245480 drops below a threshold force, the latches 245480 can resiliently return to their unactuated configuration. At this point, an unused cartridge may be placed in the loading unit to disable the missing cartridge and/or the used cartridge lockout so that the firing system may be advanced distally through its staple firing stroke. At any point, however, the proximal firing member 2460 can be retracted to retract the distal firing member 24562.

The threshold force of the lockout described above may be actuated if the staple firing system accelerates too quickly. In other words, acceleration peaks in the staple firing system may result in force peaks that exceed a threshold force of the lockout that causes the lockout to stop the staple firing system. Such a situation may occur when a firing trigger mechanically coupled to the staple firing system is squeezed too quickly and/or a power source is suddenly applied to, for example, an electric motor of the staple firing system. In at least one instance, acceleration spikes can occur when, for example, the power applied to the electric motor is incorrectly modulated and/or when a software failure occurs in the motor controller. Such acceleration and force spikes are typically transient and the firing stroke may be completed when the force transmitted through the staple firing system drops back below a threshold force.

Turning now to FIG. 84, the stapling assembly includes a shaft 21830 and a firing member 21860 extending therethrough. The suturing assembly also includes a lockout system 21880. The lockout system 21880 includes a lock arm 21882 that is rotatably mounted to the staple firing member 21860 about a pivot 21884. Each locking arm 21882 is rotatable between an unactuated position (shown in solid lines in FIG. 84) and an actuated position (shown in phantom lines in FIG. 84). The lockout system 21880 further includes a cantilever spring 21885 mounted to the staple firing member 21860 and configured to bias the lock arm 21882 to its unactuated position. The stapling assembly further comprises an actuator 21862 mounted to the firing member 21860 and configured to slide or drag against the housing of the shaft 21830 as the firing member 21860 is moved distally. When the firing member 21860 is accelerated too quickly or above a threshold level, drag between the actuator 21862 and the shaft 21830 will slow or clamp the actuator 21862 and allow the firing member 21860 to slide relative to the actuator 21862. In such instances, relative movement between the actuator 21862 and the firing member 21860 causes the locking arm 21882 to outwardly engage a rack 21881 defined in the shaft 21830 to stop, hinder or slow the distal progression of the staple firing system.

Turning now to fig. 85, the stapling assembly includes a shaft 21930 and a firing member 21960 that is configured to translate within the shaft 21930. The stapling assembly further includes a lockout system 21980 that includes a lock arm 21982 rotatably mounted to the staple firing member 21960 about a pivot 21984. Locking arm 21982 is rotatable between an unactuated position (shown in solid lines in FIG. 85) and an actuated position (shown in phantom lines in FIG. 85). The lockout system 21980 further includes a coil spring 21985 mounted to the staple firing member 21960 and a lock arm 21982 configured to bias the lock arm 21982 to its unactuated position. The lockout system 21980 further includes an actuator or weight 21989 mounted to the lock arm 21982 that is configured to rotate the lock arm 21982 via inertia as the firing member 21960 is accelerated distally. When the firing member 21960 is too fast or above a threshold level, the inertial force generated by the weight 21989 is sufficient to overcome the biasing force of the spring 21985 and rotate the locking arm 21982 into engagement with the rack 21981 defined in the shaft 21930. In such instances, the lockout system 21890 will stop, hinder, or slow the distal progression of the staple firing system until the acceleration of the firing member 21960 drops below a threshold and the spring 21985 may pull the lock arm 21982 out of engagement with the rack 21981.

In addition to or in lieu of the foregoing, the stapling assembly can include a means for adjusting the speed of the staple firing system that can reduce or smooth acceleration spikes generated within the staple firing system under various conditions. Turning now to fig. 86, the stapling assembly can comprise a shaft 22030 and a staple firing member 22060 configured to translate within the shaft 22030. The stapling assembly further comprises a damping system 22080 comprising a damping member or bumper 22081 configured to slow the distal and/or proximal translation of the staple firing member 22060. The damping member 22081 is constructed of a compliant and/or elastomeric material (e.g., rubber) configured to generate a damping force opposing the thrust force applied to the firing member 22060 when the firing member 22060 contacts the damping member 22081. The firing member 22060 extends through an aperture defined in the damping member 22081 and includes an annular ridge 22082 configured to engage the damping member 22081. Although only one shock absorbing member 22081 and shaft ridge 22082 are shown in fig. 86, the stapling assembly can include any suitable number of, for example, damping members 22081 and/or shaft ridges 22082.

In addition to the above, the bumper 22081 is positioned within the shaft 22030 such that the ridge 22082 contacts the bumper 22081 before the firing member 22060 reaches a missing cartridge and/or a used cartridge lockout. In such circumstances, the damping system 22080 can reduce the speed of the firing member 22060 before the firing member 22060 reaches the lockout, thus reducing the likelihood that the firing member 22060 will be broken by the lockout or inadvertently fail the lockout.

Turning now to fig. 87, the stapling assembly can comprise a shaft 22130 and a staple firing member 22160 configured to translate within the shaft 22130. The stapling assembly further comprises a hydraulic damping system 22180 comprising a cartridge assembly configured to slow the firing member 22160 during its staple firing stroke. The cartridge assembly includes an input piston 22181 slidably positioned in chamber 22183 that sealingly engages the side walls of chamber 22183. The cartridge assembly also includes an output piston 22184 slidably positioned in chamber 22185, which sealingly engages the side walls of chamber 22185. As shown in fig. 87, a portion of chamber 22183 is in fluid communication with a portion of chamber 22185 via restricted aperture 22189. An incompressible or substantially incompressible fluid 22182 is contained in chambers 22183 and 22185 between input piston 22181 and output piston 22184. In at least one instance, fluid 22182 comprises, for example, a hydraulic fluid. In some cases, fluid 22182 comprises, for example, saline. As the firing member 22160 is advanced distally, the firing member 22160 or a shoulder defined on the firing member 22160 contacts a cam or angled surface defined on the input piston 22181 and drives the input piston downward into the chamber 22183. In such cases, input piston 22181 moves fluid 22182 into chamber 22185, which in turn displaces output piston 22184 within chamber 22185. Movement of output piston 22184, fluid 22182, and input piston 22181 is resisted by a spring 22186 positioned in chamber 22185. As a result of the above, the damping system 22180 applies a drag force to the firing member 22160 that increases proportionally with the increase in the velocity of the firing member 22160 and can limit the maximum velocity of the firing member 22160. Similar to the above, the damping system 22180 can be positioned in the shaft 22130 such that the firing member 22160 contacts the damping system 22180 just, or at least, before the firing member 22160 reaches the lockout.

Turning now to fig. 89, the stapling assembly can comprise a shaft 22330 and a firing member 22360 that can slide within the shaft 22330. The stapling assembly further comprises a pneumatic piston arrangement 22380 configured to apply a drag force to the firing member 22360. The firing member 22360 includes a cylindrical, or at least substantially cylindrical, rod that extends through a support defined in the shaft 22330; and an integrally formed piston 22362 slidably positioned within a barrel 22383 defined in the shaft 22330. The piston arrangement 22380 includes one or more piston seals 22382 disposed within a seal groove extending around the piston 22362. Piston seal 22382 sealingly engages piston 22362 and the wall 22381 of barrel 22383. The piston arrangement 22380 also includes one or more seals 22361 that are disposed within seal grooves defined in the shaft support that sealingly engage the shaft 22330 and the firing member 22360. In various instances, the seals 22361 and 22383 comprise, for example, compliant O-rings. In any event, distal displacement of the firing member 22360 compresses air in the cartridge 22383 and forces the compressed air through the air vent 22363 defined in the shaft 22330. This arrangement applies a drag force to the firing member 22360 that increases in proportion to the speed of the firing member 22360.

In addition to the above, the diameter and/or length of the vent 22363 can be selected to limit the speed of the firing member 22360 in a desired manner. In addition, the seal 22382 sealingly engages the shaft 22330 as the firing member 22360 is advanced distally and retracted proximally, thus the piston arrangement 22380 applies a drag force to the firing member 22360 as the firing member 22360 is advanced distally and retracted proximally. In at least one embodiment, a valve (e.g., a one-way valve) may be positioned and disposed relative to the vent 22363. The valve can provide an aperture with a smaller diameter when the firing member 22360 is advanced distally and a larger diameter when the firing member 22360 is retracted proximally. In such instances, the vent can apply a greater drag force to the firing member 22360 as the firing member 22360 is advanced distally at a given speed as compared to when the firing member 22360 is retracted proximally. Thus, the valve may provide different directional speed limits.

Turning now to fig. 88, the stapling assembly can comprise a staple firing shaft 22060 that is moved distally to eject the staples from the staple cartridge. The stapling assembly further comprises a means for applying an electromagnetic and/or magnetic drag force to the staple firing shaft 22260. In at least one instance, the stapling assembly includes a wound conductor coil 22280 that is powered by a power source, such as a battery, such that current flows through the coil 22280. The wound conductor coil 22280, upon energization, generates a magnetic field that interacts with a magnetic element 22282 defined in and/or attached to the shaft 22260. In at least one instance, magnetic element 22282 comprises a permanent magnet, for example. A polarity of the power source is applied to the coil 22280 such that the coil 22280 generates a magnetic field that applies a repulsive force to the ferromagnetic element 22282 as the firing member 22260 approaches the coil 22280, thereby applying a drag force to the firing member 22360 during the staple firing stroke. The strength or strength of the magnetic field generated by the coil 22280 is stronger near the coil 22280, and thus the drag force applied to the firing member 22360 will be greater than the drag force near the coil 22280.

As such, the coil 22280 can act as a brake when energized, and in some cases, stop, or at least assist in stopping, the longitudinal movement of the firing member 22360 at the end of, for example, a staple firing stroke. In certain instances, the polarity of the voltage applied to the coil 22280 can be reversed to reverse the current flowing through the coil 22280 during the retraction stroke of the firing member 22360. In this instance, the coil 22280 can apply a braking force to the firing member 22360 as the firing member 22360 is retracted away from the coil 22280. Although only one coil 22280 is shown in fig. 88, the stapling assembly can include any suitable number of energizable coils. In addition to or in lieu of the foregoing, the stapling assembly can include one or more permanent magnets mounted to a shaft of the stapling assembly that can apply a magnetic braking force to the staple firing member.

Referring again to fig. 88, in at least one embodiment, power is not applied to the coil 22280 and the coil 22280 may act as an electric/inductive brake. In such embodiments, movement of the magnetic element 22282 through the coil 22280 generates an electrical current in the coil 22280, which in turn generates a magnetic field that opposes the movement of the magnetic element 22282. When the magnetic element 22282 is moved slowly relative to the coil 22280, the opposing magnetic field exerts a negligible braking force on the firing member 22260. When the magnetic element 22282 is moved rapidly relative to the coil 22280, the opposing magnetic field is much stronger and a much stronger braking force is applied to the firing member 22260. The coils 22280 and magnetic elements 22282 can be positioned and arranged such that a braking force is applied to the firing member 22260 just before, or at least until, the firing member 22260 reaches the missing cartridge and/or used cartridge lockout.

As described above, the firing member of the staple firing system may be driven by an electric motor. A motor controller including a processor and which may be implemented as a microcontroller may be utilized to control the voltage supplied to the electric motor and, thus, the speed of the staple firing member. In some cases, the motor controller may utilize Pulse Width Modulation (PWM) and/or Frequency Modulation (FM) to, for example, control the speed of the electric motor. In other cases, the motor controller may not modulate the power supplied to the electric motor. In either case, the stapling assembly can include a sensor system in communication with the motor controller that is configured to detect whether an unused staple cartridge or an unused staple cartridge jaw has been attached to the stapling assembly. In the event that the sensor system detects that an unused staple cartridge is attached to the stapling assembly, when a user of the stapling assembly actuates the staple firing system, the motor controller may identify a signal from the sensor system indicating the presence of the unused staple cartridge and operate the electric motor of the staple firing system. When the sensor system does not detect an unused staple cartridge attached to the stapling assembly, the motor controller receives a signal from the sensor system indicating that the unused cartridge is not attached to the stapling assembly and prevents the electric motor from operating the staple firing system. Such an arrangement may include an electronic or software latch.

In addition to or in lieu of the foregoing, the stapling system can include a sensor system configured to track the movement of the staple firing member. Referring to fig. 90, the staple firing member 22460 of the stapling assembly 22400 is movable between a proximal unfired position and a distal fired position along a staple firing path 22463. For example, a detectable magnetic element 22461 is mounted to a staple firing member 22460 that moves along, or at least substantially along, a staple firing path 22463. In at least one instance, the magnetic element 22461 is, for example, a permanent magnet composed of iron, nickel, and/or any other suitable material. The sensor system includes a first or proximal sensor 22401' and a second or distal sensor 22401 that are configured to detect the magnetic element 22461 as it is moved along the staple firing path 22463 by the translatable member 22460. The first and second sensors 22401' and 22401 each comprise a hall effect sensor; however, sensors 22401' and 22401 "may include any suitable sensors. The sensors 22401' and 22401 output a voltage that varies according to their respective distances from the magnetic element 22461 (a higher voltage is output when the distance is smaller, and a lower voltage is output when the distance is larger).

In addition to the above, the sensor system includes a sensor circuit including, for example, a voltage source 22403 or the like that communicates with the sensors 22401 'and 22401, which supplies power to the sensors 22401' and 22401. The sensor circuit also includes a first switch 22405 'in communication with the first sensor 22401' and a second switch 22405 in communication with the second sensor 22401. In at least one instance, switches 22401' and 22401 each comprise a transistor, such as a FET. The outputs 22401', 22401 of the sensors are connected to the central (gate) terminals of the switches 22405', 22405, respectively. Prior to the firing stroke of the staple firing member 22460, the output voltage from the sensors 22401', 22401 is high, so that the first and second switches 22405' and 22405 are in a closed state.

When the magnetic element 22461 passes through the first sensor 22401', the voltage output of the first sensor 22401' is sufficient to alter the first switch between a closed state and an open state. Similarly, when the magnetic element 22461 passes through the second sensor 22401, the voltage output of the second sensor 22401 is sufficient to alter the second switch 22405 between a closed state and an open state. When both the switches 22405' and 22405 are in an open state, a ground potential is applied to the operational amplifier circuit 22406. The op amp circuit 22406 is in signal communication with an input channel of the microcontroller 22490 of the motor controller, and when ground potential is applied to the op amp circuit 22406, the microcontroller 22490 receives a ground signal from the circuit 22406.

When the microcontroller 22490 receives an earth signal from the circuit 22406, the microcontroller 22490 can determine that the staple firing stroke has been completed and that the staple cartridge positioned in the stapling assembly 22400 has been fully used. Other embodiments are contemplated wherein the sensor system is configured to detect a partial firing stroke of staple firing member 22460 and provide a signal to microcontroller 22490 indicating that the staple cartridge has been at least partially used. In either case, the motor controller may be configured to prevent firing member 22460 from performing another firing stroke until the staple cartridge is replaced with an unused cartridge. In at least one instance, in addition to the above, the sensor system includes a sensor configured to detect whether a used cartridge has been detached from the stapling assembly and/or whether an unused cartridge has been assembled to the stapling assembly.

In addition to the above, a sensor system may be configured to detect whether firing member 22460 has been retracted along retraction path 22462. In at least one instance, the magnetic element 22461 may be detected by the sensor 22401 as the magnetic element 22461 retracts along the path 22462 and changes the second switch 22405 back to the closed state. Similarly, the magnetic element 22461 may be detected by the sensor 22401 'as the magnetic element 22461 retracts along the path 22463 and changes the first switch 22405' back to the closed state. By closing switches 22405 and 22405', the polarity of the voltage from battery 22403 is applied to circuit 22406, and, as a result, microprocessor 22490 receives a Vcc signal from circuit 22406 on its input path. In various circumstances, the motor controller may be configured to prevent the electric motor from being operated to perform another staple firing stroke until firing member 22460 has been fully retracted.

A stapling assembly 25700 is shown in fig. 71-74, which includes a staple cartridge 25730, a firing member 25760, and a lockout 25780. The staple cartridge 25730 includes a sled 25770 that is pushed distally by the firing member 25760 during the staple firing stroke of firing member 25760. During a staple firing stroke, the firing member 25760 pushes the sled 25770 distally from a proximal unfired position (fig. 71 and 72) toward a distal fired position (fig. 73 and 74). Sled 25770 is configured to slide under removably stored staples defined in staple cavities in staple cartridge 25730 and eject the staples from the staple cavities. In various instances, staple cartridge 25730 includes staple driving devices that, on the one hand, support the staples in the staple cartridge and, on the other hand, are driven by sled 25770 to eject the staples from the staple cavities. After the staple firing stroke of the firing member 25760 is completed, the firing member 25760 is retracted proximally. Notably, sled 25770 is not retracted proximally with firing member 25760.

In addition to the above, the latch 25780 includes a latch arm 25782. Each lock arm 25782 includes a cantilever beam including a first end mounted to a shaft of the stapling assembly 25700 and a movable second end configured to engage the firing member 25760. The firing member 25760 includes a lock aperture 25762 defined therein that is configured to receive a second end of the lock arm 25782. But when the sled 25770 is in its proximal, unfired position (fig. 71 and 72), the sled 25770 deflects the lock arm 25782 laterally away from the firing member 25760 and retains the lock arm 25782 out of the lock aperture 25762. Thus, when the staple cartridge 25730 is positioned in the stapling assembly 25700 and the sled 25770 of the staple cartridge 25730 is in its unfired position, the lockout 25780 does not prevent the firing member 25760 from performing a staple firing stroke. As the firing member 25760 advances distally during its staple firing stroke, the lockout apertures 25762 defined in the firing member 25760 are no longer aligned with the lock arm 25782, and thus the lock arm 25782 does not interfere with stapling the staple firing stroke once it begins. Following the staple firing stroke of the firing member 25760, the firing member 25760 is retracted proximally to its unfired position, as shown in fig. 73 and 74. At this point, the lock hole 25762 is realigned with the lock arm 25782, and when the slide 25770 is not returned to its unfired position, the lock arm 25782 can enter the lock hole 25762 and lockout the firing member 25760.

As a result of the above, the latches 25780 include missing cartridge latches and used cartridge latches. Alternative embodiments are contemplated in which the staple cartridge 25730 cannot be removed from the stapling assembly 25700. In such embodiments, the latch 25780 would comprise a used cartridge latch.

Referring to fig. 75 and 76, the stapling assembly 25800 comprises a staple cartridge 25830 comprising a cartridge body 25831, a sled 25870 distally movable in the cartridge body 25831 and a staple drive 25880. The cartridge body includes staple cavities 25832 defined therein, as well as staples removably stored in staple cavities 25832. The sled 25870 can distally translate between a proximal unfired position (fig. 75) and a distal fired position during a staple firing stroke. During the staple firing stroke, the sled 25870 contacts the staple driver 25880 and drives the staple driver 25880 upwardly within the staple cavity 25832, as shown in fig. 76. Notably, cartridge body 25831 includes several longitudinal rows of staple cavities 25832 defined therein, and staple drivers 25880 are arranged in longitudinal rows that are aligned with the longitudinal rows of staple cavities 25832. During the staple firing stroke of the sled 25870, the staple driver 25880 and staples are sequentially driven as the sled 25870 advances distally. In other words, the proximal-most drive device 25880 and staples are fired prior to firing the distal-most drive device 25880 and staples. In various circumstances, the firing of the proximal-most staple drive 25880 is indicative of the beginning of the staple firing stroke.

Referring again to fig. 75 and 76, the staple cartridge 25830 includes a lockout circuit configured to detect whether the staple cartridge 25830 has been at least partially fired. A portion of the latching circuit extends through cartridge body 25831 and includes electrical contacts 25834. Another portion of the lockout circuit extends through the proximal-most staple driving device 25880 and includes electrical contacts 25884 that are aligned with the electrical contacts 25834. When the staple cartridge 25830 is in its unfired state (fig. 75), the driver contacts 25884 abut the cartridge body contacts 25834 and, thus, the lockout circuit is in a closed state. When the proximal-most staple driver 25880 is lifted upward by sled 25870, the driver contacts 25884 disengage from the cartridge body contacts 25834 and the lockout circuit is opened. The lockout circuit is in signal communication with a controller of the stapling assembly 25800 that is configured to interpret that the lockout circuit is open meaning that the staple cartridge 25830 in the stapling assembly 25800 has been at least partially fired and that the staple firing system should not be operated a second time or once in addition to being operated without the staple cartridge 25830 being replaced with an unused staple cartridge 25830. Once the unused staple cartridge 25830 is positioned in the stapling assembly 25800 and the lockout circuit is closed by the unused staple cartridge 25830, the controller can allow the staple firing system to operate again.

In each case, referring again to FIG. 76, the proximal-most staple driving device 25880 is in slight friction fit engagement with the sidewalls of staple cavity 25832. Thus, the proximal-most staple driver 25880 remains in its fired position after it is lifted upward by sled 25870, and thus, once the lockout circuit is opened, the hold driver contacts 25884 are out of contact with the cartridge body contacts 25834 and the likelihood of the lockout circuit reclosing is reduced.

As described above, the staple firing stroke of the staple cartridge 25830 opens the lockout circuit. In an alternative embodiment, the staple firing stroke of the staple cartridge can close the lockout circuit. In such embodiments, the controller of the stapling assembly may interpret the closure of the lockout circuit to mean that the staple cartridge has been at least partially fired and that the staple firing system should not be operated a second time or once in addition to being operated without the staple cartridge being replaced with an unused staple cartridge.

In addition to, or in lieu of, the above, the stapling assembly can include a detection circuit configured to detect that the distal-most staple drive 25880 and the staples have been fired. In at least one such case, the distal-most staple driving device 25880 can have the contact arrangement described above and/or any other suitable arrangement that changes the state of the detection circuit. The controller of the stapling assembly may interpret the change in state of the detection circuit as meaning, for example, that the staple cartridge has been fully fired and that the staple firing system should be retracted.

Turning now to fig. 77 and 78, the stapling assembly 25900 includes a shaft 25910, an anvil jaw 25920, and a cartridge jaw removably attached to the frame of the shaft 25910. The stapling assembly 25900 further comprises an articulation joint 25940 configured to allow the anvil jaw 25920 and the cartridge jaw to articulate relative to the shaft 25910. Similar to the embodiments described herein, the cartridge jaw is movable between an open position and a closed position to clamp tissue of a patient against the anvil jaw 25920.

The stapling assembly 25900 further comprises a lockout circuit 25980 configured to detect that the cartridge jaw is in its closed position. The lockout circuit 25980 includes a conductor 25984 extending through the shaft 25910 and an electrode pad 25982 positioned in the anvil jaw 25920. The conductor 25984 communicates the electrode pad 25982 with a controller of the suturing assembly 25900, and in various circumstances, the controller can apply a voltage potential across the conductor 25984 to generate a monitoring current within the lockout circuit 25980. As described in more detail below, the controller is configured to evaluate the impedance and/or resistivity of the latch circuit 25980 and monitor changes in the impedance and/or resistivity of the latch circuit 25980 by monitoring the current.

In addition to the above, referring primarily to FIG. 78, the cartridge jaw includes a pin 25932 configured to pierce and/or deform electrode pad 25982 when the cartridge jaw is moved to its closed position. The pin 25932 is constructed of, for example, stainless steel, and breaks the impedance and/or resistivity of the lockout circuit 25980 as detected by the controller. Such a disruption can inform the controller that, on the one hand, the cartridge jaw has been attached to the stapling assembly 25900 and, on the other hand, the cartridge jaw has been closed. At this point, the controller can electronically unlock the staple firing system and allow the staple firing system to execute its staple firing stroke. In at least one such case, the staple firing system includes a motor and a battery, wherein the controller includes an electronic or software lockout that prevents the battery from supplying sufficient power to the electric motor to perform a staple firing stroke until the controller detects a sufficient parameter change in the lockout circuit 25980. Thus, the staple firing system of the stapling assembly 25900 cannot be operated until the staple cartridge jaws have been closed.

Referring again to fig. 77, the lockout circuit 25980 extends through the shaft 25910 and the anvil jaw 25920, but does not extend through the cartridge jaw. Although pin 25932 of the cartridge jaw breaks the lockout circuit 25980 as described above, pin 25932 is electrically isolated within the cartridge jaw and does not close or open the lockout circuit 25980.

Alternatively, referring again to fig. 77 and 78, the pin 25932 is part of the lockout circuit 25980 and the electrode pads 25982 include contacts that are pierced by the pin 25932. In such embodiments, when pin 25932 engages electrode pad 25982, pin 25932 closes a latching circuit so that a sense current can flow between pin 25932 and electrode pad 25982. In at least one instance, the electrode pads 25982 can be constructed of a self-healing material, such as a conductive gel. In various instances, the pin 25932 may pierce tissue prior to entering the electrode pad 25982. Referring again to fig. 77, electrode pads 25982 may include a wiping pad 25983 configured to at least partially clean pin 25932 prior to pin 25932 entering electrode pad 25982.

Referring to fig. 79 and 80, the shaft 25910 includes an outer housing 25911 that includes a longitudinal slot 25912 defined therein that is configured to slidably receive a firing member 25960. A longitudinal slot 25912 extends through the articulation joint 25940 and into the anvil jaw 25920 and the cartridge jaw. When the anvil jaw 25920 and the cartridge jaw are in the unarticulated orientation, the longitudinal slot 25912 is straight or includes no change in direction. The longitudinal slot 25912 includes a change in direction when the anvil jaw 25920 and the cartridge jaw are in an articulated orientation. Thus, the firing member 25960 needs to be flexible enough to pass through the articulation joint 25940. However, such flexibility of the firing member 25960 can cause the firing member 25960 to bend during a staple firing stroke. To prevent or reduce such bending, the stapling assembly 25900 further comprises anti-bending or anti-fracture plates 25944 positioned on opposite sides of the firing member 25960 and configured to support the firing member 25960 within and/or adjacent to the articulation joint 25940. In at least one instance, the anti-flex plate 25944 is positioned proximally in the shaft 25910 relative to the articulation joint 25940.

In addition to the above, the shaft 25910 and the articulation joint 25940 include wiring channels defined therein that are configured to receive the conductors 25984 of the lockout circuit 25980. For example, the shaft 25910 includes a channel 25915 defined in the outer housing 25911 of the shaft 25910. In at least one such case, the first conductor 25984 extends through the first channel 25915 and the second conductor 25984 extends through the second channel 25915. In addition, each bend resistant panel 25984 includes a channel 25945 defined therein that is configured to receive a conductor 25984. The channel 25945 is aligned, or at least substantially aligned, with the channel 25915.

Referring to FIG. 81, staple cartridge 26230 includes a longitudinal slot 26231 and a row of longitudinal staple cavities 26232 defined therein. During a staple firing stroke, a firing member, such as firing member 25960, is configured to slide within the longitudinal slot 26231 to distally advance a sled, such as sled 25770, to eject staples from the staple cavities 26232. Similar to the above, the firing member 25960 and sled 25770 sequentially eject the staples from the staple cavities 26232 and, thus, sequentially deform the staples against an anvil, such as the anvil 25920, for example. The thrust force transmitted through the firing member 25960 to sequentially deform the staples is rarely, if ever, constant. Instead, the thrust force typically includes a series of peaks that coincide with the staples being deformed against the anvil. Fig. 81A shows such a force peak. More specifically, fig. 81A illustrates a typical thrust (F) force profile 26260 experienced by the firing member 25960 over the length (L) of the staple firing stroke. Force profile 26260 includes a peak 26261 and a valley 26262 between the peak 26261.

In various instances, in addition to the above, a controller of the stapling assembly can be configured to monitor the thrust force applied to the firing member 25960. In at least one instance, the staple firing system includes an electric motor configured to drive the firing member 25960, and in such instances, the current drawn by the electric motor during the staple firing stroke can be monitored as a surrogate for the thrust force applied to the firing member 25960. In fact, the graph comparing the current drawn by the electric motor during the staple firing stroke may be very similar to the force profile 26260 shown in FIG. 81A. In certain embodiments, the thrust force may be monitored using a force sensor. In any event, the controller can calculate the peak 26261 of the force profile 26260 during the staple firing stroke and stop the staple firing stroke after a predetermined count threshold is reached. In at least one such instance, the staple cartridge can include 100 staples removably stored therein, and after the controller counts 100 force and/or current peaks, the controller can interrupt power to, for example, the electric motor, as it can assume that the staple firing stroke has been completed.

In various instances, in addition to the above, the stapling assembly can be configured to be used with staple cartridges having different lengths and/or different numbers of staples stored therein. For example, the stapling assembly may be used with a first staple cartridge configured to apply approximately 45mm staple line; and may be used with a second staple cartridge configured to apply approximately 60mm staple line. The first staple cartridge includes a first number of staples removably stored therein and the second staple cartridge includes a second number of staples removably stored therein, the second number being greater than the first number. When a first staple cartridge is used with the stapling assembly, the controller is configured to stop the staple firing stroke after the controller identifies a first number of force peaks, and similarly, when a second staple cartridge is used with the stapling assembly, the controller is configured to stop the staple firing stroke after the controller identifies a second number of force peaks. In other words, the controller can be configured to evaluate a force profile of the first bin, such as force profile 26260, and a force profile of the second bin, such as force profile 26260'. Further, the controller may be configured to monitor the force profile of any suitable number of staple cartridges.

In addition to the above, staple cartridges that may be used with stapling assemblies may include unique identifiers that can assist a controller of the stapling assembly in identifying the type of staple cartridge attached to the stapling assembly. In at least one instance, the staple cartridge has a unique RFID tag that can communicate, for example, with a controller of the stapling assembly. In some instances, the staple cartridge has a bar code thereon that can be scanned prior to use of the staple cartridge with a stapling assembly, for example. Once the controller identifies the type of staple cartridge attached to the stapling assembly, the controller can determine the appropriate length of staple firing stroke. In at least one instance, information regarding the proper firing stroke length of the staple cartridge can be stored in a memory device that is in communication with, for example, a microprocessor of the controller.

In addition to or in lieu of the above, a staple cartridge, such as staple cartridge 26230, can be configured to create a detectable force peak of thrust and/or a peak of current drawn by the electric motor at the end of the staple firing stroke. Referring to fig. 81, the staple cartridge 26230 includes one or more bridges 26233 extending across the longitudinal slot 26231 near the distal end of the longitudinal slot 26231, i.e., near the distal end of the staple firing stroke. As the firing member 26260 is advanced distally, the firing member 26260 contacts the bridge 26233 and fractures and/or incises the bridge 26233, thereby creating peaks in the thrust and/or supply current that are different than the peaks created when the staples are deformed. In at least one instance, the peak created by severing the bridge 26233 is much larger than the peak created by deforming the staples, and the controller is configured to identify the difference in such peaks. Once the controller identifies that certain peaks have been formed by the bridge, the controller may stop the staple firing stroke. As the reader will appreciate, such an arrangement will allow the controller to stop the staple firing system at the appropriate time regardless of the length of the staple cartridge attached to the stapling assembly and/or regardless of the number of staples stored in the staple cartridge.

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 certain instances, the motors disclosed herein may comprise one or more portions of a robotically controlled system. Further, any of the end effectors and/or tool assemblies disclosed herein may be used with a robotic surgical instrument system. Several examples of robotic SURGICAL instrument systems are disclosed in more detail in, for example, U.S. patent application serial No. 13/118,241 (now U.S. patent 9,072,535) entitled "SURGICAL INSTRUMENTS WITH robotic SURGICAL INSTRUMENTS". The entire disclosure of U.S. patent application Ser. No. 13/118,241 (now U.S. Pat. No. 9,072,535), entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS," is incorporated herein by reference.

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:

european patent application No. 12/795298 entitled "LINEAR STAPLER WITH IMPROVED FIRING STROKE" filed on 12.3.1997;

U.S. patent 5,605,272 entitled "TRIGGER MECHANISM FOR SURGICAL INSTRUMENTS" published on 25.2.1997;

U.S. patent 5,697,543 entitled "LINEAR STAPLER WITH IMPROVED dressing strong" published on 16.12.1997;

U.S. patent application publication 2005/0246881 entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE," filed 11/10/2005;

U.S. patent application publication 2007/0208359 entitled "METHOD FOR laminating TISSUE", published on 6.9.2007;

U.S. patent 4,527,724 entitled DISPOSABLE LINEAR SURGICAL STAPLING INSTRUMENT, published on 9.7.1985;

U.S. patent 5,137,198 entitled "FAST CLOSURE DEVICE FOR LINEAR SURGICAL STAPLING INSTRUMENT" published on 8, 11.1992;

U.S. patent 5,405,073 entitled "FLEXIBLE SUPPORT SHAFT ASSEMBLY" published on 11.4.1995;

U.S. patent 8,360,297 entitled "SURGICAL CUTTING AND STAPLING INSTRUMENTT WITH SELF ADJUSTING ANVIL" published in 29 months 1 and 2013;

U.S. patent application Ser. No. 14/813,242 entitled "SURGICAL INSTRUMENT COMPRISING SYSTEM FOR ASSURING THE PROPERM SEQUENTIAL OPERATION OF THE SURGICAL INSTRUMENT" filed on 30/7/2015;

U.S. patent application Ser. No. 14/813,259 entitled "SURGICAL INSTRUMENT COMPLISING APPARATUS SECURING AND TISSUE CUTTING SYSTEMS" filed on 30.7.2015;

U.S. patent application Ser. No. 14/813,266 entitled "SURGICAL INSTRUMENT COMPLEMENTING SYSTEMS FOR PERMITTING THE OPTIONAL TRANSECTION OF TISSUE" filed on 30.7.2015;

U.S. patent application Ser. No. 14/813,274 entitled "SURGICAL INSTRUMENT COMPATITING A SYSTEM FOR BYPASSING AN OPERATIONAL STEP OF THE SURGICAL INSTRUMENT"; this patent application was filed on 30/7/2015;

U.S. patent 5,403,312 entitled "ELECTROSURURGICAL HEMOSTATIC DEVICE" published on 4.4.1995;

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

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

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

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

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

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

U.S. patent application Ser. No. 11/343,803 entitled "SURGICAL INSTRUMENT HAVING RECORDING CAPABILITIES"; now us patent 7,845,537;

U.S. patent application Ser. No. 12/031,573 entitled "SURGICAL CUTTING AND FASTENING INSTRUMENTT HAVAGING RF ELECTRODES" filed on 14.2.2008;

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

U.S. patent application Ser. No. 12/235,782 entitled "MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT," now U.S. Pat. No. 8,210,411;

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

U.S. patent application Ser. No. 12/647,100 entitled "MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROL ASSEMBLY" filed 24.12.2009; now us patent 8,220,688;

U.S. patent application serial No. 12/893,461, now U.S. patent No. 8,733,613, entitled "STAPLE CARTRIDGE", filed on 9/29/2012;

U.S. patent application serial No. 13/036,647 entitled "SURGICAL STAPLING INSTRUMENT" filed on 28.2.2011, now U.S. patent No. 8,561,870;

U.S. patent application Ser. No. 13/118,241 entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS," now U.S. Pat. No. 9,072,535;

U.S. patent application Ser. No. 13/524,049 entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE" filed 6, 15/2012; now us patent 9,101,358;

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

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

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

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

While various devices have been described herein in connection with certain embodiments, many modifications and variations to these embodiments may be implemented. In addition, where materials for certain components are disclosed, other materials may also be used. Further, according to various embodiments, a single component may be replaced with multiple components, and multiple components may also be replaced with a single component, to perform a given function or functions. 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. Specifically, the repair facility and/or surgical team may remove the device and, after cleaning and/or replacing certain components of the device, may reassemble the device 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 in this application 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 keep the instrument sterile until the container is opened in a medical facility. The device may also be sterilized using any other technique known in the art, including, but not limited to, beta 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 (6)

1. A surgical instrument, comprising:

a shaft comprising a longitudinal axis;

a firing drive comprising a firing member movable along the longitudinal axis;

an end effector, the end effector comprising:

a distal end;

a channel configured to receive a staple cartridge;

an anvil block; and

a primary lockout configured to prevent movement of the firing member toward the distal end when a staple cartridge is not positioned in the channel; and

a secondary lockout actuatable to prevent movement of the firing member toward the distal end, wherein the secondary lockout is actuated in response to distal movement of the firing member being blocked by the primary lockout;

wherein the firing member comprises a first portion and a second portion, and wherein the secondary lockout is positioned intermediate the first portion and the second portion.

2. The surgical instrument of claim 1, wherein the secondary lockout is compressed above a compression threshold between the first portion and the second portion when the primary lockout prevents the distal movement of the firing member.

3. The surgical instrument of claim 2, wherein the secondary lockout engages the shaft when actuated.

4. The surgical instrument of claim 2, wherein the secondary lockout is resilient and returns to an un-actuated configuration when the compression applied to the secondary lockout falls below the compression threshold.

5. The surgical instrument of claim 1, further comprising means for reducing the speed of the firing member.

6. The surgical instrument of claim 1, further comprising the staple cartridge.

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