JP7476260B2 - Method for manufacturing metal staples for use with staple cartridge assemblies - Patent application - Google Patents

Description

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

The various features of the embodiments described herein, together with their advantages, may be understood from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of an end effector of a surgical stapling instrument in accordance with at least one embodiment; 2 is a partial perspective view of a staple cartridge for use with the end effector of FIG. 1; 3 is a perspective view of a wire staple removably stored within the staple cartridge of FIG. 2; FIG. 4 is a perspective view of a staple driver configured to eject the staples of FIG. 3 from the staple cartridge of FIG. 2 ; 2 is a partial perspective view of a staple cartridge for use with the end effector of FIG. 1; 5 is a perspective view of a staple removably stored within the staple cartridge of FIG. 4; FIG. 1. A diagram showing that the staples of the staple cartridge of FIG. 2 and the staples of the staple cartridge of FIG. 4 are alignable with the formed pockets of the anvil of the end effector of FIG. FIG. 6 is an elevational view of the staple of FIG. 5 . FIG. 6 is a partial side view of the staple of FIG. 5 . FIG. 6 is a partial side view of the staple of FIG. 5 . 6 illustrates the threads of the staple cartridge of FIG. 4 directly engaging the staple of FIG. 5; FIG. 6 is a partial cross-sectional view of the staple cartridge of FIG. 4 showing the staple of FIG. 5 in an unfired position; 6 is a partial cross-sectional view of the staple cartridge of FIG. 4 showing the staple of FIG. 5 in a fired position; 6A and 6B are perspective and elevational views of an alternative embodiment of the staple of FIG. 5 . 6A and 6B are perspective and elevation views of a variation of the staple of FIG. 5 having non-parallel staple legs. FIG. 13 is a partial top view of a staple cartridge in accordance with at least one embodiment. FIG. 16 is a rear end view of a sled for use with the staple cartridge of FIG. FIG. 17 is a perspective view of the sled of FIG. A partial cross-sectional view of the cartridge body of the staple cartridge of Figure 15. 16 is a partial plan view of an anvil for use with the staple cartridge of FIG. 15 ; FIG. 13 is a partial top view of a staple cartridge in accordance with at least one embodiment. FIG. 21 is a front end view of a sled for use with the staple cartridge of FIG. 20 .

Corresponding reference characters indicate corresponding parts throughout the several views. The examples described herein are illustrative of various embodiments of the present invention in one form only, and such examples should not be construed as limiting the scope of the present invention in any manner.

The applicant of this application owns the following U.S. patent applications, filed on June 24, 2016, each of which is incorporated by reference in its entirety herein:
- U.S. Patent Application Serial No. 15/191,807, entitled "STAPLING SYSTEM FOR USE WITH WIRE STAPLES AND STAMPED STAPLES";
- U.S. Patent Application No. 15/191,834, entitled "STAMPED STAPLES AND STAPLE CARTRIDGES USING THE SAME";
- U.S. Patent Application No. 15/191,818, entitled "STAPLE CARTRIDGE COMPRESSING OFFSET LONGITUDINAL STAPLE ROWS";
- U.S. Patent Application Serial No. 15/191,775, entitled "STAPLE CARTRIDGE COMPRESSING WIRE STAPLES AND STAMPED STAPLES."

The applicant of this application owns the following U.S. design patent applications, filed on June 24, 2016, each of which is incorporated by reference in its entirety herein:
- U.S. Design Patent Application No. 29/569,218, entitled "SURGICAL FASTENER";
- U.S. Design Patent Application No. 29/569,227, entitled "SURGICAL FASTENER";
- U.S. Design Patent Application Serial No. 29/569,259, entitled "SURGICAL FASTENER CARTRIDGE", and - U.S. Design Patent Application Serial No. 29/569,264, entitled "SURGICAL FASTENER CARTRIDGE".

The applicant of this application owns the following U.S. patent applications, filed on August 26, 2015, the entire contents of each of which are incorporated herein by reference:
- U.S. Patent Application No. 14/836,324, entitled "SURGICAL STAPLES FOR MINIMIZING STAPLE ROLL";
- U.S. Patent Application No. 14/836,411, entitled "SURGICAL STAPLES COMPRESSING HARDNESS VARIATIONS FOR IMPROVED FASTENING OF TISSUE";
- U.S. Patent Application No. 14/836,058, entitled "SURGICAL STAPLE STRIPS FOR PERMITTING VARYING STAPLE PROPERTIES AND ENABLING EASY CARTRIDGE LOADING";
- U.S. Patent Application No. 14/836,110, entitled "SURGICAL STAPLING CONFIGURATIONS FOR CURVED AND CIRCULAR STAPLING INSTRUMENTS";
- U.S. Patent Application No. 14/836,036, entitled "STAPLE CARTRIDGE ASSEMBLY WITHOUT A BOTTOM COVER";
- U.S. Patent Application No. 14/836,077, entitled "STAPLE CARTRIDGE ASSEMBLY COMPRESSING STAPLE CAVITIES FOR PROVIDING BETTER STAPLE GUIDANCE";
U.S. Patent Application No. 14/836,225, entitled "STAPLE CARTRIDGE ASSEMBLY INCLUDING STAPLE GUIDES";
- U.S. Patent Application No. 14/836,351, entitled "STAPLE CARTRIDGE ASSEMBLY COMPRESSING STAPLE ALIGNMENT FEATURES ON A FIRING MEMBER";
- U.S. Patent Application No. 14/836,163, entitled "STAPLE CARTRIDGE ASSEMBLY COMPRESSING VARIOUS TISSUE COMPRESSION GAPS AND STAPLE FORMING GAPS";
- U.S. Patent Application No. 14/836,294, entitled "STAPLES CONFIGURED TO SUPPORT AN IMPLANTABLE ADJUNCT";
- U.S. Patent Application No. 14/836,375, entitled "STAPLES COMPRESSING A COVER";
- U.S. Patent Application No. 14/836,137, entitled "STAPLE CARTRIDGE ASSEMBLY INCLUDING FEATURES FOR CONTROLLING THE ROTATION OF STAPLES WHEN BEING EJECTED THEREFROM";
- U.S. Patent Application Serial No. 14/836,020, entitled "SURGICAL STAPLES COMPRESSING FEATURES FOR IMPROVED FASTENING OF TISSUE."

The applicant also owns the following patent applications, filed on Dec. 23, 2013, the entire contents of each of which are incorporated herein by reference:
- U.S. Patent Application Serial No. 14/138,554, entitled "Surgical Instruments With Articulatable Shaft Arrangements," now U.S. Patent Application Publication No. 2015/0173789;
- U.S. Patent Application Serial No. 14/138,465, entitled "SURGICAL STAPLES AND STAPLE CARTRIDGES," now U.S. Patent Application Publication No. 2015/0173744;
- U.S. Patent Application Serial No. 14/138,474, entitled "Articulatable Surgical Instruments With Separate and Distinct Closing and Firing Systems," now U.S. Patent Application Publication No. 2015/0173745;
- U.S. Patent Application Serial No. 14/138,485, entitled "Surgical Cutting and Stapling Instruments With Independent Jaw Control Features," now U.S. Patent Application Publication No. 2015/0173746;
- U.S. Patent Application Serial No. 14/138,475, entitled "SURGICAL STAPLES AND STAPLE CARTRIDGES," now U.S. Patent Application Publication No. 2015/0173749;
- U.S. Patent Application Serial No. 14/138,481, entitled "SURGICAL STAPLES AND METHODS FOR MAKING THE SAME," now U.S. Patent Application Publication No. 2015/0173750;
- U.S. Patent Application Serial No. 14/138,489, entitled "SURGICAL STAPLES, STAPLE CARTRIDGES AND SURGICAL END EFFECTORS," now U.S. Patent Application Publication No. 2015/0173751;
- U.S. Design Application No. 29/477,488, entitled "SURGICAL FASTENER";
- U.S. Patent Application Serial No. 14/138,505, entitled "FASTENER CARTRIDGE COMPRESSING AN EXTENDABLE FIRING MEMBER," now U.S. Patent Application Publication No. 2015/0173760;
- U.S. Patent Application Serial No. 14/138,518, entitled "FASTENER CARTRIDGE COMPRISING A FIRING MEMBER CONFIGURED TO DIRECTLY ENGAGE AND EJECT FASTENERS FROM THE FASTENER CARTRIDGE," now U.S. Patent Application Publication No. 2015/0173761;
- U.S. Patent Application Serial No. 14/138,530, entitled "FASTENER CARTRIDGE COMPRESSING A FIRING MEMBER INCLUDING FASTENER TRANSFER SURFACES," now U.S. Patent Application Publication No. 2015/0173762;
- U.S. Patent Application Serial No. 14/138,507, entitled "MODULAR SURGICAL INSTRUMENTS," now U.S. Patent Application Publication No. 2015/0173747;
- U.S. Patent Application No. 14/138,497, entitled "Surgical Cutting and Stapling Instruments With Articulatable End Effectors," now U.S. Patent Application Publication No. 2015/0173755; and - U.S. Patent Application No. 14/138,516, entitled "SURGICAL CUTTING AND STAPLING METHODS," now U.S. Patent Application Publication No. 2015/0173756.

Numerous specific details are presented to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments described herein and illustrated in the accompanying drawings. Well-known operations, components, and elements are not described in detail so as not to obscure the embodiments described herein. The reader will understand that the embodiments described and illustrated herein are non-limiting examples, and therefore, it will be understood that the specific structural and functional details disclosed herein may be exemplary and illustrative. Variations and modifications thereto may be made without departing from the scope of the claims.

The terms "comprise" (any form of comprise, such as "comprises" and "comprising"), "have" (any form of have, such as "has" and "having"), "include" (any form of include, such as "includes" and "including"), and "contain" (any form of contain, such as "contains" and "containing") are open-ended linking verbs. As a result, a surgical system, device, or apparatus that "comprises", "has", "includes", or "contains" one or more elements has the one or more elements, but is not limited to having only the one or more elements. Similarly, a system, device, or element of an apparatus that "comprises," "has," "includes," or "contains" one or more features means that the system, device, or element has those one or more features, but is not limited to having only those one or more features.

The terms "proximal" and "distal" are used herein with reference to a clinician manipulating the 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 understood that for convenience and clarity, spatial terms such as "vertical," "horizontal," "upper," and "lower" 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 many surgical procedures and applications, including, for example, those associated with open surgical procedures. As the reader continues to read through the "Description of the Invention" section of this specification, the reader will further appreciate that the various instruments disclosed herein may be inserted into the body in any manner, such as through a natural opening, through an incision or puncture made in tissue, etc. The working or end effector portions of these instruments may be inserted directly into the patient's body or through an access device having a working channel through which the end effector and elongate shaft of the surgical instrument may be advanced.

The 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. The staple cartridge is insertable into and removable from the first jaw, but other embodiments are contemplated in which the staple cartridge is not removable from the first jaw, or at least not easily replaceable. The second jaw includes an anvil configured to deform staples ejected from the staple cartridge. Other embodiments are contemplated in which the second jaw is pivotable relative to the first jaw about a closure axis, but the first jaw is pivotable relative to the second jaw. The surgical stapling system further includes an articulation joint configured to rotate or articulate 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 articulation joints.

The staple cartridge comprises a cartridge body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal and distal ends. In use, the staple cartridge is positioned on a first side of the 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 within the cartridge body can then be deployed into the tissue. The cartridge body includes staple cavities defined therein, and the staples are removably stored within the staple cavities. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of a longitudinal slot and three rows of staple cavities are positioned on a second side of the longitudinal slot. Other arrangements of staple cavities and staples may be possible.

The staples are supported by staple drivers within the cartridge body. The drivers are movable between a first, or unfired, position and a second, or fired, position that ejects the staples from the staple cavities. The drivers are retained within the cartridge body by a retainer that extends around the bottom of the cartridge body and includes a resilient member configured to grip the cartridge body and hold the retainer against the cartridge body. The drivers are movable between their unfired and fired positions by a sled. The sled is movable between a proximal position adjacent a proximal end and a distal position adjacent a distal end. The sled includes a plurality of ramps configured to slide under the drivers and lift the drivers, on which the staples are supported, toward the anvil.

In addition to the above, the thread is moved distally by a firing member. The firing member is configured to contact the thread and push the thread toward the distal end. In one or more alternative embodiments, the thread is coupled to the firing member. A longitudinal slot defined in the cartridge body is configured to receive the firing member. The anvil also includes a slot configured to receive the firing member. The firing member further includes a first cam engaging the first jaw and a second cam engaging the second jaw. When advancing the firing member distally, the first cam and the second cam can control the distance between the deck of the staple cartridge and the anvil, i.e., the tissue gap. Other embodiments are contemplated in which the firing member has only one cam member or no cam member. Such embodiments may include other suitable means for holding the first and second jaws in place. In any case, the firing member also includes a knife configured to incise tissue captured between the staple cartridge and the anvil. It is desirable for the knife to be positioned at least partially proximal to the ramp so that the staples are ejected forward of the knife.

An end effector 100 of a surgical stapling system is shown in FIG. 1. The end effector 100 includes a frame 190, a cartridge jaw 110, and an anvil 120. The cartridge jaw 110 is fixedly extending from the frame 190. The anvil 120 is movable relative to the cartridge jaw 110 between an open or unclamped position and a closed or clamped position (FIG. 1). In an alternative embodiment, the cartridge jaw 110 is movable relative to the anvil 120 between an open or unclamped position and a closed or clamped position. In at least one such embodiment, the anvil 120 is fixedly extending from the frame 190.

The cartridge jaws 110 are configured to receive a staple cartridge, such as, for example, staple cartridge 130. Referring to FIG. 2, the staple cartridge 130 includes a cartridge body 132. The cartridge body 132 includes a deck 133 configured to support tissue of a patient, a longitudinal slot 135, and a row of six longitudinally extending staple cavities 134 defined in the deck. The longitudinal slots 135 are configured to receive a firing member, such as, for example, firing member 270 (FIG. 12). Each of the staple cavities 134 is configured to receive and removably store a staple 140 (FIG. 3) therein. The staple cartridge 130 further includes a staple driver, such as, for example, staple driver 180 (FIG. 3A), configured to eject the staples 140 from the staple cavities 134. 3 and 3A, each staple driver 180 includes a cradle 182 configured to support and/or engage the base or crown portion 142 of a staple 140. Other staple drivers are contemplated in which the driver includes, for example, two cradles, three cradles, or four cradles for supporting and engaging two or more staples.

In addition to the above, the staple cartridge 130 further comprises a sled configured to engage the staple driver 180. More specifically, the sled comprises one or more ramps configured to engage one or more cams defined on the staple driver 180, such as, for example, cam 185, and to lift the staple driver 180 and the staples 140 in the staple cavities 134 as the sled is moved distally through the staple cartridge 130. The firing member 270 is configured to move the sled distally from a proximal unfired position to a distal fired position during a staple firing stroke. In at least one case, each of the staples 140 is fully disposed below the deck 133 of the cartridge body 132 when the staples 140 are in the unfired position. In such a case, the staple legs 144 of the staples 140 do not extend beyond the deck 133 when the staples 140 are in the unfired position. In use, the tips 146 of the staple legs 144 emerge above the deck 133 when the staples 140 are fired. Such a configuration can reduce the likelihood that the staples 140 will catch on the patient's tissue as the staple cartridge 130 is moved relative to the tissue.

In various other cases, further to the above, the tips 146 of the staple legs 144 extend beyond the deck 133 when the staples 140 are in the unfired position. Referring primarily to FIG. 2, the cartridge body 132 further includes protrusions 136 extending above the deck 133, the protrusions being configured to at least partially surround the tips 146 when the staples 140 are in the unfired position. The lengths of the staple legs 144 are selected such that the tips 146 are disposed below the top surface of the protrusions 136 when the staples 140 are in the unfired position. The protrusions 136 are also configured to guide the staple legs 144 as the staples 140 are ejected from the staple cavities 134. In some respects, the protrusions 136 extend the staple cavities 134 above the deck 133. Such a configuration allows for the use of longer or taller staples while still protecting the staples even though they extend above the deck 133.

Further to the above, the staple 140 is constructed from a wire. The wire has a round, or at least substantially round, cross-section. However, any suitable cross-section may be used. For example, a square cross-section and/or a cross-section having at least one flat side may be used. The wire is constructed from a metal, such as, for example, titanium and/or stainless steel. However, the wire may be constructed from any suitable material, such as, for example, plastic.

Each staple 140 is comprised of a bent wire that is formed to define a crown portion 142 and staple legs 144 of the staple 140. As described in more detail below, the anvil 120 is configured to deform the staple 140 between an unfired configuration (FIG. 3) and a fired configuration. As shown in FIG. 3, the legs 144 of the staple 140 are not parallel to one another when the staple 140 is in the unfired configuration. In such an example, the staple 140 has a substantially V-shaped configuration when the staple 140 is in the unfired configuration. In certain embodiments, staples having parallel or at least substantially parallel legs when in the unfired configuration may be utilized. In such an example, the staple has a substantially U-shaped configuration when the staple is in the unfired configuration.

2, the staple cartridge 130 further includes a retainer 160 attached to the cartridge body 132. The retainer 160 extends at least partially around the bottom of the cartridge 132 and is configured to prevent the staples 140, staple drivers 180, and/or threads from falling out of the bottom of the cartridge body 132. The retainer 160 is configured to engage the cartridge body 132 in a snap-fit manner; however, the retainer 160 may be attached to the cartridge body 132 in any suitable manner. Additionally, the retainer 160 is configured to engage the cartridge jaws 110 in a snap-fit manner to releasably retain the staple cartridge 130 within the cartridge jaws 110. That is, the staple cartridge 130 may be releasably retained in the cartridge jaws 110 in any suitable manner.

In addition to the above, the end effector 100 is also configured to be used with a staple cartridge other than the staple cartridge 130, such as, for example, the staple cartridge 230 (FIG. 4). In other words, the staple cartridge 230 may be used with the end effector 100 in place of the staple cartridge 130, for example. In one example, the end effector 100 may be used with the staple cartridge 130, and after the staple cartridge 130 has been at least partially fired, the staple cartridge 130 may be removed from the first jaw 110 and then replaced with an unfired staple cartridge 230. In various examples, a surgeon may selectively and interchangeably use one or more staple cartridges 130 and one or more staple cartridges 230 in any suitable order.

Referring to FIG. 4, the staple cartridge 230 includes a cartridge body 232 and a retainer 260 attached to the cartridge body 232. The retainer 260 is similar in many respects to the retainer 160. The retainer 260 is configured to engage the cartridge body 232 in a snap-fit manner; however, the retainer 260 may be attached to the cartridge body 232 in any suitable manner. Additionally, the retainer 260 is configured to engage the cartridge jaws 110 in a snap-fit manner to releasably retain the staple cartridge 230 within the cartridge jaws 110. That is, the staple cartridge 230 may be releasably retained in the cartridge jaws 110 in any suitable manner.

The cartridge body 232 includes a deck 233 configured to support a patient's tissue, a longitudinal slot 135, and a row of longitudinally extending staple cavities defined within the deck. The deck 233 includes a first portion on a first side of the longitudinal slot 135 and a second portion on a second side of the longitudinal slot 135. The first and second portions of the deck 233 each include a first or inner longitudinally extending row of staple cavities, a second or middle longitudinally extending row of staple cavities, and a third or outer longitudinally extending row of staple cavities. The first portion of the deck 233 includes a first longitudinally extending row of staple cavities 234a, a second longitudinally extending row of staple cavities 234a, and a third longitudinally extending row of staple cavities 234a'. The second portion of the deck 233 includes a first longitudinally extending row of staple cavities 234a', a second longitudinally extending row of staple cavities 234a', and a third longitudinally extending row of staple cavities 234.

In addition to the above, staple cavity 234a and staple cavity 234a' are similar in many respects, except that they are mirror images of one another. Staple cavity 234a may be referred to as the "left" staple cavity, and staple cavity 234a' may be referred to as the "right" staple cavity. Of course, left and right are a matter of perspective, and different nomenclature, or even reverse nomenclature, may be utilized. Moreover, any suitable configuration of left staple cavity 234a and right staple cavity 234a' may be utilized.

4, 5, and 14, a staple 240 is removably stored within each staple cavity 234a. With reference to FIG. 13, a staple 240' is removably stored within each staple cavity 234a'. Staples 240 and 240' are similar in many respects, except that they are mirror images of one another. Consistent with the nomenclature used above, staple 240 is a "left" staple and staple 240' is a "right" staple.

4, the second portion of the deck 233 is a mirror image of the first portion of the deck 233. Such a configuration creates a staple line that is symmetrical with respect to the tissue cut line, i.e., the longitudinal incision formed by the cutting edge 272 defined on the firing member 270, as the firing member 270 moves distally through the longitudinal slot 135 during the firing stroke. In other embodiments, the second portion of the deck 233 is not a mirror image of the first portion of the deck 233. Such a configuration creates a staple line in the tissue being stapled that is asymmetrical with respect to the cut line.

7-10, the staple 240 includes a crown portion 242, a proximal staple leg 244p connected to the crown portion 242, and a distal leg 244d connected to the crown portion 242. More specifically, the staple 240 includes a proximal connector 248p connecting the proximal staple leg 244p to the crown portion 242, and a distal connector 248d connecting the distal staple leg 244d to the crown portion 242. The proximal connector 248p is integrally formed with the staple leg 244p and the crown portion 242, and similarly, the distal connector 248d is integrally formed with the distal staple leg 244d and the crown portion 242. The staple 240 further includes a driver 246 integrally formed with and extending from the crown portion 242. The driver 246 has a cam surface 245 defined thereon that is configured to be directly engaged by a sled 250 of the staple cartridge 230 during the staple firing stroke, as shown in FIG. 10.

As can be seen in FIGS. 7-10, the crown portion 242 and the driver 246 collectively define a height that is greater than the proximal connector 248p and/or the distal connector 248d. Additionally, the collective height of the crown portion 242 and the driver 246 defines a dimension that is greater than any cross-sectional width of the staple legs 244p and 244d.

7-10, the proximal legs 244p, the proximal connector 248p, the distal legs 244d, and the distal connector 244d do not extend below the driver 246. In other words, the driver 246 constitutes the bottom of the staple 240. Furthermore, the entire cam surface 245 is below the proximal legs 244p, the proximal connector 248p, the distal legs 244d, and the distal connector 244d. Such a configuration helps ensure that the thread 250 contacts the driver 246 of the staple 240 and does not contact another portion of the staple 240.

In addition to the above, and referring again to FIG. 13, staple 240' includes crown 242', proximal leg 244p' connected to crown 242', distal leg 244d' connected to crown 242', and driver 246' integrally formed with and extending from crown 242'. Driver 246' includes cam surface 245' defined thereon and configured to be directly engaged by sled 250 during the staple firing stroke. Unless otherwise noted, the teachings presented herein with respect to staple 240 are also applicable to staple 240'. For the sake of brevity, discussion addressing these indications may not be specifically set forth herein.

Each of the staples 240 is constructed from a unitary piece of metal, such as, for example, titanium and/or stainless steel. Other materials, such as, for example, plastic, may also be utilized. In various examples, the staples 240 are stamped from one or more sheets of material. In at least one example, a continuous flat strip of metal stock is fed into a progression die, which strikes or stamps the strip of material, pulling or pushing the crown 242 along with the staple legs 244p and 244d out of the plane. Alternatively, the staple legs 244p and 244d are pulled or pushed out of the plane along with the crown 242. In various examples, the progression die is also configured to form one or more rounded edges on the staples 240, such as, for example, on the staple legs 244p and 244d. The progressive die is also configured to mold tips 246 of staple legs 244p and 244d and remove any excess material from the strip of material in certain instances. Each of these forming steps may occur at one or more stations within the progressive die and/or within the same one or more forming stations within the progressive die, but the configuration ultimately results in producing a piece of staples 240 that is attached, for example, to a continuous bandolier. The staples 240 are removed from the bandolier and then inserted into the staple cavities 234. In certain instances, the piece of staples 240 is loaded into a loading block, where the bandolier is then removed from the staples 240. The loading block is then used to insert the staples 240 into the staple cavities 234a of the cartridge body 232. In at least one example, the loading block is also configured to receive a plurality of staples 240 ′ such that a plurality of staples 240 and 240 ′ are loaded into the cartridge body 232 simultaneously.

In addition to the above, and referring primarily to FIG. 7, the driver 246 of each staple 240 is attached to the bandolier at a connection point 249 defined distally of the driver 246. Such a configuration reduces the likelihood that, for example, burrs or tags will extend downwardly from the driver 246 and impede the longitudinal progress of the sled 250. That is, any suitable attachment point or points may be utilized to hold the staples 240 to their bandoliers. Additionally or alternatively, wire burning or electrical discharge machining (EDM) operations and/or any other suitable manufacturing process may be utilized to form the staples 240. Additionally, the staples 240' may be manufactured utilizing any of the methods described herein, among others.

8 and 9, the proximal staple leg 244p and the distal staple leg 244d of the staple 240 define a staple leg plane 241s. When the staple 240 is disposed in the staple cavity 234a, in addition to the above, the proximal staple leg 244p of the staple 240 is located proximally relative to the distal staple leg 244d. Furthermore, the proximal staple leg 244p and the distal staple leg 244d of the staple 240 are aligned with a firing axis. This firing axis is also aligned with the staple legs 244p and 244d of the other staples 240 when the staple 240 is disposed in a row of the longitudinally extending staple cavity 234a. As a result, the staple leg planes 241s of the staples 240 in the row of the longitudinally extending staple cavity 234a are aligned, or at least substantially aligned, with one another. It should be understood that staple legs 244p and 244d have a width or thickness, and staple leg plane 241s can include that width of staple legs 244p and/or 244d.

4 and 6, the left staple 240 stored in the first inner longitudinally extending row of staple cavities is removably stored therein such that the staple leg plane 241s of the staple 240 is closer to the longitudinal slot 135 than the drive plane 241c. Correspondingly, with continued reference to FIGS. 4 and 6, the right staple 240' stored in the second inner longitudinally extending row of staple cavities is also removably stored therein such that the staple leg plane 241s of the staple 240' is closer to the longitudinal slot 135 than the drive plane 241c. Similarly, the left staple 240 stored in the first intermediate longitudinally extending row of staple cavities is removably stored therein such that the staple leg plane 241s of the staple 240 is closer to the longitudinal slot 135 than the drive plane 241c. Similarly, the right staples 240' stored in the second middle longitudinally extending row of staple cavities are removably stored therein such that the staple leg plane 241s of the staples 240' is closer to the longitudinal slot 135 than the drive plane 241c. On the other hand, referring to FIGS. 4 and 6, the right staples 240' stored in the first outer longitudinally extending row of staple cavities are removably stored therein such that the drive plane 241c of the staples 240' is closer to the longitudinal slot 135 than the staple leg plane 241s. Similarly, the left staples 240 stored in the second outer longitudinally extending row of staple cavities are also removably stored therein such that the drive plane 241c of the staples 240 is closer to the longitudinal slot 135 than the staple leg plane 241s.

As described in more detail below, the staple legs 244p, 244d of the staple 240 comprise tissue-clamping or clamping portions of the staple 240 that are configured to trap the patient's tissue within the staple 240 when the staple legs 244p, 244d of the staple 240 are deformed against the anvil 120. In various examples, the proximal staple leg 244p and the distal staple leg 244d are formed within the staple leg plane 241s. In other examples, however, one or both of the staple legs 244p and 244d may be deformed out of the staple leg plane 241s.

In addition to the above, as shown in FIG. 7, the proximal staple leg 244p of the staple 240 is parallel or at least substantially parallel to the staple leg 244d when the staple 240 is in an unfired configuration. As a result, the staple legs 244p, 244d and the crown 242 of the staple 240 form a substantially U-shaped configuration when the staple 240 is in an unfired position. In such a configuration, the upward movement of the staple legs 244p and 244d as the staple 240 is being ejected from the staple cavity 234a may be easier to control compared to other configurations. In various alternative embodiments, referring to FIG. 14, the proximal staple leg 244p and the distal staple leg 244d of the staple 240 extend outwardly away from each other and/or in a direction that is not parallel to each other. In at least one such example, the staple legs 244p, 244d and the crown 242 of the staple 240 form a substantially V-shaped configuration when the staple 240 is in an unfired position. In such a configuration, the staple legs 244p and 244d of the staple 240 may contact and be resiliently biased inwardly by the sidewalls of the staple cavity 234a, which may resiliently retain the staple 240 within the staple cavity 234a.

In addition to the above, the retainer 260 extends at least partially around the bottom of the cartridge 232 and is configured to prevent the staples 240, staples 240', and/or threads 250 from falling out of the bottom of the cartridge body 232.

10, the driver 246 of the staple 240 comprises the drive portion of the staple 240. The longitudinal ramp 255 of the sled 250 is configured to sequentially engage and slide under the driver 246 of the staple 240 to lift the staple 240 upwardly within the staple cavity 234a toward the anvil 120. The cam surface 245 of each staple 240 is defined proximal to the driver 246 and includes the point at which the sled 250 initiates contact with the staple 240. The driver 246 of each staple 240 is defined in a drive plane 241c, which is aligned or at least substantially aligned with the longitudinal ramp 255. The cam surface 245 is also defined in the drive plane 241c. It should be understood that the cam surface 245 and/or the driver 246 may have a width or thickness, and the drive plane 241c may include that width of the cam surface 245 and/or the driver 246.

8 and 9, connectors 248p and 248p separate staple legs 244p and 244d, respectively, from crown 242 of staple 240. As shown in FIGS. 8 and 9, drive plane 241c of staple 240 is laterally offset from staple leg plane 241s of staple 240. As also shown in FIGS. 8 and 9, drive plane 241c of staple 240 is parallel or at least substantially parallel to staple leg plane 241s of staple 240. In such an example, drive planes 241c of longitudinally extending rows of staples 240 are aligned with one another along a longitudinal drive axis. The longitudinal drive axis is parallel to and adjacent to a longitudinal firing axis that is aligned with staple leg plane 241s as described above.

8-10, the longitudinal ramp 255 does not engage the proximal connector 248p or the distal connector of the staple 240. Similarly, the longitudinal ramp 255 does not engage the staple legs 244p and 244d of the staple 240. Additionally, no portion of the sled 250 engages the proximal connector 248p, the proximal staple legs 244p, the distal connector 248d, and the distal staple legs 244d of the staple 240. Instead, the longitudinal ramp 255 directly engages the cam surface 245 of the staple 240 as the sled 250 is moved distally during the firing stroke. As the sled 250 is moved distally, the longitudinal ramp 255 slides under the cam surface 245 and subsequently lifts the staple 240 upward toward the anvil 120 between the unfired position (FIG. 11) and the fired position (FIG. 12). In other words, the staple 240 slides up the longitudinal ramp 255 within the staple cavity 234a toward the fired position, as shown in FIG. 12.

10, the drive surface 245 of the staple 240 does not extend to the proximal connector 248p. The driver 246 includes a notch or relief 247 that separates the drive surface 245 from the proximal connector 248p. In various examples, the notch 247 is defined in the drive plane 241c. In at least one example, the notch 247 extends to the proximal connector 248p. The notch 247 is configured to ensure that the thread 250 contacts the driver 246 of the staple 240, i.e., in the drive plane 241c of the staple 240, and not the proximal connector 248p and/or the proximal leg 244p. The notch 247 also creates a clear delineation between the driver 246 and the proximal connector 248p such that the cam surface 245 is not twisted out of the drive plane 241c. Additionally, the notch 247 separates the drive plane 241c from the vertical plane that contains the proximal staple leg 244p.

As above, the drive plane 245 does not extend to the distal connector 248d.

In addition to the above, the drive plane 245 of the staple 240 extends at an angle that matches or at least substantially matches the angle of the longitudinal ramp 255 of the sled 250. That is, any suitable angle may be used.

In at least one example, further to the above, each of the staples 240 is disposed completely below the deck 233 of the cartridge body 232 when the staples 240 are in the unfired position. In such an example, the staple legs 244 of the staples 240 do not extend beyond the deck 233 when the staples 240 are in the unfired position. In use, the tips 246 of the staple legs 244 emerge above the deck 233 when the staples 240 are fired. Such a configuration can reduce the likelihood that the staples 240 will snag on the patient's tissue when the staple cartridge 230 is moved relative to the tissue.

In various examples, further to the above, the tips 246 of the staple legs 244p and/or 244d extend beyond the deck 233 when the staples 240 are in the unfired position. Referring primarily to FIGS. 4 and 6, the cartridge body 232 further includes protrusions 236 extending above the deck 233, which are configured to at least partially surround the tips 246 when the staples 240 are in the unfired position. The lengths of the staple legs 244p and 244d are selected such that the tips 246 are disposed below the upper surface of the protrusions 236 when the staples 240 are in the unfired position. In some respects, the protrusions 236 extend the staple cavities 234 above the deck 233. Such a configuration may allow for the use of longer or taller staples while protecting the staples even though they extend above the deck 233. The protrusions 236 are also configured to guide the staple legs 244 as the staples 240 are ejected from the staple cavities 234.

In addition to the above, the staple 240 reaches the fully fired configuration when the top surface 253 of the longitudinal ramp 255 passes below the bottom surface of the staple 240. Referring now to FIG. 12, the staple 240 has nearly reached the top surface 253 of the longitudinal ramp 255 and is therefore nearly in the fully fired configuration. As the top surface 253 moves distally relative to the deformed staple 240 and is no longer engaged by the deformed staple 240, the elastic reaction force and/or potential energy stored in the deformed staple 240 may again drive a portion of the deformed staple 240 into the ejected staple cavity 234a.

11 and 12, the anvil 120 includes forming pockets configured to deform the staples 240 and 240'. Each forming pocket includes, for example, a proximal forming cup 124p configured to receive the proximal staple leg 244p of the staple 240 and a distal forming cup 124d configured to receive the distal staple leg 244d of the staple 240. The proximal forming cup 124p is configured to deform the proximal staple leg 244p inwardly toward the distal staple leg 244d. Similarly, the distal forming cup 124d is configured to deform the distal staple leg 244d inwardly toward the proximal staple leg 244p. Other embodiments are also contemplated in which one or both of the staple legs 244p and 244d are bent outwardly away from one another and/or in any other suitable direction. Referring again to FIG. 12, the staples 240 and 240' are shown deformed into a B-shaped configuration by the anvil 120; however, the anvil 120 may be configured to deform the staples 240 and 240' into any suitable configuration.

As discussed above, the end effector 100 can be used with the staple cartridge 100 or alternatively with the staple cartridge 200. As a result, the anvil 120 is configured to deform the staples 140 of the staple cartridge 100, and in addition, the staples 240, 240' of the staple cartridge 200. In other words, for example, the forming pockets defined in the anvil 120 are configured to deform the staples 140 fabricated from bent wire, and the staples 240 or staples 240' punched from a flat sheet of material, respectively. For example, referring primarily to FIG. 6, the proximal forming cup 124p of the forming pocket is configured to deform the proximal staple leg 144 of the staple 140 and the proximal staple leg 244p of the staple 240. The proximal forming cup 124p of the forming pocket is also configured to deform the proximal staple leg 244p' when the staple 240' is aligned with the forming pocket in place of the staple 240. As above, the distal forming cup 124d of the forming pocket is configured to deform the distal staple leg 144 of the staple 140 and the distal staple leg 244d of the staple 240. Similarly, the distal forming cup 124d of the forming pocket is also configured to deform the distal staple leg 244d' when the staple 240' is aligned with the forming pocket in place of the staple 240.

In addition to the above, the staple cavities 134 and 234a of the staple cartridge 130 and 230 are alignable with the forming pockets of the anvil 120 such that the tips 146 and 246 of the staples 140 and 240 strike the same points or targets in the forming cups 124p and 124d depending on which staple cartridge is attached to the end effector 100. It should be understood that the tips 146 and 246 may not actually strike the same targets in the forming cups 124p and 124d, for example due to variations in tissue composition. That is, the forming cavities of the anvil 120 are configured to guide the legs 144 and 244p, 244d of the staples 140 and 240 into the desired alignment. To this end, the proximal forming cup 124p includes a guide wall 126p, and the distal forming cup 124d includes a guide wall 126d, which are configured to guide and shape the legs of the staples 140, 240, and 240' into a desired configuration.

7, the staple 240 includes a tissue engaging surface 243 defined on the top surface of the crown 242. The surface 243 of the staple 240 is configured to support and/or apply pressure to tissue captured within the staple 240 when the staple 240 is formed into the fired configuration. Now referring to FIG. 11, the surface 243 of the staple 240 is disposed well below the deck 233 of the cartridge body 232 when the staple 240 is in the unfired position. Now referring to FIG. 12, when the staple 240 is moved to the fired position, the surface 243 emerges at least partially above the deck 233. In other words, the thread 250 at least partially overdrives the staple 240. In such a case, the surface 243 of the staple 240 may abut and apply pressure to tissue when the staple 240 is being deformed. In some cases, only a portion of the surface 243 is overdriven above the deck 233 when the staple 240 is in the fully fired position. In other cases, the entire surface 243 is overdriven above the deck 233 when the staple 240 is in the fully fired position. Such a configuration allows a significant amount of clamping pressure to be applied to the tissue, which may reduce bleeding from the tissue.

In various examples, further to the above, the driver 246 of the staple 240 remains at least partially below the deck 233 when the surface 243 of the staple 240 is overdriven above the deck 233. In some cases, the staple 240 is configured such that the driver 246 does not emerge above the deck 233 regardless of the extent to which the surface 243 is overdriven above the deck 233. In such cases, the entirety of the driver 246 still remains below the deck 233 during the staple firing stroke. In at least one example, the cam surface 245 of the staple 240 does not emerge above the deck 233 when the staple 240 is overdriven. In various examples, the top surface 253 of the longitudinal ramp 255 does not extend above the deck 233. This means that the sled 250 does not drive the entirety of the staple 240 above the deck 233 during the staple firing stroke.

In addition to the above, it should be appreciated that the protrusion 236 extends above the deck 233. As shown in FIG. 12, the sled 250 is configured to at least partially overdrive the surface 243 of the staple 240 above the protrusion 236. In such an example, the surface 243 rises at least partially above the protrusion 236 when the staple 240 is moved to the fully fired position. In some cases, only a portion of the surface 243 is overdriven above the protrusion 246 when the staple 240 is in the fully fired position. In other cases, the entire surface 243 is overdriven above the protrusion 246 when the staple 240 is in the fully fired position. Such a configuration allows a significant amount of clamping pressure to be applied to the tissue, which may reduce bleeding from the tissue.

In addition to the above, the tissue engaging surface 243 may directly engage or contact tissue. In other cases, a supplemental material, such as, for example, a piece of buttress material and/or a tissue thickness compensation plate, may be disposed on the deck 233 of the staple cartridge 230 and the tissue engaging surface 243 may directly engage or contact the supplemental material. References disclosing supplemental materials are incorporated by reference elsewhere in this application.

7, the tissue engaging surface 243 includes a flat portion, a first angled portion on a first side of the flat portion, and a second angled portion on a second side of the flat portion. Such a configuration allows pressure to be applied to tissue captured within the staple 240 in three directions. That is, the tissue engaging surface 243 may include any suitable configuration, such as, for example, a completely flat configuration or a rounded configuration.

As discussed above, and referring again to FIG. 6, the staple cartridges 130 and 230 may be selectively and interchangeably used with the end effector 100. As also discussed above, the staple cartridges 130 and 230 may be removably attached to the jaws 110. In various alternative embodiments, the staple cartridges 130 and 230 each include a complete jaw that is attachable to and removable from the frame 190 of the end effector 110. In such a case, the clinician may, for example, remove the entire staple cartridge jaw from the end effector 110 and replace it with another complete staple cartridge jaw, i.e., one that has not yet been fired and includes the type and/or pattern of staples desired by the clinician.

In addition to the above, it should be understood that FIG. 6 is intended to illustrate that the end effector 100 can be used with the staple cartridge 130 and the staple cartridge 230. Although both the staple cartridge 130 and the staple cartridge 230 are shown in FIG. 6, it should be understood that the staple cartridge 130 and the staple cartridge 230 are not used simultaneously in the same end effector 100. That is, for example, various embodiments are contemplated in which the staple cartridge utilizes wire staples, in addition to utilizing staples formed from one or more sheets of material. In at least one embodiment, the staple cartridge includes, for example, staples 140 and staples 240 removably stored therein. Other embodiments are also contemplated in which the staple cartridge includes, for example, staples 140, staples 240, and staples 240'.

20, in addition to the above, the staple cartridge 430 comprises a cartridge body 432 including a deck 433 and a longitudinal slot 135 defined therein. The longitudinal slot 135 defines a longitudinal slot axis 139 extending through its center. The staple cartridge 430 further comprises, on one side of the longitudinal slot 135, a first or inner row of longitudinally extending cavities 434a, a second or middle row of longitudinally extending staple cavities 434b, and a third or outer row of longitudinally extending staple cavities 434c. Staple cartridge 430 also includes a first or inner row of longitudinally extending cavities 434a', a second or middle row of longitudinally extending staple cavities 434b', and a third or outer row of longitudinally extending staple cavities 434c' on the other side of longitudinal slot 135. Staple cavities 434a, 434a', 434b, and 434b' are similar in many respects to left staple cavity 234a (FIGS. 4 and 6). Staple cavities 434c and 434c' are similar in many respects to left staple cavity 134 (FIGS. 2 and 6). Staples 240 are removably stored in staple cavities 434a, 434a', 434b, and 434b'. Staples 140 are removably stored in staple cavities 434c and 434c'.

21, the staple cartridge 430 further includes a sled 450 configured to eject the staples 140 and 240 from the cartridge body 432. The sled 450 includes a longitudinal ramp 455a configured to directly engage the staples 240 stored in the staple cavities 434a, a longitudinal ramp 455a' configured to directly engage the staples 240 stored in the staple cavities 434a', a longitudinal ramp 455b configured to directly engage the staples 240 stored in the staple cavities 434b, and a longitudinal ramp 455b' configured to directly engage the staples 240 stored in the staple cavities 434b'. Sled 450 further comprises longitudinal ramps 455c configured to eject staples 140 from staple cavities 434c and longitudinal ramps 455c' configured to eject staples 140 from staple cavities 434c'. More specifically, staple cartridge 430 comprises a row of staple drivers configured to support and/or engage staples 140 stored within staple cavities 434c and a row of staple drivers configured to support and/or engage staples 140 stored within staple cavities 434c', and as sled 450 is advanced distally, longitudinal ramps 455c and 455c' of sled 450 engage the staple drivers to lift staples 140 upwardly within staple cavities 434c and 434c' and deform staples 140 against an anvil disposed on the opposite side of staple cartridge 430. These staple drivers may be similar in many respects to the staple drivers shown in FIG. 3A, for example.

In addition to the above, the staple cavity 434a is disposed along the longitudinal axis 437a, the staple cavity 434b is disposed along the longitudinal axis 437b, and the staple cavity 434c is disposed along the longitudinal axis 437c. Similarly, the staple cavity 434a' is disposed along the longitudinal axis 437a', the staple cavity 434b' is disposed along the longitudinal axis 437b', and the staple cavity 434c' is disposed along the longitudinal axis 437c'. The distance between the longitudinal axis 437a and the longitudinal slot axis 139 is less than the distance between the longitudinal axis 437a' and the longitudinal slot axis 139. As a result, the longitudinal axis 437a' is laterally staggered or offset compared to the longitudinal axis 437a. Similarly, the distance between the row of longitudinally extending staple cavities 434a and the longitudinal slot 135 is less than the distance between the row of longitudinally extending staple cavities 434a' and the longitudinal slot 135. In addition, the distance between the longitudinal axis 437b and the longitudinal slot axis 139 is less than the distance between the longitudinal axis 437b' and the longitudinal slot axis 139. As a result, the longitudinal axis 437b' is laterally staggered or offset compared to the longitudinal axis 437b. Similarly, the distance between the row of longitudinally extending staple cavities 434b and the longitudinal slot 135 is less than the distance between the row of longitudinally extending staple cavities 434b' and the longitudinal slot 135. Comparatively, the longitudinal axes 437c and 437c' are equidistant from the longitudinal slot axis 139. Correspondingly, the row of longitudinally extending staple cavities 343c and the row of longitudinally extending staple cavities 343c' are equidistant from the longitudinal slot 135.

The rows of longitudinally extending staple cavities defined within the staple cartridge 430 are not uniformly spaced. In many respects, the distances between the longitudinally extending rows vary. As can be seen in FIG. 20, the spacing between the rows of longitudinally extending staple cavities 434a, 434b, and 434c on one side of the longitudinal slot 135 is different than the spacing between the rows of longitudinally extending staple cavities 434a', 434b', and 434c' on the other side of the longitudinal slot 135.

In addition to the above, the longitudinal axes 437a, 437a', 437b, 437b', 437c, and 437c' include drive axes. These drive axes are aligned with the drive portion of the staple 240 and the cam surface of the staple driver supporting the staple 140, as the case may be. The longitudinal ramps of the sled 450 are aligned with these drive axes. For example, referring to Figures 20 and 21, the longitudinal ramp 455a of the sled 450 is aligned with the longitudinal axis 437a. Similarly, the longitudinal ramp 455b is aligned with the longitudinal axis 437b, and the longitudinal ramp 455c is aligned with the longitudinal axis 437c. Also, longitudinal lamp 455a' is aligned with longitudinal axis 437a', longitudinal lamp 455b' is aligned with longitudinal axis 437b', and longitudinal lamp 455c' is aligned with longitudinal axis 437c'. To this end, longitudinal lamp 455a and longitudinal axis 437a are spaced apart from longitudinal slot axis 139 by distance 457a, longitudinal lamp 455b and longitudinal axis 437b are spaced apart from longitudinal slot axis 139 by distance 457b, and longitudinal lamp 455c and longitudinal axis 437c are spaced apart from longitudinal slot axis 139 by distance 457c. Similarly, the longitudinal ramp 455a' and longitudinal axis 437a' are spaced from the longitudinal slot axis 139 by a distance 457a', the longitudinal ramp 455b' and longitudinal axis 437b' are spaced from the longitudinal slot axis 139 by a distance 457b', and the longitudinal ramp 455c' and longitudinal axis 437c' are spaced from the longitudinal slot axis 139 by a distance 457c'.

As can be seen in FIG. 21, none of the distances 457a, 457a', 457b, and 457b' are equal. They are all different. As a result, the rails of sled 450 are asymmetrically spaced apart.

21, the sled 450 includes a central portion 451 configured to move within the longitudinal slot 135 of the cartridge body 432. The central portion 451 is sized and configured to be closely received within the slot 135 such that little, if any, lateral movement is permitted between the sled 450 and the cartridge body 432 and the longitudinal ramps of the sled 450 remain properly aligned with the staple drivers configured to drive the staples 240 and 140.

20, the outer rows of staples deployed by the staple cartridge 430 are wire staples and the inner and middle rows of staples deployed by the staple cartridge 430 are formed and/or punched from flat stock. However, other configurations are contemplated. In at least one example, for example, the middle and outer rows of staples deployed by the staple cartridge are wire staples and the inner row of staples deployed by the staple cartridge are punched staples. In another example, for example, the inner and middle rows of staples deployed by the staple cartridge are wire staples and the outer row of staples deployed by the staple cartridge are punched staples. If the staple cartridge deploys more than one row of wire staples on one side of the longitudinal slot, more than one row of staple drivers may be utilized to deploy the staples from the staple cartridge. In various examples, the staple cartridge may utilize, for example, a dual driver configured to simultaneously deploy wire staples from two longitudinal rows when the longitudinal rows containing wire staples are adjacent to one another. Other driver configurations may be utilized that are configured to deploy more than two staples, such as, for example, three staples and/or four staples.

As a result of the above, the staple cartridge 430 creates an asymmetric pattern of staples in the tissue. In particular, the staple cartridge 430 creates a first pattern of staples in the tissue on a first side of the cut line and a second or different pattern of staples in the tissue on a second side of the cut line.

15-19, the staple cartridge 330 comprises a cartridge body 332 including a deck 333 and a longitudinal slot 135 defined therein. The longitudinal slot 135 defines a longitudinal slot axis 139 extending through its center. The staple cartridge 330 further comprises, on one side of the longitudinal slot 135, a first or inner row of longitudinally extending cavities 334a, a second or middle row of longitudinally extending staple cavities 334b, and a third or outer row of longitudinally extending staple cavities 334c. Staple cartridge 330 also includes a first or inner row of longitudinally extending cavities 334a', a second or middle row of longitudinally extending staple cavities 334b', and a third or outer row of longitudinally extending staple cavities 334c' on the other side of longitudinal slot 135. Staple cavities 334a, 334a', 334b, 334b', 334c, and 334c' are similar in many respects to left staple cavity 234a (FIGS. 4 and 6). Staples 240 are removably stored in staple cavities 334a, 334a', 334b, 334b', 334c, and 334c'.

16 and 17, the staple cartridge 330 further includes a sled 350 configured to eject the staples 240 from the cartridge body 332. The sled 350 includes a longitudinal ramp 355a configured to directly engage the staples 240 stored in the staple cavities 334a, a longitudinal ramp 355a' configured to directly engage the staples 240 stored in the staple cavities 334a', a longitudinal ramp 355b configured to directly engage the staples 240 stored in the staple cavities 334b, and a longitudinal ramp 355b' configured to directly engage the staples 240 stored in the staple cavities 334b'. The sled 350 further includes a longitudinal ramp 355c configured to directly engage the staple 240 stored in the staple cavity 334c, and a longitudinal ramp 355c' configured to directly engage the staple 240 stored in the staple cavity 334c'.

In addition to the above, the staple cavity 334a is disposed along the longitudinal axis 337a, the staple cavity 334b is disposed along the longitudinal axis 337b, and the staple cavity 334c is disposed along the longitudinal axis 337c. Similarly, the staple cavity 334a' is disposed along the longitudinal axis 337a', the second staple cavity 334b' is disposed along the longitudinal axis 337b', and the staple cavity 334c' is disposed along the longitudinal axis 337c'. The distance between the longitudinal axis 337a and the longitudinal slot axis 139 is less than the distance between the longitudinal axis 337a' and the longitudinal slot axis 139. As a result, the longitudinal axis 337a' is laterally staggered or offset compared to the longitudinal axis 337a. Similarly, the distance between the row of longitudinally extending staple cavities 334a and the longitudinal slot 135 is less than the distance between the row of longitudinally extending staple cavities 334a' and the longitudinal slot 135.

In addition, the distance between the longitudinal axis 337b and the longitudinal slot axis 139 is shorter than the distance between the longitudinal axis 337b' and the longitudinal slot axis 139. As a result, the longitudinal axis 337b' is laterally staggered or offset compared to the longitudinal axis 337b. Similarly, the distance between the row of longitudinally extending staple cavities 334b and the longitudinal slot 135 is shorter than the distance between the row of longitudinally extending staple cavities 334b' and the longitudinal slot 135. Furthermore, the distance between the longitudinal axis 337c and the longitudinal slot axis 139 is shorter than the distance between the longitudinal axis 337c' and the longitudinal slot axis 139. As a result, the longitudinal axis 337c' is laterally staggered or offset compared to the longitudinal axis 337c. Similarly, the distance between the row of longitudinally extending staple cavities 334c and the longitudinal slot 135 is less than the distance between the row of longitudinally extending staple cavities 334c' and the longitudinal slot 135.

In addition to the above, the longitudinal axes 337a, 337a', 337b, 337b', 337c, and 337c' include drive axes. These drive axes are aligned with the drive portion of the staple 240. The longitudinal ramps of the sled 350 are aligned with these drive axes. For example, the longitudinal ramp 355a of the sled 350 is aligned with the longitudinal axis 337a. Similarly, the longitudinal ramp 355b is aligned with the longitudinal axis 337b, and the longitudinal ramp 355c is aligned with the longitudinal axis 337c. Similarly, the longitudinal ramp 355a' is aligned with the longitudinal axis 337a', the longitudinal ramp 355b' is aligned with the longitudinal axis 337b', and the longitudinal ramp 355c' is aligned with the longitudinal axis 337c'. For this purpose, the longitudinal lamp 355a and the longitudinal axis 337a are spaced from the longitudinal slot axis 139 by a distance 357a, the longitudinal lamp 355b and the longitudinal axis 337b are spaced from the longitudinal slot axis 139 by a distance 357b, and the longitudinal lamp 355c and the longitudinal axis 337c are spaced from the longitudinal slot axis 139 by a distance 357c. Similarly, the longitudinal lamp 355a' and the longitudinal axis 337a' are spaced from the longitudinal slot axis 139 by a distance 357a', the longitudinal lamp 355b' and the longitudinal axis 337b' are spaced from the longitudinal slot axis 139 by a distance 357b', and the longitudinal lamp 355c' and the longitudinal axis 337c' are spaced from the longitudinal slot axis 139 by a distance 357c'.

17, the sled 350 includes a central portion 351 configured to move within the longitudinal slot 135 of the cartridge body 332. The central portion 351 is sized and configured to be closely received within the slot 135 such that little, if any, lateral movement is permitted between the sled 350 and the cartridge body 332, and the longitudinal ramps of the sled 350 remain properly aligned with the staples 240.

17, a gap 359a is defined between the central portion 351 of the sled 350 and the longitudinal ramp 355a. Similarly, a gap 359b is defined between the longitudinal ramp 355a and the longitudinal ramp 355b, and a gap 359c is defined between the longitudinal ramp 355b and the longitudinal ramp 355c. The gap 359a is smaller than the gap 359b, and similarly, the gap 359b is smaller than the gap 359c. Similarly, a gap 359a' is defined between the central portion 351 of the sled 350 and the longitudinal ramp 355a'. Similarly, a gap 359b' is defined between the longitudinal ramp 355a' and the longitudinal ramp 355b', and a gap 359c' is defined between the longitudinal ramp 355b' and the longitudinal ramp 355c'. Gap 359a' is smaller than gap 359b', which in turn is smaller than gap 359c'. Other arrangements are possible.

18 is a cross-sectional view of cartridge body 332 illustrating longitudinal channels defined therein that connect staple cavities within a row of staple cavities and allow longitudinal ramps of sled 350 to pass through cartridge body 332. For example, channel 338a connects staple cavities 334a longitudinally and is configured to receive longitudinal ramps 355a of sled 350. Similarly, channel 338b connects staple cavities 334b longitudinally and is configured to receive longitudinal ramps 355b of sled 350, and in addition, channel 338c connects staple cavities 334c longitudinally and is configured to receive longitudinal ramps 355c of sled 350. In addition, channel 338a' longitudinally connects staple cavities 334a' to each other and is configured to receive longitudinal ramps 355a' of sled 350, channel 338b' longitudinally connects staple cavities 334b' to each other and is configured to receive longitudinal ramps 355b' of sled 350, and channel 338c' longitudinally connects staple cavities 334c' to each other and is configured to receive longitudinal ramps 355c' of sled 350.

19, an anvil 320 is configured for use with a staple cartridge 330. The anvil 320 includes forming pockets 324 configured to deform the staples 240 removably stored within the staple cartridge 330 as the staples 240 are ejected from the staple cartridge 330. The forming pockets 324 are arranged in six longitudinal rows that can be aligned with the six longitudinal rows of staple cavities defined within the staple cartridge 330. For example, the row of longitudinally extending forming pockets 324 is defined along a longitudinally extending anvil axis 327a that can be aligned with the staple leg planes of the staples 240 stored in the row of longitudinally extending staple cavities 334a. Similarly, the row of longitudinally extending forming pockets 324 is defined along a longitudinal anvil axis 327b, which longitudinal row is alignable with the staple leg planes of the staples 240 stored in the row of longitudinally extending staple cavities 334b, and in addition, the row of longitudinally extending forming pockets 324 is defined along a longitudinal anvil axis 327c, which longitudinal row is alignable with the staple leg planes of the staples 240 stored in the row of longitudinally extending staple cavities 334c. Further, the row of longitudinally extending forming pockets 324 is defined along the longitudinally extending anvil axis 327a', the longitudinal row being alignable with the staple leg plane of the staples 240 stored in the row of longitudinally extending staple cavities 334a', the longitudinally extending forming pockets 324 are defined along the longitudinally extending anvil axis 327b', the longitudinal row being alignable with the staple leg plane of the staples 240 stored in the row of longitudinally extending staple cavities 334b', and the longitudinally extending forming pockets 324 are defined along the longitudinally extending anvil axis 327c', the longitudinal row being alignable with the staple leg plane of the staples 240 stored in the row of longitudinally extending staple cavities 334c'.

Example 1 - A surgical stapling system comprising a shaft including a proximal end and a distal end, and an end effector extending from the distal end of the shaft, the end effector being movable between an open configuration and a closed configuration. The end effector comprises a frame, an anvil extending distally from the frame, the anvil comprising a longitudinally extending row of formed pockets, and a first staple cartridge assembly attachable to the end effector. The first staple cartridge assembly comprises a first cartridge body comprising a first longitudinally extending row of staple cavities, as well as a plurality of first staples removably stored in the first longitudinally extending row of staple cavities. Each of the first staples is comprised of a bent wire and aligns with a formed pocket when the end effector is in the closed configuration. The surgical stapling system also comprises a second staple cartridge assembly attachable to the end effector in place of the first staple cartridge assembly. The second staple cartridge assembly includes a second cartridge body having a second longitudinally extending row of staple cavities and, in addition, a plurality of second staples removably stored in the second longitudinally extending row of staple cavities. Each of the second staples is formed from flat stock and aligns with a formed pocket when the end effector is in a closed configuration.

Example 2 - The surgical stapling system of Example 1, wherein each forming pocket includes a proximal forming cup and a distal forming cup.

Example 3 - The surgical stapling system of Examples 1 and 2, wherein each of the first staples has a proximal leg formed by a proximal forming cup and a distal leg formed by a distal forming cup.

Example 4 - The surgical stapling system of Examples 1, 2, and 3, wherein each of the second staples has a proximal leg formed by a proximal forming cup and a distal leg formed by a distal forming cup.

Example 5 - The surgical stapling system of Examples 1, 2, 3, and 4, wherein the end effector further comprises a jaw configured to receive the first staple cartridge assembly and a second staple cartridge assembly that replaces the first staple cartridge assembly.

Example 6 - The surgical stapling system of Example 5, wherein the jaws are rotatable relative to the anvil to position the end effector in a closed configuration.

Example 7 - The surgical stapling system of Examples 5 and 6, wherein the anvil is rotatable relative to the jaws to place the end effector in a closed configuration.

Example 8 - The surgical stapling system of Example 1, wherein the first staple cartridge assembly includes a first jaw portion that is mountable to the frame and the second cartridge assembly includes a second jaw portion that is mountable to the frame.

Example 9 - The surgical stapling system of Example 8, wherein the anvil is rotatable relative to the frame to place the end effector in a closed configuration.

Example 10 - The surgical stapling system of Examples 8 and 9, wherein the first jaw is rotatable relative to the frame to place the end effector in a closed configuration when the first jaw is attached to the frame, and the second jaw is rotatable relative to the frame to place the end effector in a closed configuration when the second jaw is attached to the frame.

Example 11 - The surgical stapling system of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10, wherein the first staple cartridge assembly includes a staple driver configured to expel the first staple from the first staple cavity, and the second staples each include an integrally formed staple driver.

Example 12 - A surgical stapling system comprising a shaft having a proximal end and a distal end, and an end effector extending from the distal end of the shaft, the end effector being movable between an unclamped configuration and a clamped configuration. The end effector comprises a frame, an anvil extending distally from the frame, the anvil comprising a longitudinally extending row of formed pockets, and a first staple cartridge assembly attachable to the end effector. The first staple cartridge assembly comprises a first cartridge body comprising a first longitudinally extending row of staple cavities, as well as a plurality of first staples removably stored in the first longitudinally extending row of staple cavities. Each of the first staples is comprised of a bent wire and aligns with a formed pocket when the end effector is in the clamped configuration. The surgical stapling system also comprises a second staple cartridge assembly attachable to the end effector as an alternative to the first staple cartridge assembly. The second staple cartridge assembly includes a second cartridge body having a second longitudinally extending row of staple cavities and, in addition, a plurality of second staples removably stored in the second longitudinally extending row of staple cavities. The second staples are punched from one or more flat sheets of material and align with the formed pockets when the end effector is in a clamped configuration.

Example 13 - The surgical stapling system of Example 12, wherein each forming pocket comprises a proximal forming cup and a distal forming cup.

Example 14 - The surgical stapling system of Examples 12 and 13, wherein each of the first staples has a proximal leg formed by a proximal forming cup and a distal leg formed by a distal forming cup.

Example 15 - The surgical stapling system of Examples 12, 13, and 14, wherein each of the second staples has a proximal leg formed by a proximal forming cup and a distal leg formed by a distal forming cup.

Example 16 - The surgical stapling system of Examples 12, 13, 14, and 15, wherein the end effector further comprises a jaw configured to receive the first staple cartridge assembly and a second staple cartridge assembly as a replacement for the first staple cartridge assembly.

Example 17 - The surgical stapling system of Example 16, wherein the jaws are rotatable relative to the anvil to place the end effector in a clamped configuration.

Example 18 - The surgical stapling system of Examples 16 and 17, wherein the anvil is rotatable relative to the jaws to place the end effector in a clamped configuration.

Example 19 - The surgical stapling system of Example 12, wherein the first staple cartridge assembly includes a first jaw portion mountable to the frame and the second cartridge assembly includes a second jaw portion mountable to the frame.

Example 20 - The surgical stapling system of example 19, wherein the anvil is rotatable relative to the jaws to place the end effector in a clamped configuration.

Example 21 - The surgical stapling system of Examples 19 and 20, wherein the first jaw is rotatable relative to the frame to place the end effector in a clamped configuration when the first jaw is attached to the frame, and the second jaw is rotatable relative to the frame to place the end effector in a clamped configuration when the second jaw is attached to the frame.

Example 22 - The surgical stapling system of Examples 12, 13, 14, 15, 16, 17, 18, 19, 20, and 21, wherein the first staple cartridge assembly includes a staple driver configured to expel the first staple from the first staple cavity, and each of the second staples includes an integrally formed staple driver.

Example 23 - A surgical fastening system comprising a shaft having a proximal end and a distal end, and an end effector extending from the distal end of the shaft, the end effector being movable between an open configuration and a closed configuration. The end effector comprises a frame and an anvil extending distally from the frame, the anvil comprising a shaped pocket. The surgical fastening system further comprises a first fastener cartridge assembly attachable to the end effector. The first fastener cartridge assembly comprises a first cartridge body having a first fastener cavity, as well as a plurality of first fasteners removably stored in the first fastener cavity. Each of the first fasteners is comprised of a bent wire, and the first fastener cavity aligns with the shaped pocket when the end effector is in the closed configuration. The surgical fastening system also includes a second fastener cartridge assembly attachable to the end effector in place of the first fastener cartridge assembly, the second fastener cartridge assembly including a second cartridge body having second fastener cavities and, in addition, a plurality of second fasteners removably stored within the second fastener cavities. Each of the second fasteners is formed from flat stock, and the second fastener cavities align with the molded pockets when the end effector is in a closed configuration.

Example 24 - A staple cartridge assembly comprising a cartridge body having a proximal end, a distal end, and a staple cavity extending between the proximal end and the distal end, and, in addition, a staple removably stored in the staple cavity, each staple being formed from flat stock. Each staple comprises a crown portion, a proximal leg, a distal leg, the proximal leg and the distal leg defining a staple leg plane, and an inclined cam surface extending from the crown portion and integrally formed with the crown portion, the inclined cam surface defining a cam plane different from the staple leg plane. Each staple also comprises a proximal connector extending between the proximal leg and the crown portion and integrally formed with the proximal leg and the crown portion, and a distal connector extending between the distal leg and the crown portion and integrally formed with the distal leg and the crown portion, wherein the inclined cam surface does not extend from the proximal connector and the inclined cam surface does not extend from the distal connector. The staple cartridge assembly also includes a sled configured to engage the ramped cam surface of the staple during the staple firing stroke to eject the staple from the staple cavity.

Example 25 - The staple cartridge assembly of Example 24, wherein the inclined cam surface is planar and the proximal and distal connectors are angled outward from the cam plane toward the staple leg plane.

Example 26 - The staple cartridge assembly of Examples 24 and 25, wherein the inclined cam surface has a proximal lead-in portion in the cam plane.

Example 27 - The staple cartridge assembly of Examples 24, 25, and 26, wherein each staple further comprises a clearance notch between the proximal lead-in portion and the proximal connector, the clearance notch being defined in the cam plane.

Example 28 - The staple cartridge assembly of Examples 24, 25, 26, and 27, wherein the proximal and distal legs of each staple extend outwardly in non-parallel directions from the crown when the staple is in an unfired configuration.

Example 29 - The staple cartridge assembly of Examples 24, 25, 26, 27, and 28, wherein the proximal and distal legs of the staple are bent inwardly by the side walls of the staple cavity when the staple is stored within the staple cavity.

Example 30 - The staple cartridge assembly of Examples 24, 25, 26, 27, 28, and 29, wherein the thread does not engage the proximal and distal connectors of the staple during the staple firing stroke.

Example 31 - The staple cartridge assembly of Examples 24, 25, 26, 27, 28, 29, and 30, wherein the entire inclined cam surface is positioned below the proximal staple leg and the distal staple leg.

Example 32 - The staple cartridge assembly of Examples 24, 25, 26, 27, 28, 29, 30, and 31, wherein the inclined cam surface provides an initial pick-up point for the sled.

Example 33 - A staple cartridge assembly comprising a cartridge body having a proximal end, a distal end, and a staple cavity extending between the proximal end and the distal end, and a staple removably stored in the staple cavity, the staple being formed from one or more metal sheets. Each staple comprises a crown portion, a proximal leg, a distal leg, and a cam surface extending from and integrally formed with the crown portion, the cam surface defining a cam plane, and the proximal and distal legs are not in the cam plane. Each staple also comprises a proximal connector extending between the proximal leg and the crown portion and integrally formed with the proximal leg and the crown portion, and a distal connector extending between the distal leg and the crown portion and integrally formed with the distal leg and the crown portion, the cam surface not extending from the proximal connector. The staple cartridge assembly also includes a sled configured to engage the camming surfaces of the staples and eject the staples from the staple cavities during the staple firing stroke.

Example 34 - The staple cartridge assembly of Example 33, wherein the cam surface is planar and the proximal and distal connectors are curved outward from the cam plane.

Example 35 - The staple cartridge assembly of Examples 33 and 34, wherein the cam surface has a proximal lead-in portion in the cam plane.

Example 36 - The staple cartridge assembly of Examples 33, 34, and 35, wherein each staple further comprises a clearance notch between the proximal lead-in portion and the proximal connector, the clearance notch being defined in the cam plane.

Example 37 - The staple cartridge assembly of Examples 33, 34, 35, and 36, wherein the proximal and distal legs of each staple extend outwardly in non-parallel directions from the crown when the staple is in an unfired configuration.

Example 38 - The staple cartridge assembly of Examples 33, 34, 35, 36, and 37, wherein the proximal and distal legs of the staple are bent inwardly by the side walls of the staple cavity when the staple is stored within the staple cavity.

Example 39 - The staple cartridge assembly of Examples 33, 34, 35, 36, 37, and 38, wherein the thread does not engage the proximal connector of the staple during the staple firing stroke.

Example 40 - The staple cartridge assembly of Examples 33, 34, 35, 36, 37, 38, and 39, wherein the entire cam surface is disposed beneath the proximal staple leg and the distal staple leg.

Example 41 - The staple cartridge assembly of Examples 33, 34, 35, 36, 37, 38, 39, and 40, wherein the cam surface provides an initial pick-up point for the sled.

Example 42 - A staple cartridge assembly comprising a cartridge body comprising a deck having a proximal end and a distal end, a longitudinal slot defined in the deck, the longitudinal slot configured to receive a firing member, a first longitudinally extending row of staple cavities, and a second longitudinally extending row of staple cavities. The staple cartridge assembly further comprises a sled movable toward the distal end by the firing member during a firing stroke, and a plurality of first staples removably stored within the first longitudinally extending row of staples, each of the first staples being comprised of a bent wire. The staple cartridge assembly also includes a plurality of staple drivers configured to support first staples, the sled being configured to engage the staple drivers during a firing stroke to eject the first staples from the first longitudinally extending row of staple cavities, and a plurality of second staples removably stored within the second longitudinally extending row of staple cavities, the second staples each formed from flat stock and having an integrally formed driver, the sled being configured to directly engage the integrally formed driver of the second staples during a firing stroke to eject the second staples from the second longitudinally extending row of staple cavities.

Example 43 - The staple cartridge assembly of Example 42, wherein the first longitudinally extending row of staple cavities is adjacent to the longitudinal slot and the first longitudinally extending row of staple cavities is intermediate the longitudinal slot and the second longitudinally extending row of staple cavities.

Example 44 - The staple cartridge assembly of Example 42, wherein the second longitudinally extending row of staple cavities is adjacent to the longitudinal slot and the second longitudinally extending row of staple cavities is intermediate the longitudinal slot and the first longitudinally extending row of staple cavities.

Example 45 - The staple cartridge assembly of Examples 42, 43, and 44, wherein the cartridge body further comprises a third longitudinally extending row of staple cavities, and the staple cartridge assembly further comprises a plurality of third staples removably stored within the third longitudinally extending row of staple cavities, each of the third staples being comprised of a bent wire.

Example 46 - The staple cartridge assembly of Example 45, wherein the third longitudinally extending row of staple cavities is adjacent to the first longitudinally extending row of staple cavities, the staple driver is configured to support a third staple, and the sled is configured to engage the staple driver during the firing stroke and eject the third staple from the third longitudinally extending row of staple cavities.

Example 47 - The staple cartridge assembly of Example 45, further comprising a plurality of staple drivers configured to support a third staple and be engaged by the threads to eject the third staples from the third longitudinally extending row of staple cavities during the firing stroke.

Example 48 - The staple cartridge assembly of Examples 42, 43, and 44, wherein the cartridge body further comprises a third longitudinally extending row of staple cavities, the staple cartridge assembly further comprises a plurality of third staples removably stored within the third longitudinally extending row of staple cavities, each of the third staples being formed from flat stock and having an integrally formed driver, and the sled is configured to directly engage the integrally formed driver of the third staple during a firing stroke to eject the third staple from the third longitudinally extending row of staple cavities.

Example 49 - The staple cartridge assembly of Example 48, wherein the third longitudinally extending row of staple cavities is adjacent to the longitudinal slot, the second longitudinally extending row of staple cavities is adjacent to the third longitudinally extending row of staple cavities, and the second longitudinally extending row of staple cavities is intermediate the first longitudinally extending row of staple cavities and the third longitudinally extending row of staple cavities.

Example 50 - A staple cartridge assembly comprising a cutting member and a cartridge body, the cartridge body comprising a deck having a proximal end and a distal end, a longitudinal slot defined in the deck, the longitudinal slot configured to receive the cutting member, a first longitudinally extending row of staple cavities, and a second longitudinally extending row of staple cavities. The staple cartridge assembly further comprises a sled movable toward the distal end by the cutting member during a firing stroke, and a plurality of first staples removably stored within the first longitudinally extending row of staples, each of the first staples being comprised of a bent wire. The staple cartridge assembly also includes a plurality of staple drivers configured to support first staples, the sled being configured to engage the staple drivers during a firing stroke to eject the first staples from the first longitudinally extending row of staple cavities, and a plurality of second staples removably stored within the second longitudinally extending staple cavities, the second staples being stamped from one or more metal sheets, the sled being configured to directly engage the second staples during a firing stroke to eject the second staples from the second longitudinally extending row of staple cavities.

Example 51 - The staple cartridge assembly of Example 50, wherein the first longitudinally extending row of staple cavities is adjacent to the longitudinal slot and the first longitudinally extending row of staple cavities is intermediate the longitudinal slot and the second longitudinally extending row of staple cavities.

Example 52 - The staple cartridge assembly of Example 50, wherein the second longitudinally extending row of staple cavities is adjacent to the longitudinal slot and the second longitudinally extending row of staple cavities is intermediate the longitudinal slot and the first longitudinally extending row of staple cavities.

Example 53 - The staple cartridge assembly of Examples 50, 51, and 52, wherein the cartridge body further comprises a third longitudinally extending row of staple cavities, and the staple cartridge assembly further comprises a plurality of third staples removably stored within the third longitudinally extending row of staple cavities, each of the third staples being comprised of a bent wire.

Example 54 - The staple cartridge assembly of Example 53, wherein the third longitudinally extending row of staple cavities is adjacent to the first longitudinally extending row of staple cavities, the staple driver is configured to support a third staple, and the sled is configured to engage the staple driver during the firing stroke to eject the third staple from the third longitudinally extending row of staple cavities.

Example 55 - The staple cartridge assembly of Example 53, further comprising a plurality of staple drivers configured to support a third staple and be engaged by the threads to eject the third staples from the third longitudinally extending row of staple cavities during the firing stroke.

Example 56 - The staple cartridge assembly of Examples 50, 51, 52, 53, 54, and 55, wherein the cartridge body further comprises a third longitudinally extending row of staple cavities, and the staple cartridge assembly further comprises a plurality of third staples removably stored within the third longitudinally extending row of staple cavities, the third staples being formed from one or more metal sheets, and the sled is configured to directly engage the third staples and eject the third staples from the third longitudinally extending staple cavities during the firing stroke.

Example 57 - The staple cartridge assembly of Examples 50, 51, and 52, wherein the third longitudinally extending row of staple cavities is adjacent to the longitudinal slot, the second longitudinally extending row of staple cavities is adjacent to the third longitudinally extending row of staple cavities, and the second longitudinally extending row of staple cavities is intermediate the first longitudinally extending row of staple cavities and the third longitudinally extending row of staple cavities.

Example 58 - A staple cartridge assembly comprising a cartridge body comprising a deck having a proximal end and a distal end, a longitudinal slot defined in the deck, the longitudinal slot configured to receive a firing member, and a plurality of staple cavities. The staple cartridge assembly further comprises a sled movable toward the distal end by the firing member during a firing stroke, a plurality of first staples removably stored in the staple cavities, each of the first staples being comprised of a bent wire, and a plurality of staple drivers, the sled configured to engage the staple driver during the firing stroke to eject the first staples from the staple cavities. The staple cartridge assembly also includes a plurality of second staples removably stored within the staple cavities, each of the second staples being formed from flat stock and including an integrally formed driver, and the sled is configured to directly engage the integrally formed driver of the second staple during the firing stroke to eject the second staple from the staple cavity.

Example 59 - A staple cartridge assembly comprising a cartridge body including a proximal end, a distal end, a deck configured to support tissue of a patient, and a plurality of staple cavities defined within the deck. The staple cartridge assembly also comprises a plurality of metal staples removably stored within the staple cavities, each of the metal staples comprising a crown portion having a tissue contacting surface, a first leg portion coupled to the crown portion, a second leg portion coupled to the crown portion, and a driver integrally formed with the crown portion. Additionally, the staple cartridge assembly comprises a sled movable toward the distal end during a firing stroke, the sled configured to directly engage the driver of the metal staple during the firing stroke to move each of the metal staples between an unfired position and a fired position, the tissue contacting surface of the crown portion being disposed above the deck when the metal staple is in the fired position, and the driver of the metal staple being disposed at least partially below the deck when the metal staple is in the fired position.

Example 60 - The staple cartridge assembly of Example 59, wherein the cartridge body further comprises a guide extending from the deck, the guide configured to support and guide the staple legs above the deck when the metal staple is moved to the fired position, and the tissue contacting surface of the crown portion is disposed at least partially above the guide when the metal staple is in the fired position.

Example 61 - The staple cartridge assembly of Examples 59 and 60, wherein the sled has one or more drive surfaces configured to engage a driver of a metal staple, each drive surface having a top surface, and the top surface of each of the drive surfaces is completely below the deck.

Example 62 - A staple cartridge assembly comprising a cartridge body having a proximal end, a distal end, a deck configured to support tissue of a patient, and a staple cavity defined within the deck. The staple cartridge assembly further comprises a staple removably stored within the staple cavity, the staple comprising a crown having a tissue engaging surface, a first leg extending from the crown, a second leg extending from the crown, and a driver integrally formed with the crown. Additionally, the staple cartridge assembly comprises a sled movable toward the distal end during a firing stroke, the sled configured to directly engage the driver of the staple during the firing stroke to move the staple between an unfired position and a fired position, the tissue engaging surface of the crown being disposed at least partially above the deck when the staple is in the fired position, and the driver being disposed at least partially below the deck when the staple is in the fired position.

Example 63 - The staple cartridge assembly of Example 62, wherein the cartridge body further comprises a guide extending from the deck, the guide configured to support and guide a first leg of the staple above the deck when the staple is moved to the fired position, and the tissue contacting surface of the crown portion is disposed at least partially above the guide when the staple is in the fired position.

Example 64 - The staple cartridge assembly of Examples 62 and 63, wherein the sled has a drive surface configured to engage a driver of the staple, the drive surface having a top surface, and the top surface is completely below the deck.

Example 65 - A staple cartridge assembly comprising a cartridge body having a proximal end, a distal end, a deck configured to support tissue of a patient, and a staple cavity defined within the deck. The staple cartridge assembly further comprises a staple removably stored within the staple cavity, the staple comprising a crown having a tissue engaging surface, a first leg extending from the crown, a second leg extending from the crown, and a driver integrally formed with the crown. The staple cartridge assembly also comprises a firing member movable toward the distal end during a firing stroke, the firing member configured to directly engage the driver of the staple during the firing stroke to move the staple between an unfired position and a fired position, the tissue engaging surface of the crown being at least partially disposed above the deck when the staple is in the fired position, and the driver being completely disposed below the deck when the staple is in the fired position.

Example 66 - The staple cartridge assembly of Example 65, wherein the cartridge body further comprises a guide extending from the deck, the guide configured to support and guide a first leg of the staple above the deck as the staple is moved to the fired position, and the tissue contacting surface of the crown portion is disposed completely or partially above the guide when the staple is in the fired position.

Example 67 - The staple cartridge assembly of Examples 65 and 66, wherein the firing member comprises a drive surface configured to engage a driver of the staple, the drive surface comprising a top surface, the top surface being completely below the deck.

Example 68 - A cartridge body comprising:
1. A staple cartridge assembly comprising: a cartridge body comprising: a deck configured to support tissue of a patient; and a longitudinal slot defined in the deck, the longitudinal slot defining a longitudinal slot axis, the longitudinal slot configured to receive a cutting member, the deck comprising a first deck portion on a first side of the longitudinal slot and a second deck portion on a second side of the longitudinal slot.
The staple cartridge assembly further comprises a first row of staple cavities defined in the first deck portion adjacent the longitudinal slot, the first row of staple cavities being defined along the first longitudinal axis, a first distance being defined between the first longitudinal axis and the longitudinal slot axis. The cartridge body also comprises a second row of staple cavities defined in the second deck portion adjacent the longitudinal slot, the second row of staple cavities being defined along the second longitudinal axis, a second distance being defined between the second longitudinal axis and the longitudinal slot axis, the second distance being different from the first distance. The staple cartridge assembly further comprises staples removably stored in the first row of staple cavities and the second row of staple cavities.

Example 69 - The staple cartridge assembly of Example 68, further comprising a sled, the sled comprising a first longitudinal ramp configured to eject staples from the first row of staple cavities and a second longitudinal ramp configured to eject staples from the second row of staple cavities.

Example 70 - The staple cartridge assembly of Example 69, wherein a first distance is defined between the first longitudinal ramp and the longitudinal slot axis and a second distance is defined between the second longitudinal ramp and the longitudinal slot axis.

Example 71 - A cartridge body comprising:
A fastener cartridge assembly comprising: a cartridge body including a deck configured to support tissue of a patient and a longitudinal slot defined in the deck, the longitudinal slot defining a longitudinal slot axis, the longitudinal slot configured to receive a cutting member, the deck including a first deck portion on a first side of the longitudinal slot and a second deck portion on a second side of the longitudinal slot.
The cartridge body further comprises a first row of fastener cavities defined in the first deck portion adjacent the longitudinal slot, the first row of fastener cavities being defined along a first longitudinal axis, a first distance being defined between the first longitudinal axis and the longitudinal slot axis. The cartridge body also comprises a second row of fastener cavities defined in the second deck portion adjacent the longitudinal slot, the second row of fastener cavities being defined along a second longitudinal axis, a second distance being defined between the second longitudinal axis and the longitudinal slot axis, the second distance being different from the first distance. The fastener cartridge assembly further comprises fasteners removably stored within the first row of fastener cavities and the second row of fastener cavities, the fasteners being formed from one or more sheets of material.

Example 72 - The fastener cartridge assembly of Example 71, wherein the first row of fastener cavities is closer to the longitudinal slot than the second row of fastener cavities.

Example 73 - The fastener cartridge assembly of Example 71, wherein the second row of fastener cavities is closer to the longitudinal slot than the first row of fastener cavities.

Example 74 - The staple cartridge assembly of Examples 71, 72, and 73, further comprising a sled, the sled comprising a first longitudinal ramp configured to eject fasteners from the first row of fastener cavities and a second longitudinal ramp configured to eject fasteners from the second row of fastener cavities.

Example 75 - The fastener cartridge assembly of Example 74, wherein the first longitudinal ramp is positioned closer to the longitudinal slot than the second longitudinal ramp.

Example 76 - The fastener cartridge assembly of Example 74, wherein the second longitudinal ramp is positioned closer to the longitudinal slot than the first longitudinal ramp.

Example 77 - A cartridge body comprising:
A staple cartridge assembly comprising: a cartridge body comprising a deck configured to support tissue of a patient and a longitudinal slot defined in the deck, the longitudinal slot configured to receive a cutting member, the deck comprising a first deck portion on a first side of the longitudinal slot and a second deck portion on a second side of the longitudinal slot. The cartridge body further comprises a first row of staple cavities defined in the first deck portion adjacent to the longitudinal slot, a first distance being defined between the first row of staple cavities and the longitudinal slot. The cartridge body also comprises a second row of staple cavities defined in the second deck portion adjacent to the longitudinal slot, a second distance being defined between the second row of staple cavities and the longitudinal slot, the second distance being different from the first distance. The staple cartridge assembly further comprises staples removably stored in the first row of staple cavities and the second row of staple cavities.

Example 78 - The staple cartridge assembly of Example 77, further comprising a sled, the sled comprising a first longitudinal ramp configured to eject staples from the first row of staple cavities and a second longitudinal ramp configured to eject staples from the second row of staple cavities.

Example 79 - The staple cartridge assembly of Example 78, wherein a first distance is defined between the first longitudinal ramp and the longitudinal slot, and a second distance is defined between the second longitudinal ramp and the longitudinal slot.

Example 80 - The staple cartridge assembly of Examples 78 and 79, wherein each staple comprises a crown portion, a cam portion integrally formed with the crown portion, the cam portion being configured such that the threads directly engage the cam portion, and a tissue clamping portion offset from the cam portion.

Example 81 - The staple cartridge assembly of Example 80, in which the cam portion of the staple is positioned closer to the longitudinal slot than the tissue clamping portion.

Example 82 - The staple cartridge assembly of Example 80, wherein the tissue clamping portion of the staple is positioned closer to the longitudinal slot than the cam portion.

Example 83 - The staple cartridge assembly of Examples 77, 78, 79, 80, 81, and 82, wherein the first distance is shorter than the second distance.

Example 84 - The staple cartridge assembly of Examples 77, 78, 79, 80, 81, and 82, wherein the second distance is shorter than the first distance.

Although the surgical tool systems described herein are described in connection with the deployment and deformation of staples, the embodiments described herein are not so limited. Various embodiments are contemplated for deploying fasteners other than staples, such as clamps or tacks. Additionally, various embodiments are contemplated for utilizing any suitable means for sealing tissue. For example, end effectors according to various embodiments may include electrodes configured to heat and seal tissue. Also for example, end effectors according to certain embodiments may apply vibrational energy to seal tissue.

The entire disclosures of the following are incorporated herein by reference:
U.S. Patent Application No. 14/822,970, filed Aug. 11, 2015, now U.S. Patent Application Publication No. 2015/0342603, entitled "ADAPTER ASSEMBLY FOR INTERCONNECTING ELECTROMECHANICAL SURGICAL DEVICES AND SURGICAL LOADING UNITS, AND SURGICAL SYSTEMS THEREOF";
No. 13/921,890, filed on June 19, 2013, now U.S. Patent Application Publication No. 2013/0282052, entitled "APPRATATS FOR ENDOSCOPIC PROCEDURES";
No. 13/924,054, filed on June 21, 2013, now U.S. Patent Application Publication No. 2014/0263545, entitled "SURGICAL STAPLING APPARATUS";
U.S. Patent Application No. 14/257,063, filed April 21, 2014, now U.S. Patent Application Publication No. 2015/0297199, entitled "ADAPTER ASSEMBLY WITH GIMBAL FOR INTERCONNECTING ELECTROMECHANICAL SURGICAL DEVICES AND SURGICAL LOADING UNITS, AND SURGICAL SYSTEMS THEREOF";
No. 14/674,152, filed March 31, 2015, now U.S. Patent Application Publication No. 2015/0366560, entitled "DISPOSABLE HOUSINGS FOR ENCASING HANDLE ASSEMBLYS AND METHODS OF USE";
U.S. Patent Application No. 14/672,973, filed March 30, 2015, now U.S. Patent Application Publication No. 2015/0374366, entitled "ADAPTER ASSEMBLY FOR INTERCONNECTING ELECTROMECHANICAL SURGICAL DEVICES AND SURGICAL LOADING UNITS, AND SURGICAL SYSTEMS THEREOF";
U.S. Patent Application No. 14/672,731, entitled "ADAPTER ASSEMBLIES FOR INTERCONNECTING ELECTROMECHANICAL HANDLE ASSEMBLIES AND SURGICAL LOADING UNITS," filed March 30, 2015, now U.S. Patent Application Publication No. 2015/0374449; and European Patent Application Publication No. EP 3005956 A1, published April 13, 2016, entitled "STAPLE CARTRIDGE WITH SHIPPING WEDGE," and PCT Publication No. WO 2016/057225, filed April 14, 2016. A1, entitled "HANDHELD ELECTROMECHANICAL SURGICAL SYSTEM," which are incorporated herein by reference.

The entire disclosures of the following are incorporated herein by reference:
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No. 13/800,067, filed March 13, 2013, entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM," now U.S. Patent Application Publication No. 2014/0263552;
U.S. Patent Application Publication No. 2007/0175955, filed on January 31, 2006, entitled "SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM"; and
U.S. Patent Application Publication No. 2010/0264194, filed April 22, 2010, entitled "SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR," now U.S. Patent No. 8,308,040.

Although various devices have been described herein with specific embodiments, modifications and variations may be made to those embodiments. Also, although materials are disclosed with respect to specific components, other materials may be used. Moreover, in accordance with various embodiments, multiple components may be substituted for a single component, and multiple components may be substituted for a single component, to perform a given function. It is intended that the foregoing description and the following claims encompass all such modifications and variations.

The devices disclosed herein can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either case, however, the device can be reconditioned for reuse after at least one use. Reconditioning can include, but is not limited to, any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular parts of the device, and then reassembly of the device. Specifically, a reconditioning facility and/or surgical team can disassemble the device, clean and/or replace particular parts of the device, and then reassemble the device for subsequent use. One of ordinary skill in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. Use of such techniques, and the resulting reconditioned devices, are all within the scope of the present invention.

The devices disclosed herein may be processed prior to surgery. First, new or used instruments may be obtained and cleaned as necessary. The instruments may then be sterilized. In one sterilization technique, the instruments are placed in a closed and sealed container, such as a plastic bag or a TYVEK bag. The container and instruments 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 instruments and in the container. The sterilized instruments may then be stored in the sterile container. The sealed container may keep the instruments sterile until they are opened in the medical facility. The devices may also be sterilized using any other technique known in the art, including, but not limited to, beta radiation, gamma radiation, ethylene oxide, hydrogen peroxide plasma, and/or water vapor.

While the invention has been described as having an exemplary design, the 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.

All patents, publications, or other disclosures incorporated herein in whole or in part are incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, descriptions, or other disclosures set forth in this disclosure. As such, and to the extent necessary, the disclosures explicitly set forth in this specification shall take precedence over any conflicting statements incorporated herein by reference. Any documents, or portions thereof, that are incorporated herein by reference but that conflict with existing definitions, descriptions, or other disclosures set forth herein shall be incorporated only to the extent that no conflict arises between the incorporated document and the existing disclosures.

[Embodiment]
(1) A staple cartridge assembly, comprising:
A cartridge body,
A proximal end portion;
A distal end portion.
a deck configured to support tissue of a patient;
a plurality of staple cavities defined in the deck; and
a plurality of metal staples removably stored within the staple cavities, each of which comprises:
a crown portion having a tissue contacting surface;
a first leg portion connected to the crown portion;
a second leg portion connected to the crown portion;
a driver integrally formed with said crown;
a sled movable toward the distal end during a firing stroke, the sled configured to directly engage the drivers of the metal staples during the firing stroke to move the metal staples between unfired and fired positions, respectively, wherein the tissue contacting surface of the crown portion is disposed above the deck when the metal staples are in the fired position and the drivers of the metal staples are disposed at least partially below the deck when the metal staples are in the fired position.
(2) The staple cartridge assembly of claim 1, wherein the cartridge body further comprises a guide extending from the deck, the guide being configured to support and guide the staple legs above the deck when the metal staples are moved to the fired position, and the tissue contacting surface of the crown portion is at least partially disposed above the guide when the metal staples are in the fired position.
(3) The staple cartridge assembly of claim 1, wherein the sled comprises one or more drive surfaces configured to engage the drivers of the metal staples, the drive surfaces each comprising a top surface, the top surface of each of the drive surfaces being completely below the deck.
(4) A staple cartridge assembly, comprising:
A cartridge body,
A proximal end portion;
A distal end portion.
a deck configured to support tissue of a patient;
a staple cavity defined in the deck; and
a staple removably stored within the staple cavity,
a crown portion having a tissue engaging surface;
a first leg extending from the crown portion;
a second leg extending from the crown portion;
a driver integrally formed with said crown;
a sled movable toward the distal end during a firing stroke, the sled configured to directly engage the driver of the staple during the firing stroke to move the staple between an unfired position and a fired position, the tissue engaging surface of the crown being positioned at least partially above the deck when the staple is in the fired position and the driver being positioned at least partially below the deck when the staple is in the fired position.
(5) The staple cartridge assembly of claim 4, wherein the cartridge body further comprises a guide extending from the deck, the guide configured to support and guide a first leg of the staple above the deck as the staple is moved to the fired position, and the tissue contacting surface of the crown is at least partially disposed above the guide when the staple is in the fired position.

6. The staple cartridge assembly of claim 4, wherein the sled comprises a drive surface configured to engage the driver of the staple, the drive surface comprising a top surface, the top surface being entirely below the deck.
(7) A staple cartridge assembly, comprising:
A cartridge body,
A proximal end portion;
A distal end portion.
a deck configured to support tissue of a patient;
a staple cavity defined in the deck; and
a staple removably stored within the staple cavity,
a crown portion having a tissue engaging surface;
a first leg extending from the crown portion;
a second leg extending from the crown portion;
a driver integrally formed with said crown;
a firing member movable toward the distal end during a firing stroke, the firing member configured to directly engage the driver of the staple during the firing stroke to move the staple between an unfired position and a fired position, the tissue engaging surface of the crown being positioned entirely above the deck when the staple is in the fired position and the driver being positioned entirely below the deck when the staple is in the fired position.
(8) The staple cartridge assembly of claim 7, wherein the cartridge body further comprises a guide extending from the deck, the guide configured to support and guide a first leg of the staple above the deck as the staple is moved to the fired position, and the tissue contacting surface of the crown is disposed completely or partially above the guide when the staple is in the fired position.
9. The staple cartridge assembly of claim 7, wherein the firing member comprises a drive surface configured to engage the driver of the staple, the drive surface comprising a top surface, the top surface being completely below the deck.

Claims (5)

1. A method of manufacturing a metal staple for use with a staple cartridge assembly, comprising:
the metal staple is a single piece of metal;
a crown portion having a tissue contacting surface;
a first leg portion connected to the crown portion;
a second leg portion connected to the crown portion;
a driver integrally formed with the crown portion,
The staple cartridge assembly includes:
A cartridge body,
A proximal end portion;
A distal end portion.
a deck configured to support tissue of a patient;
a cartridge body comprising: a plurality of staple cavities defined in the deck, the metal staples being removably stored within each of the staple cavities;
a sled movable toward the distal end during a firing stroke, the sled configured to directly engage the drivers of the metal staples during the firing stroke to lift and move each of the metal staples from an unfired position to a fired position in which the metal staples are ejected from the staple cavities, the tissue contacting surface of the crown being at least partially disposed above the deck when the metal staples are in the fired position and the drivers of the metal staples being at least partially disposed below the deck when the metal staples are in the fired position;
The manufacturing method includes:
Supplying a sheet of metal material to a progressive die;
striking the sheet of metal material with the progressive die to form a bandolier having a plurality of staples successively attached thereto;
removing each of the plurality of staples from the bandolier to form the metal staples;
each of the plurality of staples includes the crown, the first leg, the second leg, and the driver, each of the plurality of staples being attached to the bandolier at a juncture defined distal to the driver. 2. The method of claim 1, wherein the cartridge body further comprises a guide extending from the deck, the guide configured to support and guide the first and second legs of the metal staple above the deck as the metal staple is moved to the fired position, and the tissue contacting surface of the crown portion of the metal staple is at least partially positioned above the guide when the metal staple is in the fired position. The method of claim 1, wherein the sled comprises one or more drive surfaces configured to engage the drivers of the metal staples, each of the drive surfaces comprising a top surface, the top surface of each of the drive surfaces being completely below the deck. the first leg is coupled to the crown portion by a first connector, and the second leg is coupled to the crown portion by a second connector;
the driver includes a cam surface defined thereon, the cam surface of the metal staple configured to be directly engaged by the sled during the firing stroke;
2. The method of claim 1, wherein the first leg, the first connector, the second leg, and the second connector do not extend below the driver, and the cam surface is entirely below the first leg, the first connector, the second leg, and the second connector. The manufacturing method according to claim 4, wherein the connection point is distal to the cam surface.

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