Actuator support structure for surgical stapler

A surgical stapler includes first and second elongate members, a clamp member, and a firing assembly. The second elongate member is configured to receive a staple cartridge. The clamp member is operable to releasably clamp the first elongate member against the second elongate member. The firing assembly is translatable to fire the staple cartridge. The firing assembly includes a slider and an actuator configured to be selectively actuated by a user. The slider includes inner and outer engagement features. The actuator includes inner and outer engagement features. The inner engagement feature of the actuator is configured to engage with the inner engagement feature of the slider at a first interface when the actuator moves relative to the slider. The outer engagement feature of the actuator is configured to engage the outer engagement feature of the slider at a second interface when the actuator moves relative to the slider.

BACKGROUND

In some surgical operations, such as a gastrointestinal anastomosis, it may be desirable to clamp down on one or more layers of tissue, cut through the clamped layers, and simultaneously drive staples through the layers to substantially seal the severed layers of tissue together near their severed ends. One such instrument that may be used in such operations is a linear surgical stapler, also referred to as a “linear cutter.” A linear surgical stapler generally includes a first half (referred to as a “cartridge half” or “reload half”) having a distal jaw configured to support a staple cartridge (or “reload”), and a second half (referred to as an “anvil half”) having a distal jaw that supports an anvil surface having staple forming features. The stapler further includes a moveable clamp lever configured to releasably clamp the stapler halves together. The stapler halves are configured to pivot relative to one another to receive and clamp tissue between the two distal jaws when the clamp lever is closed. A firing assembly of the stapler is configured to be actuated to cut the clamped layers and simultaneously drive staples through the tissue on either side of the cut line. After firing the stapler, the clamp lever may be opened and the stapler halves separated to release the severed and stapled tissue.

While various kinds of surgical stapling instruments and associated components have been made and used, it is believed that no one prior to the inventor(s) has made or used the invention described in the appended claims.

DETAILED DESCRIPTION

For clarity of disclosure, the terms “proximal” and “distal” are defined herein relative to a surgeon, or other operator, grasping a surgical instrument having a distal surgical end effector. The term “proximal” refers to the position of an element arranged closer to the surgeon, and the term “distal” refers to the position of an element arranged closer to the surgical end effector of the surgical instrument and further away from the surgeon. Moreover, to the extent that spatial terms such as “upper,” “lower,” “vertical,” “horizontal,” or the like are used herein with reference to the drawings, it will be appreciated that such terms are used for exemplary description purposes only and are not intended to be limiting or absolute. In that regard, it will be understood that surgical instruments such as those disclosed herein may be used in a variety of orientations and positions not limited to those shown and described herein.

As used herein, the terms “about” and “approximately” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein.

I. Exemplary Linear Surgical Stapler

A. Overview of Linear Surgical Stapler

FIGS. 1 and 2show an exemplary linear surgical stapler (10) (also referred to as a “linear cutter”) suitable for use in a variety of cutting and stapling procedures, such as a gastrointestinal anastomosis procedure. Linear surgical stapler (10) includes a cartridge half (12) (also referred to as a “reload half”) and an anvil half (14) configured to releasably couple together to clamp tissue therebetween. Cartridge half (12) includes a frame (16). Frame (16) is shown as being generally U-shaped to form an elongate channel. Frame (16) includes a proximal frame portion (18), a distal frame portion (20), and a pair of upright side flanges (22) arranged medially therebetween. Proximal frame portion (18) slidably retains a portion of a firing assembly (34). Distal jaw portion (20) supports a staple cartridge (80) (or “reload”).

Cartridge half (12) further includes a clamp lever (24) pivotably coupled to an underside of frame (16) in approximate alignment with side flanges (22). Clamp lever (24) includes an elongate lever arm (26) having a free proximal end and a distal end that is pivotably coupled to frame (16) with a pivot pin (28). A pair of opposed jaws (30) extends distally from the distal end of lever arm (26) alongside flanges (22) of frame (16). Each jaw (30) includes a respective elongate slot (32) having a closed proximal end and an open distal end, and which defines upper and lower camming surfaces configured to engage a respective latch projection (56) of anvil half (14). As described below, clamp lever (24) is operable to pivot relative to frame (16) between open and closed positions to releasably clamp anvil half (14) against cartridge half (12) and thereby capture tissue layers therebetween.

As shown best inFIG. 2, firing assembly (34) of cartridge half (12) includes a slider (36), shown schematically, slidably retained within proximal frame portion (18) of frame (16), an actuator (38) (or “firing knob”) movably coupled with slider (36), and an elongate actuating beam (not shown) extending distally from slider (36) and configured to couple with a sled (100) (shown inFIG. 3) housed within staple cartridge (80). Actuator (38) of the present example is configured to pivot about the proximal end of cartridge half (12) to provide for “dual-sided firing” of stapler (10). Specifically, actuator (38) may be positioned along either lateral side of cartridge half (12) to perform a distal firing stroke, such that stapler (10) may be conveniently fired in a variety of orientations during a surgical procedure.

Slider (36) is configured to be translatably driven within proximal frame portion (18) by actuator (38) between a proximal home position shown inFIGS. 2 and 5A, and a distal fired position shown inFIG. 5B. In the proximal home position, slider (36) abuts a post (40) fixed at a proximal end of frame (16). A free end of post (40) supports a laterally extending pivot pin (42). As described below, actuator (38) may be driven distally when stapler halves (12,14) are fully coupled together and clamp lever (24) is closed. Distal advancement of actuator (38) along either lateral side of stapler (10) drives slider (36) and the elongate actuating beam distally, which in turn drives sled (100) distally through staple cartridge (80). As described below, distal translation of sled (100) through staple cartridge (80) provides for simultaneous stapling and cutting of tissue clamped between stapler halves (12,14).

As shown best inFIGS. 1 and 2, anvil half (14) of linear surgical stapler (10) includes an elongate anvil channel (50) having a proximal frame portion (52) and a distal jaw portion (54). Anvil channel (50) further includes a latch feature in the form of a pair of projections (56) that extend transversely from a medial portion of anvil channel (50) in a direction toward cartridge half (12). Each latch projection (56) may include a circular rotating cap configured to be captured within slot (32) of a respective clamp lever jaw (30) when anvil half (14) is coupled with cartridge half (12) and clamp lever (24) is pivoted from the open position to the closed position, as described below. A pair of hooks (58) extend proximally from a proximal end of frame portion (52) and are configured to releasably capture opposed lateral ends of proximal pivot pin (42) of cartridge half (12). Distal jaw portion (54) supports an anvil surface in the form of an anvil plate (60) having a plurality of staple forming pockets (not shown), and additionally supports a distal tip member (62). In other versions of stapler (10), the anvil surface may be formed integrally with or otherwise be rigidly connected to distal jaw portion (54) of anvil channel (50).

Anvil half (14) of the present example further includes a staple height adjustment mechanism (64) mounted to a medial portion of anvil channel (50). Staple height adjustment mechanism (64) is operatively coupled with anvil plate (60), for example, via one or more camming features (not shown), and includes a pair of user-engageable projections (66). Longitudinal adjustment of projections (66) between a plurality of predetermined positions causes anvil plate (60) to move transversely relative to distal jaw portion (54) of anvil channel (50). This enables adjustment of a transverse gap distance between anvil plate (60) and a deck (94) of staple cartridge (80) that defines the height of staples being formed. A larger gap distance, and thus a greater staple height, may be set when stapling tissues of greater thicknesses. Conversely, a smaller gap distance, and thus a smaller staple height, may be set when stapling tissues of lesser thicknesses. It will be appreciated that staple height adjustment mechanism (64) may be omitted in some versions, in which case the anvil surface may be fixed relative to anvil channel (50). For instance, the anvil surface may be formed integrally with or otherwise fixedly secured to distal jaw portion (54).

As shown inFIGS. 1 and 2, linear surgical stapler (10) further includes a plurality of shrouds (70,72,74) that cover select portions of stapler (10) and promote effective grip and manipulation of stapler (10) by an operator during use. In the present example, cartridge half (12) includes shroud (70) that covers an outwardly facing side of proximal frame portion (18) of frame (16). Cartridge half (12) further includes shroud (72) that covers an outwardly facing side of clamp lever (24) and is configured to pivot with clamp lever (24) relative to frame (16) and shroud (70). Anvil half (14) includes shroud (74) that covers an outwardly facing side of proximal frame portion (52) of anvil channel (50), including proximal hooks (58). Each shroud (70,72,74) may be coupled with its respective components of stapler (10) by any suitable means apparent to those of ordinary skill in the art. Additionally, each shroud (70,72,74) may be formed of one or more materials and be provided with texturing suitable to promote effective gripping of the shroud (70,72,74) by an operator to enable safe and efficient use of stapler (10) during a surgical procedure.

As shown inFIGS. 2 and 3, staple cartridge (80) of the present example is an assembly that comprises a cartridge body (82), a pan (84) that covers an open lower side of cartridge body (82), and a plurality of staple drivers (86) housed within cartridge body (82) and each being configured to drive a respective staple (88). Cartridge body (82) includes a proximal end having engagement features (90) configured to releasably engage corresponding engagement features (not shown) of distal jaw portion (20) of frame (16), and a distal end defining a tapered nose (92). An upper side of cartridge body (82) defines a generally planar deck (94) through which a longitudinal slot (96) and a plurality of staple cavities (98) open. Each staple cavity (98) houses a respective staple driver (86) and staple (88). As shown inFIG. 3, an interior of cartridge body (82) slidably houses sled (100) that comprises a sled body (102) and knife member (104). Lateral sides of sled body (102) support a plurality of cam ramps (106) that taper distally. A proximal end of sled body (102) includes a downwardly extending tab (108) configured to lockingly engage a distal end of the elongate actuating beam (not shown) of firing assembly (34) when staple cartridge (80) is mounted to cartridge half (12) of stapler (10). Knife member (104) extends upwardly from an upper side of sled body (102) and presents a distally facing cutting edge (110) configured to cut tissue.

Sled (100) is configured to translate distally through cartridge body (82) in response to distal actuation of firing assembly (34), such that knife member (104) translates distally through longitudinal slot (96) to cut tissue clamped between stapler halves (12,14). Simultaneously, cam ramps (106) translate distally through respective interior slots (not shown) of cartridge body (82) to actuate staple drivers (86) and staples (88) upwardly through staple cavities (98) so that free ends of staples (88) pierce through the clamped tissue and deform against staple forming pockets of anvil plate (60). In this manner, distal actuation of firing assembly (34) provides for simultaneous severing and stapling of tissue clamped between the distal end effector portions of stapler halves (12,14).

Linear surgical stapler (10) and staple cartridge (80) may be further configured and operable in accordance with one or more teachings of U.S. Pat. No. 7,905,381, entitled “Surgical Stapling Instrument with Cutting Member Arrangement,” issued Mar. 15, 2011; U.S. Pat. No. 7,954,686, entitled “Surgical Stapler with Apparatus for Adjusting Staple Height,” issued Jun. 7, 2011; U.S. Pat. No. 8,348,129, entitled “Surgical Stapler Having A Closure Mechanism,” issued Jan. 8, 2013; and/or U.S. Pat. No. 8,789,740, entitled “Linear Cutting and Stapling Device with Selectively Disengageable Cutting Member,” issued Jul. 29, 2014. The disclosure of each of these references is incorporated by reference herein.

B. Exemplary Use of Linear Surgical Stapler

FIGS. 4A-4Cshow exemplary coupling of stapler halves (12,14) during a surgical procedure. As shown inFIG. 4A, the proximal end of anvil half (14) is aligned with the proximal end of cartridge half (12) such that proximal pivot pin (42) of cartridge half (12) is received by proximal hooks (58) of anvil half (14). With clamp lever (24) in the open position, anvil half (14) is then pivoted toward cartridge half (12), about proximal pivot pin (42), to direct latch projections of anvil half (14) into slots (32) of clamp lever jaws (30). Once latch projections (56) are received by clamp lever jaws (30), clamp lever (24) is pivoted toward the partially closed position shown inFIG. 4B. In this partially closed position of clamp lever (24), anvil half (14) is partially clamped with cartridge half (12) such that stapler (10) may now be held with a single hand without halves (12,14) undesirably separating from one another. Additionally, in this state, the distal portions of stapler halves (12,14) remain spaced apart from one another to permit positioning of tissue between the distal portions. It will be appreciated that tissue may be positioned between the distal portions of stapler halves (12,14) before or upon achieving this partially clamped state.

As shown inFIG. 4C, clamp lever (24) is then pivoted further toward its fully closed position such that the camming surfaces of clamp lever jaws (30) draw latch projections of anvil half (14) proximally against the closed proximal ends of slots (32) of clamp lever jaws (30), thereby fully clamping stapler halves (12,14) together with tissue positioned securely therebetween. Once halves (12,14) of stapler (10) are in a fully clamped state, actuator (38) may be manipulated to fire staple cartridge (80). In particular, as shown inFIGS. 5A and 5B, actuator (38) is pivoted about the proximal end of stapler (10) to overlie one of the lateral sides of stapler (10). Actuator (38) is then driven distally to actuate firing assembly (34) in the manner described above and thereby simultaneously sever and staple the clamped tissue. Upon completing a distal firing stroke, actuator (38) may be returned to its proximal home position shown inFIG. 2, and clamp lever (24) may then be opened to separate stapler halves (12,14) from one another and release the stapled and severed tissue.

C. Exemplary Firing Assembly

FIGS. 6-10show details of firing assembly (34) of linear surgical stapler (10) ofFIG. 2. As previously described with reference toFIGS. 5A-5B, firing assembly (34) is translatable from a first longitudinal position to a second longitudinal position to fire staple cartridge (80) when first elongate member (shown as anvil half (14)) is clamped against second elongate member (shown as cartridge half (12)).FIG. 6shows a distal perspective view of firing assembly (34) of linear surgical stapler (10) ofFIG. 1. As previously described, firing assembly (34) includes slider (36) and actuator (38).FIG. 7shows a top view of actuator (38) angled relative to a shroud (74) of linear surgical stapler (10) ofFIG. 1, which may occur when an off-center load is applied to actuator (38).

As will be described in greater detail below with reference to the following figures, slider (36) includes a first body portion (shown as upper body portion (118)), a second body portion (shown as lower body portion (120)), and a third body portion (shown as central body portion (122)).FIG. 8shows an exploded proximal perspective view of firing assembly (34) ofFIG. 6, where slider (36) is slidably engaged with an elongate channel (109) of proximal frame portion (18) of cartridge half (12) ofFIG. 2, such that slider (36) and actuator (38) move longitudinally as a unit along elongate channel (109).FIG. 9shows an exploded side elevational view of actuator (38), and upper, lower, and central body portions (118,120,122) of firing assembly (34) ofFIG. 6.

Actuator (38) is described below with reference toFIGS. 6-10. Actuator (38) is configured to transmit force applied by the user to firing assembly (34) to perform a transection of tissue. Actuator (38) includes a body (126), where body (126) may include gripping features (128) for improved gripping by a user. Actuator (38) includes an inner engagement feature (130) that extends away from body (126) of actuator (38). As shown, inner engagement feature (130) includes upper and lower arcuate inner projections (132,134) that face in opposite directions from one another. Actuator (38) also includes upper and lower outer projections (136,138) that also face in opposite directions from one another. As shown, upper and lower arcuate inner projections (132,134) and upper and lower outer projections (136,138) extend vertically, and parallel, to body (126) of actuator (38). In other words, upper arcuate inner projection (132) and upper outer projection (136) both face vertically upwards, while lower arcuate inner projection (134) and lower outer projection (138) both face vertically downwards. Particularly, upper and lower outer projections (136,138) have a smooth inner surface (140) that extends vertically without any projections or other features extending therefrom.

Upper and lower body portions (118,120) are configured to longitudinally slide into central body portion (122) to collectively form slider (36). Upper body portion (118) includes first and second arms (142,144) that are separated by a longitudinal slot (146) (shown inFIG. 8). First and second arms (142,144) of upper body portion (118) include an inner engagement feature (148). As shown, inner engagement feature (148) is an upper arcuate inner recess (150) that opens into longitudinal slot (146). Upper arcuate inner recess (150) is configured to securably receive and retain upper arcuate inner projection (132) of inner engagement feature (130) of actuator (38). Longitudinal slot (146) is configured to receive central body portion (122). Particularly, longitudinal slot (146) is configured to accommodate and receive a distal projection (152) of central body portion (122). Upper body portion (118) includes a lower distal projection (154) (shown inFIG. 8) that is configured to be received within a distal slot (156) of lower body portion (120).

Similarly, lower body portion (120) includes first and second arms (158,160) that are separated by a longitudinal slot (162) (shown inFIG. 8). First and second arms (158,160) of lower body portion (120) include an inner engagement feature (164) configured to securably receive and retain inner engagement feature (130) of actuator (38). As shown, inner engagement feature (164) is a lower arcuate inner recess (166) that opens into longitudinal slot (162). Upper and lower arcuate inner recesses (150,166) of upper and lower body portions (118,120) collectively define a cavity (168) that collectively capture upper and lower arcuate inner projections (132,134) of inner engagement feature (130) of actuator (38) within cavity (168). Longitudinal slot (162) is configured to receive central body portion (122). As shown inFIG. 8, lower body portion (120) includes lower rails (170). Actuator (38) may be rotated relative to slider (36) until actuator (38) contacts a stop feature (174) of upper body portion (118) and a stop feature (176) of lower body portion (120).

FIGS. 8-9show central body portion (122) including an inner engagement feature (175). Inner engagement feature (175) may be a C-shaped engagement feature (178), that engages upper and lower arcuate inner projections (132,134) of inner engagement feature (130) of actuator (38). C-shaped engagement feature (178) includes upper and lower retention features (180,182) that oppose one another and are shown as being vertically oriented. C-shaped engagement feature (178) forms a cavity (184) that receives upper and lower arcuate inner projections (132,134) of inner engagement feature (130). Central body portion (122) includes lower rails (186). Lower rails (170) of lower body portion (120) and lower rails (186) of central body portion (122) are configured to slide along elongate channel (109), that forms a track, to vertically guide slider (36) when moved distally.

FIG. 10shows a proximal cross-sectional perspective view of linear surgical stapler (10) ofFIG. 6, where a C-shaped engagement feature (188) collectively formed by upper and lower body portions (118,120) is engaged with upper and lower arcuate inner projections (132,134) of inner engagement feature (130) of actuator (38). As such, C-shaped engagement feature (178) of central body portion (122) and C-shaped engagement feature (178) collectively formed by upper and lower body portions (118,120) create cavities (168,184) that are aligned to provide a track to prevent inner engagement feature (130) of actuator (38) from detaching.

II. Exemplary Linear Surgical Staplers Having Improved Actuator Support

In situations where the user applies an off-centered load to actuator (38) of linear surgical stapler (10), high torsional forces are applied to individual components of firing assembly (34). The high torsional forces may cause deflection of the individual components of firing assembly (34), which may allow the individual components to separate from one another. For example, these individual components may include actuator (38), upper body portion (118), lower body portion (120), and/or central body portion (122). For example,FIG. 7shows a top view of actuator (38) angled relative to a first shroud of linear surgical stapler (10) ofFIG. 1when an off-center load is applied to actuator (38). Additionally, this deflection may provide an opportunity for actuator (38) to detach from slider (36), which is undesirable. As a result, it may be desirable to strengthen the interface of slider (36) and actuator (38) to prevent, or at least minimize, the deflection of these individual components of firing assembly (34).

As described in greater detail below with reference toFIGS. 11-16B, an exemplary alternative firing system (212) and exemplary linear surgical stapler (310) may limit localized stresses and related deflections on actuator (216,316) when surgeon-applied, off-center loading creates a torsional load within firing assemblies (212,312). Firing system (212) and linear surgical stapler (310) enable the individual components of firing assemblies (212,312) to remain in close proximity to each other and behave as an integrated system rather than individual components during high firing force scenarios. For example, as described below with reference toFIGS. 11-17, the interface of the individual components of firing assembly (34) may be transformed to firing assembly (212) to minimize undesirable deflection of firing assembly (212). Additionally, as described below with reference toFIGS. 18-19, the interface between shrouds (70,74) and actuator (316) of linear surgical stapler (310) may be transformed to strengthen the interface and minimize undesirable deflection.

A. Exemplary Alternative Firing Assembly for Improved Actuator Support

FIGS. 11-17show a first exemplary alternative firing assembly (212) for use with a linear surgical stapler, such as linear surgical stapler (10) described above. Firing assembly (212) may be used in place of firing assembly (34) to strengthen firing assembly (212) and minimize undesirable deflection of firing assembly (212). Similar to firing assembly (34), firing assembly (212) is translatable from a first longitudinal position to a second longitudinal position to fire staple cartridge (80) when anvil half (14) is clamped against cartridge half (12).

FIG. 11shows a perspective view of firing assembly (212) as including a slider (214) and an actuator (216), that are similar to slider (36) and actuator (38) described above. Slider (214) includes a first body portion (shown as upper body portion (218)), a second body portion (shown as lower body portion (220)), and a third body portion (shown as central body portion (222)). Upper, lower, and central body portions (218,220,222) are similar to upper, lower, and central body portions (118,120,122) described above, except as otherwise noted. Upper and lower body portions (218,220) may be configured to slide longitudinally into central body portion (222) to collectively form slider (214). Upper, lower, and central body portions (218,220,222) may be slidable along proximal frame portion (18) of frame (16). Slider (214) is slidably engaged with an elongate channel (109) of proximal frame portion (28) of cartridge half (12) ofFIG. 2, such that slider (214) and actuator (216) may move longitudinally as a unit along elongate channel (109) of proximal frame portion (18).

FIGS. 12-14describe upper, lower, and central body portions (218,220,222) in greater detail.FIG. 12shows an exploded perspective view of firing assembly ofFIG. 11, so that individual features of upper, lower, and central body portions (218,220,222) are more easily envisioned.FIG. 13shows a side elevational view of firing assembly ofFIG. 11, showing the coupling of features of upper, lower, and central body portions (218,220,222) with actuator (216).FIG. 14shows an exploded side elevational view of actuator (216) and upper, lower, and central body portions (218,220,222) of firing assembly (212) ofFIG. 11, where actuator (216) and upper, lower, and central body portions (218,220,222) each include features to strengthen firing assembly (212) and minimize undesirable deflection of firing assembly (212) as described below.

Actuator (216) is described in greater detail below with reference toFIGS. 11-14A. Similar to actuator (38), actuator (216) is selectively actuated by a user to transmit force applied by the user to firing assembly (212) to perform a transection of tissue. Actuator (216) includes an arm (224) and a body (226). Body (226) may include gripping features (228) for improved gripping by a user. As shown, arm (224) extends perpendicular to body (226) of actuator (216). Arm (224) include inner and outer engagement features (230,231). Inner engagement feature (230) extends away from body (226) of actuator (216). As shown, inner engagement feature (230) includes upper and lower arcuate inner projections (232,234) that face in opposite directions from one another. As shown inFIGS. 14 and 16, upper and lower arcuate inner projections (232,234) extend vertically. Particularly, upper and lower arcuate inner projections (232,234) extend perpendicular to arm (224) and parallel to body (226).

Unlike actuator (38) described above, actuator (216) includes outer engagement feature (231). Outer engagement feature (231) may include upper and lower projections configured to strengthen the interface between slider (214) and actuator (216). Particularly, outer engagement feature (231) is shown as including upper and lower L-shaped arcuate outer projections (236,238). However, it is also envisioned that outer engagement feature (231) may have a variety of suitable shapes and sizes. Upper and lower L-shaped arcuate outer projections (236,238) extend in opposite directions away from arm (224). Upper L-shaped arcuate outer projection (236) includes an upper tip portion (237). As shown inFIGS. 14 and 16, upper tip portion (237) includes a vertical interface surface (239a) and a horizontal interface surface (239b). Similarly, lower L-shaped arcuate outer projection (238) includes a lower tip portion (240). As shown inFIGS. 14 and 16, lower tip portion (240) includes a vertical interface surface (241a) and a horizontal interface surface (241b). Upper and lower tip portions (237,240) of upper and lower L-shaped arcuate outer projections (236,238) are shown as extending parallel to arm (224) of actuator (216). As shown, a lower half of actuator (216) is a mirror image of upper half of actuator (216).

2. Exemplary Upper Body Portion

Upper body portion (218) includes first and second arms (242,244) that are separated by a longitudinal slot (246) (shown inFIG. 12). First and second arms (242,244) of upper body portion (218) include an inner engagement feature (248) and an outer engagement feature (249). As shown, inner engagement feature (248) is an upper arcuate inner recess (250) that opens into longitudinal slot (246) and (downwardly) toward lower body portion (220). Upper arcuate inner recess (250) is configured to securably receive and retain upper arcuate inner projection (232) of inner engagement feature (230) of actuator (216). Longitudinal slot (246) is configured to receive central body portion (222). Particularly, longitudinal slot (246) is configured to accommodate and receive a distal projection (252) of central body portion (222). Upper body portion (218) includes a lower distal projection (254) (shown inFIGS. 12 and 14) that is configured to be received within a distal slot (256) of lower body portion (220).

Unlike upper body portion (118) described above, upper body portion (218) includes outer engagement feature (249), which is shown an upper arcuate outer recess (251). However, it is also envisioned that outer engagement feature (249) may have a variety of suitable shapes and sizes. Upper arcuate outer recess (251) opens upwardly in an opposite direction than upper arcuate inner recess (250). Upper arcuate outer recess (251) includes a vertical interface surface (253a) and a horizontal interface surface (253b) that are shown as being perpendicular to each other.

3. Exemplary Lower Body Portion

Lower body portion (220) includes first and second arms (258,260) that are separated by a longitudinal slot (262) (shown inFIG. 12). First and second arms (258,260) of lower body portion (220) include an inner engagement feature (264) and an outer engagement feature (265). Inner engagement feature (264) is configured to securably receive and retain inner engagement feature (230) of actuator (216). As shown, inner engagement feature (264) is a lower arcuate inner recess (266) that opens into longitudinal slot (262). Upper and lower arcuate inner recesses (250,266) of upper and lower body portions (218,220) collectively define a cavity (268) that collectively capture upper and lower arcuate inner projections (232,234) of inner engagement feature (230) of actuator (216) within cavity (268). Longitudinal slot (262) is configured to receive central body portion (222). As shown inFIG. 12, lower body portion (220) includes lower rails (270). Actuator (216) may be rotated relative to slider (214) until actuator (216) contacts a stop feature (274) of upper body portion (218) and a stop feature (276) of lower body portion (220).

Unlike lower body portion (120) described above, lower body portion (220) includes outer engagement feature (265), which is shown a lower arcuate outer recess (272). However, it is also envisioned that outer engagement feature (265) may have a variety of suitable shapes and sizes. Lower arcuate outer recess (272) opens upwardly in an opposite direction than lower arcuate inner recess (266). Lower arcuate outer recess (272) includes a vertical interface surface (273a) and a horizontal interface surface (273b) that are shown as being perpendicular to each other.

4. Exemplary Central Body Portion

Central body portion (222) is similar to central body portion (122) and is described in greater detail below with reference toFIGS. 11-14. As shown inFIGS. 12 and 14, central body portion (222) includes an inner engagement feature (275) and an outer engagement feature (277). Inner engagement feature (275), shown as C-shaped engagement feature (278), engages upper and lower arcuate inner projections (232,234) of inner engagement feature (230) of actuator (216). C-shaped engagement feature (278) includes upper and lower opposing retention features (280,282) that are shown as being vertically oriented. C-shaped engagement feature (278) forms a cavity (284) that receives upper and lower arcuate inner projections (232,234) of inner engagement feature (230) of actuator (216). Central body portion (222) includes lower rails (286). Lower rails (270) of lower body portion (220) and lower rails (286) of central body portion (222) are configured to slide along elongate channel (109), along proximal frame portion (18), to vertically guide slider (214) when moved distally. C-shaped engagement feature (288) collectively formed by upper and lower body portions (218,220) is engaged with upper and lower arcuate inner projections (232,234) of inner engagement feature (230) of actuator (216). As shown inFIGS. 11 and 13, C-shaped engagement feature (278) of central body portion (222) and C-shaped engagement feature (288) collectively formed by upper and lower body portions (218,220) create cavities (268,284) that are aligned to provide a track to prevent inner engagement feature (230) of actuator (216) from detaching.

Unlike central body portion (122) described above, central body portion (222) includes outer engagement feature (277). Outer engagement feature (277) of central body portion (122) includes upper and lower arcuate outer recesses (290,292) that, together with upper and lower arcuate outer recesses (251,272) of upper and lower body portions (118,120), are configured to receive outer engagement feature (231) of actuator (216). Upper arcuate outer recess (290) includes a vertical interface surface (294a) and a horizontal interface surface (294b). Lower arcuate outer recess (292) includes a vertical interface surface (296a) and a horizontal interface surface (296b).

With this structure in mind,FIGS. 15-17show engagement of slider (214) and actuator (216) in greater detail.FIG. 15shows a cross-sectional perspective view of firing assembly ofFIG. 11taken along from another view, where inner engagement feature (shown as inner engagement features (248,264,275)) of slider (214) is engaged at a first interface with an inner engagement feature (230) of actuator (216) and outer engagement feature (shown as outer engagement features (249,265,277)) of slider (214) is engaged at a second interface with outer engagement feature (231) of actuator (216).FIG. 16shows an enlarged cross-sectional perspective view of an enlarged portion ofFIG. 15.FIG. 17shows a perspective view of firing assembly (212) ofFIG. 11taken along from another view, where inner engagement feature of slider (214) is engaged with an inner engagement feature (230) of actuator (216) and inner engagement feature of slider (214) is coupled with inner engagement feature (230) of actuator (216).

Inner engagement feature (230) of actuator (216) is configured to engage inner engagement feature (shown as inner engagement features (248,264,275)) of slider (214) at the first interface (e.g. an inner interface), when actuator (216) moves relative to slider (214). As shown, upper and lower arcuate inner projections (232,234) of inner engagement feature (230) of actuator (216) are securably received within cavities (168,184). Particularly, upper and lower arcuate inner projections (232,234) are configured to slide along respective upper and lower arcuate recesses when actuator (216) moves relative to slider (214). Upper and lower arcuate outer recesses (251,272) collectively extend a first lateral side (298) of slider (214) and a second lateral side (300) to guide upper and lower arcuate inner projections (232,234) of actuator (216) between first and second lateral sides (298,300) of slider (214).

Outer engagement feature (231) of actuator (216) is configured to engage outer engagement feature (shown as outer engagement features (249,265,277)) of slider (214) at the second interface (e.g. an outer interface), when actuator (216) moves relative to slider (214). For example, outer engagement feature (231) of actuator (216) may slide along outer engagement feature of slider (214), when actuator (216) moves between first and second lateral sides (298,300) of slider (214).

Upper and lower L-shaped arcuate outer projections (236,238) move relative to outer recesses of upper, lower, and central body portions (218,220,222). Upper and lower L-shaped arcuate outer projections (236,238) are configured to be received in respective upper and lower outer arcuate recesses (251,272) of upper and lower body portions (218,220) and upper and lower outer arcuate recesses (290,292) of central body portion (222) of slider (214). Particularly, upper L-shaped arcuate outer projection (236) is configured to slide along upper arcuate outer recesses (251,290) when actuator (216) moves relative to slider (214), and lower L-shaped arcuate outer projection (238) is configured to slide along lower arcuate outer recesses (272,292) when actuator (216) moves relative to slider (214).

Particularly, upper arcuate outer recesses (251,290) and lower arcuate outer recesses (272,292) extend from first lateral side (298) of slider (214) to second lateral side (300) of slider (214), such that upper arcuate outer recesses (251,290) and lower arcuate outer recesses (272,292) of upper, lower, and central body portions (218,220,222) collectively retain and guide upper and lower L-shaped arcuate outer projections (236,238) of actuator (216) between first and second lateral sides (298,300) of slider (214). Upper and lower tip portions (237,240) are configured to be received in respective upper arcuate outer recesses (251,290) and lower arcuate outer recesses (272,292) of slider (214). Relative spacing between upper and lower arcuate inner projections (232,234) of inner engagement feature (230) of actuator (216) are configured to securably receive and maintain inner engagement feature (230) of actuator (216) within cavities (268,284).

Outer engagement features (shown as outer engagement features (249,265,277)) of slider (214) and actuator (216) provide at least one additional contact point to strengthen the second interface between slider (214) and actuator (216). As shown, the second interface is spaced from the first interface. Additional contact points are configured to limit deflection of actuator (216) relative to slider (214) to improve coupling of slider (214) and actuator (216). As shown inFIGS. 15-17, vertical interface surface (239a) of upper tip portion (237) of actuator (216) slides against vertical interface surface (253a) of upper body portion (218) and horizontal interface surface (239b) of upper tip portion (237) of actuator (216) slides against horizontal interface surface (253b) of upper body portion (218). Additionally, vertical interface surface (241a) of lower tip portion (240) of actuator (216) slides against vertical interface surface (273a) of lower body portion (220) and horizontal interface surface (241b) of upper tip portion (237) of actuator (216) slides against horizontal interface surface (273b) of lower body portion (220). Additionally, as shown in the exploded side view ofFIG. 14, when actuator (216) is engaging central body portion (222), vertical interface surface (239a) of upper tip portion (237) of actuator (216) slides against vertical interface surface (294a) of central body portion (222) and horizontal interface surface (239b) of upper tip portion (237) of actuator (216) slides against horizontal interface surface (294b) of central body portion (222). Additionally, vertical interface surface (241a) of lower tip portion (240) of actuator (216) slides against vertical interface surface (296a) of central body portion (222) and horizontal interface surface (241b) of upper tip portion (237) of actuator (216) slides against horizontal interface surface (296b) of central body portion (222).

B. Exemplary Alternative Linear Surgical Stapler for Improved Actuator Support

FIG. 18shows a proximal perspective view of another exemplary linear surgical stapler (310). Linear surgical stapler (310) is generally similar to linear surgical stapler (10) described above, except as where otherwise described below. Similar to linear surgical stapler (10), linear surgical stapler (310) includes a first elongate member (shown previously as anvil half (14)), a second elongate member (shown previously as cartridge half (12)), and a clamp member (shown previously as clamp lever (24)). As previously described with reference to linear surgical stapler (10), anvil half (14) includes a distal portion (shown previously as distal jaw portion (54)) that supports an anvil surface (shown as anvil plate (60)), where anvil plate (60) includes a plurality of staple forming pockets. Similar to firing assembly (34), firing assembly (312) is translatable from a first longitudinal position to a second longitudinal position to fire staple cartridge (80) when anvil half (14) is clamped against cartridge half (12). As previously described with reference to linear surgical stapler (10), cartridge half (12) includes a distal portion (shown as distal jaw portion (20)) configured to receive staple cartridge (80), and clamp lever (24) is operable to releasably clamp anvil half (14) against cartridge half (12).

As shown inFIG. 18, firing assembly (312) includes a slider (314) and an actuator (316). Slider (314) includes a first body portion (shown as upper body portion (318)) and a second body portion (shown as lower body portion (320)). Slider (314) may include a central body portion (not shown), but similar to central body portion (122). Actuator (316) includes a body (326) that may include gripping features (328) for improved gripping by a user. Actuator (316) is shown as including upper and lower projections (330,332) that are configured to slidably engage shrouds (370,374) of linear surgical stapler (310). As shown inFIG. 18, shroud (374) is similar to shroud (74), and includes an upper ledge (376). Upper ledge (376) includes a vertical interface surface (378a) and horizontal interface surface (378b). As shown, vertical interface surface (378a) is disposed at a 90-degree angle relative to horizontal interface surface (378b). Similarly, shroud (370), similar to shroud (70), includes a lower ledge (380) that is configured to engage lower projection (332) of actuator (316). Lower ledge (380) includes a vertical interface surface (382a) and horizontal interface surface (382b). Similarly, vertical interface surface (382a) is disposed at a 90-degree angle relative to horizontal interface surface (382b).

Engagement of shrouds (370,374) with actuator (316) may stabilize actuator (316) and control deflection and/or rotation of actuator (316) when a user applies force to actuator (316) when moved distally.FIG. 19shows a top view of upper projection (330) of actuator (316) ofFIG. 18is engaged with upper ledge (376) of shroud (374) of linear surgical stapler (310) ofFIG. 18. The interface between actuator (316) and shrouds (370,374) brings actuator (316) to a 90-degree angle to shrouds (370,374) and tightens the overhang for more engagement with upper and lower ledges (376,380). The interface between actuator (316) and shrouds (370,374) also may minimize separation of upper and lower body portions (318,320) of slider (314).

A surgical stapler comprising: (a) a first elongate member having a distal portion that supports an anvil surface, wherein the anvil surface includes a plurality of staple forming pockets; (b) a second elongate member having a distal portion configured to receive a staple cartridge; (c) a clamp member operable to releasably clamp the first elongate member against the second elongate member; and (d) a firing assembly, wherein the firing assembly is translatable from a first longitudinal position to a second longitudinal position to fire the staple cartridge when the first elongate member is clamped against the second elongate member, wherein the firing assembly comprises: (i) a slider that comprises: (A) an inner engagement feature, and (B) an outer engagement feature, and (ii) an actuator configured to be selectively actuated by a user, wherein the actuator comprises: (A) an inner engagement feature configured to engage with the inner engagement feature of the slider at a first interface when the actuator moves relative to the slider, and (B) an outer engagement feature configured to engage the outer engagement feature of the slider at a second interface when the actuator moves relative to the slider.

The surgical stapler of Example 1, wherein the second interface is spaced from the first interface, wherein the first and second interfaces are configured to limit deflection of the actuator relative to the slider and to improve coupling of the slider and the actuator.

The surgical stapler of any one or more of Examples 1 through 2, wherein the outer engagement feature of the slider is formed in an outer surface of the slider, wherein the outer engagement feature of the actuator is configured to slide along the outer engagement feature of the slider when the actuator moves between a first lateral side of the slider and a second lateral side of the slider.

The surgical stapler of any one or more of Examples 1 through 2, wherein the outer engagement feature of the slider includes a first outer recess, wherein the outer engagement feature of the actuator includes a first outer projection, wherein the first outer projection is configured to slide along the first outer recess when the actuator moves between a first lateral side of the slider and a second lateral side of the slider.

The surgical stapler of Example 4, wherein the outer engagement feature of the slider includes a second outer recess, wherein the outer engagement feature of the actuator includes a second outer projection, wherein the second outer projection is configured to slide along the second outer recess when the actuator moves relative to the slider.

The surgical stapler of Example 5, wherein the first and second outer projections of the actuator include upper and lower arcuate outer projections, wherein the first and second outer recesses of the slider include upper and lower arcuate outer recesses, wherein the upper and lower arcuate outer projections are configured to slide along the upper and lower arcuate outer recesses respectively when the actuator moves relative to the slider.

The surgical stapler of Example 5, wherein the actuator includes an arm that extends perpendicular to the actuator, wherein the first and second outer projections include first and second L-shaped outer projections that extend from the arm, wherein the first and second L-shaped outer projections are configured to be received in the respective first and second outer recesses of the slider.

The surgical stapler of Example 7, wherein the first and second L-shaped projections include first and second tip portions, wherein the first and second tip portions of the first and second L-shaped outer projections extend parallel to the arm of the outer engagement feature of the actuator and are configured to be received in the respective first and second outer recesses of the slider.

The surgical stapler of any one or more of Examples 7 through 8, wherein the inner engagement feature of the actuator includes first and second inner projections that extend opposite one another and perpendicular to the arm of the outer engagement feature of the actuator.

The surgical stapler of Example 9, wherein the first and second L-shaped outer projections and the first and second inner projections are arcuate.

The surgical stapler of any one or more of Examples 1 through 10, wherein the inner engagement feature of the slider includes a C-shaped engagement feature, wherein the C-shaped engagement feature forms a cavity configured to receive the inner engagement feature of the actuator.

The surgical stapler of any one or more of Examples 1 through 11, wherein the inner engagement feature of the actuator includes first and second opposing inner projections that extend opposite one another, wherein the first and second inner projections are configured to be securably received within the cavity.

The surgical stapler of any one or more of Examples 1 through 3, wherein the slider includes first and second body portions that each include first and second outer recesses, wherein the outer engagement feature of the slider includes the first and second outer recesses that are configured to receive the outer engagement feature of the actuator.

The surgical stapler of Example 13, wherein the slider includes a third body portion that includes inner and outer engagement features, wherein the outer engagement feature of the third body portion includes first and second outer recesses that, together with the first and second outer recesses of the first and second body portions, are configured to receive the outer engagement feature of the actuator.

The surgical stapler of Example 14, wherein the first and second outer recesses of the first, second, and third body portions collectively extend along a first lateral side of the slider and a second lateral side to guide the outer engagement feature of the actuator between the first and second lateral sides of the slider.

A surgical stapler comprising: (a) a first elongate member having a distal portion that supports an anvil surface, wherein the anvil surface includes a plurality of staple forming pockets; (b) a second elongate member having a distal portion configured to receive a staple cartridge; (c) a clamp member operable to releasably clamp the first elongate member against the second elongate member; and (d) a firing assembly, wherein the firing assembly is translatable from a first longitudinal position to a second longitudinal position to fire the staple cartridge when the first elongate member is clamped against the second elongate member, wherein the firing assembly comprises: (i) a slider that includes first and second outer recesses that open in opposite directions, and (ii) an actuator configured to be selectively actuated by a user, wherein the actuator comprises: (A) a body, (B) a first outer projection extending from the body, wherein the first outer projection is configured to slide along the first outer recess when the actuator moves relative to the slider, and (C) a second outer projection extending from body, wherein the second outer projection is configured to slide along the second outer recess when the actuator moves relative to the slider.

The surgical stapler of Example 16, wherein the first and second outer projections include first and second L-shaped outer projections that are configured to be received in the first and second outer recesses of the slider, wherein tips of the first and second L-shaped outer projections extend parallel to the body.

A surgical stapler comprising: (a) a first elongate member having a distal portion that supports an anvil surface, wherein the anvil surface includes a plurality of staple forming pockets; (b) a second elongate member having a distal portion configured to receive a staple cartridge; (c) a clamp member operable to releasably clamp the first elongate member against the second elongate member; and (d) a firing assembly, wherein the firing assembly is translatable from a first longitudinal position to a second longitudinal position to fire the staple cartridge when the first elongate member is clamped against the second elongate member, wherein the firing assembly comprises: (i) a slider comprising: (A) a first body portion that includes an inner engagement feature and an outer engagement feature, (B) a second body portion that includes an inner engagement feature and an outer engagement feature, and (C) a third body portion that includes an inner engagement feature and an outer engagement feature, and (ii) an actuator comprising: (A) an inner engagement feature configured to move relative the inner engagement features of the first, second, and third body portions, and (B) an outer engagement feature configured to move relative to the outer engagement features of the first, second, and third body portions.

The surgical stapler of Example 18, wherein the outer engagement features of the first, second, and third body portions respectively include first, second, and third outer recesses, wherein the first, second, and third outer recesses collectively extend from a first lateral side of the slider and a second lateral side of the slider such that the first, second, and third outer recesses of the first, second, and third body portions collectively retain and guide the outer engagement feature of the actuator between the first and second lateral sides of the slider.

The surgical stapler of any one or more of Example 18 through 19, wherein the inner engagement features of the first, second, and third body portions respectively include first, second, and third inner recesses that collectively form a cavity, wherein the inner engagement feature of the actuator includes first and second inner projections configured to be securably received within the cavity.

Versions of the devices described above may have application in conventional medical treatments and procedures conducted by a medical professional, as well as application in robotic-assisted medical treatments and procedures. By way of example only, various teachings herein may be readily incorporated into a robotic surgical system such as the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.