Surgical stapling system comprising a spent cartridge lockout

A circular stapling instrument is disclosed which comprises a replaceable staple cartridge. The circular stapling instrument and/or staple cartridge comprises a lockout configured to prevent a previously-fired staple cartridge from being re-used.

BACKGROUND

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

DETAILED DESCRIPTION

Applicant of the present application owns the following patent applications that were filed on Apr. 1, 2016 and which are each herein incorporated by reference in their respective entireties:

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

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

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

U.S. patent application Ser. No. 15/089,263, entitled SURGICAL INSTRUMENT HANDLE ASSEMBLY WITH RECONFIGURABLE GRIP PORTION;

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

U.S. patent application Ser. No. 15/089,283, entitled CLOSURE SYSTEM ARRANGEMENTS FOR SURGICAL CUTTING AND STAPLING DEVICES WITH SEPARATE AND DISTINCT FIRING SHAFTS;

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

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

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

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

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

U.S. patent application Ser. No. 15/089,253, entitled SURGICAL STAPLING SYSTEM CONFIGURED TO APPLY ANNULAR ROWS OF STAPLES HAVING DIFFERENT HEIGHTS;

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

U.S. patent application Ser. No. 15/089,331, entitled ANVIL MODIFICATION MEMBERS FOR SURGICAL STAPLERS;

The Applicant of the present application also owns the U.S. Patent Applications identified below which were filed on Dec. 31, 2015 which are each herein incorporated by reference in their respective entirety:

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

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

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

The Applicant of the present application also owns the U.S. Patent Applications identified below which were filed on Feb. 9, 2016 which are each herein incorporated by reference in their respective entirety:

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

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

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

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

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

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

The Applicant of the present application also owns the U.S. Patent Applications identified below which were filed on Feb. 12, 2016 which are each herein incorporated by reference in their respective entirety:

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

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

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

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

Applicant of the present application owns the following patent applications that were filed on Jun. 18, 2015 and which are each herein incorporated by reference in their respective entireties:

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

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

U.S. patent application Ser. No. 14/742,914, entitled MOVABLE FIRING BEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS;

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

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

Applicant of the present application owns the following patent applications that were filed on Mar. 6, 2015 and which are each herein incorporated by reference in their respective entireties:

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

U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE TISSUE COMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR MULTIPLE TISSUE TYPES;

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

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

U.S. patent application Ser. No. 14/640,859, entitled TIME DEPENDENT EVALUATION OF SENSOR DATA TO DETERMINE STABILITY, CREEP, AND VISCOELASTIC ELEMENTS OF MEASURES;

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

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

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

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

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

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

Applicant of the present application owns the following patent applications that were filed on Feb. 27, 2015, and which are each herein incorporated by reference in their respective entireties:

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

U.S. patent application Ser. No. 14/633,546, entitled SURGICAL APPARATUS CONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER OF THE SURGICAL APPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE BAND;

U.S. patent application Ser. No. 14/633,560, entitled SURGICAL CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE BATTERIES;

U.S. patent application Ser. No. 14/633,566, entitled CHARGING SYSTEM THAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A BATTERY;

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

U.S. patent application Ser. No. 14/633,542, entitled REINFORCED BATTERY FOR A SURGICAL INSTRUMENT;

U.S. patent application Ser. No. 14/633,548, entitled POWER ADAPTER FOR A SURGICAL INSTRUMENT;

U.S. patent application Ser. No. 14/633,562, entitled SURGICAL APPARATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER.

Applicant of the present application owns the following patent applications that were filed on Dec. 18, 2014 and which are each herein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/574,478, entitled SURGICAL INSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND MEANS FOR ADJUSTING THE FIRING STROKE OF A FIRING;

U.S. patent application Ser. No. 14/575,148, entitled LOCKING ARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE SURGICAL END EFFECTORS;

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

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

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

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

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

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

Applicant of the present application owns the following patent applications that were filed on Mar. 1, 2013 and which are each herein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/782,295, entitled ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL COMMUNICATION, now U.S. Patent Application Publication No. 2014/0246471;

U.S. patent application Ser. No. 13/782,323, entitled ROTARY POWERED ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No. 2014/0246472;

U.S. patent application Ser. No. 13/782,499, entitled ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT, now U.S. Patent Application Publication No. 2014/0246474;

U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No. 2014/0246478;

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

U.S. patent application Ser. No. 13/782,518, entitled CONTROL METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS, now U.S. Patent Application Publication No. 2014/0246475;

U.S. patent application Ser. No. 13/782,375, entitled ROTARY POWERED SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM, now U.S. Patent Application Publication No. 2014/0246473; and

Applicant of the present application also owns the following patent applications that were filed on Mar. 14, 2013 and which are each herein incorporated by reference in their respective entireties:

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

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

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

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

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

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

Applicant of the present application also owns the following patent application that was filed on Mar. 7, 2014 and is herein incorporated by reference in its entirety:

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

Applicant of the present application also owns the following patent applications that were filed on Mar. 26, 2014 and are each herein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/226,106, entitled POWER MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No. 2015/0272582;

U.S. patent application Ser. No. 14/226,094, entitled VERIFICATION OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT, now U.S. Patent Application Publication No. 2015/0272580;

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

U.S. patent application Ser. No. 14/226,075, entitled MODULAR POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES, now U.S. Patent Application Publication No. 2015/0272579;

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

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

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

U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS AND METHODS FOR CONTROLLING A SEGMENTED CIRCUIT, now U.S. Patent Application Publication No. 2015/0277471;

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

Applicant of the present application also owns the following patent applications that were filed on Sep. 5, 2014 and which are each herein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY AND SENSORS FOR POWERED MEDICAL DEVICE, now U.S. Patent Application Publication No. 2016/0066912;

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

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

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

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

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

U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE MOTOR CONTROL FOR POWERED MEDICAL DEVICE, now U.S. Patent Application Publication No. 2016/0066916; and

U.S. patent application Ser. No. 14/479,108, entitled LOCAL DISPLAY OF TISSUE PARAMETER STABILIZATION, now U.S. Patent Application Publication No. 2016/0066913.

Applicant of the present application also owns the following patent applications that were filed on Apr. 9, 2014 and which are each herein incorporated by reference in their respective entireties:

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

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

U.S. patent application Ser. No. 14/248,595, entitled SURGICAL INSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE OPERATION OF THE SURGICAL INSTRUMENT, now U.S. Patent Application Publication No. 2014/0305988;

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

U.S. patent application Ser. No. 14/248,584, entitled MODULAR MOTOR DRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR ALIGNING ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS, now U.S. Patent Application Publication No. 2014/0305994;

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

U.S. patent application Ser. No. 14/248,607, entitled MODULAR MOTOR DRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION ARRANGEMENTS, now U.S. Patent Application Publication No. 2014/0305992.

Applicant of the present application also owns the following patent applications that were filed on Apr. 16, 2013 and which are each herein incorporated by reference in their respective entireties:

U.S. Provisional patent application Ser. No. 61/812,365, entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR;

U.S. Provisional patent application Ser. No. 61/812,382, entitled LINEAR CUTTER WITH MOTOR AND PISTOL GRIP;

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

U.S. Provisional patent application Ser. No. 61/812,372, entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR.

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

A surgical stapling system can comprise a shaft and an end effector extending from the shaft. The end effector comprises a first jaw and a second jaw. The first jaw comprises a staple cartridge. The staple cartridge is insertable into and removable from the first jaw; however, other embodiments are envisioned in which a staple cartridge is not removable from, or at least readily replaceable from, the first jaw. The second jaw comprises an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closure axis; however, other embodiments are envisioned in which first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises an articulation joint configured to permit the end effector to be rotated, or articulated, relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal end and the distal end. In use, the staple cartridge is positioned on a first side of 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. Thereafter, staples removably stored in the cartridge body can be deployed into the tissue. The cartridge body includes staple cavities defined therein wherein staples are removably stored in the staple cavities. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of 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 in the cartridge body. The drivers are movable between a first, or unfired position, and a second, or fired, position to eject the staples from the staple cavities. The drivers are retained in the cartridge body by a retainer which extends around the bottom of the cartridge body and includes resilient members configured to grip the cartridge body and hold the retainer to the cartridge body. The drivers are movable between their unfired positions and their fired positions by a sled. The sled is movable between a proximal position adjacent the proximal end and a distal position adjacent the distal end. The sled comprises a plurality of ramped surfaces configured to slide under the drivers and lift the drivers, and the staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. The firing member is configured to contact the sled and push the sled toward the distal end. The 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 comprises a first cam which engages the first jaw and a second cam which engages the second jaw. As the firing member is advanced distally, the first cam and the second cam can control the distance, or tissue gap, between the deck of the staple cartridge and the anvil. The firing member also comprises a knife configured to incise the tissue captured intermediate the staple cartridge and the anvil. It is desirable for the knife to be positioned at least partially proximal to the ramped surfaces such that the staples are ejected ahead of the knife.

FIG. 1depicts a motor-driven surgical system10that may be used to perform a variety of different surgical procedures. In the illustrated embodiment, the motor driven surgical system10comprises a selectively reconfigurable housing or handle assembly20that is attached to one form of an interchangeable surgical tool assembly1000. For example, the system10that is depicted inFIG. 1includes an interchangeable surgical tool assembly1000that comprises a surgical cutting and fastening instrument which may be referred to as an endocutter. As will be discussed in further detail below, the interchangeable surgical tool assemblies may include end effectors that are adapted to support different sizes and types of staple cartridges and, have different shaft lengths, sizes, and types, etc. Such arrangements, for example, may utilize any suitable fastener, or fasteners, to fasten tissue. For instance, a fastener cartridge comprising a plurality of fasteners removably stored therein can be removably inserted into and/or attached to the end effector of a surgical tool assembly. Other surgical tool assemblies may be interchangeably employed with the handle assembly20. For example, the interchangeable surgical tool assembly1000may be detached from the handle assembly20and replaced with a different surgical tool assembly that is configured to perform other surgical procedures. In other arrangements, the surgical tool assembly may not be interchangeable with other surgical tool assemblies and essentially comprise a dedicated shaft that is non-removably affixed or coupled to the handle assembly20, for example. The surgical tool assemblies may also be referred to as elongate shaft assemblies. The surgical tool assemblies may be reusable or, in other configurations, the surgical tool assemblies may be designed to be disposed of after a single use.

As the present Detailed Description proceeds, it will be understood that the various forms of interchangeable surgical tool assemblies disclosed herein may also be effectively employed in connection with robotically-controlled surgical systems. Thus, the terms “housing” and “housing assembly” may also encompass a housing or similar portion of a robotic system that houses or otherwise operably supports at least one drive system that is configured to generate and apply at least one control motion which could be used to actuate the elongate shaft assemblies disclosed herein and their respective equivalents. The term “frame” may refer to a portion of a handheld surgical instrument. The term “frame” may also represent a portion of a robotically controlled surgical instrument and/or a portion of the robotic system that may be used to operably control a surgical instrument. For example, the surgical tool assemblies disclosed herein may be employed with various robotic systems, instruments, components and methods such as, but not limited to, those disclosed in U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Patent Application Publication No. 2012/0298719 which is hereby incorporated by reference herein in its entirety.

Referring now toFIGS. 1 and 2, the housing assembly or handle assembly20comprises a primary housing portion30that may be formed from a pair of housing segments40,70that may be fabricated from plastic, polymer materials, metal, etc. and be joined together by an appropriate fastener arrangement such as, for example, adhesive, screws, press-fit features, snap-fit features, latches, etc. As will be discussed in further detail below, the primary housing portion30operably supports a plurality of drive systems therein that are configured to generate and apply various control motions to corresponding portions of the interchangeable surgical tool assembly that is operably attached thereto. The handle assembly20further comprises a grip portion100that is movably coupled to the primary housing portion30and is configured to be gripped and manipulated by the clinician in various positions relative to the primary housing portion30. The grip portion100may be fabricated from a pair of grip segments110,120that may be fabricated from plastic, polymer materials, metal, etc. and are joined together by an appropriate fastener arrangement such as, for example, adhesive, screws, press-fit features, snap-fit features, latches, etc. for assembly and maintenance purposes.

As can be seen inFIG. 2, the grip portion100comprises a grip housing130that defines a hollow cavity132that is configured to operably support a drive motor and gearbox which will be discussed in further detail below. The upper portion134of the grip housing130is configured to extend through an opening80in the primary housing portion30and be pivotally journaled on a pivot shaft180. The pivot shaft180defines a pivot axis designated as “PA”. SeeFIG. 3. For reference purposes, the handle assembly20defines a handle axis designated as “HA” that may be parallel to the shaft axis “SA” of the elongate shaft assembly of the interchangeable surgical tool that is operably attached to the handle assembly20. The pivot axis PA is transverse to the handle axis HA. SeeFIG. 1. Such arrangement enables the grip portion100to be pivoted relative to the primary housing portion30about the pivot axis PA to a position that is best suited for the type of interchangeable surgical tool assembly that is coupled to the handle assembly20. The grip housing130defines a grip axis, generally designated as “GA”. SeeFIG. 2. When the interchangeable surgical tool assembly that is coupled to the handle assembly20comprises an endocutter for example, the clinician might want to position the grip portion100relative to the primary housing portion30such that the grip axis GA is perpendicular or approximately perpendicular (angle “H1”) to the handle axis HA (referred to herein as a “first grip position”). SeeFIG. 5. However, if the handle assembly20is being used to control an interchangeable surgical tool assembly that comprises a circular stapler for example, the clinician may wish to pivot the grip portion100relative to the primary housing portion30to a position wherein the grip axis GA is at a forty-five degree or approximately forty-five degree angle or other suitable acute angle (angle “H2”) relative to the handle axis HA. This position is referred to herein as a “second grip position”.FIG. 5illustrates the grip portion100in phantom lines in the second grip position.

Referring now toFIGS. 3-5, the handle assembly20also includes a grip locking system, generally designated as150, for selectively locking the grip portion100in the desired orientation relative to the primary housing portion30. In one arrangement, the grip locking system150comprises an arcuate series152of pointed teeth154. The teeth154are spaced from each other and form a locking groove156therebetween. Each locking groove156corresponds to a particular angular locking position for the grip portion100. For example, in at least one arrangement, the teeth154and locking grooves or “locking locations”156are arranged to permit the grip portion100to be locked at 10-15 degree intervals between the first grip position and the second grip position. The arrangement may employ two stop positions which are tailored to the type of instrument (shaft arrangement) employed. For example, for an endocutter shaft arrangement, it may be approximately around ninety degrees to the shaft and for a circular stapler arrangement, the angle may be approximately forty-five degrees to the shaft while being swept forward towards the surgeon. The grip locking system150further includes a locking button160that has a locking portion that is configured to lockingly engage the locking grooves156. For example, the locking button160is pivotally mounted in the primary handle portion30on a pivot pin131to permit the locking button160to pivot into engagement with a corresponding locking groove156. A locking spring164serves to bias the locking button160into an engaged or locked position with the corresponding locking groove156. The locking portion and the teeth configurations serve to enable the teeth154to slide past the locking portion when the clinician depresses the locking button160. Thus, to adjust the angular position of the grip portion100relative to the primary housing portion30, the clinician depresses the locking button160and then pivots the grip portion100to the desired angular position. Once the grip portion100has been moved to the desired position, the clinician releases the locking button160. The locking spring164will then bias the locking button160toward the series of teeth154so that the locking portion enters the corresponding locking groove156to retain the grip portion100in that position during use.

The handle assembly20operably supports a first rotary drive system300, a second rotary drive system320and a third axial drive system400. The rotary drive systems300,320are each powered by a motor200that is operably supported in the grip portion100. As can be seen inFIG. 2, for example, the motor200is supported within the cavity132in the grip portion100and has a gear box assembly202that has an output drive shaft204protruding therefrom. In various forms, the motor200may be a DC brushed driving motor having a maximum rotation of, approximately, 25,000 RPM, for example. In other arrangements, the motor may include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The motor200may be powered by a power source210that, in one form, may comprise a removable power pack212. The power source210may comprise, for example, anyone of the various power source arrangements disclosed in further detail in U.S. Patent Application Publication No. 2015/0272575 and entitled SURGICAL INSTRUMENT COMPRISING A SENSOR SYSTEM, the entire disclosure of which is hereby incorporated by reference herein. In the illustrated arrangement, for example, the power pack212may comprise a proximal housing portion214that is configured for attachment to a distal housing portion216. The proximal housing portion214and the distal housing portion216are configured to operably support a plurality of batteries218therein. Batteries218may each comprise, for example, a Lithium Ion (“LI”) or other suitable battery. The distal housing portion216is configured for removable operable attachment to a handle circuit board assembly220which is also operably coupled to the motor200. The handle circuit board assembly220may also be generally referred to herein as the “control system or CPU224”. A number of batteries218may be connected in series may be used as the power source for the handle assembly20. In addition, the power source210may be replaceable and/or rechargeable. In other embodiments, the surgical instrument10may be powered by alternating current (AC) for example. The motor200may be controlled by a rocker switch206that is mounted to the grip portion100.

As outlined above, the motor200is operably coupled to a gear box assembly202that includes an output drive shaft204. Attached to the output drive shaft204is a driver bevel gear230. The motor200, the gear box assembly202, the output drive shaft204and the driver bevel gear230may also be collectively referred to herein as a “motor assembly231”. The driver bevel gear230interfaces with a driven bevel gear234that is attached to a system drive shaft232as well as a pivot bevel gear238that is journaled on the pivot shaft180. The driven bevel gear234is axially movable on the system drive shaft232between an engaged position wherein the driven bevel gear234is in meshing engagement with the driver bevel gear230(FIG. 5) and a disengaged position wherein the driven bevel gear234is out of meshing engagement with the drive bevel gear230(FIG. 14). A drive system spring235is journaled between the driven bevel gear234and a proximal end flange236that is formed on a proximal portion of the system drive shaft232. SeeFIGS. 4 and 14. The drive system spring235serves to bias the driven bevel gear234out of meshing engagement with the driver bevel gear230as will be discussed in further detail below. The pivot bevel gear238facilitates pivotal travel of the output drive shaft204and driver bevel gear230with the grip portion100relative to the primary handle portion30.

In the illustrated example, the system drive shaft232interfaces with a rotary drive selector system, generally designated as240. In at least one form, for example, the rotary drive selector system240comprises a shifter gear250that is selectively movable between the first rotary drive system300and the second rotary drive system320. As can be seen inFIGS. 6-9, for example, the drive selector system240comprises a shifter mounting plate242that is non-movably mounted within primary handle portion30. For example, the shifter mounting plate242may be frictionally retained between mounting lugs (not shown) formed in the housing segments40,70or be otherwise retained therein by screws, adhesive, etc. Still referring toFIGS. 6-9, the system drive shaft232extends through a hole in the shifter mounting plate242and has the central, or system, drive gear237non-rotatably attached thereto. For example the central drive gear237may be attached to the system drive shaft232by a keyway arrangement233. SeeFIGS. 6-9. In other arrangements, the system drive shaft232may be rotatably supported in the shifter mounting plate242by a corresponding bearing (not shown) that is mounted thereto. In any event, rotation of the system drive shaft232will result in rotation of the central drive gear234.

As can be seen inFIG. 3, the first drive system300includes a first drive socket302that is rotatably supported in a distal wall32formed in the primary handle portion30. The first drive socket302may comprise a first body portion304that has a splined socket formed therein. A first driven gear306is formed on or is non-movably attached to the first body portion304. The first body portion304may be rotatably supported in a corresponding hole or passage provided the distal wall32or it may be rotatably supported in a corresponding bearing (not shown) that is mounted in the distal wall32. Similarly, the second rotary drive system320includes a second drive socket322that is also rotatably supported in the distal wall32of the primary handle portion30. The second drive socket322may comprise a second body portion324that has a splined socket formed therein. A second driven gear326is formed on or is non-rotatably mounted to the second body portion324. The second body portion324may be rotatably supported in a corresponding hole or passage provided the distal wall32or it may be rotatably supported in a corresponding bearing (not shown) that is mounted in the distal wall32. The first and second drive sockets302,322are spaced from each other on each lateral side of the handle axis HA. SeeFIG. 4, for example.

As indicated above, in the illustrated example, the rotary drive selector system240includes a shifter gear250. As can be seen inFIGS. 6-9, the shifter gear250is rotatably mounted on an idler shaft252that is movably supported in an arcuate slot244in the shifter mounting plate242. The shifter gear250is mounted so as to freely rotate on the idler shaft252and remain in meshing engagement with the central drive gear234. The idler shaft252is coupled to an end of a shaft262of a shifter solenoid260. The shifter solenoid260is pinned or otherwise mounted with the primary handle housing30such that when the shifter solenoid260is actuated, the shifter gear250is moved into meshing engagement with one of the first driven gear306or the second driven gear326. For example, in one arrangement, when the solenoid shaft is262is retracted (FIGS. 6 and 7), the shifter gear250is in meshing engagement with the central drive gear234and the first driven gear306such that actuation of the motor200will result in rotation of the first drive socket302. As can be seen inFIGS. 6 and 7, a shifter spring266may be employed to bias the shifter gear250into that first actuation position. Thus, should power be lost to the surgical instrument10, the shifter spring266will automatically bias the shifter gear250into the first position. When the shifter gear250is in that position, subsequent actuation of the motor200will result in rotation of the first drive socket302of the first rotary drive system300. When the shifter solenoid is actuated, the shifter gear250is moved into meshing engagement with the second driven gear326on the second drive socket322. Thereafter, actuation of the motor200will result in actuation or rotation of the second drive socket322of the second rotary drive system320.

As will be discussed in further detail below, the first and second rotary drive systems300,320may be used to power various component portions of the interchangeable surgical tool assembly that is coupled thereto. As indicated above, in at least one arrangement, if during the actuation of the interchangeable surgical tool assembly, power was lost to the motor, the shifter spring266will bias the shifter gear250to the first position. Depending upon which component portion of the interchangeable surgical tool assembly was being operated, it may be necessary to reverse the application of the rotary drive motion to the first drive system300to enable the interchangeable surgical tool assembly to be removed from the patient. The handle assembly20of the illustrated example employs a manually actuatable “bailout” system, generally designated as330, for manually applying a rotary drive motion to the first rotary drive system300in the above described scenario, for example.

Referring now toFIGS. 3, 10 and 11, the illustrated bailout system330comprises a bailout drive train332that includes a planetary gear assembly334. In at least one form, the planetary gear assembly334includes a planetary gear housing336that houses a planetary gear arrangement (not shown) that includes a planetary bevel gear338. The planetary gear assembly334includes a bailout drive shaft340that is operably coupled to the planetary gear arrangement within the planetary gear housing336. Rotation of the planetary bevel gear338rotates the planetary gear arrangement which ultimately rotates the bailout drive shaft340. A bailout drive gear342is journaled on the bailout drive shaft340so that the bailout drive gear342can move axially on the bailout drive shaft340, yet rotate therewith. The bailout drive gear342is movable between a spring stop flange344that is formed on the bailout drive shaft340and a shaft end stop346that is formed on the distal end of the bailout drive shaft340. A bailout shaft spring348is journaled on the bailout drive shaft340between the bailout drive gear342and the spring stop flange344. The bailout shaft spring348biases the bailout drive gear342distally on the bailout drive shaft340. When the bailout drive gear342is in its distal-most position on the bail out drive shaft340, it is in meshing engagement with a bailout driven gear350that is non-rotatably mounted to the system drive shaft232. SeeFIG. 14.

Referring now toFIGS. 12 and 13, the bailout system330includes a bailout actuator assembly or bailout handle assembly360that facilitates the manual application of a bailout drive motion to the bailout drive train332. As can be seen in those Figures, the bailout handle assembly360includes a bailout bevel gear assembly362that comprises a bailout bevel gear364and a ratchet gear366. The bailout handle assembly360further includes a bailout handle370that is movably coupled to the bailout bevel gear assembly362by a pivot yoke372that is pivotally mounted on the ratchet gear366. The bailout handle370is pivotally coupled to the pivot yoke372by a pin374for selective pivotal travel between a stored position “SP” and an actuation position “AP”. SeeFIG. 12. A handle spring376is employed to bias the bailout handle370into the actuation position AP. In at least one arrangement, the angle between the axis SP representing the stored position and the axis AP representing the actuation position may be approximately thirty degrees, for example. SeeFIG. 13. As can also be seen inFIG. 13, the bailout handle assembly360further includes a ratchet pawl378that is rotatably mounted in a cavity or hole377in the pivot yoke372. The ratchet pawl378is configured to meshingly engage the ratchet gear366when rotated in an actuation direction “AD” and then rotate out of meshing engagement when rotated in the opposite direction. A ratchet spring384and ball member386are movably supported in a cavity379in the pivot yoke372and serve to lockingly engage detents380,382in the ratchet pawl378as the bailout handle370is actuated (ratcheted).

Referring now toFIGS. 3 and 10, the bailout system330further includes a bailout access panel390that is maneuverable between an open position and a closed position. In the illustrated arrangement, the bailout access panel390is configured to be removably coupled to the housing segment70of the primary housing portion30. Thus, in at least that embodiment, when the bailout access panel390is removed or detached from the primary housing portion30, it is said to be in an “open” position and when the bailout access panel390is attached to the primary housing portion30as illustrated, it is said to be in a “closed” position. Other embodiments are contemplated, however, wherein the access panel is movably coupled to the primary housing portion such that when the access panel is in the open position, it remains attached thereto. For example, in such embodiments, the access panel may be pivotally attached to the primary housing portion or slidably attached to the primary housing portion and be maneuverable between an open position and a closed position. In the illustrated example, the bailout access panel390is configured to snappingly engage corresponding portions of the housing segment70to removably retain it in a “closed” position. Other forms of mechanical fasteners such as screws, pins, etc. could also be used.

Regardless of whether the bailout access panel390is detachable from the primary housing portion30or it remains movably attached to the primary housing portion30, the bailout access panel390includes a drive system locking member or yoke392and a bailout locking member or yoke396that each protrudes out from the backside thereof or are otherwise formed thereon. The drive system locking yoke392includes a drive shaft notch394that is configured to receive a portion of the system drive shaft232therein when the bailout access panel390is installed in the primary housing portion30(i.e., the bailout access panel is in the “closed” position). When the bailout access panel390is positioned or installed in the closed position, the drive system locking yoke392serves to bias the driven bevel gear234into meshing engagement with the driver bevel gear230(against the bias of the drive system spring235). In addition, the bailout locking yoke396includes a bailout drive shaft notch397that is configured to receive a portion of the bailout drive shaft340therein when the bailout access panel390is installed or positioned in the closed position. As can be seen inFIGS. 5 and 10, the bailout locking yoke396also serves to bias the bailout drive gear342out of meshing engagement with the bailout driven gear350(against the bias of the bailout shaft spring348). Thus, the bailout locking yoke396prevents the bailout drive gear342from interfering with rotation of the system drive shaft232when the bailout access panel390is installed or in the closed position. In addition, the bailout locking yoke396includes a handle notch398for engaging the bailout handle370and retaining it in the stored position SP.

FIGS. 4, 5 and 10illustrate the configurations of the drive system components and the bailout system components when the bailout access panel390is installed or is in the closed position. As can be seen in those Figures, the drive system locking member392biases the driven bevel gear234into meshing engagement with the driver bevel gear230. Thus, when the bailout access panel390is installed or is in the closed position, actuation of the motor200will result in the rotation of the driver bevel gear230and ultimately the system drive shaft232. Also, when in that position, the bailout locking yoke396serves to bias the bailout drive gear342out of meshing engagement with the bailout driven gear350on the system drive shaft232. Thus, when the bailout access panel390is installed or is in the closed position, the drive system is actuatable by the motor200and the bailout system330is disconnected or prevented from applying any actuation motion to the system drive shaft232. To activate the bailout system330, the clinician first removes the bailout access panel390or otherwise moves the bailout access panel390to the open position. This action removes the drive system locking member392from engagement with the driven bevel gear234which thereby permits the drive system spring235to bias the driven bevel gear234out of meshing engagement with the driver bevel gear230. In addition, removal of the bailout access panel390or movement of the bailout access panel to an open position also results in the disengagement of the bailout locking yoke396with the bailout drive gear342which thereby permits the bailout shaft spring348to bias the bailout drive gear342into meshing engagement with the bailout driven gear350on the system drive shaft232. Thus, rotation of the bailout drive gear342will result in rotation of the bailout driven gear350and the system drive shaft232. Removal of the bailout access panel390or otherwise movement of the bailout access panel390to an open position also permits the handle spring376to bias the bailout handle370into the actuation position shown inFIGS. 11 and 14. When in that position, the clinician can manually ratchet the bailout handle370in the ratchet directions RD which results in the rotation of the of the ratchet bevel gear364(in a clockwise direction inFIG. 14, for example) which ultimately results in the application of a retraction rotary motion to the system drive shaft232through the bailout drive train332. The clinician may ratchet the bailout handle370a number of times until the system drive shaft232has been sufficiently rotated a number of times to retract a component of the surgical end effector portion of the surgical tool assembly that is attached to the handle assembly20. Once the bailout system330has been sufficiently manually actuated, the clinician may then replace the bailout access panel390(i.e., return the bailout access panel390to the closed position) to thereby cause the drive system locking member392to bias the driven bevel gear234into meshing engagement with the driver bevel gear230and the bailout locking yoke396to bias the bailout drive gear342out of meshing engagement with the bailout driven gear350. As was discussed above, should power be lost or interrupted, the shifter spring266will bias the shifter solenoid260into the first actuation position. As such, actuation of the bailout system330will result in the application of reversing or retraction motions to the first rotary drive system300.

As discussed above, a surgical stapling instrument can comprise a manually-actuated bailout system configured to retract a staple firing drive, for example. In many instances, the bailout system may need to be operated and/or cranked more than one time to fully retract the staple firing drive. In such instances, the user of the stapling instrument may lose track of how many times they have cranked the bailout and/or otherwise become confused as to how much further the firing drive needs to be retracted. Various embodiments are envisioned in which the stapling instrument comprises a system configured to detect the position of a firing member of the firing drive, determine the distance in which the firing member needs to be retracted, and display that distance to the user of the surgical instrument.

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

Further to the above, the display comprises an electronic display, for example, and the controller is configured to display the remaining distance on the electronic display in any suitable manner. In at least one instance, the controller displays a progress bar on the display. In such instances, an empty progress bar can represent that the firing member is at the end of its firing stroke and a full progress bar can represent that the firing member has been fully retracted, for example. In at least one instance, 0% can represent that the firing member is at the end of its firing stroke and 100% can represent that the firing member has been fully retracted, for example. In certain instances, the controller is configured to display how many actuations of the bailout mechanism are required to retract the firing member to its fully retracted position on the display.

Further to the above, the actuation of the bailout mechanism can operably disconnect a battery, or power source, of the surgical stapling instrument from an electric motor of the firing drive. In at least one embodiment, the actuation of the bailout mechanism flips a switch which electrically decouples the battery from the electric motor. Such a system would prevent the electric motor from resisting the manual retraction of the firing member.

The illustrated handle assembly20also supports a third axial drive system that is generally designated as400. As can be seen inFIGS. 3 and 4, the third axial drive system400, in at least one form, comprises a solenoid402that has a third drive actuator member or rod410protruding therefrom. The distal end412of the third drive actuator member410has a third drive cradle or socket414formed therein for receiving a corresponding portion of a drive system component of an interchangeable surgical tool assembly that is operably attached thereto. The solenoid402is wired to or otherwise communicates with the handle circuit board assembly220and the control system or CPU224. In at least one arrangement, the solenoid402is “spring loaded” such that when the solenoid402is unactuated, the spring component thereof biases the third drive actuator410back to an unactuated starting position.

As indicated above, the reconfigurable handle assembly20may be advantageously employed to actuate a variety of different interchangeable surgical tool assemblies. To that end, the handle assembly20includes a tool mounting portion that is generally designated as500for operably coupling an interchangeable surgical tool assembly thereto. In the illustrated example, the tool mounting portion500includes two inwardly facing dovetail receiving slots502that are configured to engage corresponding portions of a tool attachment module portion of the interchangeable surgical tool assembly. Each dovetail receiving slot502may be tapered or, stated another way, be somewhat V-shaped. The dovetail receiving slots502are configured to releasably receive corresponding tapered attachment or lug portions that are formed on a portion of the tool attachment nozzle portion of the interchangeable surgical tool assembly. Each interchangeable surgical tool assembly may also be equipped with a latching system that is configured to releasable engage corresponding retention pockets504that are formed in the tool mounting portion500of the handle assembly20.

The various interchangeable surgical tool assemblies may have a “primary” rotary drive system that is configured to be operably coupled to or interface with the first rotary drive system310as well as a “secondary” rotary drive system that is configured to be operably coupled to or interface with the second rotary drive system320. The primary and secondary rotary drive systems may be configured to provide various rotary motions to portions of the particular type of surgical end effector that comprises a portion of the interchangeable surgical tool assembly. To facilitate operable coupling of the primary rotary drive system to the first rotary drive system and the secondary drive system to the second rotary drive system320, the tool mounting portion500of the handle assembly20also includes a pair of insertion ramps506that are configured to bias portions of the primary and secondary rotary drive systems of the interchangeable surgical tool assembly distally during the coupling process so as to facilitate alignment and operable coupling of the primary rotary drive system to the first rotary drive system300on the handle assembly20and the secondary rotary drive system to the second rotary drive system320on the handle assembly20.

The interchangeable surgical tool assembly may also include a “tertiary” axial drive system for applying axial motion(s) to corresponding portions of the surgical end effector of the interchangeable surgical tool assembly. To facilitate operable coupling of the tertiary axial drive system to the third axial drive system400on the handle assembly20, the third drive actuator member410is provided with a socket414that is configured to operably receive a lug or other portion of the tertiary axial drive system therein.

An interchangeable tool assembly2000is illustrated inFIG. 15. The interchangeable tool assembly2000is similar to the interchangeable tool assembly1000in many respects, but is different than the interchangeable tool assembly1000in certain other respects. For instance, the interchangeable assembly2000is a circular stapling assembly. Referring primarily toFIGS. 15 and 16, the circular stapling assembly2000comprises a shaft portion2100and an end effector2200. The shaft portion2100comprises a proximal portion which is releasably attachable to the handle assembly20, for example. The end effector2200comprises a first portion2210rotatably attached to the shaft portion2100about an articulation joint2300. The end effector2200further comprises a second portion2220releasably attached to the first portion2210. The second portion2220comprises a cartridge portion2222including an annular array of staple cavities2224defined therein and a staple stored in each staple cavity2224. The second portion2220further comprises an anvil2230including a tissue compression surface2232and an annular array of forming pockets or forming pockets2234(FIG. 27) registered with the staple cavities2224which are configured to deform the staples when the staples are ejected from the staple cavities2224.

Further to the above, referring again toFIGS. 15 and 16, the second portion2220of the end effector2200is selectively attachable to and selectively detachable from the first portion2210of the end effector2200. The second portion2220comprises an outer housing2227including a proximal connector2229which is configured to be received within an aperture, or chamber,2218defined in a housing2217of the first portion2210. The fit between the connector2229of the housing2227and the housing2217of the first portion2210is snug. A compression fit between the connector2229and the housing2217can prevent the second portion2220from being accidentally displaced longitudinally and/or rotationally relative to the first portion2210. In various instances, a detent member can be utilized to releasably secure the second portion2220to the first portion2210of the end effector2200.

Referring toFIGS. 15 and 35-38, the second portion2220of the end effector2200is interchangeable with other second portions such as a second portion2220′, a second portion2220″, a second portion2220′″, and/or another second portion2220, for example. The second portions2220′,2220″, and2220′″ are similar to the second portion2220in many respects. For instance, each second portion2220,2220′,2220″, and2220′″ includes a central aperture2226defined therein. That said, the second portions2220′,2220″, and2220′″ are different than the second portion2220in other respects. For instance, the second portion2220′ has a larger diameter than the second portion2220. Moreover, the annular array of staple cavities2224defined in the second portion2220′ has a larger circumference than the annular array of staple cavities2224defined in the second portion2220. Similarly, the second portion2220″ has a larger diameter than the second portion2220′ and the annular array of staple cavities2224defined in the second portion2220″ has a larger circumference than the annular array of staple cavities2224defined in the second portion2220′. Also, similarly, the second portion2220′″ has a larger diameter than the second portion2220″ and the annular array of staple cavities2224defined in the second portion2220′″ has a larger circumference than the annular array of staple cavities2224defined in the second portion2220″.

Further to the above, the anvil2230is interchangeable with other anvils such as an anvil2230′, an anvil2230″, an anvil2230′″, and/or another anvil2230, for example. The anvils2230′,2230″, and2230′″ are similar to the anvil2230in many respects. For instance, each anvil2230,2230′,2230″, and2230′″ comprises a longitudinal shaft2236including connecting flanges2238. That said, the anvils2230′,2230″, and2230′″ are different than the anvil2230in other respects. For instance, the anvil2230′ has a larger diameter than the anvil2230. Moreover, the annular array of the forming pockets2234defined in the anvil2230′ has a larger circumference than the annular array of forming pockets2234defined in the anvil2230such that the forming pockets2234remain registered with the staple cavities2224defined in the second portion2220′. Similarly, the anvil2230″ has a larger diameter than the anvil2230′ and the annular array of forming pockets2234defined in the anvil2230″ has a larger circumference than the annular array of forming pockets2234defined in the anvil2230′ such that the forming pockets2234remain registered with the staple cavities2224defined in the second portion2220″. Also, similarly, the anvil2230′″ has a larger diameter than the anvil2230″ and the annular array of forming pockets2234defined in the second portion2220′″ has a larger circumference than the annular array of forming pockets2234defined in the anvil2230″ such that the forming pockets2234remain registered with the staple cavities2224defined in the second portion2220′″.

Referring primarily toFIG. 17, the shaft portion2100comprises a proximal connector2120and an elongate shaft portion2110extending distally from the proximal connector2120. The proximal connector2120comprises a first input2318and a second input2418. The first input2318is operably connected to an end effector articulation system and the second input2418is operably connected to an end effector clamping and staple firing system. The first input2318and the second input2418can be operated in any suitable order. For instance, the first input2318can be rotated in a first direction to articulate the end effector2200in a first direction and, correspondingly, rotated in a second direction to articulate the end effector2200in a second direction. Once the end effector2200has been suitably articulated, the second input2428can then be rotated to close the anvil2230and clamp tissue against the cartridge portion2222of the end effector2200. As discussed in greater detail further below, the second input2428can then be operated to fire the staples from the staple cavities2224and incise tissue captured within the end effector2200. In various alternative embodiments, the first input2318and the second input2328can be operated in any suitable order and/or at the same time.

The first input2318is mounted to a proximal end of an articulation shaft2310which is rotatably mounted in the shaft portion2010. Referring primarily toFIGS. 20 and 21, the rotatable articulation shaft2310comprises a distal end and a worm gear2312mounted to the distal end. The worm gear2312is threadably engaged with an articulation slide2320. More specifically, the articulation slide2320comprises a threaded aperture2322defined therein and the worm gear2312is threadably mated with the threaded aperture2322. When the articulation shaft2310is rotated in a first direction, the worm gear2312pushes the articulation slide2320distally (FIG. 32). When the articulation shaft2310is rotated in a second, or opposite, direction, the worm gear2312pulls the articulation slide2320proximally (FIG. 31). The articulation slide2320is slidably supported by an articulation block2112fixedly mounted in the distal end of the elongate shaft portion2110. The movement of the articulation slide2320is limited to proximal and distal movement by the articulation block2112by a guide slot2315defined in the articulation block2112. The articulation slide2320further comprises a longitudinal key2326extending therefrom which is closely received in a longitudinal keyway2116defined in the bottom of the guide slot2315which limits the relative movement between the articulation slide2320and the articulation block2112to a longitudinal path.

Referring again toFIGS. 20, 21, and 24, the articulation slide2320is coupled to an articulation link2330. The articulation slide2320comprises a drive pin2324extending therefrom which is positioned within a proximal aperture2334defined in the articulation link2330. The drive pin2324is closely received within the aperture2334such that the drive pin2324and the sidewalls of the aperture2334co-operate to define an axis of rotation between the articulation slide2320and the articulation link2330. The articulation link2330is also coupled to the housing2217of the end effector2200. More specifically, the articulation link2330further comprises a distal aperture2335defined therein and the housing2217comprises a pin2215positioned in the distal aperture2335. The pin2215is closely received within the aperture2335such that the pin2215and the sidewalls of the aperture2335co-operate to define an axis of rotation between the articulation link2330and the housing2217.

Further to the above, referring toFIGS. 18-21 and 24, the end effector2200is rotatably coupled to the articulation block2112of the shaft2100about the articulation joint2300. The housing2217of the end effector2200comprises apertures2213defined in opposite sides thereof and the articulation block2112comprises projections2113extending from opposite sides thereof which are positioned in the apertures2213. The projections2113are closely received within the apertures2213such that the projections2113and the sidewalls of the apertures2213co-operate to define an articulation axis about which the end effector2200can be articulated. When the articulation shaft2310is rotated to drive the articulation slide2320distally, the articulation slide2320drives the proximal end of the articulation link2330distally. In response to the distal movement of the proximal end of the articulation link2330, the articulation link2330rotates about the drive pin2324which rotates the end effector2200about the articulation joint2300. When the articulation input2310is rotated to drive the articulation slide2320proximally, similar to the above, the articulation slide2320pulls the proximal end of the articulation link2330proximally. In response to the proximal movement of the proximal end of the articulation link2330, the articulation link2330rotates about the drive pin2324which rotates the end effector2200about the articulation joint2300. The articulation link2330provides at least one degree of freedom between the articulation slide2320and the housing2217. As a result, the articulation link2330permits the end effector2200to be articulated through a wide range of articulation angles.

As discussed above, referring toFIGS. 17 and 25, the proximal connector2120of the interchangeable tool assembly2000comprises a second input2418. The second input2418comprises a drive gear2417which is meshingly engaged with a drive gear2416mounted on a proximal end of a drive shaft2410. The drive shaft2410extends through the shaft portion2110and an aperture2114defined in the articulation block2112, as illustrated inFIG. 19. The aperture2114comprises a bearing and rotatably supports the drive shaft2410. Alternatively, the aperture2114can comprise a clearance aperture. In either event, referring primarily toFIG. 22, the drive shaft2410extends through the articulation joint2300and into the chamber2218defined in the end effector housing2217. The drive shaft2410is rotatably supported by a bearing2414mounted to the drive shaft2410which is captured within a recess2214defined in the housing2217of the end effector2200. The drive shaft2410further comprises an output gear2412mounted to the distal end thereof such that the rotation of the drive shaft2410is transmitted to the output gear2412.

Referring primarily toFIGS. 18, 22, and 23, the output gear2412of the drive shaft2410is operably engaged with a transmission2420. As discussed in greater detail below, the transmission2420is configured to shift the end effector2200between a first operating mode in which the drive shaft2410moves the anvil2230relative to the cartridge body2222and a second operating mode in which the drive shaft2410fires the staples from the staple cavities2224and incises the tissue captured between the anvil2230and the cartridge body2222. The transmission2420comprises an orbit drive comprising a planetary plate2421and four planetary gears2424rotatably mounted to the planetary plate2421. The planetary plate2421comprises a clearance aperture extending through the center thereof and the drive shaft2410extends through the clearance aperture. The planetary plate2421and the planetary gears2424are positioned in a chamber2219defined in the end effector housing2217. Each planetary gear2424is rotatable about a gear pin2423extending from the planetary plate2421. The gear pins2423are positioned along a circumference surrounding the clearance aperture. The output gear2412is meshingly engaged with the planetary gears2424and, as described in greater detail below, the drive shaft2410drives the planetary gears2424.

Further to the above, the drive shaft2410extends trough the articulation joint2300. In order for the output gear2412to remain properly engaged with the planetary gears2424when the end effector2200is articulated, the drive shaft2410is flexible. In at least one instance, the drive shaft2410is comprised of plastic, for example.

As discussed above, the transmission2420comprises a first operating mode and a second operating mode. Referring primarily toFIGS. 23 and 28, the interchangeable tool assembly2000further comprises a shifter2600movable between a first position and a second position to switch the transmission2420between its first operating mode and its second operating mode. When the shifter2600is in its first position, as illustrated inFIGS. 28-30, the shifter2600is not engaged with the planetary plate2421of the transmission2420and, as a result, the planetary plate2421and the planetary gears2424are rotated by the drive shaft2410. More specifically, the drive shaft2410rotates the planetary gears2424about their respective gear pins2423and the planetary gears2424rotate the planetary plate2421owing to reactionary forces between the planetary gears2424and an annular ring of teeth2534which extends around the planetary gears2424, as described in greater detail further below. The planetary plate2421is operably coupled with an output coupling2430such that the rotation of the planetary plate2421is transmitted to the output coupling2430. Referring primarily toFIG. 23, the output coupling2430comprises an array of apertures2433extending around the outer perimeter thereof wherein the gear pins2423extending from the planetary plate2421extend into, and are closely received by, the apertures2433defined in the output coupling2430such that there is little, if any, relative movement between the planetary plate2421and the output coupling2430.

Referring primarily toFIGS. 18 and 23, the output coupling2430comprises a drive socket2432. The drive socket2432comprises a substantially hexagonal aperture, for example; however, any suitable configuration could be utilized. The drive socket2432is configured to receive a closure shaft2440extending through the second portion2220of the end effector2200. The closure shaft2440comprises a proximal drive end2442which has a substantially-hexagonal shape that is closely received within the drive socket2432such that the rotation of the drive shaft2410is transferable to the closure shaft2440. The closure shaft2440is rotatably supported within the housing2227of the second portion2220by a bearing2444. The bearing2444comprises a thrust bearing, for example; however, the bearing2444may comprise any suitable bearing.

Referring primarily toFIGS. 23 and 28-30, the closure shaft2440comprises a threaded portion2446that is threadably engaged with a threaded aperture2456defined in a trocar2450. As discussed in greater detail further below, the anvil2230is attachable to the trocar2450which can be translated to move the anvil2230toward and/or away from the cartridge body2222. Referring again toFIG. 18, the trocar2450comprises at least one longitudinal key slot2459defined therein which is configured to co-operate with at least one longitudinal key extending from an inner surface2546of the drive sleeve2540. The drive sleeve2540is part of the staple firing system, discussed further below, and the reader should understand that the trocar2450and the drive sleeve2540, one, slide relative to one another, and, two, co-operatively inhibit relative rotational movement therebetween. Owing to the threaded engagement between the closure shaft2440and the trocar2450, the closure shaft2440can displace, or translate, the trocar2450distally when the closure shaft2440is rotated in a first direction and, correspondingly, displace, or translate, the trocar2450proximally when the closure shaft2440is rotated in a second, or opposite, direction.

As discussed above, the anvil2230is attachable to the trocar2450. The anvil2230comprises connecting flanges2238which are configured to engage and grip the trocar2450. The connecting flanges2238comprise cantilever beams which are connected to the shaft portion2236of the anvil2230. Referring primarily toFIG. 23, the trocar2450comprises retention notches, or recesses,2458which are configured to releasably receive the connecting flanges2238when the anvil2230is assembled to the trocar2450. The retention notches2458and the connecting flanges2238are configured to resist the inadvertent detachment of the anvil2230from the trocar2450. The connecting flanges2238are separated by longitudinal slots2237. The longitudinal slots2237are configured to receive longitudinal ribs2457extending from the trocar2450when the anvil2230is assembled to the trocar2450. The ribs2457are closely received within the slots2237and, as a result, the anvil2230is inhibited from rotating relative to the trocar2450.

Once the anvil2230has been suitably positioned relative to the cartridge portion2222, as discussed above, the tool assembly2000can be shifted into its second operating mode. The shifter2600comprises an electrically-actuated motor, for example, which is utilized to shift the transmission2420of the end effector2200. In various other embodiments, the shifter2600can comprise any suitable device which is electrically and/or manually actuated. The shifter2600is in signal communication with a processor of the surgical stapling instrument and in power communication with a battery of the surgical stapling instrument. In various instances, insulated electrical wires, for example, extend between the shifter2600and a handle of the surgical instrument such that the processor can communicate with the shifter2600and the battery can supply power to the shifter2600. In various other instances, the shifter2600can comprise a wireless signal receiver and the processor can communicate wirelessly with the shifter2600. In certain instances, power can be supplied wirelessly to the shifter2600, such as through an inductive circuit, for example. In various instances, the shifter2600can comprise its own power source.

The shifter2600comprises a housing mounted in the chamber2218defined in the proximal end of the end effector2200. The shifter2600comprises a clutch key, or toggle,2602and an output shaft2604movable between a first position and a second position relative to the shifter housing. The clutch key2602comprises a first lock tooth2608and a second lock tooth2609and, when the clutch key2602is in its first position, the first lock tooth2608is engaged with a firing tube2530of the staple firing system and, concurrently, the second lock tooth2609is disengaged from the planetary plate2421of the transmission2420. More specifically, the first lock tooth2608is positioned in an aperture2538, which is part of an annular array of apertures2538defined around the firing tube2530, and the second lock tooth2609is not positioned in an aperture2429, which is part of an annular array of apertures2429defined around the planetary plate2421. As a result of the above, the shifter2600prevents the firing tube2530from rotating and, accordingly, locks out the staple firing system when the clutch key2602is in its first position. Although the staple firing system has been locked out by the shifter2600when the clutch key2602is in its first position, the drive shaft2410can rotate the planetary plate2421and operate the anvil closure system, as discussed above.

As illustrated primarily inFIG. 23, the firing tube2530comprises an inner annular rack of teeth2534defined in an inner sidewall2532thereof. The planetary gears2424are operably intermeshed with the rack of teeth2534. When the shifter2600is in its first position, as illustrated inFIG. 28, the firing tube2530is held in position by the shifter2600and the planetary gears2424are rotatable relative to the firing tube2530and the rack of teeth2534by the drive shaft2410. In such instances, the planetary gears2424are rotated about a longitudinal drive axis defined by the drive shaft2410and, at the same time, rotated about axes defined by their respective gear pins2423. The reader should appreciate that the planetary gears2424are directly driven by the drive shaft2410and, owing to reactionary forces created between the planetary gears2424and the firing tube2530, the planetary gears2424drive and rotate the planetary plate2421. When the shifter2600is actuated to move the clutch key2602into its second position, the first lock tooth2608is disengaged from the firing tube2530and, concurrently, the second lock tooth2609is engaged with the planetary plate2421. The planetary plate2421is held in position by the shifter2600when the clutch key2602is in its second position and, as a result, the closure drive has been locked out and cannot be operated to move the anvil2230. When the drive shaft2410is rotated in such instances, the output gear2412drives and rotates the planetary gears2424relative to the planetary plate2421about their respective gear pins2423. The planetary gears2424drive the firing tube2530via the rack of teeth2534and rotate the firing tube2530about its longitudinal axis.

Further to the above, and referring again toFIG. 23, the firing tube2530is operably coupled with the drive sleeve2540of the staple firing system. More specifically, the inner sidewall2532of the firing tube2530comprises longitudinal slots2535defined therein which are configured to closely receive longitudinal ribs2545defined on the drive sleeve2540such that the drive sleeve2540rotates with the firing tube2530. The drive sleeve2540further comprises a threaded distal end2542which is threadably engaged with a drive collar2550. More specifically, the drive collar2550comprises a threaded aperture2552which is threadably engaged with the threaded distal end2542. The drive collar2550is positioned in an aperture2228defined in the housing of the end effector2200and is prevented from rotating within the aperture2228by a longitudinal rib and groove arrangement, for example. As a result of the above, the rotation of the drive sleeve2540translates the drive collar2550longitudinally. For instance, the drive collar2550is advanced distally if the drive sleeve2540is rotated in a first direction and retracted proximally if the drive sleeve2540is rotated in a second, or opposite, direction.

When the drive collar2550is pushed distally, as discussed above, the drive collar2550pushes a staple driver block2560and a cutting member2570, such as a knife, for example, distally during a firing stroke of the staple firing system. More specifically, the drive collar2550pushes the staple driver block2560and the cutting member2570between a proximal, unfired position in which the staples are positioned in the staple cavities2224defined in the cartridge body portion2222and the cutting member2570is recessed below the deck surface of the cartridge body portion2222and a distal, fired position in which the staples have been deformed against the anvil2230and the tissue captured between the anvil2230and the cartridge body portion2222has been transected by the cutting member2570. The drive collar2550comprises a drive recess2554which is configured to abut the staple driver block2560and the cutting member2570as the drive collar2550is advanced distally. The staple driver block2560comprises a plurality of staple cradles defined therein wherein each staple cradle is configured to support the base of a staple. The staple cradles are aligned with the staple cavities2224defined in the cartridge body portion2222and are arranged in at least two concentric rows.

The staple driver block2560and the cutting member2570are attached to the drive collar2550such that, when the drive collar2550is moved proximally away from the anvil2230, the staple driver block2560and the cutting member2570are pulled proximally by the drive collar2550. In at least one instance, the staple driver block2560and the cutting member2570comprise one or more hooks which extend into apertures2557defined in the drive collar2550. In various instances, the staple driver block2560and the cutting member2570can be retracted such that they are completely retracted below the deck surface of the cartridge body portion2222.

Further to the above, the end effector2200is operable in a third operating mode in which the clutch key2602of the shifter2600is operably engaged with the anvil closure system and the staple firing system at the same time. In this operating mode, the first lock tooth2608is engaged with the firing tube2530of the staple firing system and the second lock tooth2609is engaged with the planetary plate2421of the transmission2420. In such instances, the first lock tooth2608is positioned in an aperture2538defined in the firing tube2530and the second lock tooth2609is positioned in an aperture2429defined in the planetary plate2421. As a result of the above, the drive shaft2410moves the anvil2230, the staple driver block2560, and the cutting member2570relative to the cartridge body2222at the same time.

Referring again toFIG. 15, the user of the interchangeable tool assembly2000can select from a kit of second portions2220,2220′,2220″,2220′″ and/or any other suitable second portion and assembly the selected second portion to the first portion2210of the end effector2200. Referring primarily toFIG. 18, each second portion comprises a housing connector2229which engages the housing2217of the first portion2210when the second portion is assembled to the first portion2210. In addition, each second portion comprises a closure shaft2440which operably engages the drive socket2432of the first portion2210when the second portion is assembled to the first portion2210. Moreover, each second portion comprises a drive sleeve2540which operably engages the firing tube2530of the first portion2210when the second portion is assembled to the first portion2210.

Further to the above, referring toFIGS. 35 and 36, a tool assembly2000′ is interchangeable with the tool assembly2000. The tool assembly2000′ is similar to the tool assembly2000in many respects; however, the tool assembly2000′ is configured to apply circular staple lines having larger diameters than the circular staple lines applied by the tool assembly2000. The tool assembly2000′ comprises, among other things, a wider second portion2220′, staple driver2560′, knife assembly2570′, cartridge body2222′, and anvil2230′. Referring toFIG. 37, a tool assembly2000″ is interchangeable with the tool assembly2000. The tool assembly2000″ is similar to the tool assemblies2000and2000′ in many respects; however, the tool assembly2000″ is configured to apply circular staple lines having larger diameters than the circular staple lines applied by the tool assembly2000′. The tool assembly2000″ comprises, among other things, a wider second portion2220″, staple driver2560″, knife assembly2570″, cartridge body2222″, and anvil2230″. Referring toFIG. 38, a tool assembly2000′″ is interchangeable with the tool assembly2000. The tool assembly2000″ is similar to the tool assemblies2000,2000′, and2000″ in many respects; however, the tool assembly2000′″ is configured to apply circular staple lines having larger diameters than the circular staple lines applied by the tool assembly2000″. The tool assembly2000′″ comprises, among other things, a wider second portion2220′″, staple driver2560′″, knife assembly2570′″, cartridge body2222′″, and anvil2230′″.

In various embodiments, further to the above, a surgical instrument can have any suitable number of operating modes. In at least one embodiment, a surgical stapling instrument comprises a transmission which includes a first operating mode which fires the staples, a second operating mode which deploys the cutting member, and a third operating mode which both fires the staples and deploys the cutting member at the same time. In the first operating mode, the cutting member is not deployed. Moreover, the processor of such a surgical instrument can be programmed such that the instrument cannot be placed in the second operating mode without having first completed the first operating mode. As a result of the above, the user of the surgical instrument can decide whether or not to cut the tissue after the staples have been fired.

An alternative embodiment of a staple cartridge body for use with a surgical stapler is illustrated inFIG. 34. A cartridge body2222′ comprises an annular outer row of staple cavities2224and an annular inner row of staple cavities2224′. The staple cavities2224are defined in a first step of the cartridge body deck and the staple cavities2224′ are defined in a second step of the cartridge body deck. The second step extends above the first step. Stated another way, the first step has a first deck height and the second step has a second deck height which is taller than the first deck height. A deck wall separates the first step and the second step. In various embodiments, the deck wall is sloped. In certain embodiments, the deck wall is orthogonal to the first step and/or the second step.

The cartridge body2222′ further comprises cavity extensions2229′ extending from the first step of the deck. The cavity extensions2229′ surround the ends of the staple cavities2224and extend the staple cavities2224above the first step. The cavity extensions2229′ can at least partially control the staples above the first step as the staples are ejected from the staple cavities2224. The cavity extensions2229′ are also configured to contact and compress tissue captured against the cartridge body2222′. The cavity extensions2229′ can also control the flow of tissue relative to the cartridge body2222′. For instance, the cavity extensions2229′ can limit the radial flow of the tissue. The cavity extensions2229′ can have any suitable configuration and can extend any suitable height from the first step. In at least one instance, the top surfaces of the cavity extensions2229′ are aligned with, or have the same height as, the second step, for example. In other instances, the cavity extensions2229′ can extend above or below the second step.

Further to the above, the staple cavities2224each comprise a first staple positioned therein having a first unformed height. The staple cavities2224′ each comprise a second staple positioned therein having a second unformed height which is different than the first unformed height. For instance, the first unformed height is taller than the second unformed height; however, the second unformed height could be taller than the first unformed height. In alternative embodiments, the first unformed staple height and the second unformed staple height is the same.

The first staples are deformed to a first deformed height and the second staples are deformed to a second deformed height which is different than the first deformed height. For instance, the first deformed height is taller than the second deformed height. Such an arrangement could improve blood flow into the stapled tissue. Alternatively, the second deformed height could be taller than the first deformed height. Such an arrangement could improve the pliability of the tissue along the inner transection line. In certain alternative embodiments, the first deformed height and the second deformed height is the same.

As discussed above, an interchangeable tool assembly can comprise, among other things, a shaft, an end effector, and a replaceable staple cartridge. The replaceable staple cartridge comprises a closure drive configured to move open and close the end effector to capture tissue within the end effector and a firing drive configured to staple and cut the tissue captured within the end effector. The closure drive and the firing drive of the end effector are operably coupled with a corresponding closure drive and firing drive of the shaft when the replaceable staple cartridge is assembled to the shaft. In the event that the replaceable staple cartridge is not properly assembled to the shaft, the replaceable staple cartridge may not operate in its intended manner. As described in greater detail below, the replaceable staple cartridge and/or the shaft can comprise a lockout which prevents the replaceable staple cartridge from being operated unless the replaceable staple cartridge is properly attached to the shaft.

Turning now toFIG. 39, an interchangeable tool assembly3000comprises a shaft3010and a replaceable staple cartridge3020. Similar to the above, the replaceable staple cartridge3020comprises a closure drive input and a firing drive input which are operably coupled with a closure drive output and a firing drive output, respectively, when the staple cartridge3020is fully seated onto the shaft3010. The operation of such closure and firing systems are not repeated herein for the sake of brevity.

The interchangeable tool assembly3000further comprises a lockout circuit3090. The lockout circuit3090includes conductors3096and contacts3092. A first contact3092is electrically coupled to a first conductor3096and a second contact3092is electrically coupled to a second conductor3096. The first contact3092is not electrically coupled to the second contact3092prior to the staple cartridge3020being fully seated onto the shaft3010. The staple cartridge3020comprises a contact bridge3094which engages and electrically couples the contacts3092when the staple cartridge3020is fully seated onto the shaft3010. The contacts3092and the contact bridge3094are configured and arranged such that the contact bridge3094does not electrically couple the contacts3092when the staple cartridge3020is only partially seated onto the shaft3010.

The interchangeable tool assembly3000is usable with a surgical instrument system which includes a manually-operable handle and/or a robotic system, for example. In various embodiments, the surgical instrument system includes an electric motor configured to drive the staple firing system of the tool assembly3000and, in addition, a controller configured to operate the electric motor. The lockout circuit of the tool assembly3000is in communication with the controller. When the controller detects that the contact bridge3094is not engaged with the contacts3092, or that the lockout circuit is in an open condition, the controller prevents the electric motor from operating the staple firing system. In various instances, the controller is configured such that it does not supply power to the electric motor when the lockout circuit is in an open condition. In certain other instances, the controller is configured to supply power to the electric motor such that it can operate the closure system but not the firing system when the lockout circuit is in an open condition. In at least one such instance, the controller operates a transmission coupled to the electric motor such that the output of the electric motor is only directed to the closure system. When the controller detects that the contact bridge3094is engaged with the contacts3092, or that the lockout circuit is in a closed condition, the controller allows the electric motor to operate the staple firing system.

When a surgical instrument system comprises a handle, further to the above, the controller can actuate a trigger lock which prevents a firing trigger of the handle from being actuated when the controller detects that the lockout circuit is in an open configuration. When the staple cartridge3020is fully seated onto the shaft3010and the lockout circuit is closed, the controller can retract the trigger lock and allow the firing trigger to be actuated. Such a system can be utilized with motorized and/or non-motorized firing drives. A non-motorized firing drive can be driven by a handcrank, for example.

As discussed above, an anvil2230can be assembled to the trocar shaft2450of the closure drive of the tool assembly2000. The connecting flanges2238of the anvil2230are configured to engage a recess2458defined in the trocar shaft2450to connect the anvil2230thereto. Once the anvil2230has been assembled to the trocar shaft2450, the trocar shaft2450and the anvil2230can be retracted, or pulled, toward the staple cartridge2222by the closure drive to compress tissue against the staple cartridge2222. In some instances, however, the anvil2230may not be properly assembled to the trocar shaft2450. The mis-assembly of the anvil2230to the trocar shaft2450can frequently occur when the trocar shaft2450is not sufficiently extended above the deck of the staple cartridge2222when a clinician attempts to assemble the anvil2230to the trocar shaft2450. Oftentimes, in such instances, the anvil2230is sufficiently attached to the trocar shaft2450such that the trocar shaft2450can move the anvil2230toward the staple cartridge2222but, when the anvil2230begins to compress the tissue against the staple cartridge2222, the anvil2230can detach from the trocar shaft2450.

Turning now toFIGS. 41 and 42, an interchangeable tool assembly3100is depicted which is similar in many respects to the interchangeable tool assembly2000discussed above. The tool assembly2000comprises a cartridge body3120comprising a deck3121configured to support tissue when the tissue is compressed against the cartridge body3120by the anvil2130. The tool assembly3100further comprises a closure drive configured to move the anvil2130relative to the cartridge body3120. The closure drive comprises a trocar shaft3150which, similar to the above, includes a recess defined therein. The recess comprises a distal shoulder3158which is configured to retain the anvil2130to the trocar shaft3150. In addition, the tool assembly3100further comprises a firing drive configured to eject staples from the cartridge body3120. The firing drive comprises a rotatable shaft3162and a translatable collar3160threadably engaged with the rotatable shaft3162which is configured to eject staples from the cartridge body3120. The rotatable shaft3162comprises a longitudinal aperture3164defined therein and the trocar shaft3150extends through the aperture3164.

Further to the above, the closure drive further comprises a clip3190mounted to the trocar shaft3150. The clip3190comprises a base3192mounted within a slot defined in the trocar shaft3150. The clip3190further comprises compliant arms, or appendages,3198extending from the base3192. The arms3198are movable between an extended position (FIG. 41) and a deflected position (FIG. 42). When the arms3198are in their deflected position, as illustrated inFIG. 42, the anvil2130can be locked to the trocar shaft3150. The arms3198are held in their deflected position by the translatable collar3160of the firing drive when the trocar shaft3150has been sufficiently extended above the deck3121of the cartridge body3120, as illustrated inFIG. 42. The translatable collar3160comprises an annular shoulder3168configured to resiliently bias the arms3198inwardly when the arms3198are brought into contact with the shoulder3168.

When the trocar shaft3150is not in a sufficiently extended position above the cartridge deck3121, the arms3198are not biased inwardly by the shoulder3168. In such instances, the arms3198are in their extended position, as illustrated inFIG. 41. When the arms3198are in their extended position, the arms3198prevent the anvil2130from being attached to the trocar shaft3150. More specifically, the arms3198prevent the connecting flanges2138of the anvil2130from being seated behind the shoulder3158defined in the trocar shaft3150. In such instances, the arms3198prevent the anvil2130from being partially attached to the trocar shaft3150and, as a result, the clinician attempting to assemble the anvil2130to the trocar shaft3150cannot partially assemble the anvil2130to the trocar shaft3150and can avoid the issues discussed above. The reader should appreciate that the anvil2130is often assembled to the trocar shaft3150in situ, or within a patient, and the proper assembly of the anvil2130to the trocar shaft3150expedites the completion of the surgical technique being used. The system discussed above provides a lockout which prevents a partially assembled anvil from being compressed against the tissue.

Turning now toFIGS. 43-45, an interchangeable tool assembly3200comprises a lockout configured to prevent a closure drive from being retracted without an anvil attached thereto, as discussed in greater detail below. The tool assembly3200comprises a shaft3210and an end effector3220. The end effector3220includes an outer housing3227, a cartridge body3222, and a longitudinal aperture3226defined therethrough. The tool assembly3200further comprises a closure drive including a trocar shaft3250and an anvil3230attachable to the trocar shaft3250. Similar to the above, the closure drive is configured to move the anvil3230toward and away from the cartridge body3222. The trocar shaft3250is movable between an extended position and a retracted position.FIGS. 44 and 45both illustrate the trocar shaft3250in its extended position.

Further to the above, the tool assembly3200further comprises a retraction lock3290configured to prevent the trocar shaft3250from being moved from its extended position (FIGS. 44 and 45) toward its retracted position when the anvil3230is not assembled to the trocar shaft3250. The retraction lock3290comprises a lock arm3292rotatably mounted to the housing3227about a projection, or pin,3294. The retraction lock3290further comprises a spring3296engaged with the lock arm3292which is configured to bias the lock arm3292toward the trocar shaft3250. The trocar shaft3250comprises a lock shoulder3258and, when the anvil3230is not assembled to the trocar shaft3250as illustrated inFIG. 44, the lock arm3292is configured to catch the lock shoulder3258and prevent the trocar shaft3250from being moved proximally. More specifically, the lock arm3292comprises a catch3298configured to slide under the lock shoulder3258. When the anvil3230is assembled to the trocar shaft3250, as illustrated inFIG. 45, the anvil3230contacts the lock arm3292and displaces the lock arm3292away from the lock shoulder3258. At such point, the trocar shaft3250has been unlocked and can be moved toward the cartridge body3222into its retracted position.

Turning now toFIGS. 46-48, an interchangeable tool assembly3300comprises a closure drive, a staple firing drive, and a lockout configured to prevent the staple firing drive from being operated until the anvil of the closure drive has been set to a proper tissue gap, as discussed in greater detail below. The tool assembly3300comprises a shaft3310and an end effector3320. The end effector3320includes an inner frame3329, an outer housing3327, and a cartridge body3322. Similar to the above, the closure drive includes a trocar shaft3350and an anvil2230attachable to the trocar shaft3350. Also similar to the above, the trocar shaft3350is movable between an extended position (FIG. 47) and a retracted position (FIG. 48) to move the anvil2230toward and away from the cartridge body3322. The firing drive includes a rotatable shaft3360which is configured to displace a firing drive distally to eject the staples stored in the cartridge body3322.

Further to the above, the end effector3320comprises a firing drive lock3390movably mounted to the inner frame3329. The firing drive lock3390comprises a lock pin3394and a lock spring3398positioned around the lock pin3394. The lock pin3394comprises a head3392and a stop3396. The lock spring3398is positioned intermediate the stop3396and a sidewall of a cavity3328defined in the inner frame3329. When the trocar shaft3350is in an extended position, as illustrated inFIG. 47, the lock spring3398biases the lock pin3394into a lock aperture3364defined in the rotatable shaft3360of the staple firing drive. In such instances, the interaction between the lock pin3394and the sidewalls of the lock aperture3364prevent the shaft3360from being rotated to fire the staples from the cartridge body3322. When the trocar shaft3350is sufficiently retracted, the trocar shaft3350engages the head3392of the lock pin3394. The head3392comprises a cam surface defined thereon which is configured to be engaged by the trocar shaft3350to move the firing drive lock3390between a locked configuration (FIG. 47) and an unlocked configuration (FIG. 48). When the drive lock3390is in its unlocked configuration, the shaft3360of the firing drive can be rotated.

The firing drive lockout of the tool assembly3300requires the anvil2230to be moved into a predetermined position, or within a range of predetermined positions, before the staples can be fired. Moreover, the firing drive lockout of the tool assembly3300requires the tissue gap between the anvil2230and the cartridge body3322to be less than a certain distance before the staples can be fired. As a result, the position of the anvil2230and/or the closure system deactivates the staple firing lockout. Such an arrangement can assist in preventing the malformation of the staples and/or the undercompression of the tissue, among other things.

Turning now toFIGS. 49-51, an interchangeable tool assembly3400comprises a closure drive configured to clamp tissue, a staple firing drive, and a firing drive lockout3490configured to prevent the staple firing drive from being operated prior to the closure drive applying a sufficient clamping pressure to the tissue. The closure drive comprises a trocar shaft3450and an anvil, such as anvil2230, for example, attached to the trocar shaft3450. Similar to the above, the trocar shaft3450is movable from an extended position (FIG. 50) to a retracted position (FIG. 51) to compress tissue against a cartridge body of the tool assembly3400. The firing drive comprises a rotatable shaft3460configured to displace a staple driver distally and eject staples from the cartridge body.

The firing drive lockout3490is positioned intermediate the trocar shaft3450of the closure drive and the rotatable shaft3460of the firing drive. The firing drive lockout3490comprises a distal plate3492, a proximal plate3494, and a spring3493positioned intermediate the distal plate3492and the proximal plate3494. The firing drive lockout3490further comprises a lock pin3498movable between a locked configuration (FIG. 50) in which the lock pin3498is engaged with the shaft3460and an unlocked configuration (FIG. 51) in which the lock pin3498is disengaged from the shaft3460. The lock pin3498is positioned in a pin chamber3496defined between the distal plate3492and the proximal plate3494. More specifically, the lock pin3498comprises a beveled head positioned intermediate a cam3495defined on the distal plate3492and a cam3495defined on the proximal plate3494. When the trocar shaft3450is retracted proximally, the trocar shaft3450pushes the distal plate3492proximally and the cam3495defined on the distal plate3492engages the head of the lock pin3498. In such instances, the cam3495defined on the distal plate3492, in co-operation with the cam3495defined on the proximal plate3494, displace the lock pin3498into its unlocked configuration, as illustrated inFIG. 51.

As discussed above, the cams3495of the firing drive lockout3490squeeze the head of the lock pin3498as the distal plate3492is moved toward the proximal plate3494by the trocar shaft3450. More specifically, the cams3495drive the lock pin3498inwardly and out of engagement with the rotatable shaft3460. The lock pin3498is positioned in a lock aperture3468defined in the shaft3460when the lock pin3498is in its locked configuration and, owing to the interaction between the lock pin3498and the sidewalls of the lock aperture3468, the lock pin3498prevents the shaft3460from rotating. As a result, the staples cannot be fired from the cartridge body by the firing drive. When the lock pin3498is moved into is unlocked configuration, as discussed above, the lock pin3498is moved out of the lock aperture and the shaft3460can be rotated by the firing drive to fire the staples from the cartridge body. In various embodiments, the shaft3460can include a circumferential array of lock apertures3468defined in the shaft3460, each of which is configured to receive the lock pin3498and lockout the firing drive. Referring again toFIGS. 49-51, the firing drive lockout3490further comprises a biasing member, such as a spring3499, for example, which is configured to bias the lock pin3498into a lock aperture3468.

Further to the above, the spring3493of the firing drive lockout3490is configured to resist the proximal movement of the trocar shaft3450. The spring3493is a linear coil spring; however, any suitable spring could be used. Moreover, more than one spring could be used. In any event, the spring3493, or spring system, has a stiffness which applies a spring force to the distal plate3492of the firing drive lockout3490as the trocar shaft3450is retracted. Stated another way, the force applied to the distal plate3492by the spring3493increases in proportion to the distance in which the trocar shaft3450is displaced proximally. The spring force generated by the spring3493opposes the clamping force that the anvil2230is applying to the tissue. As a result, the clamping force must overcome a certain, or predetermined, spring force being generated by the spring3493in order to sufficiently displace the distal plate3492and unlock the firing drive. In such instances, the tissue clamping force must meet a predetermined threshold before the firing drive lockout3490can be deactivated and the staple firing drive can be actuated.

As discussed in connection with various embodiments disclosed herein, a staple firing drive drives staples against an anvil to deform the staples to a desired formed height. In various instances, the staple firing drive is also configured to push a cutting member, such as a knife, for example, distally to cut tissue captured between the cartridge body and the anvil. In such instances, the knife is exposed above the deck of the cartridge body. That said, the anvil is positioned in close relationship to the cartridge body when the anvil is in its closed, or clamped, position and the knife is, for the most part, covered by the anvil even though the knife is exposed above the cartridge body. In the event that the anvil were to be moved to its open position and/or detached from the closure drive before the knife is retracted below the deck of the cartridge body, the knife would be uncovered and exposed. A tool assembly3500is illustrated inFIGS. 52-54which comprises a lockout3590configured to prevent the anvil from being moved into its open position while the knife is exposed above the cartridge deck.

The tool assembly3500comprises a closure drive and a firing drive. The closure drive comprises a trocar shaft3550and an anvil3530releasably attachable to the trocar shaft3550. Similar to the above, the trocar shaft3550is translatable proximally and distally by a rotatable closure shaft2440threadably engaged with the trocar shaft3550. The firing drive comprises a rotatable shaft3562and a translatable collar3560threadably engaged with the rotatable shaft3562. Similar to the above, the collar3560is translatable proximally and distally when the shaft3562is rotated in first and second directions, respectively. Also similar to the above, the collar3560of the firing drive is configured to advance and retract an array of staple drivers and a knife assembly2570toward and away from the anvil3530.

Further to the above, the lockout3590comprises a lock arm3592rotatably mounted to the shaft3562of the firing drive about a pivot3594. The lockout3590further comprises a biasing member, or spring,3599engaged with the lock arm3592which is configured to bias the lock arm3592into contact with the anvil3530. In use, the anvil3530is assembled to the trocar shaft3550and the trocar shaft3550is then retracted to position the anvil3530in its closed, or clamped, position relative to the cartridge body. As the anvil3530is being retracted, the lock arm3592of the lockout3590slides against the outer surface of the anvil3530until the lock arm3592is aligned with a lock recess3532defined in the anvil3530. At such point, the spring3599biases the lock arm3592into the lock recess3532, as illustrated inFIG. 53. More specifically, the lock arm3592is positioned behind a lock shoulder which defines the lock recess3532. The firing drive can then be operated to fire the staples and cut the tissue. In such instances, the cutting edge of the knife assembly2570is exposed above the cartridge body and, owing to the lockout3590, the closure drive is locked out, or prevented from being opened, until the cutting edge of the knife assembly2570is no longer exposed.

Referring primarily toFIG. 52, the lock arm3592further comprises a reset tab3593extending therefrom. The collar3560of the firing drive further comprises a cam3563configured to engage the reset tab3593when the collar3560and the knife assembly2570are retracted proximally by the firing drive. The cam3563is configured to rotate the lock arm3592downwardly out of engagement with the lock shoulder defined in the lock recess3532and unlock the closure drive. The cam3563is configured to unlock the closure drive when the cutting edge of the knife assembly2570has been retracted below the cartridge deck; however, in other embodiments, the cam3563can unlock the closure drive when the cutting edge is flush with, or at least substantially flush with, the cartridge deck. In some embodiments, the closure drive may not be unlocked until the knife assembly2570has been completely retracted. Once the closure drive has been unlocked, the closure drive can be operated to move the anvil3530to an open, or unclamped, position once again.

Once the staples of an interchangeable tool assembly have been fired, according to various embodiments, the tool assembly may not be re-used. As discussed in greater detail below, a tool assembly can include a lockout configured to prevent the tool assembly from being re-clamped onto tissue after it has been used to staple tissue.

In at least one embodiment, referring now toFIGS. 55-58, an interchangeable tool assembly3600comprises a closure drive configured to position an anvil, such as anvil2230, for example, relative to a staple cartridge and a firing drive configured to drive staples from the staple cartridge. Similar to the above, the anvil2230is attachable to a translatable trocar shaft3650of the closure drive. Also similar to the above, the firing drive comprises a rotatable shaft3660, a translatable collar2550threadably engaged with the rotatable shaft3660, and a staple firing driver2560displaceable by the rotatable shaft3660. In use, the closure drive is operable to position the anvil2230in a clamped position relative to the staple cartridge and the firing driver is then operable to fire the staples into tissue captured between the anvil2230and the staple cartridge. Thereafter, the closure drive is operated to open the anvil2230and release the tissue.

Further to the above, the tool assembly3600comprises a lockout3690configured to prevent the anvil2230from being reclamped onto the tissue. The lockout3690comprises a lock arm3692rotatably mounted to the rotatable shaft3660which is held in an unlocked configuration by the firing drive as the closure drive moves the anvil2230between an open, unclamped position (FIG. 55) and a closed, clamped position (FIG. 56). The lock arm3692is held in its unlocked configuration between the rotatable shaft3660and the translatable collar2550as the trocar shaft3650and the anvil2230are moved relative to the firing drive to position the anvil2230relative to the staple cartridge. The arm3692is held in its unlocked configuration until the firing drive is operated, as illustrated inFIG. 55. As the shaft3460is rotated in a first direction, the collar2550is displaced distally and a spring3699of the lockout3690can bias the lock arm3692against the trocar shaft3650. The trocar shaft3650rotates relative to the lock arm3692as the collar2550is displaced distally to fire the staples and then retracted proximally. The closure drive can then be operated to re-open the anvil2230to unclamp the tissue and/or detach the anvil2230from the trocar shaft3650. As the anvil2230is being re-opened, the spring3699biases the lock arm3692into a lock recess3652defined in the trocar shaft3650and/or anvil2230. Once the lock arm3692is positioned in the lock recess3652, the lock arm3692prevents the trocar shaft3650from being retracted proximally. In the event that the closure drive is operated in an attempt to retract the trocars shaft3650the lock arm3692will abut a lock shoulder defined in the lock recess3652and prevent the retraction of the trocar shaft3650and anvil2230. As a result, the lockout3690prevents the anvil2230from being re-clamped onto tissue after the tool assembly3600has undergone, or at least partially undergone, a firing cycle and the tool assembly3600cannot be used again. Moreover, the lockout3690can serve as a spent cartridge lockout.

Turning now toFIGS. 59 and 60, a tool assembly3700comprises a staple cartridge3720and an anvil3730. The tool assembly3700further comprises a closure system configured to move the anvil3730toward the staple cartridge3720and, in addition, a firing system configured to eject, or fire, staples removably stored in the staple cartridge3720. The anvil3730comprises a longitudinal shaft portion3736and attachment arms3738extending from the shaft portion3736which are configured to resiliently grip a closure actuator, or trocar,3734of the closure system. The closure actuator3734is retractable proximally by a closure drive to move the trocar3734between an open, unclamped position (FIG. 59) and a closed, clamped position (FIG. 60). When the closure system is in its open configuration, as illustrated inFIG. 59, the staple firing system is disabled and cannot be actuated to fire the staples stored in the staple cartridge3720, as described in greater detail below.

Further to the above, the staple firing system comprises a rotatable firing shaft3750comprising a threaded distal end and, in addition, a translatable firing nut2550comprising a threaded aperture configured to receive the threaded distal end of the firing shaft3750. Notably, referring toFIG. 59, a gap is present between the threaded distal end of the firing shaft3750and the threaded aperture defined in the firing nut2550when the anvil3730is in its open position. As a result, the firing shaft3750cannot displace the firing nut2550distally until the firing shaft3750is threadably engaged with the firing nut2550.

As illustrated inFIG. 60, the attachment arms3738of the anvil3730are configured to engage the firing shaft3750and deflect the firing shaft3750outwardly when the anvil3730is moved into its closed position. Referring primarily toFIGS. 59A and 60A, the attachment arms3738are configured to engage inwardly-extending projections3758defined on the firing shaft3750and push the projections3758and the perimeter of the firing shaft3750outwardly. In such instances, the threaded distal end of the firing shaft3750is pushed into operative engagement with the threaded aperture of the firing nut2550at a thread interface3790and, at such point, the firing shaft3750can displace the firing nut2550distally to eject the staples from the staple cartridge3720when the firing shaft3750is rotated by a firing drive. When the anvil3730is re-opened, the firing shaft3750will return to its original configuration and become operably disengaged from the firing nut2550.

As a result of the above, the tool assembly3700comprises a lockout which prevents the staples from being fired if the anvil3730is not attached to the closure system, if the anvil3730is improperly attached to the closure system, and/or if the anvil3730is not sufficiently closed.

Turning now toFIGS. 61 and 62, a tool assembly3800comprises a replaceable staple cartridge including staples removably stored therein, an anvil configured to deform the staples, a closure drive system configured to move the anvil relative to the staple cartridge, and a firing system configured to eject the staples from the staple cartridge. As discussed below, the tool assembly3800further comprises a lockout configured to prevent the firing system from being operated unless the staple cartridge is fully seated onto the tool assembly3800.

The staple cartridge comprises a cartridge frame3820configured to engage a shaft frame3810of the tool assembly3800. The staple cartridge further comprises a drive shaft3830which is inserted into the shaft frame3810when the staple cartridge is assembled to the tool assembly3800. More particularly, referring primarily toFIG. 64, the drive shaft3830comprises a proximal end3832including an annular gear portion3833which is configured to engage and compress a transmission3860of the firing system when the staple cartridge is assembled to the tool assembly3800. Referring primarily toFIG. 62, the transmission3860comprises a first portion3862, a second portion3864, and a third portion3868which, when pushed into operative engagement with each other, are able to transmit a rotary input motion to the drive shaft3830.

Referring primarily toFIGS. 63 and 64, the annular gear portion3833of the drive shaft3830is configured to engage a corresponding gear portion3863defined on the distal side of the first transmission portion3862and, when the first transmission portion3862is pushed proximally by the drive shaft3830, the first transmission portion3862can operably engage the second transmission portion3864. More specifically, the first transmission portion3862comprises a proximal gear portion3865which engages a distal gear portion3866of the second transmission portion3864and, concurrently, pushes the second transmission portion3864proximally when the first transmission portion3862is pushed proximally by the drive shaft3830. When the second transmission portion3864is pushed proximally by the first transmission portion3862, similar to the above, the second transmission portion3864can operably engage the third transmission portion3868. More specifically, the second transmission portion3862comprises a proximal gear portion3867which engages a distal gear portion3869of the third transmission portion3864when the first transmission portion3862and the second transmission portion3864are pushed proximally by the drive shaft3830. The third transmission portion3868is operably coupled to an input shaft and supported from being displaced proximally by the input shaft and/or the shaft housing3810.

Referring primarily toFIG. 61, the transmission3860further comprises at least one spring member3870positioned intermediate the first transmission portion3862and the second transmission portion3864. In at least one instance, the spring member3870can comprise one or more wave springs, for example. The spring member3870is configured to bias the first transmission portion3862and the second transmission portion3864apart from one another. In addition to or in lieu of the above, the transmission3860further comprises at least one spring member3870positioned intermediate the second transmission portion3864and the third transmission portion3868which, similar to the above, is configured to bias the second transmission portion3864and the third transmission portion3868apart from one another. Referring primarily toFIG. 65, each spring member3870comprises two disc springs3872which are configured to deflect when a compressive force is applied thereto; however, the springs members3870can comprise any suitable configuration.

Further to the above, and referring again toFIG. 61, the input shaft of the tool assembly3800can rotate the third transmission portion3868; however, the rotation of the third transmission portion3868cannot be transmitted to the second transmission portion3864unless the spring member3870positioned intermediate the second transmission portion3864and the third transmission portion3868has been sufficiently compressed to connect the proximal gear portion3867of the second transmission portion3864with the distal gear portion3869of the third transmission portion3868. Similarly, the second transmission portion3864cannot transmit rotary motion to the first transmission portion3862unless the spring member3870positioned intermediate the first transmission portion3862and the second transmission portion3864has been sufficiently compressed to connect the proximal gear portion3865of the first transmission portion3862and the distal gear portion3866of the second transmission portion3864. As discussed above, the drive shaft3830engages the first transmission portion3862with the second transmission portion3864and engages the second transmission portion3864with the third transmission portion3868when the staple cartridge is fully seated onto the shaft frame3810, as illustrated inFIG. 62. In such instances, the rotation of the input shaft can be transmitted to the drive shaft3830. If the staple cartridge is not fully seated onto the shaft frame3810, however, one or more of the transmission portions3862,3864, and3868are not operably engaged with each other and the rotation of the input shaft cannot be transmitted to the drive shaft3830. Thus, the tool assembly3800assures that the staples stored within the staple cartridge cannot be ejected from the staple cartridge unless the staple cartridge is fully seated onto the shaft frame3810.

Turning now toFIGS. 66-68, a tool assembly3900comprises a shaft3910and a replaceable staple cartridge3920. The replaceable staple cartridge3920comprises a closure drive configured to move an anvil relative to the staple cartridge3920and, in addition, a firing drive comprising a rotatable firing shaft3930configured to eject staples removably stored in the staple cartridge3920. Similar to the above, the tool assembly3900comprises a lockout configured to prevent the firing drive from ejecting the staples from the staple cartridge3920unless the staple cartridge3920is fully, or sufficiently, seated onto the shaft3910. More specifically, the lockout prevents the firing shaft3930from rotating within the staple cartridge3920unless the staple cartridge3920is fully, or sufficiently, seated onto the shaft3910. In various instances, referring toFIG. 67, the firing shaft3930comprises an annular array of lock apertures3939defined in the outer perimeter thereof and the staple cartridge3920comprises at least one lock3929configured to releasably engage a lock aperture3939defined in the shaft3930. The lock3929comprises a proximally-extending cantilever beam; however, any suitable configuration could be utilized. The lock3929further comprises a locking projection that extends into the lock aperture3939and prevents the firing shaft3930from rotating, or at least substantially rotating, relative to the body of the staple cartridge3920. The lock3929is configured such that it is biased into engagement with a lock aperture3939defined in the firing shaft3930until the lock3929is lifted out of the lock aperture3939when the staple cartridge3920is fully, or sufficiently, assembled to the shaft3910, as illustrated inFIG. 68. Referring toFIG. 68, the outer housing of the shaft3910comprises a wedge3919configured to lift the lock3929away from the firing shaft3930and disengage the lock3929from the lock aperture3939. The wedge3919is configured such that it does not disengage the lock3929from the firing shaft3930unless the staple cartridge3920has been fully, or sufficiently, seated onto the shaft3910, as illustrated inFIG. 68.FIG. 67illustrates a scenario where the staple cartridge3920has not been fully, or sufficiently, seated onto the shaft3910.

Turning now toFIGS. 69-71, a tool assembly4000comprises a shaft4010and a replaceable staple cartridge4020. The replaceable staple cartridge4020comprises a closure drive configured to move an anvil relative to the staple cartridge4020and, in addition, a firing drive comprising a rotatable firing shaft3930configured to eject staples removably stored in the staple cartridge4020. The staple cartridge4020comprises a lock4029configured to releasably connect the staple cartridge4020to the shaft4010. The lock4029comprises a proximally-extending cantilever and a lock shoulder4028extending therefrom. The lock4029is configured to deflect inwardly within the shaft4010as the staple cartridge4020is assembled to the shaft4010and then resiliently return to, or at least toward, its undeflected state when the lock shoulder4028of the lock4029becomes aligned with a window4019defined in the outer housing of the shaft4010. In such instances, the lock shoulder4028enters into the window4019when the staple cartridge4020has been fully, or sufficiently, seated on the shaft4010, as illustrated inFIG. 70. In order to unlock the staple cartridge4020, a clinician can insert a tool or their finger, for example, into the window and depress the lock4029away from the window4019. At such point, the staple cartridge4020can be removed from the shaft4010and, if the clinician so desires, and attach a new staple cartridge to the shaft4010.

In addition to or in lieu of the above, a surgical stapling system can comprise an electrical lockout configured to prevent the closure drive of the stapling system from clamping the anvil onto the tissue and/or prevent the firing drive from performing its firing stroke when a staple cartridge has not been fully, or sufficiently, seated onto the shaft of the stapling system. In various instances, the stapling system can comprise a sensor configured to detect whether a staple cartridge has been fully, or sufficiently, seated on the shaft and, in addition, an electrical motor configured to operate the firing drive. In the event that the sensor detects that a staple cartridge has not been fully, or sufficiently, attached to the shaft, the motor can be electrically de-activated. In various instances, the stapling system comprises a controller, such as a microprocessor, for example, which is in communication with the sensor and the electric motor. In at least one instance, the controller is configured to, one, permit the electric motor to be operated if the sensor detects a properly seated staple cartridge on the shaft and, two, prevent the electric motor from being operated if the sensor detects an improperly seated staple cartridge on the shaft.

Turning now toFIG. 72, a tool assembly kit4100comprises a shaft4110and a plurality of staple cartridges, such as4120,4120′,4120″, and4120′″, for example. Each staple cartridge4120,4120′,4120″, and4120′″ is configured to apply circular rows of staples having a different diameter. For example, the staple cartridge4120′″ is configured to apply staples in a pattern having a large diameter while the staple cartridge4120is configured to apply staples in a pattern having a small diameter. In various instances, different staple cartridges can deploy staples having different unformed heights. In at least one instance, staple cartridges that apply staples in larger patterns deploy staples having a larger undeformed height while staple cartridges that apply staples in smaller patterns deploy staples having a smaller undeformed height. In some instances, a staple cartridge can deploy staples having two or more unformed heights. In any event, a staple cartridge selected from the plurality of staple cartridges can be assembled to the shaft4110.

Referring toFIGS. 72 and 73, the tool assembly4100comprises a detection circuit4190configured to detect whether a staple cartridge is fully, or sufficiently, attached to the shaft4110. The detection circuit4190is not entirely contained within the shaft4110; rather, a staple cartridge must be properly assembled to the shaft4110to complete the detection circuit4190. The detection circuit4190comprises conductors4193that extend through a passage4192defined in the frame of the shaft4110and/or along the outer housing of the shaft4110. Referring primarily toFIG. 73, each conductor4193is electrically coupled to an electrical contact4194defined in the distal end of the housing. The staple cartridge4120, for example, comprises corresponding electrical contacts4195which are positioned and arranged on the body4122of the staple cartridge4120such that the contacts4195engage the contacts4194on the shaft4110. The staple cartridge4120further comprises conductors4196extending through and/or along the cartridge body4122. Each conductor4196is electrically coupled with a contact4195. In certain instances, the conductors4196are directly coupled to one another and, in such instances, the detection circuit4190is closed once the staple cartridge4120is properly assembled to the shaft4110.

In certain instances, further to the above, the detection circuit4190of the tool assembly4100extends through a deck portion4124of the staple cartridge4120. In at least one instance, the deck portion4124is movably attached to the cartridge body4122. More specifically, in at least one such instance, spring members4198are positioned intermediate the cartridge body4122and the deck portion4124and are configured to permit the deck portion4124to move, or float, relative to the cartridge body4122when tissue is compressed against the deck portion4124. In at least one instance, the spring members4198comprise one or more wave springs, for example. The spring members4198also form an electrically conductive pathway between the cartridge body4122and the deck portion4124. More specifically, the spring members4198are positioned intermediate electrical contacts4197and4199defined on the cartridge body4122and the deck portion4124, respectively. The conductors4196are electrically coupled to electrical contacts4197defined on the distal end of the cartridge body4122and the electrical contacts4199are electrically coupled to one another through a conductor in the deck portion4125. As discussed above, the detection circuit4190is closed once the staple cartridge4120is properly assembled to the shaft4110.

Turning now toFIGS. 74-76, a tool assembly4200comprises a lockout configured to prevent a replaceable circular staple cartridge from being fired more than once, as described in greater detail further below. In use, a replaceable circular staple cartridge4220is assembled to a shaft4210of the tool assembly4200. The tool assembly4200is then positioned in the surgical site and an anvil2230is assembled to the trocar2450of the closure drive. The closure drive is then used to move the anvil2230toward the staple cartridge4220to clamp the patient's tissue against the staple cartridge4220until the anvil2230reaches a closed, or clamped, position. This position of the anvil2230is illustrated inFIG. 74. At such point, the firing drive can be operated to deploy the staples removably stored in the staple cartridge4220. The firing drive comprises, among other things, a rotatable drive shaft4230which is threadably engaged with a drive collar4240and, in addition, a staple firing driver2560. The drive collar4240and the firing driver2560comprise separate components; however, the drive collar4240and the firing driver2560could be integrally formed in alternative embodiments. The firing drive is rotatable in a first direction during a firing stroke to push the drive collar4240and the staple firing driver2560distally between an unfired position (FIG. 74) and a fired position (FIG. 75) to eject the staples from the staple cartridge4220. The drive collar4240and the staple driver2560are prevented from rotating within the staple cartridge4220and, as a result, the drive shaft4230rotates relative to the drive collar4240and the staple driver2560.

Further to the above, the drive collar4240comprises one or more lockouts4290extending proximally therefrom. Each lockout4290comprises a lockout pin4292slidably positioned within a pin aperture4293defined in the drive collar4240. Each lockout4290further comprises a biasing member, such as a spring4294, for example, configured to bias the pins4292proximally. When the firing drive is in its unfired configuration, as illustrated inFIG. 74, the lockouts4290are not engaged with the rotatable drive shaft4230and/or the frame4222of the staple cartridge4220. As the drive collar4240and the staple driver2560are pushed distally by the drive shaft4230, the lockout pins4292move away from the drive shaft4230, as illustrated inFIG. 75. After the firing stroke has been completed and the staples have been sufficiently deformed against the anvil2230, the drive shaft4230is rotated in an opposite direction to pull the drive collar4240and the staple driver4260proximally during a retraction stroke. In such instances, the lockouts4290are moved toward the drive shaft4230. Notably, the retraction stroke is longer than the firing stroke and, as a result, the drive collar4240is moved proximally with respect to its original unfired position into a retracted position, as illustrated inFIG. 76. In this retracted position of the drive collar4240, the lockouts4290have become engaged with the drive shaft4230and the frame4222of the staple cartridge4220. More specifically, each lockout4290has entered into a lockout aperture defined between the drive shaft4230and the cartridge frame4222. Referring now toFIG. 78, each lockout aperture is defined by an aperture wall4295in the drive shaft4230and an aperture wall4296in the frame4222. Once the lockout pins4292have entered the lockout apertures, the drive collar4240cannot be rotated by the drive shaft4230and the firing system of the staple cartridge4220has become locked out. As a result, that particular staple cartridge4220cannot be used again and must be replaced with a new staple cartridge in order for the tool assembly4200to be used again.

The reader should appreciate, further to the above, that the lockout pins4292may or may not be partially positioned in the lockout apertures when the firing drive is in its unfired configuration as illustrated inFIG. 74. To the extent, however, that the lockout pins4292are partially positioned in the lockout apertures, in such instances, the pins4292can displace distally within the pin apertures4293defined in the drive collar4240when the firing drive shaft4230is rotated. As the reader should also appreciate, the lockout pins4292are seated deeply enough into the lockout apertures defined in the drive shaft4230when the drive collar4240is moved into its retracted position so as to prevent the pins4292from being displaced distally out of the lockout apertures if the firing drive shaft4230is rotated in its first direction once again.

Referring again toFIG. 78, the sidewalls4295and4296of the lockout apertures are aligned with one another when the drive collar4240is in its retracted position. When the drive shaft4230is rotated, however, the sidewalls4295defined in the drive shaft4230will rotate out of alignment with the sidewalls4296defined in the cartridge frame4222. In some instances, the sidewalls4295may momentarily rotate into re-alignment with the sidewalls4296as the firing drive4230is rotated. In any event, referring now toFIG. 77, the sidewalls4295are not aligned with the sidewalls4296when the firing system is in its unfired configuration. As a result, the lockout pins4292cannot enter into the lockout apertures when the firing system is in its unfired configuration and the staple cartridge4220cannot become unintentionally locked out.

In at least one alternative embodiment, referring now toFIG. 80, one or more lockout apertures4295″ can be exclusively defined in a drive shaft4230″ of a tool assembly4200″. In such embodiments, the drive collar4240would not be able to rotate relative to the drive shaft4230″ once the lockout pins4292entered into the lockout apertures4295″. In effect, the drive collar4240and the drive shaft4230″ would become synchronously locked together, but not necessarily locked to the frame of the tool assembly4200″, which would prevent the drive shaft4230″ from rotating relative to the drive collar2440and displacing the drive collar2440distally.

In at least one alternative embodiment, referring now toFIG. 79, each of the firing drive lockouts has a different configuration such that each lockout pin is uniquely indexed with its corresponding lockout aperture. For example, the tool assembly4200′ comprises a first lockout pin configured to enter a first lockout aperture defined by sidewalls4295and4296and a second lockout pin configured to enter a second lockout aperture defined by sidewalls4295′ and4296′. The first lockout pin of the tool assembly4200′, however, is sized and configured such that it cannot enter into the second lockout aperture and, correspondingly, the second lockout pin is sized and configured such that it cannot enter into the first lockout aperture. Moreover, neither the first lockout pin nor the second lockout pin can enter an aperture formed by a combination of sidewalls4295and4296′ or an aperture formed by a combination of sidewalls4295′ and4296.

As discussed above, a stapling instrument configured to deploy circular rows of staples can comprise an articulation joint. The articulation joint is configured to permit an end effector of the stapling instrument to articulate relative to a shaft of the stapling instrument. Such a stapling instrument can assist a surgeon in positioning the end effector within the rectum and/or colon of a patient. In various embodiments, referring toFIG. 81, a stapling instrument configured to deploy circular rows of staples, such as stapling instrument9000, for example, can be can comprise a contourable or adjustable frame9010. The frame9010can be configured to be permanently deformed during use. In at least one such embodiment, the frame9010is comprised of a malleable metal, such as silver, platinum, palladium, nickel, gold, and/or copper, for example. In certain embodiments, the frame9010is comprised of a malleable plastic, for example. In at least one embodiment, the frame is comprised of a polymer including metal ions bonded with the polymer chains, such as ionic polymer-metal composites (IPMCs), for example. A voltage potential, or potentials, can be applied to the IPMC material in order to defect the shaft in a desired manner. In certain instances, the shaft is contourable along one radius of curvature while, in other instances, the shaft is contourable along more than one radius of curvature. The voltage potential, or potentials, can be modified to contour the shaft while the shaft is within the patient, for example. In certain embodiments, the contourable portion of the frame comprises a plurality of pivotable links. In at least one embodiment, the contourable portion of the frame is comprised of a visco-elastic material.

Further to the above, the stapling instrument can further comprise a lock configured to releasably hold the contourable portion of the stapling instrument frame in its contoured configuration. In at least one instance, the stapling instrument frame comprises articulatable frame links and one or more longitudinal tension cables which can pull the frame links proximally and lock the frame links together. In certain instances, each frame link can comprise a longitudinal aperture extending therethrough which is configured to receive a distally movable rod. The rod is sufficiently flexible to pass through the longitudinal apertures, which may not be completely aligned with one another when the contourable portion has been contoured, yet sufficiently rigid to hold the stapling instrument in its contoured configuration.

As discussed herein, a surgical instrument can be comprised of a plurality of modules that are assembled to one another. For instance, in at least one embodiment, a surgical instrument comprises a first module including a handle and a second module including a shaft assembly. The shaft assembly comprises an end effector configured to staple and/or incise the tissue of a patient; however, the shaft assembly can comprise any suitable end effector. In various instances, the end effector comprises a third module attachable to the shaft assembly. Referring now toFIGS. 82 and 83, a handle, such as the handle20, for example, comprises a controller and a display10000in communication with the controller. The controller is configured to display data regarding the operation of the surgical instrument on the display10000. The data displayed on the display10000relates information to a surgeon regarding at least one operating parameter of the first module and/or at least one operating parameter of the second module. For example, the controller can display data on the display10000regarding the progress of the staple firing stroke.

Further to the above, the shaft assembly comprises a second display. For example, the shaft assembly2000comprises a display10100; however, any of the shaft assemblies disclosed herein can comprise a display such as display10100, for example. The second module comprises its own controller configured to display data regarding the operation of the surgical instrument on the display10100. Similar to the above, the data displayed on the display10100relates information regarding at least one operating parameter of the first module and/or at least one operating parameter of the second module. The controller of the second module is in signal communication with the controller of the first module; however, in other embodiments, the second module controller can operate independently of the first module controller. In certain alternative embodiments, the second module does not comprise a controller. In such embodiments, the controller of the first module is in signal communication with the first display10000and the second display10100and controls the data displayed on the first display10000and the second display10100.

As discussed above, the tool assembly2000comprises an anvil and a staple cartridge. The handle20comprises an actuation system configured to move the anvil relative to the staple cartridge. The anvil is positionable in a range of positions relative to the staple cartridge to control the distance, or gap, between the anvil and the staple cartridge and, as a result, control the forming height of the staples when the staples are ejected from the staple cartridge. For instance, the anvil is positioned closer to the staple cartridge to deform the staples to a shorter formed height and positioned further away from the staple cartridge to deform the staples to a taller formed height. In any event, the second display10100of the tool assembly2000is configured to display the position of the anvil relative to the staple cartridge and/or display the height in which the staples will be or have been formed. In various embodiments, a shaft assembly can comprise an actuator configured to control a function of the end effector and a display which displays data regarding the end effector function which is adjacent to the actuator.

Referring toFIG. 1, a tool assembly1500comprises a shaft and an end effector extending from the shaft. The shaft comprises a shaft frame a longitudinal shaft axis. The end effector comprises an end effector frame and a longitudinal end effector axis. The end effector further comprises a distal head and a rotation joint which permits the distal head to rotate relative to the end effector frame about the longitudinal end effector axis. The distal head comprises a first jaw and a second jaw. The first jaw comprises a staple cartridge including staples removably stored therein, or a channel configured to receive such a staple cartridge, and the second jaw comprises an anvil configured to deform the staples. The second jaw is movable relative to the first jaw between an open position and a closed position; however, other embodiments are envisioned in which the first jaw is movable relative to the second jaw and/or both the first jaw and the second jaw are movable relative to each other.

In certain embodiments, a tool assembly can comprise an articulation joint in addition to the rotation joint. In at least one such embodiment, the rotation joint is distal with respect to the articulation joint. In such an embodiment, the rotation of the distal head does not affect the angle in which the end effector has been articulated. That said, other embodiments are envisioned in which the articulation joint is distal with respect to the rotation joint. Such embodiments can provide a wide sweep of the distal head. In either event, the longitudinal end effector axis is movable relative to the longitudinal shaft axis. In at least one instance, the longitudinal end effector axis is movable between a position in which it is collinear with the longitudinal shaft axis to a position in which it is transverse to the longitudinal shaft axis.

Further to the above, the distal head of the tool assembly1500is rotatable between an initial position and a rotated position. In at least one instance, the distal head is rotatable between a zero, or top-dead-center, position and a second position. In certain instances, the distal head is rotatable through an at least 360 degree range of motion. In other instances, the distal head is rotatable through a less than 360 degree range of rotation. In either event, the tool assembly1500and/or the handle20is configured to track the rotational position of the distal head. In various instances, the tool assembly1500and/or the handle20comprises an electric motor operably coupled with the distal head of the end effector and, in addition, an encoder configured to directly track the rotation of the distal head and/or indirectly track the rotation of the distal head by evaluating the rotational position of the shaft of the electric motor, for example. The controller of the handle20is in signal communication with the encoder and is configured to display the rotational position of the distal head on the display10000, for example.

In at least one embodiment, the orientation and the arrangement of the data displayed on the display10000is static while the distal head of the end effector rotates. Of course, the data displayed on the display10000in such an embodiment would be updated by the surgical instrument controller; however, the data display is not re-oriented and/or re-arranged as the distal head rotates. Such an embodiment can provide a surgeon with the information necessary to properly utilize the surgical instrument in a static field. In at least one alternative embodiment, the data field on the display10000is dynamic. In this context, the term dynamic means more than the data being updated on the display10000; rather, the term dynamic means that the data is re-oriented and/or re-arranged on the display10000as the distal head is rotated. In at least one instance, the orientation of the data tracks the orientation of the distal head. For example, if the distal head is rotated 30 degrees, the data field on the display10000is rotated 330 degrees. In various instances, the distal head is rotatable 360 degrees and the data field is rotatable 360 degrees.

Further to the above, the data field can be oriented in any orientation that matches the orientation of the distal head. Such an embodiment can provide a surgeon with an accurate and intuitive sense of the orientation of the distal head. In certain embodiments, the controller orients the data field in an orientation selected from an array of discrete positions that most closely matches the orientation of the distal head. For instance, if the distal head has been rotated 27 degrees and the selectable discrete data field positions are 15 degrees apart, the controller can re-orient the data field 30 degrees from a datum orientation. Similarly, for example, if the distal head has been rotated 17 degrees and the selectable discrete data field positions are 5 degrees apart, the controller can re-orient the data field 15 degrees from the datum orientation. In at least one embodiment, the datum orientation is aligned with a feature of the surgical instrument itself. For example, the datum orientation of the handle20is aligned with an axis extending through a grip of the handle20. In such an embodiment, the controller can disregard the orientation of the handle20with respect to its environment. In at least one alternative embodiment, however, the datum orientation is aligned with respect to the gravitational axis, for example.

Further to the above, the controller is configured to re-orient the entire data field displayed on the display10000with respect to the orientation of the distal head. In other embodiments, the controller is configured to re-orient only a portion of the data field displaced on the display10000with respect to the orientation of the distal head. In such an embodiment, a portion of the data field is held static with respect to the datum orientation while another portion of the data field is rotated with respect to the datum orientation. In certain embodiments, a first portion of the data field is rotated a first angle of rotation and a second portion of the data field is rotated a second angle of rotation in the same direction. For instance, the second portion can be rotated less than the first portion. In various embodiments, a first portion of the data field is rotated in a first direction and a second portion of the data field is rotated in a second, or opposite, direction.

Further to the above, the data field is re-oriented and/or re-arranged in real time, or at least substantially in real time, with the rotation of the distal head. Such an embodiment provides a very responsive data display. In other embodiments, the re-orientation and/or re-arrangement of the data field can lag the rotation of the distal head. Such embodiments can provide a data display with less jitter. In various embodiments, a first portion of the data field is re-oriented and/or re-arranged at a first speed and a second portion of the data field is re-oriented and/or re-arranged at a second, or different, speed. For instance, the second portion can be rotated at a slower speed.

As discussed above, the data field on the display10000is rotated as the distal head of the end effector is rotated. However, in other embodiments, the data field, or a portion of the data field, is translated as the distal head is rotated. As also discussed above, the controller of the surgical instrument is configured to re-orient and/or re-arrange the data field on the handle display10000. However, the controller of the surgical instrument can re-orient and/or re-arrange the data field on a second display, such as a shaft display, for example.

Referring again toFIGS. 15 and 83, the tool assembly2000comprises an actuator10200configured to actuate the articulation drive system of the tool assembly2000. The actuator10200is rotatable about a longitudinal axis which is parallel to, or at least substantially parallel to, a longitudinal axis of the shaft2100, for example. The actuator10200is operably coupled to a rheostat, for example, which is in signal communication with a controller of the handle20. When the actuator10200is rotated in a first direction about its longitudinal axis, the rheostat detects the rotation of the actuator10200and the controller operates the electric motor to articulate the end effector2200in a first direction. Similarly, when the actuator10200is rotated in a second, or opposite, direction about its longitudinal axis, the rheostat detects the rotation of the actuator10200and the controller operates the electric motor to articulate the end effector2200in a second, or opposite, direction. In various instances, the end effector2200can be articulated approximately 30 degrees from a longitudinal axis in a first direction and/or articulated approximately 30 degrees from the longitudinal axis in a second, or opposite, direction, for example.

As the reader should appreciate, further to the above, the tool assembly2000does not have an on-board electric motor configured to operate the articulation drive system; rather, the electric motor of the articulation drive system is in the handle, such as handle20, for example, to which the tool assembly2000is attached. As a result, an actuator on the detachable shaft assembly controls the operation of the handle. In other embodiments, the electric motor of the articulation driver system can be in the tool assembly2000. In either event, the display10100is configured to display, in at least some manner, the articulation of the end effector2200. As the reader should appreciate, the display10100is adjacent the actuator10200and, as a result, the surgeon is able to easily view the input and the output of the articulation drive system at the same time.

A surgical tool assembly comprising a contourable shaft, further to the above, can be advantageously shaped to fit within the rectum or colon of a patient, for example. Such a contourable shaft, however, cannot bear a significant amount of tensile and/or compressive loads. To compensate therefor, in various embodiments, only rotatable drive systems may extend through the contourable portion of the shaft. In such instances, the shaft need only resist the rotational reaction forces generated by the rotatable drive systems. In such embodiments, the rotational motion of the drive systems can be converted to linear motion, if necessary, distally with respect to the contourable shaft portion. Such longitudinal motions can generate tensile and/or compressive forces; however, such forces can be resolved, or balanced out, within the end effector, i.e., distally with respect to the contourable shaft portion. Such embodiments can also utilize an articulation joint positioned distally with respect to the contourable shaft portion. In such embodiments, the tool assembly may not utilize push-pull drive systems which traverse the contourable shaft portion.

An anvil6020of a circular stapling instrument is illustrated inFIGS. 84 and 85. The anvil6020comprises a tissue compression surface6022and an annular array of staple forming pockets6024defined in the tissue compression surface6022. The anvil6020further comprises a frame6028, an attachment mount6026, and a stem extending from the attachment mount6026. The stem is configured to be releasably attached to a closure drive of the circular stapling instrument so that the anvil6020can be moved toward and away from a staple cartridge of the circular stapling instrument. The compression surface6022, the attachment mount6026, and the frame6028are comprised of stainless steel, for example; however, any suitable material, or materials, could be used.

Further to the above, the anvil6020comprises a tissue support6030. The tissue support6030is positioned within an annular aperture defined within the tissue support surface6022. The tissue support6030is snugly secured within the anvil6020such that there is little, if any, relative movement therebetween. The tissue support6030comprises an annular tissue support surface6032which is adjacent to the annular tissue compression surface6022of the anvil6020. The tissue support6030further comprises an inner annular wall6036defined therein and, in addition, a bottom wall6038positioned adjacent the anvil frame6028of the anvil6020.

Referring now toFIG. 86, the circular stapling instrument comprises a staple cartridge6040including a first annular row of staples6070, a second annular row of staples6080, and a firing drive configured to eject the staples6070and6080from the staple cartridge6040during a firing stroke of the firing drive. As illustrated inFIG. 86, the staples6070and6080are deformed by the forming pockets6024as they are ejected from the staple cartridge6040. In various instances, the staples6070and the staples6080are deformed to the same height while, in other instances, the staples6070and the staples6080are deformed to different heights. For example, the staples6070can be deformed to a shorter deformed height than the staples6080. In other examples, the staples6080are deformed to a shorter height than the staples6070.

In addition to or in lieu of the above, the staples6070and the staples6080can have different unformed heights. For example, the staples6070can have a shorter unformed height than the staples6080. In other examples, the staples6080have a shorter unformed height than the staples6070. In certain instances, the staples6070and the staples6080have the same unformed height.

As the staples6070and6080are deformed against the anvil6020to staple the tissue T captured between the anvil6020and the staple cartridge6040, further to the above, the stapling instrument can incise the tissue T. The firing drive, which ejects the staples from their staple cavities, drives a cutting member6050toward the tissue T and the anvil6020. The distal edge of the cutting member6050transects the tissue T and then slides along the inner sidewall6036of the tissue support6030without transecting the inner sidewall6036. The cutting edge of the cutting member6050is annular and it is aligned with the annular inner wall6036of the tissue support6030. The cutting member6050is advanced into the anvil6020until the cutting member6050transects the bottom wall6038, as illustrated inFIG. 86.

The firing drive experiences various loads when driving the staples6070and6080against the anvil6020and/or cutting the tissue. For instance, the firing drive may experience an increased load when transecting tissue that has been previously stapled, such as with staples6090(FIG. 86), for example. The transection of the bottom wall6038by the cutting member6050, however, creates a sudden change or impulse in the force transmitted through the firing drive. This sudden change by the force can be sensed by the clinician using the surgical stapler and/or an electronic sensor system configured to detect load changes in the firing drive. The tissue support6030can be comprised of a material that can snap when the cutting member6050applies a load to the bottom wall6038. In at least one instance, the tissue support6030is comprised of plastic, for example. In any event, the transection of the bottom wall6038can be detected and, once detected, the clinician and/or the electronic sensor system can determine that the cutting process has been completed.

The firing drive deforms the staples6070,6080and incises the tissue with the cutting member6050at the same time; however, it is contemplated that the staple forming and tissue cutting steps could be staggered. In at least one instance, the tissue cutting step does not begin until the staple forming step has been completed.

It should be appreciated fromFIG. 86that, while surface6032can partially support the tissue T, the cutting member6050can push the tissue T into the cavity defined between the inner wall6036of the tissue support6030and the attachment mount6026when the cutting member6050is moved toward the bottom wall6038. Stated another way, the cutting member6050can drag the tissue T along the wall6036before finally cutting it. In such instances, the incision made by the cutting member6050may not be precise. Discussed below are improvements to the embodiment disclosed inFIG. 86.

Turning now toFIGS. 87 and 88, the tissue support6030of anvil6020has been replaced with a tissue support6130. The tissue support6130comprises a first, or outer, annular wall6131and a second, or inner, annular wall6133. The inner wall6133defines an aperture6136configured to closely receive the attachment mount6026. The outer wall6131and the inner wall6133are connected by lateral walls6132. The lateral walls6132extend radially around a center of the tissue support6130between the inner wall6133and the outer wall6131. The lateral walls6132are evenly spaced apart from one another; however, alternative embodiments are contemplated in which the lateral walls6132are not evenly spaced apart from one another. In either event, the lateral walls6132define an annular array of cavities6134in the tissue support6130. In various instances, each cavity6134can be enclosed on every side but the side facing the tissue, for example. In other instances, the side of the cavity facing the tissue can be enclosed.

The outer wall6131and the inner wall6133of the tissue support6130are configured to support the tissue as the tissue is being transected by the cutting member6050. The lateral walls6132also support the tissue and, in addition, block or resist the tissue from sliding relative to the outer wall6131and the inner wall6133as the tissue is being transected. It should be understood that the tissue can enter the cavities6134when the tissue is being transected; however, the relative movement between the tissue and the sidewalls can be greatly reduced. The composition and arrangement of the lateral walls6132can be selected to provide more support to the tissue or less support to the tissue depending on the amount of support that is desired. For instance, thicker lateral walls6132can provide more tissue support than thinner lateral walls6132. Similarly, more lateral walls6132can provide more tissue support than thinner lateral walls6132.

As the cutting member6050is moved through its cutting stroke, the cutting member6050cuts the tissue and transects the lateral walls6132. The cutting member6050is annular and transects the lateral walls6132adjacent the outer wall6131; however, a cutting member could transect the walls6132at any suitable location. In any event, the lateral walls6132support the tissue before, during, and after the tissue is cut and prevent, or at least reduce the possibility of, the tissue being dragged along the outer wall6131and/or the inner wall6133. Similar to the tissue support6030, the tissue support6130comprises a bottom wall6138that is transected at the end of the cutting stroke.

A surgical stapler comprising a staple cartridge6240and an anvil6220is disclosed inFIGS. 89 and 90. The staple cartridge6240is similar to the staple cartridge6040in many respects. The anvil6220is similar to the anvil6020and the anvil6120in many respects. The anvil6220comprises an attachment stem6226and an annular tissue support6230positioned around the attachment stem6226. The tissue support6230comprises a central aperture configured to closely receive the stem6226. The tissue support6230further comprises an annular outer wall6231positioned adjacent the tissue compression surface of the anvil6220and, in addition, lateral walls6232extending radially from the outer wall6231. The tissue support6230does not comprise an inner annual wall and the inner ends of the lateral walls6232are free to deflect. The tissue support6230further comprises a bottom wall6238which is incised by the cutting member6050, similar to the above.

A surgical stapler comprising the staple cartridge6240and the anvil6220is illustrated inFIGS. 91 and 92. The reader should appreciate, however, that the tissue support6230of the anvil6220has been replaced with a tissue support6330. The tissue support6330comprises an annular central aperture configured to closely receive the stem6226. The tissue support6330further comprises a top wall6332, a bottom wall6338, and sidewalls6336extending between the top wall6332and the bottom wall6338. The top wall6332and the bottom wall6338are parallel, or at least substantial parallel; however, embodiments are envisioned in which the walls6332and6338are not parallel. The sidewalls6336are parallel, or at least substantial parallel; however, embodiments are envisioned in which the sidewalls6336are not parallel.

The walls6332,6336, and6338define an annular cavity6334therebetween. The cavity6334is enclosed, or at least substantially enclosed, on all sides. The cavity6334extends uninterrupted around the stem6226; however, other embodiments are envisioned in which the cavity6334is interrupted by sidewalls and/or changes in geometry, for example.

Similar to the above, the tissue support6330is configured to support the tissue as the tissue is being transected by the cutting member6050. The tissue support6330is closely received within the anvil6220such that the tissue support6330does not move, or at least substantially move, relative to the anvil6220. Moreover, the tissue support6330comprises a rigid box-shaped cross-section such that the deflection of the tissue support6330is minimized or insubstantial while the cutting member6050is transecting the tissue. As illustrated inFIG. 91, a gap is present between the bottom wall6338and the inner side wall6336. Such a gap can provide some flexibility in the tissue support6330; however, other embodiments are envisioned in which no such gaps are present. The tissue support6330is comprised of plastic, for example; however, in various embodiments, the tissue support6330can be comprised of a flexible and/or elastomeric material, for example.

The cutting member6050transects the tissue support6330during its cutting stroke. As illustrated inFIG. 92, the cutting member6050transects the top wall6332after transecting the tissue and then enters into the cavity6334. The top wall6332comprises an annular notch6333defined therein which is aligned with the annular cutting edge of the cutting member6050. The notch6333reduces the cross-section of the top wall6332and facilitates the incision of the top wall6332. The cutting member6050can also transect the bottom wall6338during its cutting stroke. As the reader should appreciate, the transection of the top wall6332and the bottom wall6338of the tissue support6330can create force pulses in the firing drive of the stapling instrument. The top wall6332and the bottom wall6338can be structurally configured to provide different pulses so that the clinician and/or electronic sensor system of the surgical instrument can discern the difference between the pulses and not incorrectly interpret the incision of the top wall6332as the end of the firing/cutting stroke.

Referring again toFIGS. 91 and 92, the top wall6332of the tissue support6330is aligned, or at least substantially aligned, with the tissue compression surface6022of the anvil6220. In addition to or in lieu of the above, the top wall6332can be recessed with respect to the tissue compression surface6022and/or extend above the tissue compression surface6022. The top wall6332of the tissue support extends above the forming surfaces6024of the anvil6220. In addition to or in lieu of the above, the top wall6332can be recessed with respect to the forming surfaces6024and/or aligned with the forming surfaces6024.

A surgical stapler comprising the staple cartridge6240and the anvil6220is illustrated inFIGS. 93 and 94. The reader should appreciate, however, that the tissue support6230of the anvil6220has been replaced with a tissue support6430. The tissue support6430comprises an annular central aperture configured to closely receive the stem6226. The tissue support6430further comprises a top wall6432, a bottom wall6438, and sidewalls6436extending between the top wall6432and the bottom wall6438. The walls6432,6436, and6438define an annular cavity6434therebetween. The cavity6434is enclosed, or at least substantially enclosed, on all sides. The cavity6434extends uninterrupted around the stem6226; however, other embodiments are envisioned in which the cavity6434is interrupted by sidewalls and/or changes in geometry, for example.

Similar to the above, the tissue support6430is configured to support the tissue as the tissue is being transected by the cutting member6050. The tissue support6430is closely received within the anvil6220such that the tissue support6430does not move, or at least substantially move, relative to the anvil6220. Moreover, the tissue support6430comprises a rigid polygonal cross-section such that the deflection of the tissue support6430is minimized or insubstantial while the cutting member6050is transecting the tissue. As illustrated inFIG. 93, a gap is present between the bottom wall6438and the inner side wall6436. Such a gap can provide some flexibility in the tissue support6430; however, other embodiments are envisioned in which no such gaps are present. The tissue support6430is comprised of plastic, for example; however, in various embodiments, the tissue support6430can be comprised of a flexible and/or elastomeric material, for example.

As illustrated inFIGS. 93 and 94, the inner sidewall6436is shorter than the outer sidewall3436; however, other embodiments are envisioned in which the outer sidewall6436is shorter than the inner sidewall6436. Moreover, the top wall6432is not parallel to the bottom wall6438. More specifically, the top wall6432comprises an inclined portion which extends transversely to the bottom wall6438and/or other portions of the top wall6432.

The cutting member6050transects the tissue support6430during its cutting stroke. As illustrated inFIG. 94, the cutting member6050transects the top wall6432after transecting the tissue and then enters into the cavity6434. The cutting member6050can also transect the bottom wall6438during its cutting stroke.

As discussed above, the tissue supports disclosed herein are configured to support tissue as the tissue is being incised by a cutting member. Oftentimes, the tissue being incised by the cutting member has been previously stapled, i.e., stapled during an earlier step in the surgical procedure, for example. In various instances, such staples may also be incised by the cutting member even though they are comprised of metal, such as titanium and/or stainless steel, for example. In other instances, such staples may not be incised by the cutting member; rather, they may be pushed into the material comprising the tissue support. Whether or not the staples are incised by the cutting member, the tissue supports disclosed herein, in various instances, comprise a sufficient strength and/or stiffness that prevents a staple trapped against the tissue support by the cutting member from creating more than localized plastic deformation in the tissue support. In at least one such instance, the localized plastic deformation is limited to less than one characteristic length (CL) of the staple in any direction with respect to the staple. In at least one instance, the material of the tissue support can be selected such that the staple trapped against the tissue support may only create a zone of plastic deformation in the tissue support that has a diameter of less than 2*CL, for example. In other instances, the material of the tissue support can be selected such that the staple trapped against the tissue support may only create a zone of plastic deformation in the tissue support that has a diameter of less than 1.5*CL, for example. A characteristic length of a staple can be the width of the staple crown, or backspan, and/or the formed height of the staple legs in their deformed configuration, for example. Moreover, the tissue supports disclosed herein can be comprised of a material which is sufficiently hard enough to support the staples as they are being incised by the cutting member. In at least one instance, the hardness of the material comprising the tissue support is equal to or greater than the hardness of the material comprising the staples being incised against the tissue support. In certain instances, the hardness of the material comprising the tissue support is less than the hardness of the material comprising the staples being incised; however, the structural design of the tissue support is sufficient to prevent the tissue support from plastically stretching beyond an acceptable zone of plastic deformation. In certain instances, the energy needed to incise the tissue and the formed staples in the tissue is less than the energy needed to incise the tissue support. In various instances, the material comprising the tissue support may be resistant to being gouged by the staples. In at least one instance, a biocompatible lubricant may be placed on and/or impregnated within the tissue support to prevent the staples from catching on the tissue support.

In various instances, the tissue compression surface of an anvil and the tissue contacting surface of a tissue support are flat, or at least substantially flat. Such an arrangement can distribute the force applied by the anvil onto the tissue over a large area. Other embodiments are envisioned in which the tissue compression surface of the anvil and/or the tissue contacting surface of the tissue support are not flat. In certain instances, the tissue compression surface of an anvil and/or the tissue contacting surface of a tissue support comprise tissue gripping members, or spikes, extending therefrom which are configured to engage and grip tissue. Such tissue gripping members can reduce relative movement, or slipping, between the tissue and the anvil, for example. In at least one instance, the density of the tissue gripping members on the tissue compression surface of the anvil and the tissue contacting surface of the tissue support is the same. In other instances, the density of the tissue gripping members on the tissue contacting surface of the tissue support is higher than the density of the tissue gripping members on the compression surface of the anvil. As the tissue support is positioned radially inwardly with respect to the compression surface of the anvil, the tissue gripping members can prevent the tissue from flowing or sliding radially inwardly in such an instance.

An anvil6520is disclosed inFIG. 95. The anvil6520comprises a tissue compression surface6522and, in addition, forming pockets defined in the tissue compression surface6522which are configured to deform staples into a desired configuration when the staples are ejected from their staple cartridge. Each forming pocket comprises a pair of cups, wherein each pair of cups is configured to deform the legs of a staple. For example, a pair of forming cups can include a first forming cup6530aconfigured to deform the first leg of a staple and a second forming cup6530bconfigured to deform the second leg of the staple. The first forming cup6530aand the second forming cup6530bare mirror images of one another with respect an axis6531extending between the first forming cup6530aand the second forming cup6530b; however, other arrangements can be utilized.

The first forming cup6530acomprises a first, or outer, end6532and a second, or inner, end6534. The first forming cup6530afurther comprises a bottom, or bathtub, surface6536extending between the outer end6532and the inner end6534. The first end6532is configured to receive the leg of a staple and begin the forming process of the leg. The first end6532comprises a curved surface configured to deflect the staple leg toward the second end6534. The bottom surface6536comprises a curved, or concave, surface configured to at least partially turn the staple leg back toward the staple cartridge. The second end6534comprises a curved surface which is configured to guide the staple leg out of the forming cup6530a.

The second forming cup6530bcomprises a similar construction to that of the first forming cup6530aand is configured to deform a second leg of the staple. As a result of the above, the first forming cup6530aguides the first leg of the staple toward the second leg and the second forming cup6530bguides the second leg of the staple toward the first leg. In various instances, the first forming cup6530aand the second forming cup6530bco-operate to deform the staple into a B-shaped configuration, for example; however, the forming cups can be configured to deform a staple into any suitable configuration.

Referring primarily toFIG. 96, each forming cup6530(6530aand6530b) comprises a first lateral sidewall6537and a second lateral sidewall6539extending between the first end6532and the second end6534. In various instances, the first lateral sidewall6537and the second lateral sidewall6539are mirror images of one another with respect to a longitudinal axis6533extending through the center of the forming cup6530. In other instances, the first lateral sidewall6537and the second lateral sidewall6539are not mirror images of each other. In either event, the sidewalls6537,6539are sloped or inclined so as to guide the staple leg toward the center of the forming cup, i.e., toward the axis6533, for example.

Each forming cup6530comprises a groove or channel6538defined in the bottom surface6536thereof. The groove6538extends longitudinally between the first end6532and the second end6534of the forming cup6530. The groove6538extends parallel to, and laterally offset with respect to, a central longitudinal axis6535of the forming cup6530. The groove6538is wider than the leg of the staple that is deformed by the forming cup6530; however, other embodiments are envisioned in which the groove6538is narrower than the leg of the staple. In either event, the groove6538is configured to guide the staple leg along a predetermined path within the forming cup6530.

In various instances, the grooves of the forming cups6530are configured to twist the legs of the staple while the legs are being deformed. In at least one instance, a staple is planar, or at least substantially planar, before it is deformed. In at least one such instance, the legs and the base of the staple lie in the same plane which is aligned with the longitudinal axis6535when the staple is ejected from the staple cartridge. The first ends6532and the bottom surfaces6536are sloped and/or otherwise configured to guide the legs toward the grooves6538when the staple legs enter into the forming cups6530. Once the staple legs enter into the grooves6538, the grooves6538will twist the staple legs out of plane with the base of the staple. As a result of the above, the unformed staple configuration is planar but the formed staple configuration is non-planar Other embodiments are envisioned, however, in which a staple has a non-planar configuration before and after it has been deformed.

The grooves6538of the forming cups6530, for a given set of forming cups6530, are positioned on the same side of the longitudinal axis6535and are configured to twist both of the staple legs to the same side of the staple base. Other embodiments, however, are envisioned in which a first staple leg is twisted to one side of the staple base and a second staple leg is twisted to another side of the staple base. In at least one such embodiment, a first groove6538is positioned on a first side of the longitudinal axis6535that is configured to twist a first staple leg to a first side of the staple base while a second groove6538is positioned on a second side of the longitudinal axis6535that is configured to twist a second staple leg to a second side of the staple base.

The grooves6538of the forming cups6530, for a given set of forming cups6530, are collinear, or at least substantially collinear. Other embodiments, however, are envisioned in which the grooves6538are positioned on the same side of the longitudinal axis6535but are not collinear with each other. In at least one such instance, the grooves6538are parallel to each other while, in other such instances, the grooves6538are not parallel to each other.

Referring primarily toFIG. 96, the groove6538is deeper than the bottom surface6536of the forming cup6530. Other embodiments, however, are envisioned in which the groove and the bottom surface of a forming cup have the same depth.

In various instances, the forming cups6530are arranged in longitudinal rows when the anvil6520is part of a longitudinal end effector configured to apply longitudinal rows of staples. In at least one such instance, the grooves6538of the forming cups are arranged such all of the staples deployed by the end effector are bent out of plane in the same direction. In other instances, the grooves6538are arranged in a first longitudinal row of forming cups6530to bend the staple legs in a first direction and a second longitudinal row of forming cups6530to bend the staple legs in a second, or different, direction. In certain instances, the grooves6538are arranged to bend the legs of a first staple in a staple row in a first direction and a second staple in the staple row in a second, or opposite, direction.

In various instances, the forming cups6530are arranged in annular rows when the anvil6520is part of an annular end effector configured to apply annular rows of staples. In at least one such instance, the grooves6538are positioned radially outwardly with respect to the center longitudinal axes6535of the forming cups6530. In other instances, the grooves6538are positioned radially inwardly with respect to the center longitudinal axes6535of the forming cups6530. In certain instances, the grooves6538are positioned radially outwardly in a first annular row of forming cups6530and radially inwardly in a second annular row of forming cups6530.

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

An end effector7000of a circular stapling assembly is disclosed inFIGS. 97-99. The end effector7000comprises a staple cartridge including a deck7030and a cartridge body7040. The deck7030comprises a tissue compression surface7031and staple cavities7032defined in the compression surface7031. The staple cavities7032are arranged in a first, or inner, annular row and a second, or outer, annular row. Each staple cavity7032in the inner row comprises a first staple7070aremovably stored therein and each staple cavity7032in the outer row comprises a second staple7070bremovably stored therein.

The end effector7000further comprises staple drivers which are configured to push the staples out of the staple cartridge. For instance, the staple cartridge comprises a first annular row of staple drivers7060aconfigured to eject the first row of staples7070aand a second annular row of staple drivers7060bconfigured to eject the second row of staples7070bcartridge body7040. The staple drivers7060aand7060bare positioned within and/or aligned with the staple cavities7032defined in the deck7030. The staple drivers7060aand7060bare slidable within the staple cavities7032to eject the staples7070aand7070b, respectively, from the staple cavities7032.

The end effector7000further comprises an anvil7020. The anvil7020comprises a tissue compression surface7021and staple forming pockets7022defined in the compression surface7021. The staple forming pockets7022are arranged in a first, or inner, annular row and a second, or outer, annular row. The staple forming pockets7022are aligned with the staple cavities7032such that the staples7070a,7070bcontact the staple forming pockets7022when the staples7070a,7070bare ejected from the staple cavities7032.

The end effector7000further comprises a firing member7056configured to lift the staple drivers7060aand7060bwithin the staple cavities7032to eject the staples7070aand7070b, respectively, from the staple cavities7032. The firing member7056comprises a base7054and a ramp7055. The base7054is slidably positioned within a recess7052defined in a firing drive7050. The ramp7055is slidably positioned within a slot7041defined in the cartridge body7040. As described in greater detail below, the ramp7055is configured to slide within the slot7041and progressively contact the staple drivers7060a,7060bto eject the staples7070a,7070bfrom the staple cavities7032.

Further to the above, the firing member7056is movable through a firing stroke to eject the staples7070a,7070bfrom the staple cavities7032. During the firing stroke, the firing member7056is moved along a curved, or arcuate, path which is defined by the slot7041. Referring primarily toFIG. 97, the slot7041comprises a first end7042and a second end7049and a continuous path therebetween. The ramp7055of the firing member7056is positioned in the first end7042at the beginning of the firing stroke and the second end7049at the end of the firing stroke. The first end7042of the slot7041is aligned with the inner row of staple cavities7032and the second end7049of the slot7041is aligned with the outer row of staple cavities7032. The slot7041further comprises a first circumferential portion7043that extends around a central longitudinal axis7090extending through the end effector7000. The first circumferential portion7043of the slot7041is aligned with and extends under the staple drivers7060ain the inner row of staple cavities7032. The ramp7055of the firing member sequentially engages the staple drivers7060ato sequentially fire the staples7070aas the firing member7056moves through the first circumferential portion7043of the slot7041.

The first circumferential portion7043is defined by a constant, or at least substantially constant, radius of curvature about the longitudinal axis7090; however, other embodiments are envisioned in which the radius of curvature of the first circumferential portion7043is not constant. In at least one such instance, the first circumferential portion7043comprises a spiral. Stated another way, in such an instance, the first circumferential portion7043recedes away from the longitudinal axis7090as it extends around the longitudinal axis7090.

The second circumferential portion7045of the slot7041is aligned with and extends under the staple drivers7060bin the outer row of staple cavities7032. The ramp7055of the firing member sequentially engages the staple drivers7060bto sequentially fire the staples7070bas the firing member7056moves through the second circumferential portion7045of the slot7041. The second circumferential portion7045is defined by a constant, or at least substantially constant, radius of curvature about the longitudinal axis7090; however, other embodiments are envisioned in which the radius of curvature of the second circumferential portion7045is not constant. In at least one such instance, the second circumferential portion7045comprises a spiral. Stated another way, in such an instance, the second circumferential portion7045recedes away from the longitudinal axis7090as it extends around the longitudinal axis7090.

Further to the above, the slot7041comprises a transition portion7044intermediate the first circumferential portion7043and the second circumferential portion7045. During the firing stroke, the ramp7055slides sequentially through the first circumferential portion7043, the transition portion7044, and then the second circumferential portion7045. The transition portion7044permits the firing member7056to shift between the first radius of curvature of the first staple row and the second radius of curvature of the second staple row. In certain embodiments, a transition portion7044between the first circumferential portion7043and the second circumferential portion7045may be unnecessary. In at least one such instance, the first circumferential portion7043can comprise a first spiral configuration and the second circumferential portion7045can comprise a second spiral configuration which is aligned such that the end of the first spiral configuration is aligned with the beginning of the second spiral configuration, for example.

The firing member7056is driven along its firing path by a firing drive7050. The firing drive7050is driven about the longitudinal axis7090by a handcrank and/or electric motor, for example. The firing drive7050comprises a drive recess7052defined therein. The base7054of the firing member7056is positioned in the drive recess7052. The drive recess7052is larger than the base7054of the firing member7056such that the base7054can move, or float, within the drive recess7052. The drive recess7052is defined by sidewalls which limit the movement of the base7054within the recess7052. When the firing drive7050is rotated about the longitudinal axis7090, a sidewall of the drive recess7052contacts the base7054and pushes the drive member7056through the slot7051. As discussed above, the slot7051has one or more changes in its radius of curvature and, when the firing member7056moves through such changes, the base7054of the firing member7056can slide within the drive recess.

As described above, the staples in the first, or inner, row of staples are deployed sequentially and, then, the staples in the second, or outer, row of staples are deployed sequentially. Such an embodiment can control the inner periphery of the colon before stapling outwardly, for example. In other embodiments, the staples in the outer row of staples are deployed sequentially and, then, the staples in the inner row of staples are deployed sequentially. Such an embodiment can establish a boundary in the colon tissue before stapling inwardly, for example.

In various instances, further to the above, the first staples7070aand the second staples7070bhave the same unformed height. In at least one such instance, the first staples7070aand the second staples7070bare formed to the same formed height. In other such instances, the first staples7070aare formed to a first formed height and the second staples7070bcan be formed to a second formed height which is different than the first formed height. In at least one such instance, the first formed height of the inner row of staples is shorter than the second formed height of the outer row of staples. Such an arrangement can provide for a more gradual transition between the stapled tissue and the unstapled tissue, for example. In other instances, the first formed height of the inner row of staples is taller than the second formed height of the outer row of staples. Such an arrangement can allow the innermost tissue of a stapled bowel, for example, to be more flexible, for example.

In certain instances, further to the above, the first staples7070ahave a first unformed height and the second staples7070bhave a second unformed height which is different than the first unformed height. In at least one such instance, the first staples7070aand the second staples7070bare formed to the same formed height. In other such instances, the first staples7070aare formed to a first formed height and the second staples7070bare formed to a second formed height which is different than the first formed height.

The end effector7000has two annular rows of staples; however, an end effector can have any suitable number of annular staple rows. For example, an end effector can have three annular rows of staples. In at least one such instance, the staples in a first annular row can have a first unformed staple height, the staples in a second annular row can have a second unformed staple height, and the third staples in a third annular row can have a third unformed staple height. Moreover, in at least one such instance, the staples in a first annular row can have a first deformed staple height, the staples in a second annular row can have a second deformed staple height, and the third staples in a third annular row can have a third deformed staple height.

A firing drive7150is depicted inFIGS. 100-105. The firing drive7150comprises a rotatable drive shaft7152that is rotatable about a longitudinal axis. The firing drive7150further comprises a three-stage sequential driver assembly comprising a first, or inner, driver7154a, a second, or intermediate, driver7154b, and a third, or outer, driver7154c. The drive shaft7152comprises a drive pin7151extending therefrom. The drive pin7151extends through a drive slot in each of the drivers7154a,7154b, and7154c. For instance, the first driver7154acomprises a first drive slot7153adefined therein, the second driver7154bcomprises a second drive slot7153bdefined therein, and the third driver7154ccomprises a third drive slot7153cdefined therein. The drive slots7153a,7153b, and7153cdo not have the same configuration; however, the drive slots7153a,7153b, and7153chave overlapping configurations that are aligned, or at least substantially aligned, with each other at the drive pin7151. For instance, the drive pin7151is in an unfired position inFIG. 100and the drive slots7153a,7153b, and7153care aligned with the drive pin7151.

Further to the above,FIG. 100illustrates drivers7154a,7154b, and7154cin an unfired position. When the drive shaft7152is rotated through a first portion of its firing stroke, referring now toFIG. 101, the drive pin7151is rotated through a circumferential path where the drive pin7151engages a sidewall of the drive slot7153aand pushes, or cams, the first driver7154adistally. Notably, the drive pin7151has not driven the drivers7154band7154cdistally during the first portion of the firing stroke. As can be seen inFIG. 100, the drive slots7153band7153care aligned with the circumferential path of the drive pin7151throughout the first portion of the firing stroke. The first driver7154ais configured to fire a first annular row of staples when the first driver7154ais displaced distally.

When the drive shaft7152is rotated through a second portion of its firing stroke, referring now toFIG. 102, the drive pin7151is rotated through a circumferential path where the drive pin7151engages a sidewall of the drive slot7153band pushes, or cams, the second driver7154bdistally. Notably, the drive pin7151has not driven the driver7154cdistally during the second portion of the firing stroke Similar to the above, the drive slots7153aand7153care aligned with the circumferential path of the drive pin7151throughout the second portion of the firing stroke. The second driver7154bis configured to fire a second annular row of staples when the second driver7154bis displaced distally.

When the drive shaft7152is rotated through a third portion of its firing stroke, referring now toFIG. 103, the drive pin7151is rotated through a circumferential path where the drive pin7151engages a sidewall of the drive slot7153cand pushes, or cams, the third driver7154cdistally Similar to the above, the drive slots7153aand7153bare aligned with the circumferential path of the drive pin7151throughout the third portion of the firing stroke. The third driver7154cis configured to deploy a cutting member when the third driver7154cis displaced distally; however, in certain embodiments, the third driver7154ccan deploy a third row of staples, for example.

As a result of the above, there is no overlap between the first staple firing stage, the second staple firing stage, and the tissue cutting stage. They are timed sequentially. Accordingly, the forces required to deform the staples and cut the tissue are spread out throughout the firing stroke. Moreover, the firing drive7150cannot cut the tissue until the tissue has been stapled. Various alternative embodiments are envisioned in which there is some overlap between the first staple firing stage, the second staple firing stage, and/or the tissue cutting stage. In at least one such embodiment, the configurations of the drive slots7153a,7153b, and7153ccan be adapted such that there is a partial overlap in the movement of the first driver7154aand the second driver7154band/or a partial overlap in the movement of the second driver7154band the third driver7154c.

Referring primarily toFIGS. 103 and 104, the drivers7154a,7154b, and7154ccomprise co-operating features which prevent, or at least inhibit, the drivers7154a,7154b, and7154cfrom rotating relative to one another. For instance, the first driver7154acomprises a longitudinal key7155apositioned in a longitudinal slot7156bdefined in the second driver7154b. The key7155aand the slot7156bare configured to permit the first driver7154ato slide longitudinally relative to the second driver7154bbut block rotational movement between the first driver7154aand the second driver7154b. Similarly, the second driver7154bcomprises a longitudinal key7155bpositioned in a longitudinal slot7156cdefined in the third driver7154c. The key7155band the slot7156care configured to permit the second driver7154bto slide longitudinally relative to the third driver7154cbut block rotational movement between the second driver7154band the third driver7154c.

In order to retract the drivers7154a,7154b, and7154c, the drive shaft7152is rotated in an opposite direction. In such instances, the drive shaft7152sequentially engages a sidewall of the drive slot7153c, a sidewall of the drive slot7153b, and then a sidewall of the drive slot7153ato return the third driver7154c, the second driver7154b, and the first driver7154aback to their unfired positions (FIG. 100).

A firing drive7250is illustrated inFIG. 106. The firing drive7250operates in a similar manner to that of the firing drive7150. The firing drive7250comprises a drive shaft7252which is rotatable about a longitudinal axis. The drive shaft7252comprises a cam surface, or ramp,7256which is rotated through several stages of a firing stroke. The firing drive7250further comprises a first driver7254a, a second driver7254b, and a third driver7254cwhich are engaged by the cam7256of the drive shaft7252when the firing drive7250is rotated. In the first stage of the firing stroke, the cam7256engages a cam surface7255adefined on the first driver7254aand drives the first driver7254adistally. In the second stage of the firing stroke, the cam7256engages a cam surface7255bdefined on the second driver7254band drives the second driver7254bdistally and, in the third stage of the firing stroke, the cam7256engages a cam surface7255cdefined on the third driver7254cand drives the third driver7254cdistally.

The first cam surface7255ais shorter than the second cam surface7255band, as a result, the first driver7254ahas a shorter firing stroke than the second driver7254b. Similarly, the second cam surface7255bis shorter than the third cam surface7255cand, as a result, the second driver7254bhas a shorter firing stroke than the third driver7254c. Such an arrangement may be useful to form different rows of staples to different formed heights, for example. In other embodiments, the drivers7254a,7254b, and7254cmay have any suitable firing stroke. In at least one embodiment, the drivers7254a,7254b, and7254chave the same firing stroke, for example. Such an arrangement may be useful to form different rows of staples to the same formed height, for example.

FIG. 107is a perspective view of a portion of a staple cartridge4410for use with a circular surgical stapling instrument in accordance with at least one embodiment. A variety of circular surgical stapling instruments are known. For example, U.S. patent application Ser. No. 14/836,110, filed Aug. 26, 2015, entitled SURGICAL STAPLING CONFIGURATIONS FOR CURVED AND CIRCULAR STAPLING INSTRUMENTS, which is hereby incorporated by reference in its entirety, discloses various circular surgical stapling instrument arrangements. U.S. patent application Ser. No. 14/498,070, filed Sep. 26, 2014, entitled CIRCULAR FASTENER CARTRIDGES FOR APPLYING RADIALLY EXPANDING FASTENER LINES, the entire disclosure of which is hereby incorporated by reference herein also discloses various circular surgical stapler arrangements. As discussed in those references, a circular surgical stapler generally comprises a frame assembly that comprises an attachment portion that is configured to operably couple an anvil to the circular surgical stapler.

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

Referring again toFIG. 107, the staple cartridge4410comprises a cartridge body4411that defines an annular cartridge deck surface4412. The cartridge body4411comprises an inner annular row4420of spaced inner staple cavities4422and an outer annular row4440of spaced outer staple cavities4442. The inner staple cavities4422are staggered relative to the outer spaced staple cavities4442as can be seen inFIG. 107. Supported within each inner staple cavity4422is an inner surgical staple4430and supported within each outer staple cavity4442is an outer surgical staple4450. The outer staples4450in the outer annular row4440may have different characteristics than the inner staples4430in the inner annular row4420. For example, as illustrated in the embodiment ofFIG. 108, the outer staples4450have an unformed “gullwing” configuration. In particular, each outer staple4450includes a pair of legs4454,4464that extend from a staple crown4452. Each leg4454,4464includes a vertical portion4456,4466, respectively that extends from the crown4452. The vertical portions4456,4466may be parallel to each other in one embodiment. However, in the illustrated arrangement, the vertical portions4456,4466are not parallel to each other. For example, the angle A1between the crown4452and the vertical portions4456,4466in the illustrated arrangement is greater than ninety degrees. SeeFIG. 108. Further details regarding the staple configuration may be found in U.S. patent application Ser. No. 14/319,008, filed Jun. 30, 2014, entitled FASTENER CARTRIDGE COMPRISING NON-UNIFORM FASTENERS, U.S. Patent Application Publication No. 2015/0297232, the entire disclosure of which is hereby incorporated by reference herein. However, other the vertical portions4456,4466may be arranged at other angles with respect to the crown4452. One advantage of having the vertical leg portions4456,4466oriented at angles greater than ninety degrees relative to the crown4452is that such arrangement may assist in the temporary retention of the staple within its corresponding staple cavity.

At least one leg4454,4464includes an inwardly extending end portion. In the embodiment depicted inFIG. 108for example, each leg4454,4464includes an inwardly extending leg portion. In the illustrated arrangement, leg portion4458extends inwardly from the vertical leg portion4456and the leg portion4468extends inwardly from the vertical leg portion4466. As can be seen inFIG. 108, the leg portion4458is shorter than the leg portion4468. Stated another way, the distance HAbetween the staple crown4452and the point where the leg portion4458angles inward from the vertical leg portion4456is greater than the distance HCbetween the staple crown4452and the point where the leg portion4468angles inward from the vertical leg portion4466. Thus, distance HBin at least one embodiment is shorter than the length HD. The angle A2at which the leg portion4458angles relative to the vertical leg portion4556may be equal to the angle A3at which the leg portion4468angles relative to the vertical leg portion4466or angles A2and A3may be different from each other. Further details regarding the staple configuration may be found in U.S. patent application Ser. No. 14/319,008, filed Jun. 30, 2014, entitled FASTENER CARTRIDGE COMPRISING NON-UNIFORM FASTENERS, U.S. Patent Application Publication No. 2015/0297232, which has been herein incorporated by reference.

In at least one embodiment, each inner surgical staple4430may have the configuration illustrated inFIG. 108. As can be seen inFIG. 108, the inner surgical staple4430has a crown4432and two vertical legs4434,4436extending therefrom. The vertical legs4434,4436may extend relatively perpendicularly from the crown4432or they may extend at angles A4that may be greater than ninety degrees. Such arrangement may assist in the temporary retention of the staples4430within their corresponding staple cavity4422. However, vertical legs4434,4436may extend from the crown4432at different angles. In some embodiments, angles A4are equal to each other. In other embodiments, angles A4are different from each other. In the illustrated embodiment, the inner staples4430and the outer staples4450each have the same unformed height UFH. The inner and outer staples4430,4450are formed from conventional surgical staple wire. In at least one embodiment, the diameter of the staple wire used to form the outer staples4450is greater than the diameter of the staple wire used to form the inner staples4430. In other embodiments, the inner and outer staples may have the same diameters and be formed from wires with other diameters. In some arrangements, the inner and outer staples may be formed from the same type of staple wire. Thus, in such arrangement, the wire diameters of the inner and outer staples would be the same. In yet another embodiment, however, the inner and outer staples may have the same unformed shapes/configurations, yet be formed from two different staple wires that have different wire diameters. Also in at least one arrangement, the crown width CWOof each outer staple4450is larger than the crown width CW1of each inner staple4430. Further details regarding the staple configuration may be found in U.S. patent application Ser. No. 14/319,008, filed Jun. 30, 2014, entitled FASTENER CARTRIDGE COMPRISING NON-UNIFORM FASTENERS, U.S. Patent Application Publication No. 2015/0297232, which has been herein incorporated by reference.

Returning toFIG. 107, the staple cartridge4410includes an outer rim4414that extends above the deck surface4412. During surgery, the clinician can adjust the location of the anvil relative to the cartridge of a circular stapler. In at least one such embodiment, the staple cartridge4410further comprises deck features4416and4418that extend from the deck surface4412. As can be seen inFIG. 107, a series of inner deck features4416are provided between the inner row4420of staple cavities4422and a centrally-disposed knife opening4413through which the knife or cutting member will pass during the firing process. The deck features4416may be shaped and located relative to the inner staple cavities and opening4413as shown inFIGS. 107, 109 and 110. For example, each inner deck feature4416may have a flat wall portion4415that is coextensive with the wall of the knife opening4413and a conical or sloping body portion4417that is adjacent to the row of inner staple cavities4422. SeeFIGS. 109 and 110. In the embodiment depicted inFIG. 107, the deck features4416are oriented in the gap between two adjacent inner staple cavities4422and are staggered between pairs of staple cavities4422as shown. The cavity extension arrangements or deck features in this system may serve to lower pressure that is commonly encountered in flat deck cartridges. This disclosed arrangement may also help to mitigate tissue movement and slippage. Since slippage of the tissue is generally undesirable, the outside diameter holding features may be bigger and more numerous. The internal diameter features may serve to increase tissue tension/shear as the blade passes next to the inside internal diameter which may make the system cut better. However, the deck features4416may have different shapes and configurations and may be located in different locations on the deck surface4412.

As can also be seen inFIGS. 107, 109 and 110, every other outer staple cavity4442includes an outer deck feature4418that is associated with each end thereof. Outer deck features4418extend above the deck surface4412and guide the outer staples4450toward the anvil when the staples4450are being ejected from the staple cartridge4410. In such embodiments, the outer staples4450may not extend above the outer deck features4418until they are moved toward the anvil by the firing member. Referring primarily toFIG. 107, in at least one embodiment, the outer deck features4418do not extend around the entirety of the corresponding outer staple cavity4442. A first outer deck feature4418is positioned adjacent a first end of a corresponding outer cavity4442and a second outer deck feature4418is positioned adjacent a second end of the outer cavity4442. As can be seen inFIG. 107, the outer deck features4418are associated with every other one of the outer staple cavities4442. Such arrangement may serve to lower overall pressure and minimize tissue stretch and movement. In other embodiments, first and second outer deck features4418may be associated with every one of the outer staple cavities4442, however. In yet other embodiments, an outer deck feature may extend around the entire perimeter of a corresponding outer cavity. As can be seen inFIG. 109, the inner deck features4416are shorter than the outer deck features4418. Stated another way, each inner deck feature protrudes above the deck surface4412a distance that is less than the distance that each outer deck feature4418protrudes above the deck surface4412. Each outer deck feature may protrude above the deck surface4412the same distance that the outer rim4414protrudes above the deck surface4412. In addition, as can also be seen inFIG. 109, each outer deck feature4418has a generally conical or tapered outer profile which may help to prevent tissue from snagging on the deck features during insertion of the stapler head through a patient's colon and rectum.

The above-mentioned deck feature arrangements may provide one or more advantages. For example, the upstanding outer rim may help to prevent tissue from sliding across the cartridge deck. This upstanding rim could also comprise a repeating pattern of highs and lows rather than being one continuous lip formation. The inside upstanding features may also help to retain the tissue adjacent to the blade and lead to improved cutting. The inside deck features could be between every cavity or in alternative arrangements, the deck feature(s) may comprise one continuous upstanding lip. It may be desirable to balance the number of deck features to minimize the number of high force/compression zones while attaining a desired amount of tissue immobilization. The cavity concentric features may serve the additional purpose of minimization of tissue flow in the areas where the staple legs project from. Such arrangements also facilitate desirable staple formation as the staple legs eject and transition to the receiving anvil pocket which may consist of corresponding forming pockets. Such localized pocket features increase the low compression zones while facilitating leg support from the cartridge as the staple exits the cartridge. This arrangement thereby minimizes the distance that the staple must “jump” before it meets the anvil pocket. Tissue flow tends to increase going from the center of the cartridge radially outward. Referring toFIG. 118, the improved standing outside row extensions have a tendency to stage tissue as they are inserted up through the colon because it is a tube.

FIGS. 109 and 110illustrate use of the surgical staple cartridge4410in connection with an anvil4480. The anvil4480comprises an anvil head portion4482that operably supports a staple forming insert or portion4484and a knife washer4490. The knife washer4490is supported in confronting relationship to the knife4492that is supported in the stapler head. In the illustrated embodiment, the staple forming insert4484is fabricated from, for example, steel, stainless steel, etc. and contains an inner row of inner staple forming pockets4486and an outer row of outer staple forming pockets4488. Each inner staple forming pocket4486corresponds to one of the inner staple cavities4422and each outer staple forming pocket4488corresponds to one of the outer staple cavities4442. In the illustrated arrangement, when the anvil4480is moved to its firing position relative to the cartridge deck surface4412, the inner staple forming pockets4486are closer to the cartridge deck surface4412than are the outer staple forming pockets4488. Stated another way, the first gap g1or first staple forming distance between a first staple forming portion4485and the cartridge deck surface4412is less than the second gap g2or second staple forming distance between a second staple forming portion4487and the cartridge deck surface4412.

As can be further seen inFIGS. 109 and 110, the inner staples4430are each supported within their corresponding inner staple cavity4422on a corresponding inner driver portion4502of a pusher assembly4500and each of the outer staples4450are supported within their corresponding outer staple cavity4442on a corresponding outer driver portion4504. Advancement of the pusher assembly4500toward the anvil4480will cause the inner and outer staples4430,4450to be driven into forming contact with their respective corresponding staple forming pockets4486,4488as shown inFIG. 110. In addition, the knife4492is advanced distally through the tissue that is clamped between the anvil4480and the deck surface4412and through a frangible bottom4491of the knife washer4490. Such arrangement serves to provide the outer staples4450with a formed height FHOthat is larger than the formed height FH1of the inner staples4430. Stated another way, the outer row4440of outer staples4450are formed into a larger “B” formation resulting in a greater capture volume and/or taller staple forming height to alleviate high tissue compression near the outer row of staples4440. A larger B formation may also improve blood flow toward the inner rows. In various instances, the outer row4440of outer staples4450comprise a greater resistance to unfolding by utilizing a larger staple crown, staple leg widths, and/or staple leg thicknesses.

The quantity of staples used in each row of staples can vary. In one embodiment, for example, there are more outer staples4450than there are inner staples4430. Another embodiment employs more inner staples4430than outer staples4450. In various instances, the wire diameter of the outer staples4450is larger than the wire diameter of the inner staples4430. The inner and outer staples4430,4450may have the same unformed heights UFH. The crown widths CWOin the outer row4440of outer staples4450are larger than the crown widths CW1of the inner row4420of inner staples4430. The gullwing configuration of the outer staples4450employs bends that are located at different distances from their respective crown. Use of the stepped anvil configuration with a flat (unstepped) cartridge deck surface4412with uniform driver or pusher travel yield staples with different formed heights.

FIG. 111illustrates another staple cartridge embodiment4610. As can be seen inFIG. 111, the staple cartridge4610includes a cartridge deck4612that includes an inner annular row4620of spaced inner staple cavities4622and an outer annular row4640of outer spaced staple cavities4642. The inner staple cavities4622are staggered relative to the outer spaced staple cavities4642as can be seen inFIG. 111. Supported within each inner staple cavity4622is an inner surgical staple4630and supported within each outer staple cavity4642is an outer surgical staple4650. In addition, an outer rim4614extends above the deck surface4612. In various embodiments, further to the above, the staples4630,4650do not protrude above the deck surface4612until they are moved toward the anvil by the firing member. Such embodiments may frequently utilize small staples relative to the depth of their respective staple cavity in which they are stored. In other embodiments, the legs of the staples protrude above the deck surface4612when the staples are in their unfired positions. In at least one such embodiment, the staple cartridge4610further comprises deck features4616and4618that extend from the deck surface4612.

As can also be seen inFIG. 111, every other inner staple cavity4622includes an inner deck feature4616that is associated with each end thereof. Inner deck features4616extend above the deck surface4612and guide the corresponding inner staples4630toward the anvil when the corresponding inner staples4630are being ejected from the staple cartridge4610. In such embodiments, the inner staples4630may not extend above the inner deck features4616until they are moved toward the anvil by the firing member. In the illustrated example, the inner deck features4616do not extend around the entirety of the corresponding inner staple cavity4622. A first inner deck feature4616is positioned adjacent a first end of a corresponding inner cavity4622and a second inner deck feature4616is positioned adjacent a second end of the inner cavity4622. In other embodiments, the inner deck features4416may be associated with every one of the inner staple cavities4622, however. In yet other embodiments, an inner deck feature may extend around the entire perimeter of a corresponding inner staple cavity. By employing deck features that have different heights in concentric patterns wherein they are associated with every other cavity may provide more lower pressure tissue gap areas, while balancing them with the desire to guide as many and as much of the staple leg for as long as possible. Stated another way, such arrangement may minimize the amount of tissue flow reducing the overall amount of pressure applied to the target tissue.

Still referring toFIG. 111, each outer staple cavity4642includes an outer deck feature4618that is associated with each end thereof. Outer deck features4618extend above the deck surface4612and guide the outer staples4650toward the anvil when the staples4650are being ejected from the staple cartridge4610. In such embodiments, the outer staples4650may not extend above the outer deck features4618until they are moved toward the anvil by the firing member. As can be seen inFIG. 111, in the illustrated example, the outer deck features4618do not extend around the entirety of the corresponding outer staple cavity4642. A first outer deck feature4618is positioned adjacent a first end of a corresponding outer cavity4642and a second outer deck feature4618is positioned adjacent a second end of the outer cavity4642. As can be seen inFIG. 111, outer deck features4618are associated with every one of the outer staple cavities4642. In other embodiments, first and second outer deck features4618may be associated with every other one of the outer staple cavities4642, however. In yet other embodiments, an outer deck feature may extend around the entire perimeter of a corresponding outer cavity. As can be seen inFIGS. 112 and 113, the inner deck features4616and the outer deck features4618extend above the deck surface4612the same distance. Stated another way, they have the same heights. In addition, as can also be seen inFIGS. 112 and 113, each inner deck feature4416and each outer deck feature4618has a generally conical or tapered outer profile which may help to prevent tissue from snagging on the deck features during insertion of the stapler head through a patient's colon and rectum.

FIGS. 112 and 113illustrate use of the surgical staple cartridge4610in connection with an anvil4680. The anvil4680comprises an anvil head portion4682that operably supports a staple forming insert or portion4684and a knife washer4690. The knife washer4690is supported in confronting relationship to a knife4692that is supported in the stapler head. In the illustrated embodiment, the staple forming insert4684is fabricated from, for example, steel, stainless steel, etc. and contains an inner row of inner staple forming pockets4686and an outer row of outer staple forming pockets4688. Each inner staple forming pocket4686corresponds to one of the inner staple cavities4622and each outer staple forming pocket4688corresponds to one of the outer staple cavities4642. In the illustrated arrangement, the inner staple forming pockets4686are located the same distance g1from the deck surface4612as are the outer staple forming pockets4688.

As can be further seen inFIGS. 112 and 113, an inner staple4630is supported within a corresponding inner staple cavity4622on a corresponding inner driver portion4702of a pusher assembly4700. An outer staple4650is supported within a corresponding outer staple cavity4642on a corresponding outer driver portion4704. Advancement of the pusher assembly4700toward the anvil4680will cause the inner and outer staples4630,4650to be driven into forming contact with their respective corresponding staple forming pockets4686,4688as shown inFIG. 113. In addition, the knife4692is advanced distally through the tissue that is clamped between the anvil4680and the deck surface4612and through a frangible bottom4691of the knife washer4690. In the example illustrated inFIGS. 112 and 113, each inner staple4630is formed from a first staple wire that has a first wire diameter D1and has a first unformed height L1. For example, the first wire diameter D1may be approximately 0.0079″-0.015″ (increments are usually 0.0089″, 0.0094″, and 0.00145″) and the first unformed height L1may be approximately 0.198″-0.250″. Each outer staple4650is formed from a second staple wire that has a second wire diameter D2and has a second unformed height L2. In the embodiment depicted inFIGS. 112 and 113, D1<D2and L1<L2. However, as can be seen inFIG. 113, the inner and outer staples4630,4650are formed with the same formed heights FH's. The thicker wire staples on the outside tend to provide high tear and burst strengths as compared to the inside row of smaller diameter staples which tend to hold better hemostatically. Stated another way, the tighter inside rows of staples may hold better hemostatically while the outer rows of less compressed staples may facilitate better healing and blood flow. In addition, the staples with longer legs, even when formed at the same heights as staples with shorter legs, may ensure more B-bending which may make the longer legged staples stronger and more likely to be properly formed enough to hold in high load conditions. The quantity of staples used in each row of staples can vary. In one embodiment, for example, the inner row4620has the same number of inner staples4630as does the outer row4640of outer staples4650. In various arrangements, the crown widths of the staples4650is larger than the crown widths of the inner staples4630. In other embodiments, the staples4630,4650may have identical crown widths. In other arrangements, the staples4630,4650may be of the gullwing design described above. For example, at least one leg of the staple may include an end portion that is bent inwardly or both legs may include end portions that are bent inwardly toward each other. Such staples may be employed in the inner annular row or the outer annular row or in both of the inner and outer annular rows.

FIG. 114illustrates another circular staple cartridge embodiment4810that includes a cartridge deck4812that includes three annular rows4820,4840,4860of spaced staple cavities. The inner or first row4820contains a first plurality of inner or first staple cavities4822that are each arranged at a first angle. Each inner staple cavity4822operably supports a corresponding inner or first staple4830therein. The inner cavities4822orient the first staples4830at the same uniform angle relative to the tangential direction. In the illustrated example, each inner staple4830is formed from a first staple wire that has a first staple diameter D1. In one example, the first staple wire diameter D1may be approximately 0.0079″-0.015″ (increments are usually 0.0089″, 0.0094″, and 0.00145″). Referring toFIG. 117, each inner staple4830includes a first crown4832and two first legs4834. The first crown has a first crown width C1and each first leg4834has a first unformed leg length L1In one example, the first crown width C1may be approximately 0.100″-0.300″ and the first unformed leg length L1may be approximately 0.198″-0.250″. The first legs4834may be each arranged at an angle A1relative to the first staple crown4832. The angle A1may be approximately 90° or it may be slightly greater than 90° such that the first legs4834are slightly splayed outward to assist in retaining the first staple4830in its corresponding first staple cavity4822.

Turning toFIGS. 115 and 116, the staple cartridge4810is intended to be used in connection with an anvil4900that includes two inner or first rows4902of staggered or angled first pairs4903of first staple forming pockets4904. Each first pair4903of first staple forming pockets4904correspond to one first staple4830. One first staple forming pocket4904corresponds to one first staple leg4834and the other first staple forming pocket4904of the pair4903corresponds to the other first staple leg4834. Such arrangement serves to establish a formed staple configuration wherein the first staple legs4834of a first staple4830are formed out of plane with the first crown4832of that particular first staple4830such that one first leg4834is formed on one side of the first crown4832and the other first leg4834is formed on the other side of the first crown4832. This “three-dimensional” formed staple configuration is shown with respect to some of the first staple forming pockets4904inFIG. 115.

As can be most particularly seen inFIG. 116, the cartridge deck4812is of “stepped” construction. The cartridge deck4812includes an inner or first cartridge deck portion4814that corresponds to the inner or first annular row4820of inner or first staple cavities4822. As can be further seen inFIG. 116, when the anvil4900is moved to the closed or clamping position, the portion of the anvil4900containing the first staple forming pockets4904is spaced from the deck portion4814a first gap distance g1.

Referring again toFIGS. 114, 116 and 117, the middle or second row4840contains a second plurality of middle or second staple cavities4842that are each arranged at a second angle. Each middle staple cavity4842operably supports a corresponding middle or second staple4850therein. The middle cavities4842orient the middle or second staples4850at the same uniform second angle relative to the tangential direction. However, the second angle differs from the first angle. Stated another way, when the first and second staples are supported in their respective first and second cavities, the axis of the first crown of each first staple4830, when extended, would ultimately intersect the extended axis of the second crown of an adjacent second staple4850. As can be seen inFIGS. 116 and 117, each second or middle staple4850comprises a second staple crown or base4852and two second legs4854. The staple base4852may have a somewhat rectangular cross-sectional shape and be formed from a flat sheet of material. The second staple legs4854may have a round cross-sectional profile, for example. The second or middle staples may comprise various staple configurations disclosed in, for example, U.S. patent application Ser. No. 14/836,110, filed Aug. 26, 2015, entitled SURGICAL STAPLING CONFIGURATIONS FOR CURVED AND CIRCULAR STAPLING INSTRUMENTS, which has been herein incorporated by reference in its entirety. Having round staple legs that extend from a staple base portion having the rectangular cross-sectional profile can provide a staple base portion and staple legs with no preferential bending planes. The second staple4850comprises bend portions4856where the staple legs4854extend from the staple base portion4852. The bend portions4856may comprise a substantially square cross-sectional profile. The square profile and the rectangular profile of the bend portions4856and the staple base portion4852, respectively, provide a stiff connection and backbone to the round staple legs4854. The round staple legs4854eliminate preferential bending planes that staple legs with a square, rectangular, or any shape with vertices or a non-uniform shape, cross-sections could have. Each of the second staple legs4854has a second diameter D2In at least one embodiment, D2>D1The second base or crown4852has a second crown width C2. In one arrangement, C2>C1The second legs4854may be each arranged at an angle A2relative to the second base or crown4852. The angle A2may be approximately 90° or it may be slightly greater than 90° such that the second legs4854are slightly splayed outward to assist in retaining the second staple4850in its corresponding second staple cavity4842.

Turning toFIGS. 115 and 116, the anvil4900further comprises two middle or second rows4912of staggered or angled second pairs4913of second staple forming pockets4914. Each second pair4913of second staple forming pockets4914correspond to one second staple4850. One second staple forming pocket4914corresponds to one second staple leg4854and the other second staple forming pocket4914of the pair4913corresponds to the other second staple leg4854. Such arrangement serves to establish a formed staple configuration wherein the second legs4854are formed out of plane with the second base4852of the particular second staple4850. This “three-dimensional” formed staple configuration is shown with respect to some of the second staple forming pockets4914inFIG. 115.

As can be most particularly seen inFIG. 116, the cartridge deck4812further comprises a second cartridge deck portion4816that corresponds to the middle or second annular row4840of middle or second staple cavities4842. As can be further seen inFIG. 116, when the anvil4900is moved to the closed or clamping position, the portion of the anvil4900containing the second staple forming pockets4914is spaced from the deck portion4816a second gap distance g2. In the illustrated example, g2>g1.

Referring again toFIGS. 114, 116 and 117, the outside or third row4860contains a third plurality of outside or third staple cavities4862that are sized relative to the second staple cavities4842such that each outer or third staple cavity4862spans a distance between two adjacent second cavities4842. Each outer staple cavity4862operably supports a corresponding outer or third staple4870therein. The outer cavities4862orient the outer or third staples4870tangent to the circumferential direction. As can be seen inFIGS. 116 and 117, each third or outer staple4870comprises a third staple crown or base4872and two third legs4874. The staple base4872may have a somewhat rectangular cross-sectional shape and be formed from a flat sheet of material. The third staple legs4874may have a round cross-sectional profile, for example. The third or outer staples4870may comprise various staple configurations disclosed in, for example, U.S. patent application Ser. No. 14/836,110, filed Aug. 26, 2015, entitled SURGICAL STAPLING CONFIGURATIONS FOR CURVED AND CIRCULAR STAPLING INSTRUMENTS, which has been herein incorporated by reference in its entirety. Having round staple legs that extend from a staple base portion having the rectangular cross-sectional profile can provide a staple base portion and staple legs with no preferential bending planes. The third staple4870comprises bend portions4876where the staple legs4874extend from the staple base portion4872. The bend portions4876may comprise a substantially square cross-sectional profile. The square profile and the rectangular profile of the bend portions4876and the staple base portion4872, respectively, provide a stiff connection and backbone to the round staple legs4874. The round staple legs4874eliminate preferential bending planes that staple legs with a square, rectangular, or any shape with vertices or a non-uniform shape, cross-sections could have. In at least one embodiment, D3>D2The third base or crown4872has a third crown width C3and each third leg4874has a third unformed leg length L3In one arrangement, C3>C2and L3>L2The third legs4874may be each arranged at an angle A3relative to the third base or crown4872. The angle A3may be approximately 90° or it may be slightly greater than 90° such that the third legs4874are slightly splayed outward to assist in retaining the third staple4870in its corresponding third staple cavity4862.

Turning toFIGS. 115 and 116, the anvil4900further comprises an outer row4916of outer or third staple forming pockets4918. Each third staple forming pocket4918corresponds to one third staple4870. As can be most particularly seen inFIG. 116, the cartridge deck4812further comprises a third cartridge deck portion4818that corresponds to the outer or third row4860of outer or third staple cavities4862. As can be further seen inFIG. 116, when the anvil4900is moved to the closed or clamping position, the portion of the anvil4900containing the third staple forming pockets4918is spaced from the deck portion4818a third gap distance g3. In the illustrated example, g3>g2. As can be further seen inFIG. 116, in at least one embodiment, a tissue thickness compensator4920is employed in connection with each outer or third staple4870. The tissue thickness compensator may comprise a woven material that is embedded with oxidized regenerated cellulose (ORC) to promote hemostasis. The tissue thickness compensator4920may comprise any of the various tissue thickness compensator arrangements disclosed in U.S. patent application Ser. No. 14/187,389, filed Feb. 24, 2014, entitled IMPLANTABLE LAYER ASSEMBLIES, U.S. Patent Application Publication No. 2015/0238187, the entire disclosure of which is hereby incorporated by reference herein. As can be seen inFIG. 116, the tissue thickness compensator4920has a thickness designated as “a”. In one embodiment, the tissue thickness compensator has a thickness of approximately 0.015″-0.045″. However, other thicknesses may be employed.

Thus, in at east one embodiment as depicted inFIGS. 114-117, the staple cartridge4810may employ a different number of staples in each of the three rows of staples. In one arrangement, the inner row of staples comprises conventional staples with the smallest wire diameter and the shortest unformed leg length. Each first staple has the shortest crown width and each first staple is oriented at a uniform angle relative to the tangential direction. The middle staples have a configuration that differs from the first staple configuration. Each leg of the middle staples comprises a moderate wire diameter and unformed leg length. Each middle staple has a slightly larger crown width than the crown widths of the inner staples and each middle staple is oriented at a uniform angle relative to the tangential direction, but at a different angle relative to the inner row of inner staples. Each outer staple has a configuration that is similar to the configuration of the middle staples. Each of the third legs of each outer staple comprises the largest wire diameter as compared to the wire diameters of the legs of the inner and middle staples. The crown width of each outer staple is significantly larger than the crown widths of the inner and middle staples. Each outer staple is oriented tangentially to the circumferential direction of the cartridge. The outer row of staples employs woven tissue thickness compensators (spacer fabric) that is embedded with ORC to promote hemostasis. The stepped anvil and the stepped cartridge deck yield different formed staple heights with the staples having the shortest formed heights being in the inner row and the staples having the longest formed heights being in the outer row. The anvil pockets corresponding to the inner and middle rows of staples are “tilted” to create three dimensional staples in the inner and middle rows. “Bathtub-type” anvil pockets correspond to the outer row of staples. In at least one embodiment, the staples may be sequentially fired. For example, the staples in the inner and middle rows may be fired first and the staples in the outer row fired thereafter. The annular knife cuts the clamped tissue during the firing process.

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

An anvil of a circular stapling instrument generally comprises a tissue compression surface and an annular array of staple forming pockets defined in the tissue compression surface. The anvil further comprises an attachment mount and a stem extending from the attachment mount. The stem is configured to be releasably attached to a closure drive of the circular stapling instrument so that the anvil can be moved toward and away from a staple cartridge of the circular stapling instrument.

The staple cartridge and the anvil can travel separately within a patient and are combined at the surgical field. In various instances, the staple cartridge, for example, travels through a narrow tubular body of the patient such as, for example, a colon. A staple cartridge may include several tissue-contacting features such as, for example, stepped decks and pocket extenders. To avoid unintentional injury to the patient as the staple cartridge travels toward a target tissue, the present disclosure, among other things, presents various modifications to several tissue-contacting features.

Referring toFIG. 118, a partial cross-sectional view depicts a staple cartridge15500of a circular surgical instrument pressing against tissue (T) as the staple cartridge15500travels within a patient's body. Multiple structural features of the staple cartridge15500are modified to create an especially contoured outer frame15502to protect the tissue. The staple cartridge15500includes a plurality of annular rows of staple cavities. In at least one example, an outer row15504of staple cavities15510at least partially surrounds an inner row15506of staple cavities15512, as illustrated inFIG. 118. The staple cavities15510and15512are configured to house staples15530and15531, respectively.

The terms inner and outer delineate a relationship with reference to a central axis15533. For example, an inner tissue-contacting surface15518is closer to the central axis15533than outer tissue-contacting surface15516.

As illustrated inFIG. 119, the staple cartridge15500comprises a stepped cartridge deck15508. The outer row15504is defined in an outer tissue-contacting surface15516of the stepped cartridge deck15508while the inner row15506is defined in an inner tissue-contacting surface15518of the stepped cartridge deck15508. The outer tissue-contacting surface15516is stepped down from the inner tissue-contacting surface15518which creates a gradient that reduces friction as the staple cartridge15500is pressed against the tissue.

In certain instances, the outer tissue-contacting surface15516is parallel, or at least substantially parallel, to the inner tissue-contacting surface15518. In other instances, the outer tissue-contacting surface15516is slanted such that a first plane defined by the outer tissue-contacting surface15516is transverse to a second plane defined by the inner tissue-contacting surface15518. An angle is defined between the first plane and the second plane. The angle can be an acute angle. In at least one instance, the angle can be any angle selected from a range of greater than about 0° and less than or equal to about 30°, for example. In at least one instance, the angle can be any angle selected from a range of greater than about 5° and less than or equal to about 25°, for example. In at least one instance, the angle can be any angle selected from a range of greater than about 10° and less than or equal to about 20°, for example. A slanted outer tissue-contacting surface15516can reduce friction against, or snagging of, tissue as the staple cartridge15500is moved relative to the tissue. In at least one instance, a slanted outer tissue-contacting surface15516is also stepped down from the inner tissue-contacting surface15518.

In at least one instance, an inner portion of the outer tissue-contacting surface15516is planar, or at least substantially planar while an outer edge15548of the outer tissue-contacting surface15516is pitched, radiused, and/or beveled to reduce friction against, or snagging of, tissue as the staple cartridge15500is moved relative to the tissue. The staple cavities15510reside in the planar inner portion of the outer tissue-contacting surface15516, for example. An outer edge15550of the inner tissue-contacting surface15518can also be pitched, beveled and/or radiused to reduce friction against, or snagging of, tissue as the staple cartridge15500is moved relative to the tissue.

To accommodate staples with the same, or at least substantially the same, unformed heights in the staple cavities15510of the outer row15504and the staple cavities15512of the inner row15504, the staple cavities15510of the outer row15504comprise pocket extenders15514. The pocket extenders15514are configured to control and guide the staples15530as they are ejected from their respective staple cavities15510. In certain instances, the pocket extenders15514can be configured to accommodate staples with a greater unformed height s that the staples of the inner tissue-contacting surface15518, for example.

As illustrated inFIG. 119, a staple cavity15510in the outer row15504is laterally aligned, or at least substantially aligned, with a gap15520between two adjacent staple cavities15512in the inner row15506. The staple cavity15510includes a first end15522and a second end15524. The second end15524overlaps with a first end15526of one of the two consecutive staple cavities15512such that a staple leg15530apositioned at the second end15524is radially aligned, or at least substantially aligned, with a staple leg15531apositioned at the first end15526, as illustrated inFIG. 118. Likewise, the first end15522of the staple cavity15510overlaps with a second end15528of the other one of the two consecutive staple cavities15512.

A pocket extender15514comprises a first jacket15532protruding from the outer tissue-contacting surface15516to conceal a tip15536of the staple leg15530athat extends beyond the outer tissue-contacting surface15516. The first jacket15532comprises an end15538protruding from the first end15522, an inner side wall15540and an outer side wall15542extending away from the end15538to form the first jacket15532. In at least one instance, the first jacket15532defines, or at least substantially defines, a “C” shaped wall extending on a portion of a perimeter15535of the staple cavity15510that comprises the first end15522.

To reduce friction against the tissue, the inner side wall15540protrudes from the outer tissue-contacting surface15516to a greater height than the outer side wall15542. Said another way, the outer side wall15542is lower in height than the inner side wall15540. This arrangement creates a gradient for a smooth transition from the inner side wall15540to the outer side wall15542to the outer tissue-contacting surface15516. In at least one example, the inner side wall15540and the inner tissue-contacting surface15518comprise the same, or at least substantially the same, height with reference to the outer tissue-contacting surface15516. Alternatively, the inner side wall15540and the inner tissue-contacting surface15518comprise different heights with reference to the outer tissue-contacting surface15516. In certain instances, the inner side wall15540is lower in height relative to the inner tissue-contacting surface15518with reference to the outer tissue-contacting surface15516. This arrangement creates a gradient for a smooth transition from the inner tissue-contacting surface15518to the inner side wall15540to the outer side wall15542to the outer tissue-contacting surface15516.

The inner tissue-contacting surface15518, the inner side wall15540, the outer side wall15542, and/or the outer tissue-contacting surface15516define discrete portions of the contoured outer frame15502; nonetheless, as illustrated inFIG. 118, such portions are kept sufficiently close to one another so that tissue cannot be trapped therebetween as the staple cartridge15500presses against the tissue. Furthermore, one or more of the portions may include slanted, contoured, curved, radiused, and/or beveled outer surfaces to reduce friction against the tissue. As illustrated inFIG. 118, an upper surface15544of the outer side wall15542and an upper surface15546of the inner side wall15540are slanted, contoured, curved, radiused, and/or beveled to define the contoured outer frame15502.

In at least one instance, the upper surface15544and the upper surface15546define a slanted plane that is transverse to a first plane defined by the outer tissue-contacting surface15516and a second plane defined by the inner tissue-contacting surface15518. In at least one instance, a first angle is defined between the slanted plane and the first plane. A second angle can also be defined between the slanted plane and the second plane. The first and second angles can be the same, or at least substantially the same in value. Alternatively, the first angle can be different from the second angle in value. In at least one instance, the first angle and/or the second angle are acute angles. In at least one instance, the first angle is any angle selected from a range of greater than about 0° and less than or equal to about 30°, for example. In at least one instance, the first angle is any angle selected from a range of greater than about 5° and less than or equal to about 25°, for example. In at least one instance, the first angle is any angle selected from a range of greater than about 10° and less than or equal to about 20°, for example. In at least one instance, the second angle is any angle selected from a range of greater than about 0° and less than or equal to about 30°, for example. In at least one instance, the second angle is any angle selected from a range of greater than about 5° and less than or equal to about 25°, for example. In at least one instance, the second angle is any angle selected from a range of greater than about 10° and less than or equal to about 20°, for example.

Further to the above, the pocket extender15514includes a second jacket15534that is similar in many respects to the first jacket15532. Like the first jacket15532, the second jacket15534protrudes from the outer tissue-contacting surface15516to conceal a tip of a staple leg that extends beyond the outer tissue-contacting surface15516. The second jacket15534comprises an end15538protruding from the second end15524, an inner side wall15540and an outer side wall15542extending from the end15538to form the second jacket15534.

Although one pocket extender15514is illustrated inFIG. 119, it is understood that one or more other pocket extenders15514may protrude from the outer tissue-contacting surface15516, for example. In at least one instance, the first jacket15532and the second jacket15534are connected via side walls to define a pocket extender that completely surrounds a staple cavity, for example.

Many of the surgical instrument systems described herein are motivated by an electric motor; however, the surgical instrument systems described herein can be motivated in any suitable manner. In various instances, the surgical instrument systems described herein can be motivated by a manually-operated trigger, for example. In certain instances, the motors disclosed herein may comprise a portion or portions of a robotically controlled system. Moreover, any of the end effectors and/or tool assemblies disclosed herein can be utilized with a robotic surgical instrument system.FIG. 82Aschematically depicts a robotic surgical instrument system20′; however, U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Patent Application Publication No. 2012/0298719, for example, discloses several examples of a robotic surgical instrument system in greater detail.

The surgical instrument systems described herein have been described in connection with the deployment and deformation of staples; however, the embodiments described herein are not so limited. Various embodiments are envisioned which deploy fasteners other than staples, such as clamps or tacks, for example. Moreover, various embodiments are envisioned which utilize any suitable means for sealing tissue. For instance, an end effector in accordance with various embodiments can comprise electrodes configured to heat and seal the tissue. Also, for instance, an end effector in accordance with certain embodiments can apply vibrational energy to seal the tissue.

The entire disclosures of:

European Patent Application No. EP 795298, entitled LINEAR STAPLER WITH IMPROVED FIRING STROKE, which was filed on Mar. 12, 1997;

U.S. Patent Application Publication No. 2005/0246881, entitled METHOD FOR MAKING A SURGICAL STAPLER, which published on Nov. 10, 2005;

U.S. Patent Application Publication No. 2007/0208359, entitled METHOD FOR STAPLING TISSUE, which published on Sep. 6, 2007;

U.S. Pat. No. 8,360,297, entitled SURGICAL CUTTING AND STAPLING INSTRUMENT WITH SELF ADJUSTING ANVIL, which issued on Jan. 29, 2013;

U.S. patent application Ser. No. 14/813,242, entitled SURGICAL INSTRUMENT COMPRISING SYSTEMS FOR ASSURING THE PROPER SEQUENTIAL OPERATION OF THE SURGICAL INSTRUMENT, which was filed on Jul. 30, 2015;

U.S. patent application Ser. No. 14/813,259, entitled SURGICAL INSTRUMENT COMPRISING SEPARATE TISSUE SECURING AND TISSUE CUTTING SYSTEMS, which was filed on Jul. 30, 2015;

U.S. patent application Ser. No. 14/813,266, entitled SURGICAL INSTRUMENT COMPRISING SYSTEMS FOR PERMITTING THE OPTIONAL TRANSECTION OF TISSUE, which was filed on Jul. 30, 2015;

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

U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which issued on Feb. 21, 2006;

U.S. Patent Application Publication No. 2007/0175955, entitled SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM, filed Jan. 31, 2006; and

Although various devices have been described herein in connection with certain embodiments, modifications and variations to those embodiments may be implemented. Also, where materials are disclosed for certain components, other materials may be used. Furthermore, according to various embodiments, a single component may be replaced by multiple components, and multiple components may be replaced by a single component, to perform a given function or functions. The foregoing description and following claims are intended to cover all such modification 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, a device can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps including, but not limited to, the disassembly of the device, followed by cleaning or replacement of particular pieces of the device, and subsequent reassembly of the device. In particular, a reconditioning facility and/or surgical team can disassemble a device and, after cleaning and/or replacing particular parts of the device, the device can be reassembled for subsequent use. Those skilled 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 device, are all within the scope of the present application.

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