Surgical device

A surgical device includes a first jaw and a second jaw disposed in opposed correspondence with the first jaw. The second jaw is mechanically coupled to the first jaw at a proximal end opposite a distal end. A cutting element is disposed within the second jaw, and a first driver is configured to move the cutting element proximally from the distal end toward the proximal end of the second jaw to cut a section of tissue disposed between the first and second jaws. The device may also include a stapling element disposed within the second jaw. The cutting element and the stapling element may be contiguous so as to define a cutting and stapling element, such as a wedge having a blade disposed thereon. As the wedge is moved proximally from the distal end of the second jaw to the proximal end, the wedge pushes a plurality of staples against a plurality of opposing staple guides disposed in the first jaw in order to staple a section of tissue while cutting the section of tissue.

CROSS-REFERENCE TO RELATED APPLICATIONS

FIELD OF THE INVENTION

The present invention relates to a surgical device. More specifically, the present invention relates to a linear clamping, cutting and stapling device for clamping, cutting and stapling tissue.

BACKGROUND INFORMATION

One type of surgical device is a linear clamping, cutting and stapling device. An example of such a device is shown and described in U.S. Pat. No. 6,264,087 issued on Jul. 24, 2001. Such a device may be employed in a surgical procedure to resect a cancerous or anomalous tissue from a gastro-intestinal tract.

With respect to the structural features of the conventional linear clamping, cutting and stapling instrument which is shown inFIG. 1, the device includes a pistol grip-styled structure having an elongated shaft and distal portion. The distal portion includes a pair of scissors-styled gripping elements, which clamp the open ends of the colon closed. In this device, one of the two scissors-styled gripping elements, the anvil portion, moves or pivots relative to overall structure, whereas the other gripping element remains fixed relative to the overall structure. The actuation of this scissoring device (the pivoting of the anvil portion) is controlled by a grip trigger maintained in the handle.

In addition to the scissoring device, the distal portion also includes a stapling mechanism. The fixed gripping element of the scissoring mechanism includes a staple cartridge receiving region and a mechanism for driving the staples up through the clamped end of the tissue, against the anvil portion, thereby sealing the previously opened end. The scissoring elements may be integrally formed with the shaft or may be detachable such that various scissoring and stapling elements may be interchangeable.

One problem with the foregoing surgical devices, and in particular with the foregoing linear clamping, cutting and stapling devices such as that illustrated in FIG.1, is the tendency of the opposing jaws of the clamping mechanism to be urged apart during the operation of cutting and stapling the tissue. Another problem with the foregoing surgical devices, and in particular with the foregoing linear clamping, cutting and stapling devices such as that illustrated inFIG. 1, is that the devices are difficult to maneuver. Because a linear clamping, cutting and stapling device may be employed corporeally, e.g., inside the body of a patient, the device must be small enough to be maneuvered inside the body of a patient. Conventional linear clamping, cutting and stapling devices such as that illustrated inFIG. 1have an overall length which increases the difficulty in maneuvering the device, especially inside the patient's body.

Still another problem with the foregoing surgical devices, and in particular with the foregoing linear clamping, cutting and stapling devices such as that illustrated inFIG. 1, is that the torque required to cut and staple a section of tissue is undesirably high, thereby causing stress in various components of the devices. For instance, in other linear clamping, cutting and stapling devices which move scissoring and stapling elements from the proximal end to the distal end, a high torque is required to move the scissoring and stapling elements when the scissoring and stapling elements are at the distal end. Thus, when the cutting and stapling element has traveled to the distal end of the jaws, the high torque causes stress in the scissoring and stapling elements, and driver mechanisms of the device.

SUMMARY OF THE INVENTION

The present invention, according to one example embodiment thereof, relates to a surgical device, which includes a first jaw and a second jaw disposed in opposed correspondence with the first jaw. The second jaw is mechanically coupled to the first jaw at a proximal end opposite a distal end. A cutting element, having a blade facing the proximal end, is disposed Within the second jaw, and a first driver is configured to move the cutting element from the distal end to the proximal end of the second jaw to thereby cut a section of tissue disposed between the first and second jaws.

According to an example embodiment, the device may include a stapling element disposed within the second jaw, wherein the cutting element and the stapling element are contiguous so as to define a single cutting and stapling element, such as a wedge having a blade disposed thereon. As the wedge is moved from the distal end of the second jaw to the proximal end, the wedge urges staples against opposing staple guides disposed in the first jaw in order to staple a section of tissue while the blade cuts the section of tissue.

By moving the cutting and stapling element from the distal end of the mechanism to the proximal end during the cutting and stapling operation, the example embodiment may reduce the tendency of the upper and lower jaws to separate during operation of the device. Specifically, by moving the cutting and stapling element from the distal end of the mechanism to the proximal end during the cutting and stapling operation, there may be a resulting reduction in the distance between the upper and lower jaws at their distal ends.

In addition, by moving the cutting and stapling element from the distal end of the mechanism to the proximal end during the cutting and stapling operation, the example embodiment may reduce the torque which is required during the cutting and stapling operation, thereby reducing the stress which is experienced by various components of the surgical device. By housing the cutting and stapling elements at the distal end of the mechanism, the example embodiment may also reduce the length of the surgical device relative to a conventional linear clamping, cutting and stapling device, thereby improving the device's maneuverability, especially when employed inside the body of a patient, and may enable the stroke (e.g., the distance which can be cut and stapled) to be lengthened so as to clamp, cut and staple a larger section of tissue than a conventional linear clamping, cutting and stapling device.

DETAILED DESCRIPTION

One example embodiment of a surgical device according to the present invention is illustrated inFIGS. 3 to 20. Referring toFIGS. 3 and 4, an example embodiment of the surgical device11, e.g., a linear clamping, cutting and stapling device, is illustrated. In this embodiment, a device11includes a parallel separating jaw system having a lower jaw50in opposite correspondence to an upper jaw80having a proximal end100.FIG. 3illustrates the device11in a closed position, in which the lower jaw50and the upper jaw80are in contact at both their proximal and distal ends.FIG. 4illustrates the device11in an open position, wherein the lower jaw50and the upper jaw80are separated. For the purposes of illustration only,FIGS. 3 to 20illustrate the opposing jaws50and80, which remain parallel relative to each other. In an alternative example embodiment, opposing jaws50and80may open and close in scissor-like fashion, wherein the proximal ends of opposing jaws50and80are mechanically connected by a hinge or other rotational element such that the upper jaw50is rotatably coupled to the lower jaw80.

FIG. 5is a side sectional view of the surgical device11in the closed position, corresponding to the view shown inFIG. 3.FIG. 6, on the other hand, is a side sectional view of the surgical device11in the open position, corresponding to the view shown inFIG. 4. Referring now to eitherFIG. 5orFIG. 6, the proximal end100of the upper jaw80includes a pair of threaded vertical bores90, through which extend a corresponding pair of vertical shafts130. Inner threads92of the vertical bores90match outer threads132of the vertical shafts130. The vertical shafts130engage a threaded upper horizontal shaft151at a distal end140of the upper horizontal shaft151. The outer threads152of the upper horizontal shaft151interlock with the outer threads132of the vertical shafts130. The upper horizontal shaft151includes an upper drive socket180at a proximal end170.

FIG. 5Ais another sectional view of the closed disposition of the surgical device11illustrated inFIGS. 3 and 4, according to an example embodiment of the present invention.FIG. 5Aillustrates the surgical device11coupled (removably or permanently) to an electro-mechanical surgical system510. The surgical device11includes a first driver261which is coupled to a first motor576of the system510by a first drive shaft532. As will be explained in more detail below, the first driver261, when engaged by the system510, operates to drive a cutting and stapling element within the lower jaw50. In addition, the surgical device11includes a second driver150, which is coupled to a second motor580of system510by a second drive shaft530. As will be explained in more detail below, second driver150, when engaged by system510, operates to open and close upper jaw80relative to lower jaw50.

Referring again toFIGS. 5 and 6, the surgical device11further includes a cutting element and a stapling element, which includes a wedge270, having a blade51disposed thereon. In an alternative example embodiment, the cutting and stapling elements may be separately disposed. In the example embodiment, the blade51includes a cutting edge51athat faces the proximal end170of the surgical device11. In the lower jaw50is disposed a tray220, which may be replaceable, housing one or more fasteners, e.g., staples230, and in the upper jaw80is disposed one or more staple guides240corresponding to the staples230. Each of the staples230includes a butt232protruding below the tray220and a pair of prongs234extending to the top of the tray220. The surgical device11further includes a wedge guide or channel250extending beneath the tray220. Within the channel250extends a threaded lower horizontal shaft260having outer threads262. Upon the lower horizontal shaft260travels the wedge270having a sloped top face280, a horizontal threaded bore290coaxial with the channel250, having inner threads292matching the outer threads262of the lower horizontal shaft260, and an upwardly extending blade member51. As previously mentioned, the blade member51includes a cutting edge51afacing the proximal end170of the surgical device11. The lower horizontal shaft260has at a proximal end300a second drive socket310.

In the example embodiment illustrated, the surgical device11also includes a first sensor electrode182electrically communicating via communication wires with a first contact pad187which electrically communicates with a second contact pad189via, e.g., direct contact. The second,contact pad189electrically communicates via the communication wires188awith a first contact node188. Similarly, the surgical device11further includes a second sensor electrode184electrically communicating via communication wires with a second contact node186(illustrated inFIG. 7). The contact nodes186,188electrically communicate with communication wires (not shown) in the electro-mechanical drive component510to form a sensor circuit, such that when the upper jaw80and the lower jaw50are clamped together, the sensor electrodes182,184are in contact, the sensor circuit is closed, and the operator is alerted via other circuit components (discussed in greater detail below) to the clamped position of the jaws50,80. The operator is therefore informed that it is safe and/or appropriate to begin a cutting and stapling process.

FIG. 7is a rear sectional view, taken along the line7-7, of the surgical device11illustrated inFIG. 5.FIG. 7illustrates second contact node186, as well as upper drive socket180for engaging a first drive shaft and lower drive socket310for engaging a second drive shaft.FIG. 7also illustrates data connector1272coupled to a data memory unit1174(illustrated inFIGS. 5 and 6), the purpose and operation of which are discussed in greater detail below.FIG. 8is a rear sectional view, taken along the line8-8, of the surgical device11illustrated inFIG. 5.FIG. 9is a rear sectional view, taken along the line9-9, of the surgical device11illustrated inFIG. 5.FIG. 10is a rear sectional view, taken along the line10-10, of the surgical device11illustrated inFIG. 5.

FIG. 11is a rear sectional view, taken along the line11-11, of the surgical device11illustrated in Figure.FIG. 12is a rear sectional view, taken along the line12-12, of the surgical device11illustrated inFIG. 6.FIG. 13is a rear view, taken along the line13-13, of the surgical device11illustrated inFIG. 6.FIG. 14is a rear view, taken along the line14-14, of the surgical device11illustrated inFIG. 6.

FIG. 15is a bottom view, taken along the line15-15, of the surgical device11illustrated inFIGS. 5 and 6.FIG. 16is a top sectional view, taken along the line16-16, of the surgical device11illustrated inFIGS. 5 and 6.FIG. 17is a deep top sectional view, taken along the line17-17, of the surgical device11illustrated inFIGS. 5 and 6.FIG. 18is a bottom sectional view, taken along the line18-18, of the surgical device11illustrated inFIGS. 5 and 6.FIG. 19is a top view, taken along the line19-19, of the surgical device11illustrated inFIGS. 5 and 6.FIG. 20is a side sectional view, taken along the line20-20, of the surgical device11illustrated inFIGS. 5 and 6.

Each of the example embodiments described above include a wedge270having a blade51fixedly disposed thereon. According to another example embodiment of the present invention, the surgical device11includes a blade which is moveably coupled or mounted to a wedge so that the blade may move between a first position and a second position relative to the wedge. According to one embodiment, a first position of the blade relative to the wedge may be in a retracted position, whereas a second position of the blade relative to the wedge may be in an operable position, e.g., wherein the cutting edge of the blade faces the proximal end of the lower jaw50of the surgical device11.

FIGS. 31 through 33illustrate an example embodiment, wherein the surgical device11includes a blade651rotatably coupled to a wedge670so as to rotate between a first and a second position. The operation of the surgical device11shown inFIGS. 31 through 33is discussed in greater detail below.FIGS. 31 through 33illustrate the wedge270located at the distal end of the lower jaw50. The blade651is rotatably mounted to the wedge270by a pivot member652. The blade651includes a cutting edge651athat is initially disposed in a retracted or down position, e.g., facing lower horizontal shaft260. The blade651also includes a tail region654having an actuating pin receiving face653which initially faces the proximal end170of the surgical device11. Located adjacent to actuating pin receiving face653is fixed actuating pin655, which according to the example embodiment illustrated, is fixedly attached to lower jaw50.

According to one example embodiment of the present invention, the surgical device11may be configured as an attachment to, or may be integral with, an electro-mechanical surgical system, such as electro-mechanical surgical system510. In another embodiment, the surgical device may be configured as an attachment to, or may integral with, a purely mechanical device driver system, such as that illustrated inFIG. 1.

FIG. 2is a perspective view of an example embodiment of an electro-mechanical surgical system510according to the present invention. Electro-mechanical surgical system510may include, for example, a remote power console512, which includes a housing514having a front panel515. Mounted on front panel515are a display device516and indicators518a,518b, which are more fully described hereinbelow. A flexible shaft520may extend from housing514and may be detachably secured thereto via a first coupling522. The distal end524of flexible shaft520may include a second coupling526adapted to detachably secure, e.g., the surgical device11described above, to the distal end524of flexible shaft520. It is noted, however, that the second coupling526may also be adapted to detachably secure a different surgical instrument or attachment. In another embodiment, the distal end524of the flexible shaft520may permanently secure or be integral with a surgical instrument.

Referring toFIG. 21, there is seen a side view, partially in section, of flexible shaft520. According to one embodiment, flexible shaft520includes a tubular sheath528, which may include a coating or other sealing arrangement to provide a fluid-tight seal between the interior channel540thereof and the environment. Sheath528may be formed of a tissue-compatible, sterilizable elastomeric material. The sheath528may also be formed of a material that is autoclavable. Disposed within the interior channel540of flexible shaft520, and extending along the entire length thereof, may be a second rotatable drive shaft530, a first rotatable drive shaft532, a first steering cable534, a second steering cable535, a third steering cable536, a fourth steering cable537and a data transfer cable538.FIG. 22is a cross-sectional view of flexible shaft520taken along the line22-22shown inFIG. 21and further illustrates the several cables530,532,534,535,536,537,538. Each distal end of the steering cables534,535,536,537is affixed to the distal end524of the flexible shaft520. Each of the several cables530,532,534,535,536,537,538may be contained within a respective sheath.

The second rotatable drive shaft530and the first rotatable drive shaft532may be configured, for example, as highly flexible drive shafts, such as, for example, braided or helical drive cables. It should be understood that such highly flexible drive cables have limited torque transmission characteristics and capabilities. It should also be understood that the surgical device11(or other attachments connected to the flexible shaft520) may require a higher torque input than the torque transmittable by the drive shafts530,532. The drive shafts530,532may thus be configured to transmit low torque but high speed, the high speed/low torque being converted to low speed/high torque by gearing arrangements disposed, for example, at the distal end and/or the proximal end of the drive flexible shaft520, in the surgical instrument or attachment and/or in the remote power console512. It should be appreciated that such gearing arrangement(s) may be provided at any suitable location along the power train between the motors disposed in the housing514and the attached surgical instrument or other attachment connected to the flexible shaft520. Such gearing arrangement(s) may include, for example, a spur gear arrangement, a planetary gear arrangement, a harmonic gear arrangement, cycloidal drive arrangement, an epicyclic gear arrangement, etc.

Referring now toFIG. 23, there is seen a rear end view of first coupling522. First coupling522includes a first connector544, a second connector548, a third connector552and a fourth connector556, each rotatably secured to first coupling522. Each of the connectors544,548,552,556includes a respective recess546,550,554,558. As shown inFIG. 23, each recess546,550,554,558may be hexagonally shaped. It should be appreciated, however, that the recesses546,550,554,558may have any shape and configuration to non-rotatably couple and rigidly attach the connectors544,548,552,556to respective drive shafts of the motor arrangement contained within the housing512, as more fully described below. It should be appreciated that complementary projections may be provided on respective drive shafts of the motor arrangement to thereby drive the drive elements of the flexible shaft520as described below. It should also be appreciated that the recesses may be provided on the drive shafts and complementary projections may be provided on the connectors544,548,552,556. Any other coupling arrangement configured to non-rotatably and releasably couple the connectors544,548,552,556and the drive shafts of the motor arrangement may be provided.

One of the connectors544,548,552,556is non-rotatably secured to the second drive shaft530, and another one of the connectors544,548,552,556is non-rotatably secured to the first drive shaft532. The remaining two of the connectors544,548,552,556engage with transmission elements configured to apply tensile forces on the steering cables534,535,536,537to thereby steer the distal end524of the flexible shaft520. The data transfer cable538is electrically and logically connected with data connector560. Data connector560includes, for example, electrical contacts562, corresponding to and equal in number to the number of individual wires contained in the data cable538. First coupling522includes a key structure542to properly orient the first coupling522to a mating and complementary coupling arrangement disposed on the housing512. Such key structure542may be provided on either one, or both, of the first coupling522and the mating and complementary coupling arrangement disposed on the housing512. First coupling522may include a quick-connect type connector, which may use, for example, a simple pushing motion to engage the first coupling522to the housing512. Seals may be provided in conjunction with any of the several connectors544,548,552,556,560to provide a fluid-tight seal between the interior of first coupling522and the environment.

Referring now toFIG. 24, there is seen a front end view of the second coupling526of flexible shaft520. In the example embodiment, the second coupling526includes a first connector566and a second connector568, each being rotatably secured to the second coupling526and each being non-rotatably secured to a distal end of a respective one of the first and second drive shafts532,530. A quick-connect type fitting564is provided on the second coupling526for detachably securing the device11thereto. The quick-connect type fitting564may be, for example, a rotary quick-connect type fitting, a bayonet type fitting, etc. A key structure574is provided on the second coupling526for properly aligning the device11to the second coupling526. The key structure or other arrangement for properly aligning the device11to the flexible shaft520may be provided on either one, or both, of the second coupling526and the device11. In addition, the quick-connect type fitting may be provided on the device11. A data connector570, having electrical contacts572, is also provided in the second coupling526. Like the data connector560of first coupling522, the data connector570of second coupling526includes contacts572electrically and logically connected to the respective wires of data transfer cable538and contacts562of data connector560. Seals may be provided in conjunction with the connectors566,568,570to provide a fluid-tight seal between the interior of second coupling526and the environment.

Disposed within housing514of the remote power console512are electro-mechanical driver elements configured to drive the drive shafts530,532and the steering cables534,535,536,537to thereby operate the electro-mechanical surgical system510and the linear clamping, cutting and stapling device11attached to the second coupling526. In the example embodiment illustrated schematically inFIG. 25, five electric motors576,580,584,590,596, each operating via a power source, may be disposed in the remote power console512. It should be appreciated, however, that any appropriate number of motors may be provided, and the motors may operate via battery power, line current, a DC power supply, an electronically controlled DC power supply, etc. It should also be appreciated that the motors may be connected to a DC power supply, which is in turn connected to line current and which supplies the operating current to the motors.

FIG. 25illustrates schematically one possible arrangement of motors. An output shaft578of a first motor576engages with the first connector544of the first coupling522when the first coupling522, and, therefore, flexible shaft520, is engaged with the housing514to thereby drive the second drive shaft530and first connector566of second coupling526. Similarly, an output shaft582of a second motor580engages the second connector548of first coupling522when first coupling522, and, therefore, flexible shaft520is engaged with the housing514to thereby drive the first drive shaft532and second connector568of second coupling526. An output shaft586of a third motor584engages the third connector552of the first coupling522when the first coupling522, and, therefore, flexible shaft520, is engaged with the housing514to thereby drive the first and second steering cables534,535via a first pulley arrangement588. An output shaft592of a fourth motor590engages the fourth connector556of the first coupling522when the first coupling522, and, therefore, flexible shaft520, is engaged with the housing514to thereby drive the third and fourth steering cables536,537via a second pulley arrangement594. The third and fourth motors584,590may be secured on a carriage1100, which is selectively movable via an output shaft598of a fifth motor596between a first position and a second position to selectively engage and disengage the third and fourth motors584,590with the respective pulley arrangement588,594to thereby permit the flexible shaft520to become taut and steerable or limp as necessary. It should be appreciated that other mechanical, electrical or electro-mechanical mechanisms may be used to selectively engage and disengage the steering mechanism. The motors may be arranged and configured as described, for example, in U.S. patent application Ser. No. 09/510,923, entitled “A Carriage Assembly for Controlling a Steering Wire Mechanism Within a Flexible Shaft,” which is hereby incorporated by reference herein as fully as if set forth in its entirety.

It should be appreciated, that any one or more of the motors576,580,584,590,596may be high-speed/low-torque motors or low-speed/high-torque motors. As indicated above, the second rotatable drive shaft530and the first rotatable drive shaft532may be configured to transmit high speed and low torque. Thus, the first motor576and the second motor580may be configured as high-speed/low-torque motors. Alternatively, the first motor576and the second motor580may be configured as low-speed/high-torque motors with a torque-reducing/speed-increasing gear arrangement disposed between the first motor576and the second motor580and a respective one of the second rotatable drive shaft530and the first rotatable drive shaft532. Such torque-reducing/speed-increasing gear arrangement may include, for example, a spur gear arrangement, a planetary gear arrangement, a harmonic gear arrangement, cycloidal drive arrangement, an epicyclic gear arrangement, etc. It should be appreciated that any such gear arrangement may be disposed within the remote power console512or in the proximal end of the flexible shaft520, such as, for example, in the first coupling522. It should be appreciated that the gear arrangement(s) are provided at the distal and/or proximal ends of the second rotatable drive shaft530and/or the first rotatable drive shaft532to prevent windup and breakage thereof.

Referring now toFIG. 26, there is seen a schematic view of the example electro-mechanical surgical system510. A controller1122is provided in the housing514of remote power console512and is configured to control all functions and operations of the electro-mechanical surgical system510and the linear clamping, cutting and stapling device11attached to the flexible shaft520. A memory unit1130is provided and may include memory devices, such as, a ROM component1132and/or a RAM component1134. ROM component1132is in electrical and logical communication with controller1122via line1136, and RAM component1134is in electrical and logical communication with controller1122via line1138. RAM component1134may include any type of random-access memory, such as, for example, a magnetic memory device, an optical memory device, a magneto-optical memory device, an electronic memory device, etc. Similarly, ROM component1132may include any type of read-only memory, such as, for example, a removable memory device, such as a PC-Card or PCMCIA-type device. It should be appreciated that ROM component1132and RAM component1134may be embodied as a single unit or may be separate units and that ROM component1132and/or RAM component1134may be provided in the form of a PC-Card or PCMCIA-type device.

Controller1122is further connected to front panel515of housing514and, more particularly, to display device516via line1154and indicators518a,518bvia respective lines1156,1158. Lines1116,1118,1124,1126,1128electrically and logically connect controller1122to first, second, third, fourth and fifth motors576,580,584,590,596, respectively. A wired remote control unit (“RCU”)1150is electrically and logically connected to controller1122via line1152. A wireless RCU1148is also provided and communicates via a wireless link1160with a receiving/sending unit1146connected via line1144to a transceiver1140. The transceiver1140is electrically and logically connected to controller1122via line1142. Wireless link1160may be, for example, an optical link, such as an infrared link, a radio link or any other form of wireless communication link.

A switch device1186, which may be, for example, an array of DIP switches, may be connected to controller1122via line1188. Switch device1186may be used, for example, to select one of a plurality of languages used in displaying messages and prompts on the display device516. The messages and prompts may relate to, for example, the operation and/or the status of the electro-mechanical surgical system510and/or to the surgical device11attached thereto.

According to the example embodiment of the present invention, a first encoder1106is provided within the second coupling526and is configured to output a signal in response to and in accordance with the rotation of the second drive shaft530. A second encoder1108is also provided within the second coupling526and is configured to output a signal in response to and in accordance with the rotation of the first drive shaft532. The signal output by each of the encoders1106,1108may represent the rotational position of the respective drive shaft530,532as well as the rotational direction thereof. Such encoders1106,1108may be, for example, Hall-effect devices, optical devices, etc. Although the encoders1106,1108are described as being disposed within the second coupling526, it should be appreciated that the encoders1106,1108may be provided at any location between the motor system and the linear clamping, cutting and stapling device. It should be appreciated that providing the encoders1106,1108within the second coupling526or at the distal end of the flexible shaft520provides for an accurate determination of the drive shaft rotation. If the encoders1106,1108are disposed at the proximal end of the flexible shaft520, windup of the first and second rotatable drive shafts532,530may result in measurement error.

FIG. 27is a schematic view of an encoder1106,1108, which includes a Hall-effect device. Mounted non-rotatably on drive shaft530,532is a magnet1240having a north pole1242and a south pole1244. The encoder1106,1108further includes a first sensor1246and second sensor1248, which are disposed approximately 90° apart relative to the longitudinal, or rotational, axis of drive shaft530,532. The output of the sensors1246,1248is persistent and changes its state as a function of a change of polarity of the magnetic field in the detection range of the sensor. Thus, based on the output signal from the encoders1106,1108, the angular position of the drive shaft530,532may be determined within one-quarter revolution and the direction of rotation of the drive shaft530,532may be determined. The output of each encoder1106,1108is transmitted via a respective line1110,1112of data transfer cable538to controller1122. The controller1122, by tracking the angular position and rotational direction of the drive shafts530,532based on the output signal from the encoders1106,1108, can thereby determine the position and/or state of the components of the linear clamping, cutting and stapling device connected to the electro-mechanical surgical system510. That is, by counting the revolutions of the drive shaft530,532, the controller1122can determine the position and/or state of the components of the linear clamping, cutting and stapling device connected to the electro-mechanical surgical system510.

For instance, the advancement distance of upper jaw80relative to lower jaw50, and of the wedge270are functions of, and ascertainable on the basis of, the rotation of the respective drive shaft530,532. By ascertaining an absolute position of the jaw80and the wedge270at a point in time, the relative displacement of the jaw80and wedge270, based on the output signal from the encoders1106,1108and the known pitches of the vertical drive shaft1132and lower horizontal shaft260, may be used to ascertain the absolute position of the jaw80and the wedge270at all times thereafter. The absolute position of the jaw80and the wedge270may be fixed and ascertained at the time that the surgical device11is first coupled to the flexible shaft520. Alternatively, the position of the jaw80and the wedge270relative to, for example, the lower jaw50may be determined based on the output signal from the encoders1106,1108.

The surgical device11may further include, according to one embodiment and as illustrated inFIG. 5, a data connector1272adapted by size and configuration to electrically and logically connect to connector570of second coupling526. In the example embodiment, data connector1272includes contacts equal in number to the number of leads572of connector570. Contained within the surgical device11is a memory unit1174electrically and logically connected with the data connector1272. Memory unit1174may be in the form of, for example, an EEPROM, EPROM, etc. and may be contained, for example, within the lower jaw50of the surgical device11.

FIG. 28schematically illustrates the memory unit1174. As seen inFIG. 28, data connector1272includes contacts1276, each electrically and logically connected to memory unit1174via a respective line1278. Memory unit1174is configured to store, for example, a serial number data1180, an attachment type identifier (ID) data1182and a usage data1184. Memory unit1174may additionally store other data. Both the serial number data1180and the ID data1182may be configured as read-only data. In the example embodiment, serial number data1180is data uniquely identifying the particular linear clamping, cutting and stapling device, whereas the ID data1182is data identifying the type of the attachment (when, for instance, other types of attachments may be employed by the device). The usage data1184represents usage of the particular attachment, such as, for example, the number of times the upper jaw80of the surgical device11has been opened and closed, or the number of times that the wedge270of the surgical device11has been advanced or fired.

It should be appreciated that the attachment attachable to the distal end524of the flexible shaft520, e.g., surgical device11, may be designed and configured to be used a single time or multiple times. The attachment may also be designed and configured to be used a predetermined number of times. Accordingly, the usage data1184may be used to determine whether the surgical device11has been used and whether the number of uses has exceeded the maximum number of permitted uses. As more fully described below, an attempt to use the attachment after the maximum number of permitted uses has been reached will generate an ERROR condition.

Referring again toFIG. 26, in accordance with the example embodiment of the present invention, the controller1122is configured to read the ID data1182from the memory unit1174of surgical device11when the surgical device11is initially connected to the flexible shaft520. The memory unit1174is electrically and logically connected to the controller1122via line1120of data transfer cable538. Based on the read ID data1182, the controller1122is configured to read or select from the memory unit1130, an operating program or algorithm corresponding to the type of surgical instrument or attachment connected to the flexible shaft520. The memory unit1130is configured to store the operating programs or algorithms for each available type of surgical instrument or attachment, the controller1122selecting and/or reading the operating program or algorithm from the memory unit1130in accordance with the ID data1182read from the memory unit1174of an attached surgical instrument or attachment. As indicated above, the memory unit1130may include a removable ROM component1132and/or RAM component1134. Thus, the operating programs or algorithms stored in the memory unit1130may be updated, added, deleted, improved or otherwise revised as necessary. The operating programs or algorithms stored in the memory unit1130may be customizable based on, for example, specialized needs of the user. A data entry device, such as, for example, a keyboard, a mouse, a pointing device, a touch screen, etc., may be connected to the memory unit1130via, for example, a data connector port, to facilitate the customization of the operating programs or algorithms. Alternatively or additionally, the operating programs or algorithms may be customized and preprogramed into the memory unit1130remotely from the electro-mechanical surgical system510. It should be appreciated that the serial number data1180and/or usage data1184may also be used to determine which of a plurality of operating programs or algorithms is read or selected from the memory unit1130. It should be appreciated that the operating program or algorithm may alternatively be stored in the memory unit1174of the surgical device11and transferred to the controller1122via the data transfer cable538. Once the appropriate operating program or algorithm is read or selected by, or transmitted to, the controller1122, the controller1122causes the operating program or algorithm to be executed in accordance with operations performed by the user via the wired RCU1150(described below) and/or the wireless RCU1148(described below). As indicated hereinabove, the controller1122is electrically and logically connected with the first, second, third, fourth and fifth motors576,580,584,590,596via respective lines1116,1118,1124,1126,1128and controls such motors576,580,584,590,596in accordance with the read, selected or transmitted operating program or algorithm via the respective lines1116,1118,1124,1126,1128.

Referring now toFIG. 29, there is seen a schematic view of wireless RCU1148. Wireless RCU1148includes a steering controller1300having a plurality of switches1302,1304,1306,1308arranged under a four-way rocker1310. The operation of switches1302,1304, via rocker1310, controls the operation of first and second steering cables534,535via third motor584. Similarly, the operation of switches1306,1308, via rocker1310, controls the operation of third and fourth steering cables536,537via fourth motor592. It should be appreciated that rocker1310and switches1302,1304,1306,1308are arranged so that the operation of switches1302,1304steers the flexible shaft520in the north-south direction and that the operation of switches1306,1308steers the flexible shaft520in the east-west direction. Reference herein to north, south, east and west is made to a relative coordinate system. Alternatively, a digital joystick, analog joystick, etc. may be provided in place of rocker1310and switches1302,1304,1306,1308. Potentiometers or any other type of actuator may also be used in place of switches1302,1304,1306,1308.

Wireless RCU1148further includes a steering engage/disengage switch1312, the operation of which controls the operation of fifth motor596to selectively engage and disengage the steering mechanism. Wireless RCU1148also includes a two-way rocker1314having first and second switches1316,1318operable thereby. The operation of these switches1316,1318controls certain functions of the electro-mechanical surgical system510and any surgical instrument or attachment, such as the surgical device11, attached to the flexible shaft520in accordance with the operating program or algorithm corresponding to the attached device11. For example, operation of the two-way rocker1314may control the opening and closing of the upper and lower jaws of the surgical device11. Wireless RCU1148is provided with yet another switch1320, the operation of which may further control the operation of the electro-mechanical surgical system510and the device attached to the flexible shaft520in accordance with the operating program or algorithm corresponding to the attached device. For example, operation of the switch1320may initiate the advancement, or firing sequence, of the wedge270of the surgical device11.

Wireless RCU1148includes a controller1322, which is electrically and logically connected with the switches1302,1304,1306,1308via line1324, with the switches1316,1318via line1326, with switch1312via line1328and with switch1320via line1330. Wireless RCU1148may include indicators518a′,518b′, corresponding to the indicators518a,518bof front panel515, and a display device516′, corresponding to the display device516of the front panel515. If provided, the indicators518a′,518b′ are electrically and logically connected to controller1322via respective lines1332,1334, and the display device516′ is electrically and logically connected to controller1322via line1336. Controller1322is electrically and logically connected to a transceiver1338via line1340, and transceiver1338is electrically and logically connected to a receiver/transmitter1342via line1344. A power supply, not shown, for example, a battery, may be provided in wireless RCU1148to power the same. Thus, the wireless RCU1148may be used to control the operation of the electro-mechanical surgical system510and the device11attached to the flexible shaft520via wireless link1160.

Wireless RCU1148may include a switch1346connected to controller1322via line1348. Operation of switch1346transmits a data signal to the transmitter/receiver1146via wireless link1160. The data signal includes identification data uniquely identifying the wireless RCU1148. This identification data is used by the controller1122to prevent unauthorized operation of the electro-mechanical surgical system510and to prevent interference with the operation of the electro-mechanical surgical system510by another wireless RCU. Each subsequent communication between the wireless RCU1148and the electro-mechanical device surgical510may include the identification data. Thus, the controller1122can discriminate between wireless RCUs and thereby allow only a single, identifiable wireless RCU1148to control the operation of the electro-mechanical surgical system510and the device11attached to the flexible shaft520.

Based on the positions of the components of the device attached to the flexible shaft520, as determined in accordance with the output signals from the encoders1106,1108, the controller1122may selectively enable or disable the functions of the electro-mechanical surgical system510as defined by the operating program or algorithm corresponding to the attached device. For example, for the surgical device11, the firing function controlled by the operation of the switch1320is disabled unless the space or gap between lower jaw50and upper jaw80is determined to be within an acceptable range. The space or gap between lower jaw50and upper jaw80is determined based on the output signal from the encoders1106,1108, as more fully described hereinabove. It should be appreciated that, in the example embodiment, the switch1320itself remains operable but the controller1122does not effect the corresponding function unless the space or gap is determined to be within the acceptable range.

Referring now toFIG. 30, there is seen a schematic view of a wired RCU1150. In the example embodiment, wired RCU1150includes substantially the same control elements as the wireless RCU1148and further description of such elements is omitted. Like elements are noted inFIG. 30with an accompanying prime. It should be appreciated that the functions of the electro-mechanical surgical system510and the device attached to the flexible shaft520(e.g., the surgical device11) may be controlled by the wired RCU1150and/or by the wireless RCU1148. In the event of a battery failure, for example, in the wireless RCU1148, the wired RCU1150may be used to control the functions of the electro-mechanical surgical system510and the device attached to the flexible shaft520.

As described hereinabove, the front panel515of housing514includes display device516and indicators518a,518b. The display device516may include an alpha-numeric display device, such as an LCD display device. Display device516may also include an audio output device, such as a speaker, a buzzer, etc. The display device516is operated and controlled by controller1122in accordance with the operating program or algorithm corresponding to the device attached to the flexible shaft520(e.g., the surgical device11). If no surgical instrument or attachment is so attached, a default operating program or algorithm may be read or selected by, or transmitted to, controller1122to thereby control the operation of the display device516as well as the other aspects and functions of the electro-mechanical surgical system510. If surgical device11is attached to flexible shaft520, display device516may display, for example, data indicative of the gap between lower jaw50and upper jaw80as determined in accordance with the output signal of encoders1106,1108, as more fully described hereinabove.

Similarly, the indicators518a,518bare operated and controlled by controller1122in accordance with the operating program or algorithm corresponding to the device11, attached to the flexible shaft520(e.g., the surgical device11). Indicator518aand/or indicator518bmay include an audio output device, such as a speaker, a buzzer, etc., and/or a visual indicator device, such as an LED, a lamp, a light, etc. If the surgical device11is attached to the flexible shaft520, indicator518amay indicate, for example, that the electro-mechanical surgical system510is in a power ON state, and indicator518bmay, for example, indicate whether the gap between lower jaw50and upper jaw80is determined to be within the acceptable range as more fully described hereinabove. It should be appreciated that although only two indicators518a,518bare described, any number of additional indicators may be provided as necessary. Additionally, it should be appreciated that although a single display device516is described, any number of additional display devices may be provided as necessary.

The display device516′ and indicators518a′,518b′ of wired RCU1150and the display device516″ and indicators518a″,518b″ of wireless RCU1148are similarly operated and controlled by respective controller1322,1322′ in accordance with the operating program or algorithm of the device attached to the flexible shaft520.

As previously mentioned, the surgical device11may be employed to clamp, cut and staple a section of tissue. The operation of the surgical device11will now be described in connection with the removal of a cancerous or anomalous section of tissue in a patient's bowel, which is, of course, merely one type of tissue and one type of surgery that may be performed using the surgical device11. Generally, in operation, after cancerous or anomalous tissue has ben located in the gastrointestinal tract, the patient's abdomen is initially opened to expose the bowel. Utilizing the remote actuation provided by the electro-mechanical surgical system510, the upper and lower jaws50,80of the surgical device11are driven into the open position. The tube of the bowel is then placed on a side adjacent to the cancerous tissue between the spread jaws. Again, by remote actuation, the second driver is caused to engage in reverse, and the upper jaw closes onto the bowel and the lower jaw. Once the bowel has been sufficiently clamped, the first driver is engaged, which causes the wedge to advance simultaneously from the distal end of the attachment to the proximal end thereof, thereby cutting and stapling the bowel. This step is then repeated on the other side of the cancerous tissue, thereby removing the section of bowel containing the cancerous tissue, which is stapled on either end to prevent spilling of bowel material into the open abdomen.

More specifically, according to the example embodiment of the present invention, the surgical device11is coupled to the attachment socket or coupling26of the electro-mechanical driver component510such that the upper drive socket180engages the corresponding flexible drive shaft530of the electro-mechanical driver component510and the second drive socket310engages the corresponding flexible drive shaft532of the electro-mechanical driver component510. Thus, rotation of the upper horizontal shaft151is effected by rotation of the upper drive socket180which is effected by rotation of the corresponding flexible drive shaft530of the electro-mechanical driver component510. Clockwise or counter-clockwise rotation is achieved depending on the direction of the motor580. Similarly, rotation of the lower horizontal shaft260is effected by rotation of the second drive socket310which is effected by rotation of the corresponding flexible drive shaft532of the electro-mechanical driver component510. Again, clockwise or counter-clockwise rotation is achieved depending on the direction of the motor576.

In order to clamp the exposed ends of the bowel, the upper motor580corresponding to the upper flexible drive shaft530is activated, which engages the upper drive socket180at the proximal end170of the upper horizontal shaft151, thereby causing the upper horizontal shaft151to turn in a first (e.g., clockwise) rotation. When the surgical device11is in an initial closed state as illustrated inFIG. 5, this first rotation of the upper horizontal shaft151causes the outer threads152of the upper horizontal shaft151to engage the outer threads132of the vertical shafts130, thereby causing the vertical shafts130to turn in a similar first (e.g., clockwise) rotation. This rotation of the vertical shafts130causes the outer threads132of the vertical shafts130to channel within the inner threads92of the vertical bores90, thereby causing the upper jaw80to rise in a continuous fashion (in the embodiment illustrated, in a parallel alignment with the fixed lower jaw50) and begin separating from the lower jaw50. Continuous operation of the motor in this manner eventually places the surgical device11in an open state, providing a space between the upper jaw80and the lower jaw50, as illustrated inFIG. 6.

Once the surgical device11is in this open state, the tray220of staples230may be accessible, and may be inspected to determine whether the staples230are ready for the procedure and/or replace the tray220with a more suitable tray220. In addition, the status of the surgical device11may be determined by the control system1122as described hereinabove. Once the tray220is determined to be ready and in place, a section of the colon is placed between the upper jaw80and lower jaw50. Thereafter, the upper motor580is reversed to effect a second (e.g., counter-clockwise) rotation of the upper horizontal shaft151, which in turn effects counter-clockwise rotation of the vertical shafts130, which in turn effects a lowering of the upper jaw80. Continuous operation of the upper motor580in this manner eventually returns the linear clamping and stapling device to a closed state, in which the distal end of the bowel is clamped between the upper jaw80and the lower jaw40.

The clamping of the distal end of the bowel is determined in accordance with the output sensors1246and1248or output electrodes182,184as described above. Circuit components in the electro-mechanical surgical system510may provide an alert to signal that it is safe and/or appropriate to begin the cutting and stapling procedure. To begin the stapling and cutting procedure, the lower motor576of the electro-mechanical driver component corresponding to the lower flexible drive shaft532is activated, which engages the lower drive socket310at the proximal end300of the lower horizontal shaft260, thereby causing the lower horizontal shaft260to turn in a first (e.g., counter-clockwise) rotation. When the stapling and cutting mechanism is in an initial loaded state, the wedge270and the blade51associated therewith are in the channel250at a position farthest from the proximal end300of the lower horizontal shaft260(i.e., at the distal end). The counter-clockwise rotation of the lower horizontal shaft260causes the outer threads262of the lower horizontal shaft260to engage the inner threads292of the horizontal threaded bore290of the wedge270, thereby causing the wedge270to travel through the channel250in a proximal direction toward the proximal end300of the lower horizontal shaft260. Continuous operation of the lower motor576in this manner will move the wedge270fully through the channel250. As the wedge270moves through proximally the channel, the blade51mounted to the top of the wedge cuts through the bowel, thereby transecting it. Simultaneously, the sloped top face280of the wedge270contacts the butts232of the staples230, thereby pushing the prongs234of the staples230through the tissue of the clamped distal end of bowel and against the staple guides240, which bends and closes the staples230. When the wedge270is moved proximally fully through the channel250, all of the staples230are pushed through the tray220and closed, thereby stapling closed the distal end of the bowel on both sides of the cut.

Thereafter, the upper motor580is again activated to effect a clockwise rotation of the upper horizontal shaft151, which in turn effects a clockwise rotation of the vertical shafts130, which in turn effects a raising of the upper jaw80. Continuous operation of the upper motor580in this manner eventually returns the surgical device11into the open state. Thereafter, the empty tray220is replaced with a full tray220and the same clamping, cutting and stapling procedure is performed on the proximal end of the bowel. It should be understood that prior to the secure clamping, cutting and stapling procedure, the blade51and the wedge270may be returned to the distal position by operation of the lower motor576. In order to accomplish this, the lower motor576is reversed to effect a clockwise rotation of the lower horizontal shaft260, which in turn moves the wedge270away from the proximal end300of the lower horizontal shaft260. Continuous operation of the lower motor576in this manner eventually returns the wedge270to its initial position at the distal end of the mechanism. Once the proximal end of the bowel is also clamped, cut and stapled, the attachment (i.e., the surgical device11) may be separated from the electro-mechanical driver component and discard the attachment.

As previously mentioned,FIGS. 31 to 33illustrate an alternative example embodiment, wherein the surgical device11includes a blade651rotatably coupled to a wedge670so as to rotate between a first and a second position. The steps performed in order to operate this alternative example embodiment of the surgical device11are substantially similar to the steps described above as performed in order to operate the example embodiment of the surgical device11illustrated inFIGS. 5 and 6. The operation of those additional features of the surgical device11of the alternative example embodiment illustrated inFIGS. 31 to 33will now be described. Referring toFIG. 31, and as previously discussed, the wedge270is illustrated as being located at the distal end of the lower jaw50after the clamping operation has been performed but before the cutting and stapling operation has begun. The blade651is rotatably mounted to the wedge270by pivot member652. The cutting edge651aof the blade651is initially disposed in a retracted or down position, e.g., facing lower horizontal shaft260. The tail region654of the blade651is disposed above the wedge270, so that the actuating pin receiving face653initially faces the proximal end170of the surgical device11and is adjacent to fixed actuating pin655of lower jaw50.

FIG. 32illustrates the surgical device11in which the cutting and stapling operation has begun, e.g., by rotating horizontal shaft260so as to begin moving the wedge270from the distal end of the lower jaw50toward the proximal end of the lower jaw50. As illustrated inFIG. 32, the actuating pin receiving face653located at the tail region654of blade651engages fixed actuating pin655, causing the blade651to rotate relative to the wedge270around pivot member652. By rotating relative to the wedge270around pivot member652, the cutting edge651aof the blade651is displaced from its initial position facing the lower horizontal shaft260and begins to swing upwardly.

FIG. 33illustrates the surgical device11in which the cutting and stapling operation has continued further, e.g., by further rotating horizontal shaft260so as to continue to move the wedge270from the distal end of the lower jaw50toward the proximal end of the lower jaw50. As illustrated inFIG. 33, the wedge270has moved proximally far enough toward the proximal end of the lower jaw50so as to cause actuating pin receiving face653at the tail region654of blade651to complete its engagement with fixed actuating pin655. At this point, the blade651is rotated relative to the wedge270around pivot member652such that the cutting edge651aof the blade651faces the proximal end of the lower jaw50.

As previously mentioned, one problem of conventional cutting and stapling devices is that the opposing jaws of the mechanism tend to open, or be urged apart, during operation. This follows because the force exerted by the sloped top face280of wedge270has an upward component when sloped face280contacts the butt232of the staples230in the staple tray220and urges the prongs234of the staples230into the opposing staple guides240. As prongs234contact guides240, the force of the contact tends to separate, or urge apart, the upper and lower jaws until the prongs234of the staples are bent by guides240into a closed position. If the upper and lower jaws separate by a sufficient distance, the prongs234will not be sufficiently bent by guides240into the closed position, and the inadequately stapled end of the tissue may permit its contents to spill into the open abdomen of the patient, increasing the likelihood of infection and other complications.

In accordance with the example embodiment of the present invention, movement of the cutting and stapling element, e.g., the wedge270and blade51, from the distal end of the surgical device11to the proximal end during the cutting and stapling operation may reduce the tendency of the upper and lower jaws to separate, or to be urged apart, during the cutting and stapling operation. Specifically, by moving the cutting and stapling element, e.g., the wedge270and the blade51, from the distal end of the surgical device11to the proximal end during the cutting and stapling operation, there may be a resulting reduction in the distance between the upper and lower jaws at its distal end. For instance, in linear clamping, cutting and stapling devices in which a wedge/blade is moved from the proximal end to the distal end during the stapling and cutting operation, the first staple encountered by the wedge is the staple that is located closest to the proximal end. When the wedge contacts the butt of this first staple, the wedge forces the prongs of the staple into contact with the opposing staple guide in the upper jaw. Until the prongs have been bent and closed, this contact between the prongs of the staple and the opposing staple guide causes the distance between the upper and lower jaws, at the proximal end thereof, to increase by a small amount. However, because the upper and lower jaws are mechanically, e.g., pivotably, connected at the proximal end but are free at the distal end, the small increase in the distance between the upper and lower jaws at the proximal end translates into a relatively large increase in the distance between the upper and lower jaws at the distal end. Simultaneously, while the blade is cutting the tissue clamped between the upper and lower jaws, the distal movement of the blade also tends to push the tissue clamped between the upper and lower jaws toward the distal end of the jaws. Because the jaws have been forced apart at their distal end, a greater amount (i.e., thickness) of tissue may be accommodated at the distal end of the jaws, and the pushing action of the blade against the tissue tends to push, the greater amount of tissue into the space at the distal end of the jaws. Once the additional tissue is accommodated between the distal ends of the upper and lower jaws, the tissue further acts to force the distal ends of the jaws apart. Thus, when the cutting and stapling element has traveled to the distal end of the jaws, the distance between the jaws at the distal end may be undesirably large, and effective stapling of the tissue between the distal ends of the jaws may be less than optimal.

By contrast, in accordance with the example embodiment of the present invention, the first staple230encountered by the wedge270is the staple which is located closest to the distal end of the lower jaw50. When the wedge270contacts the butt232of this first staple, the wedge270forces the prongs234of the staple230into contact with the opposing staple guide240in the upper jaw80. This contact between the prongs234of the staple230and the opposing staple guide240may cause the distance between the upper jaw80and the lower jaw50at the distal ends thereof, to increase by a small amount, because the upper jaw80and lower jaw50are free at their distal end. However, because the upper jaw80and lower jaw50are mechanically connected at their proximal ends, the small increase in the distance between the upper jaw80and lower jaw50at their distal end does not translate into a corresponding large increase in the distance between the upper jaw80and lower jaw50at their proximal ends. Furthermore, in the example embodiment of the present invention, while the blade51is cutting the tissue clamped between the upper jaw50and lower jaw80, the horizontal movement of the blade51tends to push the tissue clamped between the upper jaw80and lower jaw50towards the proximal end of the jaws. However, because the upper jaw80and lower jaw50have not been forced apart at their proximal ends, a greater amount (i.e., thickness) of tissue may not be accommodated at the proximal ends of the jaws, and the cutting force of the blade51against the tissue may not tend to push a greater amount of tissue into the space at the proximal end of the jaws. Thus, since no additional tissue may be accommodated between the proximal ends of the upper jaw80and the lower jaw50, the tissue may not further act to force the proximal ends of the jaws apart. Thus, by the time the cutting and stapling element, e.g., the blade51and the wedge270, has traveled to the proximal end of the lower jaw50, the distance between the lower jaw50and the upper jaw80at the proximal end may remain substantially unchanged, thereby insuring optimal effectiveness for stapling of the tissue between the proximal ends of the lower and upper jaws50,80. Also, when the wedge270eventually contacts the staples230at the proximal end of the jaws50,80, the distance between the upper and lower jaws50,80, at their proximal end may increase by a small amount. However, since the tissue located at the distal end has already been cut and stapled, any larger distance between the upper jaw80and the lower jaw50at the distal end at this time is irrelevant. Thus, the present invention insures optimal effectiveness of stapling by reducing the tendency of the upper and lower jaws to separate during operation.

The example embodiment of the present invention may also reduce the torque which is required to move the wedge270and may therefore reduce the stress which is experienced by various components of the surgical device. For instance, in linear clamping, cutting and stapling devices, which move a wedge/blade from the proximal end to the distal end, the torque that is required to move the wedge/blade increases as the wedge/blade moves from the proximal end to the distal end, because the distance between the wedge/blade and the proximal end of the device (the point at which the rotatable drive shaft is coupled to the device) increases. In addition, the torque that is required to move the wedge/blade also increases as the wedge/blade moves from the proximal end to the distal end, because of the additional tissue accommodated at the distal end of the device. As discussed above, while the blade is cutting the tissue clamped between the upper and lower jaws, the distal movement of the blade also tends to push the tissue clamped between the upper and lower jaws towards the distal end of the jaws. In order to cut through the greater amount (i.e., thickness) of tissue accommodated at the distal end of the jaws, a greater amount of torque is required to be imparted by the horizontal drive shaft to the wedge/blade. Thus, when the cutting and stapling element has traveled to the distal end of the jaws, the torque has increased, thereby causing stress in the wedge/blade, and drive mechanisms of the device.

In contrast, in accordance with the example embodiment of the present invention, there may be a reduction in the torque that is required to move the wedge270during the cutting and stapling operation, thereby reducing the stress that is experienced by various components of the surgical device11. For instance, in surgical device11, which moves the wedge270and blade51from the distal end to the proximal end of the lower jaw50, the torque that is required to move the wedge270and the blade51decreases as the wedge270and the blade51move from the distal end to the proximal end of lower jaw50because the distance between the wedge/blade and the proximal end of the device (the point at which the rotatable drive shaft is coupled to the device) decreases. In addition, the torque that is required to move the wedge/blade also decreases as the wedge/blade moves from the distal end of lower jaw50to the distal end, because there is no additional tissue accommodated at the proximal end of the jaws50and80. Unlike conventional linear clamping, cutting and stapling devices, while the blade51of the surgical device11is cutting the tissue clamped between the upper jaw80and the lower jaw50, the proximal movement of the blade51does not tend to push the tissue clamped between the upper jaw80and the lower jaw50toward the proximal end of the jaws. Thus, since the blade51is not required to cut through a greater amount (i.e., thickness) of tissue accommodated at the proximal end of the jaws, a greater amount of torque is not required to be imparted by the lower horizontal shaft260to the wedge270and the blade51in order to cut the tissue. When the wedge270and the blade51have traveled to the proximal end of the lower jaw50, the torque has decreased, thereby reducing the stress in the wedge270, blade51, first driver261, etc.

The example embodiment of the present invention may also reduce the length of a linear clamping, cutting and stapling device, thereby improving the device's ability to be employed in small spaces. Because a linear clamping, cutting and stapling device may be intended to be employed corporeally, e.g., inside the body of a patient, the device must be small enough to be maneuvered inside the body of the patient. In conventional linear clamping, cutting and stapling devices, which move a wedge/blade from the proximal end to the distal end, the space that is required in order to house the wedge/blade at the proximal end of the device increases the overall length of the device. This increase in the length of the device makes the device more difficult to maneuver inside the patient's body.

In contrast, in accordance with the example embodiment of the present invention, the surgical device11initially houses wedge270and blade51at the distal end of lower jaw50, which is unencumbered by the memory unit1174, vertical drive shafts130, and various other components that are located at the proximal end of surgical device11. Thus, by initially disposing the wedge270and the blade51at the distal end of lower jaw50, and by moving the wedge270and the blade51from the distal end of lower jaw50to the proximal end, the overall length of surgical device11relative to conventional linear clamping, cutting and stapling devices may be reduced. This decrease in overall length makes the surgical device11easier to maneuver inside the patient's body, as compared to conventional linear clamping, cutting and stapling devices.

By decreasing the required overall length of surgical device11relative to conventional linear clamping, cutting and stapling devices, according to an example embodiment, the surgical device11may also provide a corresponding increase (approximately 30%) in the length of its stroke, e.g., the distance which the wedge270and the blade51may travel during the cutting and stapling operation, as compared to conventional linear clamping, cutting and stapling devices. For instance, since the overall length of surgical device11may be reduced (relative to the overall length of conventional linear clamping, cutting and stapling devices) due to the space saved by initially positioning the wedge270and the blade51at the distal end, the saved space may also increase the stroke length of the surgical device11. Thus, the surgical device11may be configured, according to one example embodiment, to clamp, cut and staple larger sections of tissue than conventional linear clamping, cutting and stapling devices.

The example embodiment illustrated inFIGS. 31 to 33may also improve the safety of the surgical device11in that the cutting edge651aof the blade651is retracted, e.g., not exposed, when the wedge270is in an initial position at the distal end of lower jaw50. Specifically, according to this example embodiment, during the stage of the operation when the section of tissue to be clamped, cut and stapled is placed and clamped between upper jaw80and lower jaw50of the surgical device11, the cutting edge651aof the blade651is retracted. By retracting the cutting edge651aof the blade651during this positioning and clamping stage of the operation, the likelihood that the section of tissue will be inadvertently cut before the section of tissue is adequately clamped may be decreased. Furthermore, accidental cutting by blade651of, for example, an operator or other equipment, may be reduced by the arrangement of the retracted blade651. According to the example embodiment, only after the section of tissue has been clamped (and it has been determined that it is appropriate to start the cutting and clamping stage of the operation) is the wedge270moved toward the proximal end of the lower jaw50, thereby causing the cutting edge651aof the blade651to be disposed in a cutting position, e.g., facing the proximal end of lower jaw50.

Thus, the several aforementioned objects and advantages of the present invention are most effectively attained. Those skilled in the art will appreciate that numerous modifications of the exemplary embodiment described hereinabove may be made without departing from the spirit and scope of the invention. Although a single exemplary embodiment of the present invention has been described and disclosed in detail herein, it should be understood that this invention is in no sense limited thereby.