Patent ID: 12193666

DETAILED DESCRIPTION

The disclosed surgical stapling device will now be described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. However, it is to be understood that disclosed aspects of the surgical stapling device are merely exemplary of the disclosure and may be embodied in various forms. Well-known functions or constructions are not described in detail to avoid obscuring the disclosure in unnecessary detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the disclosure in virtually any appropriately detailed structure.

In this description, the term “proximal” is used generally to refer to that portion of the device that is closer to a clinician during use of the device in its customary fashion, while the term “distal” is used generally to refer to that portion of the device that is farther from the clinician during use of the device in its customary fashion. In addition, directional terms such as front, rear, upper, lower, top, bottom, and similar terms are used to assist in understanding the description and are not intended to limit the disclosure. Further, the term “clinician” is used generally to refer to medical personnel including doctors, nurses, surgeons, and support personnel.

The disclosure is directed to a surgical stapling device that includes a tool assembly having a drive assembly, an anvil, and a cartridge assembly. The cartridge assembly includes a replaceable staple cartridge that includes an actuation sled assembly having an actuation sled, a knife bar, and a retractor link. The retractor link is secured to the knife bar such that the actuation sled assembly is movable through a cartridge body of the staple cartridge. The retractor link is movable from a non-deformed condition disengaged from the drive assembly to a deformed condition engaged with the drive assembly to facilitate retraction of the actuation sled assembly after the stapling device is fired.

FIG.1illustrates a surgical stapling device shown generally as stapling device10that includes a handle assembly12, an adapter assembly14, and a tool assembly16. The handle assembly12is powered and includes a stationary handgrip18and actuation buttons20. The actuation buttons20are operable to actuate various functions of the tool assembly16via the adapter assembly14, i.e., approximation of the tool assembly16, and firing of the tool assembly16. In certain aspects of the disclosure, the handle assembly12includes a motor (not shown) batteries (not shown), and circuitry that couples the batteries to the motor to operate the stapling device10. Although the stapling device10is illustrated as a powered stapling device, it is envisioned that the advantages of this disclosure are suitable for use with manually powered surgical stapling devices as well as robotically controlled stapling devices. U.S. Pat. No. 5,865,361 describes a stapling device that includes exemplary aspects of a manually powered stapling device.

The adapter assembly14defines a longitudinal axis “X” and includes a proximal portion14aand a distal portion14b. The proximal portion14aof the adapter assembly14is coupled to the handle assembly12, and the distal portion14bof the adapter assembly14is coupled to the tool assembly16.

FIGS.2and3illustrate the tool assembly16which includes an anvil32and a cartridge assembly34. In aspects of the disclosure, the cartridge assembly34is pivotably supported in relation to the anvil32and the adapter assembly14such that the tool assembly16is movable between an open position (FIG.2) and a clamped position (FIG.11). Alternately, it is envisioned that the anvil32may be pivotably supported in relation to the cartridge assembly34and the adapter assembly14.

FIGS.2-5illustrate the cartridge assembly34which includes a channel member40and a staple cartridge42. The channel member40includes side walls44and a bottom wall46that define a cavity48. The staple cartridge42is removably received within the cavity48of the channel member38and is replaceable to facilitate reuse of the stapling device10. Each of the side walls44defines a recess49(FIG.3) on an upper edge of the side wall44.

FIG.4illustrates the staple cartridge42which includes a cartridge body50that defines a knife slot52and staple receiving pockets54positioned on each side of the knife slot52. In aspects of the disclosure, the knife slot is centrally located along a longitudinal axis of the cartridge body50. In aspects of the disclosure, the staple receiving pockets54are aligned in two or more rows on opposite sides of the knife slot52. The cartridge body50includes laterally extending protrusions56that are received within the recesses49(FIG.3) of the channel member40(FIG.3) to properly position the staple cartridge40within the cavity46of the channel member38. The cartridge body50also includes knife guards58that are positioned on opposite sides of the knife slot52at a proximal portion of the cartridge body50.

The staple cartridge42includes staples60, pushers62, a staple guard64, and an actuation sled assembly66. The staples60are supported on the pushers62and received within the staple receiving pockets54of the cartridge body50. The staple guard64is U-shaped and is secured to the bottom of the cartridge body50to retain the staples60and pushers62within the cartridge body50. In aspects of the disclosure, the staple guard64includes resilient fingers70that are received in snap-fit fashion in recesses72in the cartridge body50to secure a proximal portion of the staple guard64to the cartridge body50. The staple guard64may also include openings74that receive protrusions75on the cartridge body50to retain the staple guard64on the cartridge body50.

FIGS.5-12illustrate the actuation sled assembly66which includes an actuation sled76, a knife bar78, and a retractor link80. The actuation sled assembly66is received in the cartridge body50of the staple cartridge42and is movable within the cartridge body50between sled retracted and sled advanced positions. The actuation sled76includes a central portion82and spaced wedge members84that are positioned on opposite sides of the central portion82. The wedge members84are configured to engage and lift the pushers62as the actuation sled assembly66is moved from the sled retracted position to the sled advanced position to eject the staples60from staple receiving pockets54of the cartridge body50. The central portion82of the actuation sled76is received in the knife slot52of the cartridge body50and is movable through the knife slot52to limit the actuation sled assembly66to linear movement.

The knife bar78is fixedly secured to the central portion82of the actuation sled76and includes a body portion85, a base portion86, and knife88. The body portion85of the knife bar78is received in and movable through the knife slot52. The knife88is supported on an upper surface of the body portion85and includes a distally facing cutting edge88a. The cutting edge88aextends upwardly from the body portion85to a position above a tissue engaging surface50aof the cartridge body50and is shielded by the knife guards58(FIG.4). The knife guards58may be integrally formed with the cartridge body50or secured thereto. The base portion86extends downwardly from the body portion85and is secured to the central portion82of the actuation sled76. In aspects of the disclosure, the base portion86defines two openings90that receive portions of the central portion82of the actuation sled76. In certain aspects of the disclosure, the actuation sled76is formed of plastic and the knife bar78is formed from metal, and the actuation sled76is molded about the base portion86of the knife bar78.

The retractor link80is secured to the body portion85of the knife bar78in cantilevered fashion. In aspects of the disclosure, the retractor link80is formed of a resilient material, e.g., spring steel, and includes a distal portion80aand a proximal portion80b. The proximal portion80bof the retractor link80includes an engaging member which may be in the form of an inwardly extending protrusion94. The distal portion80adefines a longitudinal axis and is secured to the central portion82of the knife bar78, and the proximal portion80bextends proximally from the actuation sled76. In aspects of the disclosure, the body portion85of the knife bar78defines a longitudinally extending recess92(FIG.6A), and the distal portion80aof the retractor link80is secured within the recess92. The retractor link80is movable between a non-deformed condition and a deformed condition. In the non-deformed condition, the proximal portion of the retractor link80bends outwardly from the longitudinal axis defined by the distal portion80of the retractor link80and outwardly of the knife slot52of the cartridge body50. When the actuation sled assembly66is advanced through the knife slot52, the proximal portion80bof the retractor link80engages an inner wall of the cartridge body50defining the knife slot52and is moved to the deformed condition in which the distal and proximal portions80a,80bof the retractor link80are longitudinally aligned. The actuation sled76of the actuation sled assembly66includes a proximal portion that defines a centrally located cutout96(FIG.6B).

The stapling device10includes a drive assembly98illustrated inFIG.13which includes a working member100and a flexible drive beam102. The working member100of the drive assembly98is partly received in the cutout96of the actuation sled76when the drive assembly98is in a clamped position and the actuation sled assembly66is in a retracted position. The drive assembly98is movable from a retracted position, through a drive assembly clamped position, to advanced position and includes a flexible drive beam102that has a proximal portion (not shown) and a distal portion106that is secured to the working member100. In aspects of the disclosure, the flexible drive beam102is formed from stacked laminates. Alternately, other configurations of the flexible drive beam102are envisioned. When the drive assembly98is moved from the retracted position to the drive assembly clamped position, the working member100moves independently of the actuation sled assembly66to move the tool assembly16(FIG.1) from the unclamped position to the clamped position.

The working member100of the drive assembly98has an I-shaped configuration and includes a first beam108, a second beam110, and a vertical strut112that connects the first beam108to the second beam110. The vertical strut112is aligned with the knife slot52(FIG.16) in the cartridge body50and is positioned to engage the actuation sled assembly66. When the drive assembly98moves from the retracted position to the clamped position in the direction of arrow “A” inFIG.11, the first and second beams108,110engage the anvil32and the cartridge assembly34to pivot the cartridge assembly34in the direction of arrow “B” inFIG.11. In the clamped position of the drive assembly98, the working member100of the drive assembly98is received in the cutout96of the actuation sled76of the actuation sled assembly66and is in close approximation or abutting relation to the actuation sled assembly66. When the drive assembly98is moved from the clamped position towards the advanced position, the vertical strut112of the working member100of the drive assembly98engages and advances the actuation sled assembly66through the knife slot52to move the actuation sled assembly66between the sled retracted and advanced positions.

The vertical strut112of the working member100of the drive assembly98defines a recess or opening114. When the actuation sled assembly66is moved by the drive assembly98from the sled retracted position towards the sled advanced position, the retractor link80of the actuation sled assembly66moves with the actuation sled assembly66into the knife slot52of the cartridge body50. As the proximal portion80bof the retractor link80moves into the knife slot52of the cartridge body50, engagement of the proximal portion80bof the retractor link80with the cartridge body50moves the retractor link80from the undeformed condition to the deformed condition. When this occurs, the protrusion94of the retractor link80is received in the recess or opening114formed in the vertical strut112to secure the actuation sled assembly66to the working member100of the drive assembly98.

FIGS.13-15illustrate the tool assembly16with the drive assembly98in the drive assembly clamped position and the actuation sled assembly66in the sled retracted position. Although not described in detail herein, the cartridge assembly34includes a lockout member120that prevents refiring of the tool assembly16with a spent staple cartridge. The lockout member120does not form part of this disclosure and will not be described in further detail herein. When the drive assembly98is in the clamped position, and the actuation sled assembly66is in the sled retracted position, the retractor link80is in its non-deformed condition in which the proximal portion80bof the retractor link80is bent outwardly of the knife slot52of the cartridge body50. To accommodate the proximal portion80bof the retractor link80when the retractor link80is in the non-deformed condition, the cartridge body50defines a pocket122(FIG.14) that includes a curved wall122athat has a curvature that corresponds to the curvature of the proximal portion80bof the retractor link80in the non-deformed condition.

FIG.16illustrates the tool assembly16as the drive assembly98is moved from the clamped position towards the advanced position to move the actuation sled assembly66from the sled retracted position (FIG.14) towards the sled advanced position. When the drive assembly moves in the direction of arrow “C” from the drive assembly clamped position towards the advanced position, the working member100of the drive assembly98moves the actuation sled assembly66in the direction of arrow “D”. As the proximal portion80bof the retractor link80moves into the knife slot52of the cartridge body50, the proximal portion80bof the retractor link80engages the curved wall122aof the cartridge body50and is moved from the undeformed condition to the deformed condition in the direction of arrow “E”. As the retractor link80moves to the deformed condition, the protrusion94of the retractor link80is received within the recess114formed in the vertical strut112of the working member100to couple the actuation sled assembly66to the working member100of the drive assembly98. As the drive member98moves towards the advanced position to move the actuation sled assembly66towards the sled advanced position, the spaced wedge members84(FIG.13) of the actuation sled76engage the pushers62(FIG.4) of the staple cartridge42to eject the staples60from the staple receiving slots54of the cartridge body50into the anvil32.

FIGS.17and18illustrate the tool assembly16as the drive assembly98is returned from the advanced position to the retracted position in the direction of arrow “F”. As described above, the protrusion94of the retractor link80is received in the recess or opening114in the vertical strut112of the working member100of the drive assembly98to couple the actuation sled assembly66to the drive assembly98. Thus, as the drive assembly98returns from the advanced position to the retracted position, the actuation sled assembly66also moves from the sled advanced position to the sled retracted position. When the actuation sled assembly66returns to the sled retracted position and the drive assembly98is returned to the drive assembly clamped position, the proximal portion80bof the retractor link80becomes aligned with the pocket122in the cartridge body50. When this occurs, the proximal portion80bof the retractor link80returns to the non-deformed position in the direction of arrow “G” inFIG.18to uncouple the actuation sled assembly66from the drive assembly98. After the actuation sled assembly66is uncoupled from the drive assembly98, the drive assembly98continues to move towards the retracted position independently of the actuation sled assembly66. In this position, the spent staple cartridge42(FIG.19) can be removed from channel member34(FIG.3) and replaced with a fresh staple cartridge to facilitate reuse of the stapling device10(FIG.1).

FIGS.20-22illustrate an alternate version of the actuation sled assembly shown generally as actuation sled assembly266and the drive assembly shown generally as drive assembly298(FIG.22). The actuation sled assembly266is like actuation sled assembly66(FIG.6A) and includes an actuation sled276, a knife bar278, and a retractor link280. The knife bar278includes a knife288having a distally facing cutting edge288a. The actuation sled assembly266is received in the cartridge body50(FIG.4) of the staple cartridge42and is movable within the cartridge body50between sled retracted and sled advanced positions. The actuation sled276includes a central portion282, and spaced wedge members284that are positioned on opposite sides of the central portion282. The wedge members284are configured to engage and lift the pushers62(FIG.4) as the actuation sled assembly266is moved from the sled retracted position to the sled advanced position to eject the staples60(FIG.4) from staple receiving pockets54of the cartridge body50. The central portion282of the actuation sled276is received in the knife slot52(FIG.4) of the cartridge body50and is movable through the knife slot52to limit the actuation sled assembly266to linear movement. The actuation sled assembly266differs from the actuation sled assembly66(FIG.6A) in that the retractor link280includes a proximal portion that includes an engaging member in the form of a bend294.

The drive assembly298is like the drive assembly98and includes a working member300and a flexible drive beam302. The working member300and the flexible drive beam302are as described above regarding working member100and flexible drive beam102except that a distal portion of the flexible drive beam302defines a recess or opening314. In some aspects of the disclosure, the recess or opening314may also be formed in the vertical strut312of the working member300.

The actuation sled assembly266and the drive assembly298function in the same manner as the actuation sled assembly66and the drive assembly98. More specifically, when the drive assembly298moves from the drive assembly clamped position towards the advanced position to move the actuation sled assembly266from the sled retracted position towards the sled advanced position, the retractor link280moves into the knife slot52(FIG.4) and is deformed from the undeformed condition to the deformed condition. When this occurs, the bend294is received in the opening314defined in the drive assembly298to couple the actuation sled assembly266to the drive assembly298.

FIGS.23to28illustrate an alternate version of the actuation sled assembly and drive assembly of the stapling device10(FIG.1) shown as actuation sled assembly400and drive assembly500(FIG.27). The actuation sled assembly400includes an actuation sled402, a knife bar404, and a retractor link406. The actuation sled assembly400is like the actuation sled assemblies66(FIG.5) and266(FIG.21) except that the knife bar404is not secured to the actuation sled402. The actuation sled assembly400is received in the cartridge body50(FIG.27) of the staple cartridge42(FIG.4) and is movable within the cartridge body50between sled retracted and sled advanced positions. The actuation sled402includes a central portion408and spaced wedge members410that are positioned on opposite sides of the central portion408. The wedge members410are configured to engage and lift the pushers62(FIG.4) as the actuation sled assembly400is moved from the sled retracted position towards the sled advanced position to eject the staples60(FIG.4) from staple receiving pockets54(FIG.4) of the cartridge body50. The central portion408of the actuation sled402is received in the knife slot52of the cartridge body50and is movable through the knife slot52to limit the actuation sled assembly400to linear movement. The central portion408of the actuation sled402defines a proximally extending finger412, a longitudinally extending rib414(FIG.24), and a member416that has a flat surface416a. The rib414has a curved proximal surface414a. The actuation sled402also defines a cutout420between the wedge members410that is dimensioned to receive the knife bar404as described below. The rib414and the member416are received in the cutout420and the flat surface416aof the member416extends proximally of the cutout420.

The knife bar404includes a body portion422, a base portion424, and knife426. The body portion422of the knife bar404is received in and movable through the knife slot52of the cartridge body50(FIG.4). The knife426includes a distally facing cutting edge426aand is supported on an upper end of the body portion422of the knife bar404and projects proximally of a lower portion of the body portion422of the knife bar404. The cutting edge426aextends upwardly from the body portion422of the knife bar404to a position above the tissue engaging surface50a(FIG.4) of the cartridge body50and is shielded by the knife guards58(FIG.4) when the knife bar404is in the retracted position. The base portion424is secured to or formed on the lower end of the body portion422and defines a channel428(FIG.24) that is positioned to receive the rib414of the actuation sled402. The base portion424extends outwardly of the body portion422and is positioned to ride along a bottom wall of the staple guard64(FIG.4). The channel428in the base portion424of the knife bar404is defined in part by a curved proximal portion428a(FIG.27) that is configured to engage the curved proximal surface414aof the rib414when the knife bar404is engaged with the actuation sled402. The body portion422of the knife bar404defines a longitudinally extending recess430(FIG.24) that receives a distal portion406aof the retractor link406. In aspects of the disclosure, the actuation sled402is formed of plastic and the knife bar404is formed from metal.

The retractor link406is secured to the body portion422of the knife bar404in cantilevered fashion. In aspects of the disclosure, the retractor link406is formed of a resilient material, e.g., spring steel, and includes the distal portion406aand a proximal portion406b. The proximal portion406bof the retractor link406includes an engaging member which may be in the form of a 90-degree bend434. The distal portion406adefines a longitudinal axis and is secured to the central portion408of the knife bar404within the recess430. In aspects of the disclosure, the distal portion406aof the retractor link406has a u-shaped portion435that receives the body portion422of the knife bar404. The proximal portion406bof the retractor link406extends proximally from the knife bar404. The retractor link406as described above regarding the retractor link280(FIG.20) is movable between a non-deformed condition and a deformed condition. In the non-deformed condition, the proximal portion406bof the retractor link406bends outwardly from the longitudinal axis defined by the distal portion406aof the retractor link406and outwardly of the knife slot52(FIG.4) of the cartridge body50. When the actuation sled assembly400is advanced through the knife slot52of the cartridge body50, the proximal portion406bof the retractor link406engages an inner wall of the cartridge body50defining the knife slot52and is moved to the deformed condition in which the distal and proximal portions406aand406bof the retractor link406are longitudinally aligned.

The drive assembly500(FIG.26) is like the drive assemblies98(FIG.13) and298(FIG.22) and includes a working member502and a flexible drive beam504(FIG.27). The distal portion of the flexible drive beam504defines a recess or opening506(FIG.27) that receives the bend434in the proximal portion406bof the retractor link406when the retractor link406is deformed. The working member502of the drive assembly500defines a distally facing pocket510(FIG.27) that receives the upper portion of the body portion422and knife426of the knife bar404(FIG.26) when the working member502is moved into engagement with the knife bar404.

The actuation sled assembly400and the drive assembly500function in the same manner as the actuation sled assembly266and the drive assembly298described above except that the actuation sled402is only in abutting relation to the knife bar404and does not return to the retracted position with the knife bar404as the knife bar404is moved from the advanced position to the retracted position with the drive assembly500. More specifically, when the drive assembly500moves from the drive assembly clamped position towards the drive assembly advanced position to move the actuation sled assembly400from the sled retracted position towards the sled advanced position, the retractor link406moves into the knife slot52(FIG.4) and is deformed from the undeformed condition to the deformed condition. When this occurs, the bend434of the retractor link406is received in the opening506of the drive assembly500to couple the drive assembly500with the knife bar404. As the drive assembly500moves towards the advanced position in the direction of arrow “H” inFIG.26, the working member502of the drive assembly500engages the actuation sled402to move the actuation sled402from the sled retracted position to the sled advanced position to eject staples60(FIG.4) from the staple cartridge42. It is noted that when the working member502of the drive assembly500is engaged with the knife bar404, the knife426of the knife bar404is received within the pocket510defined in the working end502of the drive assembly500. In addition, when the knife bar404is engaged with the actuation sled402, the base portion424of the knife bar404is received in the cutout420defined by the actuation sled402. When the base portion424(FIG.24) of the knife bar404is received in the cutout420(FIG.25) of the actuation sled402, the base portion424is supported on the flat surface416aof the member416such that the rib414of the actuation sled402is received within the channel428defined in the base portion424of the knife bar404.

FIG.27illustrates the distal portion of the tool assembly16(FIG.1) as the drive assembly500is moved in the direction of arrow “I” from the advanced position back towards the retracted position. As the drive assembly500is retracted, the knife bar404which is coupled to the drive assembly500by the retractor link406also moves towards the retracted position. However, the actuation sled402which is only in abutting relation to the knife bar404disengages from the knife bar404and remains in the distal portion of the staple cartridge42. (FIG.27).

FIG.28illustrates the proximal portion of the tool assembly16as the drive assembly500approaches the retracted position. When the drive assembly500nears the retracted position, the proximal portion406bof the retractor link406becomes aligned with the pocket122in the cartridge body50of the staple cartridge42and returns to the non-deformed condition in the direction of arrow “J” to disengage the knife bar404from the drive assembly500. When this occurs, the drive assembly500continues to move to the retracted position independently of the knife bar404. Disengaging the knife bar404from the drive assembly500allows for removal and replacement of the staple cartridge42to facilitate reuse of the stapling device10(FIG.1).

Persons skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary aspects of the disclosure. It is envisioned that the elements and features illustrated or described in connection with one exemplary embodiment may be combined with the elements and features of another without departing from the scope of the disclosure. As well, one skilled in the art will appreciate further features and advantages of the disclosure based on the above-described aspects of the disclosure. Accordingly, the disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims.