Surgical stapling device with replaceable staple cartridge

Abstract

A surgical stapling device (10) includes an anvil (28), a staple cartridge (36), and a channel member (34). The staple cartridge (36) includes a structure to prevent the staple cartridge (36) from being inserted into a channel member (34) that is not sized to receive the staple cartridge (36). The staple cartridge (36) and the channel member (34) are configured to minimize the risk of loading an incorrectly sized staple cartridge (36) into the surgical stapling device (10).

Description

TECHNICAL FIELD

[0001] The present technology relates generally to surgical stapling devices, and more particularly to surgical stapling devices having replaceable staple cartridges. BACKGROUND

[0002] Surgical stapling devices for endoscopic use are well known and are commonly used to minimize patient trauma and reduce patient recovery time. Typically, endoscopic stapling devices include a tool assembly having an anvil assembly and a cartridge assembly that are coupled to one another by a pivot member and are movable relative to one another between an open position and a clamped position. The cartridge assembly includes a channel member that supports a staple cartridge. The channel member of the tool assembly is sized to receive staple cartridges of a particular size or length, e.g., 30 mm, 45 mm, 60 mm, etc.

[0003] To facilitate the reuse of the surgical stapling device, the staple cartridge of the tool assembly can be replaceable. In some such devices, the replacement of the staple cartridge deactivates a lockout assembly that prevents firing of the surgical stapling device if the staple cartridge has been used, i.e., has been fired. Serious complications can result if a staple cartridge of the wrong size is loaded onto the surgical stapling device.

[0004] There is a continuing need in the art for an endoscopic surgical stapling device that minimizes the risk of loading an improperly sized staple cartridge into the channel member of the stapling device. SUMMARY

[0005] Aspects of the present disclosure are directed to a tool assembly including an anvil and a cartridge assembly. The anvil has a proximal portion and a distal portion. The cartridge assembly is movably supported relative to the anvil between an open position and a clamped position. The cartridge assembly includes a channel member and a staple cartridge. The channel member has a bottom wall and side walls that define an open cavity. The side walls have a first end coupled to the bottom wall and a second end including a cutout. At least one of the side walls has an inner surface that defines a placement recess. The staple cartridge has a cartridge body that defines a central knife slot and a plurality of staple pockets positioned on each side of the central knife slot. The staple cartridge includes side walls. Each of the side walls of the staple cartridge includes a protrusion and a placement rib. The protrusion is received within the cutout of the channel member to secure the staple cartridge within the open cavity of the channel member, and the placement rib is received within the placement recess.

[0006] Other aspects of the present disclosure relate to a surgical stapling device comprising a handle assembly, an elongate body, and a tool assembly. The handle assembly comprises a fixed handle and a trigger. The elongate body has a proximal portion and a distal portion. The proximal portion is supported on the handle assembly. The tool assembly is supported on the distal portion of the elongate body and comprises an anvil and a cartridge assembly. The cartridge assembly is movably supported relative to the anvil between an open position and a clamped position and comprises a channel member and a staple cartridge. The channel member has a bottom wall and sidewalls that define an open cavity. The sidewalls of the channel member have a first end coupled to the bottom wall and a second end having a cutout. At least one of the sidewalls of the channel member has an inner surface that defines a placement recess. The staple cartridge has a cartridge body that defines a central knife slot and a plurality of staple pockets positioned on each side of the central knife slot. The staple cartridge comprises sidewalls that include a protrusion and a placement rib. The protrusion is received within the cutout of the channel member to secure the staple cartridge within the open cavity of the channel member and the placement rib is received within the placement recess.

[0007] In aspects of the present disclosure, the cartridge body comprises an angled wall that defines a distal end of the placement recess.

[0008] In aspects of the present disclosure, the placement rib comprises an angled distal surface that engages the angled wall of the cartridge body when the staple cartridge is inserted into the open cavity of the channel member to cause the cartridge body to move proximally within the open cavity.

[0009] In aspects of the present disclosure, the angled wall slopes upward in a distal direction toward the anvil.

[0010] In aspects of the present disclosure, the tool assembly comprises a drive assembly having a flexible beam and a working end, and the drive assembly is movable through the anvil and the cartridge assembly from a retracted position to an advanced position to actuate the tool assembly.

[0011] In aspects of the present disclosure, the working end of the drive assembly comprises a clamping member having a first beam, a second beam, and a vertical strut connecting the first beam to the second beam.

[0012] In aspects of the present disclosure, an actuation sled is positioned within the cartridge body distally of the working end of the drive assembly, and the actuation sled is movable within the cartridge body from a retracted position to an advanced position in response to the drive assembly moving from its retracted position to its advanced position.

[0013] In aspects of the present disclosure, the tool assembly comprises a lock member that is movable from a locked position to an unlocked position, wherein in the locked position, the lock member blocks the drive assembly from moving from its retracted position to its advanced position.

[0014] In some aspects of the present disclosure, the actuation sled holds the lock member in its unlocked position when the actuation sled is in its retracted position.

[0015] In certain aspects of the present disclosure, the lock member is biased to the locked position.

[0016] Other features of the present disclosure will be understood through the following description. BRIEF DESCRIPTION OF DRAWINGS

[0017] Various aspects of the present disclosure are described below with reference to the accompanying drawings, in which:

[0018] Figure 1 is a side perspective view of a surgical stapling device including a 60 mm tool assembly supporting a 60 mm cartridge assembly in accordance with aspects of the present disclosure;

[0019] Figure 2 is Figure 1 is a magnified view of the indicated area of detail shown;

[0020] Figure 3 is Figure 1 is a side perspective view of a tool assembly of the surgical stapling device with the cartridge assembly separated from the channel member of the tool assembly shown;

[0021] Figure 4 is Figure 1 is a side exploded perspective view of a cartridge assembly and drive assembly of the surgical stapling device shown;

[0022] Figure 5 is a cross-sectional view taken along an axis transverse to Figure 2 the longitudinal axis of the tool assembly shown with the tool assembly in an open position;

[0023] Figure 6 is a cross-sectional view taken along Figure 2 sectional plane line 6-6;

[0024] Figure 7 is a side perspective view of a 45 mm tool assembly with a 60 mm cartridge assembly;

[0025] Figure 8 is a side view of the 45 mm tool assembly and 60 mm staple cartridge when the 60 mm cartridge assembly is inserted into the 45 mm tool assembly;

[0026] Figure 9 is a cross-sectional view taken along Figure 8 sectional plane line 9-9; and

[0027] Figure 10is a cross-sectional view taken along a longitudinal axis of the tool assembly when the 60 mm cartridge assembly is inserted into the 45 mm tool assembly. DETAILED DESCRIPTION

[0028] 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 each of the aspects of the present disclosure are merely exemplary of the present disclosure and can be embodied in various forms. Well-known functions or structures have not been described in detail so as not to obscure the present disclosure. As such, the 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 present disclosure in virtually any appropriately detailed structure. Further, directional terms such as front, rear, top, bottom, over, under, distal, proximal, and the like are used with reference to the orientation of the device as placed in use and are not limiting.

[0029] In this specification, the term "proximal" is used generically to refer to the portion of the device closer to the clinician, while the term "distal" is used generically to refer to the portion of the device farther from the clinician. Further, the term "endoscopic" is used generically to refer to endoscopic, laparoscopic, arthroscopic, and / or any other surgery performed through a small diameter incision or cannula. Further, the term "clinician" is used generically to refer to medical personnel including doctors, nurses, and support staff.

[0030] The present disclosure relates to a tool assembly including an anvil and a cartridge assembly. The cartridge assembly includes a first size channel member and a first size replaceable staple cartridge. The first size channel member defines a placement recess and the first size staple cartridge includes a placement rib. The placement rib is received within the placement recess to allow the first size staple cartridge to be received within the first size channel member. Channel members of different sizes do not include a placement recess to prevent the first size staple cartridge from being placed into the first size channel member.

[0031] Figure 1Exemplary aspects of the disclosed surgical stapling device are shown generally as stapling device 10. Stapling device 10 includes a handle assembly 12, an elongated body 14 defining a longitudinal axis "X", and a tool assembly 16 of a first size (e.g., 60 mm). Handle assembly 12 includes a fixed handle 18 and a trigger 20 that is movable relative to fixed handle 18 to actuate tool assembly 16. In aspects of the disclosure, stapling device 10 includes a knob 22 and an articulation bar 24. Knob 22 is coupled to handle assembly 12 and supports elongated body 14 to facilitate rotation of elongated body 14 and tool assembly 16 about longitudinal axis "X" relative to handle assembly 12. Articulation bar 24 is coupled to tool assembly 16 to articulate tool assembly 16 from a position aligned with longitudinal axis "X" to a position defining an acute angle with longitudinal axis "X". In some aspects of stapling device 10, handle assembly 12 includes a retraction knob 26 for retracting a drive assembly of stapling device 10. For a more detailed description of exemplary aspects of handle assembly 12 of stapling device 10, see, for example, U.S. Patent No. 6,241, 139 ("the'139 patent"). Although handle assembly 12 is shown as a manually operated handle assembly, it is envisioned that handle assembly 12 can be an electrically powered handle assembly, such as described in U.S. Patent No. 9,055,943.

[0032] Figure 2 and Figure 3 Tool assembly 16 of stapling device 10 is shown in FIGS. 1-3. Figure 1 Tool assembly 16 includes an anvil 28 and a cartridge assembly 30 that are movable relative to one another between an open position Figure 2 and a clamped position. In aspects of the disclosure, anvil 28 and cartridge assembly 30 are coupled together with a pivot member 32 such that cartridge assembly 32 can be pivoted relative to anvil 30 between an open position Figure 1 and a clamped position Figure 8 Although cartridge assembly 30 is shown as pivoting toward fixed anvil 28, it is envisioned that anvil 30 can be adapted to pivot toward fixed cartridge assembly 30.

[0033] Cartridge assembly 30 includes a channel member 34 and a staple cartridge 36. Channel member 34 includes a bottom wall 38 and spaced side walls 40 defining an open cavity 42 Figure 3 Staple cartridge 36 is releasably received within open cavity 42 and is replaceable after each firing of stapling device 10 to facilitate stapling device 10 Figure 1The channel member 34 is sized to receive a staple cartridge 36 of a specific size. For example, in tool assembly 16, the channel member 34 is sized to receive a staple cartridge 36 of a specific size, which corresponds to the size of the channel member 34, such as 30mm, 45mm, 60mm, etc. Similarly, the anvil 28 of tool assembly 16 is sized to be used with a staple cartridge 36 of a specific size (e.g., 60mm).

[0034] Figures 4 to 6 A tool assembly 16 of a first dimension (e.g., 60 mm) is shown. This tool assembly includes a cartridge assembly 30, a drive assembly 50, an actuating slider 52, and a locking member 54. The drive assembly 50 includes a flexible drive beam 60 and a working end 62. The flexible drive beam 60 has a proximal portion 64 and a distal portion 66 supporting the working end 62 of the drive assembly 50. The distal portion 66 of the flexible drive beam 60 defines a stop surface 66a. Figure 4 In various aspects of this disclosure, the working end of the drive assembly 50 includes a clamping member in the form of an I-beam, the clamping member including a first beam 70, a second beam 72, and a vertical support 74 interconnecting the first beam 70 to the second beam 72. In various aspects of this disclosure, the vertical support 74 includes the cutting edge of a blade 76. The proximal portion 64 of the flexible drive beam 60 is coupled to an elongated body 14 supported on the surgical suture device 10. Figure 1 The drive member (not shown) is located within the drive assembly 50. The drive member (not shown) is movable to move the drive assembly 50 relative to the anvil 28 and the chamber assembly 30 between a retracted position and an advanced position.

[0035] The actuating slider 52 is supported within the pin cartridge 36 for use in the retracted position ( Figure 6 The movement between the push position and the advance position includes multiple angled cam action surfaces 78. The angled cam action surfaces 78 are positioned to engage the pusher 79 supported within the pin magazine 36. Figure 6 The actuating slider 52 is positioned distal to the working end 68 of the drive assembly 50 within the staple cartridge 36, and is engaged by the working end 68 when the drive assembly 50 moves from its retracted position toward its advanced position to move the actuating slider 52 from its retracted position to its advanced position.

[0036] The locking member 54 includes a body 80 having a centrally located pivot member 82 (only one shown), a pair of downwardly extending distal legs 84, and a proximally located stop member 86. The locking member 86 is capable of being unlocked from a first unlocked position around the pivot member 82. Figure 6) to a locked position, in which first unlocked position the stop member 86 is positioned below a stop surface 66a on the distal portion 66 of the flexible drive beam 60, in which locked position the stop surface 66a is aligned with the stop surface 66a on the distal portion 66 of the flexible drive beam 60 of the drive assembly 50. In the locked position, the locking member 54 blocks movement of the drive assembly 50 toward its advanced position. The locking member 54 is biased toward the locked position by a biasing member 87 Figure 10 When the actuation sled 52 is in its retracted position, the distal leg 84 of the locking member 54 engages the actuation sled 52 to maintain the locking member 54 in the unlocked position. The construction and operation of the locking member 54 and the actuation sled 52 are described in detail in U.S. Patent No. 9,757,126.

[0037] The staple cartridge 36 of the first size includes a cartridge body 100 defining a central knife slot 102 and a plurality of staple pockets 104 positioned on each side of the central knife slot 102. In aspects of the disclosure, the staple pockets 104 are aligned in rows on each side of the central knife slot 102. Although three rows of staple pockets 104 are shown on each side of the central knife slot 102, it is envisioned that the staple cartridge 36 can include one or more rows of staple pockets 104. The cartridge body 100 further includes a sidewall 106 (only one shown) that includes one or more protrusions 108. Each of the sidewalls 106 includes an overhang or shoulder 107 that is positioned to rest on top of the sidewall 40 of the channel 34 when the staple cartridge 36 is inserted into the open cavity 42 of the channel member 34. In aspects of the disclosure, one or more of the protrusions 108 can have an outer rib surface 110 Figure 4 ) to facilitate removal of the staple cartridge 36 from the channel member 34. The sidewall 106 can further include a protrusion 106a that is received within an opening 109a of a cartridge tray 109 to retain the cartridge tray 109 on the cartridge body 100. As is known in the art, the cartridge tray 109 is secured to the cartridge body to retain the pushers 79 Figure 6 ) and staples (not shown) within the cartridge body 100. At least one of the sidewalls 106 of the cartridge body 100 includes a placement rib 112. In aspects of the disclosure, the placement rib 112 protrudes outwardly from the at least one sidewall 106 and includes an angled distal surface 114. In certain aspects of the disclosure, each of the sidewalls 106 of the cartridge body 100 includes a placement rib 112.

[0038] As discussed above, the channel member 34 of the tool assembly 16 includes a bottom wall 38 and sidewalls 40 that define an open cavity 42. The sidewalls 40 include a cutout 120 Figure 4The cut receives the protrusion 108 of the staple cartridge 36 to secure the staple cartridge 36 within the open cavity 42 of the channel member 36. When the staple cartridge 36 is inserted into the open cavity 42 of the channel member 34, the elastic wall portion 106a of the staple cartridge 36 is biased inward from the inner surface of the side wall 40 of the channel member 34 to help retain the staple cartridge 36 within the channel member 42.

[0039] The sidewall 40 of the channel member 34 of the tool assembly 16 of the first size (e.g., 60 mm) includes a placement recess 128 positioned to receive a placement rib 112 of the staple cartridge 36. In various aspects of this disclosure, the placement recess 128 is partially formed by an angled distal sidewall 130 ( Figure 4 Defined as follows, the angled distal wall is inclined upward in the distal direction toward the anvil 28. As described below, only the channel member 34 of the first-size tool assembly 16 includes a placement recess 128. When the first-size cartridge 36 is inserted into the first-size channel member 34, the placement rib 112 is received within the placement recess 128 to allow the cartridge 36 to be received within the open cavity 42 of the channel member 34, such that the shoulder 107 on the sidewall 106 of the cartridge rests on the top of the sidewall 40 of the channel member 34. When the cartridge 36 is inserted into the channel member 34, the angled distal wall 130 defining the placement recess 128 engages the angled distal surface 114 of the placement rib 112 to push the cartridge proximally within the open cavity 42 of the channel member 34 to actuate the slide member 52 ( Figure 4 )Motion and locking components 54 ( Figure 6 ) engagement, so that locking member 54 along Figure 6 Pivot to its unlocked position in the direction indicated by arrow "A".

[0040] Figures 7 to 10 A first-sized staple cartridge 36 is shown when it is inserted into the channel member 234 of a tool assembly 216 of a different size (e.g., 45 mm). The channel member 234 of the second-sized tool assembly 216 is substantially the same as that of the first-sized tool assembly 216, except that the channel member 234 does not include a placement recess. Therefore, when the first-sized staple cartridge 36 is inserted into the second-sized channel member 234, the placement rib 112 on the staple cartridge 36 engages the upper surface 240a of the sidewall 240 of the channel member 234 of the tool assembly 216 to prevent the staple cartridge 36 from being properly positioned within the cavity 242 of the channel member 234. Figure 10 As shown, because the staple cartridge 36 cannot be properly positioned within the cavity 242 of the channel member 234 of the tool assembly 216, the actuating slider 252 of the tool assembly 216 cannot engage the locking member 254, and the locking member 254 remains in the locked position. Therefore, the suture device 10 ( Figure 1 It cannot be fired.

[0041] The first size staple cartridge 36 and the first size channel member 34 described above allow the staple cartridge 36 to be seated only within a properly sized channel member 34 and prevent the first size staple cartridge 36 from being inserted into a second size channel member 234. For example, if the first size staple cartridge 36 is a 60 mm staple cartridge and the second size channel member 234 is sized to receive a 45 mm staple cartridge, the placement rib 112 will engage the sidewall 240 of the channel member 234 to prevent the staple cartridge 36 from being properly seated within the cavity 242 when a clinician attempts to insert the staple cartridge 36 into the open cavity 242 of the channel member 234.

[0042] While the first size is described herein as a 60 mm staple cartridge or tool assembly and the second size is described as a 45 mm staple cartridge or tool assembly, it is envisioned that aspects of the present disclosure can incorporate staple cartridges and tool assemblies of various different sizes.

[0043] Those skilled in the art will appreciate that the apparatus and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary aspects of the present disclosure. It is contemplated that elements and features of one exemplary aspect of the present disclosure can be combined with elements and features of another aspect of the present disclosure without departing from the scope of the present disclosure. Likewise, it is contemplated that additional features and advantages of the present disclosure will become apparent based on the above description of aspects of the present disclosure. Accordingly, the present disclosure is not to be limited by the specific illustrative aspects disclosed herein, except insofar as limited by the appended claims.

Claims

1. A tool assembly comprising: an anvil; and a cartridge assembly movably supported relative to the anvil between an open position and a clamped position, the cartridge assembly comprising: a channel member having a bottom wall and side walls defining an open cavity, the side walls of the channel member having a first end coupled to the bottom wall and a second end including a cutout, at least one of the side walls of the channel member having an inner surface defining a placement recess; and a staple cartridge having a cartridge body defining a central knife slot and a plurality of staple pockets positioned on each side of the central knife slot, the staple cartridge including side walls, each of the side walls of the staple cartridge including a protrusion and a placement rib, wherein the protrusion is received within the cutout of the channel member to secure the staple cartridge within the open cavity of the channel member and the placement rib is received within the placement recess, wherein: the channel member includes an angled distal wall defining a distal end of the placement recess; the placement rib includes an angled distal surface that engages the angled distal wall of the channel member to cause the cartridge body to move proximally within the open cavity when the staple cartridge is inserted into the open cavity of the channel member; the tool assembly includes a drive assembly having a flexible beam and a working end, the drive assembly being movable by the anvil and the cartridge assembly from a retracted position to an advanced position to actuate the tool assembly; the tool assembly includes an actuation sled positioned within the cartridge body distally of the working end of the drive assembly, wherein the actuation sled is movable within the cartridge body from a retracted position to an advanced position in response to the drive assembly being moved from its retracted position to its advanced position; the tool assembly includes a lock member movable from a locked position to an unlocked position, wherein in the locked position the lock member blocks the drive assembly from being moved from its retracted position to its advanced position; the actuation sled is positioned to maintain the lock member in its unlocked position when the actuation sled is in its retracted position; whereby when the staple cartridge is inserted into the channel member, the angled distal wall of the placement recess engages the angled distal surface of the placement rib to push the staple cartridge proximally within the open cavity of the channel member to move the actuation sled to its retracted position, into engagement with the lock member to cause the lock member to pivot to its unlocked position.

2. The tool assembly of Claim 1, wherein the angled distal wall slopes upward in a distal direction toward the anvil.

3. The tool assembly of Claim 1, wherein the working end of the drive assembly includes a clamping member having a first beam, a second beam, and a vertical strut connecting the first beam to the second beam.

4. The tool assembly of Claim 1, wherein the lock member is biased to the locked position.

5. A surgical stapling device comprising: a handle assembly including a fixed handle and a trigger; an elongated body having a proximal portion and a distal portion, the proximal portion supported on the handle assembly; and a tool assembly according to any of claims 1-4, the tool assembly supported on the distal portion of the elongated body.

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