Surgical stapler with cartridge tray retention feature

Abstract

The present invention provides a surgical instrument end effector, which includes a first jaw, a second jaw, a nail magazine and a retaining cover. The second jaw includes an anvil having a plurality of nail forming recesses. The first jaw and the second jaw are operable to clamp and sew tissue positioned between the first jaw and the second jaw. The nail magazine is configured to be received in the first jaw. The nail magazine includes a magazine body, a lower tray and a plurality of nails. The magazine body and the lower tray are configured to be coupled together. The retaining cover is configured to be fastened to the proximal end of the magazine body and engage the lower tray. The retaining cover is further configured to fix the position of the lower tray relative to the magazine body.

Description

Background Art

[0001] In some environments, endoscopic surgical instruments are preferred over traditional open surgical devices because smaller incisions can reduce postoperative recovery time and complications. Therefore, some endoscopic surgical instruments may be suitable for placing the distal end effector at the desired surgical site through the cannula of a trocar. These distal end effectors (e.g., internal cutters, graspers, cutters, staplers, clip appliers, access devices, drug / gene therapy delivery devices, and energy delivery devices using ultrasound, RF, lasers, etc.) can engage tissue in a variety of ways to achieve diagnostic or therapeutic effects. An endoscopic surgical instrument may include a shaft between the end effector and a handle portion manipulated by a clinician. Such a shaft may enable insertion to a desired depth and rotation around the longitudinal axis of the shaft to thereby facilitate positioning the end effector within the patient's body. Positioning the end effector may also be further facilitated by including one or more articulation joints or features so that the end effector can selectively articulate or otherwise deflect relative to the longitudinal axis of the shaft.

[0002] Examples of endoscopic surgical instruments include surgical staplers. Some such staplers are operable to clamp tissue layers, cut through the clamped tissue layers, and drive staples through the tissue layers to substantially seal the severed tissue layers together near the severed ends of the tissue layers. Exemplary surgical staplers are disclosed in the following documents: U.S. Pat. No. 4,805,823, entitled “Pocket Configuration for Internal Organ Staplers,” issued February 21, 1989; U.S. Pat. No. 5,415,334, entitled “Surgical Stapler and Staple Cartridge,” issued May 16, 1995; U.S. Pat. No. 5,465,895, entitled “Surgical Stapler Instrument,” issued November 14, 1995; U.S. Pat. No. 5,597,107, entitled “Surgical Stapler Instrument,” issued January 28, 1997; U.S. Pat. No. 5,632,432, entitled “Surgical Instrument,” issued May 27, 1997; U.S. Pat. No. 5,673,840, entitled “Surgical Instrument,” issued October 7, 1997; and U.S. Pat. No. 5,465,895, entitled “Surgical Stapler Instrument,” issued January 14, 1995. U.S. Patent 5,704,534, entitled “Surgical Instruments”; U.S. Patent 5,814,055, entitled “Surgical Clamping Mechanism”, issued on September 29, 1998; U.S. Patent 6,978,921, entitled “Surgical Stapling Instrument Incorporating an E-Beam Firing Mechanism”, issued on December 27, 2005; U.S. Patent 7,000,818, entitled “Surgical Stapling Instrument Having Separate Distinct Closing and Firing Systems”, issued on February 21, 2006; U.S. Patent 7,143,923, entitled “Surgical Stapling Instrument Having a Firing Lockout for an Unclosed Anvil”, issued on December 5, 2006;U.S. Patent No. 7,303,108, entitled “Surgical Stapling Instrument Incorporating a Multi-Stroke Firing Mechanism with a Flexible Rack,” issued on December 4, 2007; U.S. Patent No. 7,367,485, entitled “Surgical Stapling Instrument Incorporating a Multistroke Firing Mechanism Having a Rotary Transmission,” issued on May 6, 2008; U.S. Patent No. 7,380,695, entitled “Surgical Stapling Instrument Having a Single Lockout Mechanism for Prevention of Firing,” issued on June 3, 2008; U.S. Patent No. 7,380,696, entitled “Articulating Surgical Stapling Instrument Incorporating a Two-Piece E-Beam Firing Mechanism,” issued on June 3, 2008; and U.S. Patent No. 7,380,697, entitled “Surgical Stapling and Cutting Instrument Incorporating a Single Lockout Mechanism for Prevention of Firing.” Device”; U.S. Patent 7,404,508, entitled “Surgical Stapling Instrument Having Multistroke Firing with Opening Lockout”, published on October 14, 2008; U.S. Patent 7,721,930, entitled “Disposable Cartridge with Adhesive for Use with a Stapling Device”, published on May 25, 2010; U.S. Patent 8,408,439, entitled “Surgical Stapling Instrument with An Articulatable End Effector”, published on April 2, 2013;and U.S. Patent No. 8,453,914, entitled “Motor-Driven Surgical Cutting Instrument with Electric Actuator Directional Control Assembly,” issued on June 4, 2013. The disclosures of each of the above-referenced U.S. patents, U.S. patent publications, and U.S. patent applications are incorporated herein by reference.

[0003] Although the surgical stapler involved above is described as being used in endoscopic surgery, it should be understood that such surgical staplers can also be used in laparotomy and / or other non-endoscopic surgeries. By way of example only, in thoracic surgery, a surgical stapler can be inserted through a thoracotomy and thus positioned between the patient's ribs to reach one or more organs, and the thoracic surgery does not use a trocar as a conduit for the stapler. Such surgery may include using a stapler to cut off and close the blood vessels leading to the lungs. For example, before an organ is removed from the chest cavity, the blood vessels leading to the organ can be cut off and closed by a stapler. Of course, the surgical stapler can be used in various other situations and operations.

[0004] While various surgical stapling instruments and associated components have been made and used, it is believed that no one prior to the inventors has made or used the invention described in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.

[0006] Figure 1 shows a perspective view of an exemplary articulating surgical stapling instrument;

[0007] Figure 2 Shown Figure 1 A side view of the device;

[0008] Figure 3 Shown Figure 1 A perspective view of an open end effector in an instrument;

[0009] Figure 4A Shown Figure 3 The end effector along Figure 3 a side cross-sectional view taken along line 4-4 of FIG. 1 , wherein the firing beam is in a proximal position;

[0010] Figure 4B Shown Figure 3 The end effector along Figure 3a side cross-sectional view taken along line 4-4 of FIG. 1 , wherein the firing beam is in a distal position;

[0011] Figure 5 Shown Figure 3 The end effector along Figure 3 an end cross-sectional view taken along line 5-5 of FIG.

[0012] Figure 6 Shown Figure 3 An exploded perspective view of an end effector;

[0013] Figure 7 Shown Figure 3 A perspective view of an end effector positioned at tissue and having been actuated once in the tissue;

[0014] Figure 8 Shown with Figure 1 A perspective view of an exemplary staple cartridge for use with an instrument;

[0015] Figure 9 Shown Figure 8 An enlarged perspective view of the proximal end of the staple cartridge;

[0016] Figure 10 Shown Figure 8 A rear cross-sectional view of the proximal end of the staple cartridge, the cross-sectional view being along Figure 8 The line 10-10 is intercepted;

[0017] Figure 11 Shown with Figure 1 A perspective view of a proximal end portion of another exemplary staple cartridge for use with an instrument;

[0018] Figure 12A An example of an assembly method is shown. Figure 11 A rear cross-sectional view of the nail cartridge, the cross-sectional view along Figure 11 The line 12-12 is intercepted;

[0019] Figure 12B Another example of an assembly method is shown. Figure 11 Another rear cross-sectional view of the nail cartridge, the cross-sectional view along Figure 11 The line 12-12 is intercepted;

[0020] Figure 13A Another example of an assembly method is shown. Figure 11 Another rear cross-sectional view of the nail magazine, the cross-sectional view along Figure 11 The line 13-13 is intercepted;

[0021] Figure 13B Another example of an assembly method is shown. Figure 11 Another rear cross-sectional view of the nail magazine, the cross-sectional view along Figure 11 The line 13-13 is intercepted;

[0022] Figure 14 Shown Figure 11 An enlarged perspective view of a proximal end of a staple cartridge for use with an exemplary retainer;

[0023] Figure 15 Shown Figure 11 A rear cross-sectional view of the nail cartridge, wherein Figure 14 The retainer is attached to the nail cartridge, this cross-sectional view along Figure 14 The line 15-15 is intercepted;

[0024] Figure 16 Shown Figure 11 The proximal end of the nail cartridge and Figure 14 An exploded perspective view of a retainer;

[0025] Figure 17 Shown Figure 11 Another enlarged perspective view of the proximal end of the staple cartridge of FIG. 1 , the staple cartridge being used with another exemplary retainer;

[0026] Figure 18 Shown Figure 11 yet another enlarged perspective view of a proximal end of a staple cartridge of FIG. 1 , the staple cartridge being used with yet another exemplary retainer; and

[0027] Figure 19 Shown Figure 11 Another enlarged perspective view of a staple cartridge for use with yet another exemplary retainer;

[0028] Figure 20 Shown with Figure 1 A perspective view of a proximal end portion of another exemplary staple cartridge for use with an instrument;

[0029] Figure 21A Shown Figure 20 A rear cross-sectional view of the nail cartridge, the cross-sectional view along Figure 20 taken along line 21-21; and

[0030] Figure 21B An example of a heat riveting assembly method is shown. Figure 20 Another rear cross-sectional view of the nail cartridge, the cross-sectional view along Figure 20 The line 21-21 is intercepted.

[0031] The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily shown in the drawings. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the invention and, together with the description, serve to explain the principles of the invention; it should be understood, however, that the invention is not limited to the precise arrangements shown. DETAILED DESCRIPTION

[0032] The following description of certain examples of the present invention should not be used to limit the scope of the present invention. Based on the following description shown by way of example, other examples, features, aspects, embodiments and advantages of the present invention will be apparent to those skilled in the art, and a best mode is contemplated for implementing the present invention. As will be appreciated, the present invention can have other different and obvious aspects, all of which do not depart from the present invention. Therefore, the drawings and description should be considered to be illustrative and non-restrictive in nature.

[0033] I. Exemplary Surgical Staplers

[0034] Figures 1 to 7 An exemplary surgical stapling and severing instrument (10) is depicted, Figure 1 In the non-articulated state depicted in FIG, it is sized to be inserted through a cannula of a trocar into a surgical site of a patient in order to perform a surgical procedure. By way of example only, such a trocar may be inserted into the patient's abdomen between two ribs or elsewhere. In some cases, the instrument (10) is used in the absence of a trocar. For example, the instrument (10) may be inserted directly through a thoracotomy or other type of incision. The instrument (10) of this example includes a handle portion (20) connected to a shaft (22). The shaft (22) terminates distally in an articulation joint (11), which is further coupled to an end effector (12). It should be understood that terms such as "proximal" and "distal" used herein refer to the handle portion (20) of the instrument (10) as grasped by the clinician. Thus, the end effector (12) is located distally relative to the more proximal handle portion (20). It should also be understood that for convenience and clarity, the diagrams herein use spatial terms such as "vertical" and "horizontal". However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and absolute.

[0035] In some versions, shaft (22) is constructed in accordance with at least some of the teachings of U.S. Patent No. 9,795,379, entitled “Surgical Instrument with Multi-Diameter Shaft,” issued on October 24, 2017, the disclosure of which is incorporated herein by reference. Other suitable configurations for shaft (22) will be apparent to those skilled in the art in view of the teachings herein.

[0036] Once the articulation joint (11) and end effector (12) are inserted through the cannula channel of the trocar, the articulation joint (11) can be remotely articulated via the articulation control (13), such as Figure 1 , depicted in phantom, so that the end effector (12) can be deflected from the longitudinal axis (LA) of the shaft (22) at a desired angle (α). As a result, the end effector (12) can reach the back of an organ or approach tissue from a desired angle or for other reasons. In some versions, the articulation joint (11) is capable of deflecting the end effector (12) along a single plane. In some other versions, the articulation joint (11) is capable of deflecting the end effector along more than one plane. The articulation joint (11) and the articulation control (13) can be constructed according to the teachings of any of the multiple references cited herein. Alternatively, the articulation joint (11) and / or the articulation control (13) can have any other suitable configuration. By way of example only, the articulation control (13) can be alternatively constructed as a knob that rotates about an axis perpendicular to the longitudinal axis (LA) of the shaft (22).

[0037] In some versions, the articulation joint (11) and / or articulation control (13) are constructed and operated in accordance with at least some of the teachings of the following U.S. patent application: U.S. Patent No. 9,186,142, filed on November 17, 2015, entitled "Surgical Instrument End Effector Articulation Drive with Pinion and Opposing Racks," the disclosure of which is incorporated herein by reference. The articulation joint (11) may also be constructed and operated in accordance with at least some of the teachings of the following U.S. patent application: U.S. Patent No. 9,795,379, published on October 24, 2017, entitled "Surgical Instrument with Multi-Diameter Shaft," the disclosure of which is incorporated herein by reference. Other suitable forms that the articulation joint (11) and articulation control (13) may take will be apparent to those skilled in the art in view of the teachings herein.

[0038] The end effector (12) of the present example includes a lower jaw (16) and an upper jaw in the form of a pivotable anvil (18). In some versions, the lower jaw (16) is constructed in accordance with at least some of the teachings of U.S. Patent No. 9,808,248, entitled “Installation Features for Surgical Instrument End Effector Cartridge,” issued on November 7, 2017, the disclosure of which is incorporated herein by reference. The anvil (18) may be constructed according to at least some of the teachings of the following U.S. patent applications: U.S. Patent No. 9,517,065, entitled “Integrated Tissue Positioning and Jaw Alignment Features for Surgical Stapler,” published on December 13, 2016, the disclosure of which is incorporated herein by reference; U.S. Patent No. 9,839,421, entitled “Jaw Closure Feature for End Effector of Surgical Instrument,” published on December 12, 2017, the disclosure of which is incorporated herein by reference; and / or U.S. Patent No. 10,092,292, entitled “Staple Forming Features for Surgical Stapling Instrument,” published on October 9, 2018, the disclosure of which is incorporated herein by reference. Other suitable forms that the lower jaw (16) and anvil (18) may take will be apparent to those skilled in the art in view of the teachings herein.

[0039] The handle portion (20) includes a pistol grip (24) and a closure trigger (26). The closure trigger (26) is capable of pivoting toward the pistol grip (24) so ​​that the anvil (18) is clamped or closed toward the lower jaw (16) of the end effector (12). Such closure of the anvil (18) is provided by a closure tube (32) and a closure ring (33), both of which translate longitudinally relative to the handle portion (20) in response to pivoting of the closure trigger (26) relative to the pistol grip (24). The closure tube (32) extends along the length of the shaft (22); and the closure ring (33) is positioned distally of the articulation joint (11). The articulation joint (11) is operable to transmit / transmit longitudinal motion from the closure tube (32) to the closure ring (33).

[0040] The handle portion (20) also includes a firing trigger (28). An elongated member (not shown) extends longitudinally through the shaft (22) and, in response to actuation of the firing trigger (28), transmits a longitudinal firing motion from the handle portion (20) to the firing beam (14). This distal translation of the firing beam (14) causes the tissue clamped in the end effector (12) to be sutured and severed, as will be described in more detail below. The triggers (26, 28) are then released to release the tissue from the end effector (12).

[0041] Figures 3 to 6 The end effector (12) is shown as employing a firing beam (14) in the form of an electron beam to perform various functions. It should be understood that the electron beam form is merely an illustrative example. The firing beam (14) may take any other suitable form, including but not limited to non-electron beam forms. As best seen in Figures 4A to 4B The firing beam (14) includes a transversely oriented upper pin (38), a firing beam cap (44), a transversely oriented middle pin (46), and a distally located cutting edge (48). The upper pin (38) is positioned within the longitudinal anvil slot (42) of the anvil (18) and is capable of translating within the longitudinal anvil slot. The firing beam cap (44) is positioned by extending the firing beam (14) through the lower jaw slot (45) ( Figure 4B The lower jaw slot (45) is formed through the lower jaw (16) and slidably engages the lower surface of the lower jaw (16). The middle pin (46) slidably engages the top surface of the lower jaw (16) to cooperate with the firing beam cover (44). Therefore, the firing beam (14) is necessarily spaced apart from the end effector (12) during firing.

[0042] Some non-electron beam versions of the firing beam (14) may lack the upper pin (38), the middle pin (46), and / or the firing beam cap (44). Some such versions of the instrument (10) may rely solely on the closed ring (33) or some other feature structure to pivot the anvil (18) to the closed position and maintain the anvil (18) in the closed position when the firing beam (14) is advanced to the distal position. By way of example only, the firing beam (14) and / or associated lockout feature may be constructed and operated in accordance with at least some of the teachings of the following U.S. Patent No. 9,717,497, entitled “Lockout Feature for Movable Cutting Member of Surgical Instrument,” published on August 1, 2017, the disclosure of which is incorporated herein by reference. Other suitable forms that the firing beam (14) may take will be apparent to those skilled in the art in light of the teachings herein.

[0043] Figure 3The present example is shown with the firing beam (14) positioned proximally and the anvil (18) pivoted to the open position, thereby allowing an unspent staple cartridge (37) to be removably installed into the channel of the lower jaw (16). As best seen in Figures 5 and 6 The staple cartridge (37) of this example includes a cartridge body (70) that presents an upper platform (72) and is coupled to a lower cartridge tray (74). Figure 3 As best shown in FIG, a vertical slot (49) is formed through a portion of the staple cartridge (37). Figure 3 As best shown in FIG, three rows of nail holes (51) are formed through the upper platform (72) on one side of the vertical slot (49), and another set of three rows of nail holes (51) are formed through the upper platform (72) on the other side of the vertical slot (49). Of course, any other suitable number of nail rows (e.g., two rows, four rows, or other numbers) may be provided. See again Figures 4A to 6 , a wedge-shaped slide (41) and a plurality of nail drivers (43) are captured between the magazine body (70) and the tray (74), wherein the wedge-shaped slide (41) is located proximal to the nail driver (43). The wedge-shaped slide (41) is capable of moving longitudinally within the nail magazine (37); and the nail driver (43) is capable of moving vertically within the nail magazine (37). The nails (47) are also positioned within the magazine body (70), above the corresponding nail drivers (43). Specifically, each nail (47) is driven vertically by the nail driver (43) within the magazine body (70) to drive the nail (47) out through the associated nail hole (51). As Figures 4A to 4B and Figure 6 As best shown in FIG, wedge sled (41) presents an inclined cam surface that urges the staple drivers (43) upwardly as the wedge sled (41) is driven distally through the staple cartridge (37).

[0044] In some versions, the staple cartridge (37) is constructed and operative in accordance with at least some of the teachings of U.S. Patent No. 9,517,065, entitled “Integrated Tissue Positioning and Jaw Alignment Features for Surgical Stapler,” published on December 13, 2016, the disclosure of which is incorporated herein by reference. Additionally or alternatively, the staple cartridge (37) may be constructed and operative in accordance with at least some of the teachings of U.S. Patent No. 9,808,248, entitled “Installation Features for Surgical Instrument End Effector Cartridge,” published on November 7, 2017, the disclosure of which is incorporated herein by reference. Other suitable forms that the staple cartridge (37) may take will be apparent to those skilled in the art in view of the teachings herein.

[0045] By advancing the closure tube (32) and the closure ring (33) distally to allow the end effector (12) to Figures 4A to 4B In the closed position shown, the firing beam (14) is advanced into engagement with the anvil (18) by passing the upper pin (38) into the longitudinal anvil slot (42). Figure 5 ) is located at the distal end of the firing beam (14) and is configured to engage the wedge slide (41) so that when the firing trigger (28) is actuated, the push block (80) pushes the wedge slide (41) distally as the firing beam (14) advances distally through the staple cartridge (37). During such firing, the cutting edge (48) of the firing beam (14) enters the vertical slot (49) of the staple cartridge (37), thereby severing the tissue clamped between the staple cartridge (37) and the anvil (18). Figures 4A to 4B As shown, the intermediate pin (46) and the push block (80) together actuate the nail magazine (37) by entering the narrow slot (49) in the nail magazine (37) to drive the wedge slide (41) into upward contact with the nail driver (43), thereby driving the nail (47) outward through the nail hole (51) and causing the nail to engage with the nail forming recess (53) on the inner surface of the anvil (18) ( Figure 3 ) to form contact. Figure 4B The firing beam (14) is shown fully translated distally after severing and stapling the tissue. Figures 4A to 4B The nail forming recess (53) is intentionally omitted in the view in FIG; however, the nail forming recess (53) is as shown in FIG. Figure 3 It should also be understood that Figure 5The anvil (18) is intentionally omitted from the view.

[0046] Figure 7 The end effector (12) is shown having been actuated through tissue (90) in a single stroke. As shown, the cutting edge (48) ( Figure 7 1 and 2. The staples (47) are arranged in a manner that is not shown in the figure and that is not shown in the figure. The staples (47) are arranged in a manner that is not shown in the figure and that is not shown in the figure. The staples (47) are arranged in a manner that is not shown in the figure and that is not shown in the figure. The staples (47) are arranged in a manner that is not shown in the figure and that is not shown in the figure. The staples (47) are arranged in a manner that is not shown in the figure and that is not shown in the figure. The staples (47) are arranged in a manner that is not shown in the figure and that is not shown in the figure. The staples (47) are arranged in a manner that is not shown in the figure and that is not shown in the figure. The staples (47) are arranged in a manner that is not shown in the figure and that is not shown in the figure. The staples (47) are arranged in a manner that is not shown in the figure and that is not shown in the figure. The staples (47) are arranged in a manner that is not shown in the figure and that is not shown in the figure.

[0047] It will be appreciated that during each actuation stroke, the cutting edge (48) can sever tissue substantially simultaneously with the driving of the staples (47) therethrough. In this example, the cutting edge (48) lags only slightly behind the driving of the staples (47) such that the staples (47) are driven through the same region of tissue just before the cutting edge (48) is driven therethrough, but it will be appreciated that this order can be reversed or that the cutting edge (48) can be synchronized directly with the adjacent staples. While Figure 7 The end effector (12) is shown being actuated in two layers (92, 94) of tissue (90), but it should be understood that the end effector (12) can be actuated through a single layer of tissue (90) or more than two layers (92, 94) of tissue. It should also be understood that the formation and positioning of the staples (47) adjacent to the cut line created by the cutting edge (48) can substantially seal the tissue at the cut line, thereby reducing or preventing bleeding and / or leakage of other body fluids at the cut line. In addition, although Figure 7 The end effector (12) is shown actuating in two substantially flat opposing planar layers (92, 94) of tissue, but it should be understood that the end effector (12) may also be actuated on tubular structures such as blood vessels, portions of the gastrointestinal tract, etc. Therefore, it should not be considered that Figure 7 No limitations are to be construed as to the contemplated uses of end effector (12). Various suitable locations and procedures in which instrument (10) may be used will be apparent to those skilled in the art in view of the teachings herein.

[0048] In one version, the instrument (10) provides motorized control of the firing beam (14). Exemplary components that can be used to provide motorized control of the firing beam (14) are shown and described in U.S. Patent No. 9,622,746, entitled "Distal Tip Features for End Effector of Surgical Instrument," published on April 18, 2017, the disclosure of which is incorporated herein by reference. In addition to or in lieu of the foregoing, at least a portion of the motorized control can be constructed in accordance with at least some of the teachings of U.S. Patent No. 8,210,411, entitled "Motor-Driven Surgical Instrument," published on July 3, 2012, the disclosure of which is incorporated herein by reference. In addition to or in lieu of the foregoing, the features operable to drive the firing beam (14) may be constructed in accordance with at least some of the teachings of U.S. Patent No. 8,453,914, the disclosure of which is incorporated herein by reference; and / or constructed in accordance with at least some of the teachings of U.S. Patent No. 8,453,914, the disclosure of which is incorporated herein by reference. Other suitable components, features, and configurations for providing motorization of the firing beam (14) will be apparent to those skilled in the art in view of the teachings herein. It will also be understood that some other versions may provide manual actuation of the firing beam (14), such that a motor may be omitted. By way of example only, the firing beam (14) may be actuated in accordance with at least some of the teachings of any other patent / publication reference cited herein.

[0049] The instrument (10) may also include a lockout switch and a lockout indicator, as shown and described in U.S. Patent No. 9,622,746, entitled “Distal Tip Features for End Effector of Surgical Instrument,” issued on April 18, 2017, the disclosure of which is incorporated herein by reference. Additionally, the lockout switch and / or lockout indicator and associated components / functionality may be constructed in accordance with at least some of the teachings of U.S. Patent No. 7,644,848, entitled “Electronic Lockouts and Surgical Instrument Including Same,” issued on January 12, 2010, the disclosure of which is incorporated herein by reference.

[0050] The instrument (10) further includes a manual return switch (116) configured to act as a "panic" feature, enabling an operator to quickly retract the firing beam (14) proximally during the firing stroke. In other words, the manual return switch (116) can be manually actuated when the firing beam (14) is only partially advanced distally. The manual return switch (116) can provide additional functionality in accordance with at least some of the teachings of U.S. Patent No. 9,622,746, entitled "Distal Tip Features for End Effector of Surgical Instrument," published on April 18, 2017, the disclosure of which is incorporated herein by reference.

[0051] When describing the operation of the instrument (10), the use of the term "pivot" (and similar terms to the underlying "pivot") should not be interpreted as necessarily requiring pivotal movement about a fixed axis. In some versions, the anvil (18) pivots about an axis defined by a pin (or similar feature) that slides along an elongated slot or channel as the anvil (18) moves toward the lower jaw (16). In this type of version, the pivot axis translates along a path defined by the slot and channel while the anvil (18) simultaneously pivots about the axis. In addition or as an alternative, the pivot axis may first slide along the slot / channel and then the anvil (18) pivots about the pivot axis after the pivot axis has slid a certain distance along the slot / channel. It should be understood that such sliding / translational pivoting movement is encompassed by terms such as "pivot," "pivoting," "pivotable," etc. Of course, some versions may provide for pivotal movement of the anvil (18) about an axis that remains fixed and does not translate within the slot or channel, etc.

[0052] It will be appreciated that the apparatus (10) may be constructed and operated in accordance with the teachings of any of the following U.S. Patents: U.S. Patent 4,805,823; U.S. Patent 5,415,334; U.S. Patent 5,465,895; U.S. Patent 5,597,107; U.S. Patent 5,632,432; U.S. Patent 5,673,840; U.S. Patent 5,704,534; U.S. Patent 5,814,055; U.S. Patent 6,978,921; U.S. Patent 7,000,818; U.S. Patent 7,143,923; U.S. Patent 7,303,108; U.S. Patent 7,367,485; U.S. Patent 7,380,695; U.S. Patent 7,380,696; U.S. Patent 7,404,508; U.S. Patent 7,434,715; U.S. Patent 7,721,930; U.S. Patent 8,408,439 and / or 8,453,914. As mentioned above, the disclosure of each of these patents is incorporated herein by reference. Other exemplary modifications that may be provided for the apparatus (10) will be described in more detail below. Various suitable ways in which the following teachings may be incorporated into the apparatus (10) will be apparent to one of ordinary skill in the art. Similarly, various suitable ways in which the following teachings may be combined with the various teachings of the patents / publications cited herein will be apparent to one of ordinary skill in the art. It should also be understood that the following teachings are not limited to the apparatus (10) or devices taught in the patents cited herein. The following teachings may be readily applied to various other types of apparatus, including apparatus that will not be classified as surgical staplers. With reference to the teachings herein, various other suitable devices and situations in which the following teachings may be applied will be apparent to one of ordinary skill in the art.

[0053] II. Nail Cartridges with Proximal Fastening Features

[0054] As described above, the end effector (12) of the instrument is configured to receive a staple cartridge (37). The distal end of the firing beam (14) can then be received in the proximal end of the staple cartridge (37) to drive the wedge slide (41) and the cutting edge (48) distally within the staple cartridge (37), thereby simultaneously severing the tissue (90) and driving the staples (47) upward to seal the tissue (90). Therefore, it should be understood that alignment between the staple cartridge (37) and the firing beam (14) is desired to facilitate proper driving of the staples (47) and severing the tissue (90).

[0055] However, in some cases, certain portions of the staple cartridge (37) may become misaligned relative to one another during packaging, shipping, and / or handling of the staple cartridge (37). For example, in some cases, portions of the cartridge body (70) may become misaligned relative to corresponding portions of the lower cartridge tray (74). In such cases, driving the firing beam (14) distally within the staple cartridge (37) may present challenges. Therefore, it should be understood that in some examples, a staple cartridge similar to the staple cartridge (37) may be desirable that incorporates features that facilitate secure fastening between the various components of the staple cartridge (37), thereby facilitating consistent and reliable alignment between the components of the staple cartridge (37). Although various suitable fastening features are described herein in particular configurations and in conjunction with particular devices, it should be understood that in other examples, such fastening features are arranged in other configurations and in conjunction with other devices.

[0056] Figures 8 to 10 An exemplary alternative staple cartridge (200) is shown that is configured to be used with the above-described instrument (10) in place of the staple cartridge (37). Unless otherwise specified herein, it should be understood that the staple cartridge (200) is substantially similar to the above-described staple cartridge (37). For example, like the staple cartridge (37), the staple cartridge (200) of this example includes a cartridge body (220). Similar to the above, the cartridge body (220) defines an upper platform (222) and is coupled to a lower cartridge tray (260). The upper platform (222) at least partially defines a vertical slot (224) formed through a portion of the staple cartridge (200). The upper platform (222) further defines three rows of staple holes (226) extending through the upper platform (222) on one side of the vertical slot (224), and another set of three rows of staple holes (226) formed through the upper platform (222) on the other side of the vertical slot (224). Of course, any other suitable number of rows of staples may be provided (eg, two rows, four rows, or another number).

[0057] It should be understood that, similar to the nail magazine (37), the nail magazine (200) of this example is configured to be used in conjunction with the wedge slide (41) and the firing beam (14) to drive multiple nail drivers (not shown). The nail driver can be captured between the magazine body (220) and the tray (260), wherein the wedge slide (41) is located proximal to the nail driver. The wedge slide (41) can move longitudinally within the nail magazine (200); while the nail driver can move vertically within the nail magazine (200). Nails (not shown) can also be positioned within the magazine body (220) above the corresponding nail driver. Therefore, each nail can be driven vertically by the corresponding nail driver within the magazine body (220) to drive the nail out of the associated nail hole (226).

[0058] The staple cartridge (200) of this example includes certain features configured to facilitate secure retention and alignment between the cartridge body (220) and the cartridge tray (260). As will be described in further detail below, such retention features are typically positioned near the proximal end of the staple cartridge (200). This proximal positioning is typically desirable because movable components of the instrument (10), such as the firing beam (140), engage directly with the proximal end of the staple cartridge (200). Therefore, proper alignment between the cartridge body (220) and the cartridge tray (260) is particularly desirable at the proximal end of the staple cartridge (200).

[0059] like Figure 9 As best seen in FIG, each side of the cartridge body (220) includes a distal laterally extending tab (230) and a proximal laterally extending tab (232). The tabs (230, 232) are generally configured to be received within corresponding windows (270, 272) of the cartridge tray (260), thereby providing a snap-fit ​​configuration between the cartridge body (220) and the cartridge tray (260).

[0060] Each protrusion (230, 232) extends outwardly from a side surface of the cartridge body (220) and defines a generally rectangular shape with rounded corners. The outward extension of each protrusion (230, 232) generally corresponds to the thickness of the cartridge tray (260). As will be described in detail below, it may be desirable to promote generally flat or flush side surfaces of the staple cartridge (200) when the cartridge body (220) and cartridge tray (260) are coupled together.

[0061] The bin tray (260) defines a distal window (270) and a proximal window (272) on each side thereof, respectively. Each window (270, 272) is constructed as a generally rectangular cutout on each side of the bin tray (260). Thus, each window (270, 272) is configured to receive a corresponding protrusion (230, 232) of the bin body (220). Although the specific shapes of the protrusions (230, 232) and windows (270, 272) are shown as generally rectangular in this example, it should be understood that in other examples, various alternative shapes may be used. For example, in some examples, the protrusions (230, 232) and windows (270, 272) may be elliptical or circular. In other examples, the protrusions (230, 232) and windows (270, 272) may be triangular, square, or any other suitable shape. Regardless of the shape, it should be understood that additional numbers of combinations of tabs (230, 232) and windows (270, 272) may be used along the length of staple cartridge (200).

[0062] The hopper body (220) also includes side recesses (238), indentations, or openings on each side of the hopper body (220). The side recesses (238) are generally configured to receive corresponding features of the hopper tray (260) to securely fasten the hopper body (220) to the hopper tray (260). In the present example, the side recesses (238) are configured as rectangular openings on the sides of the hopper body (220). Of course, various other suitable shapes may be used, as will be described in detail below. The side recesses (238) of the present example extend from the outer surface through the hopper body (220) into the inner cavity of the hopper body (220). Therefore, the side recesses (238) of the present example are through holes. Alternatively, it should be understood that in other examples, the side recesses (238) may extend only through a portion of the hopper body (220), similar to a depression, groove, or blind hole.

[0063] The bin tray (260) also includes a distal tab (278) located on each side corresponding to each side recess (238) of the bin body (220). Each distal tab (278) is configured to be received within the side recess (238) of the bin body (220) to securely fasten the bin body (220) to the bin tray (260). Each distal tab (278) defines an inverted L-shape. Thus, each distal tab (278) includes an approximately 90° bend followed by an inward extension. The specific length of the inward extension of each distal tab (278) can be any suitable amount to facilitate the connection between the bin body (220) and the bin tray (260). For example, in some examples, the inward extension of each distal tab (278) corresponds to the approximate wall thickness of the bin body (220). The extension of each distal tab (278) may be configured to retain the cartridge body (220) to the lower cartridge tray (260) and thereby prevent lateral or upward movement of the cartridge body (220).

[0064] The bin body (220) further includes a retaining cover (240). The retaining cover (240) of this example is generally configured to be fastened to a portion of the bin body (220) to capture at least a portion of the lower bin tray (260) within the bin body (220). Figure 9 As best seen in FIG, cartridge body (220) defines a proximal recess (234) configured to receive a retaining cap (240). The specific depth of proximal recess (234) is configured to provide a generally smooth transition between the surface of upper platform (222) and the surface of retaining cap (240). As will be described in detail below, this transition may be determined, at least in part, by the thickness of retaining cap (240).

[0065] The retaining cap (240) of this example is divided into a left side portion (242) and a right side portion (244), such that the retaining cap (240) can at least partially define the vertical slot (224) when secured to the cartridge body (220). Each side portion (242, 244) is generally a mirror image of the other side portion and is therefore symmetrical. However, it should be understood that in other examples, some asymmetry may exist.

[0066] The retaining cover (240) is generally formed in the shape of a square with a vertical slot (224) extending through its center. Thus, each side portion (242, 244) generally defines a rectangular shape. The thickness of each side portion (242, 244) is generally configured to support a mating arrangement with various components of the bin body (220) and the lower bin tray (260). Various suitable thicknesses of each side portion (242, 244) will be described in more detail below.

[0067] As described above, retaining cap (240) is securely fastened within proximal recess (234) of cartridge body (220). In this example, retaining cap (240) is configured to be fastened by ultrasonic welding. In other examples, it will be appreciated that various alternative fastening means may be used, such as adhesive bonding, mechanical fastening, and / or any other suitable components or techniques.

[0068] To facilitate a robust ultrasonic weld between the retaining cap (240) and the cartridge body (220), the retaining cap (240) includes a plurality of energy directors (250). Each energy director (250) is configured to engage a corresponding feature of the cartridge body (220) to focus the ultrasonic energy or vibration provided by the sonotrode during the welding process to a predetermined area or point. In this example, each side portion (242, 244) includes two energy directors (250). Each energy director (250) protrudes downwardly from the bottom surface of each side portion (242, 244) to engage a corresponding energy well (236) defined within the proximal recess (234) of the cartridge body (220).

[0069] Each energy director (250) of the present example defines a generally rectangular cross-sectional shape extending downwardly from the bottom surface of each side portion (242, 244). In addition, the ends of each energy director (250) are beveled or tapered to an edge or substantial edge. Thus, it should be understood that the edge of each energy director (250) forms a substantially triangular shape. In some examples, such an edge configuration is generally desirable to facilitate the concentration of ultrasonic energy at the tip of each energy director (250). For example, with an edge (or substantial edge), the edge will concentrate the highest stress during welding. Therefore, melting during welding will initially occur at the edge, thereby providing greater control over the melting location and the final amount of material melted during ultrasonic welding.

[0070] Each energy director (250) is positioned in an orientation to promote uniform welding overall. As can be seen, each energy director (250) begins at a respective outer corner of the corresponding side portion (242, 244) and then extends inwardly toward the centerline of each side portion (242, 244). This orientation is configured to provide uniform weld coverage across the mating surfaces between the hopper body (220) and the retaining cover (240).

[0071] As described above, the proximal recess (234) includes a plurality of energy wells (236) corresponding to each energy director (250). In this example, each energy well (236) forms an elongated indentation in the upper surface of the cartridge body (220) defined by the proximal recess (234). Because each energy well (236) is configured to receive a corresponding energy director (250), each energy well (236) has an orientation corresponding to the corresponding energy director (250). Additionally, it should be understood that the depth of each energy well (236) is relatively small relative to the downwardly extending portion of each energy director (250). This smaller depth allows at least some of each energy director (250) to melt during the ultrasonic welding process before the mating surfaces between the cartridge body (220) and the retaining cap (240) contact each other.

[0072] While various specific configurations for the energy directors (250) and energy traps (236) are described herein, various alternative configurations may be used in other examples. For example, in some examples, the energy directors (250) may be associated with the proximal recess (234), while the energy trap (236) may be associated with the retaining cap (240). Additionally or alternatively, it should be understood that the energy directors (250) (and, correspondingly, the energy traps (236)) may take various shapes, forms, and orientations. For example, while the present example includes four energy directors (250), in other examples, any other suitable number of energy directors (e.g., six, eight, or ten) may be used. Similarly, the length and orientation of each energy director (250) may vary. For example, in other examples, each energy director (250) may be oriented axially rather than at an angle. Additionally or alternatively, the combined energy directors (250) may be positioned in a linear array (e.g., rows / columns). Other suitable alternative configurations for energy guide (250) and energy well (236) will be apparent to those skilled in the art in view of the teachings herein.

[0073] While this example illustrates the use of energy guide (250) and energy well (236) in conjunction with the proximal end of cartridge body (220), it should be understood that in other examples, substantially similar features may be used on other portions of cartridge body (220). Furthermore, in other examples, features substantially similar to energy guide (250) and energy well (236) may be used in other portions of the instrument (10) described herein or in other instruments entirely. By way of example only, suitable alternative instruments may include other instruments with small mating components where secure fastening is required to achieve adequate performance.

[0074] Each side portion (242, 244) also includes a tab receiver (252) extending through a portion of each side portion (242, 244). As will be described in detail below, each tab receiver (252) is generally configured to receive and capture a portion of the lower bin tray (260) to securely fasten the lower bin tray (260) to the bin body (220). Each tab receiver (252) includes a horizontal channel (254) and a vertical channel (256) to form a generally L-shaped configuration within each side portion (242, 244). Figure 9 As best seen in the figure, a horizontal channel (254) extends inwardly from the outside of each side portion (242, 244) toward its center. The horizontal channel (254) is also formed as a rectangular cutout in the bottom surface of each side portion (242, 244). As will be described in detail below, this configuration of the horizontal channel (254) is generally configured to accommodate a horizontal extension of the lower bin tray (260) between the corresponding side portion (242, 244) and the bin body (220).

[0075] The vertical channels (256) extend upwardly from the horizontal channels (254) through the entire thickness of the corresponding side portions (242, 244). Like the horizontal channels (254), the vertical channels (256) define a generally rectangular shape. However, unlike the horizontal channels (254), the vertical channels (256) are generally configured to accommodate a vertical extension of the lower bin tray (260) to prevent the bin tray (260) from moving laterally or lateral relative to the bin body (220).

[0076] The lower bin tray (260) also includes proximal tabs (280) located on each side thereof. Each proximal tab (280) is generally configured to be received within a tab receiver (252) of each side portion (242, 244). Therefore, it should be understood that each proximal tab (280) has a cooperative relationship with a corresponding tab receiver (252) to capture the lower bin tray (260) between the bin body (220) and the retaining cover (240).

[0077] like Figure 9As best seen in FIG, the proximal tab (280) includes a horizontal extension (282) and a vertical extension (284). The horizontal extension (282) and the vertical extension (284) are rounded together to form a generally S-shaped pattern. Figure 10 As best seen in the figure, when the retaining cover (240) is secured to the bin body (220), the horizontal extensions (282) are configured to be received within the horizontal channels (254) of the corresponding tab receivers (252). Simultaneously, the vertical extensions (284) are configured to be received within the vertical channels (256) of the corresponding tab receivers (252). It should be understood that the horizontal extensions (282) ensure the vertical, or up-and-down, orientation of the lower bin tray (260) relative to the bin body (220). Simultaneously, the vertical extensions (284) secure the lateral, or left-and-right, orientation of the lower bin tray (260) relative to the bin body (220).

[0078] In some examples, it may be desirable to have a predetermined relationship between the thickness of the retaining cap (240), the length of the vertical extension (284) of the proximal tab (280), and the depth of the proximal recess (234). For example, in this example, the thickness of the retaining cap (240) generally corresponds to the length of the vertical extension (284) to promote a flush fit or slightly recessed fit between the upper end of the vertical extension (284) and the upper surface of the retaining cap (240). Such a configuration is generally desirable to prevent the proximal tab (280) from interfering with the operation of the instrument (10). In other examples, the relationship can also be configured to correspond to the depth of the proximal recess (234), so that the upper platform (222), the upper end of the vertical extension (284), and the upper surface of the retaining cap (240) are all aligned along a planar surface. Of course, in other examples, the thickness of the retaining cap (240) can be slightly larger than the depth dimension of the proximal recess (234), as shown in this example.

[0079] III. Exemplary Nail Cartridges with Twisted Portions

[0080] Figure 11An exemplary alternative staple cartridge (300) is shown that is configured to be used with the above-described instrument (10) in place of the staple cartridge (37). Unless otherwise specified herein, it should be understood that the staple cartridge (300) is substantially similar to the above-described staple cartridges (37, 200). For example, like the staple cartridge (37), the staple cartridge (300) of this example includes a cartridge body (320). Similar to the above, the cartridge body (320) defines an upper platform (322) and is coupled to a lower cartridge tray (360). The upper platform (322) at least partially defines a vertical slot (324) formed through a portion of the staple cartridge (300). The upper platform (322) further defines three rows of staple holes (326) extending through the upper platform (322) on one side of the vertical slot (324), and another set of three rows of staple holes (326) formed through the upper platform (322) on the other side of the vertical slot (324). Of course, any other suitable number of rows of staples may be provided (eg, two rows, four rows, or another number).

[0081] It should be understood that, similar to the nail magazine (37), the nail magazine (300) of this example is configured to be used in conjunction with the wedge slide (41) and the firing beam (14) to drive multiple nail drivers (not shown). The nail drivers can be captured between the magazine body (320) and the tray (360), wherein the wedge slide (41) is located proximal to the nail drivers. The wedge slide (41) can move longitudinally within the nail magazine (300); while the nail drivers can move vertically within the nail magazine (300). Nails (not shown) can also be positioned within the magazine body (320) above the corresponding nail drivers. Therefore, each nail can be driven vertically by the corresponding nail driver within the magazine body (320) to drive the nail out of the associated nail hole (326).

[0082] As with the staple cartridge (200) described above, the staple cartridge (300) of this example includes certain features configured to facilitate secure retention and alignment between the cartridge body (320) and the cartridge tray (360). Similar to the above, such retention features are typically positioned near the proximal end of the staple cartridge (300). This proximal positioning is typically desirable because movable components of the instrument (10), such as the firing beam (14), engage directly with the proximal end of the staple cartridge (300). Therefore, proper alignment between the cartridge body (320) and the cartridge tray (360) is particularly desirable at the proximal end of the staple cartridge (300).

[0083] like Figure 11As best seen in FIG, cartridge body (320) is similar to cartridge body (220), with each side of cartridge body (320) including a distally extending laterally extending tab (330) and a proximally extending laterally extending tab (332). Tabs (330, 332) are generally configured to be received within corresponding windows (370, 372) of cartridge tray (360), thereby providing a snap-fit ​​configuration between cartridge body (320) and cartridge tray (360).

[0084] As with the protrusions (230, 232) described above, each protrusion (330, 332) extends outwardly from a side surface of the cartridge body (320) and defines a generally rectangular shape with rounded corners. The outward extension of each protrusion (330, 332) generally corresponds to the thickness of the cartridge tray (360). As will be described in detail below, it may be desirable to promote generally flat or flush side surfaces of the staple cartridge (300) when the cartridge body (320) and cartridge tray (360) are coupled together.

[0085] The bin tray (360) defines a distal window (370) and a proximal window (372) on each side thereof, respectively. Each window (370, 372) is constructed as a generally rectangular cutout on each side of the bin tray (360). Thus, each window (370, 372) is configured to receive a corresponding protrusion (330, 332) of the bin body (320). Although the specific shapes of the protrusions (330, 332) and windows (370, 372) are shown as generally rectangular in this example, it should be understood that in other examples, various alternative shapes may be used. For example, in some examples, the protrusions (330, 332) and windows (370, 372) may be elliptical or circular. In other examples, the protrusions (330, 332) and windows (370, 372) may be triangular, square, or any other suitable shape. Regardless of the shape, it should be understood that additional numbers of combinations of tabs (330, 332) and windows (370, 372) may be used along the length of staple cartridge (300).

[0086] The hopper body (320) also includes side recesses (338), indentations, or openings on each side of the hopper body (320). The side recesses (338) are generally configured to receive corresponding features of the hopper tray (360) to securely fasten the hopper body (320) to the hopper tray (360). In this example, the side recesses (338) are configured as rectangular openings on the sides of the hopper body (320). Of course, various other suitable shapes may be used, as will be described in detail below. The side recesses (338) of this example extend from the outer surface through the hopper body (320) into the inner cavity of the hopper body (320). Therefore, the side recesses (338) of this example are through holes. Alternatively, it should be understood that in other examples, the side recesses (338) may extend only through a portion of the hopper body (320), similar to a depression, groove, or blind hole.

[0087] The bin tray (360) also includes a distal tab (378) located on each side corresponding to each side recess (338) of the bin body (320). Each distal tab (378) is configured to be received within the side recess (338) of the bin body (320) to securely fasten the bin body (320) to the bin tray (360). Each distal tab (378) defines an inverted L-shape. Thus, each distal tab (378) includes an approximately 90° bend followed by an inward extension. The specific length of the inward extension of each distal tab (378) can be any suitable amount to facilitate the connection between the bin body (320) and the bin tray (360). For example, in some examples, the inward extension of each distal tab (378) corresponds to the approximate wall thickness of the bin body (320). The extension of each distal tab (378) may be configured to retain the cartridge body (320) to the lower cartridge tray (360) and thereby prevent lateral or upward movement of the cartridge body (320).

[0088] Unlike the staple cartridge (200) described above, the staple cartridge (300) of this example omits certain features similar to the retaining cover (240) described above. Instead, the staple cartridge (300) of this example includes certain fastening features combined with various manipulation methods to securely fasten the cartridge body (320) to the lower cartridge tray (360). Figure 11 As best seen in FIG, the cartridge body (320) includes a pair of proximal channels (340) positioned on each side of its proximal end. Each proximal channel (340) extends downwardly from the upper platform (322) into the surface of the cartridge body (320) and extends longitudinally along a portion of the length of the cartridge body (320). In addition, each proximal channel (340) is offset inwardly from a corresponding side of the cartridge body (320) by a predetermined amount. As will be described in detail below, each proximal channel (340) is configured to receive a corresponding retaining feature of the lower cartridge tray (360).

[0089] The lower bin tray (360) includes proximal tabs (380) on each side thereof. Each proximal tab (380) corresponds to each proximal channel (340) of the bin body (320). Therefore, at least a portion of each proximal tab (380) is configured to be received within the corresponding proximal channel (340). Each proximal tab (380) includes two folds to define a 270° bend. The bend defines a structure similar to a three-sided box. In other words, each proximal tab (380) first extends horizontally and inwardly from the side of the lower bin tray (360) at an angle of approximately 90° relative to the side of the lower bin tray (360). Each proximal tab (380) then bends approximately another 90° and extends downward.

[0090] like Figure 11 As can be seen in the figure, when the hopper body (320) and the lower hopper tray (360) are coupled together, each proximal tab (380) is received within a corresponding proximal channel (340) of the hopper body (320). It can be seen that a portion of each proximal tab (380) extends on the surface of the upper platform (322) approximately the distance that each proximal channel (340) is offset inward from the side of the hopper body (320). This horizontal extension of each proximal tab (380) is configured to retain the hopper body (320) within the lower hopper tray (360) along a vertical or up-down plane or axis. Each proximal tab (380) then bends downward, extending into the corresponding proximal channel (340). This vertical extension of each proximal tab (380) is configured to retain the hopper body (320) within the lower hopper tray (360) along a horizontal or left-right plane or axis. It will therefore be appreciated that the relationship between the proximal tab (380) and the proximal channel (340) is configured to maintain the position of the bin body (320) relative to the lower bin tray (360) along at least two axes.

[0091] In some examples, it may be desirable to have additional fastening means to more securely hold the bin body (320) in position relative to the lower bin tray (360). In some examples, additional manipulation of the lower bin tray (360) may be performed after the bin body (320) and the lower bin tray (360) are coupled together to enhance the stability of their coupling. For example, Figure 12AAs can be seen in the figure, each proximal tab (380) can be manipulated after connection to deform each proximal tab (380). In the present example, the deformation involves applying a downward force to the top of each proximal tab (380) until each proximal tab (380) is deformed. In the present example, the force is applied by tapping each proximal tab (380) at one or more locations along its upper portion. By way of example only, the process of tapping each proximal tab (380) can form a series of indentations, impressions, or pits in its surface to enhance the engagement between the proximal tab (380) and the cartridge body (320). In other examples, the force can be applied by other suitable means, such as a press or any other suitable device, which will be apparent to those skilled in the art in view of the teachings herein.

[0092] In other examples, the forces described above may be applied in different ways to manipulate the proximal tab (380) as described above. Although the different force applications described herein are described separately, it should be understood that in some examples, the different force applications may be performed together to further deform the lower bin tray (360). Figure 12B Another application of force for deforming the proximal tab (380) is shown. As can be seen, Figure 12B The force application shown in is essentially similar to Figure 12A , except that the force application in this example is oriented at an angle of approximately 45° relative to the horizontal extension of the proximal tab (380). As with the force application described above, the force applied in this example is typically applied using a tapping or other pressure-applying device. However, in some examples, it may be desirable to apply the force at a 45° angle to deform the horizontal extension of the proximal tab (380), the vertical extension of the proximal tab (380), the 90° bend of the proximal tab (380), or some combination thereof.

[0093] In other examples, it may be desirable to apply the aforementioned forces to other portions of the lower bin tray (360) to deform other portions thereof. For example, Figure 13A As can be seen in FIG, in some examples, force can be applied to the sides of the lower bin tray (360). In this example, force is similarly applied using a tap or another pressure-applying device. Such force can be applied using a pointed tapping tool (390) at multiple locations along the length of the lower bin tray (360). Figure 13A As shown, this force causes the lower bin tray (360) to deform to have one or more rounded or dome-shaped indentations similar to detent features. This deformation can provide additional securement between the bin body (320) and the lower bin tray (360) by digging the lower bin tray (360) into the surface of the bin body (320).

[0094] In other examples, the force applied may be great enough to pierce the lower bin tray (360). Such piercing may be desirable to enhance the engagement between the lower bin tray (360) and the bin body (320). For example, Figure 13B As can be seen in FIG, the piercing tool (390) can be used with sufficient force so that its tip completely penetrates the side of the lower bin tray (360) (or any other portion of the lower bin tray (360)). This penetration can cause portions of the lower bin tray (360) to extend into the surface of the bin body (320), thereby strengthening the connection between the bin body (320) and the lower bin tray (360).

[0095] Although not shown, it should be understood that in other examples, similar deformation principles can be applied in different ways to enhance the connection between the warehouse body (320) and the lower warehouse tray (360). For example, in some examples, multiple portions of the lower warehouse tray (360) can be grooved to form tabs or engaging sections that can subsequently be deformed by knocking and / or other pressure means. By way of example only, in one example, a three-legged rectangle or radial groove can be pre-cut in a portion of the lower warehouse tray (360) having a larger cross-sectional area (e.g., a side) to form a tab or other feature. Such a tab can initially be flush with the rest of the lower warehouse tray (360). However, once the lower warehouse tray (360) is attached to the warehouse body (320), such a tab can be deformed to enhance the connection between the lower warehouse tray (360) and the warehouse body (320). In some examples, such a configuration may be desirable to facilitate easier or more controlled deformation of the lower warehouse tray (360).

[0096] IV. Exemplary Retainers for Staple Cartridges

[0097] In some examples, in addition to or in place of the coupling features described above with respect to staple cartridges (37, 200, 300), it may be desirable to provide additional coupling mechanisms. For example, in some examples, it may be desirable to provide external features or components to physically maintain engagement between a structure similar to cartridge body (70, 220, 320) and the aforementioned lower cartridge tray (74, 260, 360) prior to use of staple cartridge (37, 200, 300) in instrument (10). Such physical engagement structures may subsequently be removed or otherwise disabled when staple cartridge (37, 200, 300) is used in instrument (10). Such physical engagement structures may be desired to simplify the construction of staple cartridges similar to staple cartridges (37, 200, 300) or to provide additional coupling mechanisms. Examples of such engagements are described in more detail below.

[0098] Figure 14An exemplary retainer (400) is shown that can be readily used with any one or more of the staple cartridges (37, 200, 300) described herein. Although retainer (400) is shown herein for use with staple cartridge (300) described above, it should be understood that any other staple cartridge can be used with retainer (400), including staple cartridges (37, 200).

[0099] As can be seen, the retainer (400) includes a manipulator (410) and a cartridge receiving portion (420). In this example, both the manipulator (410) and the cartridge receiving portion (420) are typically formed integrally from a single plastic material. However, in some examples, it will be understood that various portions of the retainer (400) may include metal. For example, in some examples, the cartridge receiving portion (420) may include a metal insert. In some examples, such a metal insert may be desirable to prevent the cartridge receiving portion (420) from being worn by the staple cartridge (300). In examples where only plastic is used for the retainer (400), certain features of the staple cartridge (300) may be modified (e.g., rounded corners and eliminating sharp edges) to also prevent wear of the receiving portion (420).

[0100] The manipulator (410) is generally configured as a tab-shaped handle for an operator to grasp to manipulate the retainer (400). As will be described in detail below, the retainer (400) is configured to be detachable from the staple cartridge (300). Thus, the manipulator (410) can be used for manual separation. Therefore, it should be understood that, in addition to Figure 14 Besides the rounded tab shown, manipulator (410) can take a variety of forms. For example, in some examples, manipulator (410) can be an elongated square tab. Additionally or alternatively, manipulator (410) can include a plurality of gripping features, knurling, ribs, etc. Of course, various alternative configurations of manipulator (410) will be apparent to those skilled in the art in view of the teachings herein.

[0101] The cartridge receiving portion (420) is generally configured to receive at least a portion of the proximal end of the staple cartridge (300). It will be appreciated, therefore, that the cartridge receiving portion (420) is generally hollow. Furthermore, the cartridge receiving portion (420) defines a shape that closely corresponds to (e.g., provides a tight fit) the shape of the proximal end of the staple cartridge (300). In some versions, the cartridge receiving portion (420) comprises an elastomeric material that promotes friction between the cartridge receiving portion (420) and the proximal end of the staple cartridge (300). Additionally or alternatively, the cartridge receiving portion (420) may be slightly undersized relative to the proximal end of the staple cartridge (300) to provide an interference fit between the cartridge receiving portion (420) and the proximal end of the staple cartridge (300). Similarly, the interior of the cartridge receiving portion (420) may include bumps, ribs, or other features that provide an interference fit between the cartridge receiving portion (420) and the proximal end of the staple cartridge (300). In any event, the relationship between the magazine receiving portion (420) and the proximal end of the nail magazine (300) is such that the retainer (400) will not accidentally become detached from the proximal end of the nail magazine (300); however, an operator can intentionally remove the retainer (400) from the nail magazine (300) without much difficulty.

[0102] like Figure 15 As best seen in the figure, the cartridge receiving portion (420) is closely aligned with the proximal end of the staple cartridge (300) to provide a minimum gap between the cartridge receiving portion (420) and the staple cartridge (300). This minimum gap is generally desired to retain the cartridge body (320) within the lower cartridge tray (360) until the staple cartridge (300) is ready for use. Therefore, the cartridge receiving portion (420) is configured to provide a physical seal against the proximal end of the staple cartridge (300) until the staple cartridge (300) is ready for use.

[0103] like Figure 16 As can be seen in FIG, in use, the retainer (400) can be selectively connected to the proximal end of the staple cartridge (300) and then selectively detached therefrom. In such use, the retainer (400) can be attached after the staple cartridge (300) is assembled. During attachment, the retainer (400) can be used as a go / no-go gauge to verify the complete connection between the cartridge body (320) and the lower cartridge tray (360). The retainer (400) can then remain in place on the staple cartridge (300) during transport and storage to maintain alignment between the cartridge body (320) and the lower cartridge tray (360). Once the operator desires to use the staple cartridge (300), the retainer (400) can be removed before inserting the staple cartridge (300) into the instrument (10).

[0104] Figure 17An exemplary alternative retainer (500) that can be used in place of the retainer (400) described above is shown. Unless otherwise specified herein, the retainer (500) of this example is substantially similar to the retainer (400) described above. For example, the retainer (500) is generally configured to be used with the staple cartridges (37, 200, 300) described herein or any other suitable staple cartridge. Similarly, the retainer (500) is also configured to physically engage the proximal end of the staple cartridge (37, 200, 300) to maintain alignment between the cartridge body (70, 220, 320) and the lower cartridge tray (74, 260, 360). Furthermore, while the retainer (500) is described herein as being used with the staple cartridge (300), it should be understood that in other examples, the retainer (500) can be readily used with any other suitable staple cartridge, such as the staple cartridges (37, 200) described herein.

[0105] Unlike the retainer (400) described above, the retainer (500) of this example is generally configured to be able to remain fixed to the staple cartridge (300). Figure 17 As can be seen in the drawings, the retainer (500) includes a hoop portion (510) extending around the proximal end of the staple cartridge (300). The hoop portion (510) of this example is configured as a thin film polymer overwrap. The hoop portion (510) of this example is also configured to fit tightly against the proximal end of the staple cartridge (300). This tight fit is configured to provide sufficient hoop stress to maintain alignment between the cartridge body (320) and the lower cartridge tray (360).

[0106] In the present example, the hoop stress provided by hoop portion (510) is also sufficient to secure retainer (500) to staple cartridge (300). However, it should be understood that in other examples, an adhesive backing may be used to provide an adhesive bond between retainer (500) and staple cartridge (300). In such examples, the adhesive backing may be applied to the interior of hoop portion (510).

[0107] As described above, the hoop portion (510) comprises a polymer material. In this example, a bio-implantable / absorbable grade polymer material is used. Due to the attachment means used for the hoop portion (510), this bio-implantable / absorbable grade is generally desirable. For example, as described above, the hoop portion (510) of this example only uses hoop stress to secure the retainer (500) to the staple cartridge (300). Therefore, during surgery, some or all of the retainers (500) may be removed from the staple cartridge (300). Therefore, it may be desirable that the retainer (500) is of a bio-implantable / absorbable grade so that the retainer can remain in the patient's body if necessary. In contrast, if the hoop portion (510) is secured to the staple cartridge (300) by an adhesive backing, the hoop portion (510) may only comprise a biocompatible material because the retainer (500) will remain secured to the staple cartridge (300) during use.

[0108] The retainer (500) of this example further includes a plurality of perforations (520) located in the surface of the hoop portion (510). As can be seen, the perforations (520) are generally aligned with the vertical slots (324) of the staple cartridge (300). This positioning is configured to allow the cutting edge (48) of the instrument (10) to easily cut through the retainer (500) when the staple cartridge (300) is used with the instrument (10), or to otherwise allow the retainer (500) to be easily removed.

[0109] In use, the retainer (500) can be fastened to the proximal end of the staple cartridge (300) during assembly and after the coupling between the cartridge body (320) and the lower cartridge tray (360). The retainer (500) can then maintain alignment between the cartridge body (320) and the lower cartridge tray (360) during transport, storage, or at any other time prior to use with the instrument (10). Once the operator desires to use the staple cartridge (300), the retainer (500) can be separated from the staple cartridge (300) by the operator cutting the retainer (500) at the perforations (520). Alternatively, the retainer (500) can remain in place on the staple cartridge (300) during use with the instrument (10). In this use, retainer (500) may still be cut by cutting edge (48) of instrument (10), but after retainer (500) is cut by cutting edge (48), the severed portion of retainer (500) remains adhered to staple cartridge (300).

[0110] Figure 18Another exemplary alternative retainer (600) that can be used in place of the retainers (400, 500) described above is shown. Unless otherwise specified herein, the retainer (600) of this example is substantially similar to the retainer (400) described above. For example, the retainer (600) is generally configured to be used with the staples (cartridges 37, 200, 300) described herein or any other suitable staple cartridge. Similarly, the retainer (600) is also configured to physically engage the proximal end of the staple cartridge (37, 200, 300) to maintain alignment between the cartridge body (70, 220, 320) and the lower cartridge tray (74, 260, 360). Furthermore, while the retainer (600) is described herein as being used with the staple cartridge (300), it should be understood that in other examples, the retainer (600) can be readily used with any other suitable staple cartridge, such as the staple cartridge (37, 200) described herein.

[0111] Unlike the retainer (400) described above, the retainer (600) of this example is a thin film laminate comprising a proximal wall (610) having four tabs (620) extending distally therefrom. Each tab (620) comprises an adhesive backing, such that each tab (620) is configured to adhere to a surface of the staple cartridge (300). Optionally, the proximal wall (610) further comprises an adhesive backing for adhering to one or more proximal surfaces of the staple cartridge (300).

[0112] As described above, the retainer (600) of this example comprises a film, one or more portions of which have an adhesive backing. Due to the presence of the adhesive, the retainer (600) of this example is configured to remain fixed to the staple cartridge (300) even during use of the staple cartridge (300). Therefore, the retainer (300) may comprise only biocompatible polymers. However, in some examples, a bioimplantable / absorbable polymer grade may be used as needed so that portions of the retainer (600) may remain in the patient's body after use of the staple cartridge (300).

[0113] In use, the retainer (600) can initially be planar, with all of the proximal walls (610) and tabs (620) aligned with a single plane. The retainer (600) can then be applied to the staple cartridge (300) by first abutting the proximal wall (610) against the proximal end of the staple cartridge (300). Each tab (620) can then be bent approximately 90° relative to the proximal wall (610) to adhere to a corresponding surface of the staple cartridge (300), thereby attaching the retainer (600) to the staple cartridge (300). Once the retainer (600) is attached to the staple cartridge (300), the retainer (600) can remain in place during transport, storage, or any other activity. Once the operator desires to use the staple cartridge (300), the retainer (600) can be removed by pulling one or more tabs (620) away from the corresponding surface of the staple cartridge (300). Alternatively, retainer (600) may remain in place during use of staple cartridge (300) with instrument (10). In such use, it will be appreciated that cutting edge (48) of instrument (10) may be used to cut through retainer (600) without affecting the performance of instrument (10).

[0114] Figure 19 Another exemplary alternative retainer (700) is shown that can be used in place of or in addition to the retainers (400, 500, 600) described above. Unless otherwise specified herein, the retainer (700) of this example is substantially similar to the retainer (400) described above. For example, the retainer (700) is generally configured to be used with the staple cartridges (37, 200, 300) described herein or any other suitable staple cartridge. Similarly, the retainer (700) is also configured to physically engage the proximal end of the staple cartridge (37, 200, 300) to maintain alignment between the cartridge body (70, 220, 320) and the lower cartridge tray (74, 260, 360). Furthermore, while the retainer (700) is described herein as being used with the staple cartridge (300), it should be understood that in other examples, the retainer (700) can be readily used with any other suitable staple cartridge, such as the staple cartridges (37, 200) described herein.

[0115] Unlike the retainer (400) described above, the retainer (700) of this example is a portion of a biocompatible strip applied to the bottom portion of the staple cartridge (300) (e.g., opposite the upper platform (322)). The application of the retainer (700) is configured to cover the entire bottom surface of the staple cartridge (300), thereby spanning the gap defined by the vertical slots (324). This configuration may be desirable to prevent each "leg" of the staple cartridge (300) defined by the vertical slots (324) from splaying outward laterally during shipping, storage, and / or handling (or to easily identify when such a condition occurs due to tearing of the retainer (700)). Such splaying is generally undesirable because it may result in components of the staple cartridge (300) (such as staples, staple drivers, etc.) being dislodged.

[0116] Although retainer (700) of this example is shown as covering the entire bottom surface of staple cartridge (300), it should be understood that in other examples, this coverage may vary. For example, in some examples, retainer (700) may be shortened to cover only the proximal portion of the bottom surface of staple cartridge (300). Other covering configurations will be apparent to those skilled in the art in view of the teachings herein.

[0117] In use, the retainer (700) is applied during assembly of the staple cartridge (300). In some uses, application may occur after or before coupling the cartridge body (320) to the lower cartridge tray (360). In any case, once the retainer (700) is applied, the retainer (700) may remain in place during transportation, handling, and / or storage of the staple cartridge (300). Once the operator desires to use the staple cartridge (300), the retainer (700) may be removed by pulling the retainer (700) from the staple cartridge (300). Alternatively, the retainer (700) may remain in place while the staple cartridge (300) is used with the instrument (10). During such use, the retainer (700) may be easily cut using the cutting edge (48) of the instrument (10).

[0118] V. Example Warehouse Using Heat Riveting

[0119] Figure 20An exemplary alternative staple cartridge (800) is shown that is configured to be used with the above-described instrument (10) in place of the staple cartridge (37). Unless otherwise specified herein, it should be understood that the staple cartridge (800) is substantially similar to the above-described staple cartridges (37, 200, 300). For example, like the staple cartridge (37), the staple cartridge (800) of this example includes a cartridge body (820). Similar to the above, the cartridge body (820) defines an upper platform (822) and is coupled to a lower cartridge tray (860). The upper platform (822) at least partially defines a vertical slot (824) formed through a portion of the staple cartridge (800). The upper platform (822) further defines three rows of staple holes (826) extending through the upper platform (822) on one side of the vertical slot (824), and another set of three rows of staple holes (826) formed through the upper platform (822) on the other side of the vertical slot (824). Of course, any other suitable number of rows of staples may be provided (eg, two rows, four rows, or another number).

[0120] It should be understood that, similar to the nail magazine (37), the nail magazine (800) of this example is configured to be used in conjunction with the wedge slide (41) and the firing beam (14) to drive multiple nail drivers (not shown). The nail drivers can be captured between the magazine body (820) and the tray (860), wherein the wedge slide (41) is located proximal to the nail drivers. The wedge slide (41) can move longitudinally within the nail magazine (800); while the nail drivers can move vertically within the nail magazine (800). Nails (not shown) can also be positioned within the magazine body (820) above the corresponding nail drivers. Therefore, each nail can be driven vertically by the corresponding nail driver within the magazine body (820) to drive the nail out of the associated nail hole (826).

[0121] As with the above-described staple cartridges (200, 300), the staple cartridge (800) of this example includes certain features configured to facilitate secure retention and alignment between the cartridge body (820) and the cartridge tray (860). Similar to the above, such retention features are typically positioned near the proximal end of the staple cartridge (800). This proximal positioning is typically desirable because movable components of the instrument (10), such as the firing beam (14), engage directly with the proximal end of the staple cartridge (800). Therefore, proper alignment between the cartridge body (820) and the cartridge tray (860) is particularly desirable at the proximal end of the staple cartridge (800).

[0122] Similar to the above-mentioned hopper body (320), the hopper body (820) also includes side recesses (838), indentations, or openings on each side of the hopper body (820). The side recesses (838) are generally configured to receive corresponding features of the hopper tray (860) to securely fasten the hopper body (820) to the hopper tray (860). In this example, the side recesses (838) are configured as rectangular openings on the sides of the hopper body (820). Of course, various other suitable shapes may be used, as will be described in detail below. The side recesses (838) of this example extend from the outer surface through the hopper body (820) into the inner cavity of the hopper body (820). Therefore, the side recesses (838) of this example are through holes. Alternatively, it should be understood that in other examples, the side recesses (838) may extend only through a portion of the hopper body (820), similar to a depression, groove, or blind hole.

[0123] As with the above-described bin tray (360), the bin tray (860) also includes distal tabs (878) located on each side corresponding to each side recess (838) of the bin body (820). Each distal tab (878) is configured to be received within the side recess (838) of the bin body (820) to securely fasten the bin body (820) to the bin tray (860). Each distal tab (878) defines an inverted L-shape. Thus, each distal tab (878) includes an approximately 90° bend followed by an inward extension. The specific length of the inward extension of each distal tab (878) can be any suitable amount to facilitate the connection between the bin body (820) and the bin tray (860). For example, in some examples, the inward extension of each distal tab (878) corresponds to the approximate wall thickness of the bin body (820). The extension of each distal tab (878) may be configured to retain the cartridge body (820) to the lower cartridge tray (860) and thereby prevent lateral or upward movement of the cartridge body (820).

[0124] The hopper body (820) also includes a pair of proximal channels (840) similar to the proximal channels (340) described above. Like the proximal channels (340), the proximal channels (840) are located on each side of the proximal end thereof. Each proximal channel (840) extends downwardly from the upper platform (822) into the surface of the hopper body (820) and extends longitudinally along a portion of the length of the hopper body (820). In addition, each proximal channel (840) is offset inwardly from the corresponding side of the hopper body (820) by a predetermined amount. As will be described in detail below, each proximal channel (840) is configured to receive a corresponding retaining feature of the lower hopper tray (860).

[0125] The lower bin tray (860) also includes a proximal tab (880) located on each side thereof that is substantially similar to the proximal tab (380) described above. As with the proximal tab (380), each proximal tab 880 of this example corresponds to each proximal channel (840) of the bin body 820. Therefore, at least a portion of each proximal tab (880) is configured to be received within the corresponding proximal channel (840). Each proximal tab (880) includes two folds to define a 270° bend. This bend defines a structure similar to a three-sided box. In other words, each proximal tab (880) first extends horizontally and inwardly from the side of the lower bin tray (860) at an angle of approximately 90° relative to the side of the lower bin tray (860). Each proximal tab (880) then bends approximately another 90° and extends downward.

[0126] like Figure 20 As best seen in Figure 8, cartridge body (820) is similar to cartridge body (320), with each side of cartridge body (820) including a distally extending laterally extending tab (830) and a proximally extending laterally extending tab (832). Tabs (830, 832) are generally configured to be received within corresponding windows (870, 872) of cartridge tray (860).

[0127] Unlike the protrusions (330, 332) described above, the protrusions (830, 832) of this example are generally configured to provide a heat-riveted, stable form of engagement with the bin tray (860). For example, each protrusion (830, 832) extends outward from a side surface of the bin body (820) and defines a generally rectangular shape with rounded corners. The outward extension of each protrusion (830, 832) is generally greater than the thickness of the bin tray (860). As will be described in detail below, it may be desirable that this particular outward extension be excess material for each protrusion (830, 832), which material can subsequently be melted to cover at least a portion of the bin tray (860).

[0128] The cartridge tray (860) defines a distal window (870) and a proximal window (872) on each side thereof, respectively. Unless otherwise described herein, each window (870, 872) is substantially similar to each window (370, 372) described above with respect to the staple cartridge (300). For example, similar to each window (370, 372) described above, each window (870, 872) of this example is configured as a generally rectangular cutout on each side of the cartridge tray (860). Thus, each window (870, 872) is configured to receive a corresponding protrusion (830, 832) of the cartridge body (820).

[0129] Unlike each of the windows (370, 372) described above, one or more of the windows (870, 872) of this example may include a beveled edge (876) to facilitate the above-described heat staking configuration. For example, in this example, the proximal window (872) is shown as including a beveled edge (876). The beveled edge (876) is generally configured to reduce the thickness of the lower bin tray (860) in an area adjacent to the proximal window (872) to facilitate the flow of material from the bin body (820) over the lower bin tray (860). Although only the proximal window (872) is shown as including a beveled edge (876) in this example, it should be understood that in other examples, a structure similar to the beveled edge (876) may be added to both windows (870, 872).

[0130] like Figure 21A and Figure 21B As best seen in FIG, additional fastening in this example may be provided by heat riveting. Heat riveting involves using heat to melt a plastic component so that the plastic component wraps around or covers a portion of an adjacent component. In this example, the heat riveting is achieved by applying heat to the protrusions (830, 832) of the cartridge body (320). Figure 21A As can be seen in FIG, the protrusions (830, 832) initially extend outwardly through the windows (870, 872) of the lower bin tray (860). Heat is then applied to the protrusions (830, 832). The heat can be applied in a variety of ways, such as by a hot metal surface (e.g., iron). The heat causes at least some of the excess material of the protrusions (830, 832) provided by the additional lateral extensions to melt or otherwise deform. Upon melting or otherwise deforming, a portion of each protrusion (830, 832) may form a mushroom shape or twist into a Figure 21B , to cover at least a portion of the lower bin tray (860). Although not shown, it should be understood that in some examples, the process of heat riveting may also include applying a flat tool or other manipulator to each protrusion (830, 832) to manipulate each protrusion (830, 832) into a desired shape. In this example, a suitable desired shape is flat, such that each protrusion (830, 832) is substantially coplanar with the lower bin tray (860). However, in other examples, various alternative shapes may be used.

[0131] VI. Exemplary Combinations

[0132] The following examples relate to various non-exhaustive ways in which the teachings herein may be combined or applied. It should be understood that the following examples are not intended to limit the coverage of any claims that may be provided at any time in this patent application or subsequent submissions of this patent application. It is not intended to make a disclaimer. The following examples are provided solely for illustrative purposes. It is contemplated that the various teachings herein may be arranged and applied in a variety of other ways. It is also contemplated that some variations may omit certain features mentioned in the following examples. Therefore, any of the aspects or features mentioned below should not be considered decisive unless otherwise expressly indicated as such by the inventor or the inventor's successor at a later date, for example. If any claim set forth in this patent application or subsequent submissions related to this patent application includes additional features other than those mentioned below, these additional features should not be assumed to be added for any reason related to patentability.

[0133] Example 1

[0134] A surgical instrument end effector comprises: (a) a first jaw; (b) a second jaw, the second jaw comprising an anvil having a plurality of staple forming recesses, wherein the first jaw and the second jaw are operable to clamp and suturing tissue positioned between the first jaw and the second jaw; (c) a staple magazine, the staple magazine being configured to be received within the first jaw, the staple magazine comprising: (i) a magazine body, (ii) a lower tray, the magazine body and the lower tray being configured to be coupled together, and (iii) a plurality of staples; and (d) a retaining cover, the retaining cover being configured to be fastened to a proximal end of the magazine body and engage the lower tray, the retaining cover being further configured to fix a position of the lower tray relative to the magazine body.

[0135] Example 2

[0136] According to the surgical instrument end effector of embodiment 1, the cartridge body and the retaining cap each include one or more complementary ultrasonic welding features.

[0137] Example 3

[0138] In accordance with the surgical instrument end effector of Example 1, the complementary ultrasonic welding features include an energy guide and an energy well, the energy well being configured to receive the energy guide.

[0139] Example 4

[0140] According to the surgical instrument end effector of Example 3, the retaining cap includes the energy guide and the cartridge body includes the energy well.

[0141] Example 5

[0142] In the surgical instrument end effector according to embodiment 3 or 4, the energy guide includes a beveled portion forming an edge configured to engage with the energy well.

[0143] Example 6

[0144] In accordance with any one or more of the surgical instrument end effector embodiments 3 to 5, the energy guide is oriented at an oblique angle relative to a longitudinal axis defined by the staple cartridge.

[0145] Example 7

[0146] According to the surgical instrument end effector described in any one or more of Examples 2 to 5, the complementary ultrasonic welding features include 4 pairs of complementary ultrasonic welding features.

[0147] Example 8

[0148] According to the surgical instrument end effector described in any one or more of embodiments 1 to 7, the lower tray includes a tab configured to engage with the retaining cover.

[0149] Example 9

[0150] According to the surgical instrument end effector described in Example 8, the retaining cover includes a tab receiver, which is configured to receive the tab of the lower tray to capture the tab between the retaining cover and the magazine body.

[0151] Example 10

[0152] According to the surgical instrument end effector described in any one or more of Examples 8 to 9, the tab of the lower tray includes a first leg and a second leg, wherein the first leg extends inward from one side of the lower tray and the second leg extends upward relative to the first leg.

[0153] Example 11

[0154] According to the surgical instrument end effector described in Example 10, the tab receiver has a first channel and a second channel, and the first channel is configured to receive the first leg of the tab so that the first leg is arranged between the upper surface of the magazine body and the retaining cover.

[0155] Example 12

[0156] In accordance with the surgical instrument end effector of embodiment 11, the second channel is configured to receive the second leg to allow the tab to extend through the retaining cap.

[0157] Example 13

[0158] According to any one or more of the foregoing embodiments of the surgical instrument end effector, the cartridge body defines a recessed portion configured to receive the retaining cap therein.

[0159] Example 14

[0160] According to the surgical instrument end effector of any of the aforementioned embodiments, the retaining cap has a first side portion and a second side portion, and the first side portion and the second side portion are separated by a vertical narrow slot extending through the nail magazine.

[0161] Example 15

[0162] A surgical instrument comprises: (a) a body; (b) a shaft extending distally from the body; and (c) a surgical instrument end effector according to Example 1, wherein the surgical instrument end effector is disposed at the distal end of the shaft.

[0163] Example 16

[0164] A staple cartridge assembly for use with an end effector of a surgical instrument, comprising: (a) a staple cartridge configured to be received within a first jaw of the end effector of the surgical instrument, the staple cartridge comprising: (i) a cartridge body, (ii) a lower tray coupled to the cartridge body, and (iii) a plurality of staples; and (b) a retainer selectively coupled to one or both of the cartridge body or the lower tray at a proximal end of the staple cartridge, at least a portion of the retainer being configured to extend around at least a portion of the staple cartridge to secure a position of the cartridge body relative to the lower tray.

[0165] Example 17

[0166] According to the nail cartridge assembly described in Example 16, the retainer includes a handle and a cartridge receiving portion, and the cartridge receiving portion is configured to receive the proximal end of the nail cartridge.

[0167] Example 18

[0168] According to the staple cartridge assembly of Example 17, the grip is configured to be grasped by an operator for removing the retainer from the staple cartridge before the staple cartridge is received in the first jaw of the surgical instrument end effector.

[0169] Example 19

[0170] A method for securing a lower tray of a nail magazine to a magazine body, the method comprising: (a) inserting the magazine body into the lower tray, the inserting step comprising inserting a first tab of the lower tray into a first channel of the magazine body; (b) applying a force to a first portion of the lower tray or the magazine body to deform the first portion and thereby enhance engagement between the lower tray and the magazine body; and (c) further applying the force to the first portion until a predetermined amount of engagement between the lower tray and the magazine body is achieved.

[0171] Example 20

[0172] The method of embodiment 19, wherein the first portion corresponds to a portion of the first tab of the lower tray.

[0173] Example 21

[0174] According to the method described in any one or more of embodiments 19 or 20, the first tab includes a first leg and a second leg, the first leg is oriented at approximately 90° relative to the second leg, and the step of applying the force includes applying the force at an angle of approximately 90° relative to the first leg.

[0175] Example 22

[0176] According to the method described in any one or more of Examples 19 or 20, the first tab includes a first leg and a second leg, the first leg is oriented at approximately 90° relative to the second leg, and the step of applying the force includes applying the force at an angle of approximately 45° relative to the first leg.

[0177] Example 23

[0178] According to any one or more of the methods of embodiments 19 to 22, the step of applying the force includes applying the force using a tapping operation.

[0179] Example 24

[0180] The method of any one or more of embodiments 19 to 22, wherein applying the force comprises applying the force using a pressing operation.

[0181] Example 25

[0182] The method of any one or more of embodiments 19 to 24, wherein applying the force comprises applying the force to both a side of the lower tray and the first tab.

[0183] Example 26

[0184] According to the method described in any one or more of embodiments 19 to 25, the step of applying the force is performed using a tool with a sharp tip, and the step of applying the force includes penetrating at least a portion of the lower tray to deform at least some of the lower tray into the surface of the warehouse body.

[0185] Example 27

[0186] According to the method of Example 19, the bin body includes a first protrusion, the lower tray includes a first window configured to receive the first protrusion of the bin body, and the first portion corresponds to the first protrusion of the bin body.

[0187] Example 28

[0188] A method as in embodiment 27, wherein the first window comprises a beveled edge.

[0189] Example 29

[0190] A method according to any one or more of embodiments 19 to 27, wherein the step of applying the force includes applying at least some heat to the tank body.

[0191] Example 30

[0192] A method according to any one or more of embodiments 19 to 27, wherein the step of applying the force comprises using a heat staking process.

[0193] Example 31

[0194] A staple cartridge assembly for use with an end effector of a surgical instrument, comprising: (a) a staple cartridge configured to be received within a first jaw of the end effector of the surgical instrument, the staple cartridge comprising: (i) a cartridge body, (ii) a lower tray, the cartridge body and the lower tray configured to be coupled together, and (iii) a plurality of staples; (b) a retaining cover configured to be secured to a proximal end of the cartridge body and engage the lower tray, the retaining cover being further configured to fix a position of the lower tray relative to the cartridge body; and (c) a retainer selectively coupled to the proximal end of the cartridge body, at least a portion of the retainer being configured to extend around the staple cartridge to fix a position of the cartridge body relative to the lower tray.

[0195] Example 32

[0196] A staple cartridge assembly for use with an end effector of a surgical instrument, comprising: (a) a staple cartridge configured to be received within a first jaw of the end effector of the surgical instrument, the staple cartridge comprising: (i) a cartridge body, (ii) a lower tray, the cartridge body and the lower tray configured to be coupled together, and (iii) a plurality of staples; and (b) a retaining cover configured to be secured to a proximal end of the cartridge body and engage the lower tray, the retaining cover being further configured to fix a position of the lower tray relative to the cartridge body.

[0197] Example 33

[0198] A method of using with the staple cartridge assembly of embodiment 32 comprises applying a force to the lower tray to deform a portion of the lower tray to enhance engagement with the cartridge body.

[0199] VI. Miscellaneous

[0200] It should be understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. described herein. Therefore, the above teachings, expressions, embodiments, examples, etc. should not be considered in isolation from each other. Various suitable ways in which the teachings herein can be combined will be apparent to those skilled in the art with reference to the teachings herein. Such modifications and variations are intended to be included within the scope of the claims.

[0201] It should be understood that any patent, patent publication, or other public material, whether in whole or in part, allegedly incorporated herein by reference is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other public materials set forth in this disclosure. Accordingly, and to the extent necessary, the disclosure expressly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, allegedly incorporated herein that conflicts with existing definitions, statements, or other public materials set forth herein will be incorporated only to the extent that no conflict arises between the incorporated material and the existing public materials.

[0202] The types of devices described above can be applied to traditional medical treatments and surgeries performed by medical professionals, as well as robotic-assisted medical treatments and surgeries. By way of example only, the various teachings herein can be readily incorporated into robotic surgical systems, such as the DAVINCI® system from Intuitive Surgical, Inc. (Sunnyvale, California). TM system.

[0203] The types of the above-mentioned devices can be designed to be discarded after a single use, or they can be designed to be reusable. In either case or both cases, these types can be repaired for reuse after at least one use. Repair can include any combination of the following steps: disassembling the device, then cleaning or replacing specific parts and subsequently reassembling. Specifically, some types of devices can be disassembled, and any number of specific parts or parts of the device can be selectively replaced or removed in any combination. When cleaning and / or replacing specific parts, some types of the device can be reassembled at a repair facility or reassembled by the user before surgery is about to be performed for subsequent use. Those skilled in the art will appreciate that the repair of the device can utilize a variety of techniques for disassembly, cleaning / replacement, and reassembly. The use of such techniques and the resulting repair devices are all within the scope of this application.

[0204] By way of example only, the devices described herein can be sterilized before and / or after surgery. In one sterilization technique, the device is placed in a closed and sealed container, such as a plastic bag or a TYVEK bag. The container and device can then be placed in a field of radiation that can penetrate the container, such as gamma radiation, x-rays, or high-energy electrons. The radiation can kill bacteria on the device and in the container. The sterilized device can then be stored in a sterile container for later use. The device can also be sterilized using any other technique known in the art, including but not limited to beta or gamma radiation, ethylene oxide, or steam.

[0205] Various embodiments of the present invention have been shown and described, and further improvements to the methods and systems described herein may be achieved by appropriate modifications by those skilled in the art without departing from the scope of the present invention. Several such possible modifications have been mentioned, and other modifications will be apparent to those skilled in the art. For example, the embodiments, implementations, geometries, materials, dimensions, ratios, steps, etc. discussed above are illustrative and not required. Accordingly, the scope of the present invention should be considered in light of the following claims and should be understood not to be limited to the details of construction and operation shown and described in the specification and drawings.

Claims

1. A surgical instrument end effector, comprising: (a) a first jaw; (b) a second jaw comprising an anvil having a plurality of staple forming pockets, wherein the first jaw and the second jaw are operable to clamp and staple tissue positioned therebetween; (c) a staple cartridge configured to be received within the first jaw, the staple cartridge comprising: (i) a cartridge body extending distally from a proximal end to a distal end, (ii) a lower tray, the bin body and the lower tray being configured to be coupled together, and (iii) a plurality of spikes; and (d) a retaining cover configured to be secured to a proximal end of the cartridge body and engage the lower tray, the retaining cover further configured to secure a position of the lower tray relative to the cartridge body, wherein a distal end of the retaining cover is positioned proximally relative to the plurality of staples.

2. The surgical instrument end effector according to claim 1, wherein: The cartridge body and the retaining cap each include one or more complementary ultrasonic welding features.

3. The surgical instrument end effector according to claim 2, wherein: The complementary ultrasonic welding features include an energy director and an energy well configured to receive the energy director.

4. The surgical instrument end effector according to claim 3, wherein: The retaining cap includes the energy guide and the cartridge body includes the energy well.

5. The surgical instrument end effector according to claim 3, wherein: The energy guide includes a chamfered portion forming an edge configured to engage the energy sink.

6. The surgical instrument end effector according to claim 3, wherein: The energy guide is oriented at an oblique angle relative to a longitudinal axis defined by the staple cartridge.

7. The surgical instrument end effector according to claim 2, wherein: The complementary ultrasonic welding features include four pairs of complementary ultrasonic welding features.

8. The surgical instrument end effector according to claim 1, wherein: The lower tray includes a tab configured to engage the retaining cover.

9. The surgical instrument end effector according to claim 8, wherein: The retaining cover includes a tab receiver configured to receive the tab of the lower tray to capture the tab between the retaining cover and the bin body.

10. The surgical instrument end effector according to claim 9, wherein: The tab of the lower tray includes a first leg extending inward from a side of the lower tray and a second leg extending upward relative to the first leg.

11. The surgical instrument end effector according to claim 10, wherein: The tab receiver has a first channel and a second channel, the first channel being configured to receive the first leg of the tab such that the first leg is disposed between an upper surface of the cartridge body and the retaining cover.

12. The surgical instrument end effector according to claim 11, wherein: The second channel is configured to receive the second leg to allow the tab to extend through the retention cap.

13. The surgical instrument end effector according to claim 1, wherein: The cartridge body defines a recess configured to receive the retaining cap therein.

14. The surgical instrument end effector according to claim 1, wherein: The retention cover has a first side portion and a second side portion separated by a vertical slot extending through the staple cartridge.

15. A surgical instrument comprising: (a) the subject; (b) a shaft extending distally from the body; and (c) A surgical instrument end effector according to claim 1, wherein the surgical instrument end effector is disposed at the distal end of the shaft.

16. A staple cartridge assembly for use with an end effector of a surgical instrument, comprising: (a) a staple cartridge configured to be received within a first jaw of an end effector of a surgical instrument, the staple cartridge comprising: (i) a cartridge body extending distally along a longitudinal axis, (ii) a lower tray coupled to the bin body, and (iii) a plurality of spikes; and (b) a retainer selectively connectable to one or both of the magazine body or the lower tray at a proximal end of the staple magazine, at least a portion of the retainer being configured to extend completely around the staple magazine and the longitudinal axis to secure the position of the magazine body relative to the lower tray, wherein the distal end of the retainer is positioned proximally relative to the plurality of staples.

17. The staple cartridge assembly according to claim 16, wherein: The retainer includes a grip and a cartridge receiving portion configured to receive the proximal end of the staple cartridge.

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