Rotational drive surgical stapling assembly including floatable components

Abstract

A surgical stapling assembly is disclosed. The surgical stapling assembly can include a first jaw, a second jaw, an articulation joint, a closure driver including a first flexible rotary driver extending through the articulation joint, and a firing driver including a second flexible rotary driver extending through the articulation joint and rotatable independent of the first flexible rotary driver. The surgical stapling assembly can also include 3D printed components. The surgical stapling assembly can be configured to shape different staple shapes, such as non-planar staples and planar staples, can include an eccentrically driven firing assembly, and / or can include floatable components. The surgical stapling assembly can include a staple cartridge including a longitudinal support beam.

Description

Background Technology

[0001] This invention relates to surgical instruments, and in various arrangements, to surgical suturing and cutting instruments, end effectors, and staple cartridges used with them, designed to suture and cut tissue. Attached Figure Description

[0002] The various features and advantages of the implementation scheme described herein can be understood in conjunction with the following figures and the following description:

[0003] Figure 1 This is a perspective view of a surgical suturing instrument including a handle, a shaft assembly, and an end effector according to at least one aspect of this disclosure.

[0004] Figure 2 It is based on at least one aspect of this disclosure Figure 1 A perspective view of a portion of the end effector and shaft assembly of a surgical suture instrument, wherein the end effector is shown in a straight or non-articular motion configuration.

[0005] Figure 3 It is based on at least one aspect of this disclosure Figure 1 A perspective view of a portion of the end effector and shaft assembly of a surgical suture instrument, wherein the end effector is shown in an articulated configuration.

[0006] Figure 4 It is based on at least one aspect of this disclosure Figure 1 An exploded perspective view of the end effector and a portion of the shaft assembly of a surgical suture instrument.

[0007] Figure 5 It is based on at least one aspect of this disclosure Figure 1 A cross-sectional front view of a portion of the end effector and shaft assembly of a surgical suture instrument, wherein the end effector is shown in a non-firing, clamping configuration.

[0008] Figure 6 It is based on at least one aspect of this disclosure Figure 1 A plan view of the end actuator and a portion of the shaft assembly of a surgical suture instrument.

[0009] Figure 7 It is based on at least one aspect of this disclosure. Figure 6 Section line 6-6 in the middle Figure 1 A cross-sectional front view of a portion of the end effector and shaft assembly, wherein the end effector is shown in an open configuration.

[0010] Figure 8 It is based on at least one aspect of this disclosure. Figure 6 Section line 7-7 in the middle Figure 1 A cross-sectional front view of a portion of the end actuator and shaft assembly, wherein the end actuator is shown in a clamping configuration.

[0011] Figure 9 It is based on at least one aspect of this disclosure Figure 1 A perspective view of a surgical suture assembly including a shaft assembly and an end effector, wherein the end effector is attached to the shaft assembly via an articular joint.

[0012] Figure 10 It is based on at least one aspect of this disclosure Figure 9 Exploded perspective view of the surgical suture assembly.

[0013] Figure 11 It is based on at least one aspect of this disclosure Figure 9 A cross-sectional front view of a surgical suture assembly, in which the end effector is shown in a non-firing, clamping configuration.

[0014] Figure 12 It is based on at least one aspect of this disclosure Figure 1 A perspective view of a surgical suture assembly including a shaft assembly and an end effector, wherein the end effector is attached to the shaft assembly via an articular joint.

[0015] Figure 13 It is based on at least one aspect of this disclosure Figure 12 Exploded perspective view of the surgical suture assembly.

[0016] Figure 14 It is based on at least one aspect of this disclosure Figure 12 A cross-sectional front view of a surgical suture assembly, in which the end effector is shown in a non-firing, clamping configuration.

[0017] Figure 15 It is based on at least one aspect of this disclosure Figure 1 A perspective view of a surgical suture assembly including a shaft assembly and an end effector, wherein the end effector is attached to the shaft assembly via an articular joint.

[0018] Figure 16 It is based on at least one aspect of this disclosure Figure 15 Exploded perspective view of the surgical suture assembly.

[0019] Figure 17 It is based on at least one aspect of this disclosure Figure 15 A cross-sectional front view of a surgical suture assembly, in which the end effector is shown in a non-firing, clamping configuration.

[0020] Figure 18 It includes at least one aspect of this disclosure. Figure 1Perspective view of the surgical end effector assembly of the end effector and flexible firing drive system.

[0021] Figure 19 It is based on at least one aspect of this disclosure Figure 18 Exploded perspective view of the surgical suture assembly.

[0022] Figure 20 It is based on at least one aspect of this disclosure Figure 18 A cross-sectional front view of a surgical end effector assembly, wherein the surgical end effector assembly is shown in a non-firing, clamping configuration.

[0023] Figure 21 This is a perspective view of a robot controller according to at least one aspect of this disclosure.

[0024] Figure 22 This is a perspective view of a robotic arm carriage for a robotic surgical system according to at least one aspect of the present disclosure, showing manipulators on the robotic arm carriage that operatively support surgical tools.

[0025] Figure 23 It is based on at least one aspect of this disclosure Figure 22 Side view of the surgical armcart's manipulator and surgical gripper.

[0026] Figure 24 This is a perspective view of an end effector assembly including an anvil, a channel, and a cartridge, according to at least one aspect of this disclosure.

[0027] Figure 25 It is based on at least one aspect of this disclosure Figure 24 A cross-sectional perspective view of the end effector assembly.

[0028] Figure 26 It is based on at least one aspect of this disclosure Figure 24 A partial cross-sectional perspective view of an end effector assembly, wherein the end effector assembly includes a firing drive configured to deploy a nail from a nail cartridge and a closing drive configured to open and close anvil relative to a channel.

[0029] Figure 27 It is based on at least one aspect of this disclosure Figure 24 A cross-sectional front view of the end effector assembly.

[0030] Figure 28 It is based on at least one aspect of this disclosure Figure 24 A partial cross-sectional perspective view of an end effector assembly, wherein the end effector assembly includes a firing assembly comprising an upper firing member and a lower firing member, and wherein the upper firing member is shown to be detached from the lower firing member.

[0031] Figure 29 It is based on at least one aspect of this disclosure Figure 24 Exploded perspective view of the pin cartridge and support beam of the end effector assembly.

[0032] Figure 30 It is based on at least one aspect of this disclosure Figure 24 A cross-sectional perspective view of the pin cartridge and support beam of the end effector assembly.

[0033] Figure 31 It is based on at least one aspect of this disclosure Figure 24 A cross-sectional front view of the end effector assembly.

[0034] Figure 32 It is based on at least one aspect of this disclosure Figure 24 A cross-sectional perspective view of the proximal end of the end effector assembly, wherein various components are not shown for clarity.

[0035] Figure 33 It is based on at least one aspect of this disclosure Figure 24 A cross-sectional perspective view of the distal end of the end effector assembly.

[0036] Figure 34 This is a perspective view of a support beam for use with a stitching assembly, according to at least one aspect of this disclosure.

[0037] Figure 35 It is based on at least one aspect of this disclosure Figure 34 A front cross-sectional view of the support beam and the sliding member pinned to the support beam.

[0038] Figure 36 This is an exploded perspective view of a portion of a stitched assembly including a support beam, a firing member assembly, and a slider, according to at least one aspect of this disclosure.

[0039] Figure 37 It is based on at least one aspect of this disclosure Figure 33 An exploded perspective view of a portion of the suture assembly, wherein the distal end of the support beam is shown with hidden lines to show the outline of the longitudinal channel of the support beam.

[0040] Figure 38 This is a front view of a support beam for use with a stitching assembly, according to at least one aspect of this disclosure.

[0041] Figure 39 This is a front view of a support beam for use with a stitching assembly, according to at least one aspect of this disclosure.

[0042] Figure 40It is a cross-sectional front view of a stitching assembly including a staple cartridge, a slider, a cartridge support, and an I-beam, according to at least one aspect of this disclosure.

[0043] Figure 41 It is based on at least one aspect of this disclosure Figure 40 The front view of the warehouse support component.

[0044] Figure 42 This is a front view of a sac support for use with a surgical suture assembly, according to at least one aspect of this disclosure.

[0045] Figure 43 This is a cross-sectional front view of a portion of a stitched assembly including a slider and a compartment support, according to at least one aspect of this disclosure.

[0046] Figure 44 This is a front view of a slider configured to engage within a guide slot of a staple cartridge or cartridge support of a suture assembly, according to at least one aspect of this disclosure.

[0047] Figure 45 It is a cross-sectional perspective view of a portion of a compartment support configured to receive a slider, according to at least one aspect of this disclosure.

[0048] Figure 46 This is a schematic diagram of a portion of a stitched assembly comprising an anvil, a firing member, a jaw, and a slider pinned to the firing member, according to at least one aspect of this disclosure.

[0049] Figure 47 It is a cross-sectional view of a sewing assembly including a storage channel and an anvil, according to at least one aspect of this disclosure.

[0050] Figure 48 This is a perspective view of a firing member assembly including a main body and a drive nut, according to at least one aspect of this disclosure.

[0051] Figure 49 It is based on at least one aspect of this disclosure Figure 48 An exploded perspective view of the firing component assembly.

[0052] Figure 50 It includes at least one aspect of this disclosure. Figure 48 A perspective view of the main body of the firing mechanism assembly and the firing mechanism assembly with the drive nut.

[0053] Figure 51 It is based on at least one aspect of this disclosure Figure 50 An exploded perspective view of the firing component assembly.

[0054] Figure 52 It is based on at least one aspect of this disclosure Figure 50 A perspective view of the firing component assembly, in which the drive nut is welded to the main body.

[0055] Figure 53 This is a partial exploded cross-sectional perspective view of a stitching assembly including a channel jaw, a drive screw, and a firing member assembly, according to at least one aspect of this disclosure.

[0056] Figure 54 It is based on at least one aspect of this disclosure Figure 53 A front view of the firing component assembly.

[0057] Figure 55 It is based on at least one aspect of this disclosure Figure 53 An exploded front view of the firing component assembly.

[0058] Figure 56 It is based on at least one aspect of this disclosure Figure 53 A partial cross-sectional front view of the firing component assembly.

[0059] Figure 57 This is a perspective view of a firing member assembly including a main body and a drive nut, according to at least one aspect of this disclosure.

[0060] Figure 58 It is based on at least one aspect of this disclosure Figure 57 A front view of the firing component assembly.

[0061] Figure 59 It is based on at least one aspect of this disclosure Figure 57 A perspective view of the main body of the firing component assembly.

[0062] Figure 60 It is based on at least one aspect of this disclosure Figure 57 A cross-sectional front view of the firing component assembly.

[0063] Figure 61 It is a cut-off image taken through the distal aperture of the body portion according to at least one aspect of this disclosure. Figure 57 Another cross-sectional front view of the firing component assembly.

[0064] Figure 62 This is a perspective view of a firing member assembly including a main body portion and a drive nut assembly according to at least one aspect of this disclosure, the drive nut assembly including an inner drive nut and an outer drive portion.

[0065] Figure 63 It is based on at least one aspect of this disclosure Figure 62 A perspective view of the firing component assembly, in which a portion of the outer drive portion of the drive nut is cut off for illustrative purposes to expose the inner drive nut.

[0066] Figure 64 It is based on at least one aspect of this disclosure Figure 62 A perspective view of the main body of the firing component assembly and the internal drive nut.

[0067] Figure 65 It is based on at least one aspect of this disclosure Figure 62 A front view of the main body of the firing component assembly and the internal drive nut.

[0068] Figure 66 It is based on at least one aspect of this disclosure Figure 62 A perspective view of the firing component assembly.

[0069] Figure 67 This is a front view of a firing member assembly including a main body portion and a drive nut according to at least one aspect of this disclosure, wherein the main body portion includes a proximal tail extension.

[0070] Figure 68 This is a perspective view of a firing component assembly threadedly connected to a firing drive screw according to at least one aspect of this disclosure, wherein the firing component assembly includes a body portion and a drive nut.

[0071] Figure 69 It is based on at least one aspect of this disclosure Figure 68 A partial cross-sectional front view of the firing component assembly, wherein the drive nut is cut through a vertical plane.

[0072] Figure 70 It is based on at least one aspect of this disclosure Figure 68 A perspective view of the drive nut of the firing component assembly.

[0073] Figure 71 It is based on at least one aspect of this disclosure Figure 68 A perspective sectional view of the firing component assembly.

[0074] Figure 72 It is based on at least one aspect of this disclosure Figure 68 A front view of the firing component assembly.

[0075] Figure 73 This is a front view of a firing member assembly including a main body and a drive nut, according to at least one aspect of this disclosure.

[0076] Figure 74 It is a cross-sectional perspective view of an end actuator assembly including a cartridge passage, a cartridge, an anvil, and a firing assembly, according to at least one aspect of this disclosure.

[0077] Figure 75Viewed from the proximal end of the end effector assembly according to at least one aspect of this disclosure. Figure 74 A cross-sectional front view of the end effector assembly.

[0078] Figure 76 It is based on at least one aspect of this disclosure Figure 74 A partial cross-sectional perspective view of the end effector assembly, wherein the firing component assembly includes a firing drive screw and a firing component assembly.

[0079] Figure 77 It is based on at least one aspect of this disclosure Figure 74 A partial cross-sectional perspective view of the channel and firing assembly, wherein some hidden features are shown in dashed lines for illustrative purposes.

[0080] Figure 78 It is based on at least one aspect of this disclosure Figure 74 A partial cross-sectional front view of the end effector assembly.

[0081] Figure 79 This is a cross-sectional front view of a surgical suture assembly including a channel, a cartridge, an anvil, and a firing assembly according to at least one aspect of this disclosure, the firing assembly including a drive screw, a firing member assembly, and a slider.

[0082] Figure 80 It is based on at least one aspect of this disclosure Figure 79 A front view of the firing component assembly.

[0083] Figure 81 This is a cross-sectional front view of a jaw assembly for use with a surgical suture assembly according to at least one aspect of this disclosure, wherein the jaw assembly includes a channel and a firing drive screw.

[0084] Figure 82 This is a perspective view of a surgical suture assembly including a staple cartridge, a cartridge channel, and a firing drive assembly according to at least one aspect of this disclosure, wherein the staple cartridge is in Figure 82 It is hidden in the middle.

[0085] Figure 83 It is based on at least one aspect of this disclosure Figure 82 A partial cross-sectional perspective view of the surgical suture assembly.

[0086] Figure 84 It is based on at least one aspect of this disclosure Figure 82 A front view of a portion of the chamber passage and firing mechanism assembly, showing the distal support head and a pair of bushings. Figure 84 It is hidden in the middle.

[0087] Figure 85This is a perspective view of a surgical suture assembly comprising a chamber passage and a firing member assembly supported by a support flange of the chamber passage, according to at least one aspect of this disclosure.

[0088] Figure 86 This is a front view of a portion of a surgical suture assembly including a firing drive screw and a channel support according to at least one aspect of this disclosure, wherein the proximal end of the firing drive screw is pivotally mounted at the channel support.

[0089] Figure 87 It is based on at least one aspect of this disclosure Figure 86 A front view of a portion of the surgical suture assembly, in which the firing drive screw is shown in the loading configuration.

[0090] Figure 88 This is a front view of a firing member assembly including a main body portion and a drive nut that is floatably mounted within the main body portion, according to at least one aspect of this disclosure.

[0091] Figure 89 It is a pre-assembled according to at least one aspect of this disclosure. Figure 88 A front view of the firing component assembly.

[0092] Figure 90 It is an assembly according to at least one aspect of this disclosure Figure 88 A front view of the firing component assembly.

[0093] Figure 91 It is assembled in part according to at least one aspect of this disclosure. Figure 88 A front view of the firing component assembly.

[0094] Figure 92 This is a front view of a flexible firing drive screw comprising a flexible core member and an outer helical member, according to at least one aspect of this disclosure.

[0095] Figure 93 It is based on at least one aspect of this disclosure Figure 92 A cross-sectional schematic diagram of a flexible firing drive screw.

[0096] Figure 94 This is a schematic representation of a firing assembly including a flexible firing drive screw, according to at least one aspect of this disclosure.

[0097] Figure 95 This is a front view of a portion of a firing drive screw for use with a surgical suture assembly, according to at least one aspect of this disclosure.

[0098] Figure 96This is a front view of a portion of a firing drive screw for use with a surgical suture assembly, according to at least one aspect of this disclosure, wherein the firing drive screw includes a threaded, overmolded section.

[0099] Figure 97 It is based on at least one aspect of this disclosure Figure 96 A front view of a portion of the firing drive screw, in which the threaded overmolded section has been removed for clarity.

[0100] Figure 98 This is a perspective view of a shaft coupling for use with a drive system for a surgical suture assembly, according to at least one aspect of this disclosure.

[0101] Figure 99 This is a perspective view of a shaft coupling for use with a drive system for a surgical suture assembly, according to at least one aspect of this disclosure.

[0102] Figure 100 This is a perspective view of a shaft coupling for use with a drive system for a surgical suture assembly, according to at least one aspect of this disclosure.

[0103] Figure 101 This is a perspective view of a closing drive assembly including a closing drive screw and a closing wedge, according to at least one aspect of the present disclosure, the closing drive assembly being configured to open and close the jaws of the end effector assembly.

[0104] Figure 102 It is based on at least one aspect of this disclosure Figure 101 A front view of the closed drive assembly and the anvil.

[0105] Figure 103 It is based on at least one aspect of this disclosure Figure 101 A cross-sectional front view of the closed drive component.

[0106] Figure 104 This is a front cross-sectional view of a closing actuator including a drive screw and a retaining collar according to at least one aspect of this disclosure, wherein the retaining collar is not mounted on the drive screw.

[0107] Figure 105 It is based on at least one aspect of this disclosure Figure 104 A cross-sectional front view of the closed drive mechanism, in which a limiting collar is mounted on the drive screw.

[0108] Figure 106 This is a cross-sectional front view of a drive assembly mounted to a channel flange via a locking member according to at least one aspect of this disclosure, wherein... Figure 106 The drive assembly in a pre-assembled configuration is shown.

[0109] Figure 107 It is based on at least one aspect of this disclosure Figure 106 A cross-sectional front view of the drive assembly and channel flange, wherein Figure 107 The drive component in its assembled configuration is shown.

[0110] Figure 108 This is a perspective view of a surgical suture assembly according to at least one aspect of the present disclosure, the surgical suture assembly including a channel jaw, a closing drive, a firing drive, and a support member positioned within the channel jaw, and for illustrative purposes, portions of the surgical suture assembly are concealed.

[0111] Figure 109 It is based on at least one aspect of this disclosure Figure 108 A perspective view of the surgical suture assembly, in which various components are hidden for clarity.

[0112] Figure 110 It is based on at least one aspect of this disclosure Figure 108 A perspective view of the surgical suture assembly, in which various components are hidden for clarity.

[0113] Figure 111 This is a perspective view of a closing drive assembly including a closing drive device and a support element, according to at least one aspect of this disclosure.

[0114] Figure 112 It is based on at least one aspect of this disclosure Figure 111 A perspective view of the drive screw shaft of the closed drive assembly.

[0115] Figure 113 It is based on at least one aspect of this disclosure Figure 111 A perspective view of the retaining clamp of the closed drive component.

[0116] Figure 114 This is a perspective view of a closing drive device including a drive screw shaft and a closing drive nut according to at least one aspect of this disclosure.

[0117] Figure 115 It is based on at least one aspect of this disclosure Figure 114 A perspective view of the drive screw shaft.

[0118] Figure 116 It is based on at least one aspect of this disclosure Figure 114 A cross-sectional front view of the closed drive device, wherein the distal end of the drive screw shaft is shown in a pre-formed configuration.

[0119] Figure 117 It is based on at least one aspect of this disclosure Figure 114A cross-sectional front view of the closed drive mechanism, wherein the distal end of the drive screw shaft is shown in a pre-formed configuration.

[0120] Figure 118 This is a perspective view of a firing drive assembly including a rotating firing shaft, a firing member threadedly connected to the rotating firing shaft, and a relief member, according to at least one aspect of this disclosure, the relief member being configured to disengage the threaded engagement between the rotating firing shaft and the firing member.

[0121] Figure 119 It is based on at least one aspect of this disclosure Figure 118 A perspective view of the firing mechanism.

[0122] Figure 120 It is based on at least one aspect of this disclosure Figure 118 A cross-sectional front view of the firing drive assembly, in which the relief element is shown in an unactuated configuration.

[0123] Figure 121 It is cut through the housing component of the relief element according to at least one aspect of this disclosure. Figure 118 A cross-sectional front view of the firing drive assembly, in which the relief element is shown in an unactuated configuration.

[0124] Figure 122 It is based on at least one aspect of this disclosure Figure 118 A cross-sectional front view of the firing drive assembly, in which the relief element is shown in the actuation configuration.

[0125] Figure 123 It is cut through the housing component of the relief element according to at least one aspect of this disclosure. Figure 118 A cross-sectional front view of the firing drive assembly, in which the relief element is shown in the actuation configuration.

[0126] Figure 124 This is a perspective view of a surgical suture assembly according to at least one aspect of this disclosure.

[0127] Figure 125 It is based on at least one aspect of this disclosure Figure 124 A plan view of the anvil surface of the surgical suture assembly.

[0128] Figure 126 It is based on at least one aspect of this disclosure Figure 124 A plan view of the pre-formed sutures of the surgical suture assembly.

[0129] Figure 127 These are end front views and side front views of a planar-shaped nail according to at least one aspect of this disclosure.

[0130] Figure 128These are end front views and side front views of a non-planar shaped nail according to at least one aspect of this disclosure.

[0131] Figure 129 It is a cross-sectional front view of an anvil comprising a plurality of nail-shaped recesses according to at least one aspect of this disclosure.

[0132] Figure 130 This is a front view of a slider for use with a staple cartridge according to at least one aspect of this disclosure.

[0133] Figure 131 This is a front view of a first and a second nail for use with a surgical suture assembly, according to at least one aspect of this disclosure.

[0134] Figure 132 These are end front views and side front views of a planar-shaped nail according to at least one aspect of this disclosure.

[0135] Figure 133 These are end front views and side front views of a non-planar shaped nail according to at least one aspect of this disclosure.

[0136] Figure 134 It is a cross-sectional front view of a surgical suture assembly according to at least one aspect of this disclosure.

[0137] Figure 135 It is based on at least one aspect of this disclosure Figure 134 A partial cross-sectional front view of the surgical suture assembly.

[0138] Figure 136 It is based on at least one aspect of this disclosure Figure 134 A cross-sectional front view of the staple cartridge and staple driver of the surgical suture assembly.

[0139] Figure 137 This is a perspective view of a surgical suture assembly including a replaceable staple cartridge and a replaceable anvil plate according to at least one aspect of this disclosure.

[0140] Figure 138 It is shown in an unclamped configuration according to at least one aspect of this disclosure. Figure 137 A perspective view of a surgical suture assembly, wherein the anvil plate is not attached to the anvil jaws of the surgical suture assembly.

[0141] Figure 139 It is based on at least one aspect of this disclosure Figure 137 A perspective view of a surgical suture assembly, in which the anvil plate is partially attached to the anvil jaws.

[0142] In several views, corresponding reference symbols indicate corresponding parts. The examples described herein illustrate various embodiments of the invention in one form, and such examples should not be construed as limiting the scope of the invention in any way. Detailed Implementation

[0143] The applicant of this application owns the following U.S. patent applications filed on the same date as this application, each of which is incorporated herein by reference in its entirety:

[0144] - U.S. patent application entitled “METHOD OF USING A POWERED STAPLING DEVICE”, Agent’s File No. END9298USNP1 / 200859-1M;

[0145] - A U.S. patent application entitled "SURGICAL STAPLING ASSEMBLY COMPRISING NONPLANAR STAPLES ANDPLANAR STAPLE",

[0146] Agent's case file END9298USNP2 / 200859-2;

[0147] - U.S. patent application entitled “SURGICAL STAPLE CARTRIDGE COMPRISING LONGITUDINAL SUPPORT BEAM”, Agent’s File No. END9298USNP3 / 200859-3;

[0148] - U.S. patent application entitled "STAPLING ASSEMBLY COMPRISING ECCENTRICALLYDRIVEN FIRINGMEMBER", Agent's File No. END9298USNP4 / 200859-4;

[0149] - U.S. patent application entitled "DRIVERS FOR FASTENER CARTRIDGE ASSEMBLIESHAVING ROTARY DRIVESCREWS", Agent's File No. END9298USNP6 / 200859-6;

[0150] - U.S. patent application entitled “MATING FEATURES BETWEEN DRIVERS ANDUNDERSIDE OF A CARTRIDGEDECK”, Agent’s File No. END9298USNP7 / 200859-7;

[0151] - U.S. patent application entitled "LEVERAGING SURFACES FOR CARTRIDGE INSTALLATION", Agent's File No. END9298USNP8 / 200859-8;

[0152] - U.S. patent application entitled "FASTENER CARTRIDGE WITH NON-REPEATING FASTENER ROWS", Agent's File No. END9298USNP9 / 200859-9;

[0153] - U.S. patent application entitled "HAVING FLEXIBLE PORTIONS FOR ADAPTING TO ALOAD DURING ASURGICAL FIRING STROKE", Agent's File No. END9298USNP10 / 200859-10;

[0154] - U.S. patent application entitled “STAPLING ASSEMBLY COMPONENTS HAVING METALSUBSTRATES AND PLASTIC BODIES”, Agent’s File No. END9298USNP11 / 200859-11;

[0155] - U.S. patent application entitled “MULTI-AXISPIVOT JOINTS FOR SURGICALINSTRUMENTS AND METHODS OF MANUFACTURING SAME”, Agent’s File No. END9298USNP12 / 200859-12;

[0156] - U.S. patent application entitled "ARRANGEMENTS FOR MULTI-PLANAR ALIGNMENT AND SUPPORT OF OPERATIONAL DRIVE SHAFTS INARTICULATABLE SURGICAL INSTRUMENTS", Agent's File END9298USNP13 / 200859-13; and

[0157] - U.S. patent application entitled "SURGICAL INSTRUMENT ARTICULATION JOINTARRANGEMENTS COMPRISING MULTIPLE MOVING LINKAGEFEATURES", Agent's File No. END9298USNP14 / 200859-14.

[0158] The applicant of this application owns the following U.S. patent applications and U.S. patents, filed on December 19, 2017, each of which is incorporated herein by reference in its entirety:

[0159] - U.S. Patent No. 10,835,330 entitled “METHOD FOR DETERMINING THE POSITION OF AROTATABLE JAW OF ASURGICAL INSTRUMENTATTACHMENT ASSEMBLY”;

[0160] - U.S. Patent No. 10,716,565 entitled “SURGICAL INSTRUMENTS WITH DUAL ARTICULATION DRIVERS”;

[0161] - U.S. Patent Application Serial No. 15 / 847,325 entitled “SURGICAL TOOLS CONFIGURED FOR INTERCHANGEABLE USE WITH DIFFERENT CONTROLLER INTERFACES” is now published as U.S. Patent Application No. 2019 / 0183491;

[0162] - U.S. Patent No. 10,729,509 entitled "SURGICAL INSTRUMENT COMPRISING CLOSURE AND FIRING LOCKING MECHANISM";

[0163] - U.S. Patent Application Serial No. 15 / 847,315 entitled "ROBOTIC ATTACHMENT COMPRISING EXTERIOR DRIVE ACTUATOR", now published as U.S. Patent Application Publication No. 2019 / 0183594; and

[0164] - U.S. design patent number D910,847 entitled "SURGICAL INSTRUMENT ASSEMBLY".

[0165] The applicant of this application owns the following U.S. patent applications and U.S. patents, filed on June 28, 2017, each of which is incorporated herein by reference in its entirety:

[0166] - U.S. Patent Application Serial No. 15 / 635,693 entitled “SURGICAL INSTRUMENT COMPRISING AN OFFSET ARTICULATION JOINT” is now published as U.S. Patent Application No. 2019 / 0000466;

[0167] - U.S. Patent Application Serial No. 15 / 635,729 entitled “SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM RATIO” is now published as U.S. Patent Application No. 2019 / 0000467;

[0168] - U.S. Patent Application Serial No. 15 / 635,785 entitled “SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM RATIO” is now published as U.S. Patent Application No. 2019 / 0000469;

[0169] - U.S. Patent Application Serial No. 15 / 635,808 entitled “SURGICAL INSTRUMENT COMPRISING FIRING MEMBER SUPPORTS” is now published as U.S. Patent Application No. 2019 / 0000471;

[0170] - U.S. Patent Application Serial No. 15 / 635,837 entitled “SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEMLOCKABLE TO A FRAME” is now published as U.S. Patent Application No. 2019 / 0000472;

[0171] - U.S. Patent No. 10,779,824 entitled “SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM LOCKABLE BY A CLOSURE SYSTEM”;

[0172] - U.S. Patent Application Serial No. 15 / 636,029 entitled “SURGICAL INSTRUMENT COMPRISING A SHAFT INCLUDING A HOUSING ARRANGEMENT” is now published as U.S. Patent Application Publication No. 2019 / 0000477;

[0173] - U.S. Patent Application Serial No. 15 / 635,958 entitled “SURGICAL INSTRUMENT COMPRISING SELECTIVELYACTUATABLEROTATABLE COUPLERS” is now published as U.S. Patent Application No. 2019 / 0000474;

[0174] - U.S. Patent Application Serial No. 15 / 635,981 entitled “SURGICAL STAPLING INSTRUMENTS COMPRISINGSHORTENED STAPLECARTRIDGE NOSES” is now published as U.S. Patent Application No. 2019 / 0000475.

[0175] - U.S. Patent Application Serial No. 15 / 636,009 entitled “SURGICAL INSTRUMENT COMPRISING A SHAFTINCLUDING A CLOSURETUBE PROFILE” is now published as U.S. Patent Application No. 2019 / 0000476;

[0176] - U.S. Patent No. 10,765,427 entitled “METHOD FOR ARTICULATING A SURGICALINSTRUMENT”;

[0177] - U.S. Patent Application Serial No. 15 / 635,530 entitled “SURGICAL INSTRUMENTS WITH ARTICULATABLEEND EFFECTOR WITH AXIALLY SHORTENED ARTICULATION JOINT CONFIGURATIONS” is now published as U.S. Patent Application No. 2019 / 0000457;

[0178] - U.S. Patent No. 10,588,633 entitled “SURGICAL INSTRUMENTS WITH OPEN AND CLOSABLE JAWS AND AXIALLYMOVABLE FIRING MEMBER THAT ISINITIALLY PARKED IN CLOSE PROXIMITY TO THE JAWSPRIOR TO FIRING”;

[0179] - U.S. Patent Application Serial No. 15 / 635,559 entitled “SURGICAL INSTRUMENTS WITH JAWS CONSTRAINED TO PIVOT ABOUT ANAXIS UPON CONTACT WITH A CLOSUREMEMBER THAT IS PARKED IN CLOSE PROXIMITY TOTHEPIVOT AXIS” is now published as U.S. Patent Application Publication No. 2019 / 0000459;

[0180] - U.S. Patent No. 10,786,253 entitled "SURGICAL END EFFECTORS WITH IMPROVED JAWAPERTURE ARRANGEMENTS";

[0181] - U.S. Patent Application Serial No. 15 / 635,594 entitled “SURGICAL CUTTING AND FASTENING DEVICES WITH PIVOTABLE ANVIL WITH A TISSUE LOCATING ARRANGEMENT IN CLOSE PROXIMITY TO AN ANVIL PIVOTAXIS” is now published as U.S. Patent Application No. 2019 / 0000461;

[0182] - U.S. Patent Application Serial No. 15 / 635,612 entitled “JAW RETAINER ARRANGEMENT FOR RETAINING A PIVOTABLE SURGICALINSTRUMENT JAW IN PIVOTABLE RETAINING ENGAGEMENT WITH A SECOND SURGICALINSTRUMENT JAW” is now published as U.S. Patent Application No. 2019 / 0000462;

[0183] - U.S. Patent No. 10,758,232 entitled “SURGICAL INSTRUMENT WITH POSITIVE JAW OPENING FEATURES”;

[0184] - U.S. Patent No. 10,639,037 entitled "SURGICAL INSTRUMENT WITH AXIALLY MOVABLE CLOSURE MEMBER";

[0185] - U.S. Patent No. 10,695,057 entitled “SURGICAL INSTRUMENT LOCKOUT ARRANGEMENT”;

[0186] - U.S. design patent number D851,762 entitled "ANVIL";

[0187] - U.S. design patent D854,151 entitled "SURGICAL INSTRUMENT SHAFT"; and

[0188] - U.S. design patent number D869,655 entitled “SURGICAL FASTENER CARTRIDGE”.

[0189] The applicant of this application owns the following U.S. patent applications and U.S. patents, filed on June 27, 2017, each of which is incorporated herein by reference in its entirety:

[0190] - U.S. Patent Application Serial No. 15 / 634,024 entitled “SURGICAL ANVIL MANUFACTURING METHODS” is now published as U.S. Patent Application No. 2018 / 0368839.

[0191] - U.S. Patent No. 10,772,629 entitled “SURGICAL ANVIL ARRANGEMENTS”;

[0192] - U.S. Patent Application Serial No. 15 / 634,046 entitled “SURGICAL ANVIL ARRANGEMENTS” is now published as U.S. Patent Application No. 2018 / 0368841;

[0193] - U.S. Patent No. 10,856,869 entitled “SURGICAL ANVIL ARRANGEMENTS”;

[0194] - U.S. Patent Application Serial No. 15 / 634,068 entitled “SURGICAL FIRING MEMBER ARRANGEMENTS” is now published as U.S. Patent Application No. 2018 / 0368843;

[0195] - U.S. Patent Application Serial No. 15 / 634,076 entitled “STAPLE FORMING POCKET ARRANGEMENTS” is now published as U.S. Patent Application No. 2018 / 0368844;

[0196] - U.S. Patent Application Serial No. 15 / 634,090 entitled “STAPLE FORMING POCKET ARRANGEMENTS” is now published as U.S. Patent Application No. 2018 / 0368845;

[0197] - U.S. Patent Application Serial No. 15 / 634,099 entitled "SURGICAL END EFFECTORS AND ANVILS", now published as U.S. Patent Application Publication No. 2018 / 0368846; and

[0198] - U.S. Patent No. 10,631,859 entitled "ARTICULATION SYSTEMS FOR SURGICAL INSTRUMENTS".

[0199] The applicant of this application owns the following U.S. patent applications filed on June 2, 2020, each of which is incorporated herein by reference in its entirety:

[0200] - U.S. design patent application serial number 29 / 736,648 entitled "STAPLE CARTRIDGE";

[0201] - U.S. design patent application serial number 29 / 736,649 entitled "STAPLE CARTRIDGE";

[0202] - U.S. design patent application serial number 29 / 736,651 entitled "STAPLE CARTRIDGE";

[0203] - U.S. design patent application serial number 29 / 736,652 entitled “STAPLE CARTRIDGE”;

[0204] - U.S. design patent application serial number 29 / 736,653 entitled "STAPLE CARTRIDGE";

[0205] - U.S. design patent application serial number 29 / 736,654 entitled "STAPLE CARTRIDGE"; and

[0206] - U.S. design patent application serial number 29 / 736,655 entitled "STAPLE CARTRIDGE".

[0207] The applicant of this application owns the following U.S. design patent applications and U.S. patents, filed on November 14, 2016, each of which is incorporated herein by reference in its entirety:

[0208] - U.S. Patent Application Serial No. 15 / 350,621 entitled “STAPLE FORMING POCKET CONFIGURATIONS FOR CIRCULAR STAPLERANVIL” is now published as U.S. Patent Application No. 2018 / 0132849;

[0209] - U.S. Patent Application Serial No. 15 / 350,624 entitled “CIRCULAR SURGICAL STAPLER WITH ANGULARLY ASYMMETRIC DECKFEATURES” is now published as U.S. Patent Application No. 2018 / 0132854;

[0210] - U.S. design patent D833,608 entitled "STAPLING HEAD FEATURE FOR SURGICAL STAPLER"; and

[0211] - U.S. design patent number D830,550 entitled "SURGICAL STAPLER".

[0212] This document sets forth numerous specific details to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments described in the specification and illustrated in the figures. Well-known operations, components, and elements are not described in detail to avoid obscuring the embodiments described in the specification. The reader will understand that the embodiments described and illustrated herein are non-limiting examples, and thus will recognize that the specific structural and functional details disclosed herein are representative and illustrative. Variations and changes may be made to these embodiments without departing from the scope of the claims.

[0213] The terms “comprise” (and any form of “comprise”, such as “comprises” and “comprising”), “have” (and any form of “have”, such as “has” and “having”), “include” (and any form of “include”, such as “includes” and “including”), and “contain” (and any form of “contain”, such as “contains” and “containing”) are open-ended linking verbs. Therefore, a surgical system, apparatus, or device that “comprises,” “haves,” “includes,” or “contains” one or more elements has, but is not limited to, having only those elements. Similarly, the elements of a system, apparatus, or device that “comprises,” “haves,” “includes,” or “contains” one or more features have, but are not limited to, having only those features.

[0214] The terms “proximal” and “distal” are used herein in relation to the clinician manipulating the handle portion of the surgical device. The term “proximal” refers to the portion closest to the clinician, and the term “distal” refers to the portion furthest from the clinician’s position. It should also be understood that, for the sake of brevity and clarity, spatial terms such as “vertical,” “horizontal,” “upper,” and “lower” may be used in conjunction with the accompanying drawings. However, surgical devices are used in many orientations and positions, and these terms are not intended to be restrictive and / or absolute. In the following description, terms such as “first,” “second,” “top,” “bottom,” “upper,” and “lower” are convenient expressions and should not be construed as restrictive.

[0215] References to singular items should be understood to include plural items, and vice versa, unless otherwise explicitly stated or clearly evident from the text. Grammatical conjunctions are intended to express any and all transitions and connecting combinations of clauses, sentences, words, etc., unless otherwise stated or clearly evident from the context. Therefore, the term "or" should generally be understood to mean "and / or," etc.

[0216] Unless otherwise specified herein, the numerical ranges listed herein are not intended to be limiting, but rather refer individually to any or all values ​​falling within that range, and each individual value within that range is incorporated into this disclosure as individually referenced herein. When used with numerical values, the terms “about,” “approximately,” etc., should be interpreted as indicating a deviation as would be understood by one of ordinary skill in the art for satisfactory use for the intended purpose. Similarly, when used with reference to physical characteristics, approximate terms such as “about” or “substantially” should be interpreted as envisioning a range of deviations as would be understood by one of ordinary skill in the art for satisfactory use for the corresponding application, function, purpose, etc.

[0217] Any and all examples or exemplary language (“e.g.,” “such as,” etc.) provided herein are intended merely to better illustrate embodiments and are not intended to limit the scope of embodiments. No language in the specification should be construed as indicating that any element not protected by the claims is necessary for implementing the embodiments.

[0218] Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily understand that the various methods and devices disclosed herein can be used in a wide range of surgical procedures and applications, including, for example, in combination with open surgery. Continuing to refer to this specific embodiment, the reader will further understand that the various surgical devices disclosed herein can be inserted into the body in any manner, such as through natural cavities, through incisions or puncture holes formed in tissue, etc. The working portion or end effector portion of the surgical device can be inserted directly into the patient's body or through an access device having a working channel through which the end effector and elongated shaft of the surgical device can be advanced.

[0219] The surgical suturing system may include an axis and an end effector extending from the axis. The end effector includes a first jaw and a second jaw. The first jaw includes a staple cartridge. The staple cartridge is insertable into and can be removed from the first jaw; however, other embodiments are contemplated in which the staple cartridge cannot be removed from the first jaw or at least can be easily replaced from the first jaw. The second jaw includes an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closed axis; however, other embodiments are contemplated in which the first jaw is pivotable relative to the second jaw. The surgical suturing system also includes an articulation joint configured to allow the end effector to rotate or perform articulation relative to the axis. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments without an articulation joint are contemplated.

[0220] The staple cartridge includes a cartridge body. The cartridge body includes a proximal end, a distal end, and a platform extending between the proximal and distal ends. In use, the staple cartridge is positioned on a first side of the tissue to be sutured, and an anvil is positioned on a second side of the tissue to be sutured. The anvil moves toward the staple cartridge to compress the tissue and clamp it against the platform. Staples, removably stored in the cartridge body, can then be deployed into the tissue. The cartridge body includes staple cavities defined within the cartridge body, in which staples are removably stored. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of the longitudinal slots, and three rows of staple cavities are positioned on a second side of the longitudinal slots. Other arrangements of staple cavities and staples are contemplated.

[0221] The nail is supported by a nail actuator within a cartridge. The actuator is movable between a first or non-firing position and a second or firing position to eject the nail from the nail chamber. The actuator is retained within the cartridge by a retainer extending around the bottom of the cartridge and including a resilient member configured to grip the cartridge and hold the retainer to the cartridge. The actuator is movable between its non-firing position and its firing position by a slider. The slider is movable between a proximal position adjacent to the proximal end of the cartridge and a distal position adjacent to the distal end of the cartridge. The slider includes multiple ramp surfaces configured to slide beneath and lift the actuator toward the anvil, and the nail is supported on the actuator.

[0222] In addition to the above, the slider can also move distally via the firing member. The firing member is configured to contact the slider and push it distally. A longitudinal slot defined in the cartridge is configured to receive the firing member. The anvil also includes a slot configured to receive the firing member. The firing member also includes a first cam engaging a first jaw and a second cam engaging a second jaw. As the firing member advances distally, the first and second cams control the distance or tissue gap between the platform of the cartridge and the anvil. The firing member also includes a blade configured to cut into tissue captured between the cartridge and the anvil. It is desirable that the blade be positioned at least partially close to the ramp surface so that the staples are ejected into the tissue before the blade cuts through it.

[0223] Figures 1 to 8A surgical suturing instrument 10 configured to clamp, suture, and cut patient tissue is shown. The surgical suturing instrument 10 includes a handle 20, a shaft assembly 100 attached to the handle 20, and an end effector 200. For cutting and suturing patient tissue, the end effector 200 includes a jaw 201 and an anvil jaw 203. The anvil jaw 203 is pivotable relative to the jaw 203 to clamp tissue between the anvil jaw 203 and the jaw 203. Once the tissue is clamped between the jaws 201, 203, the surgical suturing instrument 10 can be actuated to advance a firing member through the jaws 201, 203 to suture and cut the tissue via the end effector 200, as discussed in more detail below.

[0224] As discussed in more detail below, the end effector 200 can be articulated via the articulated motion region 110 of the shaft assembly 100. Such articulation provides the user of the surgical suture instrument 10 with the ability to more accurately position and / or manipulate the end effector 200 near the target tissue.

[0225] The handle 20 includes a housing 21 configured to accommodate various mechanical and electrical components and a handle portion 22 extending from the housing 21. The handle portion 22 is configured to fit in and / or be grasped and / or held by the user when using the surgical suturing instrument 10. The handle 20 also includes various actuators and / or triggers configured to be actuated by the user to operate one or more functions of the surgical suturing instrument 10. The handle 20 includes a closing trigger 24, a firing trigger 25, and at least one articulation actuator 26. When actuated by the user, the closing trigger 24 is configured to grip tissue with the end effector 200 by moving the anvil jaws 203 toward the jaws 201. When actuated by the user, the firing trigger 25 is configured to cut and suture tissue with the end effector 200 by advancing the firing member to eject a nail and cutting tissue with a scalpel. When actuated by a user, the articulation actuator 26 is configured to articulate the end effector 200 relative to the shaft assembly 100 via the articulation region 110. The trigger and actuator of the surgical suture instrument 10 can trigger one or more motors within the handle 20 to actuate various functions of the surgical suture instrument 10 and / or manually drive various drive shafts and components to actuate various functions of the surgical suture instrument 10.

[0226] The handle 20 also includes a nozzle assembly 30 configured to support the shaft assembly 100 therein. The nozzle assembly 30 includes an actuating wheel 31 configured to be rotated by a user to rotate the shaft assembly 100 and the end effector 200 about a longitudinal axis LA relative to the handle 20. This mechanism allows the user of the surgical suture instrument 10 to rotate only the shaft assembly 100 and / or the end effector 200 without having to rotate the entire handle 20.

[0227] The handle 20 also includes a battery 23 configured to provide power to various electronic components, sensors, and / or motors of the surgical suturing instrument 10. Embodiments in which the surgical suturing instrument 10 is directly connected to a power source are envisioned. Embodiments in which the surgical suturing instrument 10 is entirely manual or, for example, non-powered are also envisioned. Embodiments in which the articulation of the end effector, the clamping and loosening of the jaws, the firing of end effector studs to suture and cut tissue, and the rotation of the shaft and / or end effector are all powered systems are also envisioned.

[0228] In at least one instance, the shaft assembly 100 and the end effector 200 may be modular and removable from the handle 20. In at least one instance, the end effector 200 may be modular because it can be removed from the shaft assembly 100 and replaced with a different end effector. In at least one instance, the shaft assembly 100 and / or the end effector 200 may be used in a surgical robotic environment. Such embodiments will provide power input from a surgical robot interface to actuate each function of the end effector 200. Examples of such surgical robots and surgical tools are further described in U.S. Patent Application Publication 2020 / 0138534, entitled “ROBOTIC SURGICAL SYSTEM,” published May 7, 2020, the entire contents of which are incorporated herein by reference.

[0229] In at least one instance, the shaft assembly 100 and the end effector 200 are configured to be used with a surgical robot. In such instances, the shaft assembly 100 and the end effector 200 are configured to be coupled to a surgical robot comprising multiple output drives. The multiple output drives of the surgical robot are configured to cooperate with the drive system of the shaft assembly 100 and the end effector 200. In such instances, the surgical robot can actuate the end effector 200 for various functions, such as jointing the end effector about multiple different articulation joints, rotating the shaft assembly 100 and / or the end effector 200 about its longitudinal axis, clamping the end effector 200 to clamp tissue between the jaws of the end effector 200, and / or firing the end effector 200 to cut and / or suture tissue.

[0230] The shaft assembly 100 is configured to accommodate various drive system components and / or electronic components of the surgical suture instrument 10, such that the end effector 200 and the shaft assembly 100 can be inserted through a cannula for laparoscopic surgery. The various drive system components are configured to be actuated by various triggers and actuators of the handle 20. Such components may include drive shafts for articulation, drive shafts for clamping and releasing the end effector 200, and / or drive shafts for firing the end effector 200. In instances where the shaft assembly 100 is connected to a drive system in the handle 20 or a surgical robot interface, such drive shafts may be rotatable by that drive system. In various aspects, the suture end effector may include two independently rotatable drive members—for example, one drive member for gripping tissue and one drive member for firing a staple. The suture end effector may also include an articulation joint, through which rotational motion can be transmitted. In various aspects, the suture end effector may include one or more 3D-printed components that can be incorporated into an articulation system, a gripping system, or a firing system.

[0231] In instances where the shaft assembly 100 is connected to a drive system in the shank 20 or surgical robot interface, such a drive shaft can be actuated by that drive system. Such a drive shaft can include linear actuation, rotary actuation, or a combination thereof. For example, a combination of rotary and linear actuation can employ a series of rack and pinion gears and / or drive screws.

[0232] In at least one instance, for example, the shaft assembly 100 is also configured to accommodate electrical leads for, for example, positioning within the shaft assembly 100 and / or the end effector 200 of various sensors and / or motors.

[0233] The shaft assembly 100 includes an outer shaft 101 extending from the nozzle assembly 30 to the articulated motion region 110, which includes a dual articulated joint, which will be discussed in more detail below. The articulated motion region 110 allows the end effector 200 to articulate relative to the outer shaft 101 in two different planes about two separate axes AA1, AA2.

[0234] Currently, the main reference is... Figure 4The articulation of the end effector 200 will now be described. The articulation region 110 includes two distinct articulation joints and two articulation actuators 150 and 160. This allows the end effector 200 to articulate about two independent axes AA1 and AA2 in two different planes. The articulation region 110 includes a proximal joint shaft component 120, an intermediate joint shaft component 130, and a distal joint shaft component 140. The proximal joint shaft component 120 is attached to the distal end of the shaft assembly 100, the intermediate joint shaft component 130 is pivotally connected to the proximal joint shaft component 120 and the distal joint shaft component 140, and the distal joint shaft component 140 is fixedly attached to the end effector 200 by a retaining ring 146. This arrangement provides the end effector 200 with articulation about independent axes AA1 and AA2 relative to the shaft assembly 100, as discussed in more detail below.

[0235] The proximal connector shaft assembly 120 includes a proximal annular portion 121 that is fixedly fitted within the outer shaft 101. The proximal connector shaft assembly 120 also includes a hollow channel 122 to allow various drive system components to pass through, and includes an articulated tab 123 including a pin hole 124 configured to receive an articulated pin 125. The articulated pin 125 is pivotally connected to the proximal articulated tab 131 of the intermediate connector shaft assembly 130. To enable articulation of the end effector 200 about axis AA1, the articulated actuator 150 is linearly actuated in a distal or proximal direction. For example, such an actuator may comprise a rod or bar made of any suitable material, such as metal and / or plastic. The articulated actuator 150 is pivotally mounted to the articulated linkage 151. The articulation link 151 is pivotally mounted off-axis relative to the articulation pin 125 to the intermediate joint shaft assembly 130, such that when the articulation actuator 150 is actuated, torque is applied off-axis by the articulation link 151 to the intermediate joint shaft assembly 130 relative to the articulation pin 125, causing the intermediate joint shaft assembly 130 and thus the end effector 200 to pivot about axis AA1 relative to the proximal joint shaft assembly 120.

[0236] Intermediate joint shaft component 130 is pivotally connected to proximal joint shaft component 120 via articulated pin 125 defining axis AA1. Specifically, intermediate joint shaft component 130 includes a proximal articulated tab 131 pivotally connected to proximal joint shaft component 120 via articulated pin 125. Intermediate joint shaft component 130 also includes a hollow channel 132 and a distal articulated tab 133, the hollow channel being configured to allow various drive system components to pass through it. Distal articulated tab 133 includes a pin hole 134 and a distal projecting key 135, the pin hole being configured to receive another articulated pin 136 defining axis AA2.

[0237] To enable the end effector 200 to articulate about axis AA2, articulation cable 160 is actuated to apply articulation torque to the proximal tab 141 of the distal connector shaft assembly 140 via key 135. Articulation cable 160 is secured to key 135 such that key 135 pivots relative to intermediate connector shaft assembly 130 as cable 160 rotates. Key 135 engages in keyhole 144 of distal connector shaft assembly 140. Clearly, key 135 is not secured to intermediate connector shaft assembly 130 and is rotatable relative to intermediate connector shaft assembly 130. Articulation cable 160 also contacts the proximal tab 141 surrounding pin hole 142. This provides additional torque from articulation cable 160 to distal connector shaft assembly 140. Articulation pin 136 is received within pin hole 142 to pivotally connect intermediate connector shaft assembly 130 and distal connector shaft assembly 140.

[0238] In at least one instance, the articulation cable 160 can only be pulled in the proximal direction. In such instances, only one side of the articulation cable 160 is pulled proximally to cause the end effector 200 to articulate in the desired direction. In at least one instance, the articulation cable 160 is pushed and pulled in opposition. In other words, the cable 160 may include a rigid configuration such that one side of the articulation cable 160 is pushed distally while the other side is pulled proximally. Such an arrangement allows the articulation force to be distributed between the half pushed and the half pulled of the cable 160. In at least one instance, a push-pull arrangement allows a larger articulation force to be transmitted to the corresponding articulation joint. Such a force may be necessary in an arrangement with two articulation joints. For example, if the proximal articulation joint is to be fully articulated, a larger force may be required from the articulation actuator designed to articulate the distal articulation joint due to the stretching and / or extension distance that the articulation actuator for the distal articulation joint must travel.

[0239] The distal connector shaft assembly 140 also includes a cutout 143 to allow various drive components to pass through. A retaining ring 146 secures the channel 210 of the jaw 201 to the distal connector shaft assembly 140, thereby securing the end effector assembly 200 to the distal end of the articulated motion region 110.

[0240] As discussed above, the anvil jaws 201 are movable relative to the magazine jaws 203 to clamp and release tissue via the end effector 200. The operation of this function of the end effector 200 will now be described. The magazine jaws 201 include a channel 210 and a staple cartridge 220 configured to be received within a cavity 214 of the channel 210. The channel 210 also includes an annular groove 211 configured to receive a retaining ring 146 and a pair of pivot holes 213 configured to receive a jaw coupling pin 233. The jaw coupling pin 233 allows the anvil jaws 203 to pivot relative to the magazine jaws 201.

[0241] The anvil jaws 203 include anvil body 230 and a pair of pivot holes 231. The pivot holes 231 in the proximal portion of the anvil jaws 203 are configured to receive jaw connecting pins 233, thereby pivotally connecting the anvil jaws 203 to the jaw 201. A closing drive 250 is provided for opening and closing the anvil jaws 203 relative to the jaw 201.

[0242] The closing drive 250 is actuated by a flexible drive section 175, which includes a universal movable joint arranged or formed end-to-end. In various instances, the flexible drive section 175 may include tandem 3D-printed universal joints printed together as a single continuous system. Discussed in more detail below, the flexible drive section 175 is driven by an input shaft passing through the shaft assembly 100. The flexible drive section 175 transmits rotational actuation motion via a double-articular kinematic joint. The closing drive 250 includes a closing screw 251 and a closing wedge 255 threadedly connected to the closing screw 251. The closing wedge 255 is configured to explicitly open and close the anvil jaws 203 by a cam. The closing screw 251 is supported by a first support body 258 and a second support body 259 fixed within the channel 210.

[0243] In order to be in the clamping position ( Figure 8 ) and release position ( Figure 7 The anvil jaws 203 move between the closing screw and the pin cartridge 220, actuating the closing drive shaft to actuate the flexible drive section 175. The flexible drive section 175 is configured to rotate the closing screw 251, which displaces the closing wedge 255. For example, the closing wedge 255 is threaded to the closing screw 251, and the rotational travel of the closing wedge 255 with respect to the pin cartridge 220 is restricted. The closing screw 251 drives the closing wedge 255 proximally or distally depending on the direction of rotation of the closing screw 251.

[0244] In order to release the position ( Figure 7 The clamping end actuator 200 closes the wedge 255, causing it to move proximally. As the wedge 255 moves proximally, its proximal cam surface 256 contacts the corresponding cam surface 234 defined in the proximal end 235 of the anvil body 230. When the cam surface 256 contacts the cam surface 234, a force is applied to the proximal end 235 of the anvil body 230, causing the anvil body 230 to rotate about the pin 233 into the clamping position. Figure 8 ).

[0245] To open or release the end actuator 200 from the clamped position ( Figure 8 The closing wedge 255 is moved distally by rotating the closing screw 251 in the direction opposite to the direction that causes the closing wedge 255 to move proximally. As the closing wedge 255 moves distally, a pair of protrusions 257 extending from the distal end of the closing wedge 255 contact the cam surface 234 near the downwardly extending tab 237 of the anvil body 230. When the protrusions 257 contact the cam surface 234 near the tab 237, a force is applied to the anvil body 230 to rotate the anvil body 230 about the pin 233 into the open position. Figure 7 ).

[0246] In at least one instance, the profile of cam surface 234 corresponds to the profile of cam surface 256. For example, cam surface 234 and cam surface 256 may be matched such that a maximum cam force is applied to the anvil body 230 to cause a desired rotation of the anvil body 230. Figure 8 As can be seen, for example, the cam surface 234 defined by the proximal end 235 of the anvil body 230 includes a ramp section similar to the upper ramp section of the cam surface 256.

[0247] As discussed above, the surgical suturing instrument 10 can be actuated to advance the firing member through jaws 201, 203 to suture and cut tissue via the end effector 200. The function of deploying staples 226 from the cartridge 220 and cutting tissue with a blade 283 will now be described. The cartridge 220 includes a cartridge body 221, a plurality of staple drivers 225, and a plurality of staples 226 removably stored within the cartridge body 221. The cartridge body 221 includes a platform surface 222, a plurality of staple cavities 223 arranged in a longitudinal row defined within the cartridge body 221, and a longitudinal slot 224 that bifurcates the cartridge body 221. The blade 283 is configured to be driven through the longitudinal slot 224 to cut tissue clamped between the anvil body 230 and the platform surface 221.

[0248] Platform surface 221 includes a tissue-supporting surface with a lateral profile. In various aspects, the profile of platform surface 221 may form a peak along the central portion of chamber 221. Such a peak may cover a longitudinally extending firing screw 261 that extends through the central portion of chamber 221, as will be further described herein. In various instances, the increased height along the peak may be associated with a smaller tissue gap along the firing path of blade 283. In some aspects of this disclosure, the drive height, the formed pin height, the pin recess extension height, and / or the pin overdrive distance may also vary laterally along platform surface 221. Laterally variable pin forming (e.g., a combination of 2D and 3D pins) is also contemplated and further described herein.

[0249] The nail actuator 225 is configured to be lifted by the slider 280 when the slider 280 is pushed distally through the nail magazine 220 to eject the nail 226 supported by the nail actuator 225 in the nail cavity 223. The slider 280 includes a ramp 281 to contact the nail actuator 225. The slider 280 also includes a blade 283. The slider 280 is configured to be actuated by the firing member 270.

[0250] For deploying the nail 226 and cutting tissue with the blade 283, the end effector 200 includes a firing drive 260. The firing drive 260 is actuated by a flexible drive shaft 176. Discussed in more detail below, the flexible drive shaft 176 is driven by an input shaft passing through the shaft assembly 100. The flexible drive shaft 176 transmits rotational actuation motion via a double-joint kinematic joint. The firing drive 260 includes a firing screw 261 configured to be rotatable by the flexible drive shaft 176. The firing screw 261 includes a journal supported within bearings in a support member 259 and a channel 210. In various instances, the firing screw 261 may float relative to the channel 210, as further described herein. The firing screw 261 includes a proximal end 262 supported within the support member 259 and the channel 210, a distal end 263 supported within the channel 210, and a thread 265 extending along a portion of the length of the firing screw 261.

[0251] The firing member 270 is threadedly connected to the firing screw 261 such that, as the firing screw 261 rotates, the firing member 270 advances distally or retracts proximally along the firing screw 261. Specifically, the firing member 270 includes a body portion 271, which includes a hollow channel 272 defined therein. The firing screw 261 is configured to be received within the hollow channel 272 and is configured to be threadedly connected to a threaded portion 273 of the firing member 270. Thus, as the firing screw 261 rotates, the threaded portion 273 applies a linear force to the body portion 271 to advance the firing member 270 distally or retract it proximally. When the firing member 270 advances distally, it pushes a slider 280. The distal movement of the slider 280 through engaging a plurality of pin actuators 225 causes the ejection of pins 223, as further described herein. The actuator 225 is a triple actuator configured to fire multiple pins 223 simultaneously. The actuator 225 may include lateral asymmetry, as further described herein, to maximize the width of the slider track in various instances and to receive the firing screw 261 downward along the center of the pin magazine 220.

[0252] At some point during the firing of the end effector 200, the user can retract the firing member 270 to allow the jaws 201, 203 to open. In at least one instance, full retraction of the firing member 270 is required to open the jaws 201, 203, wherein the upper cam actuating member and the lower cam actuating member are disposed on the body portion 271, and once the firing member 270 is fully retracted, it can only disengage from the jaws 201, 203.

[0253] In various instances, the firing member 270 may be a hybrid construction of plastic and metal parts as further described herein. In various instances, the threaded part 273 may be, for example, a metal part, which is incorporated into the firing member body 271 by insert molding or overmolding.

[0254] In some instances, the firing member 270 may also be referred to as an I-beam. The firing member 270 may include a complex 3D-printed geometry that includes a grid pattern space. In various instances, 3D printing may allow the firing member or a portion thereof to act as a spring and allow a portion to be more easily flexed, which may improve, for example, force distribution and / or tolerances during the firing stroke.

[0255] Figures 9 to 11 A surgical suture assembly 300 is shown, which includes a shaft assembly 310 and an attachment to the shaft assembly 310. Figures 1 to 8The end effector 200. The shaft assembly 310 may be similar in many respects to various other shaft assemblies discussed herein; however, the shaft assembly 310 includes a single articulation joint and an articulation rod configured to enable articulation of the end effector 200 about the single articulation joint. The surgical suture assembly 300 is configured to cut and suture tissue. The surgical suture assembly 300 may be attached to a surgical instrument handle and / or a surgical robot interface. The surgical instrument handle and / or the surgical robot interface may be configured to actuate various functions of the surgical suture assembly 300. The shaft assembly 310 includes an articulation joint 320. As discussed in more detail below, the end effector 200 is configured to articulate about axis AA relative to the outer axis 311 of the shaft assembly 310.

[0256] The shaft assembly 310 includes an outer shaft 311, a first shaft connector 330, and a second shaft connector 350 pivotally coupled to the first shaft connector 330 via an articulated pin 354. The first shaft connector 330 includes a proximal tube portion 331 configured to engage within the inner diameter of the outer shaft 311. Such engagement may include a press fit, for example. However, any suitable attachment device may be used. The first shaft connector 330 also includes a distal portion 332. The distal portion 332 includes an articulated tab 333 including a pin hole 334 defined therein, and a hollow channel 335 through which various actuation components of the surgical suture assembly 300 can pass. Such actuation components may include, for example, articulation actuators, closure actuators, and / or firing actuators.

[0257] The first axial connector component 330 is pivotally connected to the second axial connector component 350 via an articulation pin 354. The articulation pin 354 is also received within a pin hole 353 of a proximal articulation tab 351 of the second axial connector component 350. The pin hole 353 is axially aligned with the pin hole 334. The articulation pin 354 allows the second axial connector component 350 to articulate about the articulation axis AA relative to the first axial connector component 330. The second axial connector component 350 also includes a pin projection 352 extending from the proximal articulation tab 351. Discussed in more detail below, the pin projection 352 is configured to be pivotally coupled to an articulation drive system. The second axial connector component 350 also includes a distal portion 355, which includes an annular groove 356 configured to receive a retaining ring 358. The distal portion 355 also includes a hollow channel 357 through which various drive components of the surgical suture assembly 300 can pass. The retaining ring 358 is configured to retain the first jaw 201 to the second shaft connector 350 by engaging within the annular groove 211 of the compartment channel 210 and the annular groove 356 of the second shaft connector component 350.

[0258] To enable the end effector 200 to articulate about the joint motion axis AA, an articulation lever 360 is provided. The articulation lever 360 can be actuated by any suitable means, such as by a robot or motor input and / or a manual handle trigger. For example, the articulation lever 360 can be actuated in both proximal and distal directions. Embodiments in which, in addition to or instead of linear actuation, the articulation system includes rotary actuation are contemplated. The articulation lever 360 extends through an outer shaft 311. The articulation lever 360 includes a distal end 361 pivotally coupled to an articulation link 362. The articulation link 362 is pivotally coupled to a pin protrusion 352 that extends eccentrically relative to the joint motion axis AA from a proximal articulation tab 351. This eccentric connection of the articulated link 362 allows the articulated link 360 to apply force to the second joint shaft member 350, causing the second joint shaft member 350 and thus the end effector 200 to rotate relative to the first joint shaft member 330. The articulated link 360 can be advanced distally to rotate the end effector 200 about the articulation axis AA in a first direction, and can be retracted proximally to rotate the end effector 200 about the articulation axis AA in a second direction opposite to the first direction.

[0259] The shaft assembly 310 also includes a joint motion component support structure 340 located within the joint motion joint 320. This support structure provides support to various drive components configured to reach the end effector 200 through the joint motion joint 320 during joint motion. The support structure 340 also serves to isolate the drive components from tissue residue during use.

[0260] Figures 12 to 14 A surgical suture assembly 400 is shown, which includes a shaft assembly 410 and an attachment to the shaft assembly 410. Figures 1 to 8 The end effector 200. The shaft assembly 410 may be similar in many respects to various other shaft assemblies discussed herein; however, the shaft assembly 410 includes a single articulation joint and an articulation cable configured to enable the end effector 200 to articulate about the single articulation joint. The surgical suture assembly 400 is configured to cut and suture tissue. The surgical suture assembly 400 may be attached to a surgical instrument handle and / or a surgical robot interface. The surgical instrument handle and / or the surgical robot interface may be configured to actuate various functions of the surgical suture assembly 400. The shaft assembly 410 includes an articulation joint 420. As discussed in more detail below, the end effector 200 is configured to articulate about axis AA relative to the outer axis 411 of the shaft assembly 310.

[0261] The shaft assembly 410 includes an outer shaft 411, a first shaft connector 430, and a second shaft connector 450 pivotally coupled to the first shaft connector 430 via an articulated pin 454. The first shaft connector 430 includes a proximal tube portion 431 configured to engage within the inner diameter of the outer shaft 411. Such engagement may include, for example, a press fit. However, any suitable attachment device may be used. The first shaft connector 430 also includes a distal portion 432 comprising an articulated tab 433 including a pin hole 434 defined therein. The distal portion 432 also includes a hollow channel 435 through which various actuation components of the surgical suture assembly 400 can pass. Such actuation components may include, for example, articulation actuators, closure actuators, and / or firing actuators.

[0262] The first axial connector component 430 is pivotally connected to the second axial connector component 450 via an articulation pin 454. The articulation pin 454 is also received within a pin hole 453 of a proximal articulation tab 451 of the second axial connector component 450. The articulation pin 454 allows the second axial connector component 450 to articulate about an articulation axis AA relative to the first axial connector component 430. The second axial connector component 450 also includes a drive ring structure 452. The drive ring structure 452 extends from the proximal articulation tab 451 and also defines a portion of the pin hole 453. Discussed in more detail below, the drive ring structure 452 is configured to be engaged by an articulation drive system. The second axial connector component 450 also includes a distal portion 455, which includes an annular groove 456 configured to receive a retaining ring 458. A hollow channel 457 through the distal portion 455 is configured to receive various drive components of a surgical suture assembly 400 passing therethrough. The retaining ring 458 is configured to retain the first jaw 201 to the second shaft connector 450 by engaging within the annular groove 211 of the compartment channel 210 and the annular groove 456 of the second shaft connector component 450.

[0263] To enable the end effector 200 to articulate about the articulation axis AA, an articulation cable 460 is provided. The articulation cable 460 can be actuated by any suitable means, such as a manual trigger actuation, for example, on the handle of a robot input and / or handheld surgical instrument. The articulation cable 460 may include an anti-application profile. In other words, when a first side of the articulation cable 460 is pulled proximally, a second side of the articulation cable 460 is allowed to advance distally, like a pulley system. Similarly, when the second side is pulled proximally, the first side is allowed to advance distally. The articulation cable 460 extends through the outer shaft 411. The articulation cable 460 is positioned around and frictionally held on the drive ring structure 452 to allow the second shaft connector component 450 to rotate when the articulation cable 460 is actuated. When the articulation cable 460 is actuated, the articulation cable 460 is configured to apply rotational torque to the drive ring structure 452 of the second connector shaft component 450 and thus to the end effector 200. This torque is configured to cause the second connector shaft component 450 to rotate or pivot relative to the first connector shaft component 430, thereby causing the end effector 200 to articulate relative to the outer shaft 411. A first side of the articulation cable 460 can be pulled to rotate the end effector 200 about the articulation axis AA in a first direction, and a second side of the articulation cable 460 can be pulled to rotate the end effector 200 about the articulation axis AA in a second direction opposite to the first direction.

[0264] The shaft assembly 410 also includes a joint motion component support structure 440 located within the joint motion joint 420. This support structure 440 provides support to various drive components configured to reach the end effector 200 through the joint motion joint 420 during joint motion. The support structure 440 also serves to isolate the drive components from tissue residue during use.

[0265] The surgical suture assembly 400 also includes a closing drive shaft section 475 and a firing drive shaft section 476, each configured to transmit rotational motion to the end effector 200 via an articulation joint 420. Drive shaft sections 475 and 476 are configured to passively expand and contract longitudinally during articulation of the end effector 200. For example, articulation can cause expansion and contraction of drive shaft sections 475 and 476 to account for a corresponding longitudinal stretching or contraction of the drive shaft length due to articulation of the end effector 200 relative to the shaft assembly 410. During expansion and contraction of drive shaft sections 475 and 476, drive shaft sections 475 and 476 maintain rotational drive engagement with corresponding input and output shafts extending through the outer shaft 411 in the end effector 200. In at least one instance, the output shaft includes a closing screw 251 and a firing screw 261, the closing screw being configured to perform gripping, closing, or organization manipulation via jaws 201, 203, and the firing screw being configured to perform clamping of jaws 201, 203 and firing of the firing member 270.

[0266] Figures 15 to 17 A surgical suture assembly 500 is shown, which includes a shaft assembly 510 and an attachment to the shaft assembly 510. Figures 1 to 8 The end effector 200. The shaft assembly 510 may resemble in many respects the various other shaft assemblies discussed herein; however, the shaft assembly 510 includes a single articulated joint and a drive shaft segment configured to passively expand and contract. The surgical suture assembly 500 is configured to cut and suture tissue. The surgical suture assembly 500 may be attached to a surgical instrument handle and / or a surgical robot interface. The surgical instrument handle and / or surgical robot interface may be configured to actuate various functions of the surgical suture assembly 500. The shaft assembly 510 includes an articulated joint 520. As discussed in more detail below, the end effector 200 is configured to articulate about axis AA.

[0267] The shaft assembly 510 includes a first shaft connector portion 530 and a second shaft connector portion 540 pivotally coupled to the first shaft connector portion 530 via an articulated pin 543. The first shaft connector portion 530 is configured to attach to a shaft of a surgical instrument assembly and / or a surgical robot interface. The first shaft connector portion 530 includes a proximal portion 531 and an articulated tab 533 including a pin hole 534 defined therein. In at least one embodiment, the first shaft connector portion 530 includes a hollow channel through which various drive components of the surgical suture assembly 400 can pass. Such drive components may include, for example, articulated actuators, closure actuators, and / or firing actuators.

[0268] The first axial connector component 530 is pivotally connected to the second axial connector component 540 via an articulation pin 543. The articulation pin 543 is also received within a pin hole 542 of an articulation tab 541 extending proximally in the second axial connector component 540. The articulation pin 543 allows the second axial connector component 540 to articulate relative to the first axial connector component 530 about an articulation axis AA. The second axial connector component 540 also includes a distal portion 545 comprising an annular groove 547 configured to receive a retaining ring 548 and a hollow channel 546 through which various drive components of the surgical suture assembly 500 can pass. The retaining ring 548 is configured to retain the first jaw 201 to the second axial connector component 540 by engaging within the annular groove 211 of the compartment channel 210 and the annular groove 547 of the second axial connector component 540.

[0269] Any suitable articulation drive system can be used to articulate the end effector 200 about axis AA. In at least one instance, the end effector 200 passively articulates. In such instances, the end effector 200 may be pressed against tissue, for example, to apply a force to the end effector 200 and cause it to articulate about the articulation axis. In at least one instance, the end effector 200 also includes a spring configured to apply a neutral biasing force to the second shaft joint section 540, for example, to bias the end effector 200 toward a non-articulated configuration.

[0270] The surgical suture assembly 500 also includes a closing drive shaft section 575 and a firing drive shaft section 576, each configured to transmit rotational motion to the end effector 200 via an articulation joint 520. Drive shaft sections 575 and 576 are configured to passively expand and contract longitudinally during articulation of the end effector 200. Articulation causes drive shaft sections 575 and 576 to expand and contract to accommodate longitudinal stretching or contraction of the drive shaft length due to articulation of the end effector 200. During expansion and contraction, drive shaft sections 575 and 576 maintain rotational drive engagement with corresponding input and output shafts in the end effector 200. In at least one example, the output shaft includes a closing screw 251 and a firing screw 261, which will be further described herein.

[0271] Figures 18 to 20A surgical suturing end effector assembly 600 is shown, comprising a shaft portion 610 and an end effector 600. The end effector assembly 600 is similar in many respects to various other end effector assemblies disclosed herein; however, the end effector assembly 600 includes a multi-part firing member driven by a flexible firing shaft. The end effector assembly 600 is configured to cut and suture tissue. The end effector assembly 600 can be attached to a surgical instrument handle and / or a surgical robot interface via a proximal tab 611 of the shaft portion 610. The surgical instrument handle and / or the surgical robot interface can be configured to actuate various functions of the end effector assembly 600. The end effector assembly 600 includes a pouch passage jaw 620 and an anvil jaw 660, the anvil jaw being pivotally mounted to the pouch passage jaw 620 to clamp tissue between the pouch passage jaw 620 and the anvil jaw 660.

[0272] The cartridge channel jaw 620 includes: a channel 630 including a proximal end 631; a cartridge 640 configured to store a plurality of cartridges and configured to be received within the channel 630; and a support bracket 650 mating within the cartridge 640. The cartridge 640 and the support bracket 650 are configured to be assembled together prior to installing the cartridge 640 into the channel 630. Discussed in more detail below, the support bracket 650 is configured to further support the firing member assembly as it is advanced through the end effector assembly 600.

[0273] The anvil jaws 660 are configured to shape nails ejected from the nail cartridge 640. The anvil jaws 660 include a proximal end 661 with a pair of pin holes 662 defined therein, configured to receive a connecting pin 663. The anvil jaws 660 are pivotable about the connecting pin 663 between an open position and a fully clamped position. The connecting pin 663 is also received within a pair of pin holes 633 defined in the proximal end 631 of the channel 630. The connecting pin 663 is used to pivotally mount the anvil jaws 660 to the channel 630. In at least one embodiment, the channel 630 is mounted to the shaft portion 610 by a retaining ring or band engaging an annular groove 632 around the channel 630 and an annular groove 615 of the shaft portion 610. The retaining ring or band is configured to retain the channel 630 to the shaft portion 610.

[0274] The end effector assembly 600 includes a closing drive 670 configured to clamp tissue between the anvil jaws 660 and the cartridge channel jaws 620 by pivoting the anvil jaws 660 relative to the channel 630. The end effector assembly 600 also includes a firing drive 680 configured to clamp, suture, and cut tissue by deploying a plurality of staples from the staple cartridge 640. The closing drive 670 includes a closing screw 671 positioned within the channel 630 and a closing wedge 675 threaded to the closing screw 671. When the closing screw 671 rotates, the closing wedge 675 advances distally or retracts proximally to open or close the anvil jaws 660, respectively. The closing drive 670 can be actuated by any suitable means. For example, a rotary drive shaft can extend from the actuation interface through the shaft portion 610, for example, to rotate the closing screw 671. Other examples of suitable rotary drive shafts are further described herein.

[0275] The firing actuator 680 includes a flexible drive shaft 681 configured to move linearly through the end effector assembly 600. For example, the flexible drive shaft 681 may be actuated by a manually actuated drive shaft of the robot input and / or the handle assembly. The flexible drive shaft 681 is configured to extend through a hollow channel 614 through the distal end 613 of the shaft portion 610 and is flexible, allowing the end effector assembly 600 to articulate relative to the end effector 600 from its extending shaft. The flexible drive shaft 681 extends through a pitch slot 676 defined in a closing wedge 675 and is fixedly attached to the lower firing member 682. The lower firing member 682 is configured to be reusable with different cartridges.

[0276] The staple cartridge 640 includes a disposable upper firing member 683 configured to engage or latch onto a lower firing member 682 in a hook-like manner, such that the lower firing member 682 can push or drive the upper firing member 683 through the staple cartridge 640 and the support bracket 650. In other words, firing actuation involves a two-part firing member—the disposable upper firing member 683 incorporated into the cartridge 640 and the reusable lower firing member 682 incorporated into the firing drive mechanism 680—which can be coupled together when the staple cartridge 640 is located in the elongated channel 630. The two-part firing member is further described herein.

[0277] The upper firing member 683 includes an upper flange configured to engage and position the anvil jaws 660, a cutting edge configured to cut tissue, and a latch portion configured to engage the lower firing member 682 in a hook-like manner. The staple cartridge 640 also includes a slide 684 configured to engage a staple driver positioned within the cartridge 640 to eject staples from the cartridge 640. Because the blade and cutting edge are integrated into the disposable upper firing member 683 of the staple cartridge 640, new and / or brand-new cutting edges can be supplied with each staple cartridge loaded into the end effector assembly 600.

[0278] The lower firing member 682 and the upper firing member 683 are configured to move through the support bracket 650, such that the vertical load associated with the firing sequence is configured to be distributed through the support bracket 650, the cartridge 640, the channel 630, and the anvil jaws 660. The support bracket 650 may be made of, for example, a metal material to be inserted into the cartridge 640. The support bracket 650 includes a keyway 655 configured to engage within a corresponding keyway defined in a longitudinal slot of the cartridge 640. The support bracket 650 also includes a longitudinal slot 653 configured to receive the blade of the upper firing member 683, a cylindrical channel 657 configured to receive a portion of the upper firing member 683, a portion of the lower firing member 682, and a flexible drive shaft 681. The support bracket 650 also includes a vertical key extension 656 configured to be received within a corresponding keyhole in the cartridge platform. When the support bracket 650 is installed within the staple cartridge 640, such an extension is visible through the cartridge platform. In at least one instance, the support bracket 650 is configured to be inserted into the staple cartridge 640 from the bottom of the staple cartridge facing the channel 630.

[0279] The support bracket 650 also includes a proximal tab 651 and a distal tab 653, both configured to engage with the channel 630. Tabs 651 and 653 are configured to distribute at least some of the forces transmitted by the firing actuator 680 and corresponding components through the assembly 600. The distal tab 651 can be used to prevent the upper firing member 683 and the lower firing member 682 from being pushed through the distal end of the support bracket 650 by sharing and / or redistributing the load applied to the support bracket 650 by the firing actuator 680 with the channel 630.

[0280] When replacing the cartridge 640 to make the end effector assembly 600 reusable, the cartridge 640 is removed from the channel jaws 630. Removing the cartridge 640 from the channel jaws 630 removes the upper firing member 683, the slider 684, the support bracket 650, and the cartridge 640. A new blade can then be configured with a replacement cartridge.

[0281] The various implementation schemes disclosed herein can be used in conjunction with the robot system 700. For example, in Figures 21 to 23 An exemplary robotic system is shown in the figure. Figure 21 The main controller 701 is shown, which can be used in conjunction with a surgical robot, for example... Figure 22 The slave robotic arm 800 is shown in the diagram. The master controller 701 and the slave robotic arm 800, along with their respective components and control systems, are collectively referred to herein as the robotic system 700. Examples of such systems and devices are disclosed in U.S. Patent No. 7,524,320, entitled “MECHANICAL ACTUATOR INTERFACE SYSTEM FOR ROBOTIC SURGICAL TOOLS,” and U.S. Patent No. 9,072,535, entitled “SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS,” the entire contents of which are incorporated herein by reference. As is well known, the master controller 701 typically includes a controller (in... Figure 21 The controller (generally referred to as 703) is held and manipulated in mid-air by the surgeon while the surgeon observes the surgery via a stereoscopic display 702. The controller 701 typically includes manual input devices, which preferably move in multiple degrees of freedom and generally also have actuable handles, triggers, or actuators for actuating tools (e.g., for closing gripping jaws, applying potential to electrodes, etc.).

[0282] like Figure 22 As can be seen, in one form, the robotic arm 800 can be configured to actuate one or more surgical instruments, commonly referred to as 900. Various robotic surgical systems and methods employing a master controller and robotic arm arrangement are disclosed in U.S. Patent No. 6,132,368 entitled “MULTI-COMPONENT TELEPRESENCE SYSTEM AND METHOD,” the entire disclosure of which is incorporated herein by reference.

[0283] In various forms, the robotic arm 800 includes a base 702, which, in an illustrated embodiment, supports a surgical instrument 900. In various forms, the surgical instrument 900 may be supported by a series of manually articulated links (commonly referred to as device connector 804) and a robotic manipulator 806. In various embodiments, the link and connector arrangement may facilitate rotation of the surgical instrument about a point in space, as described more fully in U.S. Patent No. 5,817,084 entitled “REMOTE CENTER POSITIONING DEVICE WITH FLEXIBLE DRIVE,” the entire disclosure of which is hereby incorporated by reference. The parallelogram arrangement constrains rotation to pivot about axis 812a (sometimes referred to as the pitch axis). Connectors supporting the parallelogram links are pivotally mounted to device connector 804 (…). Figure 22 This allows the surgical instrument to also rotate about axis 812b (sometimes referred to as the yaw axis). The pitch axis 812a and yaw axis 812b intersect at a remote center 814, which is aligned along the slender axis of the surgical instrument 900. When supported by the manipulator 806, the surgical instrument 900 may have additional driven degrees of freedom, including sliding motion of the surgical instrument 900 along the longitudinal axis “LT-LT”. When the surgical instrument 900 moves relative to the manipulator 806 (arrow 812c) along the tool axis LT-LT, the remote center 814 remains fixed relative to the base 816 of the manipulator 806. Therefore, the entire manipulator is typically moved to reposition the remote center 814. The linkage 808 of the manipulator 806 may be driven by a series of motors 820. These motors actively move the linkage 808 in response to commands from the processor of the control system. Motors 820 may also be used to manipulate the surgical instrument 900. Alternative joint structures and device arrangements are also envisioned. Examples of other joint and device arrangements are disclosed, for example, in U.S. Patent No. 5,878,193 entitled “AUTOMATED ENDOSCOPE SYSTEM FOROPTIMAL POSITIONING,” the entire disclosure of which is incorporated herein by reference.

[0284] While the communication between the surgical instruments and the main controller 701 is initially described herein, the data communication between the robotic components and the processor of the robotic surgical system should be understood. However, similar communication can occur between the circuitry of manipulators, device connectors, endoscopes, or other image-capturing devices and the processor of the robotic surgical system, which is used for component compatibility verification, component type identification, component correction (such as offset) communication, and component-to-system connection verification. According to at least one aspect, the various surgical instruments disclosed herein can be used in conjunction with other robot-controlled or automated surgical systems, and are not necessarily limited to those... Figures 21 to 23 Used together with the specific robot system components shown and described in the above references.

[0285] During various laparoscopic surgical procedures, it is common practice to access surgical sites located within the patient's abdomen by inserting the surgical end-effector portion of a surgical instrument through a cannula already embedded in the patient's abdominal wall. In its simplest form, the cannula is a pen-shaped instrument with a sharp triangular dot at one end, typically used within a hollow tube called a cannula or trocar to form an opening into the body through which the surgical end-effector is introduced. This arrangement forms an entrance into the body cavity through which the surgical end-effector is inserted. The inner diameter of the cannula inevitably limits the size of the end-effector and drive support shaft of the surgical instrument that can be inserted through the cannula.

[0286] Regardless of the specific type of surgical procedure performed, once a surgical end effector is inserted into the patient through a cannula, it is typically necessary to move the end effector relative to the shaft assembly positioned within the cannula in order to properly position the end effector relative to the tissue or organ being treated. This movement or positioning of the end effector relative to the shaft portion held within the cannula is generally referred to as the "articular movement" of the end effector. Various articulation joints have been developed to attach the end effector to the associated shaft to facilitate this articulation. It is anticipated that in many surgical procedures, the use of surgical end effectors with the largest possible range of articulation is desirable.

[0287] Due to the dimensional constraints imposed by the size of the cannula sheath, the dimensions of the articulation joint components must be configured to allow free insertion through the cannula sheath. These dimensional constraints also limit the size and composition of various drive members and components that operatively interact with a motor and / or other control system supported in a housing, which may be handheld or part of a larger automated system. In many cases, these drive members must operatively pass through the articulation joint to be operatively coupled to or operatively interact with a surgical end effector. For example, one such drive member is typically used to apply articulated motion control to a surgical end effector. During use, the articulation drive member may be deactivated to position the surgical end effector in a non-articular position to facilitate insertion of the surgical end effector through the cannula, and then actuated to articulate the surgical end effector to the desired position as it enters the patient's body.

[0288] Therefore, the aforementioned dimensional constraints pose numerous challenges to the development of articulation systems that can achieve the desired range of motion and are suitable for the various drive systems required to operate the different features of a surgical end effector. Furthermore, once the surgical end effector is positioned in the desired articulation location, the articulation system and articulation joint must be able to hold the surgical end effector in that locked position during actuation of the end effector and completion of the surgical procedure. Such an articulation joint arrangement must also be able to withstand the external forces experienced by the end effector during use.

[0289] Various surgical instruments employ diverse drive shaft arrangements to transmit drive motion from corresponding drive motion sources supported in the handle of the surgical instrument or in other parts of an automated or robotic control system. These drive shaft arrangements must accommodate the significant articulation orientation of the end effector while efficiently transmitting such drive motion across the articulation joints of the surgical instrument. Furthermore, due to the aforementioned dimensional constraints imposed by the size of the cannula through which the instrument shaft must be inserted, these drive shaft components must occupy as little space as possible within the shaft. To accommodate these requirements, many drive shaft arrangements comprise several movable elements connected in series. The small size (e.g., 4 mm diameter) and number of components result in difficult and lengthy assembly procedures, increasing the cost and complexity of the device.

[0290] As further described herein, a powered suture device may include two independently rotatable drive members: a first rotary drive member configured to close the jaws of an end effector and a second rotary drive member configured to fire a staple cartridge mounted in the end effector. The first and second rotary drive members are flexible and configured to extend through at least one articulated joint. In such examples, the first and second rotary drive members can transmit rotational actuation motion via the articulated joint in both a non-flexible and a flexible configuration. Exemplary rotary drive members are further described herein.

[0291] The powered suture assembly also includes a first jaw, a second jaw, a closing drive, and a firing drive. The closing drive includes a first rotary drive member extending through a joint joint, and the firing drive includes a second rotary drive member extending through the joint joint. The second rotary drive member can rotate independently of the first rotary drive member. For example, the closing drive can be activated by a closing trigger, which actuates the closing drive to cause rotation of the first rotary drive member, which transmits the rotational motion to the closing screw via the joint joint. The closing drive also includes a closing wedge threaded to the closing screw, wherein the closing wedge is configured to engage the first jaw to move it from an open position to a closed position as the first rotary drive member rotates.

[0292] The firing drive mechanism can be activated by a firing trigger, for example, separate from the closing trigger. The rotation of the second rotary drive member is separate from the rotation of the first rotary drive member, and the closing motion is separate from and different from the firing motion. Actuation of the firing drive mechanism enables the rotation of the second rotary drive member, which transmits the rotational motion to the firing screw via a joint. The firing drive mechanism also includes a firing member threadedly connected to the firing screw, wherein the firing member is configured to engage the first and second jaws in a cam-like manner and move the cutting member and / or the pin-firing slider during the rotation of the second rotary drive member.

[0293] In various instances, at least one component of a powered suture device can be a 3D-printed part. 3D-printed parts can be incorporated into articulated motion systems, closure / gripping systems, and / or firing systems, as further described herein. In some instances, 3D printing technology can be utilized to improve part capabilities. For example, 3D printing can allow printed parts to exhibit metamaterial properties, resulting in greater structural strength and stiffness, while allowing for precise formation of small detail features and optimizing other part properties, such as selective flexibility and / or lubrication. Exemplary 3D-printed parts of powered suture devices are further described herein and include flexible rotatable drive components, such as tandem 3D-printed universal joints, firing components or I-beams, and / or staple cartridges and / or their sub-components. In one instance, the staple cartridge can be a composite plastic-metal 3D-printed part. 3D printing of various parts and considerations thereof are further described herein.

[0294] Methods for suturing using such surgical suture assemblies are also envisioned. The methods may include obtaining the surgical suture assembly and a closing drive mechanism actuated by a closing trigger, wherein a closing wedge is configured to engage a first jaw to move the first jaw from an open position to a closed position as the first rotary drive member rotates. The methods may also include activating a firing drive mechanism by a firing trigger, wherein a firing member is configured to engage the first and second jaws in a cam-like manner and advance a cutting member and a nail firing slider during the firing motion as the second rotary drive member rotates. Various applications of 3D-printed parts in such assemblies are further described herein.

[0295] Figures 24 to 33 An end effector assembly 1000 for suturing tissue is shown. The end effector assembly 1000 is similar to the end effector assembly 600; however, the end effector assembly 1000 and the accompanying description include further details beyond those of the end effector assembly 600. The end effector assembly 1000 includes a shaft portion 1010 and an end effector including a first jaw 1011 and a second jaw 1013 movable relative to the first jaw 1011. The end effector assembly 1000 is configured to cut and suture tissue captured between the jaws 1011 and 1013. The end effector assembly 1000 can be attached to a surgical instrument handle and / or a surgical robot interface via the shaft portion 1010. The surgical instrument handle and / or the surgical robot interface can be configured to actuate various functions of the end effector assembly 1000. The first jaw 1011 includes a storage channel 1020, and the second jaw 1013 includes an anvil 1080, which is pivotally mounted to the storage channel 1020 via a pin 1084 to clamp tissue between the jaws 1011 and 1013.

[0296] The end effector assembly 1000 also includes a replaceable staple cartridge 1050 configured to be mounted within the cartridge passage 1020 and a support beam 1100 positioned within the staple cartridge 1050. Discussed in more detail below, the support beam 1100 is configured to provide additional internal support to the end effector assembly 1100 within the staple cartridge 1050. The staple cartridge 1050 includes a cartridge body 1055, which includes a proximal end 1051, a distal end 1053, and a cartridge platform 1056. The cartridge body 1055 also includes: a plurality of staple cavities 1057 arranged in a longitudinal row defined within the platform 1056; and a longitudinal slot 1059 defined within the platform 1056 and configured to receive a portion of the firing member assembly, discussed in more detail below.

[0297] A replaceable staple cartridge 1050 is configured to removably store multiple staples within a staple cavity 1057. The staples are configured to be ejected from the cartridge and abut against an anvil surface 1083 of the anvil 1080 to form staples and suture tissue trapped between the platform 1056 and the anvil surface 1083. To eject the staples, a slider 1070 is pushed from the proximal end 1051 of the cartridge 1050 toward the distal end 1053 of the cartridge 1050 via a firing member assembly. As the slider 1070 translates longitudinally within the cartridge 1050, it is configured to contact and lift multiple staple drivers supporting the staples within the cartridge 1050 and abut against the anvil surface 1083 to form the staples.

[0298] A closing drive device 1210 is provided for opening and closing the anvil 1080 relative to the cartridge passage 1020 and the staple cartridge 1050. (See reference...) Figures 25 to 27 The closing actuator 1210 includes a rotary closing actuator 1211 configured to be actuated by, for example, a rotary output shaft of a surgical instrument handle and / or a robot interface. The rotary closing actuator 1211 is supported within the proximal end 1021 of the channel 1020 and includes a thread 1212. The closing actuator 1210 also includes a closing wedge 1220, which includes a thread 1223 threadedly engaged with the thread 1212 of the rotary closing actuator 1211. Therefore, when the rotary closing actuator 1211 rotates, the closing wedge 1220 is configured to translate longitudinally within an anvil cavity 1085 defined in the proximal end 1081 of the anvil 1080. In various embodiments, the rotary closing actuator 1211 may be referred to as a closing screw.

[0299] The closing wedge 1220 includes an opening cam surface 1222 and a closing cam protrusion 1223. To close the anvil 1080, the closing wedge 1220 is moved proximally by a rotary closing drive 1221, such that the opening cam surface 1222 defined thereon engages the proximal end 1081 of the anvil 1080, thereby pivoting the anvil 1080 about a pin 1084 toward a closed position. To open the anvil 1080, the closing wedge 1220 is moved distally by the rotary closing drive 1221, such that the closing cam protrusion 1223 engages the proximal end 1081 of the anvil 1080, thereby pivoting the anvil 1080 about a pin 1084 toward an open position. The closing wedge 1220 also includes a U-shaped slot 1221 configured to allow a linearly actuated firing drive to pass through it, which will be discussed in more detail below.

[0300] For firing the end effector assembly 1000, a firing drive 1250 is provided. The firing drive 1250 includes a flexible firing shaft 1251 configured to be actuated by a linear output shaft of a surgical instrument handle and / or a robot interface. The flexible firing shaft 1251 passes through a U-shaped slot 1221 of a closed wedge 1220 toward the firing assembly, which includes a lower firing member 1260 and an upper firing member 1270. The firing shaft 1251 includes a distal end 1252 fixed within a drive slot 1263 defined in a guide portion 1265 of the lower firing member 1260. In at least one embodiment, the firing shaft 1251 is rotatably supported (e.g., journal-connected) within the drive slot 1263, such that the firing shaft 1251 can push and pull the lower firing member 1260 while simultaneously rotating within the drive slot 1263. This configuration allows the flexible firing shaft 1251 to rotate relative to the lower firing member 1260 while maintaining a linearly actuable engagement. The anvil 1080 also includes an upper anvil cover 1090 configured to attach to the anvil 1080. For example, the anvil cover 1090 may be welded to the anvil 1080 and may be used to reinforce the anvil 1080. The channel 1020 may also include a channel cover 1030.

[0301] The lower firing member 1260 includes a lower cam-acting flange 1261 extending laterally from the lower firing member 1260, an upper cam-acting flange 1262 extending laterally from the lower firing member 1260, and a guide portion 1265 configured to be received within a support beam 1100, as discussed in more detail below. The lower cam-acting flange 1261 is configured to engage the channel 1020 during the firing stroke to maintain a defined clamping tissue gap between the staple cartridge 1050 and the anvil 1080. The upper cam-acting flange 1262 is configured to engage the support beam 1100 during the firing stroke. As discussed in more detail below, providing multiple cam-acting flanges within the firing assembly can help distribute clamping force within the end effector assembly 1000. When discussing the cam-acting flanges, it should be understood that, as can be seen in the figures, the flanges extend laterally outward from both sides of the main body portion of the firing member.

[0302] An upper firing member 1270 is also provided. The upper firing member 1270 is configured to be advanced by the lower firing member 1260 through the firing stroke. A guide portion 1265 is configured to push a guide portion 1274 of the upper firing member 1270. The upper firing member 1270 includes an upper cam-acting flange 1272 extending laterally from the upper firing member 1270, a lower cam-acting flange 1273 extending laterally from the upper firing member 1270, and a guide portion 1274 configured to be received within a support beam 1100, as discussed in more detail below. The upper cam-acting flange 1272 is configured to engage the anvil 1080 during the firing stroke. Specifically, the upper cam-acting flange 1272 is configured to apply a clamping force to the anvil 1080 within the slot 1086. At the start of the firing stroke, the upper cam action flange 1272 is configured to engage the proximal ramp portion 1087 of the slot 1086 to begin applying a clamping force within the end effector assembly 1000.

[0303] The lower cam-acting flange 1273 of the upper firing member 1270 is configured to engage the support beam 1100 during the firing stroke. This lower cam-acting flange 1273 can provide an additional cam-acting flange within the firing member assembly to help distribute clamping force within the end effector assembly 1000. The upper firing member 1270 also includes a cutting blade or knife 1271 configured to cut tissue clamped between the staple cartridge 1050 and the anvil 1280. The upper firing member 1270 also includes a drive surface 1276 defined on the front of the upper firing member 1270. The drive surface 1276 is configured to actuate the drive flange 1071 of the slider 1070. As the slider 1070 is advanced by the upper firing member 1270 through the end effector assembly 1000, the slider track 1072 of the slider 1070 is configured to engage the staple driver, lift the staple driver, and eject staples to suture tissue.

[0304] In at least one instance, the upper firing member 1270 is disposable, and the lower firing member 1260 is reusable. In such instances, the upper firing member 1270 is replaced and the accompanying cartridge 1050 is positioned in a ready-to-install or ready-to-fire position. In other words, whenever a new cartridge is to be installed, the user accepts a new upper firing member. This configuration can provide new knives, each with a completely new cartridge.

[0305] The lower firing member 1260 includes a receiving hook slot 1264, and the upper firing member 1270 includes a hook portion 1275 configured to be received within the receiving hook slot 1264. The staple cartridge 1050, including the slider 1070 and the upper firing member 1270, can be mounted at an angle similar to that of the anvil 1080 positioned in its open position. This angle allows the user to latch or hook the upper firing member 1270 into the lower firing member 1260 when the user installs the staple cartridge 1050 into the channel 1020. In at least one embodiment, the lower firing member 1260 is configured to push or pull the upper firing member 1270 within the end effector assembly 1000 by pushing the guide portion 1274 with the guide portion 1265 and pulling the hook portion 1275 with the hook portion 1264. In some instances, the alignment and / or lever features between the staple cartridge 1050 and the channel 1020 are configured to interact to ensure proper alignment and insertion of the staple cartridge 1050.

[0306] Because it provides a brand new, disposable blade each time the staple cartridge is installed, the staple cartridge 1050 also includes a blade guard 1060 extending upward from the platform 1056. When handling the staple cartridge 1050, the blade guard 1060 protects the user from being cut by the blade 1271. The blade guard 1060 also prevents unintentional cutting of tissue when it is clamped by the end effector assembly 1000 and before the cutting motion. If tissue leaks toward the blade guard 1060 before firing, the blade guard 1060 will protect unsutured tissue before firing.

[0307] As discussed above, various types of firing and clamping forces exist within the end effector assembly 1000. The support beam 1100 is configured to help distribute the clamping forces within the end effector assembly to the individual components, thereby reducing the likelihood of failure of any single component by increasing the force distribution within the end effector assembly. In end effectors without a support beam, the clamping force may be primarily applied to the channel and anvil. The end effector assembly 1000 allows for a greater distribution of clamping forces within the end effector assembly 1000.

[0308] See also Figures 28 to 33 An internal support beam 1100 is positioned within the internal longitudinal channel 1060 of the staple cartridge 1050. The internal support beam 1100 may be made of a material stronger than the cartridge body 1055. In at least one example, the support beam 1100 is made of a metallic material and the cartridge body 1055 is made of a polymer. In such examples, the support beam 1100 can help distribute clamping forces within the end effector assembly 1100 by being made of a material stronger than that of the cartridge body 1055.

[0309] The support beam 1100 includes an upper surface 1110 with a plurality of protrusions 1111 projecting therefrom and configured to be received within corresponding slots 1058 defined in the platform 1056 of the staple cartridge 1050. The protrusions 1111 provide additional lateral and longitudinal support within the staple cartridge 1050. In other words, the protrusions 1111 prevent the support beam 1100 from sliding laterally or longitudinally relative to the cartridge body 1055. The protrusions 1111 also aid in aligning the support beam 1100 with the cartridge body 1055 when assembling the support beam 1100 and the cartridge body 1055. In at least one instance, the support beam 1100 is installed in the staple cartridge 1050 prior to packaging. In such instances, a replacement staple cartridge 1050 already includes the support beam 1100. Therefore, when the staple cartridge 1050 is replaced, a new support beam is provided.

[0310] The support beam 1100 can slide vertically from the bottom of the staple cartridge 1050 opposite to the platform 1056 into the internal longitudinal channel 1060 of the cartridge body 1055. The cartridge body 1055 also includes a lateral track or lug 1062 defined on the channel wall 1061 of the internal longitudinal channel 1060. The track 1062 is configured to engage within a corresponding slot 1109 defined in the side of the support beam 1100. The track 1062 is configured to retain the support beam 1100 within the cartridge body 1055 and prevent the support beam 1100 from falling from the bottom of the cartridge body 1055. The internal longitudinal channel 1060 also includes an upper surface 1063 defined below the thickness of the platform 1056. The upper surface 1110 of the support beam 1100 is configured to abut the upper surface 1063.

[0311] In at least one instance, the cartridge 1055 is overmolded onto the support beam 1100. This configuration provides various internal features that would otherwise be difficult to provide when components need to be manufactured separately and then assembled after manufacturing. In at least one instance, the cartridge 1055 is overmolded and / or insert-molded onto the support beam 1100 and the upper firing member 1270. In such instances, the nail, nail actuator, and slider can be assembled into the nail cartridge 1050 and the support beam 1100 after the overmolding process is completed. In at least one instance, the support beam 1100 is insert-molded into the nail cartridge 1050.

[0312] The support beam 1100 also includes a longitudinal cavity 1120, which includes a lower cam slot 1121, an upper cam slot 1123, and a cylindrical slot 1122. The lower cam slot 1121 is configured to receive the upper cam actuating flange 1262 of the lower firing member 1260. The upper cam slot 1123 is configured to receive the lower cam actuating flange 1273 of the upper firing member 1270. The cylindrical slot 1122 is configured to receive guide portions 1274, guide portions 1265, and a flexible firing shaft 1251 when the upper firing member 1270 and the lower firing member 1260 are advanced through the end effector assembly 1000. The longitudinal cavity 1120 is also configured to receive the drive flange 1071 of the slider 1070 when the slider 1070 is pushed by the upper firing member 1270. In at least one embodiment, the flexible firing shaft 1251 is configured to be received tightly within the cylindrical slot 1122, such that the cross-sectional profiles of each are substantially matched. In such embodiments, the cylindrical slot 1122 helps prevent buckling of the flexible firing shaft 1251 as it is advanced through the slot. When the flexible firing shaft 1251 is subjected to compressive forces, the cylindrical slot 1122 supports the length of the flexible firing shaft 1251 positioned therein and helps prevent buckling of the flexible firing shaft 1251.

[0313] As discussed above, the support beam 1100 is configured to help distribute the clamping forces applied to the end effector assembly 1100 by flanges 1272, 1273, 1262, and 1261. Guide portions 1274 and 1265 can also apply vertical clamping forces via flanges 1272, 1273, 1262, and 1261 and further help distribute these clamping forces through the support beam 1100. When the upper firing member 1270 and the lower firing member 1260 are advanced through the end effector assembly 1000, flanges 1272, 1273, 1262, and 1261 can apply vertical clamping forces to the anvil 1080, the channel 1020, and the support beam 1100. These forces can be primarily distributed between the anvil 1080, the channel 1020, and the support beam 1100; this component is more robust than the staple cartridge 1050, which may be primarily made of metal. Distributing the clamping load through these components reduces the vertical compressive force applied to the chamber 1055 itself. This arrangement also reduces the likelihood of any of the flanges 1272, 1273, 1262, and 1261 shearing from their respective firing member bodies, as they share the vertical clamping force along the vertical length of the end effector assembly 1000. The support beam 1100 also provides additional support between the channel 1020 and the anvil 1080, rather than relying solely on the channel 1020 and anvil 1080 to handle all the clamping forces applied only by the channel flange and anvil flange.

[0314] In at least one instance, the upper firing member 1270 and the lower firing member 1260 are referred to as double I-beams. Such a configuration allows for a central longitudinal cavity, such as a cylindrical slot 1122 defined in the support beam 1100, to be positioned between the upper flange 1262 of the lower firing member 1260 and the lower flange 1273 of the upper firing member 1270.

[0315] Guide sections 1265 and 1274 can further reinforce firing members 1260 and 1270 by providing circular portions that engage with support beam 1100. The circular portions also provide a source of strength to firing members 1260 and 1270 because they can handle significant vertical forces. In the event of a failure, in some instances, they may require shear failure rather than bending failure, making the circular portions more robust than the lateral flanges. The firing member having both lateral flanges and circular portions increases the overall strength of the firing assembly because it is adapted to withstand vertical clamping forces within the end effector assembly 1000. All vertical clamping forces can be used to maintain a predefined tissue gap between the staple cartridge 1050 and the anvil 1080.

[0316] The end effector assembly 1000 is also subjected to longitudinal loads. For example, the firing member assembly may be subjected to longitudinal loads applied by tissue to the blade 1271. The firing member assembly may also be subjected to longitudinal loads generated by clamping forces applied to the channel 1020 and the anvil 1080. The firing member assembly may also be subjected to longitudinal loads when it abuts a component at its nearest position. The firing member assembly and / or the slider may also be subjected to longitudinal loads when they abut the distal end of the end effector assembly 1000. In such examples, the slider and / or the firing member assembly component may be pushed distally into the nose of the cartridge, the anvil, and / or the support beam. The end effector assembly 1000 also includes features that facilitate the distribution of these longitudinal loads within the end effector assembly 1000.

[0317] Support beam 1100 includes a proximal hook 1102 extending downward from support beam 1100. Figure 29 ) and distal hook 1104 ( Figure 30The proximal hook 1102 is configured to be received within a corresponding channel hole 1023 defined in the proximal end 1021 of the channel 1020. When the staple cartridge 1050 and support beam 1100 are installed into the channel 1020, the proximal hook 1102 can be latched into the hole 1023. The hook 1102 can be installed, accompanied by, for example, an audible click to notify the user of successful installation. The hook 1102 is also visible from below the channel 1020, allowing the user to see whether the hook 1102 has properly engaged with the channel 1020. The distal hook 1104 is configured to be received within a corresponding channel hole 1024 defined in the distal end 1022 of the channel 1020. After the proximal hook 1104 is successfully installed into the proximal end 1021 of the channel 1022, the distal hook 1102 can engage into the hole 1024 via the inclined surface 1104'. Hooks 1102 and 1104 can be used to distribute the longitudinal load experienced within the end effector assembly 1000. The distal hook 1104 causes the firing members 1260 and 1270 to apply force primarily to the channel 1020 at the end of the firing stroke, rather than to the distal end or nose 1053 of the cartridge 1050. This configuration protects the integrity of the nose 1053 of the cartridge 1050, which is typically made of a more brittle material than the channel 1020. The channel 1020 can be used to support the force applied distally by the firing members 1260 and 1270, instead of the nose 1053. The distal end 1103 of the support beam 1100 also includes a mating profile configured to engage within the nose 1053 of the cartridge 1053.

[0318] As discussed above, the upper firing member 1270 can be disposable and removed together with the staple cartridge 1050, allowing a new upper firing member to be installed in a new staple cartridge. In such an example, the upper firing member 70 can be moved to its proximal position after the firing stroke is completed. When the upper firing member 1270 is pulled to its proximal position, the anvil 1080 can be pivotally opened by the closing drive 1210. When the anvil 1080 is pivotally opened, the engagement surface 1087 allows the upper firing member to tilt proximal relative to the lower firing member 1260 and disengages the hook 1275. At this point, the staple cartridge 1050 and the upper firing member 1270 can be pried open and / or disengaged from the channel 1020, allowing a new staple cartridge, support beam, and upper firing member to be installed in the channel 1020, and the end effector assembly 1000 to be reused.

[0319] Figure 34 and Figure 35A portion of a stitching assembly 1200 is shown, comprising a support beam 1210, a firing member (such as a slider) 1220, and a connecting member 1201 connecting the firing member 1220 to the support beam 1210. The stitching assembly 1200 can be used within any suitable staple cartridge (such as those disclosed herein). The support beam 1210 includes a central drive cavity 1211 configured to receive at least a portion of the firing beam and / or firing member assembly (such as the upper and lower firing members discussed above), an upper slot 1214 configured to receive at least a portion of the firing member assembly, and a pair of horizontal slots 1213 configured to receive the connecting member 1201. The upper slot 1214 may be aligned with a longitudinal slot defined in the platform of the staple cartridge. The connecting member 1201 may be constituted, for example, a pin.

[0320] The firing member 1220 is configured to eject a nail from the nail cartridge as it is advanced through the nail cartridge and support beam 1210. The support beam 1210 also includes a at least partially curved wall or flange 1212 that partially surrounds the central drive cavity 1211. The firing member 1220 includes a drive ramp 1222 configured to eject a nail and / or nail actuator from the nail cartridge.

[0321] In at least one embodiment, the firing member assembly is configured to be actuated only on the firing member 1220 to advance the firing member 1220 through the cartridge and support beam 1210. This configuration allows most of the firing force to be applied directly to the firing member 1220. In at least one embodiment, the firing member assembly is configured to be actuated on both the connecting member 1201 and the firing member 1220 to advance the firing member 1220 through the cartridge and support beam 1210. This configuration allows for the sharing of the applied firing force and can distribute the applied firing force across the entire connecting member 1201 and the firing member 1220.

[0322] In at least one instance, the firing member assembly is configured to be actuated only on the connecting member 1201 to advance the firing member 1220 through the cartridge and support beam 1210. In some instances, such a configuration may allow a more concentrated firing force to be applied to a component made of metal rather than a component made of polymer. For example, the firing member 1220 may be made of polymer, while the connecting member 1201 may be made of metal. In at least one instance, the firing member 1220 and the connecting member 1201 comprise the same material.

[0323] For example, applying the firing force to a connecting member (such as connecting member 1201) can be done laterally relative to the longitudinal travel path of the firing member 1220. This lateral distribution helps to distribute the firing force across the entire support beam 1210. The firing member 1220 is configured to surround the bottom of the support beam 1210. This configuration allows for the use of sliders of different sizes within the compartment passage.

[0324] Figure 36 and Figure 37 A suture assembly 1300 configured for use with any suitable staple cartridge disclosed herein is shown. The suture assembly 1300 includes: a firing assembly 1310 configured to be actuated by a firing shaft; a support beam 1340 configured to be positioned with the staple cartridge; and a slider or firing member 1350 configured to eject staples from the staple cartridge. The firing assembly 1310 includes a lower firing member 1320 and an upper firing member 1330 configured to be actuated by the lower firing member 1320. The lower firing member 1320 includes a drive portion 1323 configured to drive the upper firing member 1330, a shaft connection cavity 1321 configured to receive the firing shaft therein, and a bottom 1322. The upper firing member 1330 includes an upper flange 1331 configured to engage, for example, an anvil and a lower flange 1332 configured to engage a portion of the support beam 1340.

[0325] The support beam 1340 includes a longitudinal channel 1343 configured to receive a firing member assembly 1310 therein and an opening lug 1341 configured to support a firing member 1350. A lower flange 1332 is configured to apply cam forces to the support beam 1340 within the longitudinal channel 1343. Both the upper flange 1331 and the lower flange 1332 are configured to maintain a predetermined tissue gap between the staple cartridge and the anvil.

[0326] The slider 1350 includes a guide arm 1351 configured to be supported by an opening lug 1341 of a support beam 1340 and a drive ramp 1352 configured to eject nails from the cartridge. The slider 1350 is slidable onto one end of the support beam 1340 for assembly. The slider 1350 is suspended from the opening lug 1341. This configuration allows for the use of sliders of different sizes for different cartridges and the same support beam 1340. The firing member assembly 1310 is configured to actuate the slider 1350 during the firing stroke. The opening lug 1341 can also be used to transmit the vertical cam force applied by the firing member assembly 1310 to the cartridge. In at least one instance, the vertical cam force applied by the firing member assembly 1310 is isolated from the cartridge. In such instances, for example, in addition to the anvil and / or channel, the support beam 1340 is configured to also withstand most (if not all) of the vertical clamping force. This configuration can concentrate the vertical clamping force on a more robust component, such as those made of metal.

[0327] Alternative support beam geometries were also envisioned. For example, Figure 38 A support beam 1410 configured to be positioned within a staple cartridge (such as those disclosed herein) is shown. The support beam 1410 is configured to facilitate the distribution of vertical clamping forces throughout the end effector assembly. The support beam 1410 includes a generally circular, elliptical, or radially shaped outer periphery 1411 and thus a cross-sectional profile. The support beam 1410 also includes an upper channel 1413 and a lower channel 1415. Channels 1413 and 1415 are configured to receive one or more components of the firing member assembly (such as those disclosed herein). For example, channel 1413 includes a cylindrical cavity portion 1414 and may receive a guide portion of the upper firing member. For example, channel 1415 includes a cylindrical cavity portion 1416 and may receive a guide portion of the lower firing member. The generally radial cross-sectional profile of the support beam serves to reinforce the support beam 1410. In this configuration, the support beam 1410 is less likely to fail due to bending loads imposed by the vertical clamping forces. The circular cam-actuated flange can also be used with the support beam 1410. The circular cam-actuated flange can provide a reinforcing flange system within the end effector assembly, as further described herein.

[0328] Figure 39A support beam 1420 configured to be positioned within a staple cartridge (such as those disclosed herein) is shown. The support beam 1420 is configured to facilitate the distribution of vertical clamping force throughout the end effector assembly. The support beam 1420 includes a generally circular or radially extending outer periphery 1421 and thus a cross-sectional profile. The support beam 1410 also includes a lower flange 1424 extending from the generally circular or radially extending outer periphery 1421. In at least one embodiment, the lower flange 1424 is configured to engage, for example, the bottom of the staple cartridge and may include one of the flanges in a multi-flange system. In such embodiments, the firing member of the firing member assembly may include a flange receiving cavity instead of a laterally extending flange.

[0329] The support beam 1420 also includes an upper channel 1422. The channel 1422 is configured to receive one or more components of the firing member assembly (such as those disclosed herein). For example, the channel 1422 includes a cylindrical cavity portion 1423 and may receive a guide portion of the upper firing member.

[0330] Figure 40 and Figure 41 A suture assembly 1500 configured to cut and suture patient tissue is shown. The suture assembly 1500 includes: a staple cartridge 1510 configured to removably store a plurality of staples therein; a slider 1520 including a drive ramp 1521 configured to eject staples stored within the staple cartridge 1510; and an I-beam 1570 configured to push the slider 1520 through the staple cartridge 1510. The suture assembly 1500 also includes a cartridge support 1530 positioned within a longitudinal channel 1511 of the staple cartridge 1510 defined by an inner wall 1512 and a lug 1513. The cartridge support 1530 includes an upper cam channel 1533 configured to receive a lower cam-acting flange 1572 of the I-beam 1570 and a lower cam channel 1531 configured to receive a cam-acting flange 1523 of the slider 1520.

[0331] The cam-acting flange 1523 includes a support portion 1524 and a flange 1525 extending upward into the cam channel 1531. The flange 1525 extends from the support portion 1524 to form a T-shape; however, other geometries are also contemplated. The flange 1525 moves through the cam channel 1531 as the slider 1520 is advanced through the staple cartridge 1510 and the cartridge support 1530. The cartridge support 1530 is configured to support the vertical clamping force applied within the stitching assembly 1500 by the I-beam 1570 and the slider 1520.

[0332] The suture assembly 1500 also includes a platform plate 1560 positioned on a platform surface 1514 of the staple cartridge 1510. The platform plate 1560 helps distribute clamping forces within the suture assembly 1500. The platform plate 1560 may be made of, for example, a metallic material. The platform plate 1560 includes a plurality of holes 1561 configured to align with staple cavities defined in the staple cartridge 1510. The platform plate 1560 also includes a longitudinal slot 1562 aligned with a longitudinal channel 1511. The cartridge support 1530 also includes a central cylindrical support cavity 1535 configured to receive at least a portion of the firing member assembly. For example, the central cylindrical support cavity 1535 is configured to receive, for example, a guide portion of a linear actuator, a firing member component, and / or a guide portion of a slider.

[0333] See also Figure 41 The cartridge support 1530 includes a longitudinal slot 1536 configured to receive a lug 1513 of the cartridge 1510. For example, the width 1541 and height 1542 can be adjusted to accommodate different sizes of cartridges, staples, and / or staple actuators. The width 1541 and height 1542 of the cartridge support 1530 can also be adjusted for different tissue gap distances between the cartridge 1510 and the anvil. In at least one instance, the width 1541 and height 1542 can be adjusted to tune the clamping load distribution for different scenarios. For example, suture instruments with lower clamping forces can be better served by a cartridge support with a width thinner than that of the cartridge support 1530.

[0334] Figure 42 A magazine support 1600 configured to be positioned within a magazine (such as those disclosed herein) is shown. The magazine support 1600 includes a cylindrical central portion 1606 defining a central longitudinal guide cavity 1605, an upper cam channel 1603, and a lower cam channel 1601 (each configured to receive a cam-acting flange). The central longitudinal guide cavity 1605 may be configured to receive a guide portion of one or more components of the firing assembly (such as a slider, upper firing member, or lower firing member). The central longitudinal guide cavity 1605 may also be configured to receive a firing shaft therein. Cam channels 1601, 1603 include radial cross-sections. This arrangement reduces the likelihood of failure of the respective flanges received therein due to bending loads.

[0335] Figure 43A stitched assembly 1700 is shown, including a bin support 1710 and a slider 1720. The bin support 1710 includes a longitudinal slot 1711 configured to receive at least a portion of the slider 1720 passing through it during the firing stroke. The slider 1720 includes a bottom portion 1721 and a first arm 1722 configured to be threadedly connected, for example, to a firing drive screw, the first arm extending upward from the bottom portion 1721 around a first side of the bin support 1710. The slider 1720 also includes a second arm 1723 extending upward from the bottom 1721 around a second side of the bin support 1710. Arms 1722 and 1723 each include guide teeth 1724 and 1725, respectively received within corresponding slots 1712 and 1713 of the bin support 1710. The engagement features used to secure the slider 1720 to the housing support 1710 are asymmetrical with respect to the vertical centerline plane. More specifically, arms 1722, 1723 include different geometries, such as different heights, and guide teeth 1724, 1724 also include different geometries, such as different lengths and / or shapes. Slots 1712, 1713 include profiles similar to the teeth they are configured to receive. This configuration provides a means to ensure that the slider 1720 is installed in the correct orientation. This configuration also allows for fine adjustment of the load applied to the slider 1720 via arms 1722, 1723 of different sizes.

[0336] Figure 44 A slide 1730 configured for use with any suitable staple cartridge and / or cartridge support discussed herein is shown. Unlike slide 1720, slide 1730 includes an arm 1732 having the same height and profile. Arm 1732 extends from a bottom portion 1731 and includes teeth 1733 extending outward relative to slide 1731. Due to the outwardly extending teeth 1733, such a slide can be configured to be guided by a cartridge support and / or staple cartridge within an internal guide slot defined in the cartridge support and / or staple cartridge.

[0337] Figure 45 A bin support 1740 is shown, which includes a bin support configured to receive, for example, a slider 1730 therein. Figure 45 The central cavity 1741 of the chamber. For example, the central cavity 1741 includes a laterally opposed slot 1742, which includes a vertically mounted portion 1743 configured to receive the tooth 1733. The firing component assembly may be configured to push the slider 1730 through the chamber support 1740 during the firing stroke.

[0338] Figure 46A stitching assembly 1800 is shown, comprising a jaw 1810, an anvil 1820, a firing member 1840, and a slider 1830 configured to be pushed by the firing member 1840 through the jaw 1810. The slider 1830 is pinned to the firing member 1840 by a pin 1812. For example, when the firing member 1840 is advanced by a firing shaft, the slider 1830 is pushed by the pin 1812. The firing member 1840 includes a bottom flange 1842 configured to be received within a slot 1811 of the jaw 1810 and an upper flange 1841 configured to be received within a slot 1821 defined in the anvil 1820.

[0339] Figure 47 A surgical suture assembly 1900 is shown, including a cartridge passage 1910 and an anvil 1920. The surgical suture assembly 1900 also includes a support beam 1940 and a staple cartridge 1970. The surgical suture assembly 1900 further includes a firing member 1950, which includes an upper flange 1952 configured to engage the anvil 1920 and a lower flange 1951 configured to engage the support beam 1940. The surgical suture assembly also includes a slider 1930 pinned to the staple cartridge 1970 and the support beam 1940 via a pin 1960.

[0340] In various instances, the firing element assembly, configured to be driven by a firing drive screw positioned within the end effector, can stick together during the firing stroke. Sticking can occur at the threaded engagement between the firing element assembly and the firing drive screw. In some instances, such sticking can be attributed to the location where the driving force is transmitted from the drive screw to the firing element assembly. In various instances, the location where the driving force is transmitted is immediately adjacent to the threads of the firing drive screw and the receiving threads of the firing element assembly. Because the firing drive screw is typically positioned within the jaws of the cartridge passage, the location where the force is transmitted is positioned at a distance from the center of mass and / or drive center of the firing element assembly. The application of this force can result in a torque load applied to the firing element assembly, which can cause sticking at the threaded engagement between the firing drive screw and the firing element assembly.

[0341] This document discloses various firing member assemblies that can move the force transmission location closer to the center of mass and / or drive center of the firing member assembly to reduce adhesion. More specifically, these configurations reduce the likelihood of thread adhesion between the firing member assembly and the firing drive screw. Such configurations also provide more efficient force transmission from the firing drive screw to the firing member assembly, to the slider and / or cutting member. Applying a more direct force to the slider and / or cutting member through the firing member assembly reduces the excessive drive force required by the firing drive screw. This direct force applied near the center of the firing member assembly also reduces the drive force required to maintain a predefined tissue gap using the upper and lower cam-acting flanges of the firing member assembly. This can be attributed to concentrating the force applied to the firing member assembly at or near the vertical center of the cam-acting flange.

[0342] Figure 48 and Figure 49 A firing member assembly 2000 configured for use within a surgical suturing assembly (such as those disclosed herein) is shown. The firing member assembly 2000 is configured to be actuated by a firing drive screw to cut and suture tissue. Specifically, the firing member assembly 2000 is configured to actuate a slider to deploy staples from a staple cartridge. In at least one embodiment, the slider includes a cutting member configured to cut tissue when the firing member assembly 2000 is actuated through an end effector. In another embodiment, the cutting member is part of the firing member assembly. The firing member assembly 2000 is further configured to maintain a predefined tissue gap by providing cam-actuated flanges that engage the upper and lower jaws of the end effector.

[0343] The firing member assembly 2000 includes a body portion or distal head 2010 and a drive nut 2030 configured to engage within a drive cavity or receptacle 2023 of the body portion 2010. The body portion 2010 includes an upper portion 2011 that includes a jaw engagement flange 2012. The upper portion 2011 also includes a distal nose 2013 for clamping the jaws in an unclamped position. For example, the body portion 2010 includes a drive surface 2014 configured to actuate a slider and / or cutting member. The body portion 2010 also includes a lower portion 2015 that includes a proximal portion 2016 and a distal portion 2019 defining the drive cavity 2023. The proximal portion 2016 includes a laterally extending proximal lower flange 2018 and a drive screw conduit 2017. The distal portion 2019 includes a distal lower flange 2021 and a drive screw conduit 2020. Drive screw conduits 2017 and 2020 are aligned with each other and configured to receive a firing drive screw passing through them; however, drive screw conduits 2017 and 2020 are not threadedly connected to the drive screw. Instead, drive screw conduits 2017 and 2020 may include support channels, which are configured, for example, to support a firing drive screw threadedly connected to the firing member assembly 2000 (e.g., Figure 4 and Figure 5 (The firing screw 261 in the middle).

[0344] The drive nut 2030 is configured to be threadedly connected to the firing drive screw and to apply actuating force to the body portion 2010. The drive nut 2030 is configured to engage within the drive cavity 2023. The drive nut 2030 includes: a lower threaded portion 2035, which includes a cam-acting flange 2031 configured to engage the jaws of an end effector; a threaded channel 2037 configured to be threadedly connected to the firing drive screw; and a proximal protrusion 2036 configured to engage within the drive cavity 2023. The drive nut 2030 also includes an upper drive portion 2040 extending upward from the threaded portion 2035. The drive portion 2040 includes a proximal drive surface 2041 and a distal drive surface 2043. The proximal drive surface 2041 is configured to push on the proximal drive surface 2025 of the drive cavity 2023 when the firing member assembly 2000 moves proximally, and the distal drive surface 2043 is configured to push on the distal drive surface 2024 of the drive cavity 2023 when the firing member assembly 2000 moves distally.

[0345] like Figure 49As can be seen, the drive nut 2030 is configured to apply a driving force DF to the main body portion 2010 eccentrically relative to the longitudinal screw axis SA. The longitudinal screw axis SA is defined by the longitudinal centerline of the drive screw configured to actuate the firing member assembly 2000. The longitudinal screw axis SA may also be synonymous with the longitudinal centerline defined by the conduits 2017 and 2020.

[0346] In at least one instance, the drive nut 2030 includes a cross-sectional profile substantially similar to that of the body portion 2010. The drive portion 2040 is configured to apply an axial driving force to the body portion 2010 remotely from and / or off-axis relative to the firing drive screw and thread 2037.

[0347] Figure 50 and Figure 51 A firing member assembly 2100 is shown, comprising a body portion 2010 of a firing member assembly 2000 and a drive nut 2130. The firing member assembly 2100 is similar to the firing member assembly 2000 except for the drive nut 2100. The drive nut 2100 is configured to engage within a drive cavity 2023 of the body portion 2010. Unlike the drive nut 2030, the drive nut 2130 does not include a proximal protrusion. The drive nut 2130 includes: a lower threaded portion 2135 including a cam-acting flange 2131 configured to engage the jaws of an end effector; and a threaded channel 2137 configured to be threadedly connected to a firing drive screw. The drive nut 2130 also includes an upper drive portion 2140 extending upward from the threaded portion 2135. The drive portion 2140 includes a proximal drive surface 2141 and a distal drive surface 2143. The proximal drive surface 2141 is configured to actuate on the proximal drive surface 2025 of the drive cavity 2023 when the firing member assembly moves proximally, and the distal drive surface 2043 is configured to actuate on the distal drive surface 2024 of the drive cavity 2023 when the firing member assembly moves distally. The drive portion 2140 also includes an upper surface 2145. The upper surface 2145 does not abut against the body portion 2010 within the drive cavity 2023. Embodiments in which the upper surface 2145 abuts against the body portion 2010 within the drive cavity 2023 are contemplated. In at least one instance, the flange 2131 is configured to prevent the drive nut 2130 from rotating with the firing drive screw during actuation.

[0348] Figure 52A firing member assembly 2200 is shown, comprising a main body portion 2010 of a firing member assembly 2000 and a drive nut 2130. The firing member assembly 2100 is similar to the firing member assembly 2100 except for weld portions 2251, 2253, and 2255. Unlike the firing member assembly 2100, the weld portions 2251, 2253, and 2255 provide a forced attachment mechanism within a drive cavity 2023 to attach the drive nut 2130 to the main body portion 2010. In other words, the drive nut 2130 is welded to the main body portion 2010. Welding can be performed after the drive nut 2130 is positioned within the drive cavity 2023 and threadedly connected to the firing drive screw. The threaded portion 2135 of the drive nut 2130 is welded to the proximal portion 2016 and the distal portion 2019 of the main body portion 2010. The upper surface 2045 of the drive section 2140 is also welded to the main body section 2010. These welds provide strength to the firing component assembly 2200.

[0349] Figures 53 to 56 A stitching assembly 2300 is shown, including a channel jaw 2310, a firing drive screw or rotary drive member 2320 including threads 2321, and a firing member assembly 2330. The firing member assembly 2330 is similar to the firing member assembly discussed above; however, the firing member assembly 2330 includes a different drive nut and attachment means for attaching the drive nut to the body portion. Figure 53 As can be seen, the firing component assembly 2330 is threadedly connected to the thread 2321 of the firing drive screw 2320. The firing drive screw 2320 is configured to be supported within the channel jaws 2310. The firing component assembly 2330 is configured to be actuated proximally and distally relative to the channel jaws 2310 during the firing stroke.

[0350] The firing component assembly 2330 includes a body portion 2331 and a drive nut 2360 configured to engage within a drive cavity or receptacle 2343 of the body portion 2331. The body portion 2331 includes an upper portion 2332 including an anvil engagement flange 2333. The upper portion 2332 also includes a distal nose 2334 for clamping the anvil jaws in an unclamped position. For example, the body portion 2331 includes a drive surface 2335 configured to actuate a slider and / or cutting component. The body portion 2331 also includes a lower portion 2336 including a proximal portion 2337 and a distal portion 2339 defining the drive cavity 2343. The proximal portion 2337 includes a laterally extending proximal lower flange 2338 and a drive screw conduit. The distal portion 2339 includes a distal lower flange 2341 and a drive screw conduit 2340. Flanges 2338 and 2341 are configured to engage the channel jaws 2310 to reliably maintain a consistent tissue clearance between the anvil jaws and the channel jaws 2310. The drive screw conduit and drive screw conduit 2340 of the proximal portion 2337 are aligned with each other and configured to receive the firing drive screw 2320 passing through them without threading.

[0351] The drive nut 2360 includes a threaded portion 2365 configured to be threadedly connected to the firing drive screw 2320 via threads 2366 and a drive portion 2070. The drive nut 2360 also includes a lower cam-acting flange 2361, which is also configured to cam-engage the channel jaws 2310 during the firing stroke. The drive portion 2370 includes laterally opposing tabs 2371 extending upward from the threaded portion 2365. The drive tabs 2371 are configured to support or cross a corresponding drive tab 2350 extending downward from the body portion 2331 and into the drive cavity 2343. The drive portion 2370 also includes an internal cross member or bracket 2372 that connects the tabs 2371 to each other and secures or attaches the drive portion 2370 to the drive tabs 2350 and thus secures or attaches it to the body portion 2331. The cross member 2372 is configured to be received within a drive slot 2351 defined in the drive tab 2350. When the drive nut 2360 is actuated, force can be applied from the cross member 2372 to the drive tab 2350 within the slot 2351 and to the body portion 2331. This configuration can provide a driving force to the body portion 2331 eccentrically relative to the drive screw 2320 and closer to the center of the firing member assembly 2330. In other words, the drive nut 2360 can apply a driving force to the body portion 2331 eccentrically relative to the longitudinal axis of the drive screw 2320. For example, this can... Figure 53 As seen in the image, the drive nut 2360 can apply a driving force DF to the main body portion 2310 eccentrically relative to the longitudinal screw axis SA.

[0352] The drive tab 2350 also includes a pair of drive teeth 2353 extending downward therefrom within an internal channel 2367 defined in the drive nut 2360. The drive teeth 2353 are configured to directly engage with the threads 2321 of the drive screw 2320. The teeth 2353 enhance the threaded engagement of the firing drive screw 2320 and the firing member assembly 2330 as a whole.

[0353] In at least one instance, the drive nut 2360 is molded as an insert above the drive screw 2320. This allows for complex shapes of the drive nut and allows for finely adjustable engagement features between the drive nut 2360 and the body portion 2331. Such engagement features include, for example, a cross member 2372. Once molded above the drive screw 2320 and through the slot 2351, the drive nut 2360 is permanently secured to the body portion 2331, although the drive nut 2360 can be removed from the body portion 2331 by breaking the drive nut 2360.

[0354] In at least one embodiment, the drive nut 2360 engages with the drive tab 2350. For example, the drive nut 2360 may include a degree of flexibility and manufactured cracks or breaks in the material corresponding to the internal channel 2367, thereby allowing the drive nut 2360 to unfold around and engage with the drive tab 2350. In at least one embodiment, the drive nut 2360 is separated from one side of the drive tab 2350 and the cross member 2372, such that the drive tab 2359 can be pried open to position the cross member 2372 into the slot 2351.

[0355] In at least one instance, the cross member 2372 is configured to shear off the drive nut 2360 if the firing force between the drive screw 2320 and the drive nut 2360 exceeds a predetermined threshold. This configuration provides a safety feature so that the firing member assembly is not over-driven through the firing stroke when subjected to a load higher than normal.

[0356] Figures 57 to 61 A firing component assembly 2400 is shown. The firing component assembly 2400 is similar to the firing component assembly discussed above; however, the firing component assembly 2400 includes a different drive nut and attachment means for attaching the drive nut to the body portion. The firing component assembly 2400 also includes a registration feature for use with a molding tool. The firing component assembly 2400 is configured to be threadedly connected to a firing drive screw and is configured to be actuated proximally and distally by the firing drive screw during the firing stroke.

[0357] The firing member assembly 2400 includes a body portion or distal head 2410 and a drive nut 2450 configured to engage within a drive cavity or receptacle 2430 of the body portion 2410. The body portion 2410 includes an upper portion 2411 that includes a jaw engagement flange 2412. The upper portion 2411 also includes a distal nose 2413 for clamping the anvil jaws in an unclamped position. For example, the body portion 2410 also includes a drive surface 2414 configured to actuate a slider and / or cutting member. The body portion 2410 also includes a lower portion 2415 that includes a proximal portion 2416 and a distal portion 2420 defining the drive cavity 2430. The proximal portion 2416 includes a laterally extending proximal lower flange 2417 and a drive screw conduit 2418. The distal portion 2420 includes a distal lower flange 2421 and a drive screw conduit 2422. Flanges 2417 and 2421 are configured to engage the jaws of the end effector to reliably maintain a consistent clearance between the jaws and the other jaw of the end effector. Drive screw conduits 2418 and 2422 are aligned with each other and configured to receive a firing drive screw passing through them without threading. As discussed in more detail below, the proximal portion 2416 and the distal portion 2420 each include a registration hole 2423 configured for use in overmolding and / or insert molding processes.

[0358] The drive nut 2450 includes a threaded portion or driven portion 2451 configured to be threadedly connected to the firing drive screw via threads 2453 and includes a drive portion 2460. The drive nut 2450 also includes a lower cam-acting flange 2452, which is also configured to engage the end actuator jaws in a cam manner during the firing stroke. The drive nut 2450 has a substantially trapezoidal shape. Discussed in more detail below, the firing member assembly 2400 includes a proximal spacing gap or longitudinal space 2431 defined between the proximal portion 2416 and the proximal drive surface 2454 of the threaded portion 2451, and a distal spacing gap or longitudinal space 2455 defined between the distal portion 2420 and the distal drive surface 2455 of the threaded portion 2451.

[0359] The drive portion 2460 includes laterally opposing tabs 2461 extending upward from the threaded portion 2451. It should be understood that, apart from the thread 2453, the body portion 2410 and the drive nut 2450 are symmetrical with respect to the vertical plane defined by the body portion 2410. The drive tabs 2461 are configured to support or span a corresponding drive tab 2440 extending downward from the body portion 2410 and into the upper portion 2433 of the drive cavity 2430. The drive portion 2060 also includes a plurality of internal intersecting members or ribs 2463 extending among the tabs 2461. The ribs 2463 secure or attach the drive portion 2460 to the drive tabs 2440 and thus to the body portion 2410. The ribs 2463 are configured to be received within a plurality of corresponding holes 2441 defined in the drive tabs 2440. When the drive nut 2450 is actuated, force can be applied from the rib 2463 to the drive tab 2440 within the slot 2441 and onto the body portion 2410. This configuration can provide driving force to the body portion 2331 eccentrically and closer to the center of the firing member assembly 2400 relative to the drive screw positioned within the threaded channel 2453. Figure 57 and Figure 60 As can be seen, the drive nut 2450 can apply a driving force DF to the main body 2410 eccentrically relative to the longitudinal screw axis SA.

[0360] The tab 2461 of the drive nut 2450 is further configured to apply force to the body portion 2410 within the upper portion 2433 of the drive cavity 2430, to the proximal drive surface 2443 and the distal drive surface 2445. These additional drive surfaces also allow the driving force applied to the body portion 2410 to be concentrated closer to the center of the firing member assembly 2400.

[0361] As discussed above, the firing component assembly 2400 includes gaps 2431 and 2432 positioned between the threaded portion 2451 of the drive nut 2450 and the proximal portion 2416 and distal portion 2420 of the body portion 2410. The gaps are configured to further concentrate the driving force applied within the firing component assembly 2400 from the drive nut 2450 to the body portion 2410. The gaps 2431 and 2432 prevent the threaded portion 2451 from contacting the proximal portion 2416 and distal portion 2420 of the body portion 2410, thereby preventing the application of driving force adjacent to the drive screw configured to drive the firing component assembly 2400.

[0362] The spacing gaps 2431 and 2432 can also be configured to control the overall deflection of the drive nut 2450. In various instances, the firing drive screw can deflect relative to the end effector in which it is located. This is particularly attributable to the clamping force applied to the jaws of the end effector during the firing stroke. Notably, when the drive screw deflects, the drive nut 2450 is pushed to deflect or rotate relative to the body portion 2410 along with the drive screw due to the threaded engagement between the drive nut 2450 and the firing drive screw. The trapezoidal shape and spacing gaps 2431 and 2432 provide a degree of flexibility or tolerance for the drive nut 2450 to deflect and rotate together with the firing drive screw. Allowing this tolerance within the firing component assembly 2400 can help prevent adhesion of the threaded engagement between the drive nut 2450 and the firing screw. For example, a rigid firing assembly and drive nut combination can provide little or no flexibility, further increasing the possibility of, for example, thread adhesion. In some cases, other components of the firing member assembly (such as the cam-actuated flange and / or drive cross member discussed above) may elastically deform due to bending and / or shear forces within the end effector assembly. In at least one instance, the drive cavity 2430 comprises a trapezoidal shape, in addition to or instead of the drive nut 2450.

[0363] In at least one instance, the drive nut 2450 is insert-molded above the drive screw. This allows for complex shapes of the drive nut and allows for finely adjustable engagement features between the drive nut 2450 and the body portion 2410. Such engagement features include, for example, ribs 2463. In at least one instance, the drive nut 2450 is overmolded onto the body portion 2410.

[0364] As discussed above, the proximal portion 2416 and the distal portion 2420 each include registration holes 2419 and 2423 configured for use in overmolding and / or insert molding processes. The registration holes 2419 and 2423 are configured to hold the body portion 2410 within the molding tool and align it at the equator or center of the conduits 2418 and 2020. This positioning helps align the mold for the drive nut 2450 with the conduits 2418 and 2020 for manufacturing, such that the drive nut 2450, and specifically the threaded portion 2451, is aligned with the conduits 2418 and 2020. This alignment ensures that the firing drive screw is aligned within the conduits 2018 and 2020 and the threaded portion 2451 during assembly. In at least one instance, both the firing drive screw and the body portion 2410 are presented prior to molding the drive nut 2450. In such instances, the drive nut 2450 may be molded around a pre-placed body portion 2410 and a firing drive screw. In at least one instance, only the body portion 2410 is presented prior to molding the drive nut 2450.

[0365] Figures 62 to 66 A firing member assembly 2500 is shown. The firing member assembly 2500 is similar to the firing member assembly discussed above; however, the firing member assembly 2500 includes a drive nut assembly comprising an outer drive portion 2550 and an inner drive nut 2560 positioned within the outer drive portion 2550. The firing member assembly 2500 is configured to be threadedly connected to a firing drive screw and is configured to be actuated proximally and distally through the firing stroke via the firing drive screw within the end effector assembly.

[0366] The firing member assembly 2500 includes a body portion 2510 and a drive nut assembly configured to engage within a drive cavity or receptacle 2530 of the body portion 2510. The body portion 2510 includes an upper portion 2511 that includes an anvil engagement flange 2512. The upper portion 2511 also includes a distal nose 2513 for clamping the anvil jaws in an unclamped position. For example, the body portion 2510 also includes a drive surface 2514 configured to actuate a slider and / or cutting member. The body portion 2510 also includes a lower portion 2515 that includes a proximal portion 2516 and a distal portion 2520 defining the drive cavity 2530. The proximal portion 2516 includes a laterally extending proximal lower flange 2517 and a drive screw conduit 2518. The distal portion 2520 includes a distal lower flange 2521 and a drive screw conduit 2522. The flanges 2517 and 2521 are configured to engage the jaws of the end effector to reliably maintain a consistent clearance between the jaws and the other jaw of the end effector. The drive screw conduits 2518 and 2522 are aligned with each other and configured to receive a firing drive screw passing through them without threading.

[0367] As discussed above, the drive nut assembly includes an outer drive portion 2550 and an inner drive nut 2560 positioned within the outer drive portion 2550. In at least one instance, the inner drive nut 2560 comprises a raw material drive nut, for example, made of a metallic material. In at least one instance, the outer drive portion 2550 is made of a polymer, for example, and is overmolded and / or insert-molded within the firing member assembly 2500. In such instances, the drive nut assembly comprises a hybrid multimaterial drive nut assembly and may have metamaterial properties in some instances. In at least one instance, the outer drive portion 2560 is inserted and molded into the inner drive nut 2550, and then the drive nut assembly is positioned within the drive cavity 2530 for assembly to the firing drive screw and body portion 2510. In any case, the drive nut assembly comprises a multi-piece arrangement.

[0368] The external drive portion 2550 includes a lower portion 2551 that includes a flange 2552. The lower portion 2551 is configured to surround and secure the internal drive nut 2560 within the drive nut assembly. The external drive portion 2550 also includes a drive tab portion 2553 positioned within an upper portion of the drive cavity 2530. The drive cavity 2530 also includes a pitch slot 2531 positioned between the drive tab 2553 and the body portion 2510. This pitch slot 2531 allows the drive nut assembly to float relative to the body portion 2510 together with the firing drive screw. In such an example, the body portion 2510 may be constrained by various elements of the end effector assembly, such as anvil jaws and channel jaws.

[0369] As discussed above, the external drive portion 2550 is configured to secure the internal drive nut 2560 therein and to be collinear with the screw axis SA. The screw axis SA is defined as the center of the conduits 2518, 2522 and the main cylindrical portion 2561 of the internal drive nut 2560. A thread 2562 is defined in the main cylindrical portion 2561 of the internal drive nut 2560. The thread 2562 is configured to engage or connect with the thread of the firing drive screw. The internal drive nut 2560 also includes multiple rows 2563 of gripping features 2564 configured to prevent the internal drive nut 2560 from rotating relative to the external drive portion 2550 during rotation of the drive screw. The external drive portion 2550 can enclose the internal drive nut 2560 during the molding process. The internal drive nut 2560 also includes an open proximal end 2565. Opening the proximal end 2565 facilitates the assembly of the firing component assembly 2500 with the firing drive screw. For example, the firing drive screw can be inserted through the conduit 2518 and guided by the expanded proximal end 2565 into the thread 2562 of the internal drive nut 2560.

[0370] In at least one instance, the gripping feature 2564 may facilitate the manufacturing process of the drive nut assembly. For example, the gripping feature 2564 may fit into a corresponding slot in a mold configured to hold the drive nut 2560 during the molding of the outer drive portion 2550.

[0371] Figure 67 A firing member assembly 2600 is shown. The firing member assembly 2600 is similar to the firing member assembly discussed above; however, the firing member assembly 2600 includes a proximal tail extension configured to further support the firing member assembly 2600 during the firing stroke. The firing member assembly 2600 is configured to be threadedly connected to a firing drive screw and is configured to be actuated proximally and distally through the firing stroke by the firing drive screw within the end effector assembly.

[0372] The firing member assembly 2600 includes a body portion 2610 and a drive nut 2630. The body portion 2610 includes an upper portion 2611 and a lower portion 2615. The upper portion 2611 includes an anvil-cam action flange 2612. The upper portion 2611 also includes a distal nose 2613 configured to close the jaws of the end effector from an open position to a closed position. For example, the body portion 2610 also includes a drive surface 2614 configured to actuate a slider and / or a cutting member. The lower portion 2615 includes a proximal portion 2616, which includes a proximal lower flange 2617 and a proximal tail extension 2618. The lower portion 2615 also includes a distal portion 2620, which includes a distal lower flange 2621. Flanges 2617, 2621, and 2612 may be configured to maintain a predefined tissue gap between the cartridge and the anvil throughout the entire firing stroke of the firing component assembly 2600.

[0373] The proximal tail extension 2618 is an extension of the screw channel (such as those discussed above) of the proximal portion 2616. This proximal tail extension can also support the firing member assembly 2500 during the firing stroke. This proximal tail extension also resists deflection or rotation of the main body portion 2610, which could cause the threaded engagement between the drive nut 2630 and the firing drive screw to stick.

[0374] Figures 68 to 72 A firing member assembly 2700 threadedly connected to a firing drive screw 2701 is shown. The firing assembly 2700 is similar to the firing member assembly discussed above; however, the firing member assembly 2700 includes a body portion 2710 and a drive nut 2750 engageable with the body portion 2710. The firing member assembly 2700 is configured to be actuated proximally and distally through a firing stroke via the firing drive screw 2701 within the end effector assembly.

[0375] The main body portion 2710 includes an upper portion 2711 and a lower portion 2715 defining a drive cavity 2730. A drive nut 2750 is configured to be positioned within the drive cavity 2730. The upper portion 2711 includes a jaw-cam action flange 2712. The upper portion 2711 also includes a distal nose 2713 configured to close the jaws of the end effector from an open position to a closed position. For example, the main body portion 2710 also includes a drive surface 2714 configured to actuate a slider. The lower portion 2715 includes a proximal portion 2716 including a proximal lower flange 2717. The lower portion 2715 also includes a distal portion 27720 including a distal lower flange 2721 and a drive screw conduit 2722 defined therein, configured to receive an actuating drive screw 2701 without threads. Flanges 2617, 2721, and 2712 can be configured to maintain a predefined tissue gap between the cartridge and the anvil throughout the entire firing stroke of the firing component assembly 2700.

[0376] In at least one instance, the profile or periphery of the drive screw conduit 2722 and / or the proximal portion of the drive screw conduit may be, for example, elliptical and / or rectangular or non-circular. Such a configuration reduces the likelihood of friction or interference of the deflected drive screw within the screw conduit, which can lead to stacking losses in the event of such drive screw deflection. Stacking losses can refer to various problematic engagements between the drive screw and other components within the system that would cause various interferences in scenarios where the drive screw is substantially deflected. For example, if the drive screw is substantially deflected, then, for example, as discussed above, the deflected drive screw may rub against the drive screw conduit, the deflected drive screw may cause the threads of the drive nut to stick, and / or the deflected drive screw may stick near its connection to the firing output shaft. For example, providing features that minimize such stacking losses can prevent premature failure of components and / or reduce the firing force required to drive the firing component assembly.

[0377] In at least one instance, the drive screw conduit 2722 and / or the proximal portion of the drive screw conduit includes rounded or chamfered edges. This configuration further reduces the likelihood of the conduit contacting and sticking to the firing drive screw.

[0378] In at least one instance, the screw conduit of the main body provides lateral and / or vertical support to the drive screw, such that if the drive screw is loaded to a degree sufficient to cause bending, the drive screw conduit prevents the drive screw from bending, at least near the threaded drive nut. This configuration helps prevent adhesion between the threads of the drive screw and the threaded drive nut.

[0379] In at least one embodiment, the slide of the staple cartridge may include a distally extending bracket support feature extending from the distal end of the slide. The bracket support feature may also support the firing drive screw and help prevent bending of the firing drive screw, at least near the bracket support feature. In at least one embodiment, the slide prevents bending of the drive screw in only one direction. In at least one embodiment, in addition to or in lieu of the distal bracket support feature, the slide may also include a proximal bracket support feature.

[0380] The drive nut 2750 includes a jaw engagement flange 2751, a threaded portion 2755 configured to be threadedly engaged with a firing drive screw 2701 via a thread 2756, and a laterally opposing drive tab 2760 extending upward from the threaded portion 2755. The drive nut 2750 includes a substantially trapezoidal shape, as discussed herein with respect to those drive nuts that include a trapezoidal shape.

[0381] The drive tab 2760 is configured to support or cross a corresponding drive tab 2740 extending downward from the body portion 2710. The drive tabs 2760 define a slot 2761 between them and each includes an engaging protrusion 2762 projecting inwardly therefrom. Each engaging protrusion 2762 includes an inclined upper surface 2763 and a latching surface 2764. Figure 71 As can be seen, the drive tab 2760 is configured to engage with the drive tab 2740 of the body portion 2710. Specifically, the drive tab 2740 includes a horizontally extending slot 2741 defined therein, and the engaging lug 2762 is configured to widen the drive tab 2760 sufficiently during the installation of the drive nut 2750 with the body portion 2710 to allow the latch surface 2764 to disengage from the drive protrusion 2740 and be biased inwardly into the slot 2741. In at least one instance, the engaging lug 2762 is not configured to transmit any longitudinal driving force from the firing drive screw 2701 to the body portion 2710. Instead, the drive tab 2760 is configured to engage within the drive cavity 2730 such that the drive tab 2760 directly pushes and pulls the body portion 2710 relative to the firing drive screw, similar to the various firing member assemblies discussed herein. This configuration reduces reliance on the internal cross members of the drive nut 2750 to transfer the firing force from the firing drive screw 2701 to the body portion 2710. This can be advantageous because the drive nut 2750 can be held attached to the body portion 2710 by the drive protrusion 2762 under a higher load than normal. Similar to the various drive tabs discussed herein, the drive tab 2760 of the drive nut 2750 is further configured to apply force to the body portion 2710 closer to its center. Figure 69As can be seen, the drive nut 2750 is configured to apply the driving force DF to the main body 2710 off-axis relative to the longitudinal screw axis SA.

[0382] In at least one instance, the drive nut 2750 is injection molded before being engaged with the body portion 2710. In at least one instance, the drive nut 2750 is inserted into the body portion 2710 and the firing drive screw 2701. In such instances, for example, if the drive nut 2750 wears out over time, the drive nut 2750 can be broken off and replaced.

[0383] Figure 73 A firing component assembly 2800 is shown, which includes a body portion 2810 and a drive nut 2850 configured to be threadedly connected to a firing drive screw. The firing component assembly 2800 is similar to the various firing component assemblies discussed above; however, the firing component assembly 2800 also includes a drive cavity 2830 configured to allow the body portion 2810 to flex during the firing drive stroke, as discussed in more detail below.

[0384] The body portion 2810 includes an upper portion 2811, which includes a flange 2812 and a distal nose 2813 extending laterally from the upper portion. The distal nose is configured to close the jaws from the open position during the closing stroke. For example, the body portion 2810 also includes a drive surface 2814 configured to actuate a slider and / or cutting member through the nail firing stroke. Other embodiments are contemplated in which various other surfaces on the front of the body portion 2810 are configured to actuate various components, such as, for example, sliders and / or cutting members. The body portion 2810 also includes a lower portion 2815, which includes a proximal portion 2816 having a proximal lower flange 2817 and a distal portion 2820 having a distal lower flange 2821. Commonly, flanges 2812, 2817, and 2821 are configured to reliably space the opposing jaws during the firing stroke and maintain a consistent tissue gap between the opposing jaws.

[0385] A drive nut 2850 is positioned within a drive cavity 2830 and configured to be threadedly connected to a firing drive screw. The drive nut 2850 is configured to apply an axial driving force to the body portion 2810 when the firing drive screw is actuated, causing the firing member assembly 2810 to move proximally and distally within the end effector. The drive cavity 2830 includes a lower portion 2833, in which the drive nut 2850 is primarily positioned and configured to float within it, and includes an upper triangular portion 2831. The upper triangular portion 2831 is configured to allow the body portion 2810 to flex during the firing stroke. For example, under a clamping load, the triangular portion 2831 is configured to allow the proximal portion 2816 to flex longitudinally away from the distal portion 2820. Such flexure can provide tolerance within the firing member assembly 2800 to, for example, prevent adhesion. In addition to the deflection of the main body 2810, the drive nut 2850 is configured to float within the drive cavity 2850. Together, this arrangement reduces adhesive adhesion between threaded connections and / or between the flange and the jaws.

[0386] The various drive nuts disclosed herein include laterally extending flanges aligned with the proximal and distal lower flanges of the lower portion of the body portion. Such flanges prevent the drive nut from rotating with the firing drive screw. These flanges may include rounded bottoms to reduce adhesive engagement with the corresponding jaws. For example, the proximal and distal lower flanges may be configured to handle most clamping loads, while the drive nut flange is positioned to support the drive nut but does not need to handle high clamping loads. Rounding the flange reduces overall contact with the corresponding jaws, thereby reducing the likelihood of the flange sticking to the corresponding jaws. In such examples, the flange or lateral fins of the drive nut are configured to be loose within the corresponding jaws (such as channel jaws). This loose engagement between the flange and the corresponding jaws provides an anti-rotation feature without requiring the flange to handle high clamping loads. In at least one example, the lateral fins are generally thinner and include a top edge positioned below the top edge of the corresponding proximal and distal lower flanges of the body portion.

[0387] In at least one instance, the body portion is machined from a metal material, and the drive nut is injection molded, insert molded, or overmolded from a polymer and / or plastic material. Such configurations reduce manufacturing costs and machining complexity because the various molding processes allow for more complex geometries and shapes. The various molding processes also allow for different sequences of component assembly and manufacturing. As discussed above, insert molding allows multi-material firing member assemblies to include various materials and complex integrated geometries between different materials. Furthermore, for example, insert molding allows, by means of other methods, to position the firing drive screw within the firing member assembly prior to molding the drive nut.

[0388] Figures 74 to 78 An end effector assembly 3000 configured to cut and suture patient tissue is shown. The end effector assembly 3000 includes a first jaw 3010 and a second jaw 3020 movable relative to the first jaw 3010. An embodiment in which the first jaw 3010 is movable relative to the second jaw 3020 is contemplated. The first jaw 3010 includes a cartridge channel 3100 and a replaceable staple cartridge 3300 configured to be removably positioned within the cartridge channel 3100. The second jaw 3020 includes an anvil 3200 configured to deform staples removably stored in the staple cartridge 3300 during the staple firing stroke. The second jaw 3020 is movable or pivotable relative to the first jaw 3010 to clamp tissue between the anvil 3200 and the staple cartridge 3300. Once the tissue is clamped between the anvil 3200 and the staple cartridge 3300, the firing assembly 3400 of the end effector assembly 3000 is used to fire the end effector assembly 3000 to eject the staple and cut the tissue.

[0389] The firing assembly 3400, discussed in more detail below, includes a firing drive screw 3401 supported within the cartridge channel 3100. The firing assembly 3400 also includes a firing member assembly 3409 threadedly connected to the firing drive screw 3401, the firing member assembly being configured to actuate a slider during the firing stroke to deploy staples from the staple cartridge 3300, actuate a cutting member during the firing stroke to cut tissue, and maintain a consistent tissue clearance between the staple cartridge 3300 and the anvil 3200 during the firing stroke.

[0390] The cartridge passage 3100 includes a longitudinal passage cavity 3111 within which the staple cartridge 3300 is removably positioned. The cartridge passage 3100 also includes a sidewall 3113 configured to support the staple cartridge 3300. In at least one embodiment, the staple cartridge includes a flange configured to rest on the top of the sidewall 3113. The cartridge passage 3100 also includes a base portion 3120. The base portion 3120 includes an inner bottom surface 3121 and cam-acting lugs 3123. A longitudinal slot 3125 is defined between the cam-acting lugs 3123 and configured to receive at least a portion of a firing assembly 3400 passing therethrough.

[0391] The anvil 3200 includes a body portion 3210 and an anvil cap 3220, the anvil cap being configured to attach to the body portion 3210 within a longitudinal channel 3212. The body portion 3210 includes an anvil surface 3211. The anvil surface 3211 includes a plurality of nail-forming recesses aligned with nail cavities 3312 defined in the platform 3311 of the nail cartridge body 3310. The body portion 3210 also includes a cam-acting lug 3213 extending laterally inward into the longitudinal channel 3212 and defining a longitudinal slot 3225 therebetween. Discussed in more detail below, the cam-acting lugs 3123, 3213 are configured to cooperatively engage with corresponding flanges of the firing member assembly 3409 to definitively space the jaws 3010, 3020 relative to each other. In at least one instance, during the firing stroke, a predefined tissue gap is defined between the chamber platform 3311 and the anvil surface 3211 by the engagement of the flange of the firing member assembly 3409 with the cam action lugs 3213, 3123.

[0392] The staple cartridge 3300 also includes a platform protrusion or recess extension 3314 configured to extend the effective height of each staple cavity 3312. The platform protrusion 3314 may be configured to help grasp and clamp tissue between the jaws 3010, 3020. The staple cartridge 3300 also includes a longitudinal slot 3315 configured to receive at least a portion of the firing member assembly 3409 passing through it. As discussed above, the slider and / or cutting member are configured to be advanced through the jaws 3010, 3020 to cut tissue and to fire the staple using the firing assembly 4400 during the staple firing stroke.

[0393] The firing assembly 3400 includes a firing drive screw 3401 and a firing member assembly 3409 threadedly connected to the firing drive screw 3401. The firing member assembly 3409 includes a body portion 3410, a drive nut 3450 configured to be threadedly connected to the firing drive screw 3401, and a rear support bracket 3430. The body portion 3410 includes an upper portion 3411, which includes an anvil engagement flange 3412 and a distal nose portion 3413. The anvil engagement flange 3412 is configured to move within a longitudinal channel 3212, and more specifically, is configured to apply clamping pressure to the upper surface 3214 of the cam-acting lug 3213. In at least one embodiment, an anvil cap 3220 is configured to provide an upper boundary for the anvil-cam-acting flange 3412. Nevertheless, the anvil cam action flange 3412 is configured to move within the longitudinal channel 3212 during the firing stroke to apply a cam action force thereto, ensuring a consistent tissue gap distance between the chamber platform 3311 and the anvil surface 3211.

[0394] The main body portion 3410 also includes a lower portion 3415, which includes a proximal portion 3416, comprising a channel-cam-acting flange 3417 and a screw conduit 3418 configured to receive the firing drive screw 3401 passing through it in a threadless manner. The lower portion 3415 also includes a distal portion 3420, which includes a channel-cam-acting flange 3421 and a screw conduit 3422 configured to receive the firing drive screw 3401 in a threadless manner. A drive nut 3450 is configured to fit between the proximal portion 3416 and the distal portion 3420. The drive nut 3450 includes a threaded portion 3451 configured to be threadedly connected to the firing drive screw 3401 and includes a channel-cam-acting flange 3452. In at least one instance, the channel-cam-acting flange 3452 includes a thickness less than that of the channel-cam-acting flanges 3417 and 3421. The drive nut 3450 also includes a drive tab 3460 extending upward toward the body portion 3410. The drive nut 3450 is configured to apply axial driving forces proximally and distally toward the body portion 3410 to move the firing member assembly 3409 through the jaws 3010 and 3020. The channel-cam-acting flanges 3417, 3452, and 3421 are configured to apply a cam-acting force to the cam-acting lug 3123. Commonly, the cam-acting flanges 3412 and 3417, 3452, and 3421 are configured to maintain a consistent interstitial distance between the chamber platform 3311 and the anvil surface 3211.

[0395] The firing member assembly can be subjected to loads that result in eccentric moment loads. For example, in some instances, such as when thick and / or tough tissue is clamped between jaws, an anvil lug engaging with the upper cam action flange 3412 can apply an eccentric moment load to the firing member 3400. It is advantageous to provide a means for counteracting such eccentric moment loads. The firing member assembly 3409 includes a rear support bracket 3430 extending proximally at an angle from the upper portion 3411 of the body portion 3410. The rear support bracket 3430 includes a strut member 3431 and an arcuate support portion 3433 extending from the strut member 3431. The arcuate support portion 3433 includes a laterally extending flange 3435 configured to support the rear support bracket 3430 and counteract the moment load of the body portion 3410. The flange 3435 is configured to rest on the inner bottom surface 3121. It is worth noting that the flange 3435 straddles the cam-acting lug 3123, such that the flange 3432 of the rear support bracket 3430 and the channel-cam-acting flange 3421 contact the opposite side of the base portion 3120 of the channel 3100.

[0396] In at least one instance, if the body portion 3410 is loaded and causes rotation in the opposite direction, the flange 3435 can provide flexibility to lift away from the inner bottom surface 3121 and resist torsion that would cause the anvil-cam action flange 3412 to disengage from its substantially parallel alignment with the longitudinal channel 3214. The rear support bracket 3430 can be configured to provide a degree of flexibility to allow some deflection of the body portion 3410 during loading, while preventing a deflection amount that would cause adhesion in the event of threaded engagement between the drive nut 3450 and the firing drive screw 3401. In some instances, the rear support bracket 3430 can function as a spring feature for balancing the load.

[0397] An embodiment in which flange 3435 is positioned below lug 3123 is envisioned. An embodiment in which two sets of flanges are also envisioned is further envisioned. One set of flanges may be positioned above lug 3123, and the other set of flanges may be positioned below lug 3123.

[0398] In various instances, the rear support bracket 3430 acts as a spring member of the firing element assembly 3409 to balance the various loads experienced by the firing element assembly 3409. Furthermore, a clearance is provided between the bow-shaped bracket portion 3433 and the firing drive screw 3401. This configuration prevents, for example, the I-beam from rolling and balances the I-beam or firing element assembly throughout the firing stroke. An embodiment in which the bow-shaped bracket portion 3433 is also threaded and threadedly connected to the firing drive screw 3401 is envisioned.

[0399] In various examples, the geometry of various firing mechanism components can be optimized. (Reference) Figure 78 For example, the length of the central portion of the main body 3410 is referred to as the body length BL, and the lengths of the lower flanges 3417 and 3421 are collectively referred to as the pin length PL. Generally, the pin length PL is approximately twice the length of the body length BL. This also applies to the upper flange 3412. However, in some instances, the upper flange 3412 may include a pin length shorter than twice the body length BL, at least because the rear support bracket 3430 helps prevent the upper flange 3412 from rotating and / or deflecting under load. In various instances, the longer the pin length, the more likely the corresponding flange will adhere within its slot. In such instances, the clearance slot in which the flange is positioned should be smaller to reduce adhesion between the flange and the clearance slot.

[0400] Figure 79 and Figure 80A surgical suture assembly 3700 similar to those discussed above is shown. However, in addition to the various other features discussed herein, the surgical suture assembly 3700 also incorporates a triangular drive cavity incision. The surgical suture assembly 3700 includes a channel jaw 3710, a staple cartridge 3730 configured to be received within the channel jaw 3710, and a firing drive screw 3711 supported within the channel jaw 3710. The surgical suture assembly 3700 also includes an anvil jaw 3720 configured to deform staples ejected from the staple cartridge 3730. The surgical suture assembly also includes a firing member assembly 3740 configured to be actuated by the firing drive screw 3711 through the jaws 3710 and 3720. The firing member assembly 3740 includes a body portion 3741, a rear support bracket 3745, and a drive nut 3743 threadedly connected to the firing drive screw 3711. The main body 3741 includes a triangular drive cavity incision 3745 configured to provide an additional spring feature within the firing member assembly 3740, which is configured to balance various loads experienced by the firing member assembly 3740. The surgical suture assembly 3700 also includes a blade 3750 configured to cut tissue during the firing stroke and a slide 3760 configured to deploy staples from the staple cartridge 3730. The blade 3750 and the slide 3760 can each experience loads and transfer those loads to the firing member assembly 3740.

[0401] The blade 3750 is a component of the slider 3760 and is mounted to the slider 3760 at a pivot. During the distal firing motion, the blade 3750 can take... Figure 79 The illustrated upright configuration includes a blade 3750 protruding outside the magazine and its cutting edge configured to cut tissue. During proximal firing motion, the blade 3750 can adopt a shielded configuration, wherein at least a portion of the cutting edge of the blade 3750 is shielded by the fastener magazine. The blade 3750 can pivot between the upright and shielded configurations in response to the firing direction and / or various mechanical locking and / or biasing mechanisms in the magazine.

[0402] Figure 81A jaw assembly 3800 configured to support a firing drive screw 3801 is shown. Under high loads, the firing drive screw may tend to buckle. The jaw assembly 3800 is configured to prevent buckling of the firing drive screw 3801. The jaw assembly includes a channel jaw 3810 comprising a bottom 3811 and a channel wall 3813 extending from the bottom 3811. The bottom 3811 includes a drive cavity 3815 configured to receive the firing drive screw 3801 and one or more flanges, such as cam-acting flanges discussed herein. The bottom 3811 also includes a lower support 3816 and a lateral support 3818 extending from a cam-acting mount 3817. The lower support 3816 and the lateral support 3818 are configured to limit buckling of the firing drive screw 3801 under high loads. In at least one instance, the supports 3816, 3818 are positioned only at, for example, the middle of the firing stroke and near the channel jaws. Such an arrangement may be sufficient given that the firing drive screw 3801 may tend to buckle near the center of its effective length under high loads. In at least one instance, the supports 3816, 3818 may be longitudinal ribs extending along a large portion of the length of the firing drive screw 3801 and the channel jaws 3810. The support 3818 may include a metal arm and act as a rigid obstruction to the firing drive screw 3801.

[0403] In at least one instance, the support 3818 comprises a plastic arm. In such instances, the support 3818 can be pried open by the firing member assembly without obstructing it as the firing member assembly passes by it during the firing stroke. This configuration can be advantageous, at least because once the firing member assembly reaches the position of the support 3818 during the firing stroke, it can self-support the firing drive screw 3801 and prevent it from buckling.

[0404] In various instances, balancing the I-beam or firing assembly can be advantageous to, for example, optimize the loading of the firing assembly between the anvil cam-acting flange and the channel cam-acting flange. Various forces are applied to the firing assembly. These forces are applied by the firing drive screw and / or drive nut, the anvil cam-acting flange, the channel cam-acting flange, the mechanism, and / or the slider configured to deploy the pin. Balancing these forces can be advantageous so that the driving force provided by the drive screw drives the firing assembly at an optimal position. Applying less than the optimal driving force can cause unwanted rolling, rotation, and / or rocking of the firing assembly relative to the firing screw and / or relative to the longitudinal axis defined by the firing screw. For example, torsional loads can cause such rolling, rotation, and / or rocking. Applying a driving force at a location to optimally counteract predictable torsional loads applied to the firing assembly helps prevent rolling, rotation, and / or rocking of the firing assembly.

[0405] In various instances, the channel / anvil cam-acting flange or pin includes a width and length configured to be adjustable relative to its corresponding slot through which the channel / anvil cam-acting flange or pin is received. In at least one instance, the greater the length of the flange along the longitudinal axis, the smaller the clearance required within its corresponding cam-acting slot. In other words, the corresponding cam-acting slot may include a geometry that more tightly receives the flange. Conversely, the smaller the length of the flange along the longitudinal axis, the larger the clearance required within its corresponding cam-acting slot. In other words, the corresponding cam-acting slot may include a geometry that more loosely receives the flange. In at least one instance, the ideal length of one or more flanges may include approximately twice the width of the body portion of the firing member assembly. It is worth noting that the thickness of the body portion is synonymous with the portion of the body portion configured to travel through the longitudinal staple cartridge slot.

[0406] In various instances, the drive nut disclosed herein is configured to float vertically relative to the main body of the firing component assembly, to float vertically and horizontally relative to the main body of the firing component assembly, and / or to float horizontally relative to the main body of the firing component assembly. The floating of the drive nut reduces the likelihood of the drive screw sticking to various other components. As discussed above, in some instances, the drive nut may be rigidly welded to the main body.

[0407] In various instances, the components of the surgical suture assembly disclosed herein can be assembled in a specific order to prevent accidental disassembly. For example, the components may be introduced during assembly after the firing member assembly has been introduced; otherwise, without an assembly holding force provided, for example, by the flange of the firing member assembly, the components would tend to fall out or be accidentally disassembled. For example, components and sub-assemblies other than or different from the firing member assembly may also provide assembly holding forces. For example, as discussed herein, the drive screw may be preloaded and may provide internal assembly holding forces during assembly. The drive screw may be installed into the surgical suture assembly before various other components. In some instances, the assembly holding forces discussed above may actually induce accidental disassembly of one or more components. In such instances, such components will be installed after certain components to ensure that when such components are installed, the entire assembly remains assembled at that point in time, thereby reducing the likelihood of accidental disassembly.

[0408] In at least one instance, the plastic and / or metal injection molded (MIM) drive nut of the firing component assembly can be first assembled to the body portion of the firing component assembly. Once the drive nut is positioned, the drive screw can be threaded into the drive nut through a corresponding conduit in the body portion. Assembly in this manner allows the drive screw to connect the drive nut and the body portion of the firing component assembly, thereby preventing accidental disassembly of the drive nut and the body portion.

[0409] In addition to the above, the end of the drive screw can then be coupled to its corresponding support using its corresponding attachment device. For example, any bearings and / or springs used can be assembled at this time. This will prevent the firing component assembly from disengaging from the proximal or distal end of the drive screw. Furthermore, for example, if the firing component assembly is overdriven, the thrust bearing will already be present, and the firing component assembly will predictably deflect the channel, for example, via the thrust bearing and / or channel support flange, rather than, for example, only abnormally loading the thrust bearing and / or the distal head portion of the drive screw. If the firing component assembly is pushed into the distal head portion of the thrust bearing and / or drive screw, the firing component assembly can apply unexpected loads to the distal head portion of the thrust bearing and / or drive screw, and may cause, for example, premature failure of the thrust bearing and / or the distal head portion. This can be attributed to not being assembled to, for example, its corresponding channel support flange, the end of the drive screw being designed to interact and cooperatively load with the channel support flange. For example, in the absence of a channel flange and a channel, if the distal head portion of the drive screw is prematurely loaded before it is installed into the channel support flange, the distal head portion of the drive screw may be sheared off.

[0410] In at least one instance, during actual operation of the surgical suture assembly on the drive screw, the firing component assembly is advanced beyond its most distal position, such that the flange of the firing component assembly can be inserted into its corresponding slot in, for example, an anvil, channel, and / or staple cartridge. Once the flange is aligned with its corresponding slot, the drive screw can be rotated to move the firing component assembly proximally, thereby moving the flange into its corresponding slot. For example, in such instances, the drive screw may be housed within its support flange. For example, in at least one instance, using such a sequential assembly method prevents the flange from dislodging from its corresponding slot during assembly.

[0411] For example, in at least one instance, various supports positioned within the proximal end of the end effector assembly are configured to support the proximal end of the actuation drive screw and to support a closing drive screw interlocked with the compartment channel. In such instances, after the various supports are positioned in the compartment channel, an anvil can be introduced into the end effector assembly and pinned to the compartment channel using a pivot pin. The pivot pin itself prevents disengagement of the various components of the end effector assembly due to vertical unload. In such instances, the lateral channel wall, together with the lateral tissue stop, and the sidewall of the anvil, configured to span the lateral channel wall when clamping tissue, prevent disengagement of the various components of the end effector assembly due to lateral unload. In various instances, the end effector assembly is configured such that each component and sub-assembly can be assembled and disassembled in a unique sequence. This ensures that the system can be assembled in only one manner, providing support and preventing accidental disassembly during assembly.

[0412] In various instances, one or more components of the surgical suture assembly discussed herein can be 3D printed. More specifically, such components can be manufactured using a graphite-based selective laser sintering process, which can be an additive manufacturing process that allows for complex geometries of the components while eliminating the need for expensive tooling. Specifically, the thrust bearing and / or drive nut of the firing component assembly can be manufactured using this method. In various instances, the drive nut can be 3D printed, for example, from graphite and steel. In at least one instance, about 1% to about 5% of the component comprises graphite and the remainder of the component comprises steel material. In such instances, the exposed graphite, for example, in the drive nut, can provide a degree of lubrication, for example, within a threaded connection.

[0413] In various instances, the firing component assembly is configured to be driven by a firing drive screw positioned within the end effector. The firing component assembly and / or the firing drive screw can experience various loads during the firing stroke. For example, as the firing component assembly is advanced through the firing stroke, it can experience loads imposed on it by the tissue. The firing component assembly can be subjected to various loads imposed on it by the firing drive screw itself. The firing component assembly can also experience loads generated by the engagement of the cam-acting flange of the firing component assembly with the jaws of the cartridge passage and / or the anvil jaws. The firing drive screw can also be subjected to various loads during different stages of use of the end effector assembly in which the screw is positioned. For example, when the jaws close to clamp the tissue and / or when the tissue is further clamped by the flange of the firing component assembly during the nail firing stroke, the firing drive screw can be subjected to bending loads due to the cam action and / or clamping force applied within the end effector assembly. This document discusses various arrangements configured to manage the various loads experienced by the firing component assembly and the firing drive screw. For example, such an arrangement can reduce adhesion between the firing drive screw and various components. This arrangement can also be used in conjunction with a closing drive system. For example, in various instances, the end effector assembly may include a separate closing drive screw configured to open and close the jaws relative to another jaw. In such instances, the closing drive screw may also be subjected to various loads that could cause, for example, bending and / or adhesion to various drive components.

[0414] Figures 82 to 84 A surgical suture assembly 5000 is shown, comprising a cartridge channel 5010, a staple cartridge 5050 located within the cartridge channel 5010, and a rotary drive assembly 5030 supported within the cartridge channel 5010. The cartridge channel 5010 includes a distal portion 5011, a bottom 5020, and a sidewall 5012 extending vertically from the bottom 5020. The bottom 5020 includes a distal end 5021, an annular bracket slot 5022 defined in the distal end 5021, and a pair of arcuate flanges 5023 extending upward from the bottom 5020. The arcuate flanges 5023 are configured to buoyantly support the rotary drive assembly 5030. Various features of the distal end 5021 include, for example, a distal mounting member for a drive screw 5031.

[0415] The rotary drive assembly 5030 includes a threaded screw portion 5031 and a distal end 5033 supported by a distal portion 5011 of a chamber passage 5010. The distal end 5033 of the rotary drive assembly 5030 includes, for example, two thrust bearings or bushings 5034 configured to contact an arcuate flange 5023. The distal end 5033 also includes a distal support head 5035 configured to abut against the arcuate flange 5023 to support the thrust bearings 5034. For example, the distal support head 5035 can be formed on the distal end of the firing drive screw using a track forming process. This forming process can be performed, for example, after one or more bushings and / or bearings have been positioned on the distal end of the firing drive screw.

[0416] A bow-shaped flange 5023 defines a floating cavity 5025 in the distal portion 5011 of the compartment passage 5010 between them. A portion 5032 of the rotary drive assembly 5030 is configured to be supported within the floating cavity 5025, such that, for example, when the compartment passage 5010 deflects, the distal end 5033 of the rotary drive assembly 5030 is allowed to float within the floating cavity 5025. In such an example where the distal portion 5011 of the compartment passage 5011 deflects downward, the distal end 5033 of the rotary drive assembly 5030 can be held relatively unloaded by floating within the floating cavity 5025. Figure 84 As can be seen, the floating cavity 5025 includes a vertical slot portion 5026, which is configured to allow a predefined floating distance or vertical floating limit for the drive assembly 5030 and / or the portion 5032 of the rotation drive assembly 5030. For example, the portion 5032 may have its ability to float vertically within the floating cavity 5025 limited by a flange 5023.

[0417] An embodiment is envisioned in which the vertical limiting feature defined by the bottom 5020 of the compartment channel 5010 is absent. In at least one embodiment, the annular bracket slot 5022 is configured to support the bushing 5034 and / or the distal support head 5035. In at least one embodiment, the annular bracket slot 5022 defines a lower vertical limiting feature or stop configured to prevent the distal end 5033 of the rotary drive assembly 5030 from floating below a specific threshold defined, for example, by the contact between the bushing 5034 and / or 5035 and the annular bracket slot 5022. In at least one embodiment, the vertical slot portion 5026 and the flange 5023 define an upper vertical limiting feature or stop configured to prevent the distal end 5033 of the rotary drive assembly 5030 from floating above a specific threshold defined by the contact between the distal end 5033 and the flange 5023.

[0418] like Figure 83As can be seen, the staple cartridge 5050 includes a distal nose 5051 that defines a nasal cavity 5053 therein. The nasal cavity 5053 can provide space for the distal end 5033 of the rotary drive assembly to float therein.

[0419] In at least one embodiment, the proximal end of the rotary drive assembly 5030 is fixed in place. In at least one embodiment, the proximal end of the rotary drive assembly 5030 is also configured to float relative to the compartment channel 5010.

[0420] In at least one instance, for example, a spring is disposed at a proximal and / or distal mounting position of the firing drive screw within the chamber passage. The spring is configured to bias the firing drive screw into a neutral configuration. In at least one instance, the spring is configured to counteract bending loads applied to the firing drive screw. In at least one instance, one or more magnets are disposed within the mounting position, and screw magnets of opposite polarities are disposed on the firing drive screw at the mounting position. This configuration biases the firing drive screw toward a neutral configuration and counteracts bending loads applied to the firing drive screw. For example, such a spring may include a vertically deformable bushing. In at least one instance, a helical spring is used within the mounting position.

[0421] In various instances, the flexible floating mounts described herein are configured to allow a limited vertical floating range of the rotary drive assembly relative to the chamber channel. For example, the distal mounts described herein may allow a vertical floating range of 0.0002 inches to 0.0003 inches. In other instances, a vertical floating range of 0.001 inches may be allowed, and in some instances, the flexible floating mounts may allow a vertical floating range of up to 0.0015 inches. The dimensions of the vertical floating range may be configured to prevent lateral loads from being applied to the rotary drive assembly, which is ideal for tensile loads but may cause bending under lateral loads. Instead, the rotary drive assembly may float within a limited vertical floating range to ensure that the rotary drive assembly is not laterally loaded. The vertical floating range allows for displacement of the rotary drive assembly and prevents lateral loads on the rotary drive assembly even when thick and / or tough tissue is clamped between the jaws and the anvil is bowed in the clamping configuration.

[0422] In at least one embodiment, the flange of the firing member assembly is configured to define a limited vertical floating range of the firing drive screw via the threaded connection between the firing member assembly and the firing drive screw. For example, an anvil engagement flange may contact the upper portion of the anvil slot and / or a channel engagement flange may contact the upper portion of the channel slot to provide an upper stop for the firing drive screw. In addition to the above, an anvil engagement flange may contact the lower portion of the anvil slot and / or a channel engagement flange may contact the lower portion of the channel slot to provide a lower stop for the firing drive screw. In at least one embodiment, a drive nut cutout, drive cavity, and / or receptacle configured to receive a drive nut are configured to further define the vertical floating range of the firing drive screw.

[0423] Figure 85 A surgical suture assembly 5000 is shown, which includes a storage channel 5010 of a surgical suture assembly 5100. The surgical suture assembly 5100 includes a rotary drive assembly 5130, which includes a threaded portion 5131 and a distal end 5133. The distal end 5133 includes one or more bearings 5134 configured to abut against a flange 5023 to support the distal end 5133. The distal end 5133 also includes a distal support head 5135, which includes a forged screw end 5136. The forged screw end 5136 may be externally forged and / or internally forged. The forged screw end 5136 is configured to provide a distal bearing surface for one or more bearings 5134. Similar to the rotary drive assembly 5030, the rotary drive assembly 5130 is configured to float within the storage channel 5010.

[0424] Any suitable bushing and / or bearing may be used in conjunction with any of the various rotary drive assemblies and / or firing drive screws disclosed herein. In at least one instance, a compression bushing may be used at the proximal or distal end of the firing drive screw within the chamber passage. For example, once installed in the chamber passage, such a compression bushing may provide a compression preload to the firing drive screw. This compression preload prevents the firing drive screw from disengaging from any support element supporting the firing drive screw within the chamber passage. For example, a compression bushing may be used at one or more ends of the firing drive screw to prevent the proximal and / or distal ends of the firing drive screw from disengaging from the corresponding support element (such as, for example, an arcuate flange extending from the chamber passage).

[0425] Compression preloading can be caused, for example, by springs, longitudinal screws, and / or rivets on the compression bushing. In such instances, the compression bushing will tend to extend radially under compression preloading. This radial extension can fill the annular bracket support and / or floating cavity, such as those discussed herein. This tendency of the compression bushing to fill such slots and / or cavities can, for example, help prevent the firing drive screw from shifting longitudinally, laterally, and / or vertically from the support element (such as the arcuate flange discussed herein).

[0426] In at least one instance, the bushing and / or bearing configured to support the rotary drive assembly disclosed herein includes a flange extending radially outward therefrom. The flange is configured to be positioned on the side of the channel support flange opposite the distal support head of the firing drive screw. The radial flange can then be biased away from the channel support flange and thus away from the distal support head by a spring. In such instances, for example, the spring pushes against the radial flange of the channel support flange and the bushing. In such instances, the radial flange and the spring can be configured to pull the distal support head into the channel support flange. In at least one instance, the pulling force applied to the distal support head can be configured to position the distal support head such that the firing drive screw cannot be directly lifted away from the channel support flange without first pulling the firing drive screw distally and overcoming the force applied by the spring. Overcoming this force will then disengage the distal support head from the channel support flange, allowing only the firing drive screw to be lifted away from the channel support flange.

[0427] In addition to the above, for example, the spring can be compressed by a distal fastening screw configured to pull the distal support head proximal to the channel support flange relative to a bushing including a radial flange. Other embodiments are contemplated, in which the bearing is positioned distal to the channel support flange, and a nut is then threaded onto the drive screw. The nut can then be rotated to press the bearing against the channel support flange.

[0428] Figure 86 and Figure 87 A surgical suture assembly 5200 is shown, which includes a support channel 5210 and a firing drive screw 5220 configured to actuate a firing member assembly, such as those disclosed herein. The firing drive screw 5220 defines a screw axis SA. As discussed above, the firing drive screw used in a surgical end effector assembly can be subjected to bending loads. Figure 87As can be seen, arrow 5230 indicates a bending load applied to the distal end 5223 of the firing drive screw 5220. The firing drive screw 5220 includes a proximal ball joint 25221 mounted in a ball joint socket or mounting member 5211 of the channel support 5211. This configuration allows the firing drive screw 5220 to pivot relative to the channel support 5211 when subjected to bending loads. In at least one instance, the ball joint 5221 and the socket 5211 allow the firing drive screw 5220 to pivot without causing significant bending of the firing drive screw 5220. For example, bending could cause adhesion between the threaded portion 5225 and the firing member assembly. The ball joint can be finely adjusted to allow a predefined amount of pivoting, preventing the firing drive screw 5220 from pivoting beyond the allowed predefined amount and potentially causing other problems within the end effector assembly. In at least one instance, the proximal mounting position of the firing drive screw 5220 includes a radial and / or spherical shape to allow the firing drive screw 5220 to rotate slightly relative to the screw axis SA. This configuration also prevents the firing drive screw 5220 from sticking and / or scraping within the proximal mounting position.

[0429] In at least one instance, the proximal and / or distal ends of the drive screw are supported within the channel and / or anvil, for example, by more than one support flange extending from the channel and / or anvil. For example, the more than one support flange may comprise a plurality of flanges connected in series with each other. One or more corresponding thrust bearings of the drive screw may be configured to abut against the more than one support flange. For example, such a configuration helps support the drive screw if it is to move proximally and distally. For example, in at least one instance, an independent thrust bearing is provided on the drive screw for each support flange extending from the channel and / or anvil. In at least one instance, each thrust bearing is configured to engage only its corresponding support flange. In other instances, a thrust bearing is disposed between two flanges, wherein the single thrust bearing is configured to engage both flanges in both proximal and distal directions. In such instances, one or more additional thrust bearings may be disposed proximal to and / or distal to the two support flanges. This arrangement can provide multiple thrust surfaces instead of a single thrust surface that drives the screw.

[0430] In at least one instance, for example, the thrust surface of the supporting flange includes, for example, an inner annular recess. In such instances, the thrust bearing of the drive screw can be configured to be received within this inner annular recess. In at least one instance, a deformable thrust bearing is compressed into the recess. In at least one instance, the deformable thrust bearing includes a diameter larger than the outer diameter of the recess. Such a configuration can provide additional support for the drive screw. In at least one instance, the deformable thrust bearing includes a soft, low-density polyethylene washer. In at least one instance, a track forming process is used to compress the thrust bearing. In at least one instance, the thrust bearing may include, for example, a threaded washer.

[0431] In various instances, springs and / or magnets may be integrated into various components of the end effector assembly to allow the various components of the end effector assembly to float and / or move relative to each other under load. For example, springs and / or magnets may be integrated in proximal and / or distal mounting locations where the firing drive screw is supported by, for example, a chamber channel. Another example includes integrating springs and / or magnets into the firing member assembly to allow it to drive the nut to float, for example, relative to the body portion.

[0432] Figures 88 to 91 A firing member assembly 5300 is shown, configured to push a slider and / or cutting member through a pin firing stroke within an end effector assembly. The firing member assembly 5300 includes a body portion 5010 and a threaded drive nut 5350 configured to be threadedly connected to a firing drive screw. The drive nut 5350 is configured to apply an axial driving force to the body portion 5010 to push and pull the body portion 5010 through the end effector assembly. The body portion 5010 includes an upper portion 5311 configured to engage a first jaw of the end effector assembly and a lower portion 5315 configured to engage a second jaw of the end effector assembly. The lower portion 5315 includes a proximal portion 5316 and a distal portion 5320, each configured to receive a firing drive screw passing through it without threading. A drive nut cavity 5330 is defined between a proximal portion 5316 and a distal portion 5320, and is configured to receive a drive nut 5350 therein. The firing member assembly 5300 also includes a magnetic element 5360 configured to engage the drive nut 5350 to the body portion 5310.

[0433] Magnetic element 5360 may include, for example, a cylindrical rod or pin and / or a rectangular rod or pin. Nevertheless, one magnetic element of magnetic element 5360 is attached to and elastically loaded by a spring 5361 defined in a proximal channel 5363 in the proximal portion 5316. Another magnetic element of magnetic element 5360 is attached to and elastically loaded by a spring 5361 defined in a distal channel 5365 in the distal portion 5320. To mount the drive nut 5350 to the body portion 5310, magnetic element 5360 is supported by an externally present magnet 5370. Figure 90 The externally present magnet 5370 retracts into its corresponding channels 5363, 5365, and is configured to overcome the spring force applied to the magnetic element by spring 5361. Then, the drive nut 5350 can be inserted into the drive nut cavity 5330. Once the drive nut 5350 is in place, the externally present magnet 5370 can move away from the magnetic element 5360 to allow spring 5361 to bias the magnetic element 5360 inward toward the drive nut 5350.

[0434] Specifically, the magnetic element 5360 is configured to reside within a corresponding proximal channel 5351 defined in the drive nut 5350 and a corresponding distal channel 5355 defined in the drive nut 5350. Channels 5351 and 5355 include a width and / or diameter larger than the width and / or diameter of the magnetic element 5360. This dimensional difference allows the drive nut 5350 to float relative to the body portion 5310. The amount of float of the drive nut 5350 relative to the body portion 5310 is at least partially defined and limited by the dimensional difference 5371 between the magnetic element 5360 and the channels 5351 and 5355. In at least one instance, one of the width and / or height is substantially the same as the width and / or height of the magnetic element 5360. This configuration will allow the drive nut to float in only one plane. For example, if the vertical heights of the magnetic element 5360 and the drive nut channels 5351, 5355 are substantially the same, and the width of the drive nut channels 5351, 5355 is greater than the width of the magnetic element 5360, then the drive nut 5350 is allowed to float only horizontally or laterally relative to the body portion 5310. On the other hand, if the widths are substantially the same but the vertical heights are different, then the drive nut 5350 is allowed to float only vertically relative to the body portion 5310. Any floating may ultimately be limited by the dimensions of the drive screw channels of the proximal portion 5316 and the distal portion 5320, as discussed in more detail above.

[0435] In at least one instance, channels or recesses 5363, 5365 may be machined into the metal body portion. In at least one instance, channels or recesses 5351, 5355 may be part of an injection mold when manufacturing the drive nut 5350. In at least one instance, the magnetic element 5360 comprises, for example, a steel pin. In at least one instance, the arrangement discussed above reduces the need for precise alignment of the internally threaded channel defined in the drive nut to be coupled with the corresponding drive screw channel in the body portion. In such instances, if the internally threaded channel is molded slightly eccentrically relative to the corresponding drive screw channel in the body portion, the arrangement of the magnetic element discussed above allows the drive nut 5350 to float in alignment with the body portion 5310. For example, the floating of the drive nut 5350 may also help prevent the drive nut 5350 and the drive screw from sticking together. In at least one instance, the third degree of motion can be controlled and defined by the proximal portion 5316 and the distal portion 5320, which can define the permissible amount of floating (if any) along the longitudinal axis relative to the body portion 5310.

[0436] For example, in various instances, the firing drive screw can be configured to provide a compliant drive screw that adapts to the various loads experienced by the firing drive screw and reduces the likelihood of drive screw sticking. For instance, such a compliant drive screw can automatically adapt and / or comply under different load conditions. This compliance may result in a change in the shape of the drive screw itself, as discussed in more detail below.

[0437] Figure 92 and Figure 93A firing drive screw 5400 configured to automatically adapt under load is shown. The firing drive screw 5400 includes a cable or core member 5410, which includes a proximal end 5401 and a distal end 5403. For example, the distal end 5403 may include a flange portion extending directly therefrom and / or a pressure-fitted thrust bearing. The firing drive screw 5400 also includes a spring or helical member 5420 defining a separate threaded section 5421, which is configured to provide a threaded interface, for example, for a threaded firing member assembly. The core member 5410 includes a flexible material such that the core member 5410 can flex and adapt to its shape under load. Like the core member 5410, the helical member 5420 also includes a flexible material such that the helical member 5420 can flex under load in the same manner as the core member 5410. This flexibility of the core member 5410 and the helical member 5420 allows individual threaded segments 5421 to shift relative to each other. Each individual threaded segment 5421 can shift relative to each other. However, the threaded segments 5421 can be configured to shift semi-independently. Such a configuration allows for slight shifting of each member 5421; however, all threaded segments in the threaded segments 5421 are part of a single helical member 5420, so shifting of one threaded segment 5421 may result in some shifting of one or more adjacent helical members, and so on. This can also be referred to as the unfolding of the threaded segments 5421 when the drive screw 5420 is under load. The drive screw 5420 reduces the likelihood of the drive screw sticking under load. In various instances, the core member 5410 and the helical member may comprise different materials. Although Figure 93 The schematic cross-sectional view shows the space or gap between the inner diameter of the helical member 5420 and the outer diameter of the core member 5410, but in other instances, the inner diameter of the helical member 5420 contacts and / or is adjacent to the outer diameter of the core member 5410.

[0438] Figure 94This is a schematic diagram of a firing assembly 5500 including a flexible firing drive screw 5550. The firing drive screw 5550 may include many similarities to, for example, the firing drive screw 5400 disclosed herein. The firing assembly 5500 includes a firing drive screw 5550 mounted to a channel frame 5510. The proximal drive member or solid bushing 5551 of the firing drive screw 5550 includes a flange 5552 configured to be supported by a proximal end 5511 of the channel frame 5510. The distal portion 5556 of the firing drive screw 5550 is configured to be supported by a distal support flange 5513 extending from the channel frame 5512. The firing drive screw 5550 also includes a flexible core member 5556 and a helical member 5554 surrounding the flexible core member 5556 and defining a threaded segment or region 5555. The helical member 5554 is attached to the proximal drive member 5551, and the sleeve / socket 5557 is securely attached to the distal portion 5556 of the firing drive screw 5550. For example, the proximal drive member 5551 may be forged onto the flexible core member 5556 of the firing drive screw 5556. The distal portion 5556 includes a threaded section 5558, bushings 5559, and a distal nut 5560 threaded to the threaded section 5558. A pair of bushings 5559 are positioned proximal to the distal nut 5560 in a socket and may be clamped between the distal nut 560 and the distal support flange 551 (see example). Figure 82 (Bearing 5034 in the middle).

[0439] In at least one instance, the inner diameter of the helical member 5554 is configured to surround and contact the outer diameter of the flexible core member 5553. For example, the helical member 5554 may comprise a type of helical spring. For example, the flexible core member 5553 may comprise a flexible cable. In at least one instance, the helical member 5554 is manufactured to have an inner diameter smaller than the outer diameter of the flexible core member 5553. In such instances, the helical member 5554 may be rotated in the opposite direction to increase its inner diameter for assembly onto the flexible core member 5553. Once the helical member 5554 is positioned on the flexible core member 5553, the helical member 5554 can be released. Once released, the helical member 5554 will be biased back to its neutral, no-load configuration and will tightly synchronize or clamp itself to the flexible core member 5553. In at least one instance, the helical member 5554 is welded to the flexible core member 5553 at different locations along the length of the flexible core member 5553.

[0440] In at least one instance, the nut 5560 is configured to be tightened and / or loosened to provide the desired configuration of the helical member 5554. Tightening and / or loosening the nut 5560 also allows adjustment of the tension of the flexible core member 5553. Adjustment of the tension of the flexible core member 5553 can be directly related to the amount of deflection allowed along its length under load. For example, a tighter cable allows less deflection than a looser cable. This can, for example, be adjusted to the desired tension during manufacturing. Implementations in which different adjustments are made, for example, for different sized chambers and / or surgical suture systems requiring different firing forces are envisioned.

[0441] In various instances, a firing drive screw is provided that is configured to minimize plastic deformation under a variety of loads. Such a firing drive screw may include variations in its cross-sectional geometry along its longitudinal length. These variations may result in a portion of the firing drive screw being more flexible than its adjacent portions. For example, the more flexible portion of the firing drive screw may be subjected to a greater bending load than the less flexible portion. The variation in the firing drive screw may be located in the proximal portion, the middle portion, the distal portion, or any combination thereof. For example, the location of the variation may depend on the area of ​​the firing drive screw being applied to and subjected to the highest load.

[0442] Figure 95 A firing drive screw 5600 is shown, configured for use with surgical suture assemblies such as those discussed herein. The firing drive screw 5600 includes a proximal driven end portion 5601 configured to attach to a rotary drive shaft. The firing drive screw 5600 also includes a proximal flange 5602 configured to be supported, for example, within a frame member of an end effector assembly. The firing drive screw 5600 includes a screw shaft 5610 comprising a main thread portion 5613 and a proximal necking portion 5611. The proximal necking portion 5611 includes a smaller cross-sectional diameter than the main thread portion 5613. This variation in cross-sectional diameter allows for slight bending of the necking portion 5611 to reduce excessive bending effects on the main thread portion 5613. When the firing member assembly is configured to be threadedly driven proximally and distally relative to the main thread portion 5613, reducing the bending effect on the main thread portion reduces the likelihood of the drive screw sticking to the section of the firing drive screw 5600 that engages with the firing member assembly. In at least one embodiment, the firing member assembly is also configured to thread through the necking portion 5611; however, in at least one embodiment, a high driving force may not be required over the length of the stroke comprised of the necking portion 5611.

[0443] Figure 96 and Figure 97A firing drive screw 5700 is shown, including a proximal driven end 5701 and a mounting flange 5702. The firing drive screw 5700 also includes a proximal section 5720 of thread 5721, which is, for example, overmolded and / or embedded into a proximal portion 5711 of the spindle 5710 of the firing drive screw 5700. The firing drive screw 5700 includes a main thread portion 5712, which has a cross-sectional diameter larger than the diameter of the proximal portion 5711. As discussed above, the variation in cross-sectional diameter allows for deflection of the spindle 5710 and specifically localizes this deflection to the proximal portion 5711 to reduce the likelihood of the drive screw sticking to the drive nut of the firing member assembly. For example, the thread 5721 may be made of a polymer material, while the spindle 5710 may be made of a metallic material. Thread 5721 helps maintain a consistent thread pattern along the travel of the firing component assembly connected to the firing drive screw 5700 via a threaded connection.

[0444] In at least one instance, various portions along the length of the firing drive screw include, for example, overmolded plastic threaded sections. In at least one instance, the various overmolded portions are adapted to manufacturing tolerance differences between the drive nut of the firing assembly and the thread profile of the firing drive screw, and in some instances provide, for example, a smoother thread engagement surface. In at least one instance, the central section of the firing drive screw (midway through the firing stroke) includes a varying cross-sectional profile.

[0445] Figures 98 to 100 Various types of couplings 5810, 5820, and 5830 are shown, which can be used with firing drive screws (such as those disclosed herein). Couplings 5810, 5820, and 5830 can be positioned at any location along the length of the firing drive screw to provide a location intended to localize bending of the firing drive screw. Couplings 5810, 5820, and 5830 are configured to transfer rotational shaft motion from one shaft to another. Coupling 5810 can introduce little or no backlash in the firing drive screw used with it. For example, couplings 5810, 5820, and 5830 can allow for a certain degree of angular misalignment of the shaft due to bending forces of the firing drive screw applied within the end effector, parallel misalignment of the shaft, and / or axial movement of the shaft.

[0446] Coupling 5810 may be, for example, a beam coupling. Coupling 5810 includes a proximal hub 5811 configured to attach to the distal end of a portion of the firing drive screw, a distal hub 5813 configured to attach to the proximal end of another portion of the firing drive screw, and a helical cutout 5815 configured to flex during scenarios of shaft misalignment.

[0447] Coupling 5820 may be, for example, a bellows coupling. Coupling 5820 includes a proximal hub 5821 configured to attach to a distal end of a portion of the firing drive screw, a distal hub 5823 configured to attach to a proximal end of another portion of the firing drive screw, and a flexible bellows portion 5825 configured to flex during scenarios of shaft misalignment.

[0448] Coupling 5830 may be, for example, a curved claw coupling. Coupling 5830 includes a proximal hub 5831 configured to attach to a distal end of a portion of the firing drive screw, a distal hub 5833 configured to attach to a proximal end of another portion of the firing drive screw, and a star gear including teeth 5835. The star gear may comprise a softer material configured to flex between hubs 5831 and 5833 while maintaining drive engagement between the star gear, proximal hub 5831, and distal hub 5833.

[0449] In end effector assemblies, such couplings 5810, 5820, and 5830 allow the firing drive screw to bend at the coupling itself and reduce bending within the threaded shaft itself. As discussed herein, bending of the threaded shaft can cause adhesion between the threaded firing drive screw and the firing component assembly.

[0450] Figures 101 to 103 A closure drive assembly 6000 is shown, comprising a closure actuator 6010 and a closure nut or wedge 6020 threadedly connected to the closure actuator 6010. The closure nut 6010 is configured to open and close jaws 6040 of the closure drive assembly 6000 relative to opposing jaws having a cam protrusion 6023 and a cam surface 6021, respectively. The closure drive assembly 6000 includes a support element 6030 configured to support the closure actuator 6010 thereon. The support element 6030 can be secured to, for example, a channel retainer. The support element 6030 includes bearing flanges 6031, 6032 configured to support a closure drive screw 6013 of the closure actuator 6010 therein. The closing actuator 6010 also includes a proximal driven portion 6010 configured to be driven by a rotary closing drive shaft, a thrust bearing 6012 configured to abut a flange 6032, and a distal thrust bearing portion 6016 configured to abut a flange 6031.

[0451] The closing drive screw 6013 includes a threaded section 6014 and a distal unthreaded section 6015. The closing nut 6020 also includes an internally threaded section 6025 configured to threadedly engage with the threaded section 6014, allowing the closing nut to be advanced proximally and distally along the threaded section to open and close the jaws 6003. In at least one instance, the closing nut 6020 is configured to be 3D printed onto a pre-manufactured closing actuator 6010. For example, the closing nut 6020 may comprise a metallic and / or polymeric material. The closing nut 6020 is configured to be printed around the distal unthreaded section 6015. This arrangement allows the internally threaded section 6025 of the closing nut 6020 to be printed with an effective diameter slightly smaller than that of the case where the closing nut is printed directly around the threaded section 6015. The closing nut 6020 printed on the closing drive screw 6013 can be effectively confined between the bearing 6012 and the bearing portion 6016, thereby preventing accidental disassembly after manufacturing. In at least one instance, the bearing 6012 and the bearing portion 6016 are printed on the drive screw 6013 prior to the printing of the closing nut 6020.

[0452] In at least one instance, one or more parts of the closure actuator 6010 are also 3D printed. In such instances, the closure actuator 6010 can be 3D printed to a size slightly larger than desired. For example, the closure actuator 6010 can be 0.5% larger than desired. In such instances, various details of the closure actuator 6010, requiring precise dimensions, can be machined after the closure actuator 6010 is printed. In some instances, such manufacturing processes reduce machining waste and the amount of time required to manufacture one or more parts. For example, a closure actuator comprising a shaft with unthreaded and threaded sections requires the removal of a ring of material at least the width of the thread depth at the unthreaded section, where the unthreaded section comprises a diameter less than or equal to the minor diameter of the threaded section. 3D printing of such a closure actuator allows the unthreaded section to be printed closer to the minor diameter of the thread, albeit slightly larger, for the reasons discussed above.

[0453] Figure 104 and Figure 105A closure actuator 6100 is shown, which includes a drive screw 6110 and a retaining collar 6120 configured to be secured to the drive screw 6110. The retaining collar 6120 may resemble the distal thrust bearing portion 6016 of the closure actuator 6010. For example, the retaining collar 6120 may be configured to support the closure actuator 6110 against a support flange. For example, the retaining collar 6120 may be referred to as a washer, nut, and / or flange. The drive screw 6110 includes a main thread portion 6111 having a thread 6112. The main thread portion 6111 may be configured to drive a closure nut thereon, for example, proximal and distally, to open and close the jaws of an end effector.

[0454] The drive screw 6110 also includes a distal end 6113 comprising an annular slot 6114 and a thread 6115. The annular slot 6114 is configured to support a retaining collar 6120 therein. The thread 6115 is configured to allow the retaining collar 6120 to be installed and to prevent the retaining collar 6120 from being removed from the drive screw 6110. The retaining collar 6120 includes a proximal ramp surface 6122 defined therein. The proximal ramp surface 6122 is configured to allow the retaining collar 6120 to be screwed onto the thread 6115 of the drive screw 6110, such that the retaining collar 6120 can disengage from the thread 6115 and adapt the inner support surface 6121 to the annular slot 6114. Once installed onto the drive screw 6110, the thread 6115 resides distal to the distal vertical wall 6123 defined in the retaining collar 6120. The distal wall 6123 is configured to prevent the limiting collar 6120 from being pulled out from the distal end 6113 of the drive screw 6110.

[0455] In at least one instance, the drive screw 6110 is machined and / or 3D printed from a metal material. In at least one instance, the retaining collar 6120 is molded and / or 3D printed from a polymer. In at least one instance, the retaining collar 6120 is constructed from a material that allows a degree of flexibility to allow the retaining collar 6120 to flex around the thread 6115 and disengage from the thread. A considerable amount of force may be required to attach the retaining collar 6120 to the drive screw 6110. In at least one instance, an even greater amount of force may be required to remove the retaining collar 6120 from the drive screw 6110, at least due to the distal sidewall 6123.

[0456] In at least one instance, such a limiting collar may be used with a firing drive screw configured to thread-drive the firing component assembly. In various instances, such a limiting collar is used at the proximal end, the distal end, or both ends of the drive screw.

[0457] In at least one instance, a locking washer is used to mount a retaining collar onto a drive screw. In such instances, the retaining collar is configured such that threads and / or multiple threads mounted thereon can be configured to further tighten the locking engagement of the locking washer and the retaining collar, for example, when the drive screw is under load. For example, each end of the retaining collar may include threads with opposite thread directions. For example, the proximal end of the retaining collar may include a left-hand thread, and the distal end of the retaining collar may include a right-hand thread, and vice versa. Once mounted, the retaining collar can be introduced into the opposite thread pattern such that when the retaining collar is actuated away from the distal end of the drive screw, the opposite thread pattern can be used to further tighten the locking engagement of the locking washer and the retaining collar.

[0458] In at least one instance, the firing drive screw and / or closing drive screw can be 3D printed. In such instances, various features can be directly printed using the drive screw. For example, support flanges, bearings, retaining collars, etc., can be directly printed onto the drive screw. In at least one instance, one or more of these various features may include a material different from the drive screw itself. In such instances, features including a material different from the drive screw can be directly printed onto metal, for example, onto the drive screw. In at least one instance, the various features include the same material as the drive screw. In such instances, various metals (e.g., features) can be printed onto a metal drive screw using a process such as directional energy deposition. In at least one instance, the various features may include different materials, which can be welded to the drive screw after being printed onto it, for example.

[0459] In various instances, using features made of different materials (such as flanges) on the drive screw can provide a lower coefficient of friction between the flange and the support structure, compared to, for example, a support structure and flange made of metallic materials. For example, manufacturing these features after the main portion of the drive screw has been machined can also reduce the manufacturing time and cost of the entire closed actuator.

[0460] Figure 106 and Figure 107A drive assembly 6200 is shown mounted to a channel flange 6210. The drive assembly 6200 includes a drive screw shaft 6220 with a threaded portion configured for threaded engagement with a firing member of a surgical suture assembly. The drive screw shaft 6220 also includes a distal end 6223 comprising a flange end 6224 and an annular slot 6225. A locking assembly 6230 is provided to secure the drive screw shaft 6220 to the channel flange 6210. The locking assembly 6230 includes a distal nut 6240 and a locking member 6250. The locking member 6250 is configured to lock into the annular slot 6225 to provide the distal end 6223 of the drive screw shaft 6220 abutting against its secured adjacent surface. After the locking member 6250 is positioned against the channel flange 6210 on the drive screw shaft 6220, the distal end nut 6240 may be threaded onto the distal end 6223. When the distal nut 6240 is tightened or moved proximally toward the channel flange 6210, the locking member 6250 may include a flexible material to be pushed into the annular slot 6225 by the ramp surface 6241 of the distal nut 6240. In at least one embodiment, the locking member 6250 is configured to be shaped into a mushroom and / or balloon shape when pressure is applied to it by the distal nut 6240. In at least one embodiment, the distal nut 6240 includes a metallic material. In at least one embodiment, the locking member 6250 includes a deformable restraint for the drive screw shaft 6200. For example, when a load is applied to the drive screw shaft in direction 6260, the drive screw shaft 6220 is prevented from extending proximally relative to the channel flange 6210 due to the expansion of the locking member 6250. The flange end 6224 can transfer the load to the locking member 6250, which in turn transfers the load to the channel flange 6210.

[0461] In at least one instance, the drive screw shaft (such as those discussed herein) can be manufactured using a subtractive manufacturing process (such as, for example, the Swiss screw manufacturing process). Such a process, for example, reduces material waste and manufacturing time in the drive screw. It also allows for high-precision machining of such relatively small drive screws, where the diameter along the length of the drive screw shaft can vary and includes relatively small dimensional differences.

[0462] In various instances, the locking member (such as locking member 6250) comprises, for example, rubber materials and / or low-density polyethylene and / or polypropylene. The material of the locking member can be selected based on its shearing capacity under load, such that under a predetermined threshold load, the locking member can shear to prevent failure of other components within the system. Such locking members can also automatically align the drive screw shaft because the locking member is installed by being uniformly constrained around it.

[0463] In various instances, end effector assemblies (such as those disclosed herein) may include stackable supports configured to support one or more drivers of the end effector assembly. For example, one or more stackable supports are configured to support non-concentric closing and firing drivers. The one or more stackable supports are configured to support one or more drivers against a common frame element (such as, for example, a channel jaw).

[0464] Figures 108 to 110 A surgical suture assembly 6300 is shown. The surgical suture assembly 6300 includes a connector member 6310 and a channel jaw 6320. The channel jaw 6320 is attached to the connector member 6310 by a retaining strap or ring configured to be received within an annular slot 6315 of the connector member 6310. The channel jaw 6320 includes a bottom 6321 and vertical slots 6322 on each side of the channel jaw 6320, these vertical slots being configured to receive tabs 6314 on each side of the connector member 6310. The connector member 6310 defines an articulation pin slot 6311 therein. The channel jaw 6310 is articulate about an axis defined by the articulation pin slot 6311. The connector member 6310 is configured to receive one or more drive shafts passing through it to drive a closing actuator 6340 and a firing actuator 6350 of the surgical suture assembly 6300.

[0465] The closing actuator 6340 includes a drive screw 6341 and a closing wedge 6342 threadedly connected to the drive screw 6341. The closing wedge 6342 is configured to be actuated proximally and distally by the drive screw 6341 to open and close the jaws relative to the channel jaws 6320 (such as, for example, anvil jaws). The firing actuator 6350 includes a drive screw 6351 and a firing member assembly 6353, the drive screw including a proximal end 6352, the firing member assembly being configured to be threadedly connected to the drive screw 6351. The firing actuator 6350 is configured to eject a nail from the nail cartridge and cut the patient's tissue during the nail firing stroke when the firing member assembly 6350 is actuated along the drive screw 6351.

[0466] The closing actuator 6340 and the firing actuator 6350 are supported within the channel jaws 6320 by a lower support element or mount 6380 and an upper support element or mount 6370. The support elements 6370 and 6380 may be stackable and support one or more of the closing actuator 6340 and the firing actuator 6350. The lower support element 6380 includes a lower portion 6381 and an upper portion 6383. The lower portion 6381 includes a key 6382 configured to be received within a corresponding slot defined in the channel jaws 6320. This key and slot configuration prevents movement of the lower support element 6380 relative to the channel jaws 6320. The upper portion 6383 includes a shaft support 6384, which includes a lower arched support portion 6385 and an upper arched support portion 6386. The lower arched support portion 6385 is configured to receive the input shaft 6355 of the firing driver 6350, which is configured to connect to and drive the proximal end 6352 of the drive screw 6351. The upper arched support portion 6386 is configured to receive and support the drive screw 6341 of the closing driver 6340.

[0467] The upper support element 6370 can be received on top of the lower support element 6380 in a track-like manner. For example, a corresponding cavity defined in the upper support element 6370 can be configured to receive the upper portion 6383 of the lower support element 6370, such that the upper support element 6370 adapts to and surrounds the upper portion 6383 during installation. The upper support element 6370 also includes a key 6371 configured to be received within a corresponding slot defined in the channel jaw 6320. The upper support element 6370 also includes a top surface 6373 and a distal support tab 6372 configured to receive and support a portion of the drive screw 6341 therein. The top surface 6373 is configured to support the bottom surface 6343 of the closing wedge 6342 thereon. In at least one embodiment, a closed wedge track is defined on the top surface 6373, and a closed wedge 6342 can engage with and ride along the closed wedge track during proximal and distal travel. The upper support element 6370 also includes a window 6374 configured to receive the upper portion 6383. Both the upper support element 6370 and the lower support element 6380 can be supported by the bottom 6321 of the channel jaws 6320.

[0468] In at least one embodiment, the upper support element 6370 and / or the lower support element 6380 may be supported within corresponding tracks defined in the channel jaws 6320, allowing the upper support element 6370 and the lower support element 6380 a degree of longitudinal travel while still being supported by the channel jaws 6320. This can be helpful during the clamping, releasing, and / or articulating movements of the end effector assembly, where various drive shaft components need to extend or shorten due to the clamping, releasing, and / or articulating movements of the end effector assembly and the associated forces.

[0469] In at least one instance, the upper support element 6370 and / or the lower support element 6380 are manufactured from a single material as a single component. For example, such a configuration can be achieved using metal machining processes. In at least one instance, the upper support element 6370 and / or the lower support element 6380 are manufactured separately. In such instances, for example, one of the upper support element 6370 and the lower support element 6380 comprises a machined part, and the other of the upper support element 6370 and the lower support element 6380 comprises a sheet-stamped part. In at least one instance, both the upper support element 6370 and the lower support element 6380 are stamped.

[0470] This document discloses various types of closing wedges and / or nuts. A closing wedge may include a cam-acting surface configured to close the jaws and one or more cam-acting surfaces configured to open the jaws. In various examples, the angle of the corresponding cam surface may include a sharper angle relative to the engaging surface of the jaws that engages with the surface in a cam-acting manner. The cam-acting surface may be adjusted to minimize the driving force required for the corresponding closing drive screw while maintaining a force greater than sufficient for closing drive cam force.

[0471] Figures 111 to 113A closing drive assembly 6400 is shown, configured to open and close the jaws of an end effector assembly. The closing drive assembly 6400 includes a jaw support element 6410 and a closing actuator 6420 supported by support flanges 6411, 6413 of the jaw support element 6410. The closing actuator 6420 includes a drive screw shaft 6430, which includes a proximal end portion 6431 configured to be rotatable by a rotary drive shaft, a proximal bearing portion 6432 configured to prevent distal movement of the drive screw shaft 6430 relative to the flange 6413, and a threaded portion 6433 configured to be threadedly connected to a closing wedge 6450. The drive screw shaft 6430 also includes a distal end portion 6434 supported within a flange support slot 6412 of the flange 6411 and secured to the flange 6411 by a clamp 6440. The clamp 6440 is configured to be received within a clamp slot 6435 defined in the distal end 6435 of the drive screw shaft 6430. The clamp 6440 is configured to prevent proximal movement of the drive screw shaft 6430 relative to the flange 6411. The clamp 6440 may include, for example, a clamp. However, any suitable clamp, retaining clamp, and / or retaining ring may be used. In at least one embodiment, a closing wedge 6450 may be threaded onto the drive screw shaft 6430 from the distal end 6434.

[0472] Figures 114 to 117 A closing actuator 6500 is shown, comprising a drive screw shaft 6510 and a closing drive nut or wedge 6540 configured to open and close the jaws of an end effector assembly. The drive screw shaft 6510 includes a proximal end 6511 and a distal end 6515. The proximal end 6511 includes a driven portion 6512 configured to be rotatable by a rotary drive shaft, a proximal bearing portion 6513, and a threaded portion 6514 configured to be threadedly connected to the closing wedge 6540. The distal end 6515 includes an attachment section 6516 with a diameter smaller than the diameter of the drive screw shaft 6510 immediately adjacent to the attachment section 6516. The attachment section 6516 is configured to receive a locking member or radial washer 6520 thereon.

[0473] Now go to Figures 116 to 117The mounting of the locking member 6520 will now be described. For example, the distal end 6515 may be forged to radially extend the attachment segment 6516. This radial extension can provide a friction-retaining engagement between the locking member 6520 and the attachment segment 6516. A central slot 6517 is provided. The slot 6517 can be used to insert a forging tool therein to extend the attachment segment 6516, thereby locking the locking member 6520 in place. In at least one embodiment, the locking member 6520 is deformable, and the forging of the attachment segment 6516 is, for example, configured to deform the locking member 6520 into a mounting configuration.

[0474] In at least one instance, in addition to or instead of the forging process discussed above, the locking member 6520 is pinned to the attachment section 6516. In at least one instance, the locking member 6520 further includes an annular groove, and the attachment section 6516 further includes a corresponding annular slot defined on its outer side, the corresponding annular slot being configured to receive the annular groove of the locking member 6520. In at least one instance, a hole is machined in the drive screw, and a locating pin is configured to be inserted into the hole to retain the closed wedge on the drive screw.

[0475] In at least one instance, a high-density polyethylene washer is positioned proximal to the locking member 6520. For example, the high-density polyethylene washer may also include a deformable support flange such that the washer deforms when the locking member 6520 is assembled to the drive screw shaft 6510.

[0476] In at least one instance, the deformable gasket used herein includes a grooved and / or knurled surface. Such grooved and / or knurled surfaces can be used to compensate for tolerance accumulation among various components within a drive system. For example, such grooved and / or knurled surfaces may wear slightly after the first actuation stage following assembly to compensate for tolerance accumulation.

[0477] Figures 118 to 123 A firing drive assembly 7000 is shown, comprising a rotary drive shaft 7010, a firing member 7020 threadedly connected to the rotary drive shaft 7010, and a relief assembly 7030 configured to thread the firing member 7020 to the rotary drive shaft 7010 and allow the threaded engagement between the rotary drive shaft 7010 and the firing member 7020 to disengage and / or disengage. The rotary drive shaft 7010 includes a distal end 7011 and a threaded or grooved section 7013. The firing member 7020 includes an upper flange, a proximal edge 7022, and a distal edge 7023. The firing member 7020 also includes a lower portion 7024 comprising a drive shaft conduit 7026 configured to receive the rotary drive shaft 7010 passing through it. The lower portion 7024 also includes a lower flange 7025.

[0478] The relief assembly 7030 includes a relief actuator or cable 7031 and a housing 7032 defining a housing cavity 7033. The relief assembly 7030 also includes a bias plate 7040 and an actuator plate 7050. The actuator plate 7050 includes a main plate portion 7051 and a tip or pin 7052 extending inwardly from the main plate portion to be received and driven by a threaded section 7013 of a rotary drive shaft 7013. The pin 7052 is configured to be received within a pin slot 7028 defined in a lower portion 7024 to drively engage the threaded or grooved section 7013. The actuator plate 7050 is resiliently loaded against the lower portion 7024, wherein a spring 7060 is positioned within a spring slot 7027 defined in the lower portion 7024. The spring 7060 is configured to bias the actuator plate 7050 out of thread engagement with the rotary drive shaft 7010.

[0479] To maintain the threaded engagement of the actuator plate 7050 with the rotary drive shaft 7010, a bias plate 7040 is positioned or wedged between the housing 7032 and the main plate portion 7051 within the housing cavity 7033. This wedged engagement overcomes the spring force applied to the actuator plate 7050 by the spring 7060 and retains the pin 7052 engaged with the threaded section 7013 of the rotary drive shaft 7010. In various instances, the firing drive assembly 7000 may become trapped or stuck within the end effector assembly due to various circumstances. The relief assembly 7030 allows the firing member 7020 to disengage from the rotary drive shaft 7010 and be pulled proximally independently of the rotary drive shaft 7010 to overcome the trapped or stuck scenario.

[0480] To disengage the firing drive assembly 7000, move pin 7052 from its innermost position ( Figure 120 , Figure 121 Move to the outermost position. Figure 122 , Figure 123 This disengages pin 7052 and thus firing member 7020 from rotary drive shaft 7010. To achieve this movement, bias plate 7040 is pulled proximally by actuator 7031 to move bias plate 7040 out of the path of actuator plate 7050, thereby allowing spring 7060 to push main plate portion 7051 and thus pin 7052 out of thread engagement with threaded section 7013 of rotary drive shaft 7010. At this point, actuator 7031 can be pulled proximally to apply tension to firing member 7020 via bias plate 7040. Housing cavity 7033 includes a proximal limiting wall configured to transmit tension from bias plate 7040 to firing member 7050. For example, once firing member 7020 is pulled into its proximal position, end effector assembly can be opened and removed from surgical site.

[0481] In at least one instance, the firing drive assembly 7000 and the end effector assembly employing the firing drive assembly 7000 are not reusable due to the nature of the relief assembly 7030. For example, the relief assembly 7030 may not be able to reset back into threaded engagement with the rotary drive shaft 7010. In at least one instance, the relief assembly 7030 may be able to be reset and reused. In at least one instance, another pin 7052 and a corresponding structure are provided on the other side of the firing member 7020. In such instances, the same or separate cables may be provided to actuate the other pin.

[0482] In at least one instance, a gear and pulley system may be used to control the actuator or cable. In at least one instance, the cable may be motor-driven. In at least one instance, the cable may be manually actuated. In at least one instance, the cable may be both manually actuated and motor-driven. For example, during a power failure, a manual actuation method may be used if the motor-driven system is temporarily shut down. In at least one instance, the cable is allowed to extend when the firing element is actuated so as not to prematurely actuate the relief component. The cable may move passively or actively to accommodate the movement of the firing element.

[0483] In various examples, surgical suturing devices are provided that are configured to shape staples, such as conventional suture staples, differently within a single staple cartridge. More specifically, the cartridge can store staples having, for example, the same unshaped height, size, and shape. In such examples, different features are provided to shape the same unshaped staples into different final shaped configurations. In at least one example, the varying staple shaping gradually changes along the lateral width of the cartridge. More specifically, the inner row of staples can be shaped into a planar or 2D configuration, while the middle row and / or outer row of staples can be shaped into a non-planar or 3D configuration. Such an arrangement can provide varying suture tissue compression along the lateral width of the cartridge.

[0484] In addition to the above, such surgical suture arrangements may also include tissue grasping features or staple extensions defined on the platform of the staple cartridge. These tissue grasping features may vary in shape and / or size, for example, varying laterally across the staple cartridge. The platform of the staple cartridge may include a curved surface, wherein the apex of such a curved platform is defined at a longitudinal slot of the staple cartridge. The platform of the staple cartridge may also include one or more flat surfaces that provide a single flat surface defining all staple rows in a staple row, or provide a stepped platform arrangement wherein various stepped portions of the platform include one or more corresponding staple rows defined therein.

[0485] Tissue gripping features may also be interconnected along the lateral width of the staple cartridge. For example, on each side of the longitudinal slot of the staple cartridge, the cartridge may include three rows of staple cavities, and thus three rows of staples are removably stored therein. Tissue gripping features or platform protrusions may be positioned around each cavity of each row; however, tissue gripping features may be interconnected between one or more rows of staple cavities, while still varying in shape and / or size, for example. Such tissue gripping features can provide varying tissue compression along the lateral width of the staple cartridge. Different sized tissue gripping features may be advantageous when some rows of staples are shaped into a non-planar 3D configuration and some rows of staples are shaped into a planar 2D configuration. Such features can be specifically adjusted for the corresponding staple configuration of the staples to be shaped through the tissue gripped by the feature. For example, a gripping feature configured to grip tissue to be sutured between an anvil and a row of nail cavities including nails configured to be shaped into a non-planar configuration may include a first contour, and a gripping feature configured to grip tissue to be sutured between an anvil and a row of nail cavities including nails configured to be shaped into a planar configuration may include a second contour, wherein the first contour differs from the second contour. In some instances, a gripping feature aligned with a row of 3D nails may include a cut in an area where curved, shaped legs would interfere. For example, a row aligned with 2D nails may include a full gripping feature surrounding the nail cavities, and a row aligned with 3D nails may include a gripping feature with cuts around it to accommodate nail legs during its 3D forming.

[0486] In various instances, staples shaped as planar and staples shaped as non-planar may result in different forming compression heights. This can be attributed to the distance each staple leg needs to travel to its corresponding staple forming recess defined in the anvil. For example, a staple leg shaped as non-planar may have to travel diagonally to its corresponding staple forming recess. This distance can be greater than the distance a staple leg shaped as planar needs to travel to its corresponding staple forming recess without altering any other features of the sewing assembly.

[0487] In various instances, the distance each leg must travel to form its corresponding configuration (non-planar or planar) can be adjusted by changing one or more features of the surgical suture assembly. In at least one instance, the depth of the pin-forming recess defined in the anvil is adjusted corresponding to the forming configuration of the pin to be formed. In at least one instance, the unformed length of the pin is configured to be adjustable corresponding to the forming configuration of the pin to be formed. In at least one instance, the corresponding actuator height is adjusted corresponding to the forming configuration of the pin to be formed. In at least one instance, one or more of these adjustments are combined to accommodate 2D-formed pins and 3D-formed pins.

[0488] Figures 124 to 128A surgical suture assembly 8000 is shown. The surgical suture assembly 8000 includes a magazine jaw 8001, which includes a magazine channel 8010 and a staple cartridge 8020. The surgical suture assembly 8000 also includes an anvil jaw 8003 having an anvil 8050. The staple cartridge 8020 includes a plurality of staple cavities 8030 and a longitudinal slot 8022 defined in a magazine platform 8021. The staple cartridge 8020 also includes a plurality of tissue gripping features or cavity extensions 8040 defined on the platform 8021. The staple cavities 8030 are aligned relative to each other with longitudinal row offset. In this example, the staple cartridge 8020 includes three rows of staple cavities located on each side of the longitudinal slot; however, any suitable number of rows of staple cavities may be used. The staple cavities 8030 are configured to removably store staples configured to be ejected toward a staple-forming recess defined in an anvil surface 8051 of the anvil 8050.

[0489] refer to Figure 125 and Figure 126 The anvil 8050 includes an anvil slot 8052 defined in an anvil surface 8051. The anvil 8050 also includes a pair of inner nail-forming recess rows 8061, a pair of intermediate nail-forming recess rows 8063, and a pair of outer nail-forming recess rows 8065. Rows 8061, 8063, and 8065 are aligned with the nail cavities 8030 of their respective rows. The inner nail row 8081 includes nails 8070 configured to be formed by the nail-forming recess rows 8061, the intermediate nail row 8082 includes nails 8070 configured to be formed by the nail-forming recess rows 8063, and the outer nail row 8083 includes nails 8075 configured to be formed by the nail-forming recess rows 8065. The nail tips of the recesses in the nail-shaped recess row 8065 are aligned or substantially aligned with the tips of the nails in the outer nail row 8065; however, the nail tips of these recesses may be laterally offset relative to the nails positioned in the outer nail row 8065. Nails 8070 and 8075 comprise conventional wire nails. Nails 8070 and 8075 comprise the same unformed height. Nail 8070 is formed in a planar configuration, while nail 8075 is formed in a non-planar configuration.

[0490] Each pair of shaped recesses in row 8061 includes a proximal shaped recess 8061A and a distal shaped recess 8061B. Each pair of shaped recesses in row 8063 includes a proximal shaped recess 8063A and a distal shaped recess 8063B. Each pair of shaped recesses in row 8065 includes a proximal shaped recess 8065A and a distal shaped recess 8065B. Shaped recesses 8061A and 8061B include a centerline axis or longitudinal recess axis aligned with each other along row 8061. Similarly, shaped recesses 8063A and 8063B include a centerline axis or longitudinal recess axis aligned with each other along row 8063. Shaped recesses 8065A and 8065B include a centerline axis or a transverse recess axis, which is transverse to the centerline axes of recesses 8061A and 8061B and the centerline axes of recesses 8063A and 8063B. The centerline axes of recesses 8065A and 8065B may be substantially parallel to each other. In addition to the above, the proximal leg of one of the nails 8070 is configured to enter the proximal forming recess 8065A, and the distal leg of the nail is configured to enter the distal forming recess 8065B. Forming recesses 8065A and 8065B are configured to guide the legs of the nail 8075 laterally away from the crown of the nail or laterally away from each other (see [link to relevant documentation]). Figure 126 The lateral variation in the width of 2D-shaped and 3D-shaped staples along the suture assembly 8000 relative to the longitudinal axis defined thereof can provide varying tissue compression on the sutured tissue. For example, outer 3D staples can provide less tissue compression compared to inner 2D-shaped staples near the tissue's cutting line.

[0491] like Figure 125 As can be seen, a longitudinal gap is defined between each pair of forming recesses 8061A and 8061B, a longitudinal gap is defined between each pair of forming recesses 8063A and 8063B, and a gap is defined between each pair of forming recesses 8065A and 8065B. The gap defined between forming recesses 8061A and 8061B may be substantially the same as and / or similar to the gap defined between forming recesses 8063A and 8063B. The gap defined between forming recesses 8065A and 8065B is larger than the gap defined between forming recesses 8061A and 8061B and the gap defined between forming recesses 8063A and 8063B. The gap defined between forming recesses 8065A and 8065B may be defined as the space between forming recesses 8065A and 8065B.

[0492] like Figure 127 and Figure 128As can be seen, staple 8070 is shaped into a planar configuration, and staple 8075 is shaped into a non-planar configuration. Staple 8070 includes a crown 8071 and a leg 8072 extending from the crown 8071. The leg 8072 also includes a staple tip portion 8073 configured to pierce tissue and enter a corresponding shaped recess. Staple 8070 defines a shaped compression height "X1", which is the effective height of tissue compression captured by staple 8070. Staple 8075 includes a crown 8076 and a leg 8077 extending from the crown 8076. The leg 8077 also includes a staple tip portion 8078 configured to pierce tissue and enter a corresponding shaped recess. Staple 8075 defines a shaped compression height "X2", which is the effective height of tissue compression captured by staple 8075. Due to the non-planar shaped configuration of staple 8075, the shaped compression height X2 is higher than the shaped compression height X1. In at least one instance, this is desirable, and a gradually decreasing compression is provided as the staple moves laterally away from the cutting line. For example, as the staple moves laterally outward relative to the cutting line, a tighter compression height near the cutting line provides sufficient tissue-sealing pressure, and a looser compression height further away from the cutting line gradually reduces the pressure on the tissue.

[0493] In at least one instance, the legs 8077 are shaped at different angles relative to each other, away from the crown 8076. For example, the proximal leg may be shaped at a first angle away from the crown, and the distal leg may be shaped at a second angle away from the crown in the opposite direction. The first angle is different from the second angle. This allows for a narrower occupancy area of ​​the corresponding nail-shaped recesses. Furthermore, when these recess shapes are stamped into the anvil, the different angles and / or narrower occupancy areas ensure that the walls between the forming recesses in adjacent rows are adequately maintained, which prevents features in one row from seeping into or penetrating features in adjacent rows during the stamping process.

[0494] 3D staples can be mixed within and / or across longitudinal rows, which maximizes the use of the anvil surface and allows for further nesting of recesses and a narrower occupancy area. In some instances, the mixing of 3D staple recesses can improve tissue pressure dispersion along the anvil. In at least one instance, 3D staple recesses can be positioned along the recesses of the outermost row to further reduce and / or gradually decrease tissue pressure along the edge of the staple line furthest from the cutting line.

[0495] In various instances, the gripping feature 8040 and the curved platform 8021 provide laterally varying tissue clearance. More specifically, the clearance for tissue to be captured between the corresponding staple cavity and staple forming recess in each row is different between rows. The outermost row includes the tallest gripping feature compared to the inner and middle rows. This can provide additional tissue compression in the rows in which the 3D staples are configured to be formed. This can provide greater stability during staple forming due to the additional cavity extension length of the outer staple cavity. The taller gripping feature can maintain a similar compression profile between the gripping feature and the corresponding forming recess; however, due to the lateral curvature of the platform, the portion of the platform surface 8021 defining the outer row staple cavity is farther from the anvil than the portions of the platform surface 8021 defining the inner and middle row staple cavities. In combination, in some instances, the taller gripping feature and the lower platform surface can provide a more stable platform for the 3D-formed staples.

[0496] In various instances, flat or stamped nails may be used in addition to or instead of wire nails. In various instances, two of the three rows of nails on each side of the nail cartridge are configured to be formed into a non-planar configuration, while the other row of three rows of nails on that side of the nail cartridge is configured to be formed into a planar configuration. In at least one instance, the nails in the same longitudinal row include both planar and non-planar nails. In at least one instance, the unformed height of the nails within the same row is varied. In at least one instance, the unformed height of the nails in different rows is varied. In at least one instance, the planar and non-planar nails vary along the axis of the longitudinal slot transverse to the nail cartridge to distribute nail pressure. In at least one instance, the legs of the non-planar nails are laterally formed on one side of the crown, rather than in the opposite direction away from each other relative to the crown. In such instances, the row spacing between each row can be substantially similar, at least because the legs, although formed away from the crown during ejection, can be shaped rearward toward the crown to tighten the nail wire. This configuration helps to maintain a consistent lateral row spacing between each row of nail-shaped recesses.

[0497] As discussed above, one or more adjustments can be made to change the final forming height and / or compression height of the nail, as its form can vary, for example, laterally or row by row. Figure 129 An anvil 8100 configured to deform nails ejected from a nail magazine is shown. The anvil 8100 includes an anvil body 8110, which includes an anvil surface 8111 and a firing member slot 8112 defined within the anvil body 8110. The anvil surface 8111 includes a plurality of nail-forming recess rows, including an inner row 8121, a middle row 8123, and an outer row 8125. The inner row 8121 and the middle row 8123 are configured to shape the nail into a planar configuration, and the outer row 8125 is configured to shape the nail into a non-planar configuration. Figure 129As can be seen, the inner row 8121 and the middle row 8123 define a recess depth 8131, and the outer row defines a recess depth 8135 that is shallower than the recess depth 8131. Due to the diagonal forming path of the non-planar nail, this shallower recess depth can accommodate compression loss or the final forming height. In at least one example, the recess depth is adjusted so that the final compression height is the same between non-planar and planar nails. In another example, the recess depth is adjusted so that the final compression height differs between non-planar and planar nails.

[0498] Figure 130 A slider 8200 is shown, comprising an inner ramp 8220 and an outer ramp 8230. The inner ramp is configured to lift the nail to a height 8221, and the outer ramp 8230 is configured to lift the nail to a height 8231. Ramp 8220 is configured to lift the nail to be formed into a planar configuration, and ramp 8230 is configured to lift the nail to be formed into a non-planar configuration. Due to the diagonal forming path of the non-planar nail, the height 8231 can accommodate compression loss or the final forming height.

[0499] Figure 131 A staple 8300 for use with a surgical suture assembly is shown. The staple 8300 includes a first staple 8310 having a first unformed height 8311 and a second staple 8320 having a second unformed height 8321. The first unformed height 8311 is smaller than the second unformed height 8321. The different unformed heights can accommodate compression loss or final formed height due to the diagonal forming path of the non-planar staple. The second staple 8320 can be configured to form a non-planar configuration, while the first staple 8310 can be configured to form a planar configuration.

[0500] Figure 132 and Figure 133 Staples 8410 and 8420 are shown. Staple 8410, shaped as a planar configuration, defines a final compression height 8411, and staple 8420, shaped as a non-planar configuration, defines a final compression height 8421. The final compression height 8421 is less than the compression height 8411; however, staple 8420 defines a distance 8422 defined between the apex and crown of each shaped leg. The distance 8422 may be substantially equal to the final compression height 8411. The distance 8422 may be the effective compression height of staple 8420.

[0501] In various instances, a surgical suturing assembly is provided, configured to overdrive staples from the cartridge. The amount of staple overdrive can vary row by row. In various instances, the staple actuator may include supports of varying amounts from the corresponding cartridge support walls. More specifically, due to the geometry of the cartridge and firing assembly and / or the drive screw therein, the internal staple actuator may be less supported by the cartridge support walls compared to the external staple actuator. In various instances, the tissue spacing can vary row by row while maintaining similar or identical drive distances between rows.

[0502] Figures 134 to 136 A surgical suture assembly 8500 is shown. The surgical suture assembly 8500 includes a lower jaw 8501 and an upper jaw 8502. The lower jaw 8501 includes a cartridge channel 8510 and a staple cartridge 8520 configured to be received within the cartridge channel 8510. The upper jaw 8502 includes an anvil 8530 having an anvil body 8531. The anvil body 8531 includes an anvil surface 8532 and a plurality of staple forming recesses defined in the anvil surface 8532. The anvil surface 8532 includes an inner forming recess 8533, an intermediate forming recess 8534, and an outer forming recess 8535. The staple cartridge includes a plurality of staple cavities 8522, including an inner staple cavity 8522A aligned with the inner forming recess 8533, an intermediate staple cavity 8522B aligned with the intermediate forming recess 8534, and an outer cavity 8522C aligned with the outer forming recess 8534. The nail cavity 8522 is configured to store the corresponding driver and nail, which is to be ejected into the shaped recess aligned with it.

[0503] The staple cartridge 8520 includes a curved cartridge platform 8529, which includes a plurality of staple cavities 8522 defined therein and a plurality of tissue gripping features or cavity extensions 8523, 8524, 8525 extending from the cartridge platform 8529. The staple cartridge 8520 also includes a slider 8550 having ramps 8551, 8552. The staple cartridge 8520 includes a plurality of actuators 8540, which, when lifted by ramps 8551, 8552, are sequentially aligned to eject rows of staples from the staple cavities. Each actuator 8540 includes: an inner row support or inner support column 8541 configured to support and drive nails to be stored in and ejected from an inner nail cavity 8522A; an intermediate row support or intermediate support column 8542 configured to support and drive nails to be stored in and ejected from an intermediate nail cavity 8522B; and an outer row support or outer support column 8543 configured to support and drive nails to be stored in and ejected from an outer nail cavity 8522C.

[0504] like Figure 135As can be seen, the stapling cartridge 8520 includes: an inner support wall 8526A configured to support the inner row support 8541 when the actuator 8540 is lifted by the slider 8550; an intermediate support wall or column 8526B configured to support the intermediate row support 8542 when the actuator 8540 is lifted by the slider 8550; and an outer support wall 8526c configured to support the outer row support 8543 when the actuator 8540 is lifted by the slider 8550. Figure 135 As can be seen, the level of support contact between each support member 8541, 8542, 8543 and its corresponding support walls 8526A, 8526B, 8526C varies row by row. In the unfired position, the outer support member 8541 has the most support contact, the middle support member 8542 has less support contact than the outer support member 8541, and the inner support member 8541 has the least amount of support contact. Figure 135 It can also be seen that supports 8541, 8542, and 8543 are overdriven to the same limit, resulting in the same driving forming distance for each nail supported by supports 8541, 8542, and 8543; however, the amount of overdrive relative to their corresponding gripping features 8523, 8524, and 8525 varies row by row. The outer row is overdriven the most through its gripping features, and the inner row is overdriven the least through its gripping features.

[0505] As discussed herein, the staple cartridge can be replaced within the surgical suture assembly. In various instances, an anvil plate that can also be replaced is provided. In such instances, the anvil plate may be provided with the corresponding staple cartridge, such that the new staple cartridge and anvil plate are packaged together and replaced together within the surgical suture assembly. In such instances, various features of the anvil plate and the corresponding staple cartridge can be specifically adjusted for each other. For example, different anvil plates may include staple forming recesses with different patterns, staple forming recesses with different forming depths, and / or, for example, staple forming recesses of varying rows.

[0506] A universal fitting profile is available for a variety of anvil plates, allowing the suture assembly to accommodate several different anvil plates. Replacement anvil plates can also provide new staple forming recesses. Anvil plates and staple cartridges can be paired based on staple leg length, the type of staples stored in the cartridge, and / or the desired staple forming height. In such examples, anvil jaws configured to receive anvil plates can be manufactured with or without staple forming recesses directly defined thereon. This reduces manufacturing costs because the anvil jaws can be reused in different scenarios, rather than introducing entirely different surgical suturing instruments with different types of forming recesses.

[0507] Figures 137 to 139A surgical suture assembly 8600 is shown, comprising a first jaw 8601 and a second jaw 8603 movable relative to the first jaw 8601 to clamp tissue between them. The surgical suture assembly 8600 is configured to cut and suture tissue captured between the jaws 8601 and 8603. The first jaw 8601 includes a replaceable staple cartridge 8620 configured to removably store a plurality of staples in a plurality of staple cavities 8622 defined in a platform surface 8621 of the cartridge 8620. The first jaw 8601 also includes a cartridge channel 8610 configured to receive the replaceable staple cartridge 8620 therein. As discussed above, various types of staple cartridges can be mounted within the cartridge channel 8610. Various differences between replaceable staple cartridges may include, for example, different unshaped staple leg heights and / or orientations, different cartridge lengths, and / or different staple diameters.

[0508] The second jaw 8603 includes a replaceable anvil plate 8640, which includes an anvil surface 8641 and a plurality of shaped recesses 8642 defined in the anvil surface 8641. The second jaw 8603 also includes an upper anvil jaw portion 8630 configured to receive the replaceable anvil plate 8640 therein. In at least one embodiment, the replaceable anvil plate 8640 slides into a distal end of the anvil jaw portion 8630. In at least one embodiment, the replaceable anvil plate 8640 is configured to engage with the anvil jaw portion 8630. In at least one embodiment, the anvil jaw portion 8630 includes a deformable arm made of a metallic material, for example, hanging from the periphery of the anvil jaw portion 8630. The deformable arm may be configured to deform when the jaws 8601, 8603 are clamped together after the anvil plate 8640 has been positioned. Upon reaching the fully clamped position, the deformable arm deforms and, in its deformed configuration, is configured to grip and hold the anvil plate 8640 to the anvil jaw portion 8630. In at least one embodiment, the clamping member is configured to be clamped by jaws 8601, 8603 to secure the anvil plate 8640 to the anvil jaw portion 8630. In such embodiments, the clamping member is responsible for deforming the deformable arm. After the anvil plate 8640 is secured to the anvil jaw portion 8630, the clamping member can be removed and discarded before the use of the surgical suture assembly 8600. In at least one embodiment, the deformable member is part of the anvil plate 8630 and is configured to be secured to the anvil jaw portion 8630.

[0509] In at least one embodiment, the anvil cap is configured to be positioned on the distal end of the anvil jaw portion 8630. The anvil cap is configured to secure the anvil plate 8640 to the anvil jaw portion 8630. In at least one embodiment, the anvil plate 8640 slides into the anvil jaw portion 8630 and, without the anvil cap, can only be removed by pulling the anvil plate 8640 distally from the distal end of the anvil jaw portion 8630. This type of anvil cap secures the anvil plate 8640 to the distal end of the anvil jaw portion 8630. In at least one embodiment, the distal end of the anvil jaw portion 8630 includes threads, and the anvil cap includes corresponding threads configured to thread onto the threads on the distal end of the anvil jaw portion 8630 to secure the anvil cap to the anvil jaw portion 8630. In at least one embodiment, the anvil cap comprises a polymer material. In at least one instance, the anvil cap engages with the distal end of the anvil jaw portion 8630 and disengages from the distal end of the anvil jaw portion 8630 to replace the anvil plate 8640. In various instances, the user can install and remove the anvil cap. In other instances, specific tools are required to install the anvil cap and / or remove it from the anvil jaw portion 8630. In at least one instance, the specific tool is equipped with a replaceable anvil plate 8640 and / or a replaceable staple cartridge 8620. As discussed above, the replaceable anvil plate and replaceable staple cartridge may appear together as a single replaceable unit to be installed within a surgical suture assembly. In various instances, the user can mix and match the anvil plate and replaceable staple cartridge to adjust, f...

Claims

1. A surgical suture assembly, comprising: Anvil; A storage channel, the storage channel being configured to receive staple cartridges within the storage channel; as well as The firing assembly includes: firing mechanism; and A firing drive screw, wherein the firing member is threadedly connected to the firing drive screw, and wherein rotation of the firing drive screw is configured to enable longitudinal movement of the firing member within the surgical suture assembly; and Mounting member, the mounting member being configured to support the firing drive screw within the chamber channel, wherein the mounting member is configured to allow the firing drive screw to float relative to the chamber channel within a limited vertical floating range; The mounting member defines a cavity including an upper stop and a lower stop, the upper stop and the lower stop defining the limited vertical floating range of the firing drive screw between the upper stop and the lower stop.

2. The surgical suture assembly according to claim 1, wherein, The firing component includes: Upper flange, the upper flange being configured to engage the anvil; and The lower flange is configured to engage the chamber channel, wherein the upper flange and the lower flange define the limited vertical floating range of the firing drive screw.

3. The surgical suture assembly according to claim 1, wherein, The firing member includes a drive nut cutout, wherein the drive nut cutout defines the limited vertical floating range.

4. The surgical suture assembly according to claim 1, wherein, The chamber passage includes a proximal end portion and a distal end portion, wherein the firing drive screw is mounted in the chamber passage at the proximal end portion and the distal end portion, and wherein the mounting member is positioned at the distal end portion.

5. The surgical suture assembly according to claim 4, wherein, The mounting component includes a first mounting component, wherein the compartment channel further includes a second mounting component positioned at the proximal end portion, and wherein the second mounting component includes a ball joint mounting component.

6. The surgical suture assembly of claim 1, further comprising a biasing member configured to bias the firing drive screw toward a neutral position within the mounting.

7. The surgical suture assembly according to claim 1, wherein, The mounting element includes a recessed flange and a clamp.

8. The surgical suture assembly according to claim 1, wherein, The firing drive screw includes a proximal end and a distal end, wherein the distal end is forged.

9. The surgical suture assembly of claim 1, further comprising the staple cartridge, the staple cartridge including a plurality of staples.

10. The surgical suture assembly of claim 1, wherein, The limited vertical float range includes a range between approximately 0.0002 inches and approximately 0.0003 inches.

11. The surgical suture assembly according to claim 1, wherein, The limited vertical float range includes a range of approximately 0.0001 inches.

12. A surgical end effector assembly, comprising: The surgical suture assembly according to claim 1; First jaws; The second jaw is movable relative to the first jaw; The firing assembly includes: The firing member includes: Upper flange, the upper flange being configured to engage the anvil; and Lower flange, the lower flange being configured to engage the compartment channel; and The firing drive screw includes a rotary drive screw, wherein rotation of the firing drive screw is configured to enable longitudinal movement of the firing member within the surgical end effector assembly through a firing stroke, and wherein the mounting is configured to allow the firing drive screw to float vertically relative to the mounting as the firing member is advanced through the firing stroke.

13. The surgical end effector assembly of claim 12, wherein, The upper flange and the lower flange define a limited vertical floating range.

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