Surgical stapler end effector sled with cartridge biasing feature - Patents.com

Abstract

A staple driver actuator for a staple cartridge of a surgical stapler includes a base having at least one bottom surface. The bottom surface defines a plane, and the base defines a longitudinal centerline. The base is configured to slide longitudinally relative to the staple cartridge. The staple driver actuator also includes at least one biasing member. The biasing member is positioned laterally outward relative to the longitudinal centerline of the base. The biasing member is configured to exert a biasing force on a portion of the staple cartridge in a direction toward the longitudinal centerline of the base.

Description

[Background technology]

[0001] Examples of surgical instruments include surgical staplers, which may be configured for use in laparoscopic and / or open surgical procedures. Some such staplers are operable to clamp tissue layers, cut the clamped tissue layers, and drive staples through the tissue layers to substantially seal the cut tissue layers to one another near the cut ends of the tissue layers. Examples of surgical staplers are disclosed in U.S. Pat. No. 7,404,508, entitled "Surgical Stapling and Cutting Device," issued July 29, 2008; U.S. Pat. No. 7,434,715, entitled "Surgical Stapling Instrument Having Multistroke Firing with Opening Lockout," issued October 14, 2008; U.S. Pat. No. 7,721,930, entitled "Disposable Cartridge with Adhesive for Use with a Stapling Device," issued May 25, 2010; U.S. Pat. No. 8,408,439, entitled "Surgical Stapling Instrument with An Articulatable End Effector," issued April 2, 2013; and U.S. Pat. No. 8,453,914, entitled "Motor-Driven Surgical Cutting Instrument with Electric Actuator Directional Control Assembly," issued June 4, 2013. The disclosure of each of the above-cited US patents is incorporated herein by reference in its entirety.

[0002] While many different types of surgical stapling instruments and related components have been made and used, it is believed that no one prior to the present inventors has made or used the invention as set forth in the appended claims. [Brief explanation of the drawings]

[0003] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the invention. [Figure 1] FIG. 1 illustrates a perspective view of an example of an articulating surgical stapling instrument. [Figure 2] 2 depicts a side view of the device of FIG. 1; [Figure 3] 2 depicts a perspective view of an open end effector of the instrument of FIG. 1; [Figure 4A] 4 depicts a side cross-sectional view of the end effector of FIG. 3 taken along line 4-4 of FIG. 3 with the firing beam in a proximal position. [Figure 4B] 4 depicts a side cross-sectional view of the end effector of FIG. 3 taken along line 4-4 of FIG. 3 with the firing beam in a distal position. [Figure 5] 5 depicts a cross-sectional end view of the end effector of FIG. 3 taken along line 5-5 of FIG. 3. [Figure 6] 4 depicts an exploded perspective view of the end effector of FIG. 3; [Figure 7] 4 depicts a perspective view of the end effector of FIG. 3 after being positioned in tissue and actuated once within the tissue. [Figure 8] 1 depicts a perspective view of an embodiment of a wedge-shaped sled for actuating the staple driver of the instrument of FIG. 1, showing the wedge-shaped sled having cartridge wall support features and multiple surface finishes; [Figure 9] 9 depicts a side view of the wedge-shaped sled of FIG. 8. [Figure 10] 9 depicts a cross-sectional end view of the end effector of FIG. 3 with the wedge-shaped sled of FIG. 8 captured between a cartridge body and a cartridge tray of the staple cartridge of the end effector. [Figure 11]FIG. 10 depicts a perspective view of another embodiment of a wedge-shaped sled for actuating the staple driver of the instrument of FIG. 1, showing the wedge-shaped sled having a cartridge wall support feature, a staple driver support feature, a tapered distal end, and multiple surface finishes. [Figure 12] 12 depicts a side view of the wedge-shaped sled of FIG. 11. [Figure 13] 12 depicts a cross-sectional end view of the end effector of FIG. 3 with the wedge-shaped sled of FIG. 11 captured between a cartridge body and a cartridge tray of the staple cartridge of the end effector. [Figure 14A] 11 depicts a side cross-sectional view of the end effector of FIG. 3 with the wedge-shaped sled of FIG. 11 captured between the cartridge body and cartridge tray of the staple cartridge of the end effector, showing the wedge-shaped sled in a proximal position. [Figure 14B] 11 depicts a side cross-sectional view of the end effector of FIG. 3 with the wedge-shaped sled of FIG. 11 captured between the cartridge body and cartridge tray of the staple cartridge of the end effector, showing the distal chamfer of the wedge-shaped sled partially lifting the corresponding staple driver during distal translation of the wedge-shaped sled. [Figure 14C] 11 depicts a side cross-sectional view of the end effector of FIG. 3 with the wedge-shaped sled of FIG. 11 captured between the cartridge body and cartridge tray of the staple cartridge of the end effector, showing the top surface of the base of the wedge-shaped sled, which vertically supports the corresponding staple driver during distal translation of the wedge-shaped sled. [Figure 14D] 11 depicts a side cross-sectional view of the end effector of FIG. 3 with the wedge-shaped sled of FIG. 11 captured between the cartridge body and cartridge tray of the staple cartridge of the end effector, showing the cam surface of the sled rail of the wedge-shaped sled fully lifting the corresponding staple driver during distal translation of the wedge-shaped sled. [Figure 15]FIG. 4 depicts a cross-sectional end view of the end effector of FIG. 3 with another exemplary wedge-shaped sled captured between the cartridge body and cartridge tray of the staple cartridge of the end effector, showing the wedge-shaped sled having toe-in inner and outer sled rails and undercuts. [Figure 16] FIG. 4 depicts a cross-sectional end view of the end effector of FIG. 3 with another exemplary wedge-shaped sled captured between the cartridge body and cartridge tray of the staple cartridge of the end effector, showing the wedge-shaped sled having toe-in inner and outer sled rails. [Figure 17] FIG. 4 depicts a cross-sectional end view of the end effector of FIG. 3 with another exemplary wedge-shaped sled captured between the cartridge body and cartridge tray of the staple cartridge of the end effector, showing the wedge-shaped sled having toe-in inner sled rails. [Figure 18] 1 depicts a cross-sectional view of another exemplary wedge-shaped sled having a V-shaped base. [Figure 19] 1 depicts a cross-sectional view of another exemplary wedge-shaped sled having a bifurcated central nose. [Figure 20] 4 depicts a cross-sectional end view of the end effector of FIG. 3 with an exemplary staple cartridge removably installed within a channel in the lower jaw of the end effector, showing the staple cartridge having various biasing features; [Figure 21] FIG. 4 depicts a cross-sectional end view of the end effector of FIG. 3 with an exemplary staple cartridge removably installed within a channel in the lower jaw of the end effector, showing that the staple cartridge has a cartridge tray with protrusions for reducing a tissue gap between the upper deck of the staple cartridge and the inner surface of the anvil.

[0004] The drawings are not intended to be limiting in any manner, and it is contemplated that various embodiments of the invention may be embodied in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the invention and, together with the description, serve to explain the principles of the invention, it being understood, however, that the invention is not limited to the precise configurations shown. DETAILED DESCRIPTION OF THE INVENTION

[0005] The following description of specific examples of the present invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the present invention will become apparent to those skilled in the art from the following description, which is by way of example only one of the best modes contemplated for carrying out the invention. As will be understood, the present invention is capable of other different and obvious aspects, all without departing from the present invention. Accordingly, the drawings and description should be regarded as illustrative in nature, and not as restrictive.

[0006] I. Exemplary Surgical Stapler 1-7 illustrate an example of a surgical stapling and severing instrument 10 sized for insertion through a trocar cannula, thoracotomy, or other incision in a non-articulated state as shown in FIG. 1 to a surgical site in a patient to perform a surgical procedure. The instrument 10 in this example includes a handle portion 20 connected to a shaft 22. The shaft 22 terminates distally in an articulation joint 11, which is further coupled to an end effector 12. It should be understood that the terms "proximal" and "distal" are used herein with reference to a clinician grasping the handle portion 20 of the instrument 10. Thus, the end effector 12 is distal to the more proximal handle portion 20.

[0007] Once the articulation joint (11) and end effector (12) are inserted into the patient, the articulation joint (11) can be remotely articulated by the articulation control (13), as depicted in phantom in FIG. 1, so that the end effector (12) can be deflected to a desired angle (α) from the longitudinal axis (LA) of the shaft (22). By way of example only, articulation joint 11 and / or articulation control 13 may be constructed and operative in accordance with at least part of the teachings of U.S. Patent No. 9,186,142, entitled "Surgical Instrument End Effector Articulation Drive with Pinion and Opposing Racks," issued November 17, 2015, the disclosure of which is incorporated herein by reference in its entirety, and / or U.S. Patent No. 9,795,379, entitled "Surgical Instrument with Multi-Diameter Shaft," issued October 24, 2017, the disclosure of which is incorporated herein by reference in its entirety. Other suitable forms that articulation joint 11 and articulation control 13 may take will be apparent to those skilled in the art in view of the teachings herein.

[0008] The end effector 12 of this example includes a lower jaw 16 and an upper jaw in the form of a pivotable anvil 18. By way of example only, the lower jaw 16 may be constructed and operative in accordance with at least some of the teachings of U.S. Pat. No. 9,808,248, issued November 7, 2017, entitled "Installation Features for Surgical Instrument End Effector Cartridge," the disclosure of which is incorporated herein by reference in its entirety. The anvil 18 may be constructed and operative in accordance with at least some of the teachings of U.S. Pat. No. 10,092,292, issued October 9, 2018, entitled "Staple Forming Features for Surgical Stapling Instrument," the disclosure of which is incorporated herein by reference in its entirety. Other suitable forms that the lower jaw 16 and anvil 18 may take will be apparent to those skilled in the art in view of the teachings herein.

[0009] The handle portion 20 includes a pistol grip 24 and a closure trigger 26. The closure trigger 26 is pivotable toward the pistol grip 24 to clamp or close the anvil 18 toward the lower jaw 16 of the end effector 12. Such closure of the anvil 18 is effected via a closure tube 32 and a closure ring 33, both of which translate longitudinally relative to the handle portion 20 in response to pivoting of the closure trigger 26 relative to the pistol grip 24. The closure tube 32 extends along the length of the shaft 22, and the closure ring 33 is positioned distal to the articulation joint 11. The articulation joint 11 is operable to transfer longitudinal movement from the closure tube 32 to the closure ring 33.

[0010] The handle portion (20) also includes a firing trigger (28). An elongate member (not shown) extends longitudinally through the shaft (22) and transfers longitudinal firing motion from the handle portion (20) to the firing beam (14) in response to actuation of the firing trigger (28). As described in further detail below, this distal translation of the firing beam (14) effects stapling and severing of tissue clamped within the end effector (12). The triggers (26, 28) can then be released, releasing the tissue from the end effector (12).

[0011] As best seen in FIGS. 4A and 4B , the firing beam (14) of this embodiment includes a transversely oriented upper pin (38), a firing beam cap (44), a transversely oriented middle pin (46), and a distally presented cutting edge (48). The upper pin (38) is positioned within a longitudinal anvil slot (42) of the anvil (18) and is translatable within the longitudinal anvil slot (42). The firing beam cap (44) slidably engages the underside of the lower jaw (16) by having the firing beam (14) extend through a lower jaw slot (45) (shown in FIG. 4B ) formed through the lower jaw (16). The middle pin (46) slidably engages the upper side of the lower jaw (16) in cooperation with the firing beam cap (44). This allows the firing beam (14) to reliably space the end effector (12) during firing. By way of example only, firing beam (14) and / or associated lockout features may be constructed and operative in accordance with at least some of the teachings of U.S. Patent No. 9,717,497, entitled "Lockout Feature for Movable Cutting Member of Surgical Instrument," issued August 1, 2017, the disclosure of which is incorporated herein by reference. Other suitable forms that firing beam (14) may take will be apparent to those skilled in the art in view of the teachings herein.

[0012] Figure 3 shows the firing beam (14) of this embodiment positioned proximally and the anvil (18) pivoted to an open position to allow an unused staple cartridge (37) to be removably loaded into the channel of the lower jaw (16). As best seen in Figures 5 and 6, the staple cartridge (37) of this embodiment includes a cartridge body (70) that presents an upper deck (72) and is coupled to a lower cartridge tray (74). As best seen in Figure 3, a vertical slot (49) is formed through a portion of the staple cartridge (37). Three rows of staple openings (51) are formed through the upper deck (72) on one side of the vertical slot (49), and another set of three rows of staple openings (51) are formed through the upper deck (72) on the other side of the vertical slot (49). Of course, any other suitable number of rows of staples (e.g., two rows, four rows, etc.) may be provided. 4A-6, the wedge-shaped sled 41 and the plurality of staple drivers 43 are captured between the cartridge body 70 and the tray 74, with the wedge-shaped sled 41 positioned proximal to the staple drivers 43 when the staple cartridge 37 is in a pre-fired (or "unfired") state. The wedge-shaped sled 41 is longitudinally movable within the staple cartridge 37, while the staple drivers 43 are vertically movable within the staple cartridge 37. The staples 47 are also positioned within the cartridge body 70 above their corresponding staple drivers 43. Specifically, each staple 47 is driven vertically within the cartridge body 70 by the staple driver 43 to drive the staple 47 out of an associated staple opening 51. As best seen in Figures 4A and 4B, and Figure 6, wedge-shaped sled (41) presents an inclined cam surface that urges staple driver (43) upward as wedge-shaped sled (41) is driven distally through staple cartridge (37).

[0013] By way of example only, staple cartridge (37) may be constructed and operative in accordance with at least a portion of the teachings of U.S. Patent No. 9,517,065, entitled "Integrated Tissue Positioning and Jaw Alignment Features for Surgical Stapler," issued December 13, 2016, the disclosure of which is incorporated herein by reference in its entirety. Other suitable forms that staple cartridge (37) may take will be apparent to those skilled in the art in view of the teachings herein.

[0014] As shown in Figures 4A and 4B, when the end effector 12 is closed by distally advancing the closure tube 32 and closure ring 33, the firing beam 14 advances and the upper pin 38 enters the longitudinal anvil slot 42, thereby engaging the anvil 18. A pusher block 80 (shown in Figure 5) is located at the distal end of the firing beam 14 and is configured to engage the wedge-shaped sled 41 such that the wedge-shaped sled 41 is pushed distally by the pusher block 80 as the firing beam 14 advances distally through the staple cartridge 37 upon actuation of the firing trigger 28. During such firing, the cutting edge 48 of the firing beam 14 enters the vertical slot 49 of the staple cartridge 37, severing the tissue clamped between the staple cartridge 37 and the anvil 18. As shown in FIGS. 4A and 4B, the middle pin 46 and pusher block 80 together actuate the staple cartridge 37 by entering the vertical slot 49 therein, driving the wedge-shaped sled 41 into upward camming contact with the staple driver 43, which forces the staple 47 out of the staple opening 51 and into forming contact with the staple-forming pockets 53 (shown in FIG. 3) on the inner surface of the anvil 18. FIG. 4B shows the firing beam 14 fully translated distally after the tissue has been severed and stapled. It should be understood that the staple-forming pockets 53 have been intentionally omitted from the views of FIGS. 4A and 4B, but that the staple-forming pockets 53 are shown in FIG. 3. It should also be understood that the anvil 18 has been intentionally omitted from the view of FIG. 5.

[0015] FIG. 7 shows the end effector 12 actuated with a single stroke through layers L1, L2 of tissue T. As shown, the cutting edge 48 (hidden in FIG. 7) cuts the tissue T, while the staple driver 43 drives three alternating rows of staples 47 through the tissue T on each side of the cut line created by the cutting edge 48. In this example, all of the staples 47 are oriented substantially parallel to the cut line, although it should be understood that the staples 47 may be positioned in any suitable orientation. In this example, after the first stroke is completed, the end effector 12 is withdrawn from the trocar or incision, the spent staple cartridge 37 is replaced with a new staple cartridge, and the end effector 12 is then reinserted through the trocar or incision to reach the stapling site and perform additional cutting and stapling. This process may be repeated until the desired number of cuts and staples 47 have been applied. The anvil 18 may need to be closed to facilitate insertion and removal through the trocar, and may need to be opened to facilitate replacement of the staple cartridge 37.

[0016] In some variations, the instrument 10 provides motorized control of the firing beam 14. By way of example only, such motorization may be provided in accordance with at least some of the teachings of U.S. Pat. No. 9,622,746, entitled "Distal Tip Features for End Effector of Surgical Instrument," issued April 18, 2017, the disclosure of which is incorporated herein by reference in its entirety, and / or U.S. Pat. No. 8,210,411, entitled "Motor-Driven Surgical Instrument," issued July 3, 2012, the disclosure of which is incorporated herein by reference in its entirety. Other suitable components, features, and configurations for providing motorization of the firing beam 14 will be apparent to those skilled in the art in view of the teachings herein. It should also be understood that in some other variations, manual drive of the firing beam 14 may be provided such that a motor may be omitted.

[0017] II. Exemplary Sleds with Cartridge Wall Support Features and Multiple Surface Finishes In some cases, it may be desirable to provide a wedge-shaped sled configured to provide rigidity to the staple cartridge (37) by supporting and / or stabilizing the wall of the cartridge body (70) adjacent to the wedge-shaped sled, thereby promoting alignment between the staple openings (51) and the corresponding staple-forming pockets (53) during clamping and / or firing of tissue between the staple cartridge (37) and the anvil (18). Additionally or alternatively, it may be desirable to provide a wedge-shaped sled with multiple distinct surface finishes (also referred to as "surface textures" or "surface topographies"). Such multiple distinct surface finishes may enable a wedge-shaped sled manufactured via a process that imparts an initial, relatively rough surface finish to the surface of the entire wedge-shaped sled to have selected surfaces that are provided with a final, relatively smooth surface finish so that the selected surfaces may smoothly interact with corresponding portions of the staple cartridge (37), such as the staple drivers (43). Figures 8-10 show an exemplary wedge-shaped sled (110) that provides such functionality. Wedge sled (110) is similar to wedge sled (41) described above, except as otherwise described below. For example, wedge sled (110) occupies the same amount of longitudinal space within staple cartridge (37) as wedge sled (41), making wedge sled (110) substantially interchangeable with wedge sled (41).

[0018] The wedge-shaped sled (110) of this example comprises a base including a base platform (112) and a central raised platform (114) extending upwardly from the base platform (112). In the illustrated example, the base platform (112) has a substantially flat bottom surface (116) that defines a horizontal plane and is configured to slide longitudinally along the tray (74) during longitudinal movement of the wedge-shaped sled (110) through the staple cartridge (37). The base platform (112) also has a pair of laterally opposed substantially flat top surfaces (118) that are parallel to the bottom surface (116), and the raised platform (114) similarly has a pair of laterally opposed substantially flat top surfaces (120) that are parallel to the bottom surface (116). As best shown in FIG. 10 , top surfaces (118, 120) are configured to face and / or slidably contact or otherwise engage the respective bottom surfaces of corresponding walls (71) of cartridge body (70), thereby vertically supporting corresponding walls (71) during longitudinal movement of wedge-shaped sled (110) through staple cartridge (37).

[0019] The base of this variation also includes a lower chamfer (122) that slopes upward and distally from the distal end of the bottom surface (116) to the outer and inner distal ends of the base platform (112), a pair of outer upper chamfers (124) that slope downward and distally from the respective distal ends of the top surface (118) of the base platform (112) to the outer distal end of the base platform (112), and a pair of inner upper chamfers (126) that slope downward and distally from the respective distal ends of the top surface (120) of the raised platform (114) to the inner distal end of the base platform (112). The chamfers (122, 124, 126) may also be referred to as "tapered surfaces" or "bevels." The lower chamfers (122) may extend across the width of the base platform (112) and may have a length that is greater than the thickness of the base platform (112) (e.g., between the bottom surface (116) and either top surface (118)). Similarly, the outer upper chamfers (124) may each have a length that is greater than the thickness of the base platform (112). The lower chamfers (122) may be configured to facilitate unimpeded longitudinal movement of the wedge-shaped sled (110) through the staple cartridge (37) in the distal direction by reducing the likelihood that the distal end of the base platform (112) will catch on or otherwise be obstructed by the tray (74). For example, lower chamfer (122) may bias tray (74) (which may be constructed of a flexible material) slightly downward and away from the bottom surface of wall (71) of cartridge body (70) as wedge-shaped sled (110) is driven distally through staple cartridge (37). In some variations, any one or more of chamfers (122, 124, 126) may be omitted. For example, any one or more of chamfers (122, 124, 126) may be replaced by one or more respective fillets.

[0020] The wedge-shaped sled (110) further includes a pair of laterally opposed outer sled rails (130) extending upward from the base platform (112) and a pair of laterally opposed inner sled rails (132) extending upward from both the base platform (112) and the raised platform (114). The sled rails (130, 132) may also be referred to as "cam ramps" or "cam wedges." The sled rails (130, 132) of this variation extend substantially straight and upright from the upper surfaces (118, 120) of the base platform (112) and the raised platform (114), respectively, so that the sled rails (130, 132) are oriented perpendicular to the horizontal plane and parallel to the vertical longitudinal plane. In the illustrated embodiment, the inner sled rails 132 are laterally spaced apart from the adjacent outer sled rails 130 to define the upper surface 118 of the base platform 112. In this regard, the upper surface 118 of the base platform 112 each extends at least partially along the length of the sled rails 130, 132, and the upper surface 120 of the raised platform 114 each extends at least partially along the length of the respective inner sled rail 132. In this variation, the outer sled rails 130 each have a first height relative to the bottom surface 116 of the base platform 112, while the inner sled rails 132 each have a second height relative to the bottom surface 116 of the base platform 112 that is less than the first height. Also, in the illustrated embodiment, the outer and inner thread rails (130, 132) each terminate proximally at the same longitudinal position (e.g., at the proximal end of the base platform (112)), while the outer thread rails (130) each terminate distally at a first longitudinal position and the inner thread rails (132) each terminate distally at a second longitudinal position that is distal to the first longitudinal position, such that the outer thread rails (130) each have a first length and the inner thread rails (132) each have a second length that is longer than the first length.Thus, the distal ends of the outer thread rails (130) are aligned longitudinally with one another, and the distal ends of the inner thread rails (132) are aligned longitudinally with one another and offset from the distal ends of the outer thread rails (130).

[0021] As best shown in FIG. 10 , thread rails (130, 132) are configured to be received within corresponding longitudinally extending slots (73) in cartridge body (70) and to slidably contact or otherwise engage respective sides of corresponding walls (71) of cartridge body (70), thereby horizontally stabilizing walls (71) during longitudinal movement of wedge-shaped sled (110) through staple cartridge (37). For example, outer and inner thread rails (130, 132) may inhibit lateral inward and / or lateral outward deflection (e.g., bending) of walls (71). In this regard, thread rails (130, 132) may each have a thickness equal to or slightly less than the width of the corresponding slot (73). In some variations, the sled rails (130, 132) may additionally or alternatively be configured to slidably contact or otherwise engage the respective upper slot surfaces of the corresponding slots (73) in the cartridge body (70), thereby vertically supporting the upper deck (72) during longitudinal movement of the wedge-shaped sled (110) through the staple cartridge (37).

[0022] Each thread rail (130, 132) of the wedge-shaped sled (110) exhibits one or more respective inclined cam surfaces (140, 142, 144, 146) for lifting the staple driver (43) upward as the wedge-shaped sled (110) is driven distally through the staple cartridge (37) to drive the corresponding staple (47) out through the corresponding staple opening (51). In the illustrated embodiment, each outer thread rail (130) includes a front cam surface (140) oriented at a first angle relative to the horizontal plane defined by the bottom surface (116) and a rear cam surface (142) oriented at a second angle relative to the horizontal plane, such that the outer thread rails (130) have the same side elevational profiles as one another. Similarly, each inner sled rail (132) includes a front camming surface (144) oriented at a first angle relative to the horizontal and a rear camming surface (146) oriented at a third angle relative to the horizontal, such that the inner sled rails (132) have side elevation profiles that are the same as each other and different from the side elevation profiles of the outer sled rails (130). Thus, the wedge-shaped sled (110) can be substantially symmetrical about a vertical longitudinal plane, at least with respect to the configuration of the sled rails (130, 132).

[0023] In this variation, the first angle is greater than the second angle, which is greater than the third angle. Alternatively, any other suitable relative angles may be used. In the illustrated embodiment, the top chamfers (124, 126) are also oriented at a first angle relative to the horizontal plane, such that each front cam surface (140) of the outer sled rail (130) is seamlessly continuous with (and has an overlapping side elevation profile with) its respective outer top chamfer (124) so ​​as to collectively define a single, continuous surface, and each front cam surface (144) of the inner sled rail (132) is seamlessly continuous with (and has an overlapping side elevation profile with) its respective inner top chamfer (126) so as to collectively define another, single, continuous surface.

[0024] The wedge-shaped sled (110) further includes a central nose (150) that extends upward from the raised platform (114) between the inner sled rails (132) and also extends distally from both the raised platform (114) and the base platform (112) to a distal tip (152). In the illustrated embodiment, the central nose (150) is spaced laterally from each inner sled rail (132) so as to define the upper surface (120) of the raised platform (114). More specifically, the central nose (150) is spaced equally apart from the inner sled rails (132). The central nose (150) of this variation includes a lower portion (154) extending distally from both the base platform (112) and the raised platform (114) to the distal tip (152), and an upper portion (156) extending upwardly from both the raised platform (114) and the lower portion (154).

[0025] As best shown in FIG. 9 , the lower portion (154) of the central nose (150) of this variation includes a tapered bottom surface (160) that slopes downwardly and proximally from the distal tip to the lower chamfer (122) of the base platform (112). The tapered bottom surface (160) may be configured to facilitate unimpeded longitudinal movement of the wedge-shaped sled (110) through the staple cartridge (37) in the distal direction by reducing the likelihood that the distal tip (152) will catch on or otherwise be obstructed by the tray (74). For example, as the wedge-shaped sled (110) is driven distally through the staple cartridge (37), the tapered bottom surface (160) may bias the tray (74) (which may be constructed of a flexible material) slightly downward and away from the bottom surface of the wall (71) of the cartridge body (70). In the illustrated embodiment, the tapered bottom surface (160) is oriented at the same angle as the lower chamfer (122) relative to the horizontal plane defined by the bottom surface (116), such that the tapered bottom surface (160) seamlessly continues with the lower chamfer (122) so that they collectively define a single, continuous chamfer to further facilitate unimpeded longitudinal movement of the wedge-shaped sled (110) distally through the staple cartridge (37). In some variations, the tapered bottom surface (160) may be omitted. For example, the tapered bottom surface (160) may be replaced by one or more respective fillets.

[0026] The upper portion (156) of the central nose (150) of this variation is substantially perpendicular to the horizontal plane defined by the bottom surface (116). As shown, the upper portion (156) extends longitudinally from the proximal end of the raised platform (114) to the distal tip (152), such that the upper portion (156) is positioned at least partially distal to the distal end of the base platform (112) and to the distal ends of the sled rails (130, 132), and the upper portion (156) extends at least partially along the length of each sled rail (130, 132).

[0027] In the illustrated embodiment, the lower portion (154) of the central nose (150) extends laterally outward relative to the upper portion (156) on either side of the upper portion (156) to define a pair of laterally opposed, upwardly facing ledges (162) that extend longitudinally from the upper surface (120) of each of the raised platforms (114) to the distal tip (152). More specifically, the ledges (162) are substantially flat, parallel to the horizontal plane defined by the bottom surface (116), and positioned flush with the upper surface (120) of each of the raised platforms (114) relative to the bottom surface (116) such that the ledges (162) are seamlessly continuous with the upper surface (120) of each of the raised platforms (114), collectively defining a single, continuous surface for each. As shown, each ledge (162) is positioned at least partially distal to the distal end of the base platform (112) and to the distal ends of the sled rails (130, 132).

[0028] As best shown in FIG. 10 , central nose (150) is configured to be at least partially received within vertical slot (49) of staple cartridge (37). In some variations, central nose (150) is configured to slidably contact or otherwise engage inner wall (71) of cartridge body (70), thereby vertically supporting and / or horizontally stabilizing inner wall (71) during longitudinal movement of wedge-shaped sled (110) through staple cartridge (37). In this regard, ledge surface (162) of this variation faces and slidably contacts or otherwise engages the underside of each of inner walls (71), thereby vertically supporting inner wall (71) during longitudinal movement of wedge-shaped sled (110) through staple cartridge (37). Additionally, upper portion (156) of this variation slidably contacts or otherwise engages the laterally inward surface of inner wall (71), thereby horizontally stabilizing inner wall (71) during longitudinal movement of wedge-shaped sled (110) through staple cartridge (37). For example, upper portion (156) may prevent laterally inward deflection (e.g., bending) of inner wall (71). In this regard, upper portion (156) may have a thickness equal to or slightly less than the width of vertical slot (49), while lower portion (154) may have a thickness greater than the width of vertical slot (49).

[0029] Because each ledge (162) of central nose (150) is positioned at least partially distal to the distal ends of thread rails (130, 132), ledges (162) can vertically support inner wall (71) of cartridge body (70) at a longitudinal position distal to thread rails (130, 132) during longitudinal movement of wedge-shaped sled (110) through staple cartridge (37). Similarly, because top portion (156) is positioned at least partially distal to the distal ends of thread rails (130, 132), top portion (156) can horizontally stabilize inner wall (71) of cartridge body (70) at a longitudinal position distal to thread rails (130, 132) during longitudinal movement of wedge-shaped sled (110) through staple cartridge (37). In this manner, central nose (150) can provide vertical support and / or horizontal stability to cartridge body (70) at a longitudinal position along the length of cartridge body (70) corresponding to each staple opening (51) before (e.g., at least immediately before) the corresponding threaded rails (130, 132) lift the corresponding staple driver (43) to drive the corresponding staple (47) out through the staple opening (51). By providing vertical support and / or horizontal stability to cartridge body (70) at such longitudinal position before lifting the staple driver (43) to drive the staple (47) out through the staple opening (51) at such longitudinal position, central nose (150) can facilitate proper alignment of each staple opening (51) with a corresponding staple-forming pocket (53) on the inner surface of anvil (18) prior to deploying and forming each staple (47).For example, the central nose (150) may promote vertical and / or angular alignment of each staple opening (51) with the corresponding staple forming pocket (53) by helping to maintain the upper deck (72) substantially parallel to the inner surface of the anvil (18) having the staple forming pockets (53) thereon, and / or by preventing lateral deflection of the inner wall (71) that may otherwise cause the staple openings (51) to tilt (e.g., laterally inward or laterally outward) relative to the corresponding staple forming pocket (53).

[0030] Furthermore, because the upper surfaces (118, 120) of the base platform (112) and the raised platform (114) each extend at least partially along the length of the respective threaded rails (130, 132), the upper surfaces (118, 120) can vertically support the corresponding walls (71) of the cartridge body (70) at the same longitudinal locations where the threaded rails (130, 132) are located during longitudinal movement of the wedge-shaped sled (110) through the staple cartridge (37). In this manner, the base platform (112) and / or the raised platform (114) can provide vertical support to the cartridge body (70) at longitudinal locations corresponding to each staple opening (51) along the length of the cartridge body (70) at substantially the same time (e.g., during at least a portion of the duration) that the corresponding threaded rails (130, 132) lift the corresponding staple drivers (43) and drive the corresponding staples (47) out through the staple openings (51).

[0031] By providing vertical support to cartridge body 70 in such a longitudinal position, substantially simultaneously elevating staple drivers 43 to drive staples 47 out through staple openings 51, base platform 112 and / or raised platform 114 can promote proper alignment of each staple opening 51 with a corresponding staple forming pocket 53 on the inner surface of anvil 18 while deploying and forming each staple 47. For example, base platform 112 and / or raised platform 114 can promote vertical and / or angular alignment of each staple opening 51 with a corresponding staple forming pocket 53 by helping to maintain upper deck 72 substantially parallel to the inner surface of anvil 18, which has staple forming pockets 53 thereon. Because the upper surface (120) of the raised platform (114) is seamlessly continuous with each ledge surface (162), the central nose (150) and the raised platform (114) can cooperate to promote continuous proper alignment of each staple opening (51) with a corresponding staple forming pocket (53) on the inner surface of the anvil (18) from at least immediately prior to the deployment and formation of each staple (47) until the completion of the deployment and formation of each staple (47).

[0032] Additionally, because upper portion (156) of central nose (150) extends at least partially along the length of each thread rail (130, 132), upper portion (156) can horizontally stabilize inner wall (71) of cartridge body (70) at the same longitudinal position where thread rail (130, 132) is located while wedge-shaped sled (110) moves longitudinally through staple cartridge (37). In this manner, central nose (150) can provide horizontal stability to cartridge body (70) at a longitudinal position along the length of cartridge body (70) corresponding to each staple opening (51) at substantially the same time (e.g., during at least a portion of the duration) that corresponding thread rail (130, 132) lifts corresponding staple driver (43) and drives corresponding staple (47) out through staple opening (51). By providing horizontal stability to cartridge body 70 in such a longitudinal position, substantially simultaneously elevating staple drivers 43 in such a longitudinal position to drive staples 47 out through staple openings 51, central nose 150 can promote proper alignment of each staple opening 51 with a corresponding staple forming pocket 53 on the inner surface of anvil 18 during deployment and formation of each staple 47. For example, central nose 150 can promote vertical and / or angular alignment of each staple opening 51 with a corresponding staple forming pocket 53 by inhibiting lateral deflection of inner wall 71 that could cause staple openings 51 to tilt (e.g., laterally inward or laterally outward) relative to the corresponding staple forming pocket 53.As discussed above, the thread rails (130, 132) may themselves horizontally stabilize the corresponding walls (71) of the cartridge body (70) at their respective longitudinal positions, and thus may also promote vertical and / or angular alignment of each staple opening (51) with the corresponding staple forming pocket (53) by inhibiting lateral deflection of the inner walls (71) that might otherwise tilt the staple openings (51) (e.g., laterally inward or laterally outward) relative to the corresponding staple forming pocket (53). Thus, the central nose (150) and the thread rails (130, 132) may cooperatively provide horizontal stability to the cartridge body (70) at the respective longitudinal positions of each thread rail (130, 132) during longitudinal movement of the wedge-shaped sled (110) through the staple cartridge (37). It should also be understood that the anvil (18) has been intentionally omitted from the view of FIG. 10.

[0033] The wedge-shaped thread 110 may be formed of any suitable material or combination of materials, including, but not limited to, a metallic material such as stainless steel (e.g., hardened stainless steel) or titanium. In some variations, the wedge-shaped thread 110 may be manufactured by a metal injection molding (MIM) process. It will be appreciated that such an MIM process may provide the wedge-shaped thread 110 with improved compressive support and reduced lateral deflection compared to, for example, a wedge-shaped thread 110 formed from a plastic material, allowing the wedge-shaped thread 110 to provide improved vertical support and / or lateral stability to the cartridge body 70 during use (e.g., clamping and / or firing). Such an MIM process may include, for example, molding the wedge-shaped thread 110 as a single, integral part from a liquid MIM feedstock mixture of a metal powder and a binder. The MIM process may further include subjecting the wedge-shaped thread (110) to various types of conditioning, including, but not limited to, cleaning, thermal degreasing, and / or sintering.

[0034] In any event, after the MIM process is complete, all surfaces of the wedge-shaped sled (110) may have an initial (e.g., raw MIM) surface finish, including the cam surfaces (140, 142, 144, 146) of the sled rails (130, 132). Such initial surface finish may be rough, abrasive, and / or grainy, and may generally resemble the texture of perforated sandpaper. Accordingly, selected surfaces of the wedge-shaped sled (110) may be further conditioned to refine or otherwise remove the initial surface finish from the selected surfaces and provide the selected surfaces with a final surface finish that is relatively smoother (e.g., finer, more polished) than the initial surface finish. For example, the cam surfaces (140, 142, 144, 146) of the thread rails (130, 132) may be machined to remove an initial surface finish from the cam surfaces (140, 142, 144, 146) and to provide such a final surface finish to the cam surfaces (140, 142, 144, 146). The final surface finish of the cam surfaces (140, 142, 144, 146) promotes reduced friction and a smooth interaction between the cam surfaces (140, 142, 144, 146) and the staple driver (43), thereby minimizing wear on the portions of the staple driver (43) that are contacted by the cam surfaces (140, 142, 144, 146).

[0035] While selected surfaces having a finish surface have been described in the form of cam surfaces (140, 142, 144, 146), it will be appreciated that any other surface of wedge-shaped sled (110) may additionally or alternatively have a finish surface. For example, bottom surface (116) may have a finish surface to reduce friction and promote smooth interaction between bottom surface (116) and tray (74).

[0036] In some variations, the remaining non-selected surfaces of the wedge-shaped sled 110 may not require further conditioning, such that the initial surface finish may remain on the non-selected surfaces during use (e.g., clamping and / or firing). For example, the upper surfaces 118, 120 of the base platform 112 and raised platform 114 and / or the ledge 162 of the central nose 150 may retain the initial surface finish. As another example, all surfaces of the wedge-shaped sled 110 other than the cam surfaces 140, 142, 144, 146 of the sled rails 130, 132 may retain the initial surface finish. Thus, the selected surfaces of the wedge-shaped sled 110 may have the final surface finish, while the non-selected surfaces of the wedge-shaped sled 110 may have the initial surface finish, such that the wedge-shaped sled 110 may have at least two distinct surface finishes.

[0037] The selected and non-selected surfaces may be determined based on the particular components of the staple cartridge 37 and / or firing beam 14 with which each individual surface of the wedge-shaped sled 110 interacts. In this regard, a final surface finish may be more desirable for surfaces of the wedge-shaped sled 110 that interact with certain predetermined components of the staple cartridge 37 and / or firing beam 14 than for others. For example, the cam surfaces 140, 142, 144, 146 of the sled rails 130, 132 may be selected to receive a final surface finish based on their interaction with the staple driver 43, while the remaining surfaces of the sled rails 130, 132, the upper surface 118 of the base platform 112, the upper surface 120 of the raised platform 114, and / or the ledge surface 162 of the central nose 150 may not be selected to receive a final surface finish based on their interaction with the cartridge body 70. As another example, the bottom surface (116) may be selected to receive a final surface finish based on interaction with the tray (74), while the proximal end surface of the wedge-shaped sled (110) may not be selected to receive a final surface finish based on interaction with the pusher block (80).

[0038] III. Exemplary Threads Having Cartridge Wall Support Features, Staple Driver Support Features, Tapered Distal Ends, and Multiple Surface Finishes In some cases, it may be desirable to provide a wedge-shaped sled configured to support the staple driver (43) before fully lifting it to drive the corresponding staple (47) out through the corresponding staple opening (51), thereby facilitating alignment between the staple driver (43) and the corresponding staple forming pocket (53) during firing. Additionally or alternatively, as described above with respect to the wedge-shaped sled (110), it may be desirable to provide a wedge-shaped sled configured to provide rigidity to the staple cartridge (37) and / or having multiple distinct surface finishes (also referred to as "surface textures" or "surface topographies"). Figures 11-13 illustrate an exemplary wedge-shaped sled (210) that provides such functionality. The wedge-shaped sled (210) is similar to the wedge-shaped sled (110) described above, except as otherwise described below. For example, wedge sled (210) occupies the same amount of longitudinal space within staple cartridge (37) as wedge sleds (41, 110), making wedge sled (210) substantially interchangeable with wedge sleds (41, 110).

[0039] The wedge-shaped sled (210) of this example comprises a base including a base platform (212) and a central raised platform (214) extending upwardly from the base platform (212). In the illustrated example, the base platform (212) has a substantially flat bottom surface (216) that defines a horizontal plane and is configured to slide longitudinally along the tray (74) during longitudinal movement of the wedge-shaped sled (210) through the staple cartridge (37). The base platform (212) also has a pair of laterally opposed substantially flat top surfaces (218) that are parallel to the bottom surface (216), and the raised platform (214) similarly has a pair of laterally opposed substantially flat top surfaces (220) that are parallel to the bottom surface (216). As best shown in FIG. 13 , top surfaces (218, 220) are configured to face and / or slidably contact or otherwise engage the bottom surfaces of respective corresponding walls (71) of cartridge body (70), thereby vertically supporting the corresponding walls (71) during longitudinal movement of wedge-shaped sled (210) through staple cartridge (37). In this embodiment, top surface (218) of base platform (212) is further configured to slidably contact or otherwise engage the respective staple drivers (43), thereby vertically supporting the respective staple drivers (43), during longitudinal movement of wedge-shaped sled (210) through staple cartridge (37), as described in more detail below.

[0040] The base of this variation also includes a lower chamfer (222) that slopes upward and distally from the distal end of the bottom surface (216) to the distal end of the base platform (212), a pair of distal upper chamfers (224) that slope downward and distally from the distal ends of each of the top surfaces (218) of the base platform (212) to the distal end of the base platform (212), and a pair of proximal upper chamfers (226) that slope downward and distally from the distal ends of each of the top surfaces (220) of the raised platform (214) toward the respective top surfaces (218) of the base platform. The chamfers (222, 224, 226) may also be referred to as "tapered surfaces" or "bevels." The lower chamfers (222) may extend across the width of the base platform (212) and may have a length that is greater than the thickness of the base platform (212) (e.g., between the bottom surface (216) and either top surface (218)). Similarly, the distal upper chamfers (224) may each have a length that is greater than the thickness of the base platform (212). The lower chamfers (222) may be configured to facilitate unimpeded longitudinal movement of the wedge-shaped sled (210) through the staple cartridge (37) in the distal direction by reducing the likelihood that the distal end of the base platform (212) will catch on or otherwise be obstructed by the tray (74). For example, the lower chamfers (222) may urge the tray (74) (which may be constructed of a flexible material) slightly downward and away from the bottom surface of the wall (71) of the cartridge body (70) as the wedge-shaped sled (210) is driven distally through the staple cartridge (37). The distal upper chamfers (224) may be configured to lift the staple drivers (43) partially upward and above their respective upper surfaces (218) of the base platform (212) as the wedge-shaped sled (210) is driven distally through the staple cartridge (37) without driving the corresponding staples (47) out through the corresponding staple openings (51). For example, the distal upper chamfers (224) may be configured to cam engage the staple drivers (43) to urge the staple drivers (43) above their respective upper surfaces (218).Additionally or alternatively, distal upper chamfers (224) may be configured to lift outer walls (71) of cartridge body (70) slightly upwardly above respective upper surfaces (218) of base platform (212) when wedge-shaped sled (210) is driven distally through staple cartridge (37). For example, distal upper chamfers (224) may be configured to cam-like engage outer walls (71) to bias outer walls (71) above respective upper surfaces (218), as described in more detail below. In some variations, any one or more of chamfers (222, 224, 226) may be omitted. For example, any one or more of chamfers (222, 224, 226) may be replaced by one or more respective fillets.

[0041] The wedge-shaped sled (210) further includes a pair of laterally opposed outer sled rails (230) extending upward from the base platform (212) and first and second laterally opposed inner sled rails (232, 233) extending upward from both the base platform (212) and the raised platform (214). The sled rails (230, 232, 233) may also be referred to as "cam ramps" or "cam wedges." The sled rails (230, 232, 233) of this variation extend substantially straight and upright from the upper surfaces (218, 220) of the base platform (212) and the raised platform (214), respectively, such that the sled rails (230, 232, 233) are oriented perpendicular to the horizontal plane and parallel to the vertical longitudinal plane. In the illustrated embodiment, the inner sled rails (232, 233) are laterally spaced apart from the adjacent outer sled rails (230) to define the upper surfaces (218) of the base platform (212). In this regard, the upper surfaces (218) of the base platform (212) each extend at least partially along the length of the sled rails (230, 232, 233), and the upper surfaces (220) of the raised platforms (214) each extend at least partially along the length of their respective inner sled rails (232, 233). Furthermore, the upper surfaces (218) of the base platform (212) each are positioned at least partially distal to the distal ends of the sled rails (230, 232, 233). In this variation, the outer thread rails (230) each have a first height relative to the bottom surface (216) of the base platform (212), while the inner thread rails (232, 233) each have a second height relative to the bottom surface (216) of the base platform (212) that is lower than the first height.Also, in the illustrated embodiment, the outer and inner thread rails (230, 232, 233) each terminate proximally at the same longitudinal position (e.g., the proximal end of the base platform (212)), while the outer thread rails (230) each terminate distally at a first longitudinal position, the first inner thread rail (232) terminates distally at a second longitudinal position that is distal to the first longitudinal position, and the second inner thread rail (233) terminates distally at a third longitudinal position that is distal to the first and second longitudinal positions, such that the outer thread rails (230) each have a first length, the first inner thread rail (232) has a second length that is longer than the first length, and the second inner thread rail (233) has a third length that is longer than the first and second lengths. Thus, the distal ends of the outer thread rails (230) are aligned longitudinally with one another, and the distal ends of the first and second inner thread rails (232, 233) are offset longitudinally from one another and from the distal end of the outer thread rail (230).

[0042] Each threaded rail (230, 232, 233) is longitudinally aligned with a respective distal upper chamfer (224) of the base such that a respective upper surface (218) of the base platform (212) extends longitudinally between each threaded rail (230, 232, 233) and the respective distal upper chamfer (224). In some variations, the distal ends of the threaded rails (230, 232, 233) may each be spaced apart from their respective distal upper chamfer (224) by a distance equal to or greater than the length of the corresponding staple driver (43), thereby enabling each upper surface (218) to support the corresponding staple driver (43) in an upright position between each threaded rail (230, 232, 233) and the respective distal upper chamfer (224).

[0043] As best shown in FIG. 13 , thread rails (230, 232, 233) are configured to be received within corresponding longitudinally extending slots (73) in cartridge body (70) and to slidably contact or otherwise engage respective sides of corresponding walls (71) of cartridge body (70), thereby horizontally stabilizing walls (71) during longitudinal movement of wedge-shaped sled (210) through staple cartridge (37). For example, outer and inner thread rails (230, 232, 233) may inhibit lateral inward and / or lateral outward deflection (e.g., bending) of walls (71). In this regard, thread rails (230, 232, 233) may each have a thickness equal to or slightly less than the width of the corresponding slot (73). In some variations, the sled rails (230, 232, 233) may additionally or alternatively be configured to slidably contact or otherwise engage the respective upper slot surfaces of the corresponding slots (73) in the cartridge body (70), thereby vertically supporting the upper deck (72) during longitudinal movement of the wedge-shaped sled (210) through the staple cartridge (37).

[0044] Each thread rail (230, 232, 233) of the wedge-shaped sled (210) exhibits one or more respective inclined cam surfaces (240, 242, 244, 245, 246, 247) for lifting the staple driver (43) fully upward as the wedge-shaped sled (210) is driven distally through the staple cartridge (37) to drive the corresponding staple (47) out through the corresponding staple opening (51). In the illustrated embodiment, each outer thread rail (230) includes a front cam surface (240) oriented at a first angle relative to the horizontal plane defined by the bottom surface (216) and a rear cam surface (242) oriented at a second angle relative to the horizontal plane, such that the outer thread rails (230) have the same side elevational profiles as one another. Similarly, the first and second inner thread rails (232, 233) each include a front cam surface (244, 245) oriented at a first angle relative to the horizontal. In the illustrated embodiment, the first inner thread rail (232) includes a rear cam surface (246) oriented at a third angle relative to the horizontal, and the second inner thread rail (233) includes a rear cam surface (247) oriented at a fourth angle relative to the horizontal, such that the inner thread rails (232, 233) have different height profiles from each other and from the height profile of the outer thread rail (230). Thus, the wedge-shaped thread (210) may be substantially asymmetric with respect to a vertical longitudinal plane, at least with respect to the configuration of the thread rails (230, 232, 233).

[0045] In this variation, the first angle is greater than the second angle, which is greater than the third angle, which is greater than the fourth angle, etc. Alternatively, any other suitable relative angles may be used.

[0046] The wedge-shaped sled (210) further includes a central nose (250) that extends upward from both the base platform (212) and the raised platform (214) between the inner sled rails (232, 233) and also extends distally from the raised platform (214) to a distal tip (252). In the illustrated embodiment, the central nose (250) is spaced laterally from each inner sled rail (232, 233) so as to define the upper surface (220) of the raised platform (214). More specifically, the central nose (250) is equally spaced from the inner sled rails (232, 233). The central nose 250 of this variation includes a lower portion 254 extending distally from the raised platform 214 to a distal tip 252, and an upper portion 256 extending upward from both the raised platform 214 and the lower portion 254. The upper portion 256 of this variation is substantially perpendicular to the horizontal plane. As shown, the upper portion 256 extends longitudinally from the proximal end of the raised platform 214 to the distal tip 252 such that the upper portion 256 is positioned at least partially distal to the distal ends of the sled rails 230, 232, 233 and such that the upper portion 256 extends at least partially along the length of each sled rail 230, 232, 233. The distal tip (252) of this variation is positioned at the same longitudinal position as the distal end of the base platform (212).

[0047] In the illustrated embodiment, the lower portion (254) extends laterally outward relative to the upper portion (256) on either side of the upper portion (256) to define a pair of laterally opposed, upwardly facing ledges (262) that extend longitudinally from the upper surface (220) of each of the raised platforms (214) toward the distal tip (252). More specifically, the ledges (262) are substantially flat, parallel to a horizontal plane, and positioned flush with the upper surface (220) of each of the raised platforms (214) relative to the bottom surface (216), such that the ledges (262) are seamlessly continuous with the upper surface (220) of each of the raised platforms (214) and collectively define a respective single, continuous surface. As illustrated, each ledge (262) is positioned at least partially distal to the distal end of the sled rail (230, 232, 233). The central nose (250) of this variation further includes a pair of laterally opposed distal tapered surfaces (263) that slope downwardly and distally from the distal end of each of the ledges (262) toward the distal tip (252). The tapered surfaces (263) may be configured to lift the inner wall (71) of the cartridge body (70) slightly upwardly above the respective ledges (262) of the central nose (250) as the wedge-shaped sled (210) is driven distally through the staple cartridge (37). For example, the tapered surfaces (263) may be configured to cam engage the inner wall (71) to urge the inner wall (71) onto the respective ledges (262), as described in more detail below. In some variations, any one or more of the tapered surfaces (263) may be omitted. For example, any one or more of the tapered surfaces (263) may be replaced by one or more respective fillets.

[0048] As best shown in FIG. 13 , central nose (250) is configured to be at least partially received within vertical slot (49) of staple cartridge (37). In some variations, central nose (250) is configured to slidably contact or otherwise engage inner wall (71) of cartridge body (70), thereby vertically supporting and / or horizontally stabilizing inner wall (71) during longitudinal movement of wedge-shaped sled (210) through staple cartridge (37). In this regard, ledge surface (262) of this variation faces and slidably contacts or otherwise engages the underside of each of inner walls (71), thereby vertically supporting inner wall (71) during longitudinal movement of wedge-shaped sled (210) through staple cartridge (37). Additionally, upper portion (256) of this variation contacts or otherwise engages the laterally inward surface of inner wall (71), thereby horizontally stabilizing inner wall (71) during longitudinal movement of wedge-shaped sled (210) through staple cartridge (37). For example, upper portion (256) may prevent laterally inward deflection (e.g., bending) of inner wall (71). In this regard, upper portion (256) may have a thickness equal to or slightly less than the width of vertical slot (49), and lower portion (254) may have a thickness greater than the width of vertical slot (49).

[0049] Each upper surface (218) of the base platform (212) is positioned at least partially distal to the distal end of the thread rails (230, 232, 233) so that the upper surfaces (218) can vertically support the staple driver (43) and / or the outer wall (71) of the cartridge body (70) in a longitudinal position distal to the thread rails (230, 232, 233) while the wedge-shaped thread (210) moves longitudinally through the staple cartridge (37). In this manner, base platform 212 can provide vertical support to staple driver 43 and / or cartridge body 70 at longitudinal positions along the length of cartridge body 70 corresponding to each staple opening 51 before (e.g., at least immediately before) the corresponding threaded rails 230, 232, 233 fully lift the corresponding staple driver 43 to drive the corresponding staple 47 out through the staple opening 51. By providing vertical support to cartridge body 70 at such longitudinal positions before fully lifting the staple driver 43 to drive the staple 47 out through the staple opening 51, base platform 212 can facilitate proper alignment of each staple opening 51 with the corresponding staple forming pocket 53 on the inner surface of anvil 18 prior to deploying and forming each staple 47. For example, the base platform (212) may facilitate vertical and / or angular alignment of each staple opening (51) with the corresponding staple forming pocket (53) by helping to maintain the upper deck (72) substantially parallel to the inner surface of the anvil (18) having the staple forming pockets (53).Similarly, by fully lifting the staple drivers (43) and providing vertical support to the staple drivers (43) in such longitudinal position prior to driving the staples (47) out through the staple openings (51) in such longitudinal position, the base platform (212) can facilitate proper alignment of each staple driver (43) with the corresponding staple forming pockets (53) on the inner surface of the anvil (18) prior to deploying and forming each staple (47). For example, the base platform (212) may facilitate vertical and / or angular alignment of each staple driver (43) with the corresponding staple forming pocket (53) by helping to maintain each staple driver (43) oriented substantially perpendicular to the inner surface of the anvil (18) having the staple forming pocket (53), such as by inhibiting distal tilt of the staple driver (43) that might otherwise occur when the front cam surfaces (240, 244, 245) of the thread rails (230, 232, 233) cam into engagement with the staple driver (43).

[0050] Similarly, because each ledge (262) of central nose (250) is positioned at least partially distal to the distal ends of thread rails (230, 232, 233), ledges (262) can vertically support inner wall (71) of cartridge body (70) at a longitudinal position distal to thread rails (230, 232, 233) during longitudinal movement of wedge-shaped sled (210) through staple cartridge (37). Similarly, because upper portion (256) is positioned at least partially distal to the distal ends of thread rails (230, 232, 233), upper portion (256) can horizontally stabilize inner wall (71) of cartridge body (70) at a longitudinal position distal to thread rails (230, 232, 233) during longitudinal movement of wedge-shaped sled (210) through staple cartridge (37). In this manner, central nose 250 can provide vertical support and / or horizontal stability to cartridge body 70 at a longitudinal position along the length of cartridge body 70 corresponding to each staple opening 51, before (e.g., at least immediately before) corresponding thread rails 230, 232, 233 fully lift corresponding staple drivers 43 to drive corresponding staples 47 out through staple openings 51. By providing vertical support and / or horizontal stability to cartridge body 70 at such longitudinal position, before fully lifting staple drivers 43 to drive staples 47 out through staple openings 51, central nose 250 can facilitate proper alignment of each staple opening 51 with a corresponding staple forming pocket 53 on the inner surface of anvil 18 prior to deploying and forming each staple 47.For example, the central nose (250) may promote vertical and / or angular alignment of each staple opening (51) with the corresponding staple forming pocket (53) by helping to maintain the upper deck (72) substantially parallel to the inner surface of the anvil (18) having the staple forming pockets (53) thereon, and / or by preventing lateral deflection of the inner wall (71) that may otherwise cause the staple openings (51) to tilt (e.g., laterally inward or laterally outward) relative to the corresponding staple forming pocket (53).

[0051] Furthermore, the upper surfaces (218, 220) of the base platform (212) and the raised platform (214) each extend at least partially along the length of the respective thread rails (230, 232, 233) so that the upper surfaces (218, 220) can vertically support the corresponding walls (71) of the cartridge body (70) at the same longitudinal positions where the thread rails (230, 232, 233) are located while the wedge-shaped thread (210) moves longitudinally through the staple cartridge (37). In this manner, the base platform (212) and / or the raised platform (214) can provide vertical support to the cartridge body (70) at a longitudinal position along the length of the cartridge body (70) corresponding to each staple opening (51) at substantially the same time (e.g., for at least a portion of the duration) that the corresponding thread rail (230, 232, 233) fully lifts the corresponding staple driver (43) to drive the corresponding staple (47) out through the staple opening (51). By providing vertical support to cartridge body 70 in such longitudinal position while substantially simultaneously fully elevating staple drivers 43 to drive staples 47 out through staple openings 51 in such longitudinal position, base platform 212 and / or raised platform 214 can promote proper alignment of each staple opening 51 with a corresponding staple forming pocket 53 on the inner surface of anvil 18 during deployment and formation of each staple 47. For example, base platform 212 and / or raised platform 214 can promote vertical and / or angular alignment of each staple opening 51 with a corresponding staple forming pocket 53 by helping to maintain upper deck 72 substantially parallel to the inner surface of anvil 18, which has staple forming pockets 53 therein.Because the upper surface (220) of the raised platform (214) is seamlessly continuous with each ledge surface (262), the central nose (250) and the raised platform (214) can cooperate to promote continuous proper alignment of each staple opening (51) with a corresponding staple forming pocket (53) on the inner surface of the anvil (18) at least from just prior to the deployment and formation of each staple (47) until the completion of the deployment and formation of each staple (47).

[0052] Additionally, because the upper portion (256) of the central nose (250) extends at least partially along the length of each thread rail (230, 232, 233), the upper portion (256) can horizontally stabilize the inner wall (71) of the cartridge body (70) at the same longitudinal position where the thread rail (230, 232, 233) is located while the wedge-shaped sled (210) moves longitudinally through the staple cartridge (37). In this manner, the central nose (250) can provide horizontal stability to the cartridge body (70) at a longitudinal position along the length of the cartridge body (70) corresponding to each staple opening (51) at substantially the same time (e.g., during at least a portion of the duration) that the corresponding thread rail (230, 232, 233) fully lifts the corresponding staple driver (43) and drives the corresponding staple (47) out through the staple opening (51). By providing horizontal stability to cartridge body 70 in such longitudinal position while substantially simultaneously fully elevating staple drivers 43 and driving staples 47 out through staple openings 51 in such longitudinal position, central nose 250 can promote proper alignment of each staple opening 51 with a corresponding staple forming pocket 53 on the inner surface of anvil 18 during deployment and formation of each staple 47. For example, central nose 250 can promote vertical and / or angular alignment of each staple opening 51 with a corresponding staple forming pocket 53 by inhibiting lateral deflection of inner wall 71 that could otherwise tilt staple openings 51 (e.g., laterally inward or laterally outward) relative to the corresponding staple forming pocket 53.As described above, the thread rails (230, 232, 233) may themselves horizontally stabilize the corresponding walls (71) of the cartridge body (70) at their respective longitudinal positions, and thus may also promote vertical and / or angular alignment of each staple opening (51) with the corresponding staple forming pocket (53) by inhibiting lateral deflection of the inner walls (71) that might otherwise tilt the staple openings (51) (e.g., laterally inward or laterally outward) relative to the corresponding staple forming pocket (53). Thus, during longitudinal movement of the wedge-shaped sled (210) through the staple cartridge (37), the central nose (250) and the thread rails (230, 232, 233) may cooperatively provide horizontal stability to the cartridge body (70) at the respective longitudinal positions of each thread rail (230, 232, 233). It should be understood that the anvil (18) has been intentionally omitted from the view of FIG.

[0053] The wedge-shaped sled (210) may be formed of any suitable material or combination of materials, including, but not limited to, metallic materials such as stainless steel (e.g., hardened stainless steel) or titanium. In some variations, the wedge-shaped sled (210) may be manufactured by a metal injection molding (MIM) process. It will be appreciated that such an MIM process may provide the wedge-shaped sled (210) with improved compressive support and less lateral deflection, allowing the wedge-shaped sled (210) to provide improved rigidity to the staple cartridge (37) during use (e.g., during clamping and / or firing). Such an MIM process may include, for example, molding the wedge-shaped sled (210) as a single, integral part from a liquid MIM feedstock mixture of metal powder and a binder. The MIM process may further include subjecting the wedge-shaped sled (210) to various types of conditioning, including, but not limited to, cleaning, thermal degreasing, and / or sintering.

[0054] In any event, after the MIM process is complete, all surfaces of the wedge-shaped sled (210) may have an initial (e.g., raw MIM) surface finish, including the top surface (218) of the base platform (212), the distal top chamfer (224), and the cam surfaces (240, 242, 244, 245, 246, 247) of the sled rails (230, 232, 233). Such initial surface finish may be rough, abrasive, and / or grainy, generally resembling the texture of perforated sandpaper. Accordingly, selected surfaces of the wedge-shaped sled (210) may be further conditioned to remove the initial surface finish from the selected surfaces and provide the selected surfaces with a final surface finish that is relatively smoother (e.g., finer, more polished) than the initial surface finish. For example, the upper surface (218), distal upper chamfer (224) of the base platform (212), and the cam surfaces (240, 242, 244, 245, 246, 247) of the threaded rails (230, 232, 233) may be machined to remove the initial surface finish from the upper surface (218), distal upper chamfer (224), and the cam surfaces (240, 242, 244, 245, 246, 247) and to provide such a final surface finish to the upper surface (218), distal upper chamfer (224), and the cam surfaces (240, 242, 244, 245, 246, 247). The final surface finish of the upper surface (218), the distal upper chamfer (224), and the cam surfaces (240, 242, 244, 245, 246, 247) promotes reduced friction and smooth interaction between the upper surface (218), the distal upper chamfer (224), and the cam surfaces (240, 242, 244, 245, 246, 247) and the staple driver (43), thereby minimizing wear on the portions of the staple driver (43) that contact the upper surface (218), the distal upper chamfer (224), and the cam surfaces (240, 242, 244, 245, 246, 247).

[0055] While selected surfaces having a final surface finish have been described in the form of the top surface (218) of the base platform (212), the distal top chamfer (224), and the cam surfaces (240, 242, 244, 245, 246, 247) of the sled rails (230, 232, 233), it will be appreciated that any other surface of the wedge-shaped sled (210) may additionally or alternatively have a final surface finish. For example, the bottom surface (216) may have a final surface finish to reduce friction and promote smooth interaction between the bottom surface (216) and the tray (74).

[0056] In some variations, the remaining non-selected surfaces of the wedge-shaped sled 210 may not need to be further adjusted, such that the initial surface finish may remain on the non-selected surfaces during use (e.g., clamping and / or firing). For example, the upper surface 220 of the raised platform 214 and / or the ledge 262 of the central nose 250 may retain the initial surface finish. As another example, all surfaces of the wedge-shaped sled 210 other than the upper surface 218 of the base platform 212, the distal top chamfer 224, and the cam surfaces 240, 242, 244, 245, 246, 247 of the sled rails 230, 232, 233 may retain the initial surface finish. Thus, a selected surface of the wedge-shaped thread (210) may have a final surface finish, while a non-selected surface of the wedge-shaped thread (210) may have an initial surface finish, such that the wedge-shaped thread (210) may have at least two distinct surface finishes.

[0057] The selected and non-selected surfaces may be determined based on the particular components of the staple cartridge 37 and / or firing beam 14 with which each individual surface of the wedge-shaped sled 210 interacts. In this regard, a final surface finish may be more desirable for surfaces of the wedge-shaped sled 210 that interact with certain given components of the staple cartridge 37 and / or firing beam 14 than for others. For example, the top surface (218) of the base platform (212), the distal top chamfer (224), and the cam surfaces (240, 242, 244, 245, 246, 247) of the threaded rails (230, 232, 233) may be selected to receive a final surface finish based on interaction with the staple driver (43), while the remaining surfaces of the threaded rails (230, 232, 233), the top surface (220) of the raised platform (214), and / or the ledge surface (262) of the central nose (250) may not be selected to receive a final surface finish based on interaction with the cartridge body (70). As another example, the bottom surface (216) may be selected to receive a final surface finish based on interaction with the tray (74), while the proximal end surface of the wedge-shaped thread (210) may not be selected to receive a final surface finish based on interaction with the pusher block (80).

[0058] 14A-14D, during firing, the wedge-shaped sled (210) is driven distally from the proximal position illustrated in FIG. 14A into upward camming contact with the staple drivers (43), which in turn drive the staples (47) out through the staple openings (51) into forming contact with the staple-forming pockets (53) on the inner surface of the anvil (18). More specifically, as illustrated in FIG. 14B, the distal top chamfers (224) of the base platform (212) cam into engagement with the respective staple drivers (43) during distal translation of the wedge-shaped sled (210), lifting each staple driver (43) above the tray (74). For example, the distal upper chamfers (224) may elevate each staple driver (43) to a first height above the respective upper surface (218) of the base platform (212) without ejecting the corresponding staple (47) through the corresponding staple opening (51). Thus, the distal upper chamfers (224) may be considered to "partially" elevate each staple driver (43). The upper surface (218) then vertically supports each staple driver (43) during continued distal translation of the wedge-shaped sled (210), as illustrated in FIG. 14C. For example, the upper surface (218) may temporarily maintain each staple driver (43) at the first height. The cam surfaces (240, 242, 244, 245, 246, 247) of each sled rail (230, 232) then cam engage with the respective staple driver (43) during further distal translation of the wedge-shaped sled (210), lifting the respective staple driver (43) above the respective upper surface (218) of the base platform (212), as shown in FIG. 14D. For example, the cam surfaces (240, 242, 244, 245, 246, 247) may lift the respective staple driver (43) to a second height greater than the first height, allowing the corresponding staple (47) to be ejected through the corresponding staple opening (51) and into forming contact with the corresponding staple forming pocket (53).Thus, the cam surfaces (240, 242, 244, 245, 246, 247) can be considered to "fully" lift the respective staple drivers (43). It should be understood that staple forming pockets (53) have been intentionally omitted from the views of Figures 14A-14D.

[0059] IV. Exemplary Sleds with Cartridge Biasing Features In some cases, it may be desirable to provide a wedge-shaped sled configured to provide additional lateral stability to staple cartridge (37) by biasing laterally inward a wall of cartridge body (70) adjacent to the wedge-shaped sled. Figures 15-19 show exemplary wedge-shaped sleds (310, 410, 510, 610, 710), each of which provides such functionality. Each of wedge-shaped sleds (310, 410, 510, 610, 710) is similar to wedge-shaped sled (110) and / or wedge-shaped sled (210), described above, except as otherwise described below. For example, wedge-shaped threads (310, 410, 510, 610, 710) each occupy the same amount of space longitudinally within staple cartridge (37) as wedge-shaped threads (41, 110, 210), making wedge-shaped threads (310, 410, 510, 610, 710) substantially interchangeable with wedge-shaped threads (41, 110, 210).

[0060] A. An exemplary sled with toe-in inner and outer sled rails and undercuts 15 depicts an exemplary wedge-shaped sled (310) comprising a base including a base platform (312) and a central raised platform (314) extending upwardly from the base platform (312). In the illustrated embodiment, the base platform (312) has a substantially flat bottom surface (316) that defines a horizontal plane and is configured to slide longitudinally along the tray (74) during longitudinal movement of the wedge-shaped sled (310) through the staple cartridge (37). The base platform (312) also has a pair of laterally opposed substantially flat top surfaces (318) that are parallel to the bottom surface (316), and the raised platform (314) similarly has a pair of laterally opposed substantially flat top surfaces (320) that are parallel to the bottom surface (316). As shown, the upper surfaces (318, 320) are configured to face and / or slidably contact or otherwise engage the respective bottom surfaces of the corresponding walls (71) of the cartridge body (70), thereby vertically supporting the corresponding walls (71) during longitudinal movement of the wedge-shaped sled (310) through the staple cartridge (37).

[0061] The wedge-shaped sled 310 further includes a pair of laterally opposed outer sled rails 330 extending upward from the base platform 312 and a pair of laterally opposed inner sled rails 332 extending upward from both the base platform 312 and the raised platform 314. The sled rails 330, 332 may also be referred to as "cam ramps" or "cam wedges." The sled rails 330, 332 of this variation are each angled or bent laterally inward from the upper surfaces 318, 320 of the base platform 312 and the raised platform 314, respectively, such that the sled rails 330, 332 are oriented obliquely relative to the horizontal and vertical longitudinal planes. More specifically, each sled rail (330, 332) is bent laterally inward at the same oblique angle (α) relative to the vertical longitudinal plane (or any plane parallel thereto) so that the sled rails (330, 332) on each side of the vertical longitudinal plane are parallel to one another and so that the wedge-shaped sled (310) is substantially symmetrical relative to the vertical longitudinal plane, at least with respect to the configuration of the sled rails (330, 332). In some variations, the oblique angle (α) may be approximately 7.5 degrees. Alternatively, any other suitable angle may be used. In the illustrated embodiment, the wedge-shaped sled (310) includes a pair of laterally opposed recesses (334) extending downward from the upper surface (320) of the raised platform (314) adjacent the corresponding inner sled rail (332), helping to facilitate the laterally inward bent configuration of the inner sled rails (332). The recesses (334) may also be referred to as "undercuts." In some variations, the recesses (334) may each extend at least partially along the length of the respective inner threaded rail (332).

[0062] As shown, the thread rails (330, 332) are configured to be received within corresponding longitudinally extending slots (73) in the cartridge body (70) and to slidably contact or otherwise engage the respective sides of the corresponding walls (71) of the cartridge body (70), thereby horizontally stabilizing the walls (71) during longitudinal movement of the wedge-shaped sled (310) through the staple cartridge (37). For example, the outer and inner thread rails (330, 332) may inhibit laterally inward and / or laterally outward deflection (e.g., bending) of the walls (71). In this regard, the laterally inwardly bent configuration of the thread rails (330, 332) of this variation may be particularly well-suited for inhibiting laterally outward deflection of the walls (71). For example, the thread rails (330, 332) of this variation may bias the corresponding wall (71) toward a substantially vertical orientation by countering any laterally outward forces that may be applied to the wall (71) during use (e.g., clamping and / or firing). In this regard, the bevel angle (α) may be selected to achieve a desired amount of laterally inward force applied by each thread rail (330, 332) to the corresponding wall (71) sufficient to overcome such laterally outwardly directed forces while causing limited or no laterally inward bending of the corresponding wall (71). Similarly, the thread rails (330, 332) may each be attached to the base platform (312) and the raised platform (314), respectively, with a predetermined amount of flexibility to minimize laterally inward bending of the corresponding wall (71) by allowing the thread rails (330, 332) to be elastically biased laterally outward when a threshold force is applied. Thus, sled rails (330, 332) may be considered to be resiliently biased laterally inward. In some variations, sled rails (330, 332) may additionally or alternatively be configured to slidably contact or otherwise engage respective upper slot surfaces of corresponding slots (73) in cartridge body (70), thereby vertically supporting upper deck (72) during longitudinal movement of wedge-shaped sled (310) through staple cartridge (37).

[0063] The wedge-shaped sled (310) further includes a central nose (350) extending upwardly from the raised platform (314) between the inner sled rails (332). In the illustrated embodiment, the central nose (350) is laterally spaced from each recess (334) to define the upper surface (320) of the raised platform (314).

[0064] As shown, the central nose (350) is configured to be at least partially received within the vertical slot (49) of the staple cartridge (37). In some variations, the central nose (350) is configured to slidably contact or otherwise engage the inner wall (71) of the cartridge body (70), thereby vertically supporting and / or horizontally stabilizing the inner wall (71) during longitudinal movement of the wedge-shaped sled (310) through the staple cartridge (37), as described above with respect to the central noses (150, 250). For example, the central nose (350) may resist laterally inward deflection (e.g., bending) of the inner wall (71) that may be caused by laterally inwardly directed forces applied to the inner wall (71) by the corresponding inner sled rail (332). Similarly, the inner thread rail (332) can resist laterally inward deflection (e.g., bending) of the outer wall (71) that may be caused by a laterally inward force applied to the outer wall (71) by the corresponding outer thread rail (330). In some variations, some lateral inward deflection of the inner and / or outer wall (71) can be tolerated without distorting the overall contour of the staple cartridge (37) and, more specifically, without causing misalignment of the staple openings (51) relative to the corresponding staple forming pockets (53). Thus, the central nose (350) and thread rails (330, 332) can cooperatively provide improved lateral stability to the cartridge body (70) at the respective longitudinal positions of each thread rail (330, 332) during longitudinal movement of the wedge-shaped thread (310) through the staple cartridge (37). It should be understood that the anvil (18) has been intentionally omitted from the view of FIG. 15.

[0065] B. Exemplary sled with toe-in inner and outer sled rails 16 depicts an exemplary wedge-shaped sled (410) comprising a base including a base platform (412) and a central raised platform (414) extending upwardly from the base platform (412). In the illustrated embodiment, the base platform (412) has a substantially flat bottom surface (416) that defines a horizontal plane and is configured to slide longitudinally along the tray (74) during longitudinal movement of the wedge-shaped sled (410) through the staple cartridge (37). The base platform (412) also has a pair of laterally opposed substantially flat top surfaces (418) that are parallel to the bottom surface (416), and the raised platform (414) similarly has a pair of laterally opposed substantially flat top surfaces (420) that are parallel to the bottom surface (416). As shown, the upper surfaces (418, 420) are configured to face and / or slidably contact or otherwise engage the respective bottom surfaces of the corresponding walls (71) of the cartridge body (70), thereby vertically supporting the corresponding walls (71) during longitudinal movement of the wedge-shaped sled (410) through the staple cartridge (37).

[0066] The wedge-shaped sled 410 further includes a pair of laterally opposed outer sled rails 430 extending upward from the base platform 412 and a pair of laterally opposed inner sled rails 432 extending upward from both the base platform 412 and the raised platform 414. The sled rails 430, 432 may also be referred to as "cam ramps" or "cam wedges." The sled rails 430, 432 of this variation are each angled or bent laterally inward from the upper surfaces 418, 420 of the base platform 412 and the raised platform 414, respectively, such that the sled rails 430, 432 are oriented obliquely relative to the horizontal and vertical longitudinal planes. More specifically, each sled rail (430, 432) is bent laterally inward at the same oblique angle (α) relative to the vertical longitudinal plane (or any plane parallel thereto) so that the sled rails (430, 432) on each side of the vertical longitudinal plane are parallel to one another and so that the wedge-shaped sled (410), at least with respect to the configuration of the sled rails (430, 432), is substantially symmetrical relative to the vertical longitudinal plane. In some variations, the oblique angle (α) may be approximately 7.5 degrees. Alternatively, any other suitable angle may be used.

[0067] As shown, the thread rails (430, 432) are configured to be received within corresponding longitudinally extending slots (73) in the cartridge body (70) and to slidably contact or otherwise engage the respective sides of the corresponding walls (71) of the cartridge body (70), thereby horizontally stabilizing the walls (71) during longitudinal movement of the wedge-shaped sled (410) through the staple cartridge (37). For example, the outer and inner thread rails (430, 432) may inhibit laterally inward and / or laterally outward deflection (e.g., bending) of the walls (71). In this regard, the laterally inwardly bent configuration of the thread rails (430, 432) of this variation may be particularly well-suited for inhibiting laterally outward deflection of the walls (71). For example, the thread rails (430, 432) of this variation may bias the corresponding wall (71) toward a substantially vertical orientation by countering any laterally outwardly directed force that may be applied to the wall (71) during use (e.g., clamping and / or firing). In this regard, the bevel angle (α) may be selected to achieve a desired amount of laterally inwardly directed force applied by each thread rail (430, 432) to the corresponding wall (71) sufficient to overcome such laterally outwardly directed force while causing limited or no laterally inward bending of the corresponding wall (71). Similarly, the thread rails (430, 432) may each be attached to the base platform (412) and the raised platform (414), respectively, with a predetermined amount of flexibility to minimize laterally inward bending of the corresponding wall (71) by allowing the thread rails (430, 432) to be elastically biased laterally outward when a threshold force is applied. Thus, the sled rails (430, 432) may be considered to be resiliently biased laterally inward.In some variations, the sled rails (430, 432) may additionally or alternatively be configured to slidably contact or otherwise engage the respective upper slot surfaces of the corresponding slots (73) in the cartridge body (70), thereby vertically supporting the upper deck (72) during longitudinal movement of the wedge-shaped sled (410) through the staple cartridge (37).

[0068] The wedge-shaped sled (410) further includes a central nose (450) extending upward from the raised platform (414) between the inner sled rails (432). In the illustrated embodiment, the central nose (450) is laterally spaced from each inner sled rail (432) so as to define the upper surface (420) of the raised platform (414). More specifically, the central nose (450) is equally spaced from the inner sled rails (432).

[0069] As shown, the central nose (450) is configured to be at least partially received within the vertical slot (49) of the staple cartridge (37). In some variations, the central nose (450) is configured to slidably contact or otherwise engage the inner wall (71) of the cartridge body (70), thereby vertically supporting and / or horizontally stabilizing the inner wall (71) during longitudinal movement of the wedge-shaped sled (410) through the staple cartridge (37), as described above with respect to the central noses (150, 250). For example, the central nose (450) may resist laterally inward deflection (e.g., bending) of the inner wall (71) that may be caused by laterally inwardly directed forces applied to the inner wall (71) by the corresponding inner sled rail (432). Similarly, the inner thread rail (432) can resist laterally inward deflection (e.g., bending) of the outer wall (71) that may be caused by a laterally inwardly directed force applied to the outer wall (71) by the corresponding outer thread rail (430). In some variations, some laterally inward deflection of the inner and / or outer wall (71) can be tolerated without distorting the overall contour of the staple cartridge (37) and, more specifically, without causing misalignment of the staple openings (51) relative to the corresponding staple forming pockets (53). Thus, the central nose (450) and thread rails (430, 432) can cooperatively provide improved lateral stability to the cartridge body (70) at the respective longitudinal positions of each thread rail (430, 432) during longitudinal movement of the wedge-shaped sled (410) through the staple cartridge (37). It should be understood that the anvil (18) has been intentionally omitted from the view of FIG. 16.

[0070] C. An exemplary sled with a toe-in inner sled rail 17 depicts an exemplary wedge-shaped sled (510) comprising a base including a base platform (512) and a central raised platform (514) extending upwardly from the base platform (512). In the illustrated embodiment, the base platform (512) has a substantially flat bottom surface (516) that defines a horizontal plane and is configured to slide longitudinally along the tray (74) during longitudinal movement of the wedge-shaped sled (510) through the staple cartridge (37). The base platform (512) also has a pair of laterally opposed substantially flat top surfaces (518) that are parallel to the bottom surface (516), and the raised platform (514) similarly has a pair of laterally opposed substantially flat top surfaces (520) that are parallel to the bottom surface (516). As shown, the upper surfaces (518, 520) are configured to face and / or slidably contact or otherwise engage the respective bottom surfaces of the corresponding walls (71) of the cartridge body (70), thereby vertically supporting the corresponding walls (71) during longitudinal movement of the wedge-shaped sled (510) through the staple cartridge (37).

[0071] The wedge-shaped sled (510) further includes a pair of laterally opposed outer sled rails (530) extending upward from the base platform (512) and a pair of laterally opposed inner sled rails (532) extending upward from both the base platform (512) and the raised platform (514). The sled rails (530, 532) may also be referred to as "cam ramps" or "cam wedges." The outer sled rails (530) of this variation extend substantially straight and upright from the respective upper surfaces (518) of the base platforms (512), such that the outer sled rails (530) are oriented perpendicular to the horizontal plane and parallel to the vertical longitudinal plane. In this variation, each of the inner thread rails (532) is angled or bent laterally inward from the respective upper surfaces (520) of the raised platforms (514), such that the inner thread rails (532) are oriented obliquely relative to the horizontal plane and the vertical longitudinal plane. More specifically, each inner thread rail (532) is bent laterally inward at an oblique angle (α) relative to the vertical longitudinal plane (or any plane parallel thereto) such that each inner thread rail (532) is oriented obliquely relative to the adjacent outer thread rail (530) and such that the wedge-shaped thread (510), at least with respect to the configuration of the thread rails (530, 532), is substantially symmetrical relative to the vertical longitudinal plane. In some variations, the oblique angle (α) may be approximately 7.5 degrees. Alternatively, any other suitable angle may be used.

[0072] As shown, the thread rails (530, 532) are configured to be received within corresponding longitudinally extending slots (73) in the cartridge body (70) and to slidably contact or otherwise engage the respective sides of the corresponding walls (71) of the cartridge body (70), thereby horizontally stabilizing the walls (71) during longitudinal movement of the wedge-shaped sled (510) through the staple cartridge (37). For example, the outer and inner thread rails (530, 532) may inhibit laterally inward and / or laterally outward deflection (e.g., bending) of the walls (71). In this regard, the laterally inwardly bent configuration of the inner thread rail (532) of this variation may be particularly well-suited for inhibiting laterally outward deflection of the inner wall (71). For example, the inner thread rails (532) of this variation can bias the corresponding inner wall (71) toward a substantially vertical orientation by countering any laterally outwardly directed force that may be applied to the inner wall (71) during use (e.g., clamping and / or firing). In this regard, the bevel angle (α) can be selected to achieve a desired amount of laterally inwardly directed force applied by each inner thread rail (532) to the corresponding inner wall (71) sufficient to overcome such laterally outwardly directed force while limiting or not causing any laterally inward bending of the corresponding wall (71). Similarly, the inner thread rails (532) can each be mounted on a raised platform (514) having a predetermined amount of flexibility to minimize laterally inward bending of the corresponding wall (71) by allowing the inner thread rails (532) to be resiliently biased laterally outward upon application of a threshold force. Thus, the inner thread rails (532) can be considered to be resiliently biased laterally inward. In some variations, the sled rails (530, 532) may additionally or alternatively be configured to slidably contact or otherwise engage the respective upper slot surfaces of the corresponding slots (73) in the cartridge body (70), thereby vertically supporting the upper deck (72) during longitudinal movement of the wedge-shaped sled (510) through the staple cartridge (37).

[0073] The wedge-shaped sled (510) further includes a central nose (550) extending upward from the raised platform (514) between the inner sled rails (532). In the illustrated embodiment, the central nose (550) is spaced laterally from each inner sled rail (532) so as to define the upper surface (520) of the raised platform (514). More specifically, the central nose (550) is equally spaced from the inner sled rails (532).

[0074] As shown, the central nose (550) is configured to be at least partially received within the vertical slot (49) of the staple cartridge (37). In some variations, the central nose (550) is configured to slidably contact or otherwise engage the inner wall (71) of the cartridge body (70), thereby vertically supporting and / or horizontally stabilizing the inner wall (71) during longitudinal movement of the wedge-shaped sled (510) through the staple cartridge (37), as described above with respect to the central noses (150, 250). For example, the central nose (550) may resist laterally inward deflection (e.g., bending) of the inner wall (71) that may be caused by laterally inwardly directed forces applied to the inner wall (71) by the corresponding inner sled rail (532). Similarly, the inner thread rail (532) can inhibit laterally inward deflection (e.g., bending) of the outer wall (71) that might otherwise be caused by a laterally inwardly directed force applied to the outer wall (71) by the corresponding outer thread rail (530). In some variations, some laterally inward deflection of the inner and / or outer wall (71) can be tolerated without distorting the overall contour of the staple cartridge (37) and, more specifically, without causing misalignment of the staple openings (51) relative to the corresponding staple forming pockets (53). Thus, the central nose (550) and the thread rails (530, 532) can cooperatively provide improved lateral stability to the cartridge body (70) at the respective longitudinal positions of each thread rail (530, 532) during longitudinal movement of the wedge-shaped sled (510) through the staple cartridge (37). It should be understood that the anvil (18) has been intentionally omitted from the view of FIG.

[0075] Exemplary Thread with DV-Shaped Base 18 depicts an exemplary wedge-shaped sled (610) comprising a base including a base platform (612) and a central raised platform (614) extending upwardly from the base platform (612). In the illustrated embodiment, the base platform (612) and the raised platform (614) are each bifurcated by a longitudinally extending inverted V-shaped slot (615), allowing each of the laterally opposed halves of the wedge-shaped sled (610) to tilt or bend laterally inward toward one another. In this regard, the base platform (612) has a pair of laterally opposed, substantially flat bottom surfaces (616) (e.g., collectively defined by the lowermost laterally inner edges of the bottom surfaces (616)) that are oriented obliquely relative to the horizontal. More specifically, each bottom surface (616) is bent laterally inward at the same oblique angle (θ) relative to the horizontal plane, such that the base platform (612) has a generally V-shaped cross-section, and the wedge-shaped sled (610) is substantially symmetrical about a vertical longitudinal plane, at least with respect to the configuration of the bottom surfaces (616). The base platform (612) also has a pair of laterally opposed substantially flat upper surfaces (618) parallel to the respective bottom surfaces (616), and the raised platform (614) similarly has a pair of laterally opposed substantially flat upper surfaces (620) parallel to the respective bottom surfaces (616). The upper surfaces (618, 620) are configured to face and / or slidably contact or otherwise engage the respective bottom surfaces of the corresponding walls (71) of the cartridge body (70), thereby vertically supporting the corresponding walls (71) during longitudinal movement of the wedge-shaped sled (610) through the staple cartridge (37).

[0076] The wedge-shaped sled (610) further includes a pair of laterally opposed outer sled rails (630) extending upward from the base platform (612) and a pair of laterally opposed inner sled rails (632) extending upward from both the base platform (612) and the raised platform (614). The sled rails (630, 632) may also be referred to as "cam ramps" or "cam wedges." The sled rails (630, 632) of this variation extend substantially straight and upright from the top surfaces (618, 620) of the base platform (612) and the raised platform (614), respectively, such that the sled rails (630, 632) are oriented obliquely relative to the horizontal plane and the vertical longitudinal plane via the oblique orientation of the bottom surface (616) relative to the horizontal plane. More specifically, the laterally inwardly bent configuration of the base platform (612) causes each sled rail (630, 632) to be bent laterally inward at the same oblique angle (α) relative to the vertical longitudinal plane (or any plane parallel thereto) so that the sled rails (630, 632) on each side of the vertical longitudinal plane are parallel to each other and the wedge-shaped sled (610) is substantially symmetrical relative to the vertical longitudinal plane, at least relative to the configuration of the sled rails (630, 632). In some variations, the oblique angle (α) may be approximately 7.5 degrees. Alternatively, any other suitable angle may be used.

[0077] The thread rails (630, 632) are configured to be received within corresponding longitudinally extending slots (73) in the cartridge body (70) and to slidably contact or otherwise engage the respective sides of the corresponding walls (71) of the cartridge body (70), thereby horizontally stabilizing the walls (71) during longitudinal movement of the wedge-shaped sled (610) through the staple cartridge (37). For example, the outer and inner thread rails (630, 632) may inhibit laterally inward and / or laterally outward deflection (e.g., bending) of the walls (71). In this regard, the laterally inwardly bent configuration of the thread rails (630, 632) of this variation may be particularly well-suited for inhibiting laterally outward deflection of the walls (71). For example, the thread rails (630, 632) of this variation may bias the corresponding wall (71) toward a substantially vertical orientation by counteracting any laterally outwardly directed forces that may be applied to the wall (71) during use (e.g., clamping and / or firing). In this regard, the bevel angle (θ) and / or the bevel angle (α) may be selected to achieve a desired amount of laterally inwardly directed force applied by each thread rail (630, 632) to the corresponding wall (71) sufficient to overcome such laterally outwardly directed forces while causing limited or no laterally inward bending of the corresponding wall (71). The slots (615) can provide a predetermined amount of flexibility to the laterally opposing halves of the wedge-shaped sled (610), allowing the thread rails (630, 632) to be resiliently biased laterally outward upon application of a threshold force, thereby minimizing laterally inward bending of the corresponding walls (71). Thus, the thread rails (630, 632) can be considered to be resiliently biased laterally inward. In some variations, the thread rails (630, 632) can additionally or alternatively be configured to slidably contact or otherwise engage respective upper slot surfaces of corresponding slots (73) in the cartridge body (70), thereby vertically supporting the upper deck (72) during longitudinal movement of the wedge-shaped sled (610) through the staple cartridge (37).

[0078] The wedge-shaped sled (610) further includes a central nose (650) extending upward from the raised platform (614) between the inner sled rails (632). In the illustrated embodiment, the central nose (650) is laterally spaced from each recess (634) to define the upper surface (620) of the raised platform (614).

[0079] The central nose (650) is configured to be at least partially received within the vertical slot (49) of the staple cartridge (37). In some variations, the central nose (650) is configured to slidably contact or otherwise engage the inner wall (71) of the cartridge body (70), thereby vertically supporting and / or horizontally stabilizing the inner wall (71) during longitudinal movement of the wedge-shaped sled (610) through the staple cartridge (37), as described above with respect to the central noses (150, 250). For example, the central nose (650) can inhibit laterally inward deflection (e.g., bending) of the inner wall (71) that might otherwise be caused by a laterally inwardly directed force applied to the inner wall (71) by the corresponding inner sled rail (632). Similarly, the inner thread rail (632) can inhibit laterally inward deflection (e.g., bending) of the outer wall (71) that might otherwise be caused by a laterally inwardly directed force applied to the outer wall (71) by the corresponding outer thread rail (630). In some variations, some laterally inward deflection of the inner and / or outer wall (71) can be tolerated without distorting the overall contour of the staple cartridge (37) and, more specifically, without causing misalignment of the staple openings (51) relative to the corresponding staple forming pockets (53). Thus, the central nose (650) and the thread rails (630, 632) can cooperatively provide improved lateral stability to the cartridge body (70) at the respective longitudinal positions of each thread rail (630, 632) during longitudinal movement of the wedge-shaped sled (610) through the staple cartridge (37).

[0080] E. Exemplary thread with bifurcated nose 19 depicts an exemplary wedge-shaped sled (710) comprising a base including a base platform (712) and a central raised platform (714) extending upwardly from the base platform (712). In the illustrated embodiment, the base platform (712) has a substantially flat bottom surface (716) that defines a horizontal plane and is configured to slide longitudinally along the tray (74) during longitudinal movement of the wedge-shaped sled (710) through the staple cartridge (37). The base platform (712) also has a pair of laterally opposed substantially flat top surfaces (718) that are parallel to the bottom surface (716), and the raised platform (714) similarly has a pair of laterally opposed substantially flat top surfaces (720) that are parallel to the bottom surface (716). The upper surfaces (718, 720) are configured to face and / or slidably contact or otherwise engage the respective bottom surfaces of the corresponding walls (71) of the cartridge body (70), thereby vertically supporting the corresponding walls (71) during longitudinal movement of the wedge-shaped sled (710) through the staple cartridge (37).

[0081] The wedge-shaped sled 710 further includes a pair of laterally opposed outer sled rails 730 extending upward from the base platform 712 and a pair of laterally opposed inner sled rails 732 extending upward from both the base platform 712 and the raised platform 714. The sled rails 730, 732 may also be referred to as "cam ramps" or "cam wedges." The sled rails 730, 732 of this variation are each angled or bent laterally inward from the upper surfaces 718, 720 of the base platform 712 and the raised platform 714, respectively, such that the sled rails 730, 732 are oriented obliquely relative to the horizontal and vertical longitudinal planes. More specifically, each sled rail (730, 732) is bent laterally inward at the same oblique angle (α) relative to the vertical longitudinal plane (or any plane parallel thereto) so that the sled rails (730, 732) on each side of the vertical longitudinal plane are parallel to one another and so that the wedge-shaped sled (710), at least with respect to the configuration of the sled rails (730, 732), is substantially symmetrical relative to the vertical longitudinal plane. In some variations, the oblique angle (α) may be approximately 7.5 degrees. Alternatively, any other suitable angle may be used. In the illustrated embodiment, the wedge-shaped sled (710) includes a pair of laterally opposed recesses (734) extending downward from the upper surface (720) of the raised platform (714) adjacent the corresponding inner sled rail (732), helping to facilitate the laterally inward bent configuration of the inner sled rails (732). The recesses (734) may also be referred to as "undercuts." In some variations, the recesses (734) may each extend at least partially along the length of the respective inner threaded rail (732).

[0082] The thread rails (730, 732) are configured to be received within corresponding longitudinally extending slots (73) in the cartridge body (70) and to slidably contact or otherwise engage the respective sides of the corresponding walls (71) of the cartridge body (70), thereby horizontally stabilizing the walls (71) during longitudinal movement of the wedge-shaped sled (710) through the staple cartridge (37). For example, the outer and inner thread rails (730, 732) may inhibit laterally inward and / or laterally outward deflection (e.g., bending) of the walls (71). In this regard, the laterally inwardly bent configuration of the thread rails (730, 732) of this variation may be particularly well-suited for inhibiting laterally outward deflection of the walls (71). For example, the thread rails (730, 732) of this variation may bias the corresponding wall (71) toward a substantially vertical orientation by countering any laterally outwardly directed force that may be applied to the wall (71) during use (e.g., clamping and / or firing). In this regard, the bevel angle (α) may be selected to achieve a desired amount of laterally inwardly directed force applied by each thread rail (730, 732) to the corresponding wall (71) sufficient to overcome such laterally outwardly directed force while causing limited or no laterally inward bending of the corresponding wall (71). Similarly, the thread rails (730, 732) may each be attached to the base platform (712) and the raised platform (714), respectively, with a predetermined amount of flexibility to minimize laterally inward bending of the corresponding wall (71) by allowing the thread rails (730, 732) to be elastically biased laterally outward when a threshold force is applied. Thus, the sled rails (730, 732) can be considered to be resiliently biased laterally inward.In some variations, the sled rails (730, 732) may additionally or alternatively be configured to slidably contact or otherwise engage the respective upper slot surfaces of the corresponding slots (73) in the cartridge body (70), thereby vertically supporting the upper deck (72) during longitudinal movement of the wedge-shaped sled (710) through the staple cartridge (37).

[0083] The wedge-shaped sled (710) further includes a central nose (750) extending upward from the raised platform (714) between the inner sled rails (732). In the illustrated embodiment, the central nose (750) is laterally spaced from each recess (734) to define the upper surface (720) of the raised platform (714). In this variation, the central nose (750) is bifurcated by longitudinally extending U-shaped slots (751) to facilitate lateral inward deflection (e.g., bending) of the central nose (750).

[0084] The central nose (750) is configured to be at least partially received within the vertical slot (49) of the staple cartridge (37). In some variations, the central nose (750) is configured to slidably contact or otherwise engage the inner wall (71) of the cartridge body (70), thereby vertically supporting and / or horizontally stabilizing the inner wall (71) during longitudinal movement of the wedge-shaped sled (710) through the staple cartridge (37), as described above with respect to the central noses (150, 250). For example, the central nose (750) can inhibit laterally inward deflection (e.g., bending) of the inner wall (71) that may be caused by laterally inwardly directed forces applied to the inner wall (71) by the corresponding inner sled rail (732). Similarly, the inner thread rail (732) can resist laterally inward deflection (e.g., bending) of the outer wall (71) that might otherwise be caused by a laterally inwardly directed force applied to the outer wall (71) by the corresponding outer thread rail (730). In some variations, some laterally inward deflection of the inner and / or outer wall (71) can be tolerated without distorting the overall contour of the staple cartridge (37) and, more specifically, without causing misalignment of the staple openings (51) relative to the corresponding staple forming pockets (53). In this regard, the central nose (750) can bend laterally inward to accommodate such permitted laterally inward deflection of the inner wall (71). Thus, during longitudinal movement of the wedge-shaped sled (710) through the staple cartridge (37), the central nose (750) and sled rails (730, 732) can cooperate to provide improved lateral stability to the cartridge body (70) at the respective longitudinal positions of each sled rail (730, 732).

[0085] While the present variation of wedge-shaped sled (110, 210, 310, 410, 510, 610, 710) is illustrated and described herein in connection with a staple cartridge configured for use with a laparoscopic surgical stapler, such as staple cartridge (37), it will be understood that the other variation of wedge-shaped sled (110, 210, 310, 410, 510, 610, 710) may be adapted for use with a staple cartridge configured for use with a non-laparoscopic surgical stapler in an open surgical procedure. Examples of such non-laparoscopic surgical staplers are disclosed in U.S. Patent Publication No. 2020 / 0046350, published February 13, 2020, entitled "Firing System for Linear Surgical Stapler"; U.S. Patent Publication No. 2020 / 0046351, published February 13, 2020, entitled "Decoupling Mechanism for Linear Surgical Stapler"; U.S. Patent Publication No. 2020 / 0046353, published February 13, 2020, entitled "Clamping Assembly for Linear Surgical Stapler"; and U.S. Patent Application Publication No. 16 / 537,005, filed August 9, 2019, entitled "Linear Surgical Stapler," the disclosures of which are incorporated herein by reference.

[0086] V. Exemplary Biasing Features Integrated into Cartridges In some cases, it may be desirable to provide a staple cartridge with improved lateral stability compared to staple cartridge (37) by biasing laterally inward the wall of the cartridge body adjacent wedge-shaped sled (41). Figure 20 illustrates an exemplary staple cartridge (868) that provides such functionality. Staple cartridge (868) is similar to staple cartridge (37) described above, except as specifically noted below. For example, staple cartridge (37) may be configured to be removably installed within channel (39) of lower jaw (16).

[0087] As shown, the staple cartridge (868) of this embodiment includes a cartridge body (870) having a plurality of walls (871), which presents an upper deck (872). The cartridge body (870) further includes a plurality of longitudinally extending slots (873) positioned between each of the walls (871). The cartridge body (870) is coupled to a lower cartridge tray (874). As shown, a vertical slot (849) is formed through a portion of the staple cartridge (868). Three rows of staple openings (851) are formed through the upper deck (872) on one side of the vertical slot (849), and another set of three rows of staple openings (851) is formed through the upper deck (872) on the other side of the vertical slot (849).

[0088] In this variation, cartridge body (870) includes a pair of laterally opposed upper protrusions (875) extending laterally outward from opposite sides of cartridge body (870) above tray (874). Similarly, tray (874) includes a pair of laterally opposed lower protrusions (876) extending laterally outward from opposite sides of tray (874). Protrusions (875, 876) are configured to abut or otherwise engage respective sides of channel (39) of lower jaw (16), thereby horizontally stabilizing wall (871) during longitudinal movement of a wedge-shaped sled (not shown), such as any of the wedge-shaped sleds (41, 110, 210, 310, 410, 510, 610, 710) described above, through staple cartridge (37). For example, protrusions (875, 876) may inhibit lateral outward deflection (e.g., bending) of wall (871). In this regard, protrusions (875, 876) of this variation may bias corresponding wall (871) toward a substantially vertical orientation by counteracting any lateral outwardly directed forces that may be applied to wall (871) during use (e.g., clamping and / or firing). In some variations, one or both upper protrusions (875) may be omitted. In some other variations, one or both lower protrusions (876) may be omitted.

[0089] VI. Exemplary Cartridge Having a Cartridge Tray with Protrusions to Reduce Tissue Gaps In some cases, it may be desirable to provide a staple cartridge that reduces the tissue gap between the top deck of the staple cartridge and the inner surface of the anvil (18) having the staple-forming pockets (53) compared to staple cartridge (37), thereby enabling the production of more tightly formed staples (47). Figure 21 illustrates an exemplary staple cartridge (968) that provides such functionality. Staple cartridge (968) is similar to staple cartridge (37) described above, except as specifically described below. For example, staple cartridge (37) may be configured to be removably installed within channel (39) of lower jaw (16).

[0090] As shown, the staple cartridge (968) in this embodiment includes a cartridge body (70) coupled to a lower cartridge tray (974). In this variation, the tray (974) includes a pair of laterally opposed outer protrusions (975) extending downwardly from the lower surface of the tray (974) and a pair of laterally opposed inner protrusions (976) extending downwardly from the lower surface of the tray (974). In some variations, the protrusions (975, 976) may each have a height (H) relative to the lower surface of the tray (974) that is greater than the material thickness (T) of the tray (974). For example, the protrusions (975, 976) may each have a height (H) relative to the lower surface of the tray (974) of approximately 0.010 inches, while the tray (974) may have a material thickness (T) of approximately 0.007 inches. Alternatively, protrusions (975, 976) of any other suitable height may be used. In any event, protrusions (975, 976) are configured to abut or otherwise engage the upper surface of channel (39) of lower jaw (16), thereby supporting tray (974) vertically above the upper surface of channel (39) of lower jaw (16). For example, protrusions (975, 976) may increase the height of the upper surface of tray (974) relative to the upper surface of channel (39) (e.g., along which a wedge-shaped sled, such as wedge-shaped sled (310), may translate longitudinally) by the height (H) of protrusions (975, 976), as compared to tray (74), thereby also increasing the height of upper deck (72) relative to the upper surface of channel (39) by the height (H) of protrusions (975, 976). Thus, the upper deck 72 may be spaced from the inner surface of the anvil 18 having the staple forming pockets 53 by inner and outer tissue gaps (Gi, Go), each of which is less than that provided in the absence of the protrusions 975, 976 by the height (H) of the protrusions 975, 976. For example, the inner tissue gap (Gi) may be approximately 0.04 inches and / or the outer tissue gap (Go) may be approximately 0.055 inches.In this manner, staple cartridge (968), in cooperation with anvil (18), can generate more tightly formed staples (47) compared to those generated by staple cartridge (37), and therefore may be able to clamp tissue more tightly than those generated by staple cartridge (37).

[0091] VII. Combination Examples The following examples relate to various non-exhaustive ways in which the teachings herein can be combined or applied. It should be understood that the following examples are not intended to limit the scope of any claims that may be presented at any time in this application or any subsequent application related to this application. No disclaimer is intended. The following examples are provided for illustrative purposes only. It is contemplated that the various teachings herein may be configured and applied in many other ways. It is also contemplated that certain features referred to in the following examples may be omitted in some variations. Accordingly, none of the aspects or features referred to below should be considered critical unless later expressly indicated as such by the inventors or their successors. If a claim presented in this application or a subsequent application related to this application includes additional features other than those referred to below, those additional features should not be considered added for any reasons of patentability. [Example]

[0092] 1. A staple driver actuator for a staple cartridge of a surgical stapler, the staple driver actuator comprising: (a) a base having at least one bottom surface, the at least one bottom surface defining a plane, the base defining a longitudinal centerline, the base configured to slide longitudinally relative to the staple cartridge; and (b) at least one biasing member positioned laterally outward relative to the longitudinal centerline of the base, the at least one biasing member configured to exert a biasing force on a portion of the staple cartridge in a direction toward the longitudinal centerline of the base. [Example]

[0093] 10. The staple driver actuator of claim 1, wherein the at least one biasing member includes at least one first rail extending upward from the base, the at least one first rail including at least one first cam surface, the at least one first cam surface being inclined relative to a plane. [Example]

[0094] The staple driver actuator of example 2, wherein the at least one first rail comprises at least one pair of laterally opposed rails. [Example]

[0095] 4. The staple driver actuator of claim 3, wherein the at least one pair of laterally opposed rails comprises a pair of laterally opposed inner rails and a pair of laterally opposed outer rails. [Example]

[0096] 3. The staple driver actuator of claim 2, further comprising at least one second rail extending upward from the base, the at least one second rail including at least one second cam surface, the at least one second cam surface being inclined relative to a plane. [Example]

[0097] 6. The staple driver actuator of example 5, wherein at least one second rail extends upright from the top surface of the base. [Example]

[0098] The staple driver actuator of any one or more of Examples 2-6, wherein the at least one first rail is bent laterally inward from the top surface of the base. [Example]

[0099] The staple driver actuator of any one or more of Examples 2-6, wherein the at least one first rail extends upright from a top surface of the base. [Example]

[0100] 9. The staple driver actuator of Example 8, wherein the base is substantially V-shaped. [Example]

[0101] The staple driver actuator of any one or more of Examples 2-9, wherein the base further comprises a recess extending along the at least one first rail. [Example]

[0102] The staple driver actuator of any one or more of Examples 1-10, wherein the at least one biasing member comprises a pair of laterally opposed biasing members. [Example]

[0103] The staple driver actuator of any one or more of Examples 1-11, wherein the at least one biasing member is resiliently biased laterally inward. [Example]

[0104] The staple driver actuator of any one or more of Examples 1-12, wherein the at least one biasing member is flexibly coupled to the base. [Example]

[0105] The staple driver actuator of any one or more of Examples 1-13, wherein the at least one biasing member and the base are integrally formed together as a single piece. [Example]

[0106] 15. A device comprising: (a) a staple cartridge comprising a cartridge tray and a cartridge body; and (b) a staple driver actuator according to any one or more of Examples 1-14, wherein the staple driver actuator is captured between the cartridge tray and the cartridge body such that at least one biasing member is configured to exert a biasing force on the cartridge body in a direction toward a longitudinal centerline of the base. [Example]

[0107] 1. An apparatus comprising: (a) jaws defining a longitudinal axis; (b) an anvil movable relative to the jaws; (c) a cartridge insertable into the jaws, the cartridge comprising: (i) a cartridge body; and (ii) at least one staple driver movable relative to the cartridge body; and (d) a staple driver actuator disposed within the cartridge, the staple driver actuator comprising at least one biasing member configured to bias at least a portion of the cartridge body laterally inward toward a longitudinal centerline thereof during translation of the staple driver actuator along the longitudinal axis. [Example]

[0108] 17. The device of example 16, wherein the at least one biasing member comprises at least one rail configured to cam engage the at least one staple driver during translation of the staple driver actuator along the longitudinal axis. [Example]

[0109] 18. The device of example 16 or 17, wherein the at least one biasing member is resiliently biased laterally inward. [Example]

[0110] A method of operating an apparatus including an end effector having a stapling assembly, the stapling assembly including: (a) a body extending along a longitudinal axis; (b) at least one staple driver movable relative to the body; and (c) a staple driver actuator, the staple driver actuator having at least one biasing member, the method including biasing at least a portion of the body laterally inward toward its longitudinal centerline via the at least one biasing member of the staple driver actuator during translation of the staple driver actuator along the longitudinal axis. [Example]

[0111] 20. The method of example 19, further comprising camming the at least one staple driver via at least one biasing member of the staple driver actuator during translation of the staple driver actuator along the longitudinal axis.

[0112] VIII. Other Any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be incorporated by reference in their entirety. This application may be combined with any one or more of the teachings, expressions, embodiments, examples, etc. described in U.S. patent application Ser. No. 09296USDP1 entitled "Surgical Stapler End Effector Sled," filed on the same day as this application; and / or U.S. patent application Ser. No. 09296USDP2 entitled "Surgical Stapler End Effector Sled," filed on the same day as this application. The disclosure of each of these applications is incorporated herein by reference.

[0113] It should be understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein can be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. described herein. Thus, the above teachings, expressions, embodiments, examples, etc. should not be considered in isolation from one another. Various suitable ways in which the teachings herein can be combined will be apparent to those skilled in the art in light of the teachings herein. Such modifications and variations are intended to be within the scope of the claims.

[0114] It should be understood that all or part of any patent, publication, or other disclosure referred to herein as being incorporated by reference is incorporated herein only to the extent that the incorporated material does not contradict existing definitions, opinions, or other disclosures set forth in this disclosure. As such, and to the extent necessary, the disclosures explicitly set forth herein shall supersede any conflicting statements incorporated herein by reference. Any material, or portions thereof, that is referred to herein as being incorporated by reference but that contradicts current definitions, opinions, or other disclosures set forth herein shall be incorporated only to the extent that no conflict arises between the incorporated material and the current disclosures.

[0115] Variations of the above-described devices may be applied not only to traditional medical procedures and surgeries performed by medical professionals, but also to robotic-assisted medical procedures and surgeries. By way of example only, the various teachings herein may be readily incorporated into robotic surgical systems such as the DAVINCI™ system by Intuitive Surgical, Inc. (Sunnyvale, California).

[0116] The device variations described above can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either or both cases, variations can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular parts, and subsequent reassembly. In particular, some device variations can be disassembled, and any number of particular portions or parts of the device can be selectively replaced or removed in any combination. Upon cleaning and / or replacement of particular parts, some device variations can be reassembled for subsequent use either at a reconditioning facility, or by the user immediately prior to a procedure. Those skilled in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning / replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

[0117] By way of example only, the variations described herein may be sterilized before and / or after treatment. In one sterilization technique, the device is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and device may then be placed in a radiation field that can penetrate the container, such as gamma radiation, X-rays, or a high-energy electron beam. The radiation may kill bacteria on the device and in the container. The sterilized device may then be stored in the sterile container for later use. The device may also be sterilized using any other technique known in the art, including, but not limited to, beta or gamma radiation, ethylene oxide, or steam.

[0118] While various embodiments of the present invention have been shown and described, further adaptations of the methods and systems described herein may be realized by those skilled in the art through appropriate modifications without departing from the scope of the present invention. While some such possible modifications have been described, other modifications will be apparent to those skilled in the art. For example, the examples, embodiments, geometries, materials, dimensions, proportions, steps, etc. discussed above are illustrative and not required. Accordingly, it will be understood that the scope of the present invention should be considered in terms of the claims that follow, and is not limited to the details of construction and operation shown and described in the specification and drawings.

[0119] [Embodiment] (1) A staple driver actuator for a staple cartridge of a surgical stapler, said staple driver actuator comprising: (a) a base having at least one bottom surface, the at least one bottom surface defining a plane, the base defining a longitudinal centerline, the base configured to slide longitudinally relative to the staple cartridge; (b) at least one biasing member positioned laterally outward relative to the longitudinal centerline of the base, the at least one biasing member configured to exert a biasing force on a portion of the staple cartridge in a direction toward the longitudinal centerline of the base. (2) A staple driver actuator as described in embodiment 1, wherein the at least one biasing member includes at least one first rail extending upward from the base, the at least one first rail including at least one first cam surface, and the at least one first cam surface being inclined with respect to the plane. (3) The staple driver actuator of claim 2, wherein the at least one first rail comprises at least a pair of laterally opposed rails. (4) The staple driver actuator of claim 3, wherein the at least one pair of laterally opposed rails comprises a pair of laterally opposed inner rails and a pair of laterally opposed outer rails. (5) The staple driver actuator of embodiment 2, further comprising at least one second rail extending upward from the base, the at least one second rail including at least one second cam surface, the at least one second cam surface being inclined relative to the plane.

[0120] (6) The staple driver actuator of claim 5, wherein the at least one second rail extends upright from the top surface of the base. (7) The staple driver actuator of claim 2, wherein the at least one first rail is bent laterally inward from the top surface of the base. (8) The staple driver actuator of claim 2, wherein the at least one first rail extends upright from an upper surface of the base. (9) The staple driver actuator of claim 8, wherein the base is substantially V-shaped. (10) The staple driver actuator of claim 2, wherein the base further includes a recess extending along the at least one first rail.

[0121] (11) The staple driver actuator of claim 1, wherein the at least one biasing member comprises a pair of laterally opposed biasing members. (12) The staple driver actuator of claim 1, wherein the at least one biasing member is resiliently biased laterally inward. (13) The staple driver actuator of claim 1, wherein the at least one biasing member is flexibly coupled to the base. (14) The staple driver actuator of claim 1, wherein the at least one biasing member and the base are integrally formed together as a single piece. (15) An apparatus comprising: (a) the staple cartridge including a cartridge tray and a cartridge body; (b) a staple driver actuator as described in claim 1, wherein the staple driver actuator is captured between the cartridge tray and the cartridge body, such that the at least one biasing member is configured to exert a biasing force on the cartridge body in a direction toward the longitudinal centerline of the base.

[0122] (16) An apparatus comprising: (a) a jaw defining a longitudinal axis; (b) an anvil movable relative to said jaws; (c) a cartridge, said cartridge insertable into said jaw, said cartridge comprising: (i) a cartridge body; (ii) a cartridge comprising at least one staple driver movable relative to the cartridge body; (d) a staple driver actuator disposed within the cartridge, the staple driver actuator comprising at least one biasing member configured to bias at least a portion of the cartridge body laterally inward toward its longitudinal centerline during translation of the staple driver actuator along the longitudinal axis. (17) The device of claim 16, wherein the at least one biasing member includes at least one rail configured to cam engage the at least one staple driver during translation of the staple driver actuator along the longitudinal axis. (18) The device of embodiment 16, wherein the at least one biasing member is resiliently biased laterally inward. (19) A method of operating an apparatus including an end effector having a stapling assembly, the stapling assembly including: (a) a body extending along a longitudinal axis; (b) at least one staple driver movable relative to the body; and (c) a staple driver actuator, the staple driver actuator including at least one biasing member, the method comprising: biasing at least a portion of the body laterally inward toward its longitudinal centerline via the at least one biasing member of the staple driver actuator during translation of the staple driver actuator along the longitudinal axis. (20) The method of claim 19, further comprising camming the at least one staple driver via the at least one biasing member of the staple driver actuator during translation of the staple driver actuator along the longitudinal axis.

Claims

1. 1. A staple driver actuator for a staple cartridge of a surgical stapler, said staple driver actuator comprising: (a) a base having at least one bottom surface, the at least one bottom surface defining a plane, the base defining a longitudinal centerline, the base configured to slide longitudinally relative to the staple cartridge; (b) at least one biasing member positioned laterally outward relative to the longitudinal centerline of the base, the at least one biasing member configured to exert a biasing force on a portion of the staple cartridge in a direction toward the longitudinal centerline of the base; a staple driver actuator, wherein the at least one biasing member includes at least one first rail extending upward from the base, the at least one first rail including at least one first cam surface, the at least one first cam surface being inclined relative to the plane, the at least one first cam surface being inclined relative to the plane and configured to exert a biasing force on the portion of the staple cartridge.

2. The staple driver actuator of claim 1 , wherein said at least one first rail comprises a pair of first rails, the inwardly facing surfaces of said pair of first rails laterally facing one another.

3. A staple driver actuator as described in claim 1, wherein the at least one first rail includes a pair of inner rails and a pair of outer rails, the inward-facing surfaces of the pair of inner rails facing each other laterally, and the inward-facing surfaces of the pair of outer rails facing each other laterally.

4. 2. The staple driver actuator of claim 1, further comprising at least one second rail extending upwardly from the base, the at least one second rail including at least one second cam surface, the at least one second cam surface being inclined relative to the plane.

5. The staple driver actuator of claim 4 , wherein the at least one second rail extends upright from a top surface of the base.

6. The staple driver actuator of claim 1 , wherein the at least one first rail is bent laterally inward from a top surface of the base.

7. The staple driver actuator of claim 1 , wherein the at least one first rail extends upright from a top surface of the base.

8. The staple driver actuator of claim 7 , wherein said base is V-shaped in a plane perpendicular to said longitudinal centerline of said base.

9. The staple driver actuator of claim 1 , wherein the base further includes a recess extending along the at least one first rail.

10. The staple driver actuator of claim 1 , wherein the at least one biasing member is angled laterally inward from the base.

11. The staple driver actuator of claim 1 , wherein the at least one biasing member is coupled to the base.

12. The staple driver actuator of claim 1 , wherein said at least one biasing member and said base are integrally formed together as a single piece.

13. 1. An apparatus comprising: (a) the staple cartridge including a cartridge tray and a cartridge body; (b) the staple driver actuator of claim 1, wherein the staple driver actuator is captured between the cartridge tray and the cartridge body such that the at least one biasing member is configured to exert a biasing force on the cartridge body in a direction toward the longitudinal centerline of the base.

14. 1. An apparatus comprising: (a) a jaw defining a longitudinal axis; (b) an anvil movable relative to said jaws; (c) a cartridge, said cartridge insertable into said jaw, said cartridge comprising: (i) a cartridge body; (ii) a cartridge comprising at least one staple driver movable relative to the cartridge body; (d) a staple driver actuator disposed within the cartridge, the staple driver actuator comprising: a base having a bottom surface defining a plane; and at least one biasing member configured to bias at least a portion of the cartridge body laterally inward toward a longitudinal centerline thereof during translation of the staple driver actuator along the longitudinal axis; the at least one biasing member includes at least one rail extending upward from the base, the at least one rail including at least one cam surface, the at least one cam surface being inclined relative to the plane, the at least one cam surface being configured to bias the at least a portion of the cartridge body laterally inward toward its longitudinal centerline.

15. The device of claim 14 , wherein the at least one biasing member slopes laterally inward from the base.

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