Surgical instrument having an interaction feature for correcting accidental thread displacement

Abstract

A loading unit for use with a surgical stapling instrument is disclosed. The loading unit includes a shaft and an end effector extending from the shaft. The end effector includes a first jaw including an anvil and a second jaw. At least one of the first jaw and the second jaw is movable relative to the other to grasp tissue. The second jaw includes an elongated channel including a retaining feature and a staple cartridge insertable into the elongated channel for assembly with the elongated channel. The staple cartridge includes a cartridge pan and a sled translatable relative to the cartridge pan from a first position to a second position. The retaining feature is configured to resist movement by the sled beyond the first position up to a predetermined force.

Description

[Technical Field]

[0001] The present invention relates to surgical instruments, and more particularly to surgical stapling and cutting instruments designed for stapling and cutting tissue in various devices, as well as staple cartridges for use with them. [Overview of the project] [Means for solving the problem]

[0002] In one embodiment, the present disclosure provides a loading unit for use with a surgical stapling device. The loading unit comprises a shaft and an end effector extending from the shaft. The end effector comprises a first jaw portion having an anvil and a second jaw portion. At least one of the first and second jaw portions is movable relative to the other to grasp tissue. The second jaw portion comprises an elongated channel including a retaining feature portion and a staple cartridge insertable into the elongated channel for assembly with the elongated channel. The staple cartridge comprises a cartridge pan and a thread that is translationally movable relative to the cartridge pan from a first position to a second position. The retaining feature portion is configured to resist movement by the thread beyond the first position up to a predetermined force.

[0003] In another embodiment, the disclosure provides a staple cartridge for use with a surgical staple fastener, an elongated channel, and a drive member. The staple cartridge comprises a deck defining a tissue contact surface, a housing, and a cartridge pan releasably mounted in an elongated channel. The staple cartridge further comprises a retaining feature, a staple driver housed within the housing between the deck and the cartridge pan, and staples housed within the housing. The staples are deployable through the deck into the tissue by the staple driver. The staple cartridge further comprises a thread that is translationally movable relative to the cartridge pan from a first position to a second position in order to move the staple driver and deploy the staples. The retaining feature is configured to resist the movement of the thread beyond the first position up to a predetermined force.

[0004] In another embodiment, the disclosure provides a staple cartridge assembly comprising an elongated channel having a first retaining feature, and a staple cartridge insertable into the elongated channel for assembly with the elongated channel. The staple cartridge comprises a cartridge pan having a second retaining feature, and a thread that is translationally movable relative to the cartridge pan from a first position to a second position. The retaining feature is configured to resist movement by the thread beyond the first position up to a predetermined force. [Brief explanation of the drawing]

[0005] The various features of the embodiments described herein, along with their advantages, can be understood from the following description in conjunction with the accompanying drawings. [Figure 1] This is a perspective view of a surgical instrument according to at least one aspect of the present disclosure. [Figure 2] This is a perspective view of a motor-operable internal core according to at least one aspect of the present disclosure. [Figure 3] This is a perspective view of one embodiment of the housing and internal core shown in Figure 2, which has an open configuration. [Figure 4] Figure 3 is a perspective view of the housing, which has a housing with a closed configuration and associated with different colors, and an internal core as shown in Figure 2. [Figure 5] This is an exploded assembly diagram of a non-articulated loading unit according to at least one aspect of the present disclosure. [Figure 6] This is an exploded assembly diagram of an articulated loading unit according to at least one aspect of the present disclosure. [Figure 7] This is a cross-sectional view of a loading unit according to at least one aspect of the present disclosure. [Figure 8] Figure 7 is an exploded view of a portion of the loading unit. [Figure 9] This is a partial side cross-sectional view of the distal end of the drive assembly, showing the latch member of the launch lockout assembly in the first configuration or unlock configuration. [Figure 10] This is a partial side cross-sectional view of the distal end of the drive assembly in Figure 9, showing the latch member in the second configuration or lock configuration. [Figure 11] This is a partially exploded view of a staple cartridge assembly of a loading unit according to at least one aspect of the present disclosure. [Figure 12] Figure 11 is a partial cross-sectional view of the loading unit. [Figure 13] Figure 11 is a partial cross-sectional view of the staple cartridge assembly. [Figure 14] This is a partially exploded view of a staple cartridge according to at least one aspect of the present disclosure. [Figure 15] Figure 14 is a partial cross-sectional view of a staple cartridge. [Figure 16] This is a partial perspective view of a staple cartridge according to at least one aspect of the present disclosure. [Figure 17] This is a partially exploded view of a staple cartridge according to at least one aspect of the present disclosure. [Figure 18] Figure 17 is a partial cross-sectional view of a staple cartridge. [Figure 19]Partial exploded view of a staple cartridge assembly according to at least one aspect of the present disclosure. [Figure 20] Plan view and cross-sectional view of a staple cartridge according to at least one aspect of the present disclosure. [Figure 21] Cross-sectional view of a staple cartridge assembly including the staple cartridge of FIG. 20. [Figure 22] Partial cross-sectional view of a staple cartridge including a thread and a retaining feature according to at least one aspect of the present disclosure. [Figure 23] Partial upside-down perspective view of the staple cartridge of FIG. 22. [Figure 24] Illustrates a method of assembling the thread of the staple cartridge of FIG. 22 with the retaining feature. [Figure 25] Partially illustrates a staple cartridge assembly including a staple cartridge and an elongated channel, and a drive member of a loading unit according to at least one aspect of the present disclosure. [Figure 26] Partially illustrates the staple cartridge assembly of FIG. 25 in which the staple cartridge is properly seated within the elongated channel. [Figure 27] Partial cross-sectional view of the staple cartridge assembly of FIG. 25. [Figure 28] Partial cross-sectional view of the staple cartridge assembly of FIG. 26. [Figure 29] Partial perspective of a staple cartridge according to at least one aspect of the present disclosure. [Figure 30] Partial cross-sectional view of the staple cartridge of FIG. 29. [Figure 31] Logical flow diagram of a process showing a control program or logical configuration according to at least one aspect of the present disclosure. [Figure 32] View of a surgical stapling instrument including a firing system according to at least one aspect of the present disclosure. [Figure 33]The driving members of the surgical staple fastener shown in Figure 32 are shown at three positions along those firing paths, and the threads that can be advanced by the driving members to deploy the staples of the surgical staple fastener shown in Figure 32 are shown. [Figure 34] Figure 32 illustrates the drive member at two positions along the launch path. [Figure 35] A graph according to at least one aspect of the present disclosure, showing on the x-axis the distance (δ) traveled by the drive member along the firing path from the starting position, and on the y-axis the firing speed (V) of the motor during the firing stroke of the electric surgical staple fastener and the corresponding electrical load. [Figure 36] The present disclosure illustrates a staple cartridge including a retaining feature for maintaining threads within the staple cartridge in a home position, according to at least one aspect of this disclosure. [Figure 37] Figure 36 illustrates a staple cartridge in which the thread has advanced distally beyond its home position within the staple cartridge. [Figure 38] Figure 36 illustrates the holding features of the staple cartridge. [Figure 39] A partially exploded view of a surgical staple assembly according to at least one aspect of this disclosure is shown. [Figure 40] Figure 39 is a graph showing the changing resistance of the thread detection circuit for the threads of a surgical staple assembly on the y-axis, and the corresponding travel distance on the x-axis. [Figure 41] This is a partial cross-sectional view of a staple cartridge including a thread reset circuit according to at least one aspect of the present disclosure. [Figure 42] Three positions of the thread-over staple cartridge relative to the retaining feature portion, according to at least one aspect of this disclosure, are illustrated. [Figure 43] Three positions of the thread-over staple cartridge relative to the retaining feature portion, according to at least one aspect of this disclosure, are illustrated. [Figure 44]Three positions of the thread-over staple cartridge relative to the retaining feature portion, according to at least one aspect of this disclosure, are illustrated. [Figure 45] A partial perspective view of a staple cartridge including a thread-holding feature, according to at least one aspect of this disclosure, is shown. [Figure 46] Figure 45 illustrates the staple cartridge with the cartridge pan removed to expose the thread-holding feature. [Figure 47] A simplified partial cross-sectional view of a staple cartridge assembly having a home position and threads at a position other than the home position, according to at least one aspect of the present disclosure, is shown. [Figure 48] Figure 47 shows a simplified partial cross-sectional view of the staple cartridge assembly according to at least one aspect of the present disclosure, in which the working end of the drive member is advanced and engaged with the raised portion of the thread reset member. [Figure 49] The diagram illustrates a handle for a surgical instrument, including a firing trigger movable to a first and second position, according to at least one aspect of the present disclosure. [Figure 50] A motor assembly operably connected to a thread reset member, according to at least one aspect of the present disclosure, is shown. [Figure 51] A handle for a surgical instrument, including a firing trigger and a thread reset actuator, according to at least one aspect of the present disclosure, is illustrated. [Figure 52] A partially exploded view of a loading unit, comprising an anvil and a surgical stapling assembly including a staple cartridge for an assembly having an elongated channel, according to at least one aspect of the present disclosure, is shown. [Figure 53] Figure 52 illustrates a partial cross-sectional view of the loading unit, showing the elongated channel and assembled staple cartridge in the unlocked configuration, and the anvil in the open configuration having the elongated channel. [Figure 54]Figures 52 and 53 illustrate partial cross-sectional views of the loading unit, showing the staple cartridge and elongated channel in a lock configuration, and the anvil in a closed configuration having an elongated channel. [Figure 55] A partial perspective view of the surgical staple assembly in the lock configuration is shown in Figure 52. [Figure 56] Figure 52 shows a partial perspective view of the surgical staple assembly being transitioned from a locked configuration to an unlocked configuration. [Figure 57] A partial perspective view of a surgical staple fastening assembly including a retainer, a staple cartridge, and an elongated channel, according to at least one aspect of the present disclosure, is shown. [Figure 58] Figure 57 illustrates how to use the retainer to free the staple cartridge from the elongated channel. [Figure 59] Figure 57 illustrates how to use the retainer to free the staple cartridge from the elongated channel. [Figure 60] Figure 57 illustrates how to use the retainer to free the staple cartridge from the elongated channel. [Figure 61] Figure 57 illustrates how to use the retainer to free the staple cartridge from the elongated channel. [Figure 62] A partial cross-sectional view of a staple cartridge assembly according to at least one aspect of this disclosure is shown.

[0006] Throughout the drawings, corresponding reference numerals indicate corresponding parts. The examples described herein illustrate specific embodiments of the invention as one form, and such examples should not be considered to limit the scope of the invention in any way. [Modes for carrying out the invention]

[0007] The applicant of this application also owns the following U.S. patent applications filed on the same day as this application, which are each incorporated herein by reference in their entirety.

[0008] - U.S. Patent Application, Invention Title: "METHOD FOR TISSUE TREATMENT BY SURGICAL INSTRUMENT", Agent Reference Number: END9291USNP1 / 200802-1M - US Patent Application, Title of Invention: "SURGICAL INSTRUMENTS WITH SLED LOCATION DETECTION AND ADJUSTMENT FEATURES", Agent Reference Number: END9291USNP3 / 200802-3 - US Patent Application, Title of Invention: "SURGICAL INSTRUMENT WITH CARTRIDGE RELEASE MECHANISMS", Agent Reference Number: END9291USNP4 / 200802-4 - U.S. Patent Application, Title of Invention: "DUAL-SIDED REINFORCED RELOAD FOR SURGICAL INSTRUMENTS", Agent Reference Number: END9291USNP5 / 200802-5 - US Patent Application, Invention Title: "SURGICAL SYSTEMS WITH DETACHABLE SHAFT RELOAD DETECTION", Agent Reference Number: END9291USNP6 / 200802-6 - US Patent Application, Title of Invention: "SURGICAL INSTRUMENTS WITH ELECTRICAL CONNECTORS FOR POWER TRANSMISSION ACROSS STERILE BARRIER", Agent Reference Number: END9291USNP7 / 200802-7 - U.S. Patent Application, Title of Invention: "DEVICES AND METHODS OF MANAGING ENERGY DISSIPATED WITHIN STERILE BARRIERS OF SURGICAL INSTRUMENT HOUSINGS", Agent Reference Number: END9291USNP8 / 200802-8 - US Patent Application, Invention Title: "POWERED SURGICAL INSTRUMENTS WITH EXTERNAL CONNECTORS", Agent Reference Number: END9291USNP9 / 200802-9 - US Patent Application, Invention Title: "POWERED SURGICAL INSTRUMENTS WITH SMART RELOAD WITH SEPARATELY ATTACHABLE EXTERIORLY MOUNTED WIRING CONNECTIONS", Agent Reference Number: END9291USNP10 / 200802-10 - U.S. Patent Application, Title of Invention "POWERED SURGICAL INSTRUMENTS WITH COMMUNICATION INTERFACES THROUGH STERILE BARRIER", Agent Reference Number END9291USNP11 / 200802-11, and - U.S. Patent Application, Invention Title: "POWERED SURGICAL INSTRUMENTS WITH MULTI-PHASE TISSUE TREATMENT", Agent Reference Number: END9291USNP12 / 200802-12.

[0009] The applicant of this application owns the following U.S. patent applications filed on December 4, 2018, the disclosures of each of these are incorporated herein by reference in their entirety. U.S. Patent Application No. 16 / 209,385, Title of Invention: "METHOD OF HUB COMMUNICATION, PROCESSING, STORAGE AND DISPLAY" • U.S. Patent Application No. 16 / 209,395, Title of Invention: "METHOD OF HUB COMMUNICATION" • U.S. Patent Application No. 16 / 209,403, Title of Invention: "METHOD OF CLOUD BASED DATA ANALYTICS FOR USE WITH THE HUB" U.S. Patent Application No. 16 / 209,407, Invention Title: "Method of Robotic Hub Communication, Detection, and Control" U.S. Patent Application No. 16 / 209,416, Title of Invention: "METHOD OF HUB COMMUNICATION, PROCESSING, DISPLAY, AND CLOUD ANALYTICS" U.S. Patent Application No. 16 / 209,423, Title of Invention: "Method of Compressing Tissue Within a Stapling Device and Simultaneously Displaying the Location of the Tissue Within the Jaws," U.S. Patent Application No. 16 / 209,427, Title of Invention: "Method of Using Reinforced Flexible Circuits with Multiple Sensors to Optimize Performance of Radio Frequency Devices" U.S. Patent Application No. 16 / 209,433, Title of Invention: "Method of Sensing Particulate from Smoke Evacuated from a Patient, Adjusting the Pump Speed ​​Based on the Sensed Information, and Communicating the Functional Parameters of the System to the Hub," • U.S. Patent Application No. 16 / 209,447, Title of Invention: "METHOD FOR SMOKE EVACUATION FOR SURGICAL HUB" • U.S. Patent Application No. 16 / 209,453, Title of Invention: "METHOD FOR CONTROLLING SMART ENERGY DEVICES", • U.S. Patent Application No. 16 / 209,458, Title of Invention: "METHOD FOR SMART ENERGY DEVICE INFRASTRUCTURE", U.S. Patent Application No. 16 / 209,465, Title of Invention: "METHOD FOR ADAPTIVE CONTROL SCHEMES FOR SURGICAL NETWORK CONTROL AND INTERACTION" U.S. Patent Application No. 16 / 209,478, Title of Invention: "Method for Situational Awarenness for Surgical Network or Surgical Network Connected Device Capable of Adjusting Function Based on a Sensed Situation or Usage" • U.S. Patent Application No. 16 / 209,490, Title of Invention: "METHOD FOR FACILITY DATA COLLECTION AND INTERPRETATION", and U.S. Patent Application No. 16 / 209,491, Title of Invention: "Method for Circular Stapler Control Algorithm Adjustment Based on Situational Awareness".

[0010] Numerous specific details are described herein, as illustrated in the accompanying drawings, to provide a complete understanding of the overall structure, function, manufacture, and use of the embodiments. Well-known operations, components, and elements are not described in detail so as not to obscure the embodiments described herein. The reader will understand that the embodiments described and illustrated herein are non-limiting embodiments, and therefore certain structural and functional details disclosed herein may be representative and illustrative. Modifications and changes thereto may be made without departing from the scope of the "Claims."

[0011] Various representative devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, it will be readily apparent to the reader that the various methods and devices disclosed herein can be used in many surgical procedures and applications, including, for example, those related to incisional surgical procedures. By reading further into the “Modes for Carrying Out the Invention” section of this specification, the reader will further understand that the various instruments disclosed herein can be inserted into the body in any way, for example, through a pre-existing opening, through an incision or puncture hole formed in the tissue, etc. The working portion, or end-effector, of these instruments can be inserted directly into the patient’s body, or through an access device having a working passage through which the end-effector and elongated shaft of the surgical instrument can be advanced.

[0012] A surgical stapling system may comprise a shaft and an end effector extending from the shaft. The end effector comprises a first jaw and a second jaw. The first jaw comprises a staple cartridge. The staple cartridge is insertable into and removable from the first jaw, although other embodiments can be conceived in which the staple cartridge is not removable from the first jaw, or at least not easily replaceable from the first jaw. The second jaw comprises an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closing axis, although other embodiments can be conceived in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises an articulation joint configured to rotate, i.e., articulate, the end effector relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments that do not include articulated joints can also be conceived.

[0013] A staple cartridge comprises a cartridge body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal and distal ends. During use, the staple cartridge is positioned on the first side of the tissue to be stapled, and the anvil is positioned on the second side of the tissue. The anvil moves toward the staple cartridge, pressing and clamping the tissue against the deck. Subsequently, staples, detachably housed within the cartridge body, can be deployed into the tissue. The cartridge body includes defined staple cavities, within which staples are detachably housed. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on the first side of the longitudinal slots, and three rows of staple cavities are positioned on the second side of the longitudinal slots. Other devices for staple cavities and staples may also be possible.

[0014] The staples are supported by a staple driver within the cartridge body. The driver is movable between a first, i.e., unfired position and a second, i.e., fired position, to eject the staples from the staple cavity. The driver is held within the cartridge body by a retainer extending around the lower perimeter of the cartridge body and includes an elastic member configured to grip the cartridge body and hold the retainer relative to the cartridge body. The drivers are movable between their unfired and fired positions by threads. The threads are movable between a proximal position adjacent to the proximal end and a distal position adjacent to the distal end. The threads include a plurality of inclined surfaces configured to slide beneath the driver and lift the driver, on which the staples are supported and directed toward the anvil.

[0015] In addition to the above, the thread is moved distally by the launching member. The launching member is configured to contact the thread and push it toward its distal end. A longitudinal slot defined within the cartridge body is configured to receive the launching member. The anvil also includes a slot configured to receive the launching member. The launching member further comprises a first cam that engages with a first jaw and a second cam that engages with a second jaw. As the launching member is advanced distally, the first and second cams can control the distance between the deck of the staple cartridge and the anvil, i.e., the inter-tissue gap. The launching member also includes a knife configured to excise tissue trapped between the staple cartridge and the anvil. It is desirable that the knife be positioned at least partially proximal to the inclined surface so that the staple is ejected ahead of the knife.

[0016] Referring to Figures 1 to 4, a surgical instrument system is provided, for example, an electromechanical surgical instrument system 10. The system 10 includes a handle assembly 100, a plurality of types of adapters or shaft assemblies, such as adapter assembly 200a, and a plurality of types of end effectors, such as end effector 300a. The handle assembly 100 is configured to selectively mount any one of a plurality of adapter assemblies, for example adapter assembly 200a, thereto, so that each unique adapter assembly 200a is configured for selective connection of any number of surgical loading units or end effectors, such as end effector 300a. The end effectors 300a and adapter assemblies 200a are configured for operation and manipulation by the handle assembly 100. A motorized, handheld, electromechanical surgical instrument is formed when one adapter assembly 200a is connected to, for example, a handle assembly 100, and one type of end effector, such as an end effector 300a, is connected to the selected adapter assembly 200a.

[0017] For a detailed description of the configuration and operation of typical electromechanical handheld electric surgical instruments, refer to PCT International Publication No. 2009 / 039506 and U.S. Patent Application Publication No. 2011 / 0121049, the entire contents of which are incorporated herein by reference.

[0018] Referring to Figures 1 and 2, the handle assembly 100 includes an internal core 101 and a housing or shell 110a configured to selectively receive and house the internal core 101. The internal core 101 is motor-operable and configured to drive the operation of several types of end effectors. The internal core 101 has several sets of operating parameters (e.g., the operating speed of the motor of the internal core 101, the amount of power delivered to the adapter assembly by the motor of the internal core 101, the selection of the motor of the internal core 101 to be actuated, the function of the end effector performed by the internal core 101, etc.). Each set of operating parameters of the internal core 101 is designed to drive the operation of a particular set of functions specific to each type of end effector when an end effector is coupled to the internal core 101. For example, the internal core 101 may vary its power output depending on the type of end effector coupled to the internal core 101 to deactivate or activate its particular button and / or actuate its different motors.

[0019] Referring particularly to Figure 2, the internal core 101 defines the inner housing cavity in which the power pack 106 is located. The power pack 106 is configured to control various operations of the internal core 101. The power pack 106 includes several motors 108a, 108b that are operably engaged with it. The rotation of the motors 108a, 108b functions to drive the shaft and / or gear components of the adapter assembly 200a to drive various operations of an end effector attached thereto, for example, an end effector 300a. In the embodiment illustrated in Figure 2, two motors are shown, but in other embodiments, the handle assembly may include more than two or fewer motors.

[0020] In various embodiments, the handle assembly 100 is replaced by a robotic arm of a robotic system. In such embodiments, the adapter assembly 200a may also be effectively used in conjunction with a tool drive assembly of a robotically controlled surgical system or an automated surgical system. For example, the adapter assembly disclosed herein may be used in conjunction with various robotic systems, instruments, components, and methods, such as, but not limited to, those disclosed in U.S. Patent No. 9,072,535, titled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS," which is incorporated herein by reference in its entirety.

[0021] When the end effector 300a is connected to the internal core 101, the motor of the power pack 106 is configured to drive the shaft and / or gear components of the adapter assembly 200a in order to selectively move the end effector 300a relative to the proximal body portion 302a of the end effector 300a, to rotate the end effector 300a around the longitudinal axis "X", to move the cartridge assembly 308a and anvil assembly 306a of the end effector 300a relative to each other, and / or to fire staples from within the cartridge assembly 308a of the end effector 300a.

[0022] Referring to Figures 3 and 4, the surgical instrument system 10 further includes a disposable outer housing 110. The housing 110 is configured to house an inner core 101, thereby preventing surgical debris from penetrating and contaminating the inner core 101 during surgical procedures. The housing 110 selectively houses the inner core 101 before use, and then, after use, is removed from the inner core 101 and disposed of, or, in some cases, sterilized for reuse.

[0023] Referring to Figure 3, the housing 110 includes housing portion 112a. The housing 110 further includes housing portion 112b, which is movably connected to housing portion 112b by a hinge 120a positioned along the upper edge of housing portion 112b. Housing portions 112a and 112b are pivotable relative to each other between a closed and fully connected configuration, as shown in Figure 4, and an open and partially detached configuration, as shown in Figure 3. When connected, housing portions 112a and 112b define a cavity 122a within which an internal core 101, memory 114, and microprocessor 140 can be selectively located. In certain embodiments, housing portions 112a and 112b may be manufactured from any suitable material, such as polycarbonate. In certain embodiments, the memory 114 and microprocessor 140 are incorporated, for example, into the internal core 101.

[0024] Memory 114 is intended to be a non-volatile memory, such as an electrically erasable programmable read-only memory. Memory 114 stores within itself discrete operating parameters of the internal core 101 corresponding to the operation of one type of end effector, such as an end effector 300a, and / or one type of adapter assembly, such as an adapter assembly 200a. The operating parameters stored in memory 114 may be at least one of the following: the operating speed of the motors 108a and 108b of the internal core 101; the amount of power delivered by the motors 108a and 108b of the internal core 101 during their operation (the motors 108a and 108b of the internal core 101 are operated when the internal core 101 is operated); the type of function of the end effector performed by the internal core 101; and so on.

[0025] Figure 5 shows an embodiment of a loading unit 16 that may be used in conjunction with a surgical instrument system 10, in the manner discussed in U.S. Patent No. 5,865,361 (the disclosure thereof is incorporated herein by reference in its entirety).

[0026] As shown in Figure 5, the loading unit 16 may generally include a tool assembly 17 for performing surgical procedures such as cutting tissue and applying staples to each side of the cut. In particular, the tool assembly includes a cartridge assembly 18 that houses a plurality of surgical staples inside. The tool assembly 17 also includes a staple-forming anvil assembly 20 having an anvil portion 204 having a plurality of staple deformation recesses formed on its lower surface. A cover plate 208 is generally fixed to the upper surface of the anvil portion 204, defining an anvil cavity between them. The anvil cavity is sized to receive the distal end of an axial drive assembly 212. A longitudinal slot 214 extends through the anvil portion 204, allowing the retaining flange 284 of the axial drive assembly 212 to pass easily through the anvil cavity. A cam-acting surface 209 is formed at the proximal end of the anvil portion 204 and is positioned to engage with the axial drive assembly 212 to facilitate the closure of the anvil assembly 20.

[0027] The cartridge assembly 18 generally includes a support portion 216 defining an elongated support channel 218. The elongated support channel 218 is dimensioned and configured to receive a staple cartridge 220 inside it. Such a staple cartridge 220 supports a plurality of fasteners and pushers, as is well known in the art. A plurality of spaced-apart longitudinal slots 230 extend through the staple cartridge 220 to accommodate the upright cam wedge 232 of the working thread 234. A central longitudinal slot 282 extends along the length of the staple cartridge 220 to facilitate the passage of a knife blade 280 formed on the axial drive assembly 212. During the operation of the loading unit 16, the actuating thread 234 translates through the longitudinal slot 230 of the staple cartridge 220, advancing the cam wedge 232 to sequentially contact a pusher operably supported within the cartridge 220, translating the pusher vertically within the cartridge 220 and biasing the fasteners (staples) associated with the pusher into the staple deformation cavity of the anvil assembly 20. A pair of pivot members 211 are formed on the proximal end of the anvil portion 204 and configured to be received in a slot 213 formed within the support portion 216, allowing the anvil portion 204 to pivot between an open position and a tissue clamp position.

[0028] As also seen in Figure 5, the loading unit 16 also has a housing portion 200 adapted to be snapped to or otherwise attached to the support portion 216. The axial drive assembly 212 includes an elongated drive beam 266 having a distal working head 268 and a proximal engagement section 270. As is well known, the drive beam 266 may be constructed from a single sheet of material, or preferably from multiple laminated sheets. The engagement section 270 includes a pair of engagement fingers 270a and 270b, dimensioned and configured to engage in a pair of corresponding retaining slots 272a formed in the drive member 272. The drive member 272 may include a proximal opening configured to receive the distal end of a control rod, as discussed in U.S. Patent No. 5,865,361.

[0029] The distal end of the drive beam 266 includes a vertical support column 278 that supports the knife blade 280 and a contact surface 283 that engages with the central portion of the working thread 234 during stapling. The surface 285 is located at the base of the surface 283 and is configured to receive a support member 287 that is slidably positioned along the bottom of the support portion 216. The knife blade 280 typically positions the working thread 234 in the staple cartridge 220 so as to translate it slightly backward through the central longitudinal slot 282, thereby forming an incision between rows of stapled internal tissue.

[0030] The retaining flange 284 protrudes distally from the vertical support 278 and supports the cam pin 286 at its distal end. The cam pin 286 is sized and configured to engage with the cam acting surface 209 on the anvil portion 204 to clamp the anvil portion 204 against internal tissue. A leaf spring 207 may be provided between the proximal end of the anvil portion 204 and the distal end of the housing 200 to bias the anvil assembly 20 to the normally open position. The loading unit 16 may further include a lockout device 288 and a spring 304 array as described in U.S. Patent No. 5,865,361.

[0031] Figure 6 illustrates an articulated loading unit 16', which includes a tool assembly 17 having an anvil assembly 20 and a cartridge assembly 18. The anvil assembly 20 includes an anvil portion 204 having a plurality of staple deformation recesses formed on its lower surface. A cover plate 208 is fixed to the upper surface of the anvil portion 204, defining an anvil cavity between them. The anvil cavity is sized to accommodate the distal end of an axial drive assembly 212. A longitudinal slot 214 extends through the anvil portion 204, allowing the retaining flange 284 of the axial drive assembly 212 to pass easily through the anvil cavity. A cam action surface 209 formed on the anvil portion 204 may be positioned to engage with the axial drive assembly 212 to facilitate clamping of the tissue between the anvil assembly 20 and the cartridge assembly 18.

[0032] The cartridge assembly 18 includes a support section 216 that supports the staple cartridge 220 inside. The staple cartridge 220 includes retaining slots 225 for receiving a plurality of fasteners (staples) and pushers. A plurality of spaced-apart longitudinal slots 230 extend through the staple cartridge 220 and accommodate the upright cam wedge 232 of the actuarithm thread 234. A central longitudinal slot 282 extends along the length of the staple cartridge 220 and allows the knife blade 280 to pass through easily. During the operation of the loading unit 16', the actuarithm thread 234 translates through the longitudinal slots 230 of the staple cartridge 220, advancing the cam wedge 232 and sequentially contacting the pusher which is operably supported within the cartridge 220, and the pusher biases the fasteners into the staple deformation cavity of the anvil assembly 20. A pair of pivot members 211 are formed on the anvil portion 204 and positioned within a slot 213 formed in the support portion 216, guiding the anvil portion 204 between the open position and the tissue clamping position.

[0033] The articulated loading unit 16' further includes a housing portion 200 comprising an upper housing half 250 and a lower housing half 252. The proximal end of the housing half 250 may include an engaging nub 254 for releasably engaging with an elongated body 14. The nub 254 forms a plug-in connection with the distal end of the body 14, as described in U.S. Patent No. 5,865,361. As also seen in Figure 6, the axial drive assembly 212 includes an elongated drive beam 266 having a distal working head and a proximal engaging section 270. The drive beam 266 may be constructed from a single sheet of material, or preferably from multiple laminated sheets. The engaging section 270 includes a pair of engaging fingers 270a and 270b, dimensioned and configured to engage releasably with a pair of corresponding retaining slots 272a formed in the drive member 272. The drive member 272 includes a proximal port opening configured to receive the distal end of a control rod when the proximal end of the loading unit 16' is engaged with the elongated body 14 of a surgical stapling device as disclosed in U.S. Patent No. 5,865,361.

[0034] The distal end of the drive beam 266 is defined by a vertical support column 278 that supports the knife blade 280, and a contact surface 283 that engages with the central portion of the working thread 234 during stapling. A surface 285 at the base of surface 283 may be configured to receive a support member 287 that is movably positioned along the bottom of the support portion 216. The knife blade 280 generally positions the working thread 234 in the staple cartridge 220 so as to translate it slightly backward through the central longitudinal slot 282, thereby forming an incision between rows of stapled internal tissue. A blade stabilizing member 290 is mounted within the housing portion 200 to support the drive beam 266 within the housing portion 200 as it advances axially. A retaining flange 284 protrudes distally from the vertical support column 278 and supports a pair of cylindrical cam rollers 286 at its distal end. The cam roller 286 is sized and configured to engage with the cam action surface 209 on the anvil portion 204, thereby clamping the anvil portion 204 against the body tissue.

[0035] The articulated reloading unit 16' includes an articulated joint 340, which includes a mounting assembly 202 comprising an upper mounting portion 236 and a lower mounting portion 238. A pivot pin 244 is formed on each of the mounting portions 236, 238 and functions to define a pivot axis "A1-A1" which may be substantially perpendicular to the longitudinal axis "LL" of the articulated reloading unit 16'. The mounting assembly 202 is pivotably connected to the distal end of the housing portion 200 by a pair of connecting members 246. Each of the connecting members 246 has an opening 247 through which a corresponding pin 244 passes. The proximal end 248 of each connecting member 246 is configured to be interlocked and received in corresponding grooves 251 formed in the distal end of the upper housing half 250 and the distal end of the lower housing half 252. A pair of springs 207 are provided between the proximal end of the anvil portion 204 and the upper mounting portion 236 to bias the anvil assembly 20 to the normally open position. An articulation link 256 may be provided to articulate the tool assembly 17 around the articulation axis "A1-A1" relative to the housing portion 200, as taught in U.S. Patent No. 5,865,361.

[0036] Figures 7 and 8 illustrate one embodiment of a loading unit 1100 for use with a surgical instrument system 10. The loading unit 1100 appears to be substantially described in U.S. Patent Application Publication 2013 / 0098965 and U.S. Patent Application Publication 2016 / 0249921, which are incorporated herein by reference in their entirety. The loading unit 1100 includes a proximal body portion 1102 and a tool assembly 1104.

[0037] The loading unit 1100 further includes a drive assembly 1180, which includes a drive member 1182 having a body and an operating end 1184. The operating end 1184 includes an upper flange 1186a, a lower flange 1186b, a vertical support connecting the upper flange 1186a and the lower flange 1186b, and a knife 1187 supported on or formed into the vertical support. The upper flange 1186a is positioned to be slidably received within a channel 1131 of the anvil assembly 1130, and the lower flange 1186b is positioned to be slidably positioned along the outer surface 1156a of the jaw member 1156. During use, distal movement of the drive member 1182 first advances the upper flange 1186a into the cam action surface formed on the anvil plate 134, and then advances the lower flange 1186b to engage with the cam action surface 1156b formed on the jaw member 1156, pivoting the cartridge assembly 1150 toward the anvil assembly 1130 to a close or closed position. Continued advance of the drive member 1182 maintains a minimum tissue gap between the anvil assembly 1130 and the cartridge assembly 1150 adjacent to the working end 184 of the drive assembly 1180 as the working end 1184 moves through the tool assembly 1104.

[0038] The working thread 1162 is positioned distal to the working end 1184 within the cartridge assembly 1150. When the working end 1184 is in its nearest position and the tool assembly 1104 is in the open or non-approach position, the thread 1162 and the working end 1184 are in their initial positions. The thread 1162 includes multiple cam-operated surfaces positioned to engage with and lift a pusher within the staple-retaining slot of the cartridge body of the cartridge assembly 1150. The pusher is positioned within the cartridge assembly 1150 and ejects staples from the cartridge body when the thread 1162 is advanced through the tool assembly 1104.

[0039] Referring to Figures 7 to 10, the loading unit 1100 includes a launch lockout assembly 1221 which includes a latch member 1222 pivotally supported on the distal end of the lower mounting portion 1174. The latch member 1222 includes a U-shaped body having a proximal base member 224 and two spaced distally extending legs. The base member 1224 is provided with a blocking member which defines a blocking surface and is welded or fixed to the base member 1224 to provide additional support to the base member 1224. Alternatively, the base member 1224 and the blocking member are formed integrally or as a single unit. The latch member 1222 pivots from a first position (Figure 9) to a second position (Figure 10). In the first position shown in Figure 9, the blocking member 1224a of the latch member 1222 is aligned with the stop surface 1184a of the drive member 1182, preventing the drive member 1182 from moving forward within the tool assembly 1104. In the second position shown in Figure 10, the blocking member 1224a is not aligned with the stop surface 1184a of the drive member 1182, allowing the drive member 1182 to move forward within the tool assembly 1104.

[0040] In addition to the above, the insertion of the unfired cartridge assembly 1150 into the elongated channel 1157 of the jaw member 1156 pivots the latch member 1222 to a second position, thereby allowing the drive member 1182 to advance within the tool assembly 1104. The proximal portion of the thread 1162 holds the latch member 1222 in the second position against the biasing force of the biasing member 1230. During firing, if the thread 1162 is advanced distally through the cartridge assembly 1150, the thread 1162 disengages from the latch member 1222, and the biasing member 230 causes the latch member 1222 to return to a first position where it re-engages with the drive member 182 in a locked position.

[0041] In particular, accidental collisions or vibrations of the unfired cartridge assembly 1150 may cause slight movement of the threads 1162 within the unfired cartridge assembly 1150. Such movement can be problematic because the misaligned threads 1162 cannot deactivate the launch lockout assembly 1221 by moving the latch member 1222 to a second position when the unfired cartridge assembly 1150 is inserted. As a result, even if the new unfired cartridge assembly 1150 is ready to launch, the forward movement of the drive member 1182 remains obstructed.

[0042] In addition to the above, a properly installed unfired cartridge assembly 1150 may suffer the same fate due to an accidental collision or vibration of the loading unit 1100. A slight movement of the thread 1162 may cause the latch member 1222 to disengage from the thread 1162, thereby allowing the latch member 1222 to be returned to its first position by the biasing force of the biasing member 1230. As a result, the firing lockout assembly 1221 is prematurely reactivated by an accidental collision or vibration of the loading unit 1100 before actual firing begins.

[0043] In any case, the misalignment of thread 1162 could cause frustration for a user who expects a properly positioned unfired cartridge assembly 1150 to fire, deploying staples into the tissue grasped between the anvil assembly 1130 and the cartridge assembly 1500, resulting in an inability to achieve their objective. If firing inevitably fails, the user has no choice but to release the tissue, sacrificing all the time spent identifying the most appropriate tissue piece and aligning the loading unit 1100 with it for grasping. Furthermore, confident that the cartridge assembly is new and unfired, the user may attempt to replace the loading unit 1100 and / or the surgical instrument system 10, but this would be costly and would not be a successful remedy if the user were to mount the cartridge assembly 1150 with the misaligned thread 1162 onto a new loading unit 1100.

[0044] This disclosure provides various solutions for maintaining the thread 1162 in the proper position relative to the unfired cartridge assembly 1150. Additionally or alternatively, this disclosure provides various mechanisms for detecting accidental movement of the thread 1162 from its proper position. This disclosure further provides various mechanisms for actively returning the thread 1162 to its proper position.

[0045] Referring to Figures 11-13, the loading unit 1200 is similar in many respects to the loading unit 1100. For example, the loading unit 1200 includes a proximal body portion 1102 (Figure 8) and a tool assembly 1204 including an end effector with jaws 1236 including an anvil assembly 1230 and jaws 1256 including a staple cartridge assembly 1250. At least one of the jaws 1236, 1256 is movable relative to the other to grasp tissue between the anvil assembly 1230 and the staple cartridge assembly 1250.

[0046] Furthermore, the staple cartridge assembly 1250 includes an elongated channel 1257 that is dimensioned and designed to receive and releasably hold a staple cartridge 1220, which is similar in many respects to other staple cartridges described elsewhere in this specification, such as staple cartridge 220. Staples are deployed from the staple cartridge 1220 through the cartridge deck 1255 into the tissue via a staple driver moved by a thread 1262, in a manner similar to that described in relation to the loading units 16, 16', 1100 in Figures 1 to 8. The staples and staple driver are housed within the cartridge body 1259 of the staple cartridge 1220.

[0047] The cartridge pan 1258 is attached to the bottom of the cartridge body 1259 to prevent the staple driver from falling out of the cartridge body 1259. The cartridge pan 1258 includes a pan slot 1254 aligned with a cartridge slot defined within the cartridge deck 1255. The pan slot 1254 is also aligned with a channel slot 1253 defined in the base portion 1252 of an elongated channel 1257. During firing, the working end 1184 of the drive member 1182 (Figure 9) moves slidably through the cartridge slot, the pan slot 1254, and the channel slot 1253, advancing the thread 1262 distally from a first position to a second position within the cartridge body, causing the staples to be deployed to the staple driver through the cartridge deck 1255.

[0048] Furthermore, the loading unit 1200 includes a firing lockout assembly 1221 configured to prevent the drive member 1182 from moving forward when there is no unfired staple cartridge 1220 having a suitably positioned thread 1262. To resist movement of the thread 1262 due to accidental collision or vibration of the staple cartridge 1220, the base portion 1252 includes one or more retaining features (e.g., retaining features 1270a, 1270b) configured to engage with the thread 1262 and resist movement of the thread 1262 up to a predetermined force.

[0049] In certain cases, as illustrated in Figure 13, the thread 1262 includes one or more openings, holes, grooves, or retaining portions (e.g., retaining portions 1272a, 1272b) defined within the thread base 1263. The retaining portions 1272a, 1272b are configured to align with and receive the retaining features 1270a, 1270b when the thread 1262 is positioned in a first position. In the embodiments illustrated in Figures 11 to 13, the retaining features 1270a, 1270b extend through corresponding openings or cutouts 1274a, 1274b within the cartridge pan 1258 when the staple cartridge 1220 is properly seated within the elongated channel 1257.

[0050] In the illustrated embodiment, when the thread 1262 is in a first position, the retaining feature 1270a, the return feature 1272a, and the cutout 1274a are located on the first side of a plane that bisects the staple cartridge 1220 longitudinally and extends longitudinally along the cartridge slot, the pan slot 1254, and the channel slot 1253. The retaining feature 1270b, the return feature 1272b, and the cutout 1274b are located on the second side of the plane opposite to the first side.

[0051] In various embodiments, the retaining features 1270a, 1270b are in the form of bumps or projections extending upward from the base portion 1252. The retaining features 1270a, 1270b may define an inclined and / or curved outer shape having a radius of curvature dimensioned to resist the forward movement of the thread 1262 when the driving force applied to the thread 1262 by the drive member 1182 is less than or equal to a predetermined force.

[0052] In various embodiments, the retaining feature may include a triangular prism shape, a partially elliptical shape, a partially spherical shape, a partially cylindrical shape, or a truncated pyramidal shape. Other shapes are also contemplated in this disclosure. In various embodiments, the height of the retaining feature may be less than or equal to the depth of the corresponding stopper portion of the thread, thereby ensuring that the thread is not lifted by the retaining feature when assembled with them. In various embodiments, the number of retaining features may be more than two or less. In one embodiment, a single retaining feature may be used with the corresponding stopper portion and cutout portion. In another embodiment, three or more retaining features may be used with the corresponding stopper portion and cutout portion. In a particular embodiment, a dedicated cutout portion is replaced by a single cutout portion corresponding to the passage of multiple retaining features through which it passes.

[0053] If the driving force applied by the drive member 1182 exceeds a predetermined force, the thread 1262 moves toward a second position, disengaging from its alignment with the retaining features 1270a and 1270b. After the thread 1262 reaches the second position, the drive member 1182 retracts to a starting position where the firing lockout assembly 1221 is reactivated to prevent the drive member 1182 from moving forward again until the unfired staple cartridge 1220 is assembled with the elongated channel so that the thread 1262 is properly positioned in the first position. The proximal portion of the thread 1262 engages with the latch member 1222, deactivating the firing lockout assembly 1221.

[0054] Figure 13 illustrates an embodiment of a retaining feature 1270a of an unfired staple cartridge 1220 that is properly seated within an elongated channel 1257. The retaining portion 1272a of the thread 1262 of the unfired staple cartridge 1220 is appropriately aligned to receive the retaining feature 1270a through the cutout portion 1274a in a first position, which results in an unlock configuration of the firing lockout assembly 1221. The retaining feature 1270a includes a base portion 1277 that protrudes from the elongated channel 1257 and extends into the cutout portion 1274a, and a head portion 1279 that protrudes from the base portion and extends into the retaining portion 1272a of the thread 1262. The head portion 1279 extends through the cutout portion 1274a beyond the cartridge pan 1258 into the retaining portion 1272a, but the base portion 1277 does not.

[0055] The base portion 1277 ensures proper alignment of the staple cartridge 1220 with the elongated channel 1257, and the head portion 1279 ensures that the thread 1262 remains in the first position until a driving force greater than a predetermined driving force is applied thereto. In the illustrated embodiment, the base portion 1277 has a rectangular or at least substantially rectangular cross-section. In particular, the head portion 1279 has a curved shape that defines an inclination that resists the advance of the thread 1262 with a force less than or equal to a predetermined force defined by the radius of curvature of the head portion 1279.

[0056] Furthermore, the head portion 1277 is slightly smaller in size than the retaining portion 1272a, allowing for slight movement of the thread relative to the head portion 1279 without an unintended transition from the unlocked configuration to the locked configuration in the firing lockout assembly. In the illustrated embodiment, the retaining portion 1272a has a length d2 that is longer by a distance Δd (the difference between d1 and d2) than the length d1 of the head portion 1279. Thus, the thread is slidably moved a distance Δd relative to the cartridge pan 1258 without impairing the mating engagement between the head portion 1279 and the retaining portion 1272a.

[0057] Figures 14 and 15 illustrate staple cartridge 1220', which is similar in many respects to staple cartridges 220 and 1220. For example, staple cartridge 1220' includes threads 1262 with a return stop 1272a. However, unlike staple cartridge 1220, the cartridge pan 1258' of staple cartridge 1220' does not include a cutout for accommodating the retaining features of the elongated channel. Instead, the cartridge pan 1258' includes retaining features 1270a' and 1270b' that protrude from the cartridge pan 1258'. The retaining features 1270a' and 1270b' are similar in many respects to retaining features 1270a and 1270b. For example, the retaining features 1270a' and 1270b' are configured to engage with the return stoppers 1272a and 1272b of the thread 1262 to maintain the thread 1262 in a first position corresponding to the unlock configuration of the launch lockout assembly 1221 (Figure 9).

[0058] In the embodiments illustrated in Figures 14 and 15, the retaining features 1270a' and 1270b' are located on both sides of the pan slot 1254. The retaining features 1270a' and 1270b' are defined on the base portion of the cartridge pan 1258' adjacent to the side walls 1273a and 1273b. In the exemplary embodiment, the retaining features 1270a' and 1270b' are aligned across the pan slot 1254. In other embodiments, the retaining features 1270a' and 1270b' may be offset.

[0059] Figure 16 illustrates an alternative staple cartridge 1220'' which is similar in many respects to other staple cartridges described elsewhere in this specification, such as staple cartridges 220, 1220, and 1220'. Staples are deployed from the staple cartridge 1220'' through the cartridge deck into the tissue via a staple driver moved by a thread 1162, in a manner similar to that described in relation to the loading units 16, 16', and 1100 in Figures 1 to 8. The drive member 1182 is configured to deploy staples from the cartridge body through the cartridge deck by advancing the thread 1162 distally from a first position to a second position relative to the cartridge pan 1258''. The staple cartridge 1220'' includes retaining features 1270a'' and 1270b'' defined within the base portion 1252'' of the cartridge pan 1258'' above both sides of the pan slot 1254.

[0060] Staple cartridge 1220'' differs from staple cartridge 1220'' in that the retaining features 1270a'', 1270b'' are in the form of tabs bent away from the base portion 1252''. The retaining features 1270a'', 1270b'' define a foldable inclined portion configured to resist the movement of the thread 1162 beyond a first position, thereby maintaining the launch lockout assembly 1221 (Figure 9) in an unlocked configuration while the thread 1162 is in the first position.

[0061] In the illustrated embodiment, the thread 1162 may be moved slightly slidably from its first position before engaging with the retaining features 1270a'', 1270b'', allowing movement to be insufficient to disengage the thread 1162 from the latch member 1222 and therefore insufficient to prematurely transition the launch lockout assembly 1221 to the locked configuration. When the distal portion of the thread 1162 engages with the retaining features 1270a'', 1270b'', any further forward movement of the thread 1162 is resisted by the retaining features 1270a'', 1270b'',

[0062] If the driving force applied to the thread 1162 by the drive member 1182 exceeds a predetermined driving force, the thread 1162 moves forward on the retaining feature portions 1270a'', 1270b'',. In specific cases, the retaining feature portions 1270a'', 1270b'', fold under the thread 1162 if the driving force applied to the thread 1162 by the drive member 1182 exceeds a predetermined driving force.

[0063] Figures 17 and 18 illustrate staple cartridge 1320, which is in many respects similar to other staple cartridges described elsewhere in this specification, such as staple cartridges 220, 1220, and 1220'. Staples are deployed from staple cartridge 1320 through cartridge deck 1355 into the tissue via a staple driver moved by thread 1362, in a manner similar to that described in relation to loading units 16, 16', and 1100 in Figures 1 to 8. The staples and staple driver are housed in cartridge body 1359 of staple cartridge 1320.

[0064] In addition to the above, the threads 1362 of the unfired staple cartridge 1320 are maintained in a predetermined first position using retaining features 1370a, 1370b defined in the proximal portion of the sidewall of the cartridge pan 1358. In the embodiment illustrated in Figure 17, the retaining features 1370a, 1370b are in the form of inwardly projecting leaf springs. The leaf springs may be punched or formed in the sidewall of the cartridge pan 1358. The retaining feature 1370a includes a base attached to and projecting from the sidewall of the cartridge pan 1358. The apex portion extends from the base, passes through a cutout defined in the cartridge body 1359 (e.g., cutout 1374a), and enters into a retaining portion defined in the sidewall of the threads 1362 (e.g., retaining portion 1372a). The retaining feature portion 1370a defines an inclined portion that resists distal advancement of the thread 1362 up to a predetermined driving force.

[0065] Figure 19 illustrates an alternative staple cartridge assembly 1450 that is similar in many respects to the cartridge assembly 1250. For example, similar to the staple cartridge assembly 1250, the staple cartridge assembly 1450 includes a staple cartridge 1420, which includes a thread 1462 configured to deploy the staples from the cartridge body through the cartridge deck by sliding the thread 1462 distally forward from a first position to a second position relative to the cartridge pan 1458. When the unfired staple cartridge 1420 is properly assembled with the elongated channel 1457 of the loading unit, the firing lockout assembly 1221 transitions to an unlocked configuration, allowing the drive member 1182 to advance distally and move the thread 1462 to deploy the staples.

[0066] The staple cartridge assembly 1450 differs from the staple cartridge assembly 1250 in that the elongated channel 1457 includes retaining features 1470a, 1470b in the form of grooves, holes, openings, or stoppers. The retaining features 1470a, 1470b are configured to receive thread projections 1472a, 1472b through cutouts 1474a, 1474b defined in the base portion of the cartridge pan 1458. The retaining features 1470a, 1470b are configured to resist the movement of the thread 1462 up to a predetermined force. If the driving force of the drive member 1182 is greater than the predetermined force, the thread 1462 is advanced distally beyond the first position, causing the thread projections 1472a, 1472b to exit the retaining features 1470a, 1470b.

[0067] Figures 20–21 illustrate an alternative staple cartridge assembly 1550 that is similar in many respects to cartridge assemblies 1250 and 1450. Staple cartridge assembly 1550 includes a staple cartridge 1520 that is similar in many respects to other staple cartridges described elsewhere in this specification, such as staple cartridges 220, 1220, 1220', 1220'', and 1420. Staples are deployed from the staple cartridge 1520 into the tissue through the cartridge deck 1555 via a staple driver moved by a thread 1562, in a manner similar to that described in relation to loading units 16, 16', and 1100 in Figures 1–8. The drive member 1182 is configured to deploy staples from the cartridge body through the cartridge deck 1555 by advancing the thread 1562 distally from a first position to a second position relative to the cartridge pan 1558.

[0068] The staple cartridge 1520 includes one or more retaining features (e.g., retaining features 1570a, 1570b) configured to resist distal advancement of the threads 1562 until the staple cartridge 1520 is fully seated or assembled with the elongated channel 1557 of the loading unit. In an exemplary embodiment, retaining feature 1570b is in the form of a folding leaf spring defined within the cartridge pan 1558 by bending an existing pan sheet metal. In an exemplary embodiment, retaining feature 1570b includes a first portion bent toward the cartridge deck 1555 and a second portion bent away from the cartridge deck 1555. The curved portion extends between the first and second portions and connects them. In an exemplary embodiment, the second portion is slightly longer than the first portion.

[0069] When the staple cartridge 1520 is inserted into the elongated channel 1557, the retaining features 1570a and 1570b fold or flatten relative to the elongated channel 1557, as shown in Figure 21, thereby allowing the thread 1562 to move distally by the drive member 1182. The retaining features 1570a and 1570b resist the forward movement of the thread 1562 until they fold due to the insertion of the staple cartridge 1520 into the elongated channel 1557. In other words, the retaining features 1570a and 1570b are configured to maintain the thread 1562 in a first position until the staple cartridge 1520 is inserted into the elongated channel 1557. In doing so, the retaining features 1570a and 1570b ensure that the thread 1562 transitions the launch lockout assembly 1221 to an unlocked configuration, allowing the drive member 1182 to move forward.

[0070] Figures 22–24 show an alternative staple cartridge 1620 having a retaining feature 1670 that is similar in many respects to the staple cartridge 1520 and its retaining features 1570a, 1570b. For example, the retaining feature 1670 is also in the form of a folding leaf spring defined within the cartridge pan 1658 by bending an existing pan sheet metal. However, unlike the retaining features 1570a, 1570b, the retaining feature 1670 is not folded or flattened by the insertion of the staple cartridge 1620 into the elongated channel of the loading unit. Instead, the threads 1662 of the staple cartridge 1620 include grooves, openings, holes, or retaining sections 1672 configured to receive the retaining feature 1670, as shown in Figure 22.

[0071] Similar to other folding retaining features described elsewhere in this specification, the retaining feature 1670 is configured to hold the thread 1662 in a first position, thereby ensuring the unlocked configuration of the launch lockout assembly 1221 through persistent engagement between the latch member 1222 and the thread 1662. If the driving force exerted on the thread 1662 by the drive member 1182 exceeds a predetermined threshold, the retaining feature 1670 folds away from the retaining feature 1672, allowing the thread 1662 to advance further.

[0072] In an exemplary embodiment, the retaining feature 1670 includes a first portion 1671, a second portion 1673, and an intermediate bent portion 1675 extending between portions 1671 and 1673 and connecting them. Portion 1671 includes an opening 1679. During assembly, as shown in Figure 24, a hook member 1681 engages with portion 1671 at the opening 1679, temporarily pulling back the retaining feature 1670 and allowing the thread 1662 to slide into a first position. The hook member 1681 then releases portion 1671, which allows the retaining feature 1670 to be received within the retaining portion 1672.

[0073] Referring here to Figures 25 to 28, the staple cartridge assembly 1750 is in many respects similar to other staple cartridge assemblies described elsewhere in this specification, such as staple cartridge assembly 1250. For example, staple cartridge assembly 1750 includes an elongated channel 1757 that is dimensioned and designed to receive and releasably hold staple cartridge 1720, which is in many respects similar to other staple cartridges described elsewhere in this specification, such as staple cartridges 220, 1220. Staples are deployed from staple cartridge 1720 through the cartridge deck into the tissue via a staple driver moved by thread 1762, in a manner similar to that described in relation to loading units 16, 16', 1100 in Figures 1 to 8. The staples and staple driver are housed within the cartridge body of staple cartridge 1720. During firing, the working end of the drive member 1182 advances the thread 1762 distally within the cartridge body from a first position to a second position, causing the staples to be deployed by the staple driver.

[0074] Similar to the staple cartridge assembly 1250, the staple cartridge assembly 1750 includes a retaining feature 1770 positioned within an elongated channel 1757. In an exemplary embodiment, the retaining feature 1770 is in the form of a leaf spring, flattened, or at least partially flattened, in a biased configuration by hard stop portions including hard stop portions 1771a, 1771b defined within the opposing side walls 1757a, 1757b of the elongated channel 1757. When an unfired staple cartridge 1720 is properly assembled with the elongated channel 1757, the threads 1762 press the hard stop portions 1771a, 1771b into the opposing side walls 1757a, 1757b, respectively, thereby allowing the retaining feature 1770 to be released from the hard stop portions 1771a, 1771b.

[0075] Next, the distal portion of the retaining feature 1770 engages with the corresponding return stopper 1772 in the thread 1762, pulling and holding the thread 1762 to a first position corresponding to the unlocked configuration of the lockout firing assembly 1221. In the exemplary embodiment, the engagement between the retaining feature 1770 and the return stopper 1772 allows for slight movement of the thread 1762 within a predetermined threshold distance "d" without transitioning the firing lockout assembly 1221 to a locked configuration.

[0076] As will be described in more detail in other retaining features of this disclosure, the retaining feature 1770 is configured to resist the forward movement of the thread 1762 up to a predetermined force. If the driving force of the drive member 1182 is greater than the predetermined force, the thread 1762 is released from the retaining feature 1770 and moves distally beyond the first position. As the thread 1762 moves forward on the retaining feature 1770, the retaining feature 1770 resets and locks into engagement with the hard stop portions 1771a and 1771b.

[0077] Next, the retaining feature 1770 is maintained in a flattened, or at least partially flattened, configuration by the hard stop portions 1771a, 1771b until another unfired staple cartridge 1720 is inserted into the elongated channel 1757. In the exemplary embodiment, by maintaining the retaining feature 1770 in a flattened, or at least partially flattened, configuration reduces resistance to the drive member 1182 during the remainder of firing.

[0078] In an exemplary embodiment, the thread 1762 includes one or more feature portions 1773 designed and dimensioned to engage hard stop portions 1771a, 1771b and press them into opposing side walls 1757a, 1757b. The hard stop portions 1771a, 1771b may be spring-biased so that after disengaging from one or more feature portions 1773, they return to a locked engagement with the retaining feature portion 1770.

[0079] In various embodiments, one or more of the thread positioning and / or mechanism holding described herein can be combined to position and / or maintain the thread within the staple cartridge before and after insertion of the staple cartridge into the elongated channel of the loading unit. For example, a first mechanism positioning and / or mechanism holding can be used to maintain the thread in a first position within the staple cartridge before insertion of the staple cartridge into the elongated channel. Then, a second mechanism positioning and / or mechanism holding can be used to maintain the thread in the first position within the staple cartridge after insertion of the staple cartridge into the elongated channel.

[0080] In the embodiments illustrated in Figures 25 to 28, one or more feature portions 1773 may be received within corresponding openings or cutouts of a cartridge pan, as described in relation to the loading unit 1200 in Figures 11 to 13. The feature portion 1773 maintains the threads in a first position within the staple cartridge 1720 before insertion of the staple cartridge 1720 into the elongated channel 1757. However, after insertion, the threads 1762 are maintained in the first position by the retaining feature portion 1770. Thus, a staple cartridge assembly (e.g., staple cartridge assembly 1750) may be configured to maintain the threads in different first positions before and after insertion into the elongated channel. In other words, insertion of a staple cartridge into the elongated channel may deactivate an activated retaining feature portion and activate a deactivated retaining feature portion.

[0081] Referring to Figures 29–30, staple cartridge 1820 is similar to other staple cartridges described elsewhere in this specification, such as staple cartridge 220. Like staple cartridge 220, for example, staple cartridge 1820 includes a knife blade 280 (Figure 5). A central longitudinal slot 1882 is defined within staple cartridge 220 along a central longitudinal plane 1884. The knife blade 280 is generally positioned to translate slightly behind the threads 1860 through the central longitudinal slot 1882 within staple cartridge 1820, forming an incision between rows of internal tissue to be stapled.

[0082] In various embodiments, the thread 1860 is maintained in a first or home position by a retaining feature 1855 extending across the central longitudinal slot 1882. In an exemplary embodiment, the retaining feature 1855 includes a fragile central portion 1885c extending between portions 1885a and 1885b that define a hinge gate, one end of which is attached to the side walls 1882a and 1882b, respectively. In an exemplary embodiment, the central portion 1885c includes a perforated, breakable body. In other embodiments, the central portion 1885c may include a thickness thinner than portions 1885a and 1885b.

[0083] In any case, the central portion 1885c is designed and dimensioned to resist the forward movement of the thread 1860 up to a predetermined driving force threshold. Once the threshold is exceeded, the knife blade 280 applies a force to the thread 1860 that breaks through the central portion 1885c, causing portions 1885a and 1885b to fold or vibrate open, allowing the thread 1860 to move distally beyond the first or home position.

[0084] As will be described in more detail elsewhere in this specification, accidental collisions or vibrations of an unfired staple cartridge may cause unintended movement of threads within the unfired staple cartridge. Figure 31 illustrates a logic flow diagram of process 1920, which shows a control program or logic configuration for detecting the position of threads in an electric surgical stapler along its firing path (1922) and adjusting one or more motor settings or motor control programs of the electric surgical stapler based on the position of threads along its firing path (1924).

[0085] Figures 32 to 34 illustrate an electrically operated surgical staple fastener 1901, which includes a firing system 1902 configured to detect the position of a thread along its firing path according to process 1920 and to adjust one or more motor settings or motor control programs based on the position of the thread along its firing path. The firing system 1902 includes a control circuit 1930 configured to perform process 1920. In an exemplary embodiment, the control circuit 1930 includes a controller 1932 which includes a processor 1934 and a memory 1936 for storing program instructions, which, when executed by the processor 1934, causes the processor 1934 to perform one or more aspects of process 1920.

[0086] The surgical stapling device 1901 further includes a loading unit 1900 which is similar in many respects to other loading units described elsewhere in this specification, such as loading units 1100, 1200, for example. Similar to loading unit 1100, loading unit 1900 includes a drive assembly 1980 which includes a drive member 1982. The motor assembly 1904 includes a motor configured to move the drive member 1982 along a predetermined firing path to advance the thread 1962 distally, thereby deploying the staple 1908 from the staple cartridge 1921 into the tissue grasped between the staple cartridge 1921 and the anvil assembly 1931. The thread 1962 includes a plurality of cam-operated surfaces positioned to engage with a pusher and lift it within the staple-holding slot of the cartridge body of the staple cartridge 1921. The pusher is positioned within the staple cartridge 1921 so as to eject the staple 1908 from the cartridge body when the thread 1962 is advanced by the drive member 1982, as shown in Figures 33 and 34.

[0087] Figure 35 is a graph 1940 showing the firing speed (V) of the motor during the firing stroke of the electric surgical staple fastener 1901 (Figure 32) and the corresponding electrical load, represented on the y axis by lines 1942', 1944', 1946', 1948', 1950', 1952', and lines 1942, 1944, 1946, 1948, 1950, 1952, respectively, with the distance (δ) traveled by the drive member 1982 along the firing path from the starting position on the x-axis, and the firing speed (V) of the motor during the firing stroke of the electric surgical staple fastener 1901 (Figure 32). The division Δδ along the firing path SC This defines an acceptable initial thread contact position, where the drive member 1982 is configured to first engage with the thread 1962 as it advances along the launch path (see Figure 33). Also, section Δδ along the launch path IS This defines an acceptable initial staple contact position in which the thread 1962, driven by the drive member 1982, first engages with the pusher of the staple 1908 in the staple cartridge 1921 (see Figure 33).

[0088] In a successful launch, as shown by lines 1942, 1944, the drive member 1982 is configured to first contact the thread 1982 within the section Δδ (1M, 2M), and the thread 1962 driven by the drive member 1982 is configured to first contact the pusher of the staple 1908 within the section Δδ SC (1M’, 2M’). IS In various aspects, a rapid increase or growth of the electrical load of the motor to a value (F, FIG. 33) within a predetermined range (F-sled

[0089] ~F-sled 最小 ~F-sled 最大 ) indicates that an initial contact between the drive member 1982 and the thread 1962 has been detected. In various aspects, the control circuit 1930 detects the position of the thread 1962 by monitoring at least one parameter indicative of the electrical load of the motor, such as the motor's inrush current, for example. S1 Similarly, a rapid increase or growth of the electrical load of the motor beyond a predetermined range (F-sled

[0090] ~F-sled 最小 ~F-sled 最大 ) to a value (F, FIG. 33) within a predetermined range (F-staple 最小 ~F-staple 最大 ) indicates that an initial contact between the thread 1962 driven by the drive member 1982 and the pusher of the staple 1908 has been detected. In various aspects, the control circuit 1930 detects the initial contact between the thread 1962 and the staple pusher by monitoring at least one parameter indicative of the electrical load of the motor, such as the motor's inrush current, for example. S2 A rapid increase in the electrical load of the motor in section Δδ

[0091] SC ​If detected within the system, the control circuit 1930 will drive the drive member 1982 along the firing path of the thread 1962 at a predetermined maximum speed until the thread 1982 engages with the pusher of the staple cartridge 1921. 最大 This allows the motor to continue moving forward at a speed below (F), but as mentioned above, this depends on the value of the motor's electrical load (F). S2 This is characterized by another rapid increase to (Figure 33). The detection of the first contact between the thread 1962 and the staple pusher causes the control circuit 1930 to set the speed of the drive member 1982 to a predetermined minimum speed (V-firing). 最小 Faster than ) and at a predetermined maximum speed (V-firing 最大 Increase the speed to the following (Round 1, Round 2).

[0092] However, the control circuit 1930 is divided into sections Δδ, as shown by line 1950. SC If the position of the internal thread 1962 is not detected (4M), the control circuit 1930 may stop the drive member 1982, for example, by causing the motor assembly 1904 to stop the motor (4R). Since the absence of thread 1962 may result from a previously fired staple cartridge being mounted in the cartridge channel of the loading unit 1900, or from the absence of a staple cartridge, the control circuit 1930 may further prompt the user through the user interface 1909 to replace the staple cartridge. If the user approves, the drive member 1982 is returned to its starting position (b). However, if the user is certain that an unfired staple cartridge is mounted in the cartridge channel, thread 1962 may be moved or misaligned due to an accidental collision of the staple cartridge.

[0093] To solve the problem, the control circuit 1930 (a) a predetermined maximum threshold δ of movement without thread detection 最大 The user is prompted to grant permission to continue advancing the drive member 1982 until it reaches (5M, 5R). If thread 1962 is not detected, a predetermined maximum threshold δ is reached. 最大If this is reached, the control circuit 1930 causes the drive member to return to its starting position (5R').

[0094] However, a predetermined threshold δ 最大 If thread 1962 is detected before reaching (6M, 6R), the control circuit 1930 will connect the drive assembly 1980 to thread 1962 by a predetermined segment Δδ, as will be described in more detail below. SL Within this, additional forward movement (6R') of the drive member 1982 can be enabled. SL This defines a functional window for thread movement to ensure that a connection has been established between the drive member 1982 and the thread 1962.

[0095] Next, the control circuit 1980 causes the motor to retract the drive member 1980 to its starting position, thereby returning the thread 1962 to its home position (6R) in the unfired staple cartridge. The control circuit 1930 may further prompt the user to push down any staple 1908 that has been accidentally lifted onto the cartridge deck by the unintended forward movement of the thread 1962. Once the thread is back in its home position, the control circuit 1930 may prompt the user to (c) resume the firing stroke.

[0096] In addition to the above, classification Δδ SC The successful detection of thread 1962 within (1M) is due to segment Δδ IS With the failure to detect initial contact (3M') between the internal thread 1962 and the staple pusher, the control circuit 1930 is directed to section Δδ IS The forward movement of the drive member 1982 is stopped at or near the end of (3R). The control circuit 1930 may further return the drive member 1982 to the starting position.

[0097] Although process 1920 is described as being performed by control circuit 1930, this is for the sake of brevity only, and it should be understood that process 1920, and other processes described elsewhere in this specification, may include various hardware and / or software components and may be performed by circuits that may be located in or associated with various preferred systems described herein, such as combinational logic circuits or sequential logic circuits.

[0098] In various configurations, the motor assembly 1904 may be, for example, a DC-driven brushed motor having a maximum rotational speed of approximately 25,000 RPM. In other configurations, the motor may be a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The motor may be powered by a power supply 1910, which in one configuration may include a removable power pack. The power supply 1910 may include any one of the various power supply configurations disclosed in more detail, for example, U.S. Patent Application Publication No. 2015 / 0272575, titled “SURGICAL INSTRUMENT COMPRISING A SENSOR SYSTEM”, the entirety of which is incorporated herein by reference.

[0099] In at least one embodiment, the surgical stapling instrument 1901 is implemented as a handheld surgical instrument similar in many respects to the surgical instrument system 10 of Figure 1. In another embodiment, the surgical stapling instrument 1901 is implemented as a robotic surgical stapling instrument similar to that disclosed in U.S. Patent No. 9,072,535, title of the invention, “SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS,” which is incorporated herein by reference in its entirety.

[0100] In various embodiments, the surgical instrument 1901 includes a sensor 1938 comprising one or more sensors configured to monitor parameters indicating the position of the drive member 1982 along the firing path. The sensor 1938 may further include one or more sensors configured to monitor the motor's draw current. The reading sensor 1938 is controlled by a control circuit 1930, and the drive member 1982 is divided into section Δδ SC or classification Δδ IS This can assist in detecting the presence of a staple inside, detecting initial contact between the drive member 1982 and the thread 1962, and / or detecting initial contact between the thread 1962 driven by the drive member 1982 and the pusher of the staple 1908.

[0101] In various embodiments, the sensor 1938 may include, for example, magnetic sensors such as Hall effect sensors, inductive sensors such as strain gauges, pressure sensors, and eddy current sensors, resistance sensors, capacitive sensors, optical sensors, and / or any other suitable sensors for performing one or more embodiments of process 1920.

[0102] Referring here to Figures 36-38, the staple cartridge 2020 includes a retaining feature 2072 configured to maintain the thread 2062 within the staple cartridge 2020 in a home or start position. The staple cartridge 2020 is similar in many respects to other staple cartridges described elsewhere in this specification, such as staple cartridges 1520, 1620, etc. To resist movement of the thread 2062 due to accidental collision or vibration of the staple cartridge 2020, the cartridge pan 2058 of the staple cartridge 2020 includes one or more retaining features (e.g., retaining feature 2020) configured to mate and engage with the thread 2062 and resist movement of the thread 2062 up to a predetermined force.

[0103] In an exemplary embodiment, the retaining feature 2072 is in the form of a leaf spring that protrudes inward or is bent. The leaf spring may be punched or formed in the proximal portion of the base of the cartridge pan 2058. The retaining feature 2072 includes a base that is attached to and protrudes from the base portion of the cartridge pan 2058. The apex portion is sized to extend from the base, pass through a cutout portion defined within the cartridge pan 2058 (e.g., cutout portion 2022), and enter into a retaining portion defined within the sidewall of the thread 2062 (e.g., retaining portion 2063). The retaining feature 2072 defines an inclined portion that resists the distal advance of the thread 2062 up to a predetermined driving force. The retaining feature 2072 is flattened by the advance of the thread 2072 when a driving member (e.g., driving member 1982) applies a driving force greater than the predetermined driving force to the thread 2072.

[0104] The staple cartridge 2020 includes a thread detection circuit 2073 configured to determine whether the thread 2062 is outside the home or start position. The thread detection circuit 2073 includes a retaining feature portion 2072 and a wire or rod 2071 extending through a groove 2077 defined from the distal portion 2075 of the retaining feature portion 2072 to the proximal portion 2078 of the retaining feature portion 2072. The wire 2071 is terminated at an electrical contact portion 2079, such as a pogo pin. The electrical contact portion 2079 is configured to cause the thread detection circuit 2073 to transition between a closed configuration while the retaining feature portion 2072 is bent as shown in Figure 36 and an open configuration while the retaining feature portion 2072 is flattened by the thread 2062 as shown in Figure 37.

[0105] Therefore, a control circuit, such as the control circuit 1930 of a surgical instrument 1901, may determine whether the thread 2062 is outside the home or start position by using the thread detection circuit 2073 to detect whether the thread detection circuit 2073 has transitioned from a closed configuration to an open configuration. Switching the thread detection circuit 2073 from a closed configuration to an open configuration signals the control circuit 1930 that the thread 2062 has advanced distally beyond the home or start position. Furthermore, when the thread detection circuit 2073 returns to the closed configuration, it signals the control circuit 1930 that the thread detection circuit 2073 has returned to the home or start position.

[0106] Referring here to Figure 39, the staple cartridge assembly 2150 may be used with a loading unit, for example, loading units 1100, 1200. In an exemplary embodiment, the staple cartridge assembly 2150 includes an elongated channel 2157 that is dimensioned and designed to receive and releasably hold a staple cartridge 2120, which is similar in many respects to other staple cartridges described elsewhere in this specification, such as staple cartridge 220. For example, staples are also deployed from the staple cartridge 2120 through the cartridge deck into the tissue via a staple driver or pusher moved by a thread 2162, in a manner similar to that described in relation to loading units 16, 16', 1100 in Figures 1 to 8. The staples and staple driver are housed within the cartridge body of the staple cartridge 2120.

[0107] The cartridge pan 2158 is attached to the bottom of the cartridge body to prevent the staple driver from falling out of the staple cartridge 2120. The cartridge pan 2158 includes a pan slot 2154 aligned with a cartridge slot defined within the cartridge deck. The pan slot 2154 is also aligned with a channel slot 2153 defined in the base portion 2152 of an elongated channel 2157. During firing, the working end 1184 of the drive member 1182 slides through the cartridge slot, the pan slot 2154, and the channel slot 2153, advancing the thread 2162 distally from a first position to a second position within the cartridge body, causing the staples to be deployed to the staple driver through the cartridge deck.

[0108] As described in more detail above, a thread, such as thread 2162, may move from its home or start position due to accidental collision or vibration of the staple cartridge 2120. To detect such movement, the staple cartridge assembly 2150 includes a thread detection circuit 2160 configured to detect the position of thread 2162 as a home or start position and an additional position distal to the home or start position via a series of spaced-apart electrical contacts 2170a, 2170b on either side of the channel slot 2153. When the corresponding electrical contacts 2172a, 2172b of a thread are positioned relative to a pair of electrical contacts 2170a, 2170b, the thread detection circuit 2160 transitions to a closed configuration, and a signal specific to such a position is transmitted to a control circuit, such as control circuit 1930, as shown in Figure 41.

[0109] The control circuit 1930 may determine the position of thread 2162 based on the received signal. For example, memory 1936 may store an algorithm, formula, or lookup table for determining the position of a thread based on one or more parameters of the received signal. The processor 1934 may use such an algorithm, formula, and / or lookup table to determine the position of a thread based on a reading of one or more parameters. In one embodiment, the reading is a current reading or a voltage reading indicating the position of thread 2162.

[0110] In at least one embodiment, sensor 1938 includes a current sensor configured to measure the current passing through the thread detection circuit 2160 in a closed configuration. For a given voltage, the measured current value varies depending on the resistance. Figure 41 shows typical resistances associated with different locations of thread 2162 along the firing path. Each location is designed to yield a unique resistance, and therefore a unique current value associated with that location. Thus, the current readings from the current sensor can help a control circuit (e.g., control circuit 1930) determine whether thread 2162 is at the home or start position, or at any other more distal location.

[0111] As illustrated in Figure 40, a specific reference resistance exists in the thread detection circuit 2160, which returns to the control circuit 1930. Each time a thread 2162 completes the thread detection circuit 2160, an additional resistance specific to the line in the channel increases the total resistance, thus resulting in a unique current reading for each position along the firing path. In various embodiments, intentionally high-resistance circuit materials and / or actual resistors may be used at each contact.

[0112] In exemplary embodiments, electrical contacts 2170a and 2170b protrude above the base portion 2152 of the elongated channel 2157 and define biasing members configured to ensure good connection with the staple cartridge 2120. The electrical contacts 2170a and 2170b extend through cutouts 2174a and 2174b defined in the base portion 2159 of the cartridge pan 2158. In various embodiments, the cartridge pan 2158 is coated with a thin film electrical insulator to prevent short circuits. Similarly, the inner surface of the base portion 2152 may be coated with a thin film electrical insulator to prevent short circuits. The electrical contacts 2170a and 2170b extend through the electrical insulating film of the cartridge pan 2158.

[0113] In various embodiments, a signal from the thread detection circuit 2160 indicates the completion of the firing stroke. The electrical contacts 2170a and 2170b may be positioned at or near the end of the firing path. In an exemplary embodiment, the electrical contacts 2170a and 2170b are positioned at or near a distance of 60 mm from the home or start position. When the thread 2162 reaches the end of the firing stroke, the electrical contacts 2172a and 2172b engage with the electrical contacts 2170a and 2170b, causing the thread detection circuit 2160 to transition to a closed configuration and generate a unique signal indicating the completion of the firing stroke.

[0114] In the exemplary embodiment, the thread 2162 is insulated except for the conductive portion 2161 that defines the electrical contacts 2172a and 2172b. However, in other embodiments, the entire thread 2162 may be constructed from a conductive material. In such cases, the entire thread 2162 becomes part of the thread detection circuit 2160.

[0115] Referring here to Figure 41, a staple cartridge 2220 is shown. The staple cartridge 2220 is in many respects similar to other staple cartridges described elsewhere in this specification, such as staple cartridges 1220', 1220'', 1320, and 1620. For example, the staple cartridge 2220 includes a retaining feature 2270 configured to resist accidental movement of the threads 2262 within the staple cartridge 2220, for example, due to accidental collisions of the staple cartridge 2220.

[0116] The staple cartridge 2220 further includes a thread reset circuit 2264 configured to retract the thread 2262 to a home position or starting position 2267. In an exemplary embodiment, the thread 2262 includes one or more openings, holes, grooves, or retaining portions (e.g., retaining portion 2272) defined within the thread base 2263. The retaining portion 2272 is aligned with and configured to receive a retaining feature portion 2270. A driving force greater than a predetermined threshold is required to separate the retaining feature portion 2270 from the thread 2262. Therefore, the retaining feature portion 2270 is configured to resist the advancement of the thread 2262 up to a predetermined threshold.

[0117] Furthermore, the retaining feature 2270 rests within a channel 2266 defined within the cartridge pan 2258 of the staple cartridge 2220. The proximal wall 2266a of channel 2266 defines the proximal resting position for the retaining feature 2270, which corresponds to the home or starting position 2267 of the thread 2262. The distal wall 2266b of channel 2266 defines the distal resting position of the retaining feature 2270 within channel 2266. Since the retaining feature 2270 cannot move beyond the distal wall 2266b, any further movement of the thread 2262 will separate the thread 2262 from the retaining feature 2270.

[0118] In addition to the above, channel 2266 allows accidental movement of thread 2262 and retaining feature 2270 within a predetermined range defined by the length of channel 2266 or the distance between the proximal wall 2266a and the distal wall 2266b, without separating thread 2262 from retaining feature 2270. However, before firing, thread reset circuit 2264 is activated to retract retaining feature 2270 so that it abuts against the proximal wall 2266a. Retraction of retaining feature 2270 retracts thread 2262 to the home position or starting position 2267. In exemplary embodiments, thread reset circuit 2264 includes a solenoid 2269 configured, when activated, to pull or retract a wire or rod 2268 connected to retaining feature 2270.

[0119] As described elsewhere in this specification, the thread 2262 of the unfired staple cartridge 2220 prevents the firing lockout assembly 1221 from transitioning to a locked configuration while the thread 2262 is in the home or start position 2267. Thus, the retraction of the thread 2262 by the thread reset circuit 2264 ensures that the unfired staple cartridge 2220 is not mistaken for a previously fired staple cartridge 2220 due to accidental advancement of the thread from the home or start position 2267. In particular, the thread reset circuit 2264 can retract the thread 2262 only if the retaining feature 2270 is coupled to the thread 2262. When the thread 2262 advances distally beyond its coupling engagement with the retaining feature 2270 by the drive member, the staple cartridge 2220 is considered fired.

[0120] In various embodiments, the thread reset circuit 2264 may be incorporated into other staple cartridges disclosed elsewhere in this specification. In certain embodiments, the thread reset circuit 2264 may be coupled to a control circuit 1930 and actuated by the control circuit 1930 in response to a determination by the control circuit 1930 that the thread 2262 is not in the home position or start position 2267. In such embodiments, one or more of the sensors 1938 may detect that the thread 2262 is in a position beyond the home position or start position 2267. In response, the control circuit 1930 may actuate the thread reset circuit 2264 before initializing the firing stroke to return the thread 2262 to the home position or start position 2267.

[0121] Referring here to Figures 42 to 44, an alternative embodiment of the thread reset circuit 2364 is shown. Similar to the thread reset circuit 2264, the thread reset circuit 2364 is also configured to retract the thread 2362 to a home or start position within a predetermined range of movement of the thread 2362, while the retaining feature 2370 remains movably connected to the thread 2362. If it exceeds the predetermined range, a drive member moves the thread 2362 to separate it from the retaining feature 2370. The retaining feature 2370 is then retracted to a proximal start position by the thread reset circuit 2364.

[0122] Referring here to Figures 45-46, the surgical staple fastening assembly 2450 includes a staple cartridge 2420 containing threads 2462. The staple cartridge assembly 2450 is transitionable to a closed configuration to grasp tissue in a manner similar to that described in relation to other staple cartridge assemblies, such as staple cartridge assemblies 1150, 1250, etc. The working end 2484 of the drive member (e.g., drive member 1182) defines an I-beam configured to produce a firing of the surgical staple fastening assembly 2450.

[0123] The working end 2484 includes a first flange 2484a, a second flange, a vertical support 2484c that interconnects the first flange 2484a and the second flange, and a knife supported on or formed into the vertical support 2484c. The second flange is positioned to be slidably received within a channel of an anvil assembly (e.g., anvil assembly 1130), and the first flange 2484a is positioned to be slidably positioned along the outer surface of a surgical staple fastening assembly 2450. The working thread 2462 is located within the cartridge assembly 2450 at a distal position to the working end 2484.

[0124] In various embodiments, the flexible arm 2470 extends from its working end 2484 into a channel 2471 defined in the side wall of the cartridge body 2459 of the staple cartridge 2420. In an exemplary embodiment, the flexible arm 2470 passes through the channel 2471 and defines a leaf spring arm member that engages with the distal portion of the thread 2470. The flexible arm 2470 is configured to retract the thread 2462 to a home or start position.

[0125] In channel 2471, the flexible arm 2470 is flattened so as to naturally press against the side of the thread 2462. In at least one embodiment, the distal end of the flexible arm 2470 passes through the distal end of the thread 2462. The tab 2472 extends from the flexible arm 2470 in the relaxed position and engages with the front side edge of the thread 2462. The motion of the working end 2484 that occurs before driving the knife of the staple cartridge assembly 2450 during the full firing stroke allows the flexible arm 2470 to pull the thread 2462 back to the home or start position, as long as the thread 2462 is within a threshold defined by the length of the side channel 2471.

[0126] Figures 47–51 illustrate various embodiments of the thread reset mechanism 2500 for retracting the thread of a staple cartridge (e.g., staple cartridge 2520) to its home position (H) before firing a surgical instrument to deploy the staples of the staple cartridge 2520. As discussed elsewhere in this specification, the thread of an unfired staple cartridge may be inadvertently moved if the staple cartridge is struck or vibrated, which may cause the staple cartridge to be considered to have been misfired and / or cause the firing lockout assembly to be activated. The thread reset mechanism 2500 is configured to return any inadvertently moved thread to its home position (H) within the staple cartridge, provided that the thread has not moved beyond a predetermined distance (d1) from the home position (H).

[0127] Figure 47 illustrates the thread 2562 of a staple cartridge 2520, which is distal to the home position (H) but proximal to a distal position (A) defined by a predetermined distance (d1). Before firing, a thread reset member 2592 retracts the thread 2562 to the home position (H). The thread reset member 2592 may be in the form of a hook or a bent portion and includes a catcher 2595 configured to engage with the distal portion of the thread 2562 to return the thread 2562 to the home position (H).

[0128] In various embodiments, a portion of the thread reset member 2592 extends below the thread 2562, for example, within a channel defined in the cartridge pan of the staple cartridge 2520, and is slidably movable. In at least one embodiment, as shown in Figure 51, the thread reset member 2592 is manually operable by an actuator 2593 defined in a handle 2507. The user can pull the actuator 2593 proximally before activating the firing mechanism to return the thread 2562 to the home position (H).

[0129] In another embodiment, as shown in Figures 49 and 50, the thread reset member 2592 is powered by a motor assembly 2504 which is in many respects similar to the motor drive assembly 1904 of the surgical instrument 1901. In an exemplary embodiment, the motor drive assembly 2504 includes a linear threaded coupler 2598 which is operably connected to the thread reset member 2592. In an exemplary embodiment, the motor assembly 2504 is housed in a handle 2510 which includes a trigger member 2512. Movement of the trigger member 2512 to a first position causes the motor assembly 2504 to retract the thread reset member 2592, thereby returning the thread 2562 to the home position (H). A second movement of the trigger member 2512 from the first position to a second position acts as a firing stroke or firing motion to deploy the staples from the staple cartridge 2520.

[0130] The thread reset mechanism 2500 may be implemented in combination with other preferred embodiments of the present disclosure, such as a thread detection circuit. Furthermore, the thread reset mechanism 2500 may be implemented in combination with preferred components of the surgical stapling device 1901. For example, the control circuit 1930 may determine, based on the thread detection circuit, that the thread is in a position other than the home position. In response, the control circuit 1930 may cause the motor assembly 2504 to return the thread to the home position, which may be verified, for example, by the thread detection circuit.

[0131] During use, the thread 2562 is returned to its home position (H) by the thread reset member 2592, as shown in Figure 47. The drive member (e.g., drive member 1182) is then configured to advance its working end (e.g., working end 1184) to engage with the thread 2562, thereby advancing the thread 2562 and deploying the staples from the staple cartridge 2520. In various embodiments, as shown in Figure 48, the thread reset member 2592 includes a raised portion 2597, which may be in the form of an inclined portion positioned proximal to the catcher 2595. While the drive member 2582 is advancing, the working end 2584 may engage with the raised portion 2597 before engaging with the thread 2562, thereby moving the catcher 2595 out of the firing path 2503 of the thread 2562. In at least one embodiment, the working end 2584 drops the catcher 2595 into a channel defined within the cartridge pan of the staple cartridge 2520, thereby allowing the thread 3562 to advance further.

[0132] In various embodiments, setting acceptable and / or unacceptable thread positions along the firing path, or thread distances from the home position, also referred to herein as the functional window, may depend, at least in part, on the size of the staple cartridge. Therefore, to accurately set such positions or distances, the surgical cartridge may include an identification code that can be communicated to a control circuit (e.g., control circuit 1930) after the staple cartridge has been attached to a surgical instrument (e.g., surgical instrument 1901). Communication may be via a wired connection to the staple cartridge or wirelessly.

[0133] In various embodiments, the control circuit may select a suitable functional window based on the expected position of the thread contacts, assuming a communicated identification code of the cartridge. In various embodiments, the firing system may further adjust one or more parameters of a given firing program, such as force / velocity / stroke of both a sensing area based on the identification of the cartridge and / or a working area based on the timing / position of the sensed thread relative to its expected position.

[0134] Referring here to Figures 52 to 56, the loading unit 2600 is in many respects similar to other loading units described elsewhere in this specification, such as loading units 1100 and 1200. For example, the loading unit 2600 includes a staple cartridge assembly 2650 and an anvil assembly 2630. At least one of the anvil assembly 2630 and the staple cartridge assembly 2650 is movable relative to the other from an open configuration, as illustrated in Figure 53, to a closed configuration, as illustrated in Figure 54, for gripping tissue. Staples are deployed into the tissue from a staple cavity 2621 defined within the cartridge body 2622 of the staple cartridge 2620 of the staple cartridge assembly 2650. The anvil assembly 2630 includes a pocket configured to deform the staples.

[0135] In addition to the above, the staple cartridge 2620 includes a cartridge pan 2658 configured to prevent staples from falling out of the staple cavity 2621. The cartridge body 2622 is attachable to the cartridge pan 2658 by projections 2623 that can be received into corresponding cutouts 2653 defined on the side wall of the cartridge pan 2658. In various embodiments, the cutouts 26523 are sized and shaped to receive the corresponding cutouts 2653 in order to secure the cartridge body 2622 to the cartridge pan 2657.

[0136] During use, the staple cartridge 2620 is inserted into the elongated channel 2657 and assembled together. In various embodiments, the staple cartridge 2620 and the elongated channel 2657 are equipped with corresponding locking features. In an exemplary embodiment, when the staple cartridge 2620 is inserted into the elongated channel 2657, a pan projection 2656 defined on the side wall of the cartridge pan 2658 is received in the L-shaped slot 2659.

[0137] The corresponding locking features of the staple cartridge 2620 and the elongated channel 2657 enable proximal translation of the cartridge pan 2658 relative to the elongated channel 2658 for locking the staple cartridge 2620 into the elongated channel 2657, and distal translation of the cartridge pan 2658 relative to the elongated channel 2658 for unlocking the staple cartridge 2620 from the elongated channel 2657. In an exemplary embodiment, the L-shaped slot 2659 is sized and shaped such that the corresponding projection 2656 translates proximal by a distance "X" within the long arm of the L-shaped slot 2659, thereby locking the staple cartridge 2620 into the elongated channel 2657, and distally by a distance "X" within the long arm of the L-shaped slot 2659, thereby unlocking the staple cartridge 2620 from the elongated channel 2657.

[0138] In other embodiments, the protrusion may be defined within an elongated channel, and the corresponding L-shaped slot may be defined within the cartridge pan of the staple cartridge. Furthermore, other suitable fitting and locking mechanisms may be implemented to provide locking and unlocking configurations for the staple cartridge and the elongated channel. For example, a slot of another suitable shape can be replaced with an L-shaped slot.

[0139] In addition to the above, the locking mechanism for the staple cartridge 2620 relative to the elongated channel 2657 is performed automatically during the transition of the anvil assembly 2630 and the staple cartridge assembly 2650 to the closed configuration, as shown in Figures 53 and 54. In certain embodiments, the anvil assembly 2630 is configured to translate the cartridge pan 2658 proximal to the elongated channel 2657 to the locked configuration. In exemplary embodiments, the anvil assembly 2630 includes a cam acting member 2631 configured to retract the cartridge pan 2658 to the locked configuration when the loading unit 2600 is transitioned to the closed configuration (Figure 54).

[0140] In an exemplary embodiment, the cartridge pan 2658 includes a proximal tongue portion 2662 bisected by a pan slot 2663. The proximal tongue portion 2662 includes cutout portions 2661 on both sides of the pan slot 2663. A cam acting member 2631 is configured to engage with the proximal edge 2664 of the cutout 2661 during the closing motion of the loading unit 2600. When the loading unit 2600 transitions to the closed configuration, the cam acting member 2631 exerts a camming force on the proximal edge 2664 of the cutout 2661, thereby translating the cartridge pan 2658 proximal to the locked configuration. Thus, the closing motion of the loading unit 2600 automatically transitions the staple cartridge 2620 to the locked configuration with the elongated channel 2657.

[0141] In an exemplary embodiment, the proximal end of the proximal tongue portion 2662 is bent toward the cutout portion 2661 to ensure proper engagement with the cam acting member 2631, thereby forming an edge portion 2664. The cam acting member 2631 is configured to engage with the edge portion 2664 as it pivots toward the staple cartridge 2620 together with the anvil assembly 2630. In other embodiments, the anvil assembly including the cam acting member 2631 may be fixed, and the elongated channel pivots toward the anvil assembly to result in a closed configuration. In such embodiments, the edge portion 2664 moves toward the cam acting member 2631. When the edge portion 2664 engages with the cam acting member 2641, the camming force translates the cartridge pan 2658 proximal to a locked configuration.

[0142] In addition to the above, the elongated channel 2657 includes a proximal slot or cutout portion 2671 defined in the proximal portion of the base 2672 of the elongated channel 2657. The cutout portion 2671 is aligned laterally or transversely with the cutout portion 2661, or at least partially aligned. In the unlocked configuration, as shown in Figure 53, the cutout portion 2661 is distal to the cutout portion 2671. However, in the locked configuration, as shown in Figure 54, the cutout portion 2661 is aligned longitudinally with the cutout portion 2671, or at least closer to longitudinal alignment with the cutout portion 2671 than in the unlocked configuration. When the cam operating member 1631 moves pivotably within the cutout portions 2661 and 2671, the cam operating member 2631 is configured to move the cutout portion 2661 proximal by a distance "X", as shown in Figure 54, to align it with the cutout portion 2671, or at least partially align it.

[0143] After the firing stroke is complete, the used staple cartridge 2620 is removed from the elongated channel 2657 by translating the cartridge pan 2658 into an unlocked configuration. In exemplary embodiments, the cartridge pan 2658 includes a release feature 2655, which may be in the form of a finger tab. The release feature 2655 is slidably movable distally within a corresponding slot 2620 defined within the nose portion 2626 of the cartridge body 2622, in order to move the staple cartridge 2620 into an unlocked configuration, as shown in Figures 55 and 56.

[0144] Referring here to Figures 57 to 61, the staple surgical assembly 2750 includes an elongated channel 2757, a staple cartridge 2758, and a retainer 2730. The staple surgical assembly 2750 is in many respects similar to other staple surgical assemblies described elsewhere in this specification. For example, the staple surgical assembly 2750 can be incorporated into any suitable surgical instrument described elsewhere in this specification.

[0145] In the embodiment illustrated in Figure 57, the staple cartridge assembly 2750 is in a first configuration in which a retainer 2730 is assembled with the staple cartridge 2720 to prevent staples from accidentally falling out of the staple cavity of the staple cartridge 2720. In the first configuration, the long tab 2731 of the retainer 2730 defines a retainer arm that engages with the cartridge pan 2758 of the staple cartridge 2720, and the short tab 2732 defines a retainer arm that engages with the cartridge body 2721 of the staple cartridge 2720. The tabs 2731 and 2732 cooperate to hold the retainer 2730, which is pressed against the deck 2722 of the cartridge body 2721 in the first configuration, thereby holding the staples within their staple cavities. In the exemplary embodiment, the cartridge body 2721 includes a shelf-like portion 2723 that extends laterally from the deck 2722. The shelf-like portion 2723 is engaged by a short tab 2732 in the first configuration.

[0146] After the firing stroke is complete, the used staple cartridge 2720 is removed from the elongated channel 2757 by the retainer 2730, as shown in Figures 58 to 61. In a second configuration, the long tab 2731 of the retainer 2730 is inserted through a track or notch 2724 defined within the cartridge body 2721, as best illustrated in Figure 60. The tab 2731 releases the folding member 2755 of the cartridge pan 2558 from the corresponding opening 2756 of the elongated channel 2757, allowing the staple cartridge 2720 to be removed from the elongated channel 2757 by the retainer 2730, as shown in Figure 61.

[0147] In an exemplary embodiment, the folding member 2755 is in the form of a leaf spring that may be punched or formed in the side wall of the cartridge pan 2758. The tab 2731 is configured to fold the folding member 2755 as the tab 2731 moves forward in the track 2724, thereby releasing the folding member 2755 from the opening 2756, as shown in Figure 60, and includes a hook feature 2733 further configured to form a movable locking engagement with the folded folding member 2755 in a second configuration.

[0148] Next, as shown in Figure 61, the retainer 2730 is pulled away from the elongated channel 2757, thereby removing the staple cartridge 2720 from the elongated channel 2757. When the retainer 2730 is pulled away, the hook feature 2733 lifts the folding member 2755 from the track 2724, thereby freeing the staple cartridge 2720 from the elongated channel 2757.

[0149] In an exemplary embodiment, the opening 2756 is defined in the form of a cutout in the side wall of the elongated channel 2757. In other embodiments, the opening 2756 can be replaced by a recess or slot defined on the inner surface of the inner wall of the elongated channel 2757. The recess or slot is shaped and sized to accommodate the folding members 2755 in their natural state, in a manner similar to that illustrated in Figure 59 with respect to the opening 2756.

[0150] Referring still to Figures 59–61, a method is shown for using a retainer 2730 to remove a used staple cartridge 2720 from an elongated channel 2757. This method includes separating the retainer 2730 from the staple cartridge assembly 2750. The method further includes inserting a tab 2731 into the track 2724, releasing the folding member 2755 from the opening 2756 by the hook feature 2733 of the tab 2731, and forming a movable locking engagement between the folded folding member 2755 and the hook feature 2733 in the track 2724. The method further includes pulling the retainer 2730 away from the elongated channel 2757 in order to remove the used staple cartridge 2720 from the elongated channel 2757.

[0151] Referring here to Figure 62, the staple surgical assembly 2850 includes an immediate-open feature that facilitates the removal of the staple cartridge 2820 from the elongated channel 2857 of the surgical instrument. The staple surgical assembly 2850 is similar in many respects to other staple surgical assemblies described elsewhere in this specification. For example, the staple surgical assembly 2850 can be incorporated into any suitable surgical instrument described elsewhere in this specification.

[0152] The staple cartridge 2820 includes a cartridge body 2821 and a cartridge pan 2858. Furthermore, the staple cartridge 2858 includes a cartridge release member 2822 movably disposed within the nose portion 2823 of the cartridge body 2821. In an exemplary embodiment, the cartridge release member 2822 is linearly movable from a non-operated configuration to an operated configuration through a passage 2824 defined within the nose portion 2823. In the non-operated configuration, as shown in Figure 62, the cartridge release member 2822 protrudes from the nose portion 2823 through one end of the passage 2824. When operated, for example by applying external pressure thereto, the cartridge release member 2822 moves within the passage 2824 and protrudes from the other end of the passage 2824. The cartridge release member 2822 then presses against an elongated channel 2857, releasing the staple cartridge 2820 from the elongated channel 2857. In an exemplary embodiment, the passage 2824 defines the direction of motion of the cartridge release member 2822, which is at an acute angle with respect to the elongated channel 2857.

[0153] The surgical instrument systems described herein are operated by electric motors; however, the surgical instrument systems described herein may be driven in any preferred manner. In particular cases, the motors disclosed herein may comprise one or more parts of a robotic control system. For example, U.S. Patent Application No. 13 / 118,241, titled “SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS” (now U.S. Patent No. 9,072,535) discloses in more detail several embodiments of robotic surgical instrument systems, the entirety of which is incorporated herein by reference. PCT International Publication No. 2017 / 083125, published May 18, 2017, title of invention "STAPLER WITH COMPOSITE CARDAN AND SCREW DRIVE"; PCT International Publication No. 2017 / 083126, published May 18, 2017, title of invention "STAPLE PUSHER WITH LOST MOTION BETWEEN RAMPS"; PCT International Publication No. 2015 / 153642, published October 8, 2015, title of invention "SURGICAL INSTRUMENT WITH SHIFTABLE TRANSMISSION"; U.S. Patent Application Publication No. 2017 / 0265954, filed March 17, 2017, title of invention "STAPLER WITH CABLE-DRIVEN ADVANCEABLE CLAMPING ELEMENT AND DUAL DISTAL The inventions “STAPLER WITH CABLE-DRIVEN ADVANCEABLE CLAMPING ELEMENT AND DISTAL PULLEY,” U.S. Patent Application Publication No. 2017 / 0265865, filed February 15, 2017, and U.S. Patent Application Publication No. 2017 / 0290586, filed March 29, 2017, are incorporated herein by reference in their entirety.

[0154] While the surgical instrument systems described herein have been described in relation to the deployment and deformation of staples, the embodiments described herein are not limited thereto. For example, various embodiments for deploying fasteners other than staples, such as clamps or tucks, are conceivable. Furthermore, various embodiments utilizing any suitable means for sealing tissue can also be conceived. For example, end effectors according to various embodiments may include electrodes configured to heat and seal tissue. Also, for example, end effectors according to certain embodiments may be able to apply vibrational energy to seal tissue. [Examples]

[0155] Various aspects of the subject matter described herein are illustrated in the following numbered examples.

[0156] Example 1 - Loading unit for use with a surgical stapling device. The loading unit comprises a shaft and an end effector extending from the shaft. The end effector comprises a first jaw portion having an anvil and a second jaw portion. At least one of the first and second jaw portions is movable relative to the other to grasp tissue. The second jaw portion comprises an elongated channel having a retaining feature and a staple cartridge insertable into the elongated channel for assembly with the elongated channel. The staple cartridge comprises a cartridge pan and a thread that is translationally movable relative to the cartridge pan from a first position to a second position. The retaining feature is configured to resist movement by the thread beyond the first position up to a predetermined force.

[0157] Example 2 - The loading unit according to Example 1, further comprising a drive member configured to move the thread toward a second position.

[0158] Example 3 - The loading unit according to Example 1 or 2, further comprising a firing lockout assembly configured to prevent the forward movement of the drive member.

[0159] Example 4 - The loading unit according to Example 3, wherein the lockout assembly is deactivated when the thread is held in a first position by the retaining feature.

[0160] Example 5 - A loading unit according to Example 1, 2, 3, or 4, wherein the cartridge pan comprises a longitudinal pan slot extending longitudinally along a portion thereof, and the drive member defines a plane extending along the longitudinal pan slot.

[0161] Example 6 - The loading unit according to Example 5, wherein the retaining feature portion is located on both sides of the plane.

[0162] Example 7 - The loading unit according to Example 1, 2, 3, 4, 5, or 6, wherein the thread has a hole configured to receive a retaining feature when the thread is in a first position.

[0163] Example 8 - The loading unit according to Example 7, wherein the retaining feature is configured to extend through the cartridge pan into a hole defined within the thread in order to maintain the thread in a first position.

[0164] Example 9 - The loading unit according to Example 1, 2, 3, 4, 5, 6, 7, or 8, wherein the retaining feature portion is equipped with a leaf spring.

[0165] Example 10 - The loading unit according to Example 1, 2, 3, 4, 5, 6, 7, 8, or 9, wherein the retaining feature portion comprises a protrusion including a radius of curvature.

[0166] Example 11 - A loading unit of Example 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10, wherein the retaining feature is foldable.

[0167] Example 12 - A loading unit according to Example 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11, wherein the retaining feature is defined on the side wall of an elongated channel, and the retaining feature is configured to be received in a corresponding groove of the thread when the thread is in a first position.

[0168] Example 13 - A staple cartridge for use with a surgical staple fastener, an elongated channel, and a drive member. The staple cartridge comprises a deck defining a tissue contact surface, a housing, and a cartridge pan releasably mountable to an elongated channel. The staple cartridge further comprises a retaining feature, a staple driver housed within the housing between the deck and the cartridge pan, and staples housed within the housing. The staples are deployable through the deck into the tissue by the staple driver. The staple cartridge further comprises a thread that is translationally movable relative to the cartridge pan from a first position to a second position in order to move the staple driver and deploy the staples. The retaining feature is configured to resist the movement of the thread beyond the first position up to a predetermined force.

[0169] Example 14 - The staple cartridge according to Example 13, wherein the cartridge pan has a longitudinal pan slot extending longitudinally along a portion thereof, and the drive member defines a plane extending along the longitudinal pan slot, with the retaining features located on both sides of the plane.

[0170] Example 15 - The staple cartridge according to Example 13 or 14, wherein the retaining feature comprises a perforated, breakable door portion located between a first position and a second position.

[0171] Example 16 - A staple cartridge according to Example 13, 14, or 15, wherein the retaining feature is foldable.

[0172] Example 17 - The staple cartridge according to Example 13, 14, 15, or 16, wherein the retaining feature is deactivated when the staple cartridge is assembled with an elongated channel.

[0173] Example 18 - A staple cartridge assembly comprising an elongated channel having a first retaining feature, and a staple cartridge insertable into the elongated channel for assembly together with the staple cartridge. The staple cartridge comprises a cartridge pan having a second retaining feature, and a thread that is translationally movable relative to the cartridge pan from a first position to a second position. The retaining feature is configured to resist movement by the thread beyond the first position up to a predetermined force.

[0174] Example 19 - The staple cartridge assembly according to Example 18, wherein the first retaining feature is configured to maintain the thread before the staple cartridge is inserted into the elongated channel, rather than after the staple cartridge is inserted into the elongated channel.

[0175] Example 20 - The staple cartridge assembly according to Example 18 or 19, wherein the second retaining feature is configured to maintain the thread after the staple cartridge has been inserted into the elongated channel, rather than before the staple cartridge has been inserted into the elongated channel.

[0176] While several forms have been shown and described, it is not the applicant's intention to limit or restrict the attached claims to such details. Many modifications, variations, alterations, substitutions, combinations, and equivalents of these forms can be implemented and will be conceivable to those skilled in the art without departing from the scope of this disclosure. Furthermore, the structure of each element related to the described form may be described alternatively as a means for providing the function performed by that element. Also, while materials are disclosed with respect to specific components, other materials may be used. Therefore, it should be understood that the above description and the attached claims are intended to cover all such modifications, combinations, and variations as being included within the scope of the disclosed forms. The attached claims are intended to cover all such modifications, variations, alterations, substitutions, alterations, and equivalents.

[0177] The detailed descriptions above have used block diagrams, flowcharts, and / or embodiments to describe various forms of apparatus and / or processes. To the extent that such block diagrams, flowcharts, and / or embodiments include one or more functions and / or operations, it will be understood by those skilled in the art that each function and / or operation included in such block diagrams, flowcharts, and / or embodiments can be individually and / or collectively implemented by a variety of hardware, software, firmware, or any de facto combination thereof. It will be recognized by those skilled in the art that some of the forms disclosed herein, in whole or in part, can be equivalently implemented on integrated circuits as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more processors (e.g., as one or more programs running on one or more microprocessors), as firmware, or as any substantially any combination thereof, and that designing circuits and / or writing software and / or firmware code falls within the scope of the skills of those skilled in the art in view of this disclosure. It should be understood by those skilled in the art that the mechanisms of the subject matter described herein can be distributed in various forms as one or more program products, and that the specific forms of the subject matter described herein are applicable regardless of the particular type of signal carrier medium used to actually carry out the distribution.

[0178] Instructions used to program logic to implement various disclosed embodiments may be stored in system memory such as dynamic random access memory (DRAM), cache, flash memory, or other storage. Furthermore, instructions may be distributed over a network or by other computer-readable media. Thus, machine-readable media may include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer), but are not limited to floppy diskettes, optical disks, compact disks, read-only memory (CD-ROMs), and magneto-optical disks, read-only memory (ROMs), random access memory (RAMs), erasable programmable read-only memory (EPROMs), electrically erasable programmable read-only memory (EEPROMs), magnetic or optical cards, flash memory, or tangible machine-readable storage used for transmitting information over the Internet via electrical, optical, acoustic, or other propagating signals (e.g., carrier waves, infrared signals, digital signals, etc.). Thus, non-temporary computer-readable media may include any type of tangible machine-readable media suitable for storing or transmitting electronic instructions or information in a form readable by a machine (e.g., a computer).

[0179] Where used in any aspect of this specification, the term “control circuit” may mean, for example, hardwired circuits, programmable circuits (e.g., computer processors, processing units, processors, microcontrollers, microcontroller units, controllers, digital signal processors (DSPs), programmable logic devices (PLDs), programmable logic arrays (PLAs), or field programmable gate arrays (FPGAs) including one or more individual instruction processing cores), state machine circuits, firmware that stores instructions executed by programmable circuits, and any combination thereof. Control circuits may be embodied collectively or individually as circuits that form part of a larger system, such as an integrated circuit (IC), an application-specific integrated circuit (ASIC), a system-on-a-chip (SoC), a desktop computer, a laptop computer, a tablet computer, a server, or a smartphone. Accordingly, as used herein, “control circuit” includes, but is not limited to, an electrical circuit having at least one separate electrical circuit, an electrical circuit having at least one integrated circuit, an electrical circuit having at least one application-specific integrated circuit, an electrical circuit forming a general-purpose computing device configured by a computer program (e.g., a general-purpose computer configured by a computer program that performs at least part of the processes and / or devices described herein, or a microprocessor configured by a computer program that performs at least part of the processes and / or devices described herein), an electrical circuit forming a memory device (e.g., in the form of random access memory), and / or an electrical circuit forming a communication device (e.g., a modem, a communication switch, or an optical-electric installation). Those skilled in the art will recognize that the subject matter described herein may be implemented in analog form, digital form, or some combination thereof.

[0180] Where used in any aspect of this specification, the term “logic” may mean an application, software, firmware, and / or circuit configured to perform any of the operations described above. Software may be embodied as software packages, code, instructions, instruction sets, and / or data recorded on a non-temporary computer-readable storage medium. Firmware may be embodied as code, instructions, or instruction sets, and / or hardcoded (e.g., non-volatile) data in a memory device.

[0181] Where used in any aspect of this specification, terms such as “component,” “system,” and “module” may refer to computer-related entities that are hardware, a combination of hardware and software, software, or running software.

[0182] Where used in any aspect of this specification, “algorithm” means a self-consistent sequence of steps leading to a desired result, and “step” means the manipulation of physical quantities and / or logical states that can take the form of electrical or magnetic signals, which are not necessarily required to be stored, transferred, combined, compared, and otherwise manipulated. These signals are commonly referred to as bits, values, elements, symbols, characters, terms, numbers, etc. These and similar terms may be associated with appropriate physical quantities, or simply are convenient labels applied to these quantities and / or states.

[0183] A packet-switched network may be an example of a network. Communication devices can communicate with each other using a selected packet-switched network communication protocol. One typical communication protocol may be the Ethernet communication protocol, which can enable communication using the Transmission Control Protocol / Internet Protocol (TCP / IP). The Ethernet protocol may conform to or be compatible with the Ethernet standard published by the Institute of Electrical and Electronics Engineers (IEEE) in December 2008, titled "IEEE 802.3 Standard," and / or later versions of this standard. Alternatively or additionally, communication devices may communicate with each other using the X.25 communication protocol. The X.25 communication protocol may conform to or be compatible with standards published by the International Telecommunication Union - Telecommunication Standardization Sector (ITU-T). Alternatively or additionally, communication devices may communicate with each other using the Frame Relay communication protocol. The Frame Relay communication protocol conforms to or may be compatible with standards published by the Consultative Committee for International Telegraph and Telephone (CCITT) and / or the American National Standards Institute (ANSI). Alternatively or additionally, transceivers may communicate with each other using the Asynchronous Transfer Mode (ATM) communication protocol. The ATM communication protocol conforms to or may be compatible with the ATM standard and / or later versions of this standard, published by the ATM Forum in August 2001 under the title "ATM-MPLS Network Interworking 2.0". Naturally, different and / or later developed connection-oriented network communication protocols are equally construed herein.

[0184] Unless otherwise explicitly stated, as is evident from the foregoing disclosures, any use of terms such as “processing,” “computing,” “calculating,” “determining,” and “displaying” throughout the foregoing disclosures should be understood to refer to the actions and processes of a computer system or similar electronic computing device that manipulate and convert data represented as physical (electronic) quantities in the registers and memory of a computer system into other data similarly represented as physical quantities in the memory or registers of a computer system or other such information storage, transmission, or display device.

[0185] One or more components may be referred to herein as “configured to,” “configurable to,” “operable / operative to,” “adapted / adaptable,” “able to,” “conformable / conformed to,” etc. It will be recognized by those skilled in the art that “configured to” generally encompasses active components and / or inactive components and / or standby components, unless the context should interpret it otherwise.

[0186] The terms “proximal” and “distal” are used herein in reference to the clinician operating the handle portion of a surgical instrument. “Proximal” refers to the part closest to the clinician, and “distal” refers to the part further away from the clinician. For convenience and clarity, spatial terms such as “vertical,” “horizontal,” “up,” and “down” may be used herein in reference to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be restrictive and / or absolute.

[0187] A person skilled in the art will generally recognize that the terms used herein, and especially in the appended claims (e.g., the text of the appended claims), are generally intended to be "open" terms (for example, the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," and the term "includes" should be interpreted as "includes but is not limited to"). Furthermore, a person skilled in the art will understand that if a particular number is intended in an introduced claim recitation, such intent is clearly stated in the claim, and if such statement is not made, such intent does not exist. For example, to aid understanding, subsequent appended claims may include the introductory phrases "at least one" and "one or more" to introduce the claim recitation. However, the use of such phrases should not be interpreted as suggesting that any particular claim containing such introduced claim description is limited to claims containing only one such description, even if the same claim contains an introductory phrase such as "one or more" or "at least one" and the indefinite article "a" or "an" (for example, "a" and / or "an" should generally be interpreted as meaning "at least one" or "one or more"). The same applies when introducing a claim description using a definite article.

[0188] Furthermore, even if a specific number is explicitly stated in the introduced claim, it will be recognized by those skilled in the art that such a statement should typically be interpreted as meaning at least the stated number (for example, if there is a statement that is simply “two descriptions” without any other modifiers, it generally means at least two descriptions, or two or three or more descriptions). In addition, when a statement similar to “at least one of A, B, and C, etc.” is used, such a construction is generally intended to be understood in a way that those skilled in the art would understand (for example, “a system having at least one of A, B, and C” is not limited to systems having only A, only B, only C, both A and B, both A and C, both B and C and / or all of A, B and C, etc.). When expressions similar to "at least one of A, B, or C" are used, such expressions are generally intended to be understood in a way that a person skilled in the art would understand (for example, "a system having at least one of A, B, or C" is not limiting, but includes systems having only A, only B, only C, both A and B, both A and C, both B and C and / or all of A, B and C). Furthermore, a person skilled in the art will recognize that, typically, any disjunctive word and / or phrase representing two or more selective terms should be understood, whether in the specification, claims, or drawings, as intended to include the possibility of including one of those terms, any of those terms, or both of those terms, unless the context requires a different interpretation. For example, the phrase "A or B" will typically be understood to include the possibility of "A" or "B" or "A and B".

[0189] With respect to the attached claims, it will be understood by those skilled in the art that the operations cited herein may generally be performed in any order. Furthermore, while flowcharts of various operations are shown in sequence, it should be understood that the operations may be performed in any order other than those shown, or simultaneously. Examples of such alternative orderings may include repetition, alternation, interruption, reordering, augmentation, preliminary, additional, simultaneous, reverse, or other different orderings, unless the context should interpret them otherwise. Moreover, terms such as “responding to,” “related to,” or other past tense adjectives are not generally intended to exclude such variations, unless the context should interpret them otherwise.

[0190] It is worth noting that any reference to “one aspect,” “aspect,” “example,” or “example” means that the specific feature, structure, or characteristic described in relation to that aspect is included in at least one aspect. Therefore, the phrases “in one aspect,” “in aspect,” “example,” and “example,” which appear in various places throughout this specification, do not necessarily all refer to the same aspect. Furthermore, specific features, structures, or characteristics may be combined in any preferred manner in one or more aspects.

[0191] In this specification, unless otherwise specified, the terms “about” or “approximately” as used in this disclosure mean a tolerance for a particular value as determined by a person skilled in the art, which depends in part on the method by which the value is measured or determined. In certain embodiments, the terms “about” or “approximately” mean one, two, three, or four standard deviations. In certain embodiments, the terms “about” or “approximately” mean within 50%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.

[0192] In this specification, unless otherwise indicated, all numerical parameters should be understood in all cases as being preceded and modified by the word “approximately,” and such numerical parameters have variability characteristics inherent to the underlying measurement method used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should be interpreted by taking into account the reported significant figures and applying the usual rounding method.

[0193] Furthermore, any numerical range described herein includes all subranges contained within the described range. For example, the range "1 to 10" includes all subranges between the stated minimum value of 1 and the stated maximum value of 10 (and including both the minimum and maximum values), i.e., all subranges having a minimum value of 1 or greater and a maximum value of 10 or less. Also, all ranges described herein include the endpoints of the described range. For example, the range "1 to 10" includes the endpoints 1 and 10. Any maximum numerical limit described herein is intended to include all smaller numerical limits contained within it, and any minimum numerical limit described herein is intended to include all larger numerical limits contained within it. Accordingly, the applicant has the right to amend this specification, including the claims, to include all explicitly described subranges contained within the explicitly described range. All such ranges are originally described herein.

[0194] Any patent application, patent, non-patent publication, or other disclosure material referenced herein and / or listed in any application data sheet is incorporated herein by reference to the extent that the incorporated material does not conflict with this Specified. Any disclosure expressly stated herein, either in itself or to the extent required, shall supersede any conflicting statement incorporated herein by reference. Any material, or any portion thereof, that is referred to as being incorporated herein by reference but conflicts with current definitions, views, or other disclosures stated herein shall be incorporated only to the extent that it does not create a conflict between the incorporated material and the current disclosures.

[0195] In summary, the numerous benefits that can be obtained as a result of using the concepts described herein have been described. The above descriptions of one or more forms are presented for illustrative and explanatory purposes only. They are not intended to be comprehensive or to be limited to the exact forms disclosed. Modifications or variations are possible in light of the above teachings. One or more forms have been selected and described to illustrate the principle and practical applications, thereby enabling a person skilled in the art to utilize the various forms, along with various modifications, for specific conceivable uses. The claims presented herein are intended to define the overall scope.

[0196] [Implementation Method] (1) A loading unit for use with a surgical staple fastening device, The shaft and An end effector extending from the shaft, wherein the end effector is A first jaw section equipped with an anvil, The apparatus comprises a second jaw portion, wherein at least one of the first jaw portion and the second jaw portion is movable relative to the other to grasp tissue, and the second jaw portion is An elongated channel having a retention feature portion, A staple cartridge that can be inserted into the elongated channel for assembly with the elongated channel, wherein the staple cartridge is Cartridge pan and A loading unit comprising: an end effector, a staple cartridge, and a staple cartridge, the staple cartridge having a thread that is translationally movable from a first position to a second position relative to the cartridge pan, wherein the retaining feature is configured to resist movement by the thread beyond the first position up to a predetermined force. (2) The loading unit according to Embodiment 1, further comprising a drive member configured to move the thread toward the second position. (3) The loading unit according to embodiment 2, further comprising a firing lockout assembly configured to prevent the forward movement of the drive member. (4) The loading unit according to Embodiment 3, wherein the lockout assembly is deactivated when the thread is maintained in the first position by the retaining feature. (5) The loading unit according to Embodiment 1, wherein the cartridge pan has a longitudinal pan slot that extends longitudinally along a portion thereof, and the drive member defines a plane that extends along the longitudinal pan slot.

[0197] (6) The loading unit according to Embodiment 5, wherein the retaining feature portion is located on both sides of the plane. (7) The loading unit according to Embodiment 1, wherein the thread has a hole configured to receive the retaining feature when the thread is in the first position. (8) The loading unit according to Embodiment 7, wherein the retaining feature is configured to extend through the cartridge pan into the hole defined within the thread in order to maintain the thread in the first position. (9) The loading unit according to Embodiment 1, wherein the retaining feature portion is equipped with a leaf spring. (10) The loading unit according to Embodiment 1, wherein the retaining feature portion includes a protruding portion with a radius of curvature.

[0198] (11) The loading unit according to Embodiment 1, wherein the retaining feature is foldable. (12) The loading unit according to Embodiment 1, wherein the retaining feature portion is defined on the side wall of the elongated channel, and the retaining feature portion is configured to be received in the corresponding side groove of the thread when the thread is in the first position. (13) A staple cartridge for use with surgical staple fasteners, elongated channels, and drive members, A deck that defines the tissue contact surface, Housing and A cartridge pan that can be removably attached to the aforementioned elongated channel, Retaining feature part, Between the deck and the cartridge pan, a staple driver is housed within the housing, Staples stored within the housing, wherein the staples can be deployed into the tissue through the deck by the staple driver, A staple cartridge comprising a thread that is translationally movable relative to the cartridge pan from a first position to a second position for the staple driver to deploy the staples, wherein the retaining feature is configured to resist the movement of the thread beyond the first position up to a predetermined force. (14) The staple cartridge according to Embodiment 13, wherein the cartridge pan has a longitudinal pan slot extending longitudinally along a portion thereof, the drive member defines a plane extending along the longitudinal pan slot, and the retaining feature portion is located on both sides of the plane. (15) The staple cartridge according to embodiment 13, wherein the retaining feature portion comprises a perforated, breakable door portion located between the first position and the second position.

[0199] (16) The staple cartridge according to embodiment 13, wherein the retaining feature is foldable. (17) The staple cartridge according to embodiment 13, wherein the retaining feature is deactivated when the staple cartridge is assembled with the elongated channel. (18) A staple cartridge assembly, An elongated channel having a first retention feature portion, A staple cartridge that can be inserted into the elongated channel for assembly with the elongated channel, wherein the staple cartridge is A cartridge pan having a second holding feature, A staple cartridge assembly comprising: a staple cartridge having a thread that is translationally movable relative to the cartridge pan from a first position to a second position, wherein the retaining feature is configured to resist movement by the thread beyond the first position up to a predetermined force. (19) The staple cartridge assembly according to embodiment 18, wherein the first retaining feature is configured to maintain the thread before the staple cartridge is inserted into the elongated channel, rather than after the staple cartridge is inserted into the elongated channel. (20) The staple cartridge assembly according to Embodiment 18, wherein the second retaining feature is configured to maintain the thread after the staple cartridge has been inserted into the elongated channel, rather than before the staple cartridge has been inserted into the elongated channel.

Claims

1. A loading unit for use with surgical stapling devices, The shaft and An end effector extending from the shaft, wherein the end effector is A first jaw section equipped with an anvil, The apparatus comprises a second jaw portion, wherein at least one of the first jaw portion and the second jaw portion is movable relative to the other to grasp tissue, and the second jaw portion is An elongated channel having a retention feature portion, A staple cartridge that can be inserted into the elongated channel for assembly with the elongated channel, wherein the staple cartridge is Cartridge pan and The end effector comprises a staple cartridge having a thread that is translationally movable from a first position to a second position relative to the cartridge pan, The drive member is further configured to move the thread toward the second position, The thread has a hole configured to receive the retaining feature portion, When the retaining feature is received in the hole, the retaining feature resists the movement of the thread, and the thread is maintained in the first position. A loading unit in which the drive member pushes the thread with a force greater than a predetermined threshold, causing the retaining feature to disengage from the hole and the thread to move from a first position to a second position.

2. The loading unit according to claim 1, further comprising a firing lockout assembly configured to prevent the forward movement of the drive member.

3. The loading unit according to claim 2, wherein the lockout assembly is deactivated when the thread is maintained in the first position by the retaining feature.

4. The loading unit according to claim 1, wherein the cartridge pan comprises a longitudinal pan slot extending longitudinally along a portion thereof.

5. The loading unit according to claim 1, wherein the retaining feature is configured to extend through the cartridge pan into the hole defined within the thread in order to maintain the thread in the first position.

6. The loading unit according to claim 1, wherein the retaining feature portion comprises a leaf spring.

7. The loading unit according to claim 1, wherein the retaining feature portion includes a protruding portion with a radius of curvature.

8. The loading unit according to claim 1, wherein the retaining feature is foldable.

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