Title of Invention

SURGICAL STAPLING INSTRUMENT WITH MULTISTROKE FIRING INCORPORATING AN ANTI-BACKUP MECHANISM

Abstract A surgical stapling and severing instrument particularly suited to endoscopic procedures incorporates a handle that produces separate closing and firing motions to actuate an end effector. In particular, the handle produces multiple firing strokes in order to reduce the required amount of force required to fire (i.e., staple and sever) the end effector. A linked transmission reduces the required handle longitudinal length, yet achieves a rigid, strong configuration when straightened for firing. A traction biased firing mechanism avoids binding in driving this straightened linked rack in cooperation with an anti-backup mechanism, with a lockout mechanism that prevents releasing the closure trigger during firing. Furthermore, an external indicator gives ft edback to the surgeon as to how far firing has progressed, as well as providing a manual retraction capability.
Full Text SURGICAL STAPLING INSTRUMENT'WITH MULTISTROKE
FIRING INCORPORATING AN ANTI-BACKUP MECHANISM
Cross Reference to Related Applications
[00011 The present application is related tc four co-pending and commonly-owned
applications filed on even date herewith, the disclosure of each is hereby incorporated
by reference in their entirety, these four applications being respectively entitled:
"SURGICAL STAPLING INSTRUMENT HAVING MULTISTROKE
FIRING WITH OPENING LOCKOUT, Scr. No.___, to Frederick E. Shelton, Jeffrey
S. Swayze, Douglas B. Hoffman;
"SURGICAL STAPLING INSTRUMENT INCORPORATING A FIRING
MECHANISM HAVING A LINKED RACK TRANSMISSION", Ser. No.___, to
Jeffrey S. Swayze, Frederick E. Shelton IV';
"SURGICAL STAPLING INSTRUMENT HAVING MULTISTROKE
FIRING INCORPORATING A TRACTION-BIASED RATCHETING
MECHANISM, Ser. No.___, to Jeffrey S Swayze, Frederick E. Shelton IV; and
"SURGICAL STAPLING INSTRUMENT INCORPORATING A
MULTISTROKE FIRING POSITION INDICATOR AND RETRACTION
MECHANISM", Ser. No.___, to Jeffrey S. Swayze, Frederick E. Shelton IV.
Field of the Invention
[00021 The present invention relates in general to surgical stapler instruments that are
capable of applying lines of staples to tissue while cutting the tissue between those
staple lines and, more particularly, to improvements relating to stapler instruments
and improvements in processes for forming various components of such stapler
instruments that accomplish firing with multiple strokes of a trigger.
Background of the Invention
[00031 Endoscopic surgical instruments are often preferred over traditional open
surgical devices since a smaller incision vends to reduce the post-operative recovery
time and complications. Consequently, significant development has gone into a range
of endoscopic surgical instruments that are suitable for precise placement of a distal
end effector at a desired surgical site through a cannula of a trocar. These distal end
effectors engage the tissue in a number of ways to achieve a diagnostic or therapeutic
effect (e.g., endocutter, grasper, cutter, staplers, clip applier, access device, drug/gene
therapy delivery device, and energy device using ultrasound, RF, laser, etc.).
[00041 Known surgical staplers include an end effector that simultaneously makes a
longitudinal incision in tissue and applies lines of staples on opposing sides of the
incision. The end effector includes a pair of cooperating jaw members that, if the
instrument is intended for endoscopic or laparoscopic applications, are capable of
passing through a cannula passageway. One of the jaw members receives a staple
cartridge having at least two laterally spaced rows of staples. The other jaw member
defines an anvil having staple-forming pockets aligned with the rows of staples in the
cartridge. The instrument includes a plurality of reciprocating wedges which, when
driven distally, pass through openings in the staple cartridge and engage drivers
supporting the staples to effect the firing of the staples toward the anvil.
[0005] An example of a surgical stapler suitable for endoscopic applications is
described in U.S. Pat. No. 5,465,895, which advantageously provides distinct closing
and firing actions. Thereby, a clinician is able to close the jaw members upon tissue
to position the tissue prior to firing. Once the clinician has determined that the jaw
members are properly gripping tissue, the clinician can then fire the surgical stapler
with a single firing stroke, thereby severing and stapling the tissue. The simultaneous
severing and stapling avoids complications that may arise when performing such
actions sequentially with different surgical tools that respectively only sever or staple.
[0006] One specific advantage of being able to close upon tissue before firing is that
the clinician is able to verify via an endoscope that desired location for the cut has
been achieved, including a sufficient amount of tissue has been captured between
opposing jaws. Otherwise, opposing jaws may be drawn too close together,
especially pinching at their distal ends, and thus not effectively forming closed staples
in the severed tissue. At the other extreme, an excessive amount of clamped tissue
may cause binding and an incomplete firing.
[0007] Generally, a single closing stroke followed by a single firing stroke is a
convenient and efficient way to perform severing and stapling. However, in some
instances, it would be desirable for multiple firing strokes to be required. For
example, surgeons are able to select from a range of jaw sizes with a corresponding
length of staple cartridge for the desired length of cut. Longer staple cartridges
require a longer firing stroke. Thus, a hand-squeezed trigger to effect the firing is
required to exert a larger force for these longer staple cartridges in order to sever more
tissue and drive more staples as compared lo a shorter staple cartridge. It would be
desirable for the amount of force to be lower and comparable to shorter cartridges so
as not to exceed the hand strength of some surgeons. In addition, some surgeons not
familiar with the larger staple cartridges may become concerned that binding or other
malfunction has occurred when an unexpectedly higher force is required.
[0008] One approach to lower the required force for a firing stroke is a ratcheting
mechanism that allows a firing trigger to be stroked multiple times, as described in
U.S. Pat. Nos. 5,762,256 and 6,330,965. These known surgical stapling instruments
with multiple-stroke firing mechanisms do not have the advantages of a separate
closure and firing action. Moreover, the ratcheting mechanism relies upon a toothed
rack and driving pawl to achieve the ratcheting motion, with the length of a handle
encompassing these components thus increased to accommodate the toothed rack.
This increased length is inconvenient given the close confines and increasing amount
of equipment associated with a surgical procedure.
[0009]| Furthermore, between each stroke of the multiple-stroke firing mechanism, it
is desirable that any inadvertent retraction be prevented. Pressure exerted by tissue in
the end effector, for instance, tends to push back against the firing system between
strokes. In addition, in some instances, the firing mechanism includes a retraction
bias that may tend to draw back the firing mechanism between strokes, reducing the
effectiveness of the instrument, such as staple malformation, increased number of
firing strokes, or an inability to achieve a full firing sequence altogether.
[0010] Consequently, a significant need exists for a surgical stapling instrument with
a multiple stroke firing mechanism that prevents inadvertent retraction of the firing
mechanism between firing strokes.
Brief Summary of the Invention
[0011] The invention overcomes the above-noted and other deficiencies of the prior
art by providing a surgical stapling instrument that affirmatively prevents a firing
member from returning during firing even when a firing mechanism is uncoupled
between strokes, such as when a firing trigger is released. Thus, surgical instruments
used to perform surgical operations that could misfire during to such return motion
are rendered more reliable and effective.
[0012] In one aspect of the invention, a surgical instrument has an end effector that
responds to a longitudinal firing motion between an unfired position and a fully fired
position received from a firing member in a shaft to perform a surgical operation. An
anti-backup mechanism prevents the return of the firing member during firing by
having a locking plate with an aperture ciroumferentially encompassing the firing
member. The locking plate pivots between a locking position and an unlocking
position responsive to a locking device that in turn responds to the instrument being in
the process of firing. A retract mechanism causes the locking plate to unlock.
Thereby, resistance that could cause inadvertent return of the firing member is
prevented.
[0013] In another aspect of the invention, a surgical instrument has the end effector
connected to a handle via the shaft. Within the handle, a rack is distally coupled to
the firing member. A firing control responds to an operator to move in a firing
direction and a return direction. A firing mechanism couples the firing control to the
rack to impart the firing motion in response to the firing direction and to uncouple the
firing control from the rack in response to the return direction. This firing control
works in concert with a locking mechanism that impedes firing member motion in the
return direction in response to the firing member having traveled between an initial,
unfired position and a fired position. This approach has particular advantages for
multiple stroke firing approaches wherein the firing member may be released between
strokes. These and other objects and advantages of the present invention shall be
made apparent from the accompanying draw ings and the description thereof.
Brief Description of the Figures
[0014] The accompanying drawings, which are incorporated in and constitute a part
of this specification, illustrate embodiments of the invention, and, together with the
general description of the invention given above, and the detailed description of the
embodiments given below, serve to explain the principles of the present invention.
[0015] FIG. 1 is a right side elevation view of a surgical stapling and severing
instrument in an open (start) condition, with a shaft partially cutaway to expose a
closure tube and firing rod.
[0016] FIG. 2 is a left side elevation view laken along line 2-2 in longitudinal cross
section of an end effector at a distal portion of the surgical stapling instrument of
FIG. I.
[0017] FIG. 3 is a front perspective view of the end effector of FIG. 2.
[0018] FIG. 4 is a perspective, exploded view of an implement portion of the surgical
stapling and severing instrument of FIG. 1.
[0019] FIG. 5 depicts a left side elevation \ lew in section of the end effector of FIG. 3
of the surgical instrument of FIG. 1, the section generally taken along lines 5-5 of
FIG. 3 to expose portions of a staple cartridge but also depicting the firing bar along
the longitudinal centerline.
[0020] FIG. 6 depicts a left side elevation \ lew in section of the end effector of FIG. 5
after the firing bar has fully fired.
[00211 FIG. 7 is a left side elevation view of the handle of the surgical stapling and
severing instrument of FIG. I with a left handle housing removed.
[0022] FIG. 8 is a perspective, exploded view of the handle of FIG. 7.
[00231 FIG. 9 is a perspective view from an elevated, aft, left vantage point of the
linked transmission firing mechanism of the handle of FIG. 7.
[00241 FIG. 10 is a detail left side elevatior view of the linked rack of the firing
mechanism of FIG. 9.
[00251 FIGS. 11-14 are left side elevation \ iews in cross section generally along the
longitudinal axis of the ramped central track of the linked rack and the pawl of the
firing mechanism, and additionally showing the firing trigger, biasing wheel and ramp
of the traction biasing mechanism, depicting a sequence during a firing stroke.
[0026] FIG. 15 is a right-side elevation view partially disassembled to expose a distal
portion of an anti-backup mechanism in a locked condition in the surgical stapling
and severing instrument of FIG. I.
[0027] FIG. 16 is a perspective view from a top, aft, right vantage point of the anti-
backup mechanism of FIG. 15 with the anti-backup cam tube removed.
[0028] FIG. 17 is a right-side elevation view partially disassembled to expose a distal
portion of an anti-backup mechanism in an unlocked condition in the surgical stapling
and severing instrument of FIG. 1.
[0029] FIG. 18 is a right-side elevation view partially disassembled to expose a distal
portion of an anti-backup mechanism in an unlocked condition in the surgical stapling
and severing instrument of FIG. 1.
[0030] FIG. 19 is a rear elevation view of the surgical stapling and severing
instrument of FIG. 1 with the right half shell of the handle housing removed to expose
the anti-backup release lever in phantom in a locking condition and in an unlocked
condition.
[0031] FIGS. 20-25 are detail views of tht; anti-backup release lever of FIG. 18
depicting respectively a firing sequence of unflred, one firing stroke, two firing
strokes, three firing strokes, returning or release button pushed, and fully returned.
[0032] FIGS. 26-27 are perspective view from a top, left, distal vantage point of the
surgical stapling and severing instrument with the right half shell of the handle
housing removed to expose a closure release lockout mechanism, respectively in an
initial position with lockout removed and closure release button depressed, and then a
lockout being activated during initial firing.
[0033] FIG. 28 is perspective view of a surgical stapling and severing instrument in
an open condition similar to FIG. I but incorporating a top-accessible retraction lever.
[0034] FIG. 29 is a left side elevation view of the surgical stapling and severing
instrument of FIG. 28 with the left half shell of the handle housing removed to expose
an intermittently toothed indicator gear presenting a first dwell area to the idler gear.
[0035] FIG. 30 is a left side elevation view ot the surgical stapling and severing
instrument of FIG. 28 with the left half shell of the handle housing removed to expose
an intermittently toothed indicator gear presenting a second dwell area to the idler
gear.
Detailed Description of the Invention
[0036] Turning to the Drawings, wherein like numerals denote like components
throughout the several views, FIGS. 1 and 2 depict a surgical stapling and severing
instrument 10 that is capable of practicing the unique benefits of the present
invention. The surgical stapling and severing instrument 10 incorporates an end
effector 12 having an anvil 14 pivotally attached to an elongate channel 16, forming
opposing jaws for clamping tissue to be severed and stapled. The end effector 12 is
coupled by a shaft 18 to a handle 20. An i mplement portion 22, formed by the end
effector 12 and shaft 18, is advantageously sized for insertion through a trocar or
small laparoscopic opening to perform an endoscopic surgical procedure while being
controlled by a surgeon grasping the handle 20. The handle 20 advantageously
includes features that allow separate closure motion of the end effector 12 from firing,
as well as enabling multiple firing strokes to effect firing (i.e., severing and stapling)
of the end effector 12 while indicating the degree of firing to the surgeon.
[0037] To these ends, a closure tube 24 of the shaft 18 is coupled between a closure
trigger 26 and the anvil 14 to cause closure of the end effector 12. Within the closure
tube 24, a frame 28 is coupled between the elongate channel 16 and the handle 20 to
longitudinally position and support the end effector 12. A rotation knob 30 is coupled
with the frame 28, and both elements are rotatably coupled to the handle 20 with
respect to a rotational movement about a longitudinal axis of the shaft 18. Thus, the
surgeon can rotate the end effector 12 by turning the rotation knob 30. The closure
tube 24 is also rotated by the rotation knob 30 but retains a degree of longitudinal
movement relative thereto to cause the closure of the end effector 12. Within the
frame 28, a firing rod 32 is positioned for longitudinal movement and coupled
between the anvil 14 of the end effector 12 and a multiple-stroke firing trigger 34.
The closure trigger 26 is distal to a pistoi grip 36 of the handle 20 with the firing
trigger 34 distal to both the pistol grip 3() and closure trigger 26.
[0038] In endoscopic operation, once the implement portion 22 is inserted into a
patient to access a surgical site, a surgeon refers to an endoscopic or other diagnostic
imaging device to position tissue between the anvil 14 and elongate channel 16.
Grasping the closure trigger 26 and pistol grip 36, the surgeon may repeatedly grasp
and position the tissue. Once satisfied as to the location of the tissue relative to the
end effector 12 and the amount of tissue therein, the surgeon depresses the closure
trigger 26 fully toward the pistol grip 36, clamping the tissue in the end effector 12
and locking the closure trigger 26 in this damped (closed) position. If not satisfied
with this position, the surgeon may release the closure trigger 26 by depressing a
closure release button 38 and thereafter repeat the procedure to clamp tissue.
[0039] If clamping is correct, the surgeon may proceed with firing the surgical
stapling and severing instrument 10. Specifically, the surgeon grasps the firing trigger
34 and pistol grip 36, depressing the firing trigger 34 a predetermined number of
times. The number of firing strokes necessary is ergonomically determined based on a
maximum hand size, maximum amount of force to be imparted to the instrument
during each firing stroke, and the longitudinal distance and force needed to be
transferred through the firing rod 32 to the end effector 12 during firing. As will be
appreciated in the discussion below, individual surgeons may choose to cycle the
firing trigger 34 a different angular range of motion, and thus increase or decrease the
number of firing strokes, yet the handle 20 still effects firing without binding.
[0040] During these strokes, the surgeon may reference an indicator, depicted as an
indicating retraction knob 40, that positionally rotates in response to the multiple
firing strokes. Additionally, the position of the retraction knob may confirm that full
firing has occurred when encountering resistance to further cycling of the firing
trigger 34. It should be appreciated that various indicia and instructions may be added
to the handle 20 to enhance the indication provided by the rotation of the indicating
retraction knob 40. Upon full travel of the firing rod 32 and when the firing trigger 34
is released, the handle 20 automatically retracts the firing rod 32. Alternatively, the
surgeon, with knowledge that the instrument 10 has not fully fired as depicted by the
indicating retraction knob 40, may depress an anti-backup release button 42 and
release the firing trigger 34. Both of these actions allow the handle 20 to
automatically retract the firing rod 32.
[0041] It will be appreciated that the terms "proximal" and "distal" are used herein
with reference to a clinician gripping a handle of an instrument. Thus, the end effector
12 is distal with respect to the more proximal handle 20. It will be further appreciated
that for convenience and clarity, spatial terms such as "vertical" and "horizontal" are
used herein with respect to the drawings. However, surgical instruments are used in
many orientations and positions, and these terms are not intended to be limiting and
absolute.
[0042] The present invention is being disc;ussed in terms of endoscopic procedures
and apparatus. However, use herein of terms such as "endoscopic", should not be
construed to limit the present invention tc a surgical stapling and severing instrument
for use only in conjunction with an endoscopic tube (i.e., trocar). On the contrary, it
is believed that the present invention may find use in any procedure where access is
limited to a small incision, including but not limited to laparoscopic procedures, as
well as open procedures.
[0043] E-Beam End Effector.
[0044] The advantages of a handle 20 capable of providing multiple-stroke firing
motion has application to a number of instruments, with one such end effector 12
being depicted in FIGS. 2-6. The end effector 12 responds to the closure motion from
the handle 20 (not depicted in FIGS. 2-6) first by including an anvil face 50 (FIGS. 2,
4, 6) connecting to an anvil proximal end 52 that includes a pair of laterally projecting
anvil pivot pins 54 that are distal to a vertically projecting anvil feature 56 (Fig. 4).
The anvil pivot pins 54 translate within kidney shaped openings 58 in the elongate
channel 16 to open and close anvil 14 relative to elongate channel 16. The anvil
feature 56 engages a bent tab 59 extending inwardly in tab aperture 60 on a distal end
62 of the closure tube 24, the latter dislally terminating in a distal edge 64 that pushes
against the anvil face 50. Thus, when the closure tube 24 moves proximally from its
the open position, the bent tab 59 of the closure tube 24 draws the anvil feature 56
proximally, and the anvil pivot pins 54 follow the kidney shaped openings 58 of the
channel 16 causing the anvil 14 to simultaneously translate proximally and rotate
upward to the open position. When the closure tube 24 moves distally, the tab
aperture 60 releases from the anvil feature 56 and the distal edge 64 pushes on the
anvil face 50, closing the anvil 14.
[0045) With continued reference to FIG. 4, the implement portion 22 also includes
components that respond to the firing motion of the firing rod 32. In particular, the
firing rod 32 rotatably engages a firing trough member 66 having a longitudinal recess
68. Firing trough member 66 moves longitudinally within frame 28 in direct response
to longitudinal motion of firing rod 32. A longitudinal slot 70 in the closure tube 24
operably couples with the rotation knob 30 (not shown in FIGS. 2-6). The length of
the longitudinal slot 70 in the closure tube 24 is sufficiently long as to allow relative
longitudinal motion with the rotation knob 30 to accomplish firing and closure
motions respectively.
[0046] The distal end of the frame trough member 66 is attached to a proximal end of
a firing bar 76 that moves with the frame 28, including a guide 78 therein, to distally
project an E-beam 80 into the end effector 12. The end effector 12 includes a staple
cartridge 82 that is actuated by the E-beam 80. The staple cartridge 82 has a tray 84
that holds a staple cartridge body 86, a wedge sled driver 88, staple drivers 90 and
staples 92. It will be appreciated that the wedge sled driver 88 longitudinally moves
within a recess 94 located between a cartridge tray 84 and the cartridge body 86. The
wedge sled driver 88 presents camming surfaces that contact and lift the staple
drivers 90 upward, driving the staples 92 up from staple apertures 96 into contact with
staple forming grooves 98 of the anvil 14, creating formed "B" shaped staples, such as
depicted at 100 of FIG. 6. With particulai reference to FIG. 3, the staple cartridge
body 86 further includes a proximally open, vertical slot 102 for passage of the E-
beam 80. Cutting surface 104 is provided along a distal end of E-beam 80 to cut
tissue after it is stapled.
[0047] In FIGS. 2, 5, 6, respectively, the end effector 12 is depicted in a sequence of
open (i.e., start) condition, clamped and unfired condition, and fully fired condition.
Features of the E-beam 80 that facilitate firing of the end effector 12, in particular, are
depicted. In FIG. 2, the wedge sled driver 88 is in its fully proximally position,
indicating an unfired staple cartridge 82. A middle pin 106 is aligned to enter the
firing recess 94 in the staple cartridge 82, for distally driving the wedge sled driver
88. A bottom pin or cap 108 of the E-beani 82 slides along a bottom surface of the
elongate channel 16, thus the middle and bottom pins 106, 108 slidingly engage the
elongate channel 16. In the open and unfired state of FIG. 2, a top pin 110 of the E-
beam 80 has entered and is residing within an anvil pocket 112 of the anvil 14, and
thus does not impede repeated opening and closing of the anvil 14.
[00481 In FIG. 5, the end effector 12 is depicted as clamped and ready to fire. The
top pin 110 of the E-beam 80 is aligned with an anvil slot 114 in the anvil 14 distal to
and communicating with the anvil pocket 112. In FIG. 6, the E-beam 80 has been
fully fired, with the upper pin 110 translating down the anvil slot 114, affirmatively
spacing the anvil 14 from the elongate channel 16 as the cutting surface 104 severs
clamped tissue. Simultaneously, the middle pin 106 has actuated the staple cartridge
82 as previously described. Thereafter, the E-beam 80 is retracted prior to opening
the end effector 12 and replacing the staple cartridge 82 for an additional operation.
[0049] The illustrative end effector 12 is described in greater detail in five co-pending
and commonly-owned U.S. patent applications, the disclosure of each being hereby
incorporated by reference in their entiret): (1) "SURGICAL STAPLING
INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR
PREVENTION OF FIRING", Ser. No. 10/441,424, to Frederick E. Shelton, Mike
Setser, Bruce Weisenburgh, filed 20 Junf 2003; (2) "SURGICAL STAPLING
INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING
SYSTEMS", Ser. No. 10/441,632, to Frederick E. Shelton, Mike Setser, Brian J.
Hemmelgam, filed 20 June 2003: (3) "SURGICAL STAPLING INSTRUMENT
HAVING A SPENT CARTRIDGE LOCKOUT", Ser. No. 10/441,565, to Frederick
E. Shelton, Mike Setser, Bruce Weisenburgh, filed 20 June 2003; (4) "SURGICAL
STAPLING INSTRUMENT HAVING A FIRING LOCKOUT FOR AN
UNCLOSED ANVIL", Ser. No. 10/441,580, to Frederick E. Shelton, Mike Setser,
Bruce Weisenburgh, filed 20 June 2003 and (5) "SURGICAL STAPLING
INSTRUMENT INCORPORATING AN E-BEAM HRING MECHANISM", Ser.
No. 10/443,617, to Frederick E. Shelton, Mike Setser, Bruce Weisenburgh, filed 20
June 2003.
[0050] It should be appreciated that although a nonarticulating shaft 18 is illustrated
herein, applications of the present invention may include instruments capable of
articulation, such as described in five co-pending and commonly owned U.S. patent
applications, the disclosure of each being hereby incorporated by reference in their
entirety: (1) "SURGICAL INSTRUMENT INCORPORATING AN
ARTICULATION MECHANISM HAVING ROTATION ABOUT THE
LONGITUDINAL AXIS", Ser. No. 10/615,973, to Frederick E. Shelton, Brian J.
Hemmelgam, Jeff Swayze, Kenneth S. Wales, filed 9 July 2003; (2) "SURGICAL
STAPLING INSTRUMENT INCORPORATING AN ARTICULATION JOINT FOR
A FIRING BAR TRACK", Ser. No. 10/615,962, to Brian J. Hemmelgam, filed 9 July
2003; (3) "A SURGICAL INSTRUMENT WITH A LATERAL-MOVING
ARTICULATION CONTROL", Ser. No. 10/615972, to Jeff Swayze, filed 9 July
2003; (4) "SURGICAL STAPLING INSTRUMENT INCORPORATING A
TAPERED FIRING BAR FOR INCREASED FLEXIBILITY AROUND THE
ARTICULATION JOINT', Ser. No. 10/615,974, to Frederick E. Shelton, Mike
Setser, Bruce Weisenburgh, filed 9 July 2003; and (5) "SURGICAL STAPLING
INSTRUMENT HAVING ARTICULATION JOINT SUPPORT PLATES FOR
SUPPORTING A FIRING BAR", Ser. No. 10/615,971, to Jeff Swayze, Joseph
Charles Hueil, filed 9 July 2003.
[0051] It should further be appreciated that the linked rack 200 further may enhance a
compact design for the handle 20 by progressing at least partially into the shaft 18 of
the implement portion 22 as well as around a comer and into a pistol grip 36 of the
handle. Moreover, instead of communicating the firing force to a firing rod 32, a
linked rack consistent with aspects of the invention may travel farther toward the end
effector 12 to include an articulation mechanism. A pivotal connection between links
may thus enhance the ability of the instrament to articulate.
[0052] Multi-stroke firing handle.
[0053] In FIGS. 7-8, the handle 20 of the surgical stapling and severing instmment 10
is shown in greater detail, illustrating a linked transmission firing mechanism 150 that
provides features such as increased strength, reduced handle size, minimized binding,
etc.
[00541 Closure of the end effector 12 (not shown in FIGS. 7-8) is caused by
depressing the closure trigger 26 toward the pistol grip 36 of handle 20. The closure
trigger 26 pivots about a closure trigger pin 152 that is coupled to a handle housing
154 composed of right and left half shells 156, 158, causing an upper portion 160 of
the closure trigger 26 to move forward. The closure tube 24 receives this closure
movement via a closure yoke 162 that is pinned to a closure link 164 and to the upper
portion 160 of the closure trigger 26 respecti\ely by a closure yoke pin 166 and a
closure link pin 168.
[0055] In the fully open position of FIG. 7. the upper portion 160 of the closure
trigger 26 contacts and holds a locking arnr 172 of the pivoting closure release button
38 in the position shown. When the closure trigger 26 reaches its fully depressed
position, the closure trigger 26 releases the locking arm 172 and an abutting surface
170 rotates into engagement with a distal nghtward notch 171 of the pivoting locking
arm 172, holding the closure trigger 26 in this clamped or closed position. A
proximal end of the locking arm 172 pivots about a lateral pivotal connection 174
with the housing 154 to expose the closure release button 38. An intermediate, distal
side 178 of the closure release button 38 is urged proximally by a compression spring
180, which is compressed between a housing structure 182 and closure release button
38. The result is that the closure release button 38 urges the locking arm 172
counterclockwise (when viewed from the left) into locking contact with the abutting
surface 170 of closure trigger 26, which prevents unclamping of closure trigger 26
when the linked transmission firing system 150 is in an unretracted condition, as
described in greater detail below.
[0056] With the closure trigger 26 retracted fully depressed, the firing trigger 34 is
unlocked and may be depressed toward the pistol grip 36 multiple times to effect
firing of the end effector 12. As depicted, the linked transmission firing mechanism
150, is initially retracted, urged to remain in this position by a combination
tension/compression spring 184 that is constrained within the pistol grip 36 of the
handle 20, with its nonmoving end 186 connected to the housing 154 and a moving
end 188 connected to a downwardly flexed and proximal, retracted end 190 of a steel
band 192.
[0057] A distally-disposed end 194 of the steel band 192 is attached to a link coupling
195 for structural loading and front link 196a of a plurality of links 196a-196d that
form a linked rack 200. Linked rack 200 is flexible yet has distal links that form a
straight rigid rack assembly that may transfer a significant firing force through the
firing rod 32 in the implement portion 22. yet readily retract into the pistol grip 36 to
minimize the longitudinal length of the handle 20.
[0058] It should be appreciated that a dual tension/compression spring 184 increases
the amount of firing travel available while essentially reducing the minimum length
by half over a single spring.
[00591 The firing trigger 34 pivots about a firing trigger pin 202 that is connected to
the housing 154. An upper portion 204 of the firing trigger 34 moves distally about
the firing trigger pin 202 as the firing trigger 34 is depressed towards pistol grip 36,
stretching a proximally placed firing trigger tension spring 206 proximally connected
between the upper portion 204 of the firing trigger 34 and the housing 154. The upper
portion 204 of the firing trigger 34 engages the linked rack 200 during each firing
trigger depression by a traction biasing mechanism 210 that also disengages when the
firing trigger 34 is released. Firing trigger tension spring 206 urges the firing trigger
34 distally when released and disengages the traction biasing mechanism 210.
[0060] As the firing mechanism 150 actuates, an idler gear 220 is rotated
counterclockwise (as viewed from the left side) by engagement with a toothed upper
surface 222 of the linked rack 200. This rcitation is coupled to an indicator gear 230,
which thus rotates clockwise in response to the idler gear 220. Both the idler gear 220
and indicator gear 230 are rotatably connected to the housing 154. The gear
relationship between the linked rack 200, idler gear 220 and indicator gear 230 may
be advantageously selected so that the toothed upper surface 222 has tooth dimensions
that are suitably strong and that the indicator gear 230 makes no more than one
revolution during the full firing travel of the firing mechanism 150.
[0061] As described in greater detail belov/, the indicator gear 230 performs at least
four functions. First, when the linked rack 200 is fully retracted and both triggers 26,
34 are open as shown in FIG. 7, an opening 240 in a circular ridge 242 on the left side
of the indicator gear 230 is presented to an upper surface 244 of the locking arm 172.
Locking arm 172 is biased into the opening 240 by contact with the closure trigger 26,
which in turn is urged to the open position by a closure tension spring 246. Closure
trigger tension spring 246 is connected proximally to the upper portion 160 of the
closure trigger 26 and the handle housing 154, and thus has energy stored during
closing of the closure trigger 26 that urges rhe closure trigger 26 distally to its
unclosed position.
[0062] A second function of the indicator gear 230 is that it is connected to the
indicating retraction knob 40 externally disposed on the handle 20. Thus, the
indicator gear 230 communicates the relative position of the firing mechanism 150 to
the indicating retraction knob 40 so that the surgeon has a visual indication of how
many strokes of the firing trigger 34 are required to complete firing.
[0063] A third function of the indicator gear 230 is to longitudinally and to angularly
move an anti-backup release lever 248 of an anti-backup mechanism 250 as the
surgical stapling and severing instrument 10 is operated. During the firing strokes,
proximal movement of anti-backup release lever 248 by indicator gear 230 activates a
one-way clutch mechanism or anti-backup 250 (FIGS. 15-16) that allows distal
movement of firing bar 32 and prevents proximal motion of firing bar 32. This
movement also extends the anti-backup release button 42 from the proximal end of
the housing 154 for the operator to actuate should the need arise for the firing
mechanism to be retracted during the firing strokes. After completion of the firing
strokes, the indicator gear 230 reverses direction of rotation as the firing mechanism
150 retracts. The reversed rotation deactivates the anti-backup 250, withdraws the
anti-backup release button 42 into the handle 20, and rotates the anti-backup release
lever 248 laterally (FIG. 19) to allow continued reverse rotation of the indicator gear
230.
[0064] A fourth function of the indicator gear 230 is to receive a manual rotation from
the indicating retraction knob 40 (clockwise in the depiction of FIG. 7) to retract the
firing mechanism 150 with anti-backup mechanism 250 is unlocked, thereby
overcoming any binding in the firing mechanism 150 that is not readily overcome by
the combination tension/compression spring 184. This manual retraction may be
employed after a partial firing of the firing mechanism 150 that would otherwise be
prevented by the anti-backup mechanism 250 by depression of the anti-backup release
button 42, which laterally moves the anti-backup release lever 248.
[0065] Anti- backup mechanism 250 consists of an operator accessible anti-backup
release lever 248 operably coupled at the proximal end to anti-backup release lever 42
and at the distal end to an anti-backup yoke 256. In particular, a distal end 254 of the
anti-backup release lever 248 is engaged to the anti-backup yoke 256 by an anti-
backup yoke pin 258. The anti-backup >oke 256 moves longitudinally to impart a
rotation to an anti-backup cam slot tube 252 that is longitudinally constrained by the
housing 154 and that encompasses the firing rod 32 distally to the connection of the
firing rod 32 to the front link 196a of the linked rack 200. The anti-backup yoke 256
communicates the longitudinal movement from the anti-backup release lever 248 via
a cam slot tube pin 260 to the anti-backup cam slot tube 252. That is, longitudinal
movement of cam slot tube pin 260 in an angled slot in the anti-backup cam slot tube
252 rotates the tube 252.
[0066] Trapped between a proximal end of the frame 28 and the anti-backup cam slot
tube 252 respectively are an anti-backup compression spring 264, an anti-backup plate
266, and an anti-backup cam tube 268. As depicted, distal movement of the firing rod
32 causes the anti-backup plate 266 to pivot top to the rear, presenting an increased
frictional contact to the firing rod 32 that resists proximal movement of the firing rod
32.'
[0067] This anti-backup plate 266 pivots in a manner similar to that of a screen door
lock that holds open a screen door when the anti-backup cam slot tube 252 is spaced
away from the anti-backup cam tube 268. Specifically, the anti-backup compression
spring 264 is able to act upon a top surfact- of the plate 266 to tip the plate 266 to its
locked position. Rotation of the anti-backup cam slot tube 252 causes a distal
camming movement of the anti-backup cam tube 268 forcing the top of the plate 266
distally, overcoming the force from the anli-backup compression spring 264, thus
positioning the anti-backup plate 266 in an unlocked position that allows proximal
retraction of the firing rod 32
[0068] With particular reference to FIGS. 8-10, the traction biasing mechanism 210 is
depicted as being composed of a paw I 270 that has a distally projecting narrow tip
272 and a rightwardly projecting lateral pin 274 at its proximal end that is rotatably
inserted through a hole 276 in the upper portion 204 of the firing trigger 34. On the
right side of the firing trigger 34, the lateral pin 274 receives a biasing member,
depicted as biasing wheel 278. As the firing trigger 34 translates fore and aft, the
biasing wheel 278 traverses an arc proximate to the right half shell 156 of the handle
housing 154, overrunning at its distal portion of travel a biasing ramp 280 integrally
formed in the right half shell 156. The biasing wheel 278 may advantageously be
formed from a resilient, frictional material that induces a counterclockwise rotation
(when viewed from the left) into the lateral pin 274 of the pawl 270, thus traction
biasing the distally projecting narrow tip 2"'2 downward into a ramped central track
282 of the nearest link 196a-d to engage the linked rack 200. As the firing trigger 34
is released, the biasing wheel 278 thus traclionally biases the pawl 270 in the opposite
direction, raising the narrow tip 272 from the ramped central track 282 of the linked
rack 200. To ensure disengagement of the tip 272 under high load conditions and at
nearly full distal travel of the pawl 270, the narrow tip 272 ramps up onto a
proximally and upwardly facing beveled surface 284 on the closure yoke 162 to
disengage the narrow tip 272 from the ramped central track 282. If the firing trigger
34 is released at any point other than full closure, the biasing wheel 278 is used to lift
the narrow tip 272 from the ramped central track 282. Whereas a biasing wheel 278
is depicted, it should be appreciated that the shape of the biasing member or wheel
278 is illustrative and may be varied to accommodate a variety of shapes that use
friction or traction to engage or disengage the firing of the end effector.
[0069] Linked rack.
[0070] With particular reference to FIG. 10, the linked rack 200 is depicted in greater
detail to illustrate a number of advantages. Each link 196a-d is pinned to adjacent
links 196a-d for downward, proximal rotation into the pistol grip 36. Although
bendable in this direction, the linked rack 200 forms a rigid configuration when
against a columnar loading, especially a loading that would other urge the distal links
I96a-d to bend upwardly. In particular, each link 196a-d proximally terminates in a
male extension 300 having lateral through hole 302 on a lower portion thereof. A left
side 304 of each link 196a-d includes the toothed upper surface 222 and a right side
306 parallels the left side 304 defining between them the ramped central track 282
that terminates in the male extension 300.
[0071] The proximal portion of the centra track 282 terminates before the right and
left sides 304, 306, forming a device 308 "or receiving a male extension 300 from a
leading link 196a-d, which is hingedly attached by a pivot pin 310. Each leading link
196a-d has a flat 312 at the proximal end that is generally perpendicular to the
direction of columnar loading from the firing rod 32. Each trailing link 196a-d has a
contact surface 314 at the distal end that is also generally perpendicular to the
direction of columnar loading. The lateral through hole 302 is spaced away sufficient
so that a notch 316 is formed between lower portions of adjacent flat 312 and contact
surface 314 to provide clearance for downward pivoting of the trailing link 196a-d
relative to the leading link 196a-d. Yet, the upper portions of the adjacent flat 312
and contact surface 314 are registered for abutment as the leading and trailing links
196a-d are longitudinally aligned, thereby esisting further upward deflection. As
shown, when adjacent links 196a-d are horizontal, the holes 302 and pins 310 are
located below the line of action of the firing rod 32. When loads are applied to the
firing trigger 34, the traction biasing mechanism 210 applies a pushing load along the
line of action and biases consecutive horizontal links 196a-d together. Thus,
imparting a line of action of a firing force above the pivot pins 310 maintains any
leading links I96a-d in a rigid, straight configuration. The ramped central track 282
of a trailing link 196b-d directs the distally projecting narrow tip 272 of the pawl 270
into engagement with the male extension 300 of the leading link 196a-c.
[00721 The front link 196a is distally attached to the link coupling 195 that includes
features that couple to the proximal end of the firing rod 32 as well as including a
male extension 300 and flat 312 similar to the links 196a-d, with sufficient spacing to
receive therebetween tabs 320, 322 (FIG. 8) of the distally-disposed end 194 of the
steel band 192, the tabs 320, 322 attached by the same pivot pin 310 that attaches the
front link 196a to the link coupling 195. Application of the retraction force at this
force advantageously reduces frictional forces by applying the force along the
longitudinal axis of the firing rod 32 and straight portion of the linked rack 200.
[00731 Having a toothed upper surface 222 on the left side 304 that is distinct from
the ramped central track 282 advantageously allows a nonbinding, strong engagement
between the pawl 270 and the linked rack 200, even if the firing trigger 34 has been
stroked with varying ranges of motion. Meanwhile the toothed upper surface 222
provides a continuous engagement with the idler gear 220 for the advantages
described above.
[0074] It should be appreciated that although a pinned clevis connection between
links 196a-d has been advantageously depicted, a resilient or flexible connection may
be used. In addition, four links 196a-d are depicted, but various numbers and lengths
of links may be selected depending on firing travel, radius of curvature, etc.
[0075] Traction-Biasing Mechanism.
[0076] In FIGS. 11-14, the linked transmission firing mechanism 150 is depicted in a
sequence that illustrates how the traction biasing mechanism 210 (i.e., pawl 270,
biasing wheel 278, and biasing ramp 280) affirmatively respond to the direction of
travel of the firing trigger 34. Moreover, since the biasing wheel 278 makes a
frictional contact with the biasing ramp 280, the biasing wheel 278 slides when full
disengagement or engagement movement of the pawl 270 is achieved.
[0077] In FIG. 11, the firing trigger 34 has been partially depressed to where the
traction biasing mechanism 210 begins to initiate engagement of the firing trigger 34
movement to the linked rack 200. In particular, the biasing wheel 278 has contacted
the proximal end of the biasing ramp 280, and thus begins to rotate counterclockwise,
as viewed from the left, imparting this rotation to the pawl 270, which is initially
disengaged from the linked rack 200. In FIG. 12, the firing mechanism 150 has
advanced a distance sufficient for the pawl 270 to have fully rotated into engagement
with the ramped central track 282 of the first link 196a, abutting the link coupling 195
and thereby transferring a firing motion into the firing rod 32. In FIG. 13, the firing
trigger 34 and overall firing mechanism 150 has continued to a nearly full travel
position, during which movement the biasing wheel 278 has slid along the biasing
ramp 280. At the end of the firing stroke, the farside lower edge of the pawl 270 (FIG.
8) contacts the proximally and upwardly lacing beveled surface 284 of the closure
yoke 162 and lifts the pawl 270 from engagement with a link 196, allowing the linked
rack 200 to retract.
[0078] In FIG. 14, the firing trigger 34 has been released sufficient for the biasing
wheel 278 to gain traction proximally on the biasing ramp 280, causing a clockwise
rotation, when viewed from the left, and raising the pawl 270. Given the proximally
directed slope of the ramped central track 282 of the linked rack 200, the firing
mechanism 150 is not obstructed in being moved proximally in preparation for either
another firing stroke or for a retraction eye c.
[00791 It should be appreciated that the traction biasing mechanism 210 may be
implemented in an instrument that performs at least a single stroke.
[00801 Anti-backup Mechanism.
[00811 As described above, the anti-backup mechanism 250 locks during the firing
strokes to prevent the firing rod 32 and thus the firing mechanism 150 from retracting
until full firing travel is achieved or the user selects to retract. In FIG. 15, the anti-
backup mechanism 250 is depicted in a locked condition. The anti-backup release
lever 248 is in the proximal-most position ind has rotated anti-backup cam slot tube
252 to engage the anti-backup cam tube 268 to form a minimum longitudinal length,
creating an increased space for the locking plate 266. Locking plate 266 is tipped to
the angle shown by the anti-backup compression spring 264 and grips on the firing
rod 32, as shown in FIG. 16.
[0082] In FIG. 16, a proximal end 400 of the frame 28 include a half spool portion
402 that receives the anti-backup compression spring 264 against its distal annular
ring 404. Proximal to the spring 264, the frame 28 has a top and proximally open
trough 406 that communicates with the interior of the frame 28. The anti-backup
plate 266 is a generally flat plate shaped to fit into the open trough 406 adjacent to the
spring 264. Central orifice 408 extends through plate 266. In particular, the top
portion of the anti-backup plate 266 that is exposed from the open trough 406 projects
upwardly to receive a force from the spring 264. The lower portion of the anti-backup
plate 266 is longitudinally constrained and not in contact with the spring 264. Thus,
unless restrained by the anti-backup cam tube 268, the top of the anti-backup plate
266 is urged to tip proximally, causing the central orifice 408 in the anti-backup plate
266 to bind against the firing rod 32.
[00831 In FIG, 17, the anti-backup mechanism 250 is depicted as unlocked. The anti-
lock release lever 248 has laterally moved to the right, impart a movement to the right
of the anti-backup yoke 256, thereby imparting a clockwise rotation of the anti-
backup cam slot tube 252, when viewed from a proximal position. A camming
surface 410 of the anti-backup cam slot tube 252 departs from a proximal cutout 412
in the anti-backup cam tube 268, forcing the latter to move distally against the anti-
backup plate 266, which in turn moves to a perpendicular, unlocked position and
further compresses anti-backup compression spring 264.
[00841 In FIG. 18, the interaction between the anti-backup release lever 248 and the
right side of the indicator gear 230 are depicted after the firing trigger 34 has been
fired twice. A lever opening 420 extends through anti-backup release lever 248 to
receive and interact with a curved ramp 434 extending outwardly from the right side
of the indicator gear 230. Rotation of the indicator gear 230 drives the anti-backup
release lever 248 distally, which bottoms cut the anti-backup release button 42 into a
button receptacle 422 and disengages the anti-backup mechanism 250, and
proximally, which exposes the anti-backup release button 42 as depicted, as well as
kicking the anti-backup release lever 248 to the right to actuate the anti-backup
mechanism 250. The anti-backup yoke 256 allows this motion with a longitudinal
slotted connection with the anti-backup yoke pin 258 (not shown). These movements
of the anti-backup release lever 248 are caused by a curved ramp 430 that surrounds
almost a quarter of the circumference of an indicator pin 432, about which the
indicator gear 230 turns. The clockwise most portion (when viewed from the right),
or peak 434, of the curved ramp 430 projects the farthest to the right away from the
surface of the indicator gear 230. The counterclockwise most portion or entry 436 of
the curved ramp 430 is thus flush with the surface of the indicator gear 230.
[00851 In FIGS. 18-25, the lever opening 420 is shaped with a horizontal slot 440 that
defines the proximal and distal movement available to the anti-backup release lever
248, with the indicator pin 432 residing within this horizontal slot 440. A top recess
442 and a bottom recess 444 vertically widen and communicate with the horizontal
slot 440 and define at what angular position the clockwise most portion 434 of the
curved ramp 430 longitudinally translates the anti-backup release lever 248. The top
and bottom recesses 442,444 are sized to allow the curved ramp 430 to enter the
respective recess 442, 444 without tipping the anti-backup release lever 248 until the
end of normal firing. The lever opening 420 is above the longitudinal axis of the anti-
backup mechanism 250, and thus a rightward force creates a rotating force of the anti-
backup cam slot tube 252.
[0086] In FIG. 20, the anti-backup release lever 248 and indicator gear 230 are shown
in their initial condition that remains through the time in which the closure trigger 26
is being actuated. In particular, the anti-bac kup release lever 248 is distally
positioned, bottoming out the anti-backup release button 42 in its button receptacle
422. The curved ramp430 is at its counterclockwise extreme, with its peak434 at
approximately the 6 o'clock position adjacent distally to a proximal vertical surface of
the lower recess 444 of the lever recess 420 w ith the entry 436 of the ramp 430 at
about 3 o'clock.
[0087] In FIG. 21, the first firing stroke of the firing trigger 34 has occurred, wherein
the peak 434 has acted against the proximal vertical surface of the bottom recess 444
and the curved ramp 430 has rotated clockwise to about the 9 o'clock position.
Thereby, the anti-backup release lever 248 has translated proximally to exposes the
anti-backup release button 42 from the button receptacle 422 and actuated the anti-
backup mechanism 250. The relationship of the rate of clockwise rotation of the
indicator gear 230 to the desired number of full firing strokes is selected so that the
curved ramp 430 continues unimpeded as subsequent firing strokes are made, as
depicted in FIG. 22 wherein the two firing strokes have been completed moving the
peak to approximately the twelve o'clock position. Thus, the peak 434 is proximal to
and adjacent to the distal vertical edge of the upper recess 442, positioned so that a
subsequent firing stroke will act upon the anti-backup release lever 248 to cause distal
horizontal movement. Note that during these liring strokes that the curved ramp 430
resides proximal to the indicator pin 432. Depressing the release button 42 would
cause the proximal edge of the lever opening 420 to ride up onto the curved ramp 430,
tilting the anti-backup release lever 248 as Depicted in FIG. 19.
[0088] In FIG. 23, the final firing stroke is concluding, during which the peak 434 has
moved to approximately 3 o'clock while moving the proximal end of the horizontal
slot 440 up against the indicator pin 432, bottoming out the anti-backup release button
42, releasing the anti-backup mechanism 2.i0 and initiating the retraction of linked
transmission firing mechanism 150.
[0089] In FIG. 24, the unlocked anti-backup mechanism 250 has allowed the spring-
powered retraction of the linked rack 200 to occur, which in turn causes a
counterclockwise rotation, when viewed from the right, of the indicator gear 230. As
the firing mechanism 150 begins to retract, the counterclockwise rotation of indicator
gear 230 slides the angled surface of curved ramp 430 into ramped contact with the
proximal edge of the top recess 442. Continued rotation of indicator gear 230 drives
the curved ramp 430 under the upper portion of backup release lever 248 and tilts or
deflects lever 248 to the position shown in FIG. 19. The tilting motion of the backup
release lever 248 is provided to prevent longitudinal motion of lever 248 by the
curved ramp 430 during retraction of the linked rack 200. Should the linked rack 200
not retract at the end of the last stroke afte r anti-backup mechanism 250 is
automatically unlocked at the end of the firing sequence, turning the indicator knob 40
(not shown in FIGS. 20-25) would provide extra force to retract the linked rack 200.
It should further be appreciated that during partial firing of the firing mechanism 150,
such as depicted in FIGS. 22, depressing the release button 42 would also retract the
linked rack 200 by move the backup release lever 248 distally to unlock the anti-
backup mechanism 250. The retraction motion continues until the indicator gear is
returned to its initial position, as depictec in FIG. 25.
[0090] It should be appreciated that the shape of the lever opening 420 and arcuate
size of the arced ramp 430 are illustrative and may be varied to accommodate a
handle configured for a different number of firing strokes.
[0091] It should be appreciated that the rotary release mechanism formed by the
interaction of the indicator gear 230 and the lever opening 420 may be replaced with
other linkages. In addition, one or both of the anti-backup plate 266 and firing rod 32
may advantageously include surface treatments (e.g., coating, knerling, sandblasted
texture, ridges, etc.) to enhance the frictional engagement therebetween.
[00921 Opening Lockout.
[0093] In FIG. 26, the surgical stapling and severing instrument 10 is in its initial
open condition with both closure and firing triggers 26, 34 forward and the linked
rack 200 retracted. As described above, in this unfired condition, the indicator gear
230 presents its opening 240 in circular ricge 242 to the upper surface 244 of the
locking arm 172, which is ordinarily rotated downward out of the opening 240 by the
action of the compression spring 180 between the housing structure 182 and the
intermediate distal side 178 of the closure elease button 38. In FIG. 26, the closure
release button 38 has been depressed, causing the upper surface 244 into the opening
240. In FIG. 27, the closure trigger 26 and the locking arm 172 are in clamping
abutment after closing with the closure trigger 26 against the pistol grip 36 and the
firing trigger 34 swung into position for firing. The closure release button 38 is not
depressed, as noted by the expanded closure spring 180. The upper surface 244 of the
locking arm 172 is swung below circular ridge 242 and indicator gear 230 is unlocked
and free to rotate counterclockwise. The downward movement of locking arm 172
unlocks the indicator gear 230 and connectid linked transmission firing mechanism
150 and allows the firing trigger 34 to be actuated. Thus, as the indicator gear 230
continues to rotate with further firing, the closure release button 38 is precluded from
releasing the clamped closure trigger 26.
[0094] Position Indicator and Release Mecliatiism.
[0095] In FIG. 28, a surgical stapling and s-.nering instrument 610 has the indicator
retraction knob replaced by an alternate indicator device 640 upwardly extended to
present a top-accessible retraction lever 642 that functions as a stuck firing retractor
that may be readily actuated by either hand. The instrument is shown opened and
unfired, as indicated by the distally forward closure and firing triggers 26, 34 and the
open end effector 12. When firing has not commenced, the retraction lever 642 is
normally distally rotated adjacent to the handle housing 154. The indicator 640 may
be coupled (not shown) to the previously described idler gear 220 and a firing
mechanism 150 as described previously in which the retraction lever 642 would rotate
proximally as the linked transmission is fired, presenting a visual indication of firing
as well as allowing a way of assisting automatic retraction by applying a manual distal
force thereto as a rotary position indicator, the direction of rotation must be reversed
so it must be attached to the idler gear 220 for this embodiment.
[0096] In FIG 29, another alternate firing mechanism 650 incorporates the afore-
described top-accessible retraction lever 642 and indicator device 640 that is coupled
to an indicator gear 660 having first and second dwell areas 662, 664 within a toothed
area 668. The first dwell area 662 is presented to the idler gear 220 when the
retraction lever 642 is at its distal position adjacent to the handle housing 154.
Thereby, the idler gear 220 is allowed free clockwise and counterclockwise rotation
as driven by the longitudinally moving linked rack 200. Should the E-beam 80 (not
shown in FIG. 29) become stuck within tht." end effector 12 for any reason and cannot
be withdrawn proximally by the combination tension/compression spring 184, the
retraction lever 642 may be pulled proximally by the surgeon to rotate the indicator
gear 660 clockwise, as viewed from the lett. This rotational movement of the
retraction lever 660 rotates the indicator gear 660 and brings a curved tooth segment
670 that is between the first and second dw ell 662, 664 into contact with the teeth of
the idler gear 220 to operably couple the retraction lever 642 to the firing mechanism
650.
[0097] Once coupled, the surgeon may apply extra force to the retraction lever 642 to
retract the firing mechanism 650, thereby rotating the idler gear 220 counterclockwise
and longitudinally moving the linked rack 200 proximally to retract the E-beam 80.
As the retraction lever 642 is further rotated to the position of FIG 30, the idler gear
220 disengages with the curved tooth segment 670 and is decoupled from the
retraction lever 642 by second dwell area 664. At this point, the application of force
has freed the stuck firing mechanism 650 and the combination tension/compression
springs 184 will fully retract the linked rack 200.
[00981 An alternate design (not shown) in\olves the addition of a one way slip clutch
such as a Sprague clutch or an equivalent (lot shown) between the retraction lever
642 and the indicator gear 660. In the previous design, the range of motion of the
retraction lever 642 is limited by contact with the handle housing 154 at each end of
the range or motion less than a full revolution. This limits the distance that the firing
system 650 can be retracted for one movement of the retraction lever 642. The
addition of the one way slip clutch between the retraction lever 642 and indicator gear
660 allows the retraction lever 642 to operably engage with the indicator gear 660 as
the retraction lever 642 rotates back (distal to proximal) and disengages as the lever
moves forward (proximal to distal). This ensures full retraction of the firing
mechanism 650 by allowing multiple pulls on the retraction lever 642. Second dwell
area 664 may be removed from the indicator gear 660 to ensure more tooth to tooth
engagement. Additionally, the incorporation of a clutch mechanism allows the
retraction lever to be rotated adjacent to the handle after use.
[0099] In use, the surgeon positions the end effector 12 and shaft 18 through the
cannula or a trocar to a surgical site, positii)ned the anvil 14 and elongate channel 16
as opposing jaws to grasp tissue to be stapled and severed. Once satisfied with the
position of end effector 12, the closure trigger 26 is full depressed toward the pistol
grip 36 of the handle 20, causing the upper portion 160 of the closure trigger 26 to
lock against a locking arm 172 that is pivotally attached to the closure release button
38. Then, the firing trigger 34 is depressed and released a predetermined number of
times to effect full firing travel to drive a firing rod 32 down the shaft 18 to the E-
beam 80 in the end effector 12. During firing, the anti-backup mechanism 250 is in a
locked condition, with an anti-backup plate 266 allowed to tip back, binding any
proximal motion of the firing rod 32. The distal firing motion is imparted to the firing
rod 32 by a linked transmission firing mechanism 150 that includes linked rack 200
proximally attached to the firing rod 32, wilh each link 196a-d pinned to adjacent
links 196a-d such that bending is allowed down into the pistol grip 36 but not upward,
forming a rigid structure when straight with a force imparted above the pivot pins 310
between links 196a-d. Specifically, a traction biasing mechanism 210 coupled to the
firing trigger 34 includes a biasing wheel 278 that is frictionally coupled the handle
housing 154 such that a distal firing motion imparts an engaging bias to the pawl 270,
urging the pawl 270 into engagement with the linked rack 200. At the end of the
stroke, the pawl 270 is lifted from firing engagement with link 196 by being brought
into contact with angled surface 284 of the closure yoke 162. A return motion of the
firing mechanism 150 causes the biasing wheel 278 to impart a reversing bias to the
pawl 270, holding pawl 270 above the linkeiJ rack 200 that is thereby held in place by
the anti-backup mechanism 250. Upon full iring travel, the indicator gear 230
includes the curved ramp 430 that trips the inti-backup release lever 248 that forces
the anti-backup plate 266 into an unlocked condition, allowing the linked rack 200,
and thus the firing rod 32, to be withdrawn by a compressive force stored in a
combination tension/compression spring 184. Thereby, the linked rack 200 is
withdrawn into the handle grip 36. Alternatively, during the firing strokes, the
surgeon may depress the anti-backup release button 42 that causes the anti-backup
release lever to tip. The indicator knob 40 may advantageously allow the surgeon to
know how far firing has progressed and to assist in retracting the E-beam 80 that has
encountered binding.
[00100] While the present invention has bet n illustrated by description of several
embodiments and while the illustrative embodiments have been described in
considerable detail, it is not the intention of the applicant to restrict or in any way
limit the scope of the appended claims to such detail. Additional advantages and
modifications may readily appear to those skilled in the art.
[00101] For instance, while a surgical stapling and severing instrument 10 is described
herein that advantageously has separate and distinct closing and firing actuation,
providing clinical flexibility. However, it should be appreciated that applications
consistent with the present invention may include a handle that converts a single user
actuation into a firing motion that closes and fires the instrument.
[00102] In addition, while a manually actuited handle is illustrated, a motorized or
otherwise powered handle may benefit from incorporating a linked rack as described
herein, allowing reduction of the size of the handle or other benefits. For instance,
while partially stowing the linked rack into the pistol grip is convenient, it should be
appreciated that the pivot connection between links allows for stowing the link
parallel to the straight portion defined by the shaft and the barrel of the handle.
[00103] As another example, while a linked rack 200 is advantageously depicted, a
surgical instrument having a nonbendable- rack may also benefit from an anti-backup
mechanism.
[00104] As yet another example, it should be appreciated that a circular firing rod 32 is
illustrative and that many cross sectional shapes may be employed.
[00105] What is claimed is:
We Claim:
1. A surgical stapling instrument, comprising:
an end effector responsive to a longitudinal firing motion to
perform a surgical operation;
a shaft distally connected to the end effector;
a firing member slidingly receiving by the shaft to transfer the
firing motion to the end effectoi- between an unfired position and a
fully fired position; and
an anti-backup mechanism comprising:
a locking plate including an aperture circumferential ly
encompassing the firing member, the locking plate pivotal between
a locking position wherein the aperture lockingly engages the
firing member and an unlocking position wherein the aperture
slidingly engages the firing member,
a locking device responsive to the firing member having traversed
from the unfired position toward the fully fired position to tilt the
locking plate to the locked position, and
a retract mechanism responsive to a retract condition to position
the locking plate to the unlock position.
2. The surgical stapling instrument as claimed in claim 1, wherein the
anti-backup mechanism includes a user control for releasing said
locking plate from engagement with said firing member at any point
during the longitudinal firing motion.
3. The surgical stapling instrument as claimed in claim 1, wherein the
retract mechanism is a user control that receives the retract condition
is a user control input.
4. The surgical stapling instrument as claimed in claim 1, wherein the
retract condition is a selected one of a group consisting of the fully
fired position of the firing member and a user control input for
retracting of the firing member.
5. The surgical stapling instrument as claimed in claim 1, wherein the
end effector is further responsive to a closure motion, the handle and
shaft configured to respectively to generate and to carry the closure
motion to the end effector.
6. The surgical stapling instrument as claimed in claim 1, wherein said
end effector comprises:
an elongate channel connected to said shaft;
an anvil pivotally coupled to said elongate channel for clamping
tissue; and
a staple cartridge received in said elongate channel;
wherein said firing member distally terminates in a firing bar operably
configured to actuate said staple cartridge to form staples in the
clamped tissue.
7. The surgical stapling instrument as claimed in claim 1, wherein said
firing member includes a frictional surface finish to enhance
engagement with said locking plate.
8. The surgical stapling instrument as claimed in claim 7, wherein said
firing member surface finish is textured.
9. A surgical stapling instrument, comprising:
an end effector responsive to a longitudinal firing motion to perform a
surgical operation;
a shaft distally connected to the end effector;
a firing member slidingly receiving by the shaft to transfer the firing
motion to the end effector; and
a handle proximally connected to the shaft and firing member,
comprising:
a rack distally coupled to the firing member,
a firing control responsive to an operator to move in a firing direction
and a return direction,
a firing mechanism operably configured to couple the firing control to
the rack to impart the firing motion in response to the firing direction
and to uncouple the firing control from the rack in response to the
return direction, and
a locking mechanism operably configured to impede firing member
motion in the return direction in response to the firing member having
traveled between an initial, unfired position and a fired position.
10. The surgical stapling instrument as claimed in claim 9, wherein said
end effector comprises a stapling device responsive to the longitudinal
firing motion to perform the surgical operation of stapling.
11. The surgical stapling instrument as claimed in claim 10, wherein said
end effector comprises:
an elongate channel connected to said shaft;
an anvil pivotally coupled to said elongate channel for clamping
tissue; and
a staple cartridge received in said elongate channel;
wherein said firing member distally terminates in a firing bar operably
configured to actuate said staple cartridge to form staples in the
clamped tissue.
12. A surgical stapling instrument, comprising:
a end effector responsive to a longitudinal firing motion to perform a
surgical operation;
a shaft distally connected to the end effector;
a firing member slidingly receiving by the shaft to transfer the firing
motion to the end effector between an proximal unfired position and a
distal fully fired position; and
an anti-backup mechanism including a locking plate having an
aperture circumferentially encompassing the firing member, the anti
backup mechanism biasing the locking plate into locking engagement
with the firing member in response to the firing motion and out of
locking engagement with the firing member just prior to the fully fired
position, said locking engagement allowing distal movement of said
firing member and preventing proximal movement of said firing
member.
13. The surgical stapling instrument as claimed in claim 12, wherein said
end effector comprises:
an elongate channel connected to said shaft;
an anvil pivotally coupled to said elongate channel for clamping
tissue; and
a staple cartridge received in said elongate channel;
wherein said firing member distally terminates in a firing bar operably
configured to actuate said staple cartridge to form staples in the
clamped tissue.
14. The surgical stapling instrument as claimed in claim 12, further
comprising a firing mechanism operably configured to transfer
sequential firing strokes as a distal longitudinal movement into said
firing member.
15. The surgical stapling instrument as claimed in claim 14, wherein said
firing mechanism comprises a means for traction biased coupling of
multiple firing trigger depressions by an operator.
16. The surgical stapling instrument as claimed in claim 14, wherein said
firing mechanism comprises a means for linked rack coupling of firing
trigger depression by an operator to said firing member.
17. The surgical stapling instrument as claimed in claim 16, wherein said
firing mechanism further comprises a means for traction biased
coupling of multiple firing trigger depressions by an operator.

A surgical stapling and severing instrument particularly suited to endoscopic procedures
incorporates a handle that produces separate closing and firing motions to actuate an end
effector. In particular, the handle produces multiple firing strokes in order to reduce the
required amount of force required to fire (i.e., staple and sever) the end effector. A linked
transmission reduces the required handle longitudinal length, yet achieves a rigid, strong
configuration when straightened for firing. A traction biased firing mechanism avoids
binding in driving this straightened linked rack in cooperation with an anti-backup
mechanism, with a lockout mechanism that prevents releasing the closure trigger during
firing. Furthermore, an external indicator gives ft edback to the surgeon as to how far firing
has progressed, as well as providing a manual retraction capability.

Documents:

586-kol -2004-granted-abstract.pdf

586-kol -2004-granted-claims.pdf

586-kol -2004-granted-correspondence.pdf

586-kol -2004-granted-description (complete).pdf

586-kol -2004-granted-drawings.pdf

586-kol -2004-granted-examination report.pdf

586-kol -2004-granted-form 1.pdf

586-kol -2004-granted-form 18.pdf

586-kol -2004-granted-form 2.pdf

586-kol -2004-granted-form 26.pdf

586-kol -2004-granted-form 3.pdf

586-kol -2004-granted-form 5.pdf

586-kol -2004-granted-reply to examination report.pdf

586-kol -2004-granted-specification.pdf

586-kol -2004-granted-translated copy of priority document.pdf

586-kol-2004-abstract.pdf

586-kol-2004-claims.pdf

586-kol-2004-correspondence.pdf

586-kol-2004-description (complete).pdf

586-kol-2004-drawings.pdf

586-kol-2004-examination report.pdf

586-kol-2004-form 1.pdf

586-kol-2004-form 18.pdf

586-kol-2004-form 2.pdf

586-kol-2004-form 26.pdf

586-kol-2004-form 3.pdf

586-kol-2004-form 5.pdf

586-KOL-2004-FORM-27.pdf

586-kol-2004-reply to examination report.pdf

586-kol-2004-specification.pdf

586-kol-2004-translated copy of priority document.pdf


Patent Number 239876
Indian Patent Application Number 586/KOL/2004
PG Journal Number 15/2010
Publication Date 09-Apr-2010
Grant Date 06-Apr-2010
Date of Filing 27-Sep-2004
Name of Patentee ETHICON ENDO-SURGERY INC.
Applicant Address 4545 CREEK ROAD, CINCINNATI, OHIO
Inventors:
# Inventor's Name Inventor's Address
1 MICHAEL E. SETSER 2538 FLAGSTONE COURT, BURLINGTON, KENTUCKY 41005
2 FREDERICK E. SHELTON IV 245 EAST MAIN STREET, HILLSBORO, OHIO 45133
PCT International Classification Number A61B 17/068
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/673,929 2003-09-29 U.S.A.