US-12616471-B2 - Surgical stapler with partial pockets

US12616471B2US 12616471 B2US12616471 B2US 12616471B2US-12616471-B2

Abstract

A surgical stapler includes a jaw assembly at a distal end connected to a handle assembly that is configured to control the stapler and actuate the deployment of staples. The surgical stapler successfully eliminates intermediate caming portions commonly known as pushers that are located between the staples and a translating slider. The staples are located in pockets at an angle such that the base of the staple is parallel to an angled caming surface of the slider. The translating slider comes into direct contact with staples during deployment as the slider moves through each staple pocket where staples are partially supported by recesses along the slider pathway. The staples are deployed at an angle against the anvil surface. Because there are no pushers, a great deal of space is saved resulting in a much smaller diameter surgical stapler that is particularly suitable for laparoscopic stapling applications.

Inventors

Timothy M. Hopkins
Donald L. Gadberry
Matthew M. Becerra
Babak Jasemian
Gary M. Johnson
Steven E. Decker

Assignees

APPLIED MEDICAL RESOURCES CORPORATION

Dates

Publication Date: 20260505
Application Date: 20231006

Claims (20)

1 . A surgical stapler comprising: an elongate shaft assembly having a proximal end and a distal end; and a jaw assembly at the distal end of the elongate shaft assembly; the jaw assembly comprising: a first jaw having an anvil surface; a second jaw; the first jaw being movable relative to the second jaw and having a closed position in which the anvil surface is adjacent to the second jaw and a gap is defined between the second jaw and the anvil surface; the second jaw comprising a staple cartridge receiving portion; and a staple cartridge positionable in the staple cartridge receiving portion, the staple cartridge comprising: a first plate, a second plate, and a third plate connected together, the first plate having an inner surface and an outer surface opposite the inner surface, the first plate comprising a plurality of staple holding locations formed therein, each staple holding location defined by a substantially U-shaped recess formed in the inner surface of the first plate, the second plate having a first outer surface and a second outer surface opposite the first outer surface, a first slot between the inner surface of the first plate and the first outer surface of the second plate, wherein each staple holding location formed in the inner surface of the first plate and a corresponding portion of the first outer surface of the second plate opposite each staple holding location together define a staple pocket; a plurality of staples positioned in the recesses of the plurality of staple holding locations; and a slider comprising a slider base and at least two angled caming surfaces extending upwardly from the slider base, one of the at least two angled caming surfaces positioned in the first slot, wherein the slider is advanceable longitudinally within the jaw assembly such that the angled caming surface positioned in the first slot sequentially contacts the plurality of staples and urges them out of the staple cartridge towards the anvil surface of the first jaw as the slider translates along the jaw assembly and wherein with the plurality of staples in the staple holding locations, an unsupported portion of each staple of the plurality of staples is positioned in the first slot.
2 . The surgical stapler of claim 1 , wherein the recess comprises a front sidewall, a rear sidewall parallel to the front sidewall, and a bottom wall interconnected to the rear sidewall to form a generally L-shaped continuous wall.
3 . The surgical stapler of claim 1 , wherein the angled caming surface of the slider sequentially contacts the unsupported portions of the plurality of staples as the slider translates along the jaw assembly.
4 . The surgical stapler of claim 1 , wherein the second jaw extends from a proximal end to a distal end along a longitudinal axis and wherein the staple holding locations extend at an angle between 30 and 90 degrees relative to the longitudinal axis.
5 . The surgical stapler of claim 4 , wherein each of the at least two caming surfaces of the slider has an angled distal end extending from the slider base at an angle relative to the longitudinal axis, the angle of the angled distal end corresponding to the angle of the staple holding locations.
6 . The surgical stapler of claim 5 , wherein each staple of the plurality of staples comprises a first leg and a second leg interconnected by a base, and wherein the angled distal end of the each of the at least two caming surfaces pushes each staple normal to the base of the staple.
7 . The surgical stapler of claim 1 , wherein the outer surface of the first plate is substantially flat and smooth.
8 . The surgical stapler of claim 1 , wherein the second plate has a first substantially smooth outer surface facing the inner surface of the first plate.
9 . The surgical stapler of claim 8 , wherein the third plate is a mirror image of the first plate.
10 . The surgical stapler of claim 9 , wherein the second plate has a second substantially smooth outer surface opposite the first substantially smooth outer surface, the second substantially smooth outer surface facing the third plate.
11 . The surgical stapler of claim 1 , wherein the staple cartridge receiving portion has a proximal end and a distal end, and wherein the staple cartridge receiving portion comprises a ledge formed at the distal end and a tongue formed at the proximal end.
12 . The surgical stapler of claim 11 , wherein the staple cartridge has a proximal end and a distal end, and wherein the staple cartridge comprises a tongue at the distal end engageable with the ledge of the staple cartridge receiving portion and a groove at the proximal end engageable with the tongue of the staple cartridge receiving portion.
13 . The surgical stapler of claim 1 , wherein the first plate extends from a proximal end to a distal end and further comprises a proximal spacer protruding from the inner surface at the proximal end of the first plate and a distal spacer protruding from the inner surface at the distal end of the first plate such that when the first plate is stacked with the second plate, the proximal spacer and the distal spacer space the first plate from the second plate to define the first slot.
14 . A surgical stapler comprising: a shaft assembly; the shaft assembly having a proximal end and a distal end and a longitudinal axis extending between the proximal end and the distal end; the shaft assembly comprising: a jaw assembly at the distal end of the shaft assembly and extending longitudinally distally relative to the longitudinal axis; the jaw assembly comprising: a first jaw having an anvil surface; a second jaw having a top surface defining a horizontal plane; the first jaw being movable relative to the second jaw and having a closed position in which the anvil surface is adjacent to the top surface and a gap is defined between the top surface and the anvil surface; the second jaw including a plurality of staple pockets; each staple pocket comprising an opening to the top surface of the second jaw and a staple holding location beneath the opening with respect to a vertical plane orthogonal to the horizontal plane; a slider movable longitudinally within the second jaw, the slider comprising a caming surface; and a plurality of staples positioned in the plurality of staple pockets, wherein each staple comprises a supported portion positioned within the staple holding location and an unsupported portion contacted by the caming surface of the slider as the slider is moved longitudinally within the second jaw, wherein the caming surface is angled relative to the longitudinal axis to contact the staples; and wherein each staple holding location comprises a recess formed in a surface of the second jaw, the recess comprising a first sidewall, a second sidewall parallel to the first sidewall, and a bottom wall.
15 . The surgical stapler of claim 14 , wherein each staple holding location extends from the opening at an angle less than 90 degrees with respect to the top surface.
16 . The surgical stapler of claim 15 , wherein the angle is greater than 30 degrees with respect to the top surface.
17 . The surgical stapler of claim 14 , wherein the anvil surface comprises a flat smooth surface without staple forming pockets therein.
18 . The surgical stapler of claim 14 , wherein the anvil surface comprises a plurality of channels formed therein.
19 . The surgical stapler of claim 1 , further comprising a second staple cartridge positionable in the staple cartridge receiving portion, the staple cartridge and the second staple cartridge positioned to define a passageway therebetween.
20 . A surgical stapler comprising: a shaft assembly; the shaft assembly having a proximal end and a distal end and a longitudinal axis extending between the proximal end and the distal end; the shaft assembly comprising: a jaw assembly at the distal end of the shaft assembly and extending longitudinally distally relative to the longitudinal axis; the jaw assembly comprising: a first jaw having an anvil surface; a second jaw having a top surface defining a horizontal plane; the first jaw being movable relative to the second jaw and having a closed position in which the anvil surface is adjacent to the top surface and a gap is defined between the top surface and the anvil surface; the second jaw including a plurality of staple pockets; each staple pocket comprising an opening to the top surface of the second jaw and a staple holding location beneath the opening with respect to a vertical plane orthogonal to the horizontal plane; a slider movable longitudinally within the second jaw, the slider comprising a caming surface; and a plurality of staples positioned in the plurality of staple pockets, wherein each staple comprises a supported portion positioned within the staple holding location and an unsupported portion contacted by the caming surface of the slider as the slider is moved longitudinally within the second jaw, wherein the caming surface is angled relative to the longitudinal axis to contact the staples; and wherein each staple holding location extends from the opening at an angle less than 90 degrees with respect to the top surface; and wherein the angle is greater than 30 degrees with respect to the top surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 17/144,957, entitled “Surgical stapler with partial pockets,” filed Jan. 8, 2021, which is a continuation of U.S. patent application Ser. No. 15/847,575, entitled “Surgical stapler with partial pockets,” filed Dec. 19, 2017, now U.S. Pat. No. 11,051,812, which is a continuation of U.S. patent application Ser. No. 14/212,357, entitled “Surgical stapler with partial pockets,” filed Mar. 14, 2014, now U.S. Pat. No. 9,872,683, issued Jan. 23, 2018, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/785,100 filed on Mar. 14, 2013 entitled “Surgical stapler with partial pockets” which are incorporated herein by reference in their entirety. FIELD This disclosure relates to surgical instruments, and more particularly, to surgical stapling instruments and staples for sequentially applying a plurality of surgical staples to body tissue. BACKGROUND A typical surgical stapler apparatus comprises a handle at a proximal end and two elongated jaw-like members joined together at a hinge at a distal end. The jaw-like members articulate to open and close to capture tissue between the jaw-like members. The user controls the device from the handle to open and close the jaw-like members, actuate deployment of staples and in general manipulate and control the device. One of the jaw members carries a disposable cartridge containing staples arranged in two or more rows. The other one of the jaw-like members comprises an anvil against which the staples are driven to deform the staple legs. Staples are driven out of the cartridge by a caming surface or slider that moves longitudinally against a plurality of laterally positioned pushers that push each staple out of the cartridge individually. The caming surface of the slider is angled to complement the angular surface of the pushers. The cooperation between the angular surfaces of the pushers and the slider is a key step of the surgical stapling process. Misalignment can cause the staples to jam the device. Some staplers include a blade that follows the caming surface so as to cut the tissue between the two or more rows of delivered staples. Surgical staplers are used in a variety of surgical techniques including laparoscopic and/or endoscopic or other minimally invasive surgical procedures in which the stapler is inserted through a cannula or tube positioned within a small incision in a patient's body. In laparoscopic, endoscopic or minimally invasive surgery, a trocar or cannula is inserted across body tissue of a patient to access a body cavity and to create a channel for the insertion of a camera, such as a laparoscope. The camera provides a live video feed capturing images that are then displayed to the surgeon on one or more monitors. Additional trocars are inserted to create additional pathways through which surgical instruments, including surgical staplers, can be inserted for performing procedures observed on the monitor. The targeted tissue location such as the abdomen is typically enlarged by delivering carbon dioxide gas to insufflate the body cavity and create a working space large enough to accommodate the scope and instruments used by the surgeon. The insufflation pressure in the tissue cavity is maintained by using specialized trocars having seals that prevent the insufflation gas from escaping and collapsing the surgical working space. Laparoscopic surgery offers a number of advantages when compared with an open procedure. These advantages include reduced pain and hemorrhaging and shorter recovery times. As laparoscopic surgery evolves to become even more minimally invasive with incisions and cannula diameters becoming smaller and smaller, surgical staplers for use in laparoscopic/endoscopic procedures must be designed to fit within the small lumen of a cannula. Generally, a surgical stapler is inserted into a cannula such that the jaw-like members are in a closed orientation to inside the patient where the jaw-like members are opened to grasp and staple tissue. The handle of the stapler resides outside of the patient in control of the surgeon user. A portion of the shaft of the stapler between the jaw-like members and the handle is long enough to extend from outside the patient to inside the patient. During the surgical procedure, the elongate shaft of the stapler resides inside the cannula into which it was inserted. The distal jaw-like members include many components such as an anvil for forming staples, a staple cartridge with a plurality of staples, a caming surface such as a slider, pushers, a blade and other components which must all be small enough to fit through a small diameter cannula and made to function reliably and repeatedly from outside the patient. While conventional laparoscopic staplers are approximately 12 millimeters in diameter, the present invention provides a surgical stapler designed to fit inside a cannula h