CN110799107B

CN110799107B - Surgical anvil arrangement

Info

Publication number: CN110799107B
Application number: CN201880042896.6A
Authority: CN
Inventors: F·E·谢尔顿四世; J·R·摩根; J·L·哈里斯; G·J·巴克斯
Original assignee: Ethicon LLC
Current assignee: Ethicon LLC
Priority date: 2017-06-27
Filing date: 2018-06-14
Publication date: 2023-06-06
Anticipated expiration: 2038-06-14
Also published as: MX2019015649A; WO2019003031A1; CN110799107A; BR112019026738A2; JP2020525154A; JP7150763B2

Abstract

A surgical stapling anvil includes an anvil body that includes a longitudinal slot configured to receive a firing member therein and a tissue-facing surface that includes a plurality of staple forming pockets defined therein. The anvil further includes an anvil cap and a plurality of welds that weld the anvil cap and the anvil body together. The weld includes a shallow weld region having a first weld depth and a deep weld region having a second weld depth different from the first weld depth, wherein the shallow weld region and the deep weld region are configured to increase a total weld depth of the plurality of welds.

Description

Surgical anvil arrangement

Background

The present invention relates to surgical instruments and, in various arrangements, to surgical stapling and severing instruments designed to staple and sever tissue and staple cartridges for use therewith.

Drawings

The various features of the embodiments described herein, together with their advantages, may be understood from the following description taken in conjunction with the following drawings:

FIG. 1 is a side elevational view of a surgical system including a handle assembly and a plurality of interchangeable surgical tool assemblies usable therewith;

FIG. 2 is a perspective view of one of the interchangeable surgical tool assemblies of FIG. 1 operably coupled to the handle assembly of FIG. 1;

FIG. 3 is an exploded assembly view of portions of the handle assembly and interchangeable surgical tool assembly of FIGS. 1 and 2;

FIG. 4 is a perspective view of another of the interchangeable surgical tool assemblies depicted in FIG. 1;

FIG. 5 is a partial cross-sectional perspective view of the interchangeable surgical tool assembly of FIG. 4;

FIG. 6 is another partial cross-sectional view of a portion of the interchangeable surgical tool assembly of FIGS. 4 and 5;

FIG. 7 is an exploded assembly view of a portion of the interchangeable surgical tool assembly of FIGS. 4-6;

FIG. 7A is an enlarged top view of a portion of the resilient spine member of the interchangeable surgical tool assembly of FIG. 7;

FIG. 8 is an exploded assembly view of a portion of the interchangeable surgical tool assembly of FIGS. 4-7;

FIG. 9 is a cross-sectional perspective view of the surgical end effector portion of the interchangeable surgical tool assembly of FIGS. 4-8;

FIG. 10 is an exploded assembly view of the surgical end effector portion of the interchangeable surgical tool assembly depicted in FIG. 9;

FIG. 11 is a perspective, side elevational and front elevational view of a firing member that may be employed in the interchangeable surgical tool assembly of FIGS. 4-10;

FIG. 12 is a perspective view of an anvil that may be employed in the interchangeable surgical tool assembly of FIGS. 4-11;

FIG. 13 is a cross-sectional side elevational view of the anvil of FIG. 12;

FIG. 14 is a bottom view of the anvil of FIGS. 12 and 13;

FIG. 15 is a cross-sectional side elevational view of a portion of the surgical end effector and shaft portion of the interchangeable surgical tool assembly of FIG. 4 with a virgin surgical staple cartridge properly positioned within the elongate channel of the surgical end effector;

FIG. 16 is a cross-sectional side elevational view of the surgical end effector and shaft portion of FIG. 15 with the surgical staple cartridge having been fired during a staple firing stroke and the firing member retracted to a starting position after the staple firing stroke;

FIG. 17 is another cross-sectional side elevational view of the surgical end effector and shaft portion of FIG. 16 with the firing member having been fully retracted to its starting position;

FIG. 18 is a top cross-sectional view of the surgical end effector and shaft portion depicted in FIG. 15 with a virgin surgical staple cartridge properly positioned with an elongate channel of the surgical end effector;

FIG. 19 is another top cross-sectional view of the surgical end effector of FIG. 15 with a fired surgical staple cartridge mounted therein, showing the firing member retained in a lockout position;

FIG. 20 is a partial cross-sectional view of a portion of the anvil and elongate channel of the interchangeable tool assembly of FIG. 4;

FIG. 21 is an exploded side elevational view of the anvil and portions of the elongate channel of FIG. 20;

FIG. 22 is a rear perspective view of an anvil mounting portion of an anvil according to at least one embodiment;

FIG. 23 is a rear perspective view of an anvil mounting portion of another anvil in accordance with at least one embodiment;

FIG. 24 is a rear perspective view of an anvil mounting portion of another anvil in accordance with at least one embodiment;

FIG. 25 is a perspective view of an anvil according to at least one embodiment;

FIG. 26 is an exploded perspective view of the anvil of FIG. 25;

FIG. 27 is a cross-sectional end view of the anvil of FIG. 25;

FIG. 28 is a perspective view of another anvil according to at least one embodiment;

FIG. 29 is an exploded perspective view of the anvil embodiment of FIG. 28;

FIG. 30 is a top view of a distal end portion of the anvil body portion of the anvil of FIG. 28;

FIG. 31 is a top view of a distal end portion of an anvil body portion of another anvil according to at least one embodiment;

FIG. 32 is a cross-sectional end perspective view of the anvil of FIG. 31;

FIG. 33 is a cross-sectional end perspective view of an anvil according to at least one embodiment;

FIG. 34 provides a comparison between a first embodiment of an anvil and a second embodiment of an anvil;

FIG. 35 is a cross-sectional view of an end effector including the second anvil embodiment of FIG. 34;

FIG. 36 is a partial cross-sectional view of the first anvil embodiment of FIG. 34 and a firing member configured to engage the first anvil embodiment;

FIG. 37 is a partial front view of the firing member of FIG. 36;

FIG. 38 is a graphical representation depicting stress concentrations in the firing member of FIG. 36 and the first anvil embodiment of FIG. 34;

FIG. 39 is another illustration depicting stress concentrations in the firing member of FIG. 36;

FIG. 40 is a perspective view of a firing member according to at least one embodiment;

FIG. 41 is a side elevational view of the firing member of FIG. 40;

FIG. 42 is a front elevational view of the firing member of FIG. 40;

FIG. 43 is a partial perspective view of a firing member according to at least one embodiment;

FIG. 44 is a partial side elevational view of the firing member of FIG. 43;

FIG. 45 is a partial front elevational view of the firing member of FIG. 43;

FIG. 46 is a partial perspective view of a firing member according to at least one embodiment;

FIG. 47 is a partial side elevational view of the firing member of FIG. 46;

FIG. 48 is a partial front elevational view of the firing member of FIG. 46;

FIG. 49 is a partial perspective view of a firing member according to at least one embodiment;

FIG. 50 is a partial side elevational view of the firing member of FIG. 49;

FIG. 51 is a partial front elevational view of the firing member of FIG. 49;

FIG. 52 is a partial perspective view of a firing member according to at least one embodiment;

FIG. 53 is a partial side elevational view of the firing member of FIG. 52;

FIG. 54 is a partial front elevational view of the firing member of FIG. 52;

FIG. 55 is a partial perspective view of a firing member according to at least one embodiment;

FIG. 56 is a partial side elevational view of the firing member of FIG. 55;

FIG. 57 is a partial front elevational view of the firing member of FIG. 55;

FIG. 58 is a partial perspective view of a firing member according to at least one embodiment;

FIG. 59 is a partial side elevational view of the firing member of FIG. 58;

FIG. 60 is a partial front elevational view of the firing member of FIG. 58;

FIG. 61 is a partial perspective view of a firing member according to at least one embodiment;

FIG. 62 is a partial side elevational view of the firing member of FIG. 61;

FIG. 63 is a partial front elevational view of the firing member of FIG. 61;

FIG. 64 is a partial perspective view of a firing member according to at least one embodiment;

FIG. 65 is a partial side elevational view of the firing member of FIG. 64;

FIG. 66 is another partial perspective view of the firing member of FIG. 64;

FIG. 67 is a partial front elevational view of the firing member of FIG. 64;

FIG. 68 is a schematic drawing depicting the energy required to advance the firing members disclosed herein through a staple firing stroke;

FIG. 69 is a detailed view of a lateral projection extending from the firing member of FIG. 43, schematically illustrating interaction between the lateral projection and the anvil in a bent state;

FIG. 70 is a detailed view of a lateral projection extending from the firing member of FIG. 58, schematically illustrating interaction between the lateral projection and the anvil in a bent state;

FIG. 71 is a detailed view of a lateral projection extending from the firing member of FIG. 58, schematically illustrating interaction between the lateral projection and the anvil in another bent state;

FIG. 72 is a perspective view of an anvil of the surgical stapling instrument including an anvil body and anvil cap;

FIG. 73 is an exploded view of the anvil of FIG. 72;

FIG. 74 is a partial cross-sectional view of a welding anvil including a vertical welding surface;

FIG. 75 is a partial cross-sectional view of a welding anvil including a horizontal welding surface;

FIG. 76 is a partial cross-sectional view of a welding anvil including a fillet weld surface;

FIG. 77 is a cross-sectional view of an anvil including an anvil body and anvil cap wherein the anvil body and anvil cap are welded to one another;

FIG. 78 is a photomicrograph of a surgical stapling anvil including a first anvil member and a second anvil member that are welded to one another;

FIG. 79 is a cross-sectional view of a surgical stapling anvil including an anvil body and anvil cap;

FIG. 80 is a chart showing four different surgical stapling anvil arrangements subjected to two different loading conditions, including deflection and stress data for a first condition and stress data for a second condition;

FIG. 81 is a perspective view of an anvil including a first anvil member and a second anvil member wherein the anvil member includes a welding configuration configured to increase the overall depth of weld;

FIG. 82 is a cross-sectional view of the surgical stapling anvil of FIG. 81 prior to welding, taken along line 82-82 in FIG. 81;

FIG. 83 is a cross-sectional view of the surgical stapling anvil of FIG. 81 after welding, taken along line 83-83 in FIG. 81;

FIG. 84 is a cross-sectional view of a surgical stapling anvil including a first anvil member and a second anvil member welded to one another;

FIG. 85 is a partial cross-sectional, partially exploded view of the surgical stapling anvil of FIG. 84;

FIG. 86 is a cross-sectional view of a surgical stapling anvil including a first anvil member and a second anvil member welded to each other wherein the anvil members include interlocking features;

FIG. 87 is a cross-sectional view of a surgical stapling anvil including a first anvil member and a second anvil member welded to each other, wherein the anvil members include interlocking features;

FIG. 88 is a perspective view of the end effector assembly shown in an open configuration;

FIG. 89 is a perspective view of the end effector assembly shown in FIG. 88 shown in a closed configuration;

FIG. 90 is a partial cross-sectional view of the end effector assembly of FIG. 88 taken along line 90-90 of FIG. 88;

FIG. 91 is a partial cross-sectional view of the end effector assembly of FIG. 89 taken along line 91-91 in FIG. 88;

FIG. 92 is a cross-sectional view of the end effector assembly of FIG. 89 taken along line 92-92 in FIG. 88;

FIG. 93 is a perspective view of a cartridge channel including a channel body and a channel cap welded thereto;

FIG. 94 is an exploded view of the cartridge channel of FIG. 93;

FIG. 95 is a cross-sectional view of a cartridge channel including a first channel member and a second channel member welded to each other;

FIG. 96 is a perspective view of a firing member for use with a surgical instrument wherein the firing member includes a first jaw coupling member and a second jaw coupling member;

FIG. 97 is a perspective view of another firing member for use with a surgical instrument wherein the firing member includes a first jaw coupling member and a second jaw coupling member;

FIG. 98 is a front view of the firing member of FIG. 96;

FIG. 99 is a front view of the firing member of FIG. 96;

FIG. 100 is a front view of the firing member of FIG. 97;

FIG. 101 is a front view of the firing member of FIG. 97;

FIG. 102 is a partial front view of the firing member of FIG. 96;

FIG. 103 is a partial front view of the firing member of FIG. 97;

FIG. 104 is a cross-sectional view of a stapling system that includes the firing member of FIG. 97;

FIG. 105 is a cross-sectional view of a suturing system including the firing member of FIG. 96;

FIG. 106 is a partial cross-sectional view of the anvil and firing member of the stapling system of FIG. 105;

FIG. 107 is a partial cross-sectional view of the anvil and firing member of the stapling system of FIG. 104; and is also provided with

FIG. 108 is a stress analysis of the anvil of the stapling system of FIG. 105;

corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate various embodiments of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

Detailed Description

The applicant of the present application owns the following U.S. patent applications filed on even date herewith and each of which is incorporated by reference herein in its entirety:

U.S. patent application serial No. ________, entitled "SURGICAL ANVIL MANUFACTURING METHODS"; agent case number END8165USNP/170079M;

U.S. patent application serial No. __________ entitled "surgeal ANVIL ARRANGEMENTS"; agent record number END8168USNP/170080;

U.S. patent application serial No. __________ entitled "surgeal ANVIL ARRANGEMENTS"; agent record number END8170USNP/170081;

U.S. patent application serial No. __________, entitled "SURGICAL FIRING MEMBER ARRANGEMENTS"; agent case number END8169USNP/170083;

U.S. patent application serial No. __________, entitled "STAPLE FORMING POCKET ARRANGEMENTS"; agent record number END8167USNP/170085;

U.S. patent application serial No. __________, entitled "STAPLE FORMING POCKET ARRANGEMENTS"; agent record number END8232USNP/170086;

U.S. patent application serial No. __________, entitled "SURGICAL END EFFECTORS AND ANVILS"; agent case number END8166USNP/170087; and

U.S. patent application serial No. __________, entitled "ARTICULATION SYSTEMS FOR SURGICAL INSTRUMENTS"; agent case number END8171USNP/170088.

The applicant of the present application owns the following U.S. patent applications filed on 21 decursions 2016 and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 15/386,185, entitled "SURGICAL STAPLING INSTRUMENTS AND REPLACEABLE TOOL ASSEMBLIES THEREOF";

U.S. patent application Ser. No. 15/386,230, entitled "ARTICULATABLE SURGICAL STAPLING INSTRUMENTS";

U.S. patent application Ser. No. 15/386,221, entitled "LOCKOUT ARRANGEMENTS FOR SURGICAL END EFFECTORS";

U.S. patent application Ser. No. 15/386,209 entitled "SURGICAL END EFFECTORS AND FIRING MEMBERS THEEOF";

U.S. patent application Ser. No. 15/386,198 entitled "LOCKOUT ARRANGEMENTS FOR SURGICAL END EFFECTORS AND REPLACEABLE TOOL ASSEMBLIES";

U.S. patent application Ser. No. 15/386,240 entitled "SURGICAL END EFFECTORS AND ADAPTABLE FIRING MEMBERS THEREFOR";

U.S. patent application Ser. No. 15/385,939 entitled "STAPLE CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN";

U.S. patent application Ser. No. 15/385,941, entitled "SURGICAL TOOL ASSEMBLIES WITH CLUTCHING ARRANGEMENTS FOR SHIFTING BETWEEN CLOSURE SYSTEMS WITH CLOSURE STROKE REDUCTION FEATURES AND ARTICULATION AND FIRING SYSTEMS";

U.S. patent application Ser. No. 15/385,943, entitled "SURGICAL STAPLING INSTRUMENTS AND STAPLE-form ANVILS";

U.S. patent application Ser. No. 15/385,950, entitled "SURGICAL TOOL ASSEMBLIES WITH CLOSURE STROKE REDUCTION FEATURES";

U.S. patent application Ser. No. 15/385,945, entitled "STAPLE CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN";

U.S. patent application Ser. No. 15/385,946, entitled "SURGICAL STAPLING INSTRUMENTS AND STAPLE-form ANVILS";

U.S. patent application Ser. No. 15/385,951 entitled "SURGICAL INSTRUMENTS WITH JAW OPENING FEATURES FOR INCREASING A JAW OPENING DISTANCE";

U.S. patent application Ser. No. 15/385,953 entitled "METHODS OF STAPLING TISSUE";

U.S. patent application Ser. No. 15/385,954 entitled "FIRING MEMBERS WITH NON-PARALLEL JAW ENGAGEMENT FEATURES FOR SURGICAL END EFFECTORS";

U.S. patent application Ser. No. 15/385,955 entitled "SURGICAL END EFFECTORS WITH EXPANDABLE TISSUE STOP ARRANGEMENTS";

U.S. patent application Ser. No. 15/385,948, entitled "SURGICAL STAPLING INSTRUMENTS AND STAPLE-form ANVILS";

U.S. patent application Ser. No. 15/385,956 entitled "SURGICAL INSTRUMENTS WITH POSITIVE JAW OPENING FEATURES";

U.S. patent application Ser. No. 15/385,958 entitled "SURGICAL INSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTING FIRING SYSTEM ACTUATION UNLESS AN UNSPENT STAPLE CARTRIDGE IS PRESENT";

U.S. patent application Ser. No. 15/385,947, entitled "STAPLE CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN";

U.S. patent application Ser. No. 15/385,896 entitled "METHOD FOR RESETTING A FUSE OF A SURGICAL INSTRUMENT SHAFT";

U.S. patent application Ser. No. 15/385,898, entitled "STAPLE FORMING POCKET ARRANGEMENT TO ACCOMMODATE DIFFERENT TYPES OF STAPLES";

U.S. patent application Ser. No. 15/385,899 entitled "SURGICAL INSTRUMENT COMPRISING IMPROVED JAW CONTROL";

U.S. patent application Ser. No. 15/385,901 entitled "STAPLE CARTRIDGE AND STAPLE CARTRIDGE CHANNEL COMPRISING WINDOWS DEFINED THEREIN";

U.S. patent application Ser. No. 15/385,902 entitled "SURGICAL INSTRUMENT COMPRISING A CUTTING MEMBER";

U.S. patent application Ser. No. 15/385,904 entitled "STAPLE FIRING MEMBER COMPRISING A MISSING CARTRIDGE AND/OR SPENT CARTRIDGE LOCOUT";

U.S. patent application Ser. No. 15/385,905 entitled "FIRING ASSEMBLY COMPRISING A LOCKOUT";

U.S. patent application Ser. No. 15/385,907 entitled "SURGICAL INSTRUMENT SYSTEM COMPRISING AN END EFFECTOR LOCKOUT AND A FIRING ASSEMBLY LOCKOUT";

U.S. patent application Ser. No. 15/385,908 entitled "FIRING ASSEMBLY COMPRISING A FUSE";

U.S. patent application Ser. No. 15/385,909 entitled "FIRING ASSEMBLY COMPRISING A MULTIPLE FAILED-STATE FUSE";

U.S. patent application Ser. No. 15/385,920 entitled "STAPLE FORMING POCKET ARRANGEMENTS";

U.S. patent application Ser. No. 15/385,913, entitled "ANVIL ARRANGEMENTS FOR SURGICAL STAPLE/FASTENERS";

U.S. patent application Ser. No. 15/385,914 entitled "METHOD OF DEFORMING STAPLES FROM TWO DIFFERENT TYPES OF STAPLE CARTRIDGES WITH THE SAME SURGICAL STAPLING INSTRUMENT";

U.S. patent application Ser. No. 15/385,893 entitled "BILATERRALLY ASYMMETRIC STAPLE FORMING POCKET PAIRS";

U.S. patent application Ser. No. 15/385,929 entitled "CLOSURE MEMBERS WITH CAM SURFACE ARRANGEMENTS FOR SURGICAL INSTRUMENTS WITH SEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS";

U.S. patent application Ser. No. 15/385,911 entitled "SURGICAL STAPLE/FASTENERS WITH INDEPENDENTLY ACTUATABLE CLOSING AND FIRING SYSTEMS";

U.S. patent application Ser. No. 15/385,927 entitled "SURGICAL STAPLING INSTRUMENTS WITH SMART STAPLE CARTRIDGES";

U.S. patent application Ser. No. 15/385,917 entitled "STAPLE CARTRIDGE COMPRISING STAPLES WITH DIFFERENT CLAMPING BREADTHS";

U.S. patent application Ser. No. 15/385,900 entitled "STAPLE FORMING POCKET ARRANGEMENTS COMPRISING PRIMARY SIDEWALLS AND POCKET SIDEWALLS";

U.S. patent application Ser. No. 15/385,931, entitled "NO-CARTRIDGE AND SPENT CARTRIDGE LOCKOUT ARRANGEMENTS FOR SURGICAL STAPLE/FASTENERS";

U.S. patent application Ser. No. 15/385,915, entitled "FIRING MEMBER PIN ANGLE";

U.S. patent application Ser. No. 15/385,897 entitled "STAPLE FORMING POCKET ARRANGEMENTS COMPRISING ZONED FORMING SURFACE GROOVES";

U.S. patent application Ser. No. 15/385,922, entitled "SURGICAL INSTRUMENT WITH MULTIPLE FAILURE RESPONSE MODES";

U.S. patent application Ser. No. 15/385,924 entitled "SURGICAL INSTRUMENT WITH PRIMARY AND SAFETY PROCESSORS";

U.S. patent application Ser. No. 15/385,912, entitled "SURGICAL INSTRUMENTS WITH JAWS THAT ARE PIVOTABLE ABOUT A FIXED AXIS AND INCLUDE SEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS";

U.S. patent application Ser. No. 15/385,910 entitled "ANVIL HAVING A KNIFE SLOT WIDTH";

U.S. patent application Ser. No. 15/385,906 entitled "FIRING MEMBER PIN CONFIGURATIONS";

U.S. patent application Ser. No. 15/386,188 entitled "STEPPED STAPLE CARTRIDGE WITH ASYMMETRICAL STAPLES";

U.S. patent application Ser. No. 15/386,192, entitled "STEPPED STAPLE CARTRIDGE WITH TISSUE RETENTION AND GAP SETTING FEATURES";

U.S. patent application Ser. No. 15/386,206, entitled "STAPLE CARTRIDGE WITH DEFORMABLE DRIVER RETENTION FEATURES";

U.S. patent application Ser. No. 15/386,226 entitled "DURABILITY FEATURES FOR END EFFECTORS AND FIRING ASSEMBLIES OF SURGICAL STAPLING INSTRUMENTS";

U.S. patent application Ser. No. 15/386,222 entitled "SURGICAL STAPLING INSTRUMENTS HAVING END EFFECTORS WITH POSITIVE OPENING FEATURES";

U.S. patent application Ser. No. 15/386,236 entitled "CONNECTION PORTIONS FOR DEPOSABLE LOADING UNITS FOR SURGICAL STAPLING INSTRUMENTS".

U.S. patent application Ser. No. 15/385,887 entitled "METHOD FOR ATTACHING A SHAFT ASSEMBLY TO A SURGICAL INSTRUMENT AND, ALTERNATIVELY, TO A SURGICAL ROBOT";

U.S. patent application Ser. No. 15/385,889 entitled "SHAFT ASSEMBLY COMPRISING A MANUALLY-OPERABLE RETRACTION SYSTEM FOR USE WITH A MOTORIZED SURGICAL INSTRUMENT SYSTEM";

U.S. patent application Ser. No. 15/385,890 entitled "SHAFT ASSEMBLY COMPRISING SEPARATELY ACTUATABLE AND RETRACTABLE SYSTEMS";

U.S. patent application Ser. No. 15/385,891, entitled "SHAFT ASSEMBLY COMPRISING A CLUTCH CONFIGURED TO ADAPT THE OUTPUT OF A ROTARY FIRING MEMBER TO TWO DIFFERENT SYSTEMS";

U.S. patent application Ser. No. 15/385,892 entitled "SURGICAL SYSTEM COMPRISING A FIRING MEMBER ROTATABLE INTO AN ARTICULATION STATE TO ARTICULATE AN END EFFECTOR OF THE SURGICAL SYSTEM";

U.S. patent application Ser. No. 15/385,894 entitled "SHAFT ASSEMBLY COMPRISING A LOCKOUT";

U.S. patent application Ser. No. 15/385,895 entitled "SHAFT ASSEMBLY COMPRISING FIRST AND SECOND ARTICULATION LOCKOUTS";

U.S. patent application Ser. No. 15/385,916 entitled "SURGICAL STAPLING SYSTEMS";

U.S. patent application Ser. No. 15/385,918, entitled "SURGICAL STAPLING SYSTEMS";

U.S. patent application Ser. No. 15/385,919 entitled "SURGICAL STAPLING SYSTEMS";

U.S. patent application Ser. No. 15/385,921 entitled "SURGICAL STAPLE/FASTENER CARTRIDGE WITH MOVABLE CAMMING MEMBER CONFIGURED TO DISENGAGE FIRING MEMBER LOCKOUT FEATURES";

U.S. patent application Ser. No. 15/385,923 entitled "SURGICAL STAPLING SYSTEMS";

U.S. patent application Ser. No. 15/385,925 entitled "JAW ACTUATED LOCK ARRANGEMENTS FOR PREVENTING ADVANCEMENT OF A FIRING MEMBER IN A SURGICAL END EFFECTOR UNLESS AN FIRED CARTRIDGE IS INSTALLED IN THE END EFFECTOR";

U.S. patent application Ser. No. 15/385,926, entitled "AXIALLY MOVABLE CLOSURE SYSTEM ARRANGEMENTS FOR APPLYING CLOSURE MOTIONS TO JAWS OF SURGICAL INSTRUMENTS";

U.S. patent application Ser. No. 15/385,928 entitled "PROTECTIVE COVER ARRANGEMENTS FOR A JOINT INTERFACE BETWEEN A MOVABLE JAW AND ACTUATOR SHAFT OF A SURGICAL INSTRUMENT";

U.S. patent application Ser. No. 15/385,930 entitled "SURGICAL END EFFECTOR WITH TWO SEPARATE COOPERATING OPENING FEATURES FOR OPENING AND CLOSING END EFFECTOR JAWS";

U.S. patent application Ser. No. 15/385,932 entitled "ARTICULATABLE SURGICAL END EFFECTOR WITH ASYMMETRIC SHAFT ARRANGEMENT";

U.S. patent application Ser. No. 15/385,933 entitled "ARTICULATABLE SURGICAL INSTRUMENT WITH INDEPENDENT PIVOTABLE LINKAGE DISTAL OF AN ARTICULATION LOCK";

U.S. patent application Ser. No. 15/385,934, entitled "ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END EFFECTOR IN AN ARTICULATED POSITION IN RESPONSE TO ACTUATION OF A JAW CLOSURE SYSTEM";

U.S. patent application Ser. No. 15/385,935 entitled "LATERALLY ACTUATABLE ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END EFFECTOR OF A SURGICAL INSTRUMENT IN AN ARTICULATED CONFIGURATION"; and

U.S. patent application Ser. No. 15/385,936 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH ARTICULATION STROKE AMPLIFICATION FEATURES".

The applicant of the present application owns the following U.S. patent applications filed on date 2016, 6, 24, and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 15/191,775 entitled "STAPLE CARTRIDGE COMPRISING WIRE STAPLES AND STAMPED STAPLES";

U.S. patent application Ser. No. 15/191,807 entitled "STAPLING SYSTEM FOR USE WITH WIRE STAPLES AND STAMPED STAPLES";

U.S. patent application Ser. No. 15/191,834 entitled "STAMPED STAPLES AND STAPLE CARTRIDGES USING THE SAME";

U.S. patent application Ser. No. 15/191,788, entitled "STAPLE CARTRIDGE COMPRISING OVERDRIVEN STAPLES"; and

U.S. patent application Ser. No. 15/191,818, entitled "STAPLE CARTRIDGE COMPRISING OFFSET LONGITUDINAL STAPLE ROWS".

U.S. design patent application Ser. No. 29/569,218, entitled "SURGICAL FASTENER";

U.S. design patent application Ser. No. 29/569,227 entitled "SURGICAL FASTENER";

U.S. design patent application Ser. No. 29/569,259, entitled "SURGICAL FASTENER CARTRIDGE"; and

U.S. design patent application Ser. No. 29/569,264 entitled "SURGICAL FASTENER CARTRIDGE".

The applicant of the present application owns the following patent applications filed on date 2016, 4, 1 and each incorporated herein by reference in their entirety:

U.S. patent application Ser. No. 15/089,325 entitled "METHOD FOR OPERATING A SURGICAL STAPLING SYSTEM";

U.S. patent application Ser. No. 15/089,321, entitled "MODULAR SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY";

U.S. patent application Ser. No. 15/089,326, entitled "SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE DISPLAY FIELD";

U.S. patent application Ser. No. 15/089,263, entitled "SURGICAL INSTRUMENT HANDLE ASSEMBLY WITH RECONFIGURABLE GRIP PORTION";

U.S. patent application Ser. No. 15/089,262 entitled "ROTARY POWERED SURGICAL INSTRUMENT WITH MANUALLY ACTUATABLE BAILOUT SYSTEM";

U.S. patent application Ser. No. 15/089,277, entitled "SURGICAL CUTTING AND STAPLING END EFFECTOR WITH ANVIL CONCENTRIC DRIVE MEMBER";

U.S. patent application Ser. No. 15/089,296, entitled "INTERCHANGEABLE SURGICAL TOOL ASSEMBLY WITH A SURGICAL END EFFECTOR THAT IS SELECTIVELY ROTATABLE ABOUT A SHAFT AXIS";

U.S. patent application Ser. No. 15/089,258 entitled "SURGICAL STAPLING SYSTEM COMPRISING A SHIFTABLE TRANSMISSION";

U.S. patent application Ser. No. 15/089,278 entitled "SURGICAL STAPLING SYSTEM CONFIGURED TO PROVIDE SELECTIVE CUTTING OF TISSUE";

U.S. patent application Ser. No. 15/089,284 entitled "SURGICAL STAPLING SYSTEM COMPRISING A CONTOURABLE SHAFT";

U.S. patent application Ser. No. 15/089,295 entitled "SURGICAL STAPLING SYSTEM COMPRISING A TISSUE COMPRESSION LOCKOUT";

U.S. patent application Ser. No. 15/089,300, entitled "SURGICAL STAPLING SYSTEM COMPRISING AN UNCLAMPING LOCKOUT";

U.S. patent application Ser. No. 15/089,196 entitled "SURGICAL STAPLING SYSTEM COMPRISING A JAW CLOSURE LOCKOUT";

U.S. patent application Ser. No. 15/089,203 entitled "SURGICAL STAPLING SYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT";

U.S. patent application Ser. No. 15/089,210, entitled "SURGICAL STAPLING SYSTEM COMPRISING A SPENT CARTRIDGE LOCKOUT";

U.S. patent application Ser. No. 15/089,324, entitled "SURGICAL INSTRUMENT COMPRISING A SHIFTING MECHANISM";

U.S. patent application Ser. No. 15/089,335, entitled "SURGICAL STAPLING INSTRUMENT COMPRISING MULTIPLE LOCKOUTS";

U.S. patent application Ser. No. 15/089,339, entitled "SURGICAL STAPLING INSTRUMENT";

U.S. patent application Ser. No. 15/089,253 entitled "SURGICAL STAPLING SYSTEM CONFIGURED TO APPLY ANNULAR ROWS OF STAPLES HAVING DIFFERENT HEIGHTS";

U.S. patent application Ser. No. 15/089,304 entitled "SURGICAL STAPLING SYSTEM COMPRISING A GROOVED FORMING POCKET";

U.S. patent application Ser. No. 15/089,331, entitled "ANVIL MODIFICATION MEMBERS FOR SURGICAL STAPLE/FASTENERS";

U.S. patent application Ser. No. 15/089,336, entitled "STAPLE CARTRIDGES WITH ATRAUMATIC FEATURES";

U.S. patent application Ser. No. 15/089,312, entitled "CIRCULAR STAPLING SYSTEM COMPRISING AN INCISABLE TISSUE SUPPORT";

U.S. patent application Ser. No. 15/089,309, entitled "CIRCULAR STAPLING SYSTEM COMPRISING ROTARY FIRING SYSTEM"; and

U.S. patent application Ser. No. 15/089,349 entitled "CIRCULAR STAPLING SYSTEM COMPRISING LOAD CONTROL".

The applicant of the present application also owns the following identified U.S. patent applications filed on 12 months 31 2015, each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/984,488 entitled "MECHANISMS FOR COMPENSATING FOR BATTERY PACK FAILURE IN POWERED SURGICAL INSTRUMENTS";

U.S. patent application Ser. No. 14/984,525, entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS"; and

U.S. patent application Ser. No. 14/984,552, entitled "SURGICAL INSTRUMENTS WITH SEPARABLE MOTORS AND MOTOR CONTROL CIRCUITS".

The applicant of the present application also owns the following identified U.S. patent applications filed on february 9 2016 and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 15/019,220 entitled "SURGICAL INSTRUMENT WITH ARTICULATING AND AXIALLY TRANSLATABLE END EFFECTOR";

U.S. patent application Ser. No. 15/019,228 entitled "SURGICAL INSTRUMENTS WITH MULTIPLE LINK ARTICULATION ARRANGEMENTS";

U.S. patent application Ser. No. 15/019,196 entitled "SURGICAL INSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY CONSTRAINT";

U.S. patent application Ser. No. 15/019,206, entitled "SURGICAL INSTRUMENTS WITH AN END EFFECTOR THAT IS HIGHLY ARTICULATABLE RELATIVE TO AN ELONGATE SHAFT ASSEMBLY";

U.S. patent application Ser. No. 15/019,215, entitled "SURGICAL INSTRUMENTS WITH NON-SYMMETRICAL ARTICULATION ARRANGEMENTS";

U.S. patent application Ser. No. 15/019,227 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH SINGLE ARTICULATION LINK ARRANGEMENTS";

U.S. patent application Ser. No. 15/019,235 entitled "SURGICAL INSTRUMENTS WITH TENSIONING ARRANGEMENTS FOR CABLE DRIVEN ARTICULATION SYSTEMS";

U.S. patent application Ser. No. 15/019,230, entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH OFF-AXIS FIRING BEAM ARRANGEMENTS"; and

U.S. patent application Ser. No. 15/019,245, entitled "SURGICAL INSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS".

The applicant of the present application also owns the following identified U.S. patent applications filed on february 12 2016 and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 15/043,254 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS";

U.S. patent application Ser. No. 15/043,259, entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS";

U.S. patent application Ser. No. 15/043,275, entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS"; and

U.S. patent application Ser. No. 15/043,289, entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS".

The applicant of the present application owns the following patent applications filed on 18 th month 6 2015, each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/742,925, now U.S. patent application publication 2016/0367256, entitled "SURGICAL END EFFECTORS WITH POSITIVE JAW OPENING ARRANGEMENTS";

U.S. patent application Ser. No. 14/742,941, entitled "SURGICAL END EFFECTORS WITH DUAL CAM ACTUATED JAW CLOSING FEATURES," now U.S. patent application publication 2016/0367248;

U.S. patent application Ser. No. 14/742,914, entitled "MOVABLE FIRING BEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS", now U.S. patent application publication 2016/0367255;

U.S. patent application Ser. No. 14/742,900, entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH COMPOSITE FIRING BEAM STRUCTURES WITH CENTER FIRING SUPPORT MEMBER FOR ARTICULATION SUPPORT," now U.S. patent application publication 2016/0367254;

U.S. patent application Ser. No. 14/742,885, entitled "DUAL ARTICULATION DRIVE SYSTEM ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS", now U.S. patent application publication 2016/0367246; and

U.S. patent application Ser. No. 14/742,876, entitled "PUSH/PULL ARTICULATION DRIVE SYSTEMS FOR ARTICULATABLE SURGICAL INSTRUMENTS", now U.S. patent application publication 2016/0367245.

The applicant of the present application owns the following patent applications filed on 3/6/2015, each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/640,746, entitled "POWERED SURGICAL INSTRUMENT", now U.S. patent application publication 2016/0256184;

U.S. patent application Ser. No. 14/640,795, entitled "MULTIPLE LEVEL THRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL INSTRUMENTS," now U.S. patent application publication 2016/02561185;

U.S. patent application Ser. No. 14/640,832, entitled "ADAPTIVE TISSUE COMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR MULTIPLE TISSUE TYPES", now U.S. patent application publication 2016/0256154;

U.S. patent application Ser. No. 14/640,935, entitled "OVERLAID MULTI SENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE TISSUE COMPRESSION", now U.S. patent application publication 2016/0256071;

U.S. patent application Ser. No. 14/640,831, entitled "MONITORING SPEED CONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED SURGICAL INSTRUMENTS," now U.S. patent application publication 2016/0256153;

U.S. patent application Ser. No. 14/640,859, entitled "TIME DEPENDENT EVALUATION OF SENSOR DATA TO DETERMINE STABILITY, CREEP, AND VISCOELASTIC ELEMENTS OF MEASURES", now U.S. patent application publication 2016/0256187;

U.S. patent application Ser. No. 14/640,817, entitled "INTERACTIVE FEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS", now U.S. patent application publication 2016/0256186;

U.S. patent application Ser. No. 14/640,844, entitled "CONTROL TECHNIQUES AND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH SELECT CONTROL PROCESSING FROM HANDLE", now U.S. patent application publication 2016/0256155;

U.S. patent application Ser. No. 14/640,837, entitled "SMART SENSORS WITH LOCAL SIGNAL PROCESSING," now U.S. patent application publication 2016/0256163;

U.S. patent application Ser. No. 14/640,765, entitled "System FOR DETECTING THE MIS-INSERT OF ASTAPLE CARTRIDGE INTO A SURGICAL STAPLE/FASTENER", now U.S. patent application publication 2016/0256160;

U.S. patent application Ser. No. 14/640,799, entitled "SIGNAL AND POWER COMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT," now U.S. patent application publication 2016/0256162; and

U.S. patent application Ser. No. 14/640,780, entitled "SURGICAL INSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING," now U.S. patent application publication 2016/0256161.

The applicant of the present application owns the following patent applications filed on 27 months 2.2015 and each incorporated herein by reference in their entirety:

U.S. patent application Ser. No. 14/633,576, entitled "SURGICAL INSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION", now U.S. patent application publication 2016/0249949;

U.S. patent application Ser. No. 14/633,546, entitled "SURGICAL APPARATUS CONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER OF THE SURGICAL APPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE BAND," now U.S. patent application publication 2016/0249115;

U.S. patent application Ser. No. 14/633,560, entitled "SURGICAL CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE BATTERIES", now U.S. patent application publication 2016/0249910;

U.S. patent application Ser. No. 14/633,566, entitled "CHARGING SYSTEM THAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A BATTERY", now U.S. patent application publication 2016/0249218;

U.S. patent application Ser. No. 14/633,555, now U.S. patent application publication 2016/024996, entitled "SYSTEM FOR MONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED";

U.S. patent application Ser. No. 14/633,542, entitled "REINFORCED BATTERY FOR A SURGICAL INSTRUMENT", now U.S. patent application publication 2016/0249508;

U.S. patent application Ser. No. 14/633,548, entitled "POWER ADAPTER FOR A SURGICAL INSTRUMENT," now U.S. patent application publication 2016/0249009;

U.S. patent application Ser. No. 14/633,526, entitled "ADAPTABLE SURGICAL INSTRUMENT HANDLE," now U.S. patent application publication 2016/0249945;

U.S. patent application Ser. No. 14/633,541, entitled "MODULAR STAPLING ASSEMBLY", now U.S. patent application publication 2016/0249977; and

U.S. patent application Ser. No. 14/633,562, entitled "SURGICAL APPARATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER", now U.S. patent application publication 2016/0249117.

The applicant of the present application owns the following patent applications filed on date 18 of 12 of 2014, each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/574,478, entitled "SURGICAL INSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND MEANS FOR ADJUSTING THE FIRING STROKE OF A FIRING MEMBER", now U.S. patent application publication 2016/0174977;

U.S. patent application Ser. No. 14/574,483, entitled "SURGICAL INSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS", now U.S. patent application publication 2016/0174969;

U.S. patent application Ser. No. 14/575,139, entitled "DRIVE ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS," now U.S. patent application publication 2016/0174978;

U.S. patent application Ser. No. 14/575,148, entitled "LOCKING ARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE SURGICAL END EFFECTORS," now U.S. patent application publication 2016/0174976;

U.S. patent application Ser. No. 14/575,130, entitled "SURGICAL INSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A DISCRETE NON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE, now U.S. patent application publication 2016/0174972;

U.S. patent application Ser. No. 14/575,143, entitled "SURGICAL INSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS," now U.S. patent application publication 2016/0174983;

U.S. patent application Ser. No. 14/575,117, entitled "SURGICAL INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING BEAM SUPPORT ARRANGEMENTS," now U.S. patent application publication 2016/0174975;

U.S. patent application Ser. No. 14/575,154, entitled "SURGICAL INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING BEAM SUPPORT ARRANGEMENTS," now U.S. patent application publication 2016/0174973;

U.S. patent application Ser. No. 14/574,493, entitled "SURGICAL INSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM"; now U.S. patent application publication 2016/0174970; and

U.S. patent application Ser. No. 14/574,500, entitled "SURGICAL INSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM," now U.S. patent application publication 2016/0174971.

The applicant of the present application owns the following patent applications filed on 1-3 of 2013, each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 13/782,295, entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL COMMUNICATION," now U.S. patent application publication 2014/024671;

U.S. patent application Ser. No. 13/782,323, entitled "ROTARY POWERED ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS," now U.S. patent application publication 2014/024672;

U.S. patent application Ser. No. 13/782,338, entitled "THUMBWHEEL SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/024957;

U.S. patent application Ser. No. 13/782,499, entitled "ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT," now U.S. patent application publication 9,358,003;

U.S. patent application Ser. No. 13/782,460, now U.S. Pat. No. 9,554,794, entitled "MULTIPLE PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS";

U.S. patent application Ser. No. 13/782,358, entitled "JOYSTICK SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS," now U.S. patent application publication 9,326,767;

U.S. patent application Ser. No. 13/782,481, entitled "SENSOR STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR", now U.S. patent application publication 9,468,438;

U.S. patent application Ser. No. 13/782,518, entitled "CONTROL METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS", now U.S. patent application publication 2014/024675;

U.S. patent application Ser. No. 13/782,375, entitled "ROTARY POWERED SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM," now U.S. patent application publication 9,398,911; and

U.S. patent application Ser. No. 13/782,536, entitled "SURGICAL INSTRUMENT SOFT STOP," now U.S. patent application publication 9,307,986.

The applicant of the present application also owns the following patent applications filed on 14 days 3.2013, each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 13/803,097, entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE", now U.S. patent application publication 2014/0263542;

U.S. patent application Ser. No. 13/803,193, entitled "CONTROL ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT," now U.S. patent application publication 9,332,987;

U.S. patent application Ser. No. 13/803,053, entitled "INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT", now U.S. patent application publication 2014/0263564;

U.S. patent application Ser. No. 13/803,086, entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK", now U.S. patent application publication 2014/0263541;

U.S. patent application Ser. No. 13/803,210, entitled "SENSOR ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0263538;

U.S. patent application Ser. No. 13/803,148, entitled "MULTI-FUNCTION MOTOR FOR A SURGICAL INSTRUMENT", now U.S. patent application publication 2014/0263554;

U.S. patent application Ser. No. 13/803,066, entitled "DRIVE SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS," now U.S. patent application publication 9,629,623;

U.S. patent application Ser. No. 13/803,117, entitled "ARTICULATION CONTROL SYSTEM FOR ARTICULATABLE SURGICAL INSTRUMENTS," now U.S. patent application publication 9,351,726;

U.S. patent application Ser. No. 13/803,130, entitled "DRIVE TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS," now U.S. patent application publication 9,351,727; and

U.S. patent application Ser. No. 13/803,159, entitled "METHOD AND SYSTEM FOR OPERATING A SURGICAL INSTRUMENT," now U.S. patent application publication 2014/0277017.

The applicant of the present application also owns the following patent applications filed on 7.3.2014 and incorporated herein by reference in their entirety:

U.S. patent application Ser. No. 14/200,111, entitled "CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS", now U.S. Pat. No. 9,629,629;

the applicant of the present application also owns the following patent applications filed on month 3 and 26 of 2014, each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/226,106, entitled "POWER MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2015/0272582;

U.S. patent application Ser. No. 14/226,099, entitled "STERILIZATION VERIFICATION CIRCUIT," now U.S. patent application publication 2015/0272581;

U.S. patent application Ser. No. 14/226,094, entitled "VERIFICATION OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT," now U.S. patent application publication 2015/0272580;

U.S. patent application Ser. No. 14/226,117, entitled "POWER MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP CONTROL," now U.S. patent application publication 2015/0272574;

U.S. patent application Ser. No. 14/226,075, entitled "MODULAR POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES", now U.S. patent application publication 2015/0272579;

U.S. patent application Ser. No. 14/226,093, entitled "FEEDBACK ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS," now U.S. patent application publication 2015/0272569;

U.S. patent application Ser. No. 14/226,116, entitled "SURGICAL INSTRUMENT UTILIZING SENSOR ADAPTATION", now U.S. patent application publication 2015/0272571;

U.S. patent application Ser. No. 14/226,071, entitled "SURGICAL INSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR", now U.S. patent application publication 2015/0272578;

U.S. patent application Ser. No. 14/226,097, entitled "SURGICAL INSTRUMENT COMPRISING INTERACTIVE SYSTEMS," now U.S. patent application publication 2015/0272570;

U.S. patent application Ser. No. 14/226,126, entitled "INTERFACE SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS", now U.S. patent application publication 2015/0272572;

U.S. patent application Ser. No. 14/226,133, entitled "MODULAR SURGICAL INSTRUMENT SYSTEM", now U.S. patent application publication 2015/0272557;

U.S. patent application Ser. No. 14/226,081, entitled "SYSTEMS AND METHODS FOR CONTROLLING A SEGMENTED CIRCUIT", now U.S. patent application publication 2015/0277471;

U.S. patent application Ser. No. 14/226,076, entitled "POWER MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE PROTECTION", now U.S. patent application publication 2015/0280424;

U.S. patent application Ser. No. 14/226,111, entitled "SURGICAL STAPLING INSTRUMENT SYSTEM," now U.S. patent application publication 2015/0272583; and

U.S. patent application Ser. No. 14/226,125, entitled "SURGICAL INSTRUMENT COMPRISING A ROTATABLE SHAFT," now U.S. patent application publication 2015/0280384.

The applicant of the present application also owns the following patent applications filed on 5/9/2014 and each incorporated herein by reference in their entirety:

U.S. patent application Ser. No. 14/479,103, entitled "CIRCUITRY AND SENSORS FOR POWERED MEDICAL DEVICE," now U.S. patent application publication 2016/0066912;

U.S. patent application Ser. No. 14/479,119, entitled "ADJUNCT WITH INTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION," now U.S. patent application publication 2016/0066914;

U.S. patent application Ser. No. 14/478,908, entitled "MONITORING DEVICE DEGRADATION BASED ON COMPONENT EVALUATION", now U.S. patent application publication 2016/0066910;

U.S. patent application Ser. No. 14/478,895, entitled "MULTIPLE SENSORS WITH ONE SENSOR AFFECTING A SECOND SENSOR' S OUTPUT OR INTERPRETATION", now U.S. patent application publication 2016/0066909;

U.S. patent application Ser. No. 14/479,110, entitled "POLARITY OF HALL MAGNET TO DETECT MISLOADED CARTRIDGE", now U.S. patent application publication 2016/0066915;

U.S. patent application Ser. No. 14/479,098, entitled "SMART CARTRIDGE WAKE UP OPERATION AND DATA RETENTION," now U.S. patent application publication 2016/0066911;

U.S. patent application Ser. No. 14/479,115, entitled "MULTIPLE MOTOR CONTROL FOR POWERED MEDICAL DEVICE," now U.S. patent application publication 2016/0066916; and

U.S. patent application Ser. No. 14/479,108, entitled "LOCAL DISPLAY OF TISSUE PARAMETER STABILIZATION," now U.S. patent application publication 2016/0066913.

The applicant of the present application also owns the following patent applications filed on date 2014, 4, 9, and each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/248,590, entitled "MOTOR DRIVEN SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS", now U.S. patent application publication 2014/0305987;

U.S. patent application Ser. No. 14/248,581, entitled "SURGICAL INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE OPERATED FROM THE SAME ROTATABLE OUTPUT," now U.S. Pat. No. 9,649,110;

U.S. patent application Ser. No. 14/248,595, entitled "SURGICAL INSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE OPERATION OF THE SURGICAL INSTRUMENT", now U.S. patent application publication 2014/0305988;

U.S. patent application Ser. No. 14/248,588, entitled "POWERED LINEAR SURGICAL STAPLE/FASTENER", now U.S. patent application publication 2014/0309666;

U.S. patent application Ser. No. 14/248,591, entitled "TRANSMISSION ARRANGEMENT FOR A SURGICAL INSTRUMENT", now U.S. patent application publication 2014/0305991;

U.S. patent application Ser. No. 14/248,584, entitled "MODULAR MOTOR DRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR ALIGNING ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS," now U.S. patent application publication 2014/0305994;

U.S. patent application Ser. No. 14/248,587, entitled "POWERED SURGICAL STAPLE/FASTENER", now U.S. patent application publication 2014/0309665;

U.S. patent application Ser. No. 14/248,586, entitled "DRIVE SYSTEM DECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT", now U.S. patent application publication 2014/0305990; and

U.S. patent application Ser. No. 14/248,607, entitled "MODULAR MOTOR DRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION ARRANGEMENTS", now U.S. patent application publication 2014/0305992.

The applicant of the present application also owns the following patent applications filed on date 16 of 2013, 4, and each of which is incorporated herein by reference in its entirety:

U.S. provisional patent application Ser. No. 61/812,365 entitled "SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR";

U.S. provisional patent application Ser. No. 61/812,376, entitled "LINEAR CUTTER WITH POWER";

U.S. provisional patent application Ser. No. 61/812,382 entitled "LINEAR CUTTER WITH MOTOR AND PISTOL GRIP";

U.S. provisional patent application Ser. No. 61/812,385 entitled "SURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION MOTORS AND MOTOR CONTROL"; and

U.S. provisional patent application Ser. No. 61/812,372 entitled "SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR".

Numerous specific details are set forth herein to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments described in the specification and shown in the drawings. Well-known operations, components and elements have not been described in detail so as not to obscure the embodiments described in the specification. The reader will appreciate that the embodiments described and illustrated herein are non-limiting examples, so that it can be appreciated that the specific structural and functional details disclosed herein may be representative and exemplary. Modifications and changes may be made to these embodiments without departing from the scope of the claims.

The term "include" (and any form of "include"), such as "include" and "comprise", "have" (and any form of "have"), such as "have" and "have", "include", any form of "contain" (and "contain") such as "contain" and "contain" (and "contain") are open-system verbs. Thus, a surgical system, apparatus, or device that "comprises," "has," "contains," or "contains" one or more elements has those one or more elements, but is not limited to having only those one or more elements. Likewise, an element of a system, apparatus, or device that "comprises," "has," "includes" or "contains" one or more features has those one or more features, but is not limited to having only those one or more features.

The terms "proximal" and "distal" are used herein with respect to a clinician manipulating a handle portion of a surgical instrument. The term "proximal" refers to the portion closest to the clinician, and the term "distal" refers to the portion located away from the clinician. It will also be appreciated that for simplicity and clarity, spatial terms such as "vertical," "horizontal," "upper," and "lower" may be 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/or absolute.

Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily appreciate that the various methods and devices disclosed herein can be used in a variety of surgical procedures and applications, including, for example, in connection with open surgical procedures. With continued reference to this detailed description, the reader will further appreciate that the various instruments disclosed herein can be inserted into the body in any manner, such as through a natural orifice, through an incision or puncture formed in tissue, etc. The working portion or end effector portion of the instrument may be inserted directly into the patient or may be inserted through an access device having a working channel through which the end effector and elongate shaft of the surgical instrument may be advanced.

The surgical stapling system can include a shaft and an end effector extending from the shaft. The end effector includes a first jaw and a second jaw. The first jaw includes a staple cartridge. The staple cartridge is insertable into and removable from the first jaw; however, other embodiments are contemplated in which the staple cartridge is not removable from the first jaw, or at least is easily replaceable from the first jaw. The second jaw includes an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closure axis; however, other embodiments are contemplated in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further includes an articulation joint configured to allow the end effector to rotate or articulate relative to the shaft. The end effector is rotatable about an articulation axis that extends through the articulation joint. Other embodiments are contemplated that do not include an articulation joint.

The nail bin comprises a bin body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal end and the distal end. In use, the staple cartridge is positioned on a first side of tissue to be stapled and the anvil is positioned on a second side of tissue. The anvil is moved toward the cartridge to compress and clamp the tissue against the deck. Staples removably stored in the cartridge body can then be deployed into tissue. The cartridge body includes a staple cavity defined therein, wherein staples are removably stored in the staple cavity. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of the longitudinal slot and three rows of staple cavities are positioned on a second side of the longitudinal slot. Other arrangements of the staple cavities and staples are also possible.

The staples are supported by a staple driving device in the cartridge body. The drive device is movable between a first or unfired position and a second or fired position to eject staples from the staple cartridge. The drive device is retained in the cartridge body by a retainer that extends around the bottom of the cartridge body and includes an elastic member configured to be able to grip the cartridge body and to retain the retainer to the cartridge body. The drive is movable by the sled between its unfired and fired positions. The slider is movable between a proximal position adjacent the proximal end and a distal position adjacent the distal end. The sled includes a plurality of ramp surfaces configured to slide under the drive and lift the drive toward the anvil and the staples are supported on the drive.

In addition to the above, the sled may be moved distally by the firing member. The firing member is configured to contact the sled and push the sled toward the distal end. A longitudinal slot defined in the cartridge body is configured to receive a firing member. The anvil further includes a slot configured to receive a firing member. The firing member further includes a first cam that engages the first jaw and a second cam that engages the second jaw. The first cam and the second cam may control a distance or tissue gap between the deck of the staple cartridge and the anvil as the firing member is advanced distally. The firing member further includes a knife configured to incise tissue trapped intermediate the staple cartridge and the anvil. It is desirable that the knife be positioned at least partially adjacent to the ramp surface so that the staples are ejected prior to the knife.

Fig. 1 illustrates a motor driven surgical system 10 that may be used to perform a variety of different surgical procedures. As can be seen in this figure, one example of a surgical system 10 includes four interchangeable

surgical tool assemblies

100, 200, 300, and 1000, each adapted for use interchangeably with a handle assembly 500. Each interchangeable

surgical tool assembly

100, 200, 300, and 1000 can be designed for use in connection with the performance of one or more specific surgical procedures. In another surgical system embodiment, the interchangeable surgical tool assembly can be effectively used with a robotic-controlled surgical system or a tool drive assembly of an automated surgical system. For example, the surgical tool assemblies disclosed herein may be used with a variety of robotic systems, instruments, components, and methods, such as, but not limited to, those disclosed in U.S. patent 9,072,535, entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS," which is hereby incorporated by reference in its entirety.

Fig. 2 illustrates one form of interchangeable surgical tool assembly 100 operably coupled to a handle assembly 500. Fig. 3 illustrates the attachment of the interchangeable surgical tool assembly 100 to a handle assembly 500. The attachment arrangement and method depicted in fig. 3 may also be used in conjunction with the attachment of any of the interchangeable

surgical tool assemblies

100, 200, 300, and 1000 to a tool drive part or tool driver housing of a robotic system. The handle assembly 500 may include a handle housing 502, the handle housing 502 including a pistol grip portion 504 that may be grasped and manipulated by the clinician. As will be briefly discussed below, the handle assembly 500 operably supports a plurality of drive systems configured to generate and apply various control motions to corresponding portions of the interchangeable

surgical tool assemblies

100, 200, 300, and/or 1000 operably attached thereto.

Referring now to fig. 3, the handle assembly 500 may further include a frame 506 that operably supports a plurality of drive systems. For example, the frame 506 may operably support a "first" or closure drive system, generally designated 510, which may be used to apply the closing and opening motions to the interchangeable

surgical tool assemblies

100, 200, 300, and/or 1000 operably attached or coupled to the handle assembly 500. In at least one form, the closure drive system 510 may include an actuator in the form of a closure trigger 512 pivotally supported by the frame 506. Such a configuration enables the closure trigger 512 to be manipulated by a clinician such that the closure trigger 512 can pivot from a start or "unactuated" position to an "actuated" position, and more particularly to a fully compressed or fully actuated position, when the clinician grips the pistol grip portion 504 of the handle assembly 500. In various forms, the closure drive system 510 further includes a closure link assembly 514, the closure link assembly 514 being pivotably coupled to the closure trigger 512 or otherwise operatively connected with the closure trigger 512. As will be discussed in further detail below, the closure link assembly 514 includes a lateral attachment pin 516 that facilitates attachment to a corresponding drive system on a surgical tool assembly. To actuate the closure drive system, the clinician depresses the closure trigger 512 toward the pistol grip portion 504. As described in further detail in U.S. patent application serial No. 14/226,142, entitled "SURGICAL INSTRUMENT COMPRISING A SENSOR SYSTEM," which is incorporated herein by reference in its entirety, and now U.S. patent application publication 2015/0272575, when a clinician fully depresses the closure trigger 512 to achieve a full closure stroke, the closure drive system is configured to lock the closure trigger 512 into a fully depressed or fully actuated position. When the clinician desires to unlock the closure trigger 512 to allow the closure trigger 512 to be biased to the unactuated position, the clinician simply activates the closure release button assembly 518 that enables the closure trigger to return to the unactuated position. The closure release button 518 may also be configured to interact with various sensors that communicate with a microcontroller 520 in the handle assembly 500 for tracking the position of the closure trigger 512. Further details regarding the construction and operation of the closure release button assembly 518 can be found in U.S. patent application publication 2015/0272575.

In at least one form, the handle assembly 500 and the frame 506 may operably support another drive system, referred to herein as a firing drive system 530, configured to apply firing motions to corresponding portions of an interchangeable surgical tool assembly attached thereto. As described in detail in U.S. patent application publication 2015/0272575, the firing drive system 530 may employ an electric motor (not shown in fig. 1-3) located in the pistol grip portion 504 of the handle assembly 500. In various forms, the motor may be a DC brush drive motor, for example, having a maximum speed of about 25,000 RPM. In other constructions, the motor may include 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 source 522, which in one form may include a removable power pack. The power pack may support a plurality of lithium-ion ("LI") or other suitable batteries therein. A plurality of batteries, which may be connected in series, may be used as the power source 522 of the surgical system 10. In addition, the power source 522 may be replaceable and/or rechargeable.

The electric motor is configured to drive the longitudinally movable drive member 540 axially in distal and proximal directions depending on the polarity of the voltage applied to the motor. For example, when the motor is driven in one rotational direction, the longitudinally movable drive member 540 will be driven axially in the distal direction "DD". When the motor is driven in the opposite rotational direction, the longitudinally movable drive member 540 will be driven axially in the proximal direction "PD". The handle assembly 500 may include a switch 513 that may be configured to reverse the polarity applied to the electric motor by the power source 522 or otherwise control the motor. The handle assembly 500 may also include one or more sensors configured to detect the position of the drive member 540 and/or the direction in which the drive member 540 moves. Actuation of the motor may be controlled by a firing trigger 532 (fig. 1) pivotally supported on the handle assembly 500. The firing trigger 532 is pivotable between an unactuated position and an actuated position. The firing trigger 532 may be biased into the unactuated position by a spring or other biasing arrangement such that when the clinician releases the firing trigger 532, the firing trigger 532 may be pivoted or otherwise returned to the unactuated position by the spring or biasing arrangement. In at least one form, the firing trigger 532 may be positioned "outboard" of the closure trigger 512 as described above. As discussed in U.S. patent application publication 2015/0272575, the handle assembly 500 can be equipped with a firing trigger safety button to prevent inadvertent actuation of the firing trigger 532. When the closure trigger 512 is in the unactuated position, a safety button is housed in the handle assembly 500, in which case the safety button is not readily accessible to a clinician and moves between a safety position preventing actuation of the firing trigger 532 and a firing position in which the firing trigger 532 may be fired. When the clinician depresses the closure trigger 512, the safety button and firing trigger 532 pivot downward, where they can then be manipulated by the clinician.

In at least one form, the longitudinally movable drive member 540 may have a rack formed thereon for meshing engagement with a corresponding drive gear arrangement interfaced with the motor. Further details regarding those features can be found in U.S. patent application publication 2015/0272575. In at least one form, the handle assembly 500 further includes a manually actuatable "rescue" assembly configured to enable the clinician to manually retract the longitudinally movable drive member 540 with the motor disabled. The rescue assembly may include a lever or rescue handle assembly that is stored within the handle assembly 500 below the releasable door 550. The lever is configured to be manually pivotable into ratchet engagement with teeth in the drive member 540. Thus, the clinician can manually retract the drive member 540 using the rescue handle assembly to ratchet the drive member 5400 in the proximal direction "PD". U.S. patent application Ser. No. 12/249,117, entitled "POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM" (now U.S. patent 8,608,045, the entire disclosure of which is hereby incorporated by reference) discloses a rescue arrangement that may also be employed with the various surgical tool assemblies disclosed herein.

Turning now to fig. 2, the interchangeable surgical tool assembly 100 includes a surgical end effector 110 that includes a first jaw and a second jaw. In one arrangement, the first jaw includes an elongate channel 112 configured to operably support a surgical staple cartridge 116 therein. The second jaw includes an anvil 114 pivotally supported relative to the elongate channel 112. The interchangeable surgical tool assembly 100 also includes a lockable articulation joint 120 that can be configured to releasably retain the end effector 110 in a desired position relative to the shaft axis SA. Details regarding the various configurations and operations of the end effector 110, articulation joint 120, and articulation lock are set forth in U.S. patent application Ser. No. 13/803,086, entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK" (now U.S. patent application publication 2014/0263541, which is hereby incorporated by reference in its entirety). As can be further seen in fig. 2 and 3, the interchangeable surgical tool assembly 100 can include a proximal housing or nozzle 130 and a closure tube assembly 140 that can be used to close and/or open the anvil 114 of the end effector 110. As discussed in U.S. patent application publication 2015/0272575, the closure tube assembly 140 is movably supported on a spine 145 that supports an articulation driver arrangement 147 configured to apply an articulation motion to the surgical end effector 110. The ridge 145 is configured to: first, a firing bar 170 slidably supported therein; second, the closure tube assembly 140 extending around the ridge 145 is slidably supported. In various cases, the ridge 145 includes a proximal end rotatably supported in the base 150. See fig. 3. In one arrangement, for example, the proximal end of the ridge 145 is attached to a ridge bearing configured to be supported within the base 150. This arrangement facilitates rotatable attachment of the ridge 145 to the base 150 such that the ridge 145 can selectively rotate relative to the base 150 about the shaft axis SA.

Still referring to fig. 3, the interchangeable surgical tool assembly 100 includes a closure shuttle 160 slidably supported within the chassis 150 such that the closure shuttle 160 can move axially relative to the chassis 150. As seen in fig. 3, the closure shuttle 160 includes a pair of proximally projecting hooks 162 configured to attach to an attachment pin 516 that attaches to a closure link assembly 514 in the handle assembly 500. The proximal closure tube segment 146 of the closure tube assembly 140 is rotatably coupled to a closure shuttle 160. Thus, when the hook 162 hooks onto the pin 516, actuation of the closure trigger 512 will cause the closure shuttle 160, and ultimately the closure tube assembly 140 on the ridge 145, to move axially. The closure spring may also be journaled on the closure tube assembly 140 and used to bias the closure tube assembly 140 in a proximal direction "PD," which may be used to pivot the closure trigger 512 into an unactuated position when the shaft assembly 100 is operably coupled to the handle assembly 500. In use, the closure tube assembly 140 translates distally (direction DD) to close the anvil 114 in response to actuation of the closure trigger 512. The closure tube assembly 140 includes a distal closure tube segment 142 pivotally pinned to a distal end of a proximal closure tube segment 146. The distal closure tube segment 142 is configured to move axially with the proximal closure tube segment 146 relative to the surgical end effector 110. When the distal end of the distal closure tube segment 142 strikes the proximal surface or ledge 115 on the anvil 114, the anvil 114 pivots into closure. Further details regarding the closure of the anvil 114 may be found in the above-mentioned U.S. patent application publication 2014/0263541, and will be discussed in further detail below. As also described in detail in U.S. patent application publication 2014/0263541, the anvil 114 is opened by translating the distal closure tube segment 142 proximally. The distal closure tube segment 142 has a horseshoe aperture 143 therein defining a downwardly extending return tab that cooperates with an anvil tab 117 formed on the proximal end of the anvil 114 to pivot the anvil 114 back to the open position. In the fully open position, the closure tube assembly 140 is in its proximal-most or unactuated position.

As also described above, the interchangeable surgical tool assembly 100 also includes a firing bar 170 that is supported for axial travel within the shaft spine 145. The firing bar 170 includes an intermediate firing shaft portion configured to be attached to a distal cutting portion or knife bar configured for axial travel through the surgical end effector 110. In at least one arrangement, the interchangeable surgical tool assembly 100 includes a clutch assembly that can be configured to selectively and releasably couple the articulation driver to the firing bar 170. Further details regarding clutch assembly features and operation can be found in U.S. patent application publication 2014/0263541. As discussed in U.S. patent application publication 2014/0263541, when the clutch assembly is in its engaged position, distal movement of the firing bar 170 can move the articulation driver arrangement 147 distally and, correspondingly, proximal movement of the firing bar 170 can move the articulation driver arrangement 147 proximally. When the clutch assembly is in its disengaged position, movement of the firing bar 170 is not transferred to the articulation driver arrangement 147 and, as a result, the firing bar 170 may move independently of the articulation driver arrangement 147. The interchangeable surgical tool assembly 100 may also include a slip ring assembly that may be configured to conduct power to and/or from the end effector 110 and/or to transmit signals to and/or from the end effector 110. Further details regarding slip ring assemblies can be found in U.S. patent application publication 2014/0263541. U.S. patent application Ser. No. 13/800,067, entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM," now U.S. patent application publication 2014/0263552, incorporated by reference in its entirety. U.S. patent 9,345,481, entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM," is also hereby incorporated by reference in its entirety.

Still referring to fig. 3, the base 150 has formed thereon one or more tapered attachment portions 152 adapted to be received within corresponding dovetail slots 507 formed in the distal end of the frame 506. Each dovetail slot 507 may be tapered or, in other words, may be slightly V-shaped to receive the tapered attachment portion 152 therein in a seated manner. As can be further seen in fig. 3, a shaft attachment ear 172 is formed on the proximal end of the firing shaft 170. When the interchangeable surgical tool assembly 100 is coupled to the handle assembly 500, the shaft attachment ear 172 is received in a firing shaft attachment bracket 542 formed in the distal end of the longitudinally movable drive member 540. The interchangeable surgical tool assembly 100 also employs a latching system 180 for releasably locking the shaft assembly 100 to the frame 506 of the handle assembly 500. In at least one form, for example, the latching system 180 includes a locking member or yoke 182 movably coupled to the base 150. The locking yoke 182 includes two proximally projecting locking ears 184 configured for releasable engagement with corresponding locking detents or grooves 509 in the distal attachment flange of the frame 506. In various forms, the lock yoke 182 is biased in the proximal direction by a spring or biasing member. Actuation of the lock yoke 182 may be accomplished by a latch button 186 slidably mounted on a latch actuator assembly mounted to the base 150. The latch button 186 may be biased in a proximal direction relative to the lock yoke 182. As will be discussed in further detail below, the lock yoke 182 may be moved to the unlocked position by biasing the latch button 186 in the distal direction DD, which also pivots the lock yoke 182 out of retaining engagement with the distal attachment flange of the frame 506. When the locking yoke 182 is "held in engagement" with the distal attachment flange of the frame 506, the locking lugs 184 remain disposed within corresponding locking detents or grooves 509 in the distal end of the frame 506. Further details regarding the latching system can be found in U.S. patent application publication 2014/0263541.

To attach the interchangeable surgical tool assembly 100 to the handle assembly 500A, a clinician may position the base 150 of the interchangeable surgical tool assembly 100 over or near the distal end of the frame 506 such that the tapered attachment portion 152 formed on the base 150 is aligned with the dovetail slot 507 in the frame 506. The clinician may then move the surgical tool assembly 100 along a mounting axis IA perpendicular to the shaft axis SA to position the tapered attachment portion 152 into operative engagement with a corresponding dovetail receiving slot 507 in the distal end of the frame 506. In so doing, the shaft attachment lugs 172 on the firing shaft 170 will likewise seat in the brackets 542 in the longitudinally movable drive member 540, and portions of the pins 516 on the closure link 514 will seat in the corresponding hooks 162 in the closure shuttle 160. As used herein, the term "operably engaged" in the context of two components means that the two components are sufficiently engaged with one another that upon application of an actuation motion thereto, the components perform their intended actions, functions, and/or procedures.

Returning now to fig. 1, surgical system 10 includes four interchangeable

surgical tool assemblies

100, 200, 300, and 1000, each of which may be effectively used with the same handle assembly 500 to perform different surgical procedures. The construction of an exemplary form of interchangeable surgical tool assembly 100 is briefly discussed above and in further detail in U.S. patent application publication 2014/0263541. Various details regarding interchangeable

surgical tool assemblies

200 and 300 can be found in various U.S. patent applications that have been incorporated by reference herein. Various details regarding the interchangeable surgical tool assembly 1000 will be discussed in further detail below.

As shown in fig. 1, each of the

surgical tool assemblies

100, 200, 300, and 1000 includes a pair of jaws, wherein at least one jaw is movable to capture, manipulate, and/or clamp tissue between the two jaws. The movable jaws move between an open position and a closed position upon application of a closing motion and an opening motion thereto by a robotic or automated surgical system to which the handle assembly or surgical tool assembly is operably coupled. Further, each of the interchangeable surgical tool assemblies shown includes a firing member configured to cut tissue and fire staples from a staple cartridge supported in one jaw in response to a firing motion applied thereto by a handle assembly or robotic system. Each surgical tool assembly may be uniquely designed to perform a particular procedure, for example, for cutting and fastening tissue of a particular type and thickness within a particular region of the body. The closure, firing, and articulation control system in the handle assembly 500 or robotic system may be configured to generate axial control motions and/or rotational control motions depending on the type of closure, firing, and articulation system configuration employed in the surgical tool assembly. In one arrangement, when the closure control system in the handle assembly or robotic system is fully actuated, one of the closure system control components moves axially from the unactuated position to its fully actuated position. The axial distance that the closure tube assembly moves when moving from its unactuated position to its fully actuated position may be referred to herein as its "closure stroke length". Similarly, when the firing system in the handle assembly or robotic system is fully actuated, one of the firing system control components moves axially from its unactuated position to its fully actuated or fired position. The axial distance that the longitudinally movable drive member moves when moving from its unactuated position to its fully fired position may be referred to herein as its "firing stroke length". For those surgical tool assemblies employing an articulatable end effector arrangement, the handle assembly or robotic system may employ an articulation control member that moves axially through an "articulation drive stroke length". In many cases, the closing stroke length, firing stroke length, and articulation drive stroke length are fixed for a particular handle assembly or robotic system. Thus, each of the surgical tool assemblies must be able to accommodate the controlled movement of the closure, firing, and/or articulation components through each of its full stroke lengths without placing undue stress on the surgical tool components, as this may result in damage to the surgical tool components.

Turning now to fig. 4-10, the interchangeable surgical tool assembly 1000 includes a surgical end effector 1100 including an elongate channel 1102 configured to operably support a staple cartridge 1110 therein. The end effector 1100 may further include an anvil 1130 that is pivotally supported relative to the elongate channel 1102. The interchangeable surgical tool assembly 1000 can also include an articulation joint 1200 and an articulation lock 1210 (fig. 5 and 8-10) that can be configured to releasably retain the end effector 1100 in a desired articulated position relative to the shaft axis SA. Details regarding the construction and operation of the articulation lock 1210 can be found in U.S. patent application Ser. No. 13/803,086, entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK," now U.S. patent application publication 2014/0263541, the entire disclosure of which is hereby incorporated by reference. Additional details regarding this articulation lock may also be found in U.S. patent application Ser. No. 15/019,196, entitled "SURGICAL INSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY CONSTRAINT," filed on even date 2 and 9 of 2016, the entire disclosure of which is hereby incorporated by reference. As can be seen in fig. 7, the interchangeable surgical tool assembly 1000 can further include a proximal housing or nozzle 1300 comprised of

nozzle portions

1302, 1304 and an actuator wheel portion 1306 configured to be coupled to the assembled

nozzle portions

1302, 1304, such as by snaps, lugs, and/or screws. The interchangeable surgical tool assembly 1000 can also include a closure tube assembly 1400 that can be used to close and/or open the anvil 1130 of the end effector 1100, as will be discussed in further detail below. Referring now primarily to fig. 8 and 9, the interchangeable surgical tool assembly 1000 can include a spine assembly 1500 that can be configured to support an articulation lock 1210. The spine assembly 1500 includes a "resilient" spine or frame member 1510, which will be described in further detail below. The distal end portion 1522 of the resilient spine member 1510 is attached to a distal frame segment 1560 that operably supports the articulation lock 1210 therein. As can be seen in fig. 7 and 8, the spine assembly 1500 is configured to: first, a firing member assembly 1600 slidably supported therein; second, the closure tube assembly 1400 extending around the spine assembly 1500 is slidably supported. The spine assembly 1500 may also be configured to slidably support the proximal articulation driver 1700.

As shown in fig. 10, distal frame segment 1560 is pivotally coupled to elongate channel 1102 by end effector mounting assembly 1230. For example, in one arrangement, the distal end 1562 of the distal frame segment 1560 has a pivot pin 1564 formed thereon. Pivot pin 1564 is adapted to be pivotally received within pivot hole 1234 formed in pivot base portion 1232 of end effector mounting assembly 1230. An end effector mount assembly 1230 is attached to the proximal end 1103 of the elongate channel 1102 by a spring pin 1108 or other suitable means. Pivot pin 1564 defines an articulation axis B-B transverse to shaft axis SA. See fig. 4. This arrangement facilitates pivotal travel (i.e., articulation) of the end effector 1100 relative to the spine assembly 1500 about an articulation axis B-B.

Still referring to fig. 10, the articulation driver 1700 has a distal end 1702 that is configured to operably engage an articulation lock 1210. The articulation lock 1210 includes an articulation frame 1212 adapted to operably engage a drive pin 1238 on a pivot base portion 1232 of the end effector mount assembly 1230. In addition, a cross-connect 1237 can be coupled to the drive pin 1238 and the articulation frame 1212 to assist in articulation of the end effector 1100. As described above, more details regarding the operation of the articulation lock 1210 and the articulation frame 1212 can be found in U.S. patent application Ser. No. 13/803,086, now U.S. patent application publication 2014/0263541. Additional details regarding the end effector mounting assembly and cross-connect can be found in U.S. patent application Ser. No. 15/019,245, entitled "SURGICAL INSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS," filed on even date 2016, the entire disclosure of which is hereby incorporated by reference. In various instances, the resilient spine member 1510 includes a proximal end 1514 rotatably supported in the chassis 1800. In one arrangement, for example, the proximal end 1514 of the resilient spine member 1510 has threads 1516 formed thereon for threaded attachment to a spine bearing configured to be supportable within the chassis 1800. Such an arrangement facilitates rotatable attachment of the resilient spine member 1510 to the base 1800 such that the spine assembly 1500 may be selectively rotated relative to the base 1800 about the shaft axis SA.

Referring primarily to fig. 7, the interchangeable surgical tool assembly 1000 includes a closure shuttle 1420 slidably supported within the chassis 1800 such that the closure shuttle 1420 is movable circumferentially relative to the chassis 1800. In one form, the closure shuttle 1420 includes a pair of proximally projecting hooks 1421 configured to be attached to an attachment pin 516 that is attached to the closure link assembly 514 of the handle assembly 500, as discussed above. The proximal end 1412 of the proximal closure tube segment 1410 is rotatably coupled to the closure shuttle 1420. For example, the U-shaped connector 1424 is inserted into the annular slot 1414 in the proximal end 1412 of the proximal closure tube segment 1410 and retained within the vertical slot 1422 in the closure shuttle 1420. See fig. 7. Such an arrangement serves to attach the proximal closure tube segment 1410 to the closure shuttle 1420 to travel axially with the closure shuttle while enabling the closure tube assembly 1400 to rotate about the shaft axis SA relative to the closure shuttle 1420. The closure spring is journaled on the proximal end 1412 of the proximal closure tube segment 1410 and is used to bias the closure tube assembly 1400 in the proximal direction PD, which may be used to pivot the closure trigger 512 on the handle assembly 500 (fig. 3) to an unactuated position when the interchangeable surgical tool assembly 1000 is operably coupled to the handle assembly 500.

As described above, the illustrated interchangeable surgical tool assembly 1000 includes an articulation joint 1200. However, other interchangeable surgical tool assemblies may not be capable of articulation. As can be seen in fig. 10, the superior and inferior tangs 1415, 1416 project distally from the distal end of the proximal closure tube segment 1410 to movably couple to an end effector closure sleeve or distal closure tube segment 1430 of the closure tube assembly 1400. As can be seen in fig. 10, the distal closure tube segment 1430 includes an upper tang 1434 and a lower tang 1436 that project proximally from its proximal end. The upper double pivot link 1220 includes proximal and distal pins that engage corresponding holes in the

upper tangs

1415, 1434 of the proximal and distal

closure tube segments

1410, 1430, respectively. Similarly, the lower dual pivot connection 1222 includes proximal and distal pins that engage corresponding holes in the inferior tangs 1416 and 1436 of the proximal and distal

closure tube segments

1410 and 1430, respectively. As will be discussed in further detail below, distal and proximal axial translation of the closure tube assembly 1400 will cause the anvil 1130 to close and open relative to the elongate channel 1102.

As described above, the interchangeable surgical tool assembly 1000 also includes a firing member assembly 1600 that is supported for axial travel within the spine assembly 1500. The firing member assembly 1600 includes an intermediate firing shaft portion 1602 configured to be attached to a distal cutting portion or knife bar 1610. The firing member assembly 1600 may also be referred to herein as a "second shaft" and/or a "second shaft assembly. As seen in fig. 7-10, the intermediate firing shaft portion 1602 may include a longitudinal slot 1604 in a distal end thereof that may be configured to receive a tab on a proximal end of the knife bar 1610. The proximal ends of the longitudinal slot 1604 and knife bar 1610 can be sized and configured such that they allow relative movement therebetween and can include a sliding joint 1612. The sliding joint 1612 may allow the intermediate firing shaft portion 1602 of the firing member assembly 1600 to move to articulate the end effector 1100 without moving, or at least substantially without moving, the knife bar 1610. Once the end effector 1100 has been properly oriented, the intermediate firing shaft portion 1602 can be advanced distally until the proximal side wall of the longitudinal slot 1604 comes into contact with the tabs on the knife bar 1610 in order to advance the knife bar 1610 and fire the staple cartridge 1110 positioned within the elongate channel 1102. As can be further seen in fig. 8 and 9, the resilient spine member 1520 has an elongated opening or window 1525 therein to facilitate assembly and insertion of the intermediate firing shaft portion 1602 into the resilient spine member 1520. Once the intermediate firing shaft portion 1602 has been inserted into the resilient spine member 1520, the top frame segment 1527 may be engaged with the resilient spine member to enclose the intermediate firing shaft portion 1602 and knife bar 1610 therein. Further description of the operation of the Guan Jifa component assembly 1600 can be found in U.S. patent application Ser. No. 13/803,086 (now U.S. patent application publication 2014/0263541).

In addition to the above, the interchangeable tool assembly 1000 can include a clutch assembly 1620 that can be configured to selectively and releasably couple the articulation driver 1700 to the firing member assembly 1600. In one form, the clutch assembly 1620 includes a lock collar or lock sleeve 1622 positioned about the firing member assembly 1600, wherein the lock sleeve 1622 is rotatable between an engaged position in which the lock sleeve 1622 couples the articulation driver 1700 to the firing member assembly 1600 and a disengaged position in which the articulation driver 1700 is not operably coupled to the firing member assembly 1600. When the lockout sleeve 1622 is in its engaged position, distal movement of the firing member assembly 1600 may move the articulation driver 1700 distally, and, correspondingly, proximal movement of the firing member assembly 1600 may move the articulation driver 1700 proximally. When the lockout sleeve 1622 is in its disengaged position, movement of the firing member assembly 1600 is not transferred to the articulation driver 1700 and, thus, the firing member assembly 1600 may move independently of the articulation driver 1700. In various circumstances, the articulation driver 1700 may be held in place by the articulation lock 1210 when the articulation driver 1700 is not being moved in a proximal or distal direction by the firing member assembly 1600.

Referring primarily to FIG. 7, the lockout sleeve 1622 may include a cylindrical, or at least substantially cylindrical, body including a longitudinal bore 1624 defined therein and configured to receive the firing member assembly 1600. The locking sleeve 1622 may include diametrically opposed inwardly facing locking

protrusions

1626, 1628 and an outwardly facing locking member 1629. The

lockout tabs

1626, 1628 may be configured to selectively engage the intermediate firing shaft portion 1602 of the firing member assembly 1600. More specifically, when the lockout sleeve 1622 is in its engaged position, the

lockout protrusions

1626, 1628 are positioned within a drive recess 1605 defined in the intermediate firing shaft portion 1602 such that a distal pushing force and/or a proximal pulling force may be transferred from the firing member assembly 1600 to the lockout sleeve 1622. When the locking sleeve 1622 is in its engaged position, the second locking member 1629 is received within a drive notch 1704 defined in the articulation driver 1700 such that a distal pushing force and/or a proximal pulling force applied to the locking sleeve 1622 may be transferred to the articulation driver 1700. In fact, when the lockout sleeve 1622 is in its engaged position, the firing member assembly 1600, lockout sleeve 1622, and articulation driver 1700 will move together. On the other hand, when the lockout sleeve 1622 is in its disengaged position, the

lockout tabs

1626, 1628 may not be positioned within the drive recess 1605 of the intermediate firing shaft portion 1602 of the firing member assembly 1600; and, as such, distal pushing force and/or proximal pulling force may not be transferred from the firing member assembly 1600 to the lockout sleeve 1622. Accordingly, distal pushing force and/or proximal pulling force may not be transferred to the articulation driver 1700. In such cases, the firing member assembly 1600 may slide proximally and/or distally relative to the lockout sleeve 1622 and the proximal articulation driver 1700. The clutch assembly 1620 also includes a shift barrel 1630 engaged with the locking sleeve 1622. Additional details regarding the operation of the switch drum and locking sleeve 1622 may be found in U.S. patent application Ser. No. 13/803,086 (now U.S. patent application publication 2014/0263541 and Ser. No. 15/019,196). The switch barrel 1630 may also include at least partially circumferentially defined

openings

1632, 1634 therein that may receive a circumferential mount 1305 extending from the

nozzle halves

1302, 1304 and allow for relative rotation but not relative translation between the switch barrel 1630 and the proximal nozzle 1300. See fig. 6. Rotation of the nozzle 1300 to a point where the mounting bracket reaches the end of its

respective slot

1632, 1634 in the switch barrel 1630 will cause the switch barrel 1630 to rotate about the shaft axis SA. Rotation of the shift barrel 1630 ultimately will cause the locking sleeve 1622 to move between its engaged and disengaged positions. Thus, in essence, the nozzle 1300 may be used to operably engage and disengage an articulation drive system with a firing drive system in a variety of ways that are described in more detail in the following patent applications: U.S. patent application Ser. No. 13/803,086, now U.S. patent application publication 2014/0263541; U.S. patent application Ser. No. 15/019,196; each of these patents is incorporated by reference herein in its entirety.

In the illustrated arrangement, the switching barrel 1630 includes an L-shaped slot 1636 that extends into a distal opening 1637 in the switching barrel 1630. Distal opening 1637 receives a transverse pin 1639 of a moving plate 1638. In one example, the movement plate 1638 is received within a longitudinal slot provided in the locking sleeve 1622 to facilitate axial movement of the locking sleeve 1622 when engaged with the articulation driver 1700. Further details regarding the operation of the moving plate and moving drum arrangement can be found in U.S. patent application Ser. No. 14/868,718 (now U.S. patent publication 2017/0086823), entitled "SURGICAL STAPLING INSTRUMENT WITH SHAFT RELEASE, POWERED FIRING AND POWERED ARTICULATION," filed on September 28, 2015, the entire disclosure of which is hereby incorporated by reference.

As also shown in fig. 7 and 8, the interchangeable tool assembly 1000 can include a slip ring assembly 1640 that can be configured to conduct power to and/or from the end effector 1100 and/or to transmit signals to and/or from the end effector 1100 back to, for example, a microcontroller or robotic system controller in the handle assembly. Additional details of the Guan Huahuan assembly 1640 and associated connector can be found in U.S. patent application Ser. No. 13/803,086 (now U.S. patent application publication 2014/0263541) and U.S. patent application Ser. No. 15/019,196 (each of which is incorporated by reference herein in its entirety) and U.S. patent application Ser. No. 13/800,067 (now U.S. patent application publication 2014/0263552, which is incorporated by reference herein in its entirety) entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM". As also described in further detail in the aforementioned patent applications, which have been incorporated by reference herein, the interchangeable surgical tool assembly 1000 can also include at least one sensor configured to detect the position of the switch barrel 1630.

Referring again to fig. 7, the base 1800 includes one or more tapered attachment portions 1802 formed thereon that are adapted to be received within corresponding dovetail slots 507 formed within a distal end portion of the frame 506 of the handle assembly 500, as discussed above. As can be further seen in fig. 7, a shaft attachment ear 1605 is formed on the proximal end of the intermediate firing shaft 1602. As will be discussed in further detail below, when the interchangeable surgical tool assembly 1000 is coupled to the handle assembly 500, the shaft attachment lugs 1605 are received in firing shaft attachment brackets 542 formed in the distal end of the longitudinal drive member 540. See fig. 3.

The various interchangeable surgical tool assemblies employ a latching system 1810 for removably coupling the interchangeable surgical tool assembly 1000 to the frame 506 of the handle assembly 500. In at least one form, as seen in fig. 7, the latching system 1810 includes a locking member or locking yoke 1812 movably coupled to the base 1800. The lock yoke 1812 is U-shaped with two spaced apart and downwardly extending legs 1814. The legs 1814 each have pivot lugs formed thereon that are adapted to be received in corresponding holes 1816 formed in the base 1800. Such a configuration facilitates the pivotal attachment of lock yoke 1812 to base 1800. The locking yoke 1812 may include two proximally projecting locking lugs 1818 configured to releasably engage with corresponding locking pawls or grooves 509 in the distal end of the frame 506 of the handle assembly 500. See fig. 3. In various forms, the lock yoke 1812 is biased in the proximal direction by a spring or biasing member 1819. Actuation of the lock yoke 1812 may be accomplished by a latch button 1820 slidably mounted on a latch actuator assembly 1822 that is mounted to the chassis 1800. The latch button 1820 may be biased in a proximal direction relative to the lock yoke 1812. The lock yoke 1812 may be moved to the unlocked position by biasing the latch button 1820 in the distal direction, which also pivots the lock yoke 1812 out of retaining engagement with the distal end of the frame 506. When the locking yoke 1812 remains engaged with the distal end of the frame 506, the locking lugs 1818 remain seated within corresponding locking detents or grooves 509 in the distal end of the frame 506.

In the arrangement shown, the locking yoke 1812 includes at least one and preferably two locking hooks 1824 that are adapted to contact corresponding locking tab portions 1426 formed on the closure shuttle 1420. When the closure shuttle 1420 is in the unactuated position, the lock yoke 1812 may pivot in a distal direction to unlock the interchangeable surgical tool assembly 1000 from the handle assembly 500. When in this position, the locking hook 1824 does not contact the locking tab portion 1426 on the closure shuttle 1420. However, when the closure shuttle 1420 is moved to the actuated position, the lock yoke 1812 is prevented from pivoting to the unlocked position. In other words, if a clinician attempts to pivot the lock yoke 1812 to the unlocked position, or for example, the lock yoke 1812 is inadvertently bumped or contacted in a manner that would otherwise cause it to pivot distally, the lock hook 1824 on the lock yoke 1812 will contact the lock tab 1426 on the closure shuttle 1420 and prevent the lock yoke 1812 from moving to the unlocked position.

Still referring to fig. 10, knife bar 1610 can include a laminated beam structure comprising at least two beam layers. The beam layers may comprise, for example, stainless steel strips interconnected at their proximal ends and/or other locations along the length of the strips by, for example, welding and/or pins. In alternative embodiments, the distal ends of the bands are not connected together to allow the laminate or bands to be deployed relative to each other as the end effector is articulated. Such an arrangement allows knife bar 1610 to be flexible enough to accommodate articulation of the end effector. Various laminated knife bar arrangements are disclosed in U.S. patent application Ser. No. 15/019,245. As can also be seen in fig. 10, the intermediate support member 1614 serves to provide lateral support to the knife bar 1610 as it flexes to accommodate articulation of the surgical end effector 1100. Further details regarding intermediate support members and alternative knife bar support arrangements are disclosed in U.S. patent application Ser. No. 15/019,245. As also seen in fig. 10, a firing member or knife member 1620 is attached to the distal end of the knife bar 1610.

FIG. 11 illustrates one form of firing member 1660 that can be used with the interchangeable tool assembly 1000. The firing member 1660 includes a body portion 1662 that includes a proximally extending connector member 1663 configured to be received in a correspondingly shaped connector opening 1614 in the distal end of the knife bar 1610. See fig. 10. For example, connector 1663 may be retained within connector opening 1614 by friction, welding, and/or a suitable adhesive. 15-17, the main body portion 1662 protrudes through the elongated slot 1104 in the elongated channel 1102 and terminates in foot members 1664 extending laterally on each side of the main body portion 1662. When the firing member 1660 is driven distally through the surgical staple cartridge 1110, the foot member 1664 rides in the elongate channel 1102 positioned within the channel under the surgical staple cartridge 1110. As seen in fig. 11, the firing member 1660 may also include a laterally protruding central tab, pin, or retainer feature 1680. When the firing member 1660 is driven distally through the surgical staple cartridge 1110, the central retainer feature 1680 rides on the inner surface 1106 of the elongate channel 1102. The body portion 1662 of the firing member 1660 further includes a tissue cutting edge or feature 1666 disposed between the distally projecting shoulder 1665 and the distally projecting top nose portion 1670. As can be further seen in fig. 11, the firing member 1660 can also include two laterally extending top tabs, pins, or anvil engagement features 1665. See fig. 13 and 14. When the firing member 1660 is driven distally, a top portion of the main body 1662 extends through a centrally disposed anvil slot 1138 (fig. 14) and the top anvil engagement feature 1672 rides over corresponding bosses 1136 formed on each side of the anvil slot 1134.

Returning to fig. 10, the firing member 1660 is configured to be operably coupled with a sled 1120 that is supported within the body 1111 of the surgical staple cartridge 1110. The sled 1120 is slidably displaceable within the surgical staple cartridge body 1111 from a proximal end starting position adjacent to the proximal end 1112 of the cartridge body 1111 to an ending position adjacent to the distal end 1113 of the cartridge body 1111. The cartridge body 1111 is operable to support a plurality of staple drivers (not shown in fig. 10) therein, which are aligned in rows on each side of the centrally disposed slot 1114. A centrally disposed slot 1114 enables a firing member 1660 to pass therethrough and cut tissue clamped between the anvil 1130 and the staple cartridge 1110. The drives are associated with corresponding pockets 1115 that pass through the upper deck surface of the cartridge body. Each of the staple drivers supports one or more surgical staples or fasteners thereon. Slider 1120 includes a plurality of angled or wedge cams 1122, wherein each cam 1122 corresponds to a particular line of fasteners or drivers located on the sides of slot 1114. In the illustrated example, one cam 1122 is aligned with a row of "double" drivers each supporting two staples or fasteners thereon, and the other cam 1122 is aligned with another row of "single" drivers on the same side of slot 1114 each supporting a single surgical staple or fastener thereon. Thus, in the illustrated example, when the surgical staple cartridge 1110 is "fired," there will be three rows of staples on each side of the tissue cut line. However, other cartridge and driver configurations may be employed to fire other staple/fastener arrangements. The sled 1120 has a central body portion 1124 configured to be engaged by a shoulder 1665 of the firing member 1660. When the firing member 1660 is fired or driven distally, the firing member 1660 also drives the sled 1120 distally. As firing member 1660 moves distally through cartridge 1110, tissue cutting feature 1666 cuts tissue clamped between anvil assembly 1130 and cartridge 1110 and also sled 1120 drives up drivers in the cartridge that drive corresponding staples or fasteners into contact with anvil assembly 1130.

In embodiments where the firing member includes a tissue cutting surface, it may be desirable that the elongate shaft assembly be configured in such a manner: the firing member is prevented from being inadvertently advanced unless an unused staple cartridge is properly supported in the elongate channel 1102 of the surgical end effector 1100. For example, if there is no staple cartridge at all and the firing member is advanced distally through the end effector, the tissue will be severed, but not stapled. Similarly, if there is a spent staple cartridge (i.e., a staple cartridge from which at least some staples have been fired) in the end effector and the firing member is advanced, the tissue will be severed, but may not be fully stapled. It should be appreciated that such conditions may lead to undesirable results during a surgical procedure. U.S. patent 6,988,649 to "SURGICAL STAPLING INSTRUMENT HAVING A SPENT CARTRIDGE LOCOUT," U.S. patent 7,044,352 to "SURGICAL STAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR PREVENTION OF FIRING," U.S. patent 7,380,695 to "SURGICAL STAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR PREVENTION OF FIRING," and U.S. patent application Ser. No. 14/742,933 to "SURGICAL STAPLING INSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTING FIRING SYSTEM ACTUATION WHEN A CARTRIDGE IS SPENT OR MISSING," each disclose various firing member LOCKOUT arrangements. Each of these U.S. patents is incorporated by reference herein in its entirety.

"unfired", "unused", "fresh" or "new" fastener cartridge 1110 means that the fastener cartridge 1110 has all of its fasteners in its "ready to fire" position. A new cartridge 1110 is disposed within the elongate channel 1102 and can be retained therein by snap features on the cartridge body that are configured to remain engaged with corresponding portions of the elongate channel 1102. Fig. 15 and 18 illustrate a portion of a surgical end effector 1100 with a new or unfired surgical staple cartridge 1110 disposed therein. As can be seen in fig. 15 and 18, the slider 1120 is in its home position. To prevent the firing system from being activated, and more precisely, to prevent the firing member 1660 from being driven distally through the end effector 1110, the interchangeable surgical tool assembly 1000 employs a firing member lockout system, generally designated 1650, unless an unfired or new surgical staple cartridge has been properly positioned within the elongate channel 1102.

Referring now to fig. 10 and 15-19, the firing member lockout system 1650 includes a movable lockout member 1652 configured to maintain engagement with the firing member 1660 when a new surgical staple cartridge 1110 is improperly positioned within the elongate channel 1102. More specifically, the lockout member 1652 includes at least one laterally movable lockout portion 1654 configured to maintain engagement with a corresponding portion of the firing member 1660 when the sled 1120 is not present within the cartridge 1110 in its home position. In effect, the lockout member 1652 employs two laterally displaced lockout portions 1654 that each engage a laterally extending portion of the firing member 1660. Other latching arrangements may be used.

The locking member 1652 includes a generally U-shaped spring member with each laterally movable leg or locking portion 1654 extending from the central spring portion 1653 and being configured to be movable in a lateral direction represented by "L" in fig. 18 and 19. It should be understood that the term "lateral" refers to a direction transverse to the shaft axis SA (fig. 2). For example, the spring or locking member 1652 may be made of high strength spring steel and/or the like. The center spring portion 1653 is disposed within a slot 1236 in the end effector mount assembly 1230. See fig. 10. As seen in fig. 15-17, each of the laterally movable legs or locking portions 1654 has a distal end 1656 having a locking window 1658 therein. When the lockout member 1652 is in the lockout position, a central retainer feature 1680 on each side of the firing member 1660 extends into a corresponding lockout window 1658 defined in the lockout portion 1654 to retain the lockout member from being advanced distally or axially.

The operation of the firing member lockout system will be described with reference to fig. 15-19. Fig. 15 and 18 illustrate a portion of a surgical end effector 1100 in which a new unfired cartridge 1110 is properly installed. As can be seen in fig. 15 and 18, the slider 1120 includes an unlocking feature 1126 that corresponds to each of the laterally movable locking portions 1654. An unlocking feature 1126 is provided on or extends proximally from each of the central wedge cams 1122. In an alternative arrangement, the unlocking feature 1126 may include a proximal protruding portion of the corresponding wedge cam 1122. As can be seen in fig. 18, when the slider 1120 is in its home position, the unlocking feature 1124 engages and laterally biases the corresponding locking portion 1654 in a direction transverse to the shaft axis SA (fig. 2). When the locking portion 1654 is in such an unlocked orientation, the central retainer feature 1680 does not remain engaged with the locking window 1658. In such cases, the firing member 1660 can be advanced distally or axially (fired). However, when a cartridge is not present in the elongate channel 1102 or the sled 1120 has moved out of its home position (which means that the cartridge is partially or fully fired), the lockout portion 1654 resiliently remains laterally engaged with the firing member 1660. In such cases, referring to fig. 19, the firing member 1660 cannot be moved distally.

Fig. 16 and 17 illustrate the firing member 1660 retracted to its starting or unfired position after the staple firing stroke is performed as discussed above. Fig. 16 depicts an initial re-engagement of the retention feature 1680 with its corresponding locking window 1658. FIG. 17 illustrates the retention feature in its locked position when the firing member 1660 has been fully retracted to its starting position. To assist in locking the lateral displacement of the locking portion 1654 when it is in contact with the proximally moving retention features 1680, each of the retention features 1680 may be provided with a proximally facing, laterally tapered end portion. Such lockout systems prevent the firing member 1660 from being actuated when a new unfired cartridge is not present or when a new unfired cartridge is present but not properly seated in the elongate channel 1102. Additionally, the lockout system may prevent the clinician from distally advancing the firing member if a spent or partially fired cartridge has been inadvertently properly positioned within the elongate channel. Another advantage that the lockout system 1650 may provide is that the firing member 1660 remains aligned with the cartridge channel when in the locked and unlocked positions, unlike other firing member lockout arrangements that require moving the firing member to align and misalign with a corresponding slot/channel in the staple cartridge. The lockout portion 1654 is designed to be laterally movable into and out of engagement with a corresponding side of the firing member. Such lateral movement of one or more lockout portions may distinguish it from other lockout arrangements that move in a vertical direction to engage and disengage portions of the firing member.

Returning to fig. 13 and 14, the anvil 1130 includes an elongate anvil body portion 1132 and a proximal anvil mounting portion 1150. The elongate anvil body portion 1132 includes an outer surface 1134 that defines two downwardly extending tissue stop members 1136 that are adjacent the proximal anvil mounting portion 1150. The elongate anvil body portion 1132 further includes an underside 1135 that defines an elongate anvil slot 1138. In the example arrangement shown in fig. 14, anvil slot 1138 is centrally disposed in underside 1135. The underside 1135 includes three

rows

1140, 1141, 1142 of

staple forming pockets

1143, 1144, and 1145 positioned on each side of the anvil slot 1138. Adjacent to each side of anvil slot 1138 are two elongated anvil passages 1146. Each passageway 1146 has a proximal ramp portion 1148. See fig. 13. As the firing member 1660 is advanced distally, the top anvil engagement feature 1632 initially enters the corresponding proximal ramp portion 1148 and into the corresponding elongate anvil channel 1146.

Turning to fig. 12 and 13, the anvil slot 1138 and proximal ramp portion 1148 extend into the anvil mounting portion 1150. In other words, the anvil slot 1138 divides or splits the anvil mounting portion 1150 into two anvil attachment flanges 1151. The anvil attachment flanges 1151 are coupled together at their proximal ends by a connecting bridge 1153. The connecting bridge 1153 supports the anvil attachment flange 1151 and may serve to make the anvil mounting portion 1150 more rigid than other anvil arrangements that are not connected together at its proximal end. As can also be seen in fig. 12 and 14, the anvil slot 1138 has a wider portion 1139 to accommodate a top portion of the firing member 1660 including the top anvil engagement feature 1632 when the firing member 1660 is in its proximal unfired position.

As seen in fig. 13 and 20-24, each of the anvil attachment flanges 1151 includes a transverse mounting hole 1156 that is configured to receive a pivot pin 1158 (fig. 10 and 20) therein. The anvil mounting portion 1150 is pivotally pinned to the proximal end 1103 of the elongate channel 1102 by a pivot pin 1158 that extends through a mounting hole 1107 in the proximal end 1103 of the elongate channel 1102 and a mounting hole 1156 in the anvil mounting portion 1150. This arrangement pivotally attaches the anvil 1130 to the elongate channel 1102s such that the anvil 1130 is pivotable about a fixed anvil axis A-A transverse to the shaft axis SA. See fig. 5. The anvil mounting portion 1150 further includes a cam surface 1152 that extends from the concentrated firing member parking region 1154 to an outer surface 1134 of the anvil body portion 1132.

In addition to the above, the anvil 1130 may be moved between an open position and a closed position by axially advancing and retracting the distal closure tube segment 1430, as discussed further below. The distal end portion of the distal closure tube segment 1430 has an internal cam surface formed thereon that is configured to engage the cam surface 1552 or cam surface formed on the anvil mounting portion 1150 and move the anvil 1130. Fig. 22 illustrates a cam surface 1152a that is formed on the anvil mounting portion 1150 to establish a single contact path 1155a with an internal cam surface 1444, for example, on the distal closure tube segment 1430. Fig. 23 shows a cam surface 1152b that is configured relative to an internal cam surface 1444 on the distal closure tube segment to establish two separate and distinct arcuate contact paths 1155b between the cam surface 1152 on the anvil mounting portion 1150 and the internal cam surface 1444 on the distal closure tube segment 1430. Among other potential advantages discussed herein, such an arrangement may better distribute the closing force from the distal closure tube segment 1430 to the anvil 1130. Fig. 24 illustrates a cam surface 1152c that is configured relative to an inner cam surface 1444 of the distal closure tube segment 1430 to establish three

distinct contact areas

1155c and 1155d between the anvil mounting portion 1150 and the cam surface on the distal closure tube segment 1430. The

regions

1155c, 1155d establish a greater cam contact area between the distal closure tube segment 1430 and one or more cam surfaces on the anvil mounting portion 1150 and may better distribute the closure force to the anvil 1130.

When the distal closure tube segment 1430 cams against the anvil mounting portion 1150 of the anvil 1130, the anvil 1130 pivots about the anvil axis AA (fig. 5), which causes the distal end of the end 1133 of the elongate anvil body portion 1132 to pivotally move toward the surgical staple cartridge 1110 and the distal end 1105 of the elongate channel 1102. As the anvil body portion 1132 begins to pivot, it contacts the tissue to be cut and stapled, which is now positioned between the underside 1135 of the elongate anvil body portion 1132 and the platform 1116 of the surgical staple cartridge 1110. As the anvil body portion 1132 is compressed against the tissue, the anvil 1130 may experience substantial resistance and/or bending loads, for example. These resistances are overcome as the distal closure tube 1430 continues its distal advancement. However, depending on the magnitude of these resistances and the point of application thereof to the anvil body portion 1132, these resistances may tend to bend a portion of the anvil 1130 away from the staple cartridge 1110, which may generally be undesirable. For example, such bending may cause the firing member 1660 to be misaligned with the

passages

1148, 1146 within the anvil 1130. In the event of an excessive bending, such bending may significantly increase the amount of firing force required to fire the instrument (i.e., drive the firing member 1660 through tissue from its starting position to its ending position). Such excessive firing forces can result in damage to the end effector, firing member, knife bar, and/or firing drive system components, for example. Thus, it may be advantageous to configure the anvil to resist such deflection.

Fig. 25-27 illustrate an anvil 1130' that includes features that improve the stiffness of the anvil body and its resistance to bending forces that may be generated during the closing and/or firing process. The anvil 1130' may be identical in construction to the anvil 1130 described above, except for the differences discussed herein. As seen in fig. 25-27, the anvil 1130 'has an elongate anvil body 1132' having an upper body portion 1165 and an anvil cap 1170 attached thereto. The anvil cap 1170 is generally rectangular in shape and has an outer cap perimeter 1172, but the anvil cap 1170 can have any suitable shape. The perimeter 1172 of the anvil cap 1170 is configured to be inserted into a corresponding shaped opening 1137 formed in the upper body portion 1165 and to be positioned against an axially extending inner boss portion 1139 formed therein. See fig. 27. The inner tab portion 1139 is configured to support a corresponding long side 1177 of the anvil cap 1170. In alternative embodiments, the anvil cap 1170 may be slid onto the inner boss 1139 through an opening in the distal end 1133 of the anvil body 1132'. In yet another embodiment, no internal boss portion is provided. The anvil body 1132' and anvil cap 1170 may be made of a suitable metal to facilitate welding. The first weld 1178 may extend around the entire cap perimeter 1172 of the anvil cap 1170, or it may be located only along the long side 1177 of the anvil cap 1170 and not along its distal end 1173 and/or its proximal end 1175. The first weld 1178 may be continuous or it may be discontinuous or intermittent. In those embodiments in which the first weld 1178 is discontinuous or intermittent, the weld segments may be evenly distributed along the long side 1177 of the anvil cap 1170, more closely spaced closer to the distal end of the long side 1177, and/or more closely spaced closer to the proximal end of the long side 1177. In some arrangements, the welded sections may be more densely spaced in a central region of the long side 1177 of the anvil cap 1170.

Fig. 28-30 illustrate an anvil cap 1170 'that is configured to mechanically interlock with the anvil body 1132' and to be welded to the upper body portion 1165. In this embodiment, a plurality of retaining structures 1182 are defined in a wall 1180 of the upper body portion 1165 that defines an opening 1137. As used in this context, the term "mechanically interlocked" means that the anvil cap will remain attached to the elongate anvil body regardless of the orientation of the elongate anvil body and without any additional holding or fastening, such as welding and/or adhesive. The retaining structure 1182 may protrude inwardly from the opening wall 1180 into the opening 1137, although any suitable arrangement may be used. The retaining structure 1182 may be integrally formed in or otherwise attached to the wall 1180. The retaining structure 1182 is designed to frictionally engage a corresponding portion of the anvil cap 1170' when the anvil cap 1170' is installed in the opening 1137 to frictionally retain the anvil cap 1170' therein. The retaining structure 1182 protrudes inwardly into the opening 1137 and is configured to be frictionally received within a corresponding shaped engagement region 1184 formed in the outer periphery 1172 'of the anvil cap 1170'. The retaining structure 1182 corresponds only to the long side 1177' of the anvil cap 1170' and is not disposed in the portion of the wall 1180 corresponding to the distal end 1173 or the proximal end 1175 of the anvil cap 1170 '. In an alternative arrangement, the retaining structure 1182 may also be provided in a portion of the wall 1180 corresponding with the distal end 1173 and the proximal end 1175 of the anvil cap 1170 'and its long side 1177'. In further arrangements, the retaining structure 1182 may be disposed only in a portion of the wall 1180 corresponding to one or both of the distal end 1173 and the proximal end 1175 of the anvil cap 1170'. In further arrangements, the retaining structure 1182 may be disposed in a portion of the wall 1180 corresponding to the long side 1177 'and corresponding to only one of the proximal end 1173 and the distal end 1175 of the anvil cap 1170'. It should also be appreciated that the retention tabs in all of the foregoing embodiments may alternatively be formed on the anvil cap with the engagement region formed in the elongate anvil body.

In the embodiment shown in fig. 28-30, the retaining structures 1182 are equally spaced or evenly distributed along the wall portion 1180 of the anvil cap 1170'. In alternative embodiments, the retaining structures 1182 may be more densely spaced closer to the distal end of the long side 1177', or more densely spaced closer to the proximal end of the long side 1177'. In other words, the spacing between those retaining structures adjacent the distal end, adjacent the proximal end, or both the distal and proximal ends may be less than the spacing between structures positioned in the central portion of the anvil cap 1170'. In further arrangements, the retaining structures 1182 may be more densely spaced in the central region of the long side 1177 'of the anvil cap 1170'. In some alternative embodiments, the correspondingly shaped engagement region 1184 may not be disposed in the outer periphery 1172' or may not be disposed in a portion of the outer periphery 1172' of the anvil cap 1170 '. In other embodiments, the retaining structures and correspondingly shaped engagement regions may be provided with different shapes and sizes. In an alternative arrangement, the retaining structure may be sized relative to the engagement region such that there is no interference fit between the retaining structure and the engagement region. In such an arrangement, the anvil cap may be held in place, for example, by welding and/or adhesive.

In the example shown, the weld 1178' extends around the entire perimeter 1172' of the anvil cap 1170 '. Alternatively, the weld 1178' is located along the long side 1177' of the anvil cap 1170' rather than the distal end 1173 and/or proximal end 1175 thereof. The weld 1178' may be continuous or it may be discontinuous or intermittent. In those embodiments in which the weld 1178' is discontinuous or intermittent, the weld segments may be evenly distributed along the long side 1177' of the anvil cap 1170', or the weld segments may be more densely spaced closer to the distal end of the long side 1177', or more densely spaced closer to the proximal end of the long side 1177 '. In further arrangements, the welded sections may be more densely spaced in a central region of the long side 1177 'of the anvil cap 1170'.

Fig. 31 and 32 illustrate another anvil arrangement 1130 "with an anvil cap 1170" attached thereto. The anvil cap 1170 "is generally rectangular in shape and has an outer cap perimeter 1172"; however, the anvil cap 1170 "can comprise any suitable configuration. The outer cap perimeter 1172 "is configured to be inserted into a correspondingly shaped opening 1137" in the upper body portion 1165 of the anvil body 1132 "and to be received over axially extending inner boss portions 1139" and 1190 "formed therein. See fig. 32. The male portions 1139 "and 1190" are configured to support corresponding long sides 1177 "of the anvil cap 1170". In an alternative embodiment, the anvil cap 1170 "is slid onto the inner protrusions 1139" and 1190 "through an opening in the distal end 1133" of the anvil body 1132'. The anvil body 1132 "and anvil cap 1170" may be made of a metallic material that facilitates welding. The first weld 1178 "may extend around the entire perimeter 1172" of the anvil cap 1170", or it may be located only along the long side 1177" of the anvil cap 1170 "and not along its distal end 1173" and/or its proximal end. The weld 1178 "may be continuous or it may be discontinuous or intermittent. It should be appreciated that the continuous weld embodiment has a greater weld surface area due to the irregularly shaped perimeter of the anvil cap 1170 "as compared to an embodiment having a straight perimeter side, such as the anvil cap shown in fig. 26. In those embodiments in which the welds 1178 "are discontinuous or intermittent, the weld segments may be evenly distributed along the long side 1177" of the anvil cap 1170", or the weld segments may be more densely spaced closer to the distal end of the long side 1177", or more densely spaced closer to the proximal end of the long side 1177". In further arrangements, the welded sections may be more densely spaced in the central region of the long side 1177 "of the anvil cap 1170".

Still referring to fig. 31 and 32, the anvil cap 1170 "may be additionally welded to the anvil body 1132" by a plurality of second discrete "deep" welds 1192". For example, each weld 1192 "may be disposed at the bottom of a corresponding hole or opening 1194" provided through the anvil cap 1170 "such that discrete welds 1192" may be formed along the portion of the anvil body 1132 "between the projections 1190" and 1139 ". See fig. 32. The welds 1192 "may be evenly distributed along the long side 1177" of the anvil cap 1170", or the distal ends of the welds 1192" that are closer to the long side 1177 "may be more densely spaced, or the proximal ends that are closer to the long side 1177" may be more densely spaced. In further arrangements, the welds 1192 "may be more densely spaced in the central region of the long side 1177" of the anvil cap 1170 ".

Fig. 33 illustrates another anvil cap 1170 '"that is configured to mechanically interlock with the anvil body 1132'" and to be welded to the upper body portion 1165. In this embodiment, a tongue-in groove arrangement is employed along each long side 1177 '"of the anvil cap 1170'". In particular, laterally extending continuous or intermittent tabs 1195 ' "protrude from each long side 1177 '" of the anvil cap 1170 ' ". Each tab 1195 "corresponds to an axial slot 1197 '" formed in the anvil body 1132' ". The anvil cap 1170 ' "is slid in from an opening in the distal end of the anvil body 1132 '" to "mechanically" attach the anvil cap to the anvil body 1132 ' ". The tab 1195 '"and slot 1197'" can be sized relative to each other to establish a sliding friction fit therebetween. In addition, the anvil cap 1170 '"can be welded to the anvil body 1132'". The anvil body 1132 '"and anvil cap 1170'" can be made of a metal that facilitates welding. The weld 1178 ' "may extend around the entire perimeter 1172 '" of the anvil cap 1170 ' ", or it may be located only along the long side 1177 '" of the anvil cap 1170 ' ". The weld 1178' "may be continuous or it may be discontinuous or intermittent. In those embodiments in which the weld 1178 ' "is discontinuous or intermittent, the weld segments may be evenly distributed along the long side 1177 '" of the anvil cap 1170 ' ", or the weld segments may be more densely spaced closer to the distal end of the long side 1177 '", or more densely spaced closer to the proximal end of the long side 1177 ' ". In further arrangements, the welded sections may be more densely spaced in a central region of the long side 1177 '"of the anvil cap 1170'".

The anvil embodiments with anvil caps described herein may provide several advantages. For example, one advantage may make the anvil and firing member assembly process easier. That is, when the anvil is attached to the elongate channel, the firing member may be installed through an opening in the anvil body. Another advantage is that the upper cover may improve the stiffness of the anvil and its resistance to the bending forces that may be encountered when clamping tissue. By resisting such bending, the friction normally encountered by the firing member 1660 may be reduced. Thus, the amount of firing force required to drive the firing member from its starting position to its ending position in the surgical staple cartridge may also be reduced.

FIG. 34 provides a side-by-side comparison of two anvils. A portion of a first anvil 2030 of the end effector 2000 is depicted in the right half of fig. 34, and a portion of a second anvil 2030 'of the end effector 2000' is depicted in the left half of fig. 34. The anvil 2030 includes a first longitudinal row of forming pockets 2032a, a second longitudinal row of forming pockets 2032b, and a third longitudinal row of forming pockets 2032c. The anvil 2030 further includes a longitudinal slot 2033 configured to receive a firing member, such as the firing member 2040, for example, as the firing member is advanced through a staple firing stroke. The first longitudinal row of forming pockets 2032a is positioned intermediate the longitudinal slot 2033 and the second longitudinal row of forming pockets 2032b, and the second longitudinal row of forming pockets 2032b is positioned intermediate the first longitudinal row of forming pockets 2032a and the third longitudinal row of forming pockets 2032c. Thus, the first longitudinal row of forming pockets 2032a includes an inner row, the third longitudinal row of forming pockets 2032c includes an outer row, and the second longitudinal row of forming pockets 2032b includes a middle row.

Similar to the above, the anvil 2030' includes a first longitudinal row of forming pockets 2032a, a second longitudinal row of forming pockets 2032b, and a third longitudinal row of forming pockets 2032c. The anvil 2030' further includes a longitudinal slot 2033' configured to receive a firing member, such as firing member 2040', for example, as the firing member is advanced through a staple firing stroke. The first longitudinal row of forming pockets 2032a is positioned intermediate the longitudinal slot 2033' and the second longitudinal row of forming pockets 2032b, and the second longitudinal row of forming pockets 2032b is positioned intermediate the first longitudinal row of forming pockets 2032a and the third longitudinal row of forming pockets 2032c. Thus, the first longitudinal row of forming pockets 2032a includes an inner row, the third longitudinal row of forming pockets 2032c includes an outer row, and the second longitudinal row of forming pockets 2032b includes a middle row.

The anvil 2030 includes a flat or at least substantially flat tissue-engaging surface 2031. Forming

pockets

2032a, 2032b, and 2032c are defined in a planar surface 2031. The flat surface 2031 has no steps defined therein; however, embodiments are contemplated in which the anvil 2030 may include a stepped tissue engagement surface. For example, the anvil 2030 'includes a stepped tissue engagement surface 2031'. In this embodiment, forming pockets 2032a and 2032b are defined in a lower step, and forming pocket 2032c is defined in an upper step.

The firing member 2040 'includes a coupling member 2042' that includes a cutting portion 2041. Cutting portion 2041 is configured and arranged to cut into tissue captured between anvil 2030' and staple cartridge 2010 (fig. 35), for example. The firing member 2040' is configured to push a sled having an angled surface distally during a staple firing stroke. The sloped surface is configured to lift a staple driver within staple cartridge 2010 to form staples 2020 against anvil 2030' and eject staples 2020 from staple cartridge 2010. The coupling member 2042' includes a protrusion or cam 2043' extending laterally therefrom that is configured to engage the anvil 2030' during a staple firing stroke. Referring to fig. 37, the projection 2043 'is comprised of a longitudinally elongated shoulder extending from the coupling member 2042'. In other embodiments, the protrusion 2043 'comprises a barrel pin extending through the coupling member 2042'. In any event, the projection 2043 'has a flat side or end 2047'.

The longitudinal slot 2033 'includes a lateral portion 2033l' extending laterally from the central portion 2033c 'and configured to receive the protrusion 2043'. As shown in fig. 34, the lateral portion 2033l 'of the longitudinal slot 2033' has a rectangular or at least substantially rectangular configuration with sharp corners. Each lateral portion 2033l 'of the slot 2033' includes a longitudinal cam surface 2035 'configured to engage with the protrusion 2043' during a staple firing stroke. Each longitudinal cam surface 2035' is defined on an upper side of a tab 2037' that extends longitudinally along the slot 2033 '. Each longitudinal protrusion 2037 'includes a beam including a fixed end attached to the body portion of the anvil 2030' and a free end configured to be movable relative to the fixed end. Thus, each longitudinal protrusion 2037' may include a cantilever beam.

The coupling member 2042' also includes a foot or cam 2044 (fig. 35) configured to engage the staple cartridge 2010 or to support the jaws of the staple cartridge 2010 during a staple firing stroke. Further, the projections 2043 'and the feet 2044 cooperate to position the anvil 2030' and the staple cartridge 2010 relative to one another. When the anvil 2030' is movable relative to the staple cartridge 2010, the coupling member 2042' can cam the anvil 2030' into position relative to the staple cartridge 2010. When the staple cartridge 2010 or the jaws supporting the staple cartridge 2010 are movable relative to the anvil 2030', the coupling member 2042' can cam the staple cartridge 2010 in place relative to the anvil 2030 '.

In addition to the above, the firing member 2040 includes a coupling member 2042 that includes a cutting portion 2041. Cutting portion 2041 is configured and arranged to cut into tissue captured between anvil 2030 and staple cartridge 2010 (fig. 35). The firing member 2040 is configured to push a sled having an inclined surface distally during a staple firing stroke. The sloped surface is configured to lift a staple driver within staple cartridge 2010 to form staples 2020 against anvil 2030 and eject staples 2020 from staple cartridge 2010. The coupling member 2042 includes a protrusion or cam 2043 extending laterally therefrom that is configured to engage the anvil 2030 during a staple firing stroke. The projection 2043 has curved or rounded sides or ends 2047. The lateral ends 2047 of the protruding portion 2043 are completely bent or completely rounded. Each lateral end 2047 includes an arcuate profile extending between a top surface of the protrusion 2043 and a bottom surface of the protrusion 2043. In other embodiments, the lateral ends 2047 of the projections 2043 are only partially curved.

The longitudinal slot 2033 includes a lateral portion 2033l extending laterally from the central portion 2033c, the lateral portion being configured to receive the protrusion 2043. Each lateral portion 2033l of the slot 2033 includes a longitudinal cam surface 2035 configured to engage with the protrusion 2043 during a staple firing stroke. Each longitudinal cam surface 2035 is defined on an upper side of a tab 2037 that extends longitudinally along the slot 2033. Each longitudinal boss 2037 includes a beam including a fixed end attached to a body portion of the anvil 2030 and a free end configured to be movable relative to the fixed end. Thus, each longitudinal protrusion 2037 may include a cantilever beam. As shown in fig. 34, the lateral portion of the longitudinal slot 2033 includes a curved or rounded profile that matches or at least substantially matches the curved end 2047 of the protrusion 2043.

The coupling member 2042 also includes a foot or cam 2044 (fig. 35) that is configured to engage the staple cartridge 2010 or to support the jaws of the staple cartridge 2010 during a staple firing stroke. Further, the projections 2043 and feet 2044 cooperate to position the anvil 2030 and staple cartridge 2010 relative to one another. When the anvil 2030 is movable relative to the staple cartridge 2010, the coupling member 2042 can cam the anvil 2030 into position relative to the staple cartridge 2010. As the staple cartridge 2010 or the jaws supporting the staple cartridge 2010 are movable relative to the anvil 2030, the coupling member 2042 can cam the staple cartridge 2010 into position relative to the anvil 2030.

Referring again to fig. 34, a lateral portion 2033l 'of the longitudinal slot 2033' extends a distance 2034 'from a centerline CL of the anvil 2030'. The lateral portion 2033l 'extends above or behind the forming pocket 2032a in the anvil 2030'. As shown in fig. 34, the lateral ends of the lateral portions 2033l' are aligned with the outer edges of the forming pockets 2032 a. Other embodiments are contemplated in which, for example, the lateral portion 2033l' extends laterally beyond the forming pocket 2032 a. That is, referring to fig. 36, the boss 2037' of the anvil 2030' is long and, in some cases, the boss 2037' may deflect significantly under load. In some cases, the boss 2037 'may deflect downward such that a majority of the drive surface 2045' defined on the bottom of the protrusion 2043 'is not in contact with the cam surface 2035'. In this case, the contact between the protrusion 2043' and the cam surface 2035' may be reduced to one point, such as point 2047'. In some cases, the contact between the protrusion 2043 'and the cam surface 2035' may be reduced to a longitudinally extending line that may appear to be a point when viewed from the distal end of the end effector, as shown in fig. 36.

Further, referring again to fig. 34, the projections 2043 'extend over or behind the forming pockets 2032a in the anvil 2030'. The lateral ends of the projections 2043' extend above the longitudinal centerline 2062a of the forming pocket 2032 a. Other embodiments are contemplated in which the lateral ends of the projections 2043' are aligned with the longitudinal centerline 2062a of the forming pocket 2032 a. Certain embodiments are contemplated in which the lateral ends of the projections 2043' do not extend to the longitudinal centerline 2062a of the forming pocket 2032 a. In any event, referring again to fig. 36, the protrusion 2043' may deflect upward (especially when the protrusion 2043' is longer) such that a majority of the drive surface 2045' of the protrusion 2043' is not in contact with the cam surface 2035 '. This situation may further exacerbate the situation discussed above in connection with protrusion 2037'. That is, for example, when the protrusion 2043 'extends to or beyond the outer edge of the forming pocket 2032a, the protrusion 2043' can better control the staple forming process that occurs in the forming pocket 2032a and/or the forming

pockets

2032b and 2032 c.

In addition to the above, the boss 2037' and the protrusion 2043' may deflect in a manner such that a load flowing between the firing member 2040' and the anvil 2030' is applied at the inner end of the boss 2037 '. As shown in fig. 36, contact point 2048 'is positioned at or near the inner end of boss 2037'. The deflection of the boss 2037 'and the protrusion 2043' is the same as or similar to the deflection of the cantilever beam. As the reader will appreciate, when a load is applied at the end of the cantilever beam, the deflection of the cantilever beam is proportional to the cube of the beam length. In any event, when the boss 2037 'and/or the protrusion 2043' deflect, a gap may be formed between the boss 2037 'and the protrusion 2043'. This gap between the protrusion 2037 'and the portion of the protrusion 2043' means that the force flowing between them will flow through a very small area, which will thereby increase the stress and strain experienced by the protrusion 2037 'and the protrusion 2043'. This interaction is represented by stress risers or stress risers 2039' and 2049' in fig. 38 and 39, where stress riser 2039' is present in boss 2037' and stress riser 2049' is present at the interconnection between protrusion 2043' and coupling member 2042 '. Other stress risers or concentrators may be present, but as discussed below, it is desirable to reduce or eliminate such stress risers.

Referring again to fig. 34 and 35, lateral portions 2033l of longitudinal slot 2033 each extend a distance 2034 from a centerline CL of anvil 2030. Distance 2034 is shorter than distance 2034'. Nonetheless, the lateral portion 2033l extends above or behind the forming pocket 2032a in the anvil 2030. As shown in fig. 34, the lateral ends of the lateral portions 2033l are not aligned with the outer edges of the forming pockets 2032 a. Further, the lateral ends of the lateral portions 2033l do not extend beyond the outer edges of the forming pockets 2032 a. However, the lateral portion 2033l extends above the longitudinal centerline 2062a of the forming pocket 2032 a. In addition to the above, the protrusion 2037 is shorter than the protrusion 2037'. Thus, for a given force applied thereto, the protrusion 2037 will experience less deflection, stress, and strain than the protrusion 2037'.

Other embodiments are contemplated in which the lateral portions 2033l of the slot 2033 do not extend to the longitudinal centerline 2062a of the forming pocket 2032 a. In certain embodiments, the lateral portion 2033l does not extend laterally over or overlap the forming pocket 2032 a. In addition to the above, such shorter lateral portions 2033l may reduce deflection, stress, and strain in the protrusion 2037. Due to the reduced deflection of the boss 2037, the drive surface 2045 defined on the bottom of the protrusion 2043 may remain in contact with the cam surface 2035 of the boss 2037. In this case, the contact area between the protrusion 2043 and the cam surface 2035 may be increased as compared to the contact area between the protrusion 2043 'and the cam surface 2035'.

In addition to the above, unlike the protrusion 2037' having a constant cross-sectional thickness, the cross-sectional thickness of the protrusion 2037 is not constant. The protrusions 2037 have a gradually decreasing cross-sectional thickness, wherein the base of each protrusion 2037 is wider than its inner end due to the rounded lateral ends of the lateral slot portions 2033 l. Such a configuration may be used to strengthen or stiffen the protrusion 2037 and reduce deflection, stress, and strain of the protrusion 2037 as compared to the protrusion 2037'. In at least one instance, a portion of the protrusion 2037 is tapered, while another portion of the protrusion 2037 has a constant cross-sectional thickness. In at least one other instance, the entire protrusion 2037 may be tapered such that the cross-sectional thickness is constant everywhere.

Further, referring again to fig. 34 and 35, the projections 2043 extend over or behind the forming pockets 2032a in the anvil 2030. The lateral ends of the projections 2043 do not extend above the longitudinal centerline 2062a of the forming pocket 2032 a. Other embodiments are contemplated in which the lateral ends of the projections 2043 are aligned with the longitudinal centerline 2062a of the forming pocket 2032 a. Certain embodiments are contemplated in which the lateral ends of the projections 2043 do not extend above the forming pockets 2032a at all. In any event, the upward deflection of the projection 2043 may be less than the deflection of the projection 2043', and thus, there may be a greater contact area between the drive surface 2045 and the cam surface 2035.

In addition to the above, the boss 2037 and the protrusion 2043 may deflect in a manner such that a load flowing between the firing member 2040 and the anvil 2030 is applied laterally along the length of the boss 2037 rather than at a single point and/or at the end of the boss 2037. Thus, the forces flowing therebetween will flow through a larger area, which in turn will reduce the stress and strain experienced by the protrusion 2037 and the protrusion 2043, which in turn may reduce or eliminate stress risers such as discussed above in connection with the protrusion 2037 'and the protrusion 2043'.

Referring again to fig. 35, the feet 2044 of the coupling member 2042 are wider than the projections 2033. In other words, the lateral width of the foot 2044 is wider than the width between the lateral ends of the tab 2033. In this case, the foot 2044 may deflect or strain more than the tab, so that deflection of the tab 2033 may be reduced. Alternative embodiments are contemplated in which the lateral width of foot 2044 is equal to or less than the width between the lateral ends of tab 2033; however, these embodiments may be otherwise configured to provide the desired deflection and/or strain within the protrusion 2033.

As described above, the end effector may include, for example, an anvil that is movable between an open position and a closed position. In some instances, for example, when a firing member, such as firing member 2040 or 2040', is moved distally, the firing member moves the anvil toward its closed position. In other cases, the anvil is moved toward its closed position prior to distally advancing the firing member to perform a staple firing stroke. In any event, the anvil may not move to its fully closed position until the firing member approaches or reaches the end of its staple firing stroke. Thus, the anvil is progressively closed by the firing member. In at least one such instance, the anvil can progressively close due to thicker tissue captured between the anvil and the staple cartridge. In some instances, the anvil may actually deflect or deform during the staple firing stroke of the firing member. However, this condition is typically controlled by the upper tab and foot of the firing member.

Turning now to fig. 37, the drive surface 2045 'defined on the tab 2043' is planar or at least substantially planar. Further, the drive surface 2045 'is configured to snappingly engage a flat or at least substantially flat cam surface 2035' defined on the anvil 2030 'when the anvil 2030' is in the fully closed position. In other words, when the anvil 2030' is in a fully flat orientation, the drive surface 2045' engages the cam surface 2035' in face-to-face relationship. The flat orientation of the anvil 2030' is depicted in dashed lines in fig. 37. In this case, during a staple firing stroke, the drive surface 2045 'is parallel, or at least substantially parallel, to the longitudinal path of the firing member 2040'. However, as described above, the anvil 2030 'may be progressively closed during the firing stroke, and thus, the anvil 2030' may not always be in the fully closed position. Thus, the drive surface 2045 'may not always be aligned with the cam surface 2035', and in such a case, the protrusion 2043 'may dig into the boss 2037' of the anvil 2030. Fig. 37 depicts such an example in solid lines.

In addition to the above, if the firing member 2040 'must progressively close the anvil 2030' to its fully closed position, the drive surface 2045 'of the tab 2043' and/or the cam surface 2035 'defined on the boss 2037' may be plastically deformed. In some instances, the cam surface 2035' may wear, for example, which may increase the force required to complete the staple firing stroke. More specifically, when the metal deformation exceeds the plastic limit, plastic strain of the protrusions 2043 'and/or anvil projections 2037' may cause energy loss. At this time, abrasion occurs, and the friction coefficient of the coupling increases significantly. For example, the energy loss may be about 10% to 30%, which may increase the force required to fire the firing member by about 10% to 30%. Further, in this case, if the end effector 2000 'is reused, the force required to complete a subsequent staple firing stroke with the end effector 2000' may increase.

Turning now to fig. 40-42, the firing member 2140 includes a firing bar and a coupling member 2142 attached to the firing bar. The coupling member 2142 includes a connector 2148 that connects the coupling member 2142 to a firing rod. The coupling member 2142 also includes a cutting member 2041 configured to cut into tissue of a patient during a staple firing stroke. The coupling member 2142 further includes: a protrusion 2143 configured to engage an anvil, such as

anvil

2030 or 2030'; and a foot 2144 configured to engage the cartridge jaw during a staple firing stroke. Each protrusion 2143 includes a drive surface 2145 defined on a bottom side thereof. Each protrusion 2143 also includes a proximally extending cam transition 2147 and a rounded transition 2149 extending around the perimeter of the protrusion 2143. The coupling member 2142 also includes a medial protrusion 2146 extending laterally therefrom that is configured to prevent the firing member 2140 from performing a staple firing stroke when an unused staple cartridge is not positioned forward of the firing member 2140 at the beginning of a staple firing stroke.

In addition to the above, the drive surface 2145 of the protrusion 2143 is not parallel to the longitudinal path 2160 of the firing member 2140. Instead, the drive surface 2145 extends transverse to the longitudinal path 2160. In at least one instance, the distal end of each drive surface 2145 is positioned farther from the longitudinal path 2160 than the proximal end. Such an arrangement may reduce or eliminate the problems described above in connection with progressive closure of the anvil 2130. More specifically, in at least one instance, if the anvil 2130 is moved through a range of motion at an angle of between about 4 degrees and about 0 degrees relative to the longitudinal path 2160 during progressive closure, the drive surface 2145 may be oriented, for example, at about 2 degrees relative to the longitudinal path 2160, which represents a midpoint of the progressive closure range. Other embodiments are also possible. For example, if the anvil 2130 is moved through a range of motion at an angle of between about 1 degree to about 0 degrees relative to the longitudinal path 2160 during progressive closure, the drive surface 2145 may be oriented at about 1 degree, for example, relative to the longitudinal path 2160, which represents an upper end of the progressive closure range. In various circumstances, for example, the firing member 2140 may be required to progressively close the anvil 2130 through a range of motion of 5 degrees. In other instances, for example, the firing member 2140 may be required to progressively close the anvil 2130 through a 10 degree range of motion. In some cases, the anvil 2130 may not reach its fully closed position, and thus, the progressive closure of the anvil 2130 may not reach 0 degrees.

In addition to the above, drive surface 2145 of protrusion 2143 is not parallel to the drive surface of foot 2144. Referring primarily to fig. 41, drive surface 2145 extends along axis 2183 and the drive surface of foot 2144 extends along axis 2184. In at least one instance, for example, drive surface 2145 is oriented at an angle of about 0.5 degrees relative to the drive surface of foot 2144. Examples are contemplated in which, for example, drive surface 2145 is oriented at an angle of about 1 degree relative to the drive surface of foot 2144. Certain examples are contemplated in which, for example, drive surface 2145 is oriented at an angle between about 0.5 degrees and about 5 degrees relative to a drive surface of foot 2144. The drive surface of foot 2144 is parallel to longitudinal path 2160; however, other embodiments are also contemplated in which the drive surface of foot 2144 is not parallel to longitudinal path 2160.

The examples provided above were discussed in connection with a movable anvil; however, it should be understood that the teachings of these examples can be applied to any suitable movable jaw, such as a movable staple cartridge jaw. Similarly, examples provided elsewhere in this application may be applicable to any movable jaw.

Turning now to fig. 43-45, the firing member 2240 includes a firing bar and a coupling member 2242 attached to the firing bar. The link member 2242 includes a connector 2148 that connects the link member 2242 to a firing bar. The coupling member 2242 also includes a cutting member 2041 configured to cut into the patient's tissue during the staple firing stroke. The link member 2242 further includes: a tab 2243 configured to engage an anvil, such as

anvil

2030 or 2030'; and a foot 2144 configured to engage the cartridge jaw during a staple firing stroke. Each tab 2243 includes a drive surface 2245 defined on its bottom side. Each tab 2243 also includes a rounded transition 2249 extending around its perimeter. The coupling member 2242 also includes a middle tab 2146 extending laterally therefrom that is configured to prevent the firing member 2240 from performing a staple firing stroke when an unused staple cartridge is not positioned in front of the firing member 2240 at the beginning of the staple firing stroke.

In addition to the above, each tab 2243 includes a front or proximal end 2251 configured to engage an anvil, and a rear end. The front end of each tab 2243 is different from the rear or trailing end of the tab 2243. The front end 2251 includes a radius extending from the bottom drive surface 2245 of the tab 2243 to a location positioned above the longitudinal centerline 2250 of the tab 2243. The front end 2251 includes a single radius of curvature; however, the front end 2251 may include more than one radius of curvature. Each of the protrusions 2243 also includes a rounded edge 2259 between the rounded front end 2251 and the top surface of the protrusion 2243. The radius of curvature of the edge 2259 is smaller than the radius of curvature of the front end 2251. Other embodiments are also contemplated in which the entire front end 2251, or at least a portion thereof, is linear. In any event, the configuration of the front end 2251 may offset the force or load transferred between the firing member 2240 and the anvil away from the front end 2251 toward the rear end of the tab 2243. In other words, the configuration of the front end 2251 may prevent the front end 2251 from being the focal point of the force transferred between the firing member 2240 and the anvil. Such an arrangement may prevent or reduce the likelihood that the firing member 2240 will bind the anvil and may reduce the force required to move the firing member 2240 distally.

Turning now to fig. 46-48, the firing member 2340 includes a firing bar and a coupling member 2342 attached to the firing bar. The coupling member 2342 includes a connector 2148 that connects the coupling member 2342 to the firing rod. The coupling member 2342 also includes a cutting member 2041 configured to cut into the patient's tissue during a staple firing stroke. The coupling member 2342 further includes: a tab 2343 configured to engage an anvil, such as

anvil

2030 or 2030'; and a foot 2144 configured to engage the cartridge jaw during a staple firing stroke. Each tab 2343 includes a drive surface defined on a bottom side thereof. Each tab 2343 also includes a rounded transition 2349 extending around its perimeter. The coupling member 2342 also includes a medial projection 2146 extending laterally therefrom that is configured to prevent the firing member 2340 from performing a staple firing stroke when an unused staple cartridge is not positioned in front of the firing member 2340 at the beginning of the staple firing stroke.

In addition to the above, each tab 2343 includes a rounded front end 2351. The front end 2351 is similar to the front end 2251 and includes a curved surface that extends across a centerline 2350 of the protrusion 2343. The front end 2251 has a different configuration than the rear end of the tab 2243. Each tab 2343 also includes a lateral or lateral end 2352. Each lateral end 2352 includes a planar surface positioned intermediate the rounded or curved edges 2347. The first rounded edge 2347 is positioned intermediate the top surface of the protrusion 2343 and the lateral end 2352, and in addition, the second rounded edge 2347 is positioned intermediate the bottom surface of the protrusion 2343 and the lateral end 2352.

Turning now to fig. 49-51, the firing member 2440 includes a firing bar and a coupling member 2442 attached to the firing bar. The coupling member 2442 includes a connector 2148 that connects the coupling member 2442 to a firing rod. The coupling member 2442 further includes a cutting member 2041 configured to cut into the tissue of the patient during the staple firing stroke. The coupling member 2442 further includes: a protrusion 2443 configured to engage an anvil, such as

anvil

2030 or 2030'; and a foot 2144 configured to engage the cartridge jaw during a staple firing stroke. Each tab 2443 includes a drive surface 2445 defined on a bottom side thereof. Each tab 2443 also includes a rounded transition extending around its perimeter. The coupling member 2442 further includes a medial projection 2146 extending laterally therefrom that is configured to prevent the firing member 2440 from performing a staple firing stroke when an unused staple cartridge is not positioned forward of the firing member 2440 at the beginning of the staple firing stroke.

In addition to the above, the lateral or lateral ends of each projection 2443 are defined by more than one radius of curvature. Each protrusion 2443 includes a first radius of curvature 2447a extending from the bottom drive surface 2445 and a second radius of curvature 2447b extending from the top surface of the protrusion 2443. First radius of curvature 2447a is different from second radius of curvature 2447b. For example, first radius of curvature 2447a is greater than second radius of curvature 2447b. However,

curvatures

2447a and 2447b may comprise any suitable configuration. Referring primarily to fig. 51, a first radius of curvature 2447a extends upwardly through a centerline 2450 of the protrusion 2443.

Turning now to fig. 52-54, the firing member 2540 includes a firing bar and a coupling member 2542 attached to the firing bar. The coupling member 2542 includes a connector 2148 that connects the coupling member 2542 to a firing rod. The coupling member 2542 also includes a cutting member 2041 that is configured to cut into the patient's tissue during a staple firing stroke. The coupling member 2542 further includes: a protrusion 2543 configured to engage an anvil, such as

anvil

2030 or 2030'; and a foot 2144 configured to engage the cartridge jaw during a staple firing stroke. Each protrusion 2543 includes a drive surface defined on a bottom side thereof. Each protrusion 2543 also includes a rounded transition extending around its perimeter. The coupling member 2542 further includes a medial projection 2146 extending laterally therefrom that is configured to prevent the firing member 2540 from performing a staple firing stroke when an unused staple cartridge is not positioned forward of the firing member 2540 at the beginning of the staple firing stroke.

In addition to the above, each protrusion 2543 includes a side or lateral end 2552 that is planar or at least substantially planar. Each protrusion 2543 also includes a rounded transition 2547 extending around the lateral end 2552. Each protrusion 2543 is symmetrical or at least substantially symmetrical about a longitudinal centerline extending through lateral end 2552. Further, the top and bottom surfaces of each protrusion 2543 are parallel to each other.

Referring primarily to fig. 53, the front end 2551 of each protrusion 2543 is positioned distally relative to the cutting edge 2042 of the cutting portion 2041. The trailing end 2559 of each protrusion 2543 is positioned proximally relative to the cutting edge 2042. Thus, the protrusion 2043 longitudinally spans the cutting edge 2042. In this case, the firing member 2540 can hold the anvil and staple cartridge together directly in the position where the tissue is cut.

Turning now to fig. 55-57, the firing member 2640 includes a firing bar and a coupling member 2642 attached to the firing bar. The coupling member 2642 includes a connector 2148 that connects the coupling member 2642 to the firing rod. The coupling member 2642 also includes a cutting member 2041 configured to cut into the patient's tissue during a staple firing stroke. The coupling member 2642 further includes: a projection 2643 configured to engage an anvil such as

anvil

2030 or 2030'; and a foot 2144 configured to engage the cartridge jaw during a staple firing stroke. Each projection 2643 includes a drive surface 2645 defined on a bottom side thereof. Each projection 2643 further includes a rounded transition 2649 extending around its perimeter. The coupling member 2642 further includes a medial projection 2146 extending laterally therefrom that is configured to prevent the firing member 2640 from performing a staple firing stroke when an unused staple cartridge is not positioned forward of the firing member 2640 at the beginning of the staple firing stroke.

In addition to the above, each projection 2643 includes a lateral end 2652, a bottom drive surface 2645, and a top surface 2647. The bottom drive surface 2645 is planar and parallel to the longitudinal firing path 2660 of the firing member 2640. Referring primarily to fig. 57, the top surface 2647 is flat but not parallel to the longitudinal firing path 2660. In addition, top surface 2647 is not parallel to bottom surface 2645. Thus, each projection 2643 is asymmetric. In effect, the orientation of the top surface 2647 shifts the moment of inertia of the projection 2643 above the lateral end 2652. This arrangement can increase the bending stiffness of the projection 2643, so that deflection of the projection 2643 can be reduced.

Turning now to fig. 58-60, the firing member 2740 includes a firing bar and a coupling member 2742 attached to the firing bar. The coupling member 2742 includes a connector 2148 that connects the coupling member 2742 to the firing rod. The coupling member 2742 also includes a cutting member 2041 configured to cut into the patient's tissue during a staple firing stroke. The coupling member 2742 further includes: a tab 2743 configured to engage an anvil, such as

anvil

2030 or 2030'; and a foot 2144 configured to engage the cartridge jaw during a staple firing stroke. Each tab 2743 includes a drive surface defined on a bottom side thereof. Coupling member 2742 also includes a medial projection 2146 extending laterally therefrom that is configured to prevent firing member 2740 from performing a staple firing stroke when an unused staple cartridge is not positioned in front of firing member 2740 at the beginning of the staple firing stroke.

In addition to the above, each tab 2743 includes a first portion or front 2753a and a second portion or rear 2753b positioned distally rearward of front 2753 a. The front portion 2753a includes a curved lead-in surface 2751 defined on a distal end thereof that is configured to initially engage the anvil. The front portion 2753a also includes a first or front drive surface 2745a defined on a bottom side thereof. Similarly, the rear portion 2753b includes a second or rear drive surface 2745b defined on a bottom side thereof. Each tab 2743 also includes a transition 2752 defined between the front 2753a and the rear 2753b.

As firing member 2740 advances distally, drive

surfaces

2745a and 2745b can cooperate to engage and position the anvil in addition to those described above. In certain embodiments, during a staple firing stroke,

drive surfaces

2745a and 2745b define a drive plane that is parallel, or at least substantially parallel, to longitudinal path 2760 of firing member 2740. However, in some cases, only the front drive surface 2745a may engage a cam surface defined on the anvil. This may occur, for example, when firing member 2740 progressively closes the anvil.

In other embodiments, referring to fig. 69 and 71, the front drive surface 2745a is positioned above the rear drive surface 2745b. In other words, the front drive surface 2745a is positioned farther from the longitudinal path 2760 than the rear drive surface 2745b such that both drive

surfaces

2745a and 2745b remain in contact with the anvil during the staple firing stroke. In at least one instance, the drive surfaces 2745a and 2745b can define a drive plane that is transverse to the longitudinal path 2760. In some cases, an angle of, for example, 1 degree may be defined between the drive plane and the longitudinal path 2760. In various cases, the front drive surface 2745a is positioned vertically above the rear drive surface 2745b by a distance of, for example, approximately 0.001 ". In other embodiments, the front drive surface 2745a is positioned vertically above the rear drive surface 2745b by a distance of, for example, about 0.002 ". In some cases, the front drive surface 2745a is positioned above the rear drive surface 2745b at a distance of between about 0.001 "to about 0.002".

In some instances, referring again to fig. 70, as the firing member 2740 progressively closes the anvil, only the rear drive surface 2745b may be in contact with the cam surface of the anvil. In this case, the front drive surface 2745a is not in contact with the cam surface of the anvil. This arrangement may reduce plastic deformation of the protrusion 2743 and may reduce the force required to advance the firing member 2740 distally compared to when only the front drive surface 2745a is in contact with the cam surface of the anvil. When the anvil begins to bend due to the staple forming load applied to the anvil, in some cases, the anvil may bend upward to contact the front drive surface 2745a, as shown in fig. 71.

Front portion 2753a is thicker than rear portion 2753 b. In other words, the front portion 2753a has a greater bending moment of inertia than the rear portion 2753b, which can resist upward bending of the protruding portion 2743. Thus, the rear portion 2753b may deflect upward more than the front portion 2753 a. In this case, even though firing member 2740 is used to progressively close the anvil, the two

portions

2753a and 2753b of tab 2743 are more likely to remain in contact with the anvil during the staple firing stroke. In addition, the front portion 2753a also has a greater shear thickness than the rear portion 2753b, which may better resist shear forces transmitted through the protrusions 2743. The front portion 2753a tends to be exposed to greater shear forces than the rear portion 2753b, and thus may benefit from increased shear thickness. If it is believed that the rear portion 2753b may experience greater shear force than the front protruding portion 2753a, for example, the rear portion 2753b may have a greater shear thickness than the front portion 2753 a.

Turning now to fig. 61-63, the firing member 2840 includes a firing bar and a coupling member 2842 attached to the firing bar. The coupling member 2842 includes a connector 2148 that connects the coupling member 2842 to the firing rod. The coupling member 2842 also includes a cutting member 2041 configured to cut into the patient's tissue during a staple firing stroke. The coupling member 2842 further includes: a protrusion configured to engage an anvil, such as

anvil

2030 or 2030'; and a foot 2144 configured to engage the cartridge jaw during a staple firing stroke. As described in more detail below, each projection includes a drive surface defined on a bottom side thereof. The coupling member 2842 also includes a medial projection 2146 extending laterally therefrom that is configured to prevent the firing member 2840 from performing a staple firing stroke when an unused staple cartridge is not positioned forward of the firing member 2840 at the beginning of the staple firing stroke.

In addition to the above, each side of the coupling member includes a first or front tab 2843d and a second or rear tab 2843p positioned rearward of the front tab 2843 d. The front tab 2843d includes a curved lead-in surface 2851d defined on its distal end, which is configured to initially engage the anvil. The front tab 2843d also includes a first or front drive surface 2845d defined on a bottom side thereof. Similarly, the rear tab 2843p includes a curved lead-in surface 2851p defined on a distal end thereof, the lead-in surface configured to engage the anvil. The rear projection 2843p also includes a second or rear drive surface 2845p defined on a bottom side thereof.

As the firing member 2840 advances distally, the drive surfaces 2845d and 2845p may cooperate to engage and position the anvil in addition to those described above. In certain embodiments, during a staple firing stroke, the drive surfaces 2845d and 2845p define a drive plane that is parallel, or at least substantially parallel, to the longitudinal path 2860 of the firing member 2840. In other embodiments, the front drive surface 2845d is positioned above the rear drive surface 2845 p. In other words, the front drive surface 2845d is positioned farther from the longitudinal path 2860 than the rear drive surface 2845 p. In at least one instance, the drive surfaces 2845d and 2845p can define a drive plane transverse to the longitudinal path 2860. In some cases, an angle of, for example, 1 degree may be defined between the drive plane and the longitudinal path 2860.

In addition to the above, the front and

rear protrusions

2843d and 2843p may move relative to each other. In various cases, the front projection 2843d and the rear projection 2843p on one side of the coupling member 2842 may move independently of each other. This arrangement may allow the

protrusions

2843d and 2843p to independently accommodate the orientation of the anvil, particularly when the firing member 2840 is used to progressively close the anvil. Thus, both the

protrusions

2843d and 2843p can remain engaged with the anvil such that force flows between the firing member 2840 and the anvil at multiple locations and such that plastic deformation of the protrusions is reduced.

FIG. 68 depicts the energy required for the first firing member to complete the firing stroke, labeled 2090', and the energy required for the second firing member to complete the firing stroke, labeled 3090. The firing stroke 2090' represents a condition in which significant plastic deformation and wear occurs. Firing stroke 3090 represents an improvement over firing stroke 2090', wherein the deformation of the firing member and anvil tab is largely elastic. It is believed that in certain instances, for example, by employing the teachings disclosed herein, the plastic strain experienced by the firing member and/or anvil may be reduced by about 40% to 60%.

Various embodiments described herein may be used to balance the load transferred between the firing member and the anvil. These embodiments may also be used to balance the load transferred between the firing member and the cartridge jaw. In any event, the firing member may be designed to provide the desired result, but it should be appreciated that such desired result may not be achieved in some cases due to, for example, manufacturing tolerances of the stapling instrument and/or variability in the thickness of tissue captured within the end effector. In at least one instance, the upper protrusion and/or foot of the firing member can, for example, comprise a wearable feature configured to allow the firing member to define a balanced connection with the anvil.

In addition to the above, referring now to fig. 64-67, the firing member 2940 includes a lateral protrusion 2943. Each projection 2943 includes a longitudinal ridge 2945 extending from a bottom thereof. The spine 2945 is configured to plastically deform and/or smear as the firing member 2940 is advanced distally to engage the anvil. The ridge 2945 is configured to quickly break in or establish an over-bent position to increase the contact area between the protrusion 2943 and the anvil and provide better load balancing between the firing member 2940 and the anvil. This arrangement may be particularly useful when the end effector is used to perform several staple firing strokes. In addition to or in lieu of the above, one or more wearable pads can be attached to a protrusion of a firing member that can be configured to be plastically deformed.

Fig. 72 and 73 depict a surgical stapling anvil or anvil jaw 3100 for use with a surgical stapling instrument. The anvil 3100 is configured to deform staples during a surgical stapling procedure. Anvil 3100 includes an anvil body 3101 and anvil cap 3110. Anvil body 3101 and anvil cap 3110 are welded together. The anvil body 3101 includes a proximal portion 3102 that includes a coupling portion 3103. The coupling portion 3103 is configured to be assembled to an end effector of a surgical stapling instrument to allow the anvil jaw 3000 to rotate relative to a corresponding jaw (e.g., a staple cartridge jaw). Embodiments are contemplated in which the anvil jaw is fixed relative to the cartridge jaw, and in such cases, the cartridge jaw can rotate relative to the anvil jaw. Anvil body 3101 further includes a distal tip portion 3104, an outer edge 3107, and a planar tissue-facing surface 3106. Tissue-facing surface 3106 includes staple forming pockets defined therein that are configured to deform staples during a surgical stapling procedure. The anvil body 3101 further comprises a longitudinal cavity or bore 3105 configured to receive an anvil cap 3110 therein. As discussed in more detail below, the longitudinal cavity 3105 may include corresponding surfaces configured to mate with corresponding surfaces of the anvil cap 3110 during assembly. Some surfaces may be configured for welding while other surfaces may be configured only for alignment during assembly.

Anvil cap 3110 includes a proximal end 3111, a distal end 3112 and a continuous perimeter or edge 3113. When the anvil body 3101 and anvil cap 3110 are assembled and/or welded together, the edge 3113 may be flush or substantially flush with the top surface 3108 of the anvil body 3101 so as to provide a smooth upper surface of the surgical stapling anvil 3100, although steps in the seam therebetween may be possible. In addition to the above, anvil cap 3110 further includes a rounded upper surface 3114. The upper surface 3114 may be shaped and/or rounded, for example, to provide a continuously curved upper surface of the surgical stapling anvil 3100 when the anvil body 3101 and anvil cap 3110 are welded together. In each case, the continuous edge 3113 is a feature configured for welding, as discussed below.

The two-piece surgical stapling anvil 3100 can allow for polishing of the inner surfaces within the anvil 3100 during manufacture. Manufacturing these parts may include processes that result in a surface finish of various surfaces within the anvil that is less than desired. Improving the finish of the various interior surfaces may reduce the internal friction between the anvil and the staple firing member passing therethrough. Reducing the internal friction may reduce the force required to move the firing member through its staple firing stroke. Reducing the force required to move the firing member through its staple firing stroke may result in a reduction in the size of certain components, thereby resulting in a desired overall instrument size reduction. This arrangement may also reduce the number of instrument failures. That is, two-piece welding anvils present challenges. For example, in some cases, a two-piece welded anvil may deflect more than a unitary anvil. In other words, the hardness of the two-piece anvil may be less than the hardness of the unitary anvil, and the bending resistance is also less. In addition, lateral deflection or rotation of the sides of the anvil away from the firing member or longitudinal instrument axis can cause the staples to be improperly deformed. Such deflection can result in vertical expansion of the overall system, resulting in a formed height of the formed staples that is not the intended formed height. Further, such deflection may allow the firing member to vertically tear the anvil past its cam. Likewise, lateral deflection or rotation may require more firing force to be applied to the firing member to complete its firing stroke. For example, the distal portion of the anvil may deflect away from the staple cartridge due to the pressure caused by the tissue. Minimizing such deflection is important to create a properly formed staple. As mentioned above, the presence of lateral and sideways deflections may have a combined effect. In fact, the lateral deflection may cause a lateral deflection of the anvil.

Fig. 74 depicts a portion of a surgical stapling anvil 3200 that includes an anvil body 3210 and an anvil cap 3220 welded to anvil body 3210 by a weld 3201. Although only a portion of surgical staple 3200 is shown, it should be understood that there is a mirror image of the portion shown to complete surgical staple 3200. The illustration and mirror portions will be discussed simultaneously. The anvil body 3210 includes: a tissue facing surface 3211 including a plurality of staple forming pockets 3212 defined therein; a boss 3215 including cam surfaces 3216 configured to be contacted by anvil cam features of a firing member of the surgical stapling instrument, and a longitudinal slot 3213 configured to receive the firing member therein. Anvil body 3210 also includes an outer edge 3214. The boss 3215 is configured to receive or support a distributed load force 3231 applied by the firing member as the firing member moves through the staple firing stroke. Anvil body 3210 also includes a tab 3217 configured to retain anvil cap 3220 during welding. The boss 3217 may aid in assembly and may ensure proper alignment of the anvil cap 3220 and anvil body 3210. The protrusions 3217 may also serve as features to improve the overall anvil stiffness. The anvil cap 3220 includes an upper portion 3223, a lower portion 3221, and a boss 3224 configured to rest on the boss 3217 before, during, and after welding.

The upper portion 3223 of the anvil cap 3220 and the anvil body 3210 are welded together by welds 3201. The beveled edges on one or both of the anvil body 3210 and anvil cap 3220 provide a welding channel. In this case, the welding surfaces of the anvil body 3210 and the anvil cap 3220 are vertical, and thus, the welding 3201 is vertical. The weld 3201 has a weld length or depth marked by 3202. For example, weld depth 3202 is about 0.030 inches. Notably, the weld 3201 does not penetrate the anvil 3200 to reach the horizontal surfaces of the

protrusions

3217, 3224. With this arrangement, the anvil body 3210 will tend to deflect rotationally about the pivot axis P due to the combination of the firing member and the force that the tissue applies to the anvil body 3210. When the firing member cams surface 3216 by pressing on boss 3215 (represented by distributed load force 3231) and the tissue and cartridge are pushed on tissue-facing surface 3211 (represented by distributed load force 3232), both sides of anvil body 3210 (only one side is shown in fig. 74) may tend to rotate about pivot axis P and deflect vertically and/or outwardly relative to the firing member and anvil cap 3220. This deflection (represented by deflection 3233) is allowed due to the lack of weld penetration of the provided welding apparatus. In some cases, the anvil body 3210 and anvil cap 3220 may diverge at a non-welded portion or seam 3204 having a length 3203.

Fig. 75 depicts a portion of a surgical stapling anvil 3300 that includes an anvil body 3310 and an anvil cap 3320 that is welded to anvil body 3310 by a weld 3301. Although only a portion of the surgical stapling anvil 3300 is shown, it should be understood that there is a mirror image portion of the portion shown to complete the surgical stapling anvil 3300. The illustration and mirror portions will be discussed simultaneously. The anvil body 3310 includes: a tissue facing surface 3311 including a plurality of staple forming pockets 3312 defined therein; a boss 3315 including cam surfaces 3316 configured to be contacted by anvil cam features of a firing member of the surgical stapling instrument, and a longitudinal slot 3313 configured to receive the firing member therein. The anvil body 3310 also includes an outer edge 3314. The ledge 3315 is configured to receive or support a distributed load force 3331 applied by the firing member as the firing member moves through the staple firing stroke. The anvil body 3310 also includes an upper portion 3317 that extends from the slot 3313 to an outer edge 3314. The anvil cap 3320 includes an upper portion 3323, a lower portion 3321, and a protuberance 3224 configured to rest on the upper portion 3317 before, during, and after welding.

The boss 3324 of the anvil cap 3320 and the upper portion 3317 of the anvil body 3310 are welded together by a weld 3301. The beveled edge of anvil cap 3320 provides a welding channel. In this case, the weld surfaces of the anvil body 3310 and anvil cap 3320 are horizontal and, therefore, the weld 3301 is horizontal. The weld 3301 has a weld length or depth marked 3302. For example, the weld depth 3302 is about 0.030 inches. However, such a weld depth 3302 produces a non-welded portion 3304 having a non-weld width 3303. For example, the non-weld width is about 0.080 inches. With this arrangement, the anvil body 3310 will tend to deflect rotationally about the pivot axis P and the upper portion 3317 and boss 3324 will tend to compress during deflection. However, the non-weld width 3303 extends between the slots 3313 and beyond the second row of staple forming pockets 3312. In various circumstances, the combination of forces exerted by the firing member and tissue on the anvil body 3310 may generate a deflection indicated by deflection 3333. When the firing member tilts the anvil 3300 toward the opposing cartridge cam by pressing on the boss 3315 (represented by distributed load force 3331), and when the tissue and cartridge are pushed against the tissue-facing surface 3311 (represented by distributed load force 3332), both sides of the anvil body 3310 (only one side shown in fig. 75) may tend to rotate and deflect perpendicularly and/or outwardly relative to the firing member. This deflection 3333 occurs due to the lack of weld penetration, significant non-weld width 3304, and horizontal welding arrangement 3301.

Fig. 76 depicts a portion of a surgical stapling anvil 3400 that includes an anvil body 3410 and an anvil cap 3420 that is welded to the anvil body 3410 by a weld 3401. Although only a portion of the surgical stapling anvil 3400 is illustrated, it should be appreciated that there is a mirror image portion of the illustrated portion to complete the surgical stapling anvil 3400. The illustration and mirror portions will be discussed simultaneously. The anvil body 3410 includes: a tissue-facing surface 3411 including a plurality of staple forming pockets 3412 defined therein; a boss 3415 including cam surfaces 3416 configured to be contacted by anvil cam features of a firing member of the surgical stapling instrument; and a longitudinal slot 3413 configured to receive a firing member therein. Anvil body 3410 further includes an outer edge 3414. The boss 3415 is configured to receive or support a distributed load force 3431 applied by the firing member as the firing member moves through the staple firing stroke. Anvil body 3410 further includes a boss 3417 configured to retain anvil cap 3420 during welding. The protrusions 3417 can help assemble cap 3420 and body 3410 and can ensure proper alignment of anvil cap 3420 and anvil body 3410. The protrusions 3417 may also improve the overall anvil stiffness of the anvil 3400. Anvil cap 3420 includes an upper portion 3423, a lower portion 3421, and a boss 3424 configured to rest on boss 3417 before, during, and after welding.

The upper portion 3423 of the anvil cap 3420 and the anvil body 3410 are welded together by a weld 3401. A welding channel is provided by the beveled edges of one or both of anvil body 3410 and anvil cap 3420. In this case, the weld surfaces of the anvil body 3410 and anvil cap 3420 are angled, and thus, the weld 3401 is angled. The weld 3401 has a weld length or depth marked by 3402. For example, the weld depth 3402 is about 0.030 inches. Notably, the weld 3401 does not penetrate the anvil 3400 to reach the horizontal surfaces of the

protrusions

3417, 3424, and with this arrangement, the anvil body 3410 will tend to rotationally deflect about the pivot axis P. Specifically, the combination of forces exerted by the firing member and tissue onto the anvil body 3410 may generate a deflection represented by deflection 3433. When the firing member tilts the anvil 3400 toward the opposing cartridge cam by pressing on the boss 3415 (represented by distributed load force 3431) and when the tissue and cartridge are pushed on the tissue-facing surface 3411 (represented by distributed load force 3432), both sides (only one side is shown in fig. 76) of the anvil body 3410 may tend to rotate about pivot axis P. However, as the sides of the anvil body 3410 rotate, the angled weld surfaces will tend to compress, which may limit the amount of deflection experienced by the anvil 3400. The anvil body 3410 and anvil cap 3420 may tend to compress at the non-welded portion 3404 having a length 3403, resulting in a very secure interconnection between the cap 3420 and body 3410.

Fig. 77 depicts a surgical stapling anvil 3500 for use with a surgical stapling instrument. Anvil 3500 includes an anvil body 3510 and an anvil cap 3520. The anvil body 3510 includes: a tissue-facing surface 3511 comprising a plurality of staple forming pockets 3512 defined therein; a tab 3515 comprising cam surfaces 3516 configured to be engaged by anvil cam features of a firing member of a surgical stapling instrument; and a longitudinal slot 3513 configured to receive a firing member therein. The boss 3415 is configured to receive or support a distributed load force applied by the firing member as the firing member moves through the staple firing stroke. The anvil body 3510 further includes a tab 3517 configured to hold the anvil cap 3520 in place during welding. The protrusions 3517 can help assemble the cap 3520 and anvil body 3510 and can ensure proper alignment of the anvil cap 3520 and anvil body 3510. The protrusions 3517 may also improve the overall stiffness of the anvil 3500. Anvil cap 3520 includes an upper portion 3523, a lower portion 3521, and a boss 3524 configured to rest on boss 3517 before, during, and after welding.

The upper portion 3523 of the anvil cap 3520 and the anvil body 3510 are welded together by a weld 3501. Only one weld 3501 is shown to provide clarity of the relationship of the anvil body 3510 and anvil cap 3520 before and after welding. In this case, the weld surfaces of the anvil body 3510 and anvil cap 3520 are angled, and thus, the weld 3501 is angled. The weld 3501 has a weld length or depth marked by 3502. The weld depth or penetration 3502 may be between about 0.015 inches and about 0.040 inches. In some cases, the weld depth is, for example, 0.030 inches. Notably, the weld 3501 penetrates the anvil 3500 to reach the horizontal surfaces of the

projections

3517, 3524. Providing an angled weld surface configured to match the weld penetration may help to rotate and prevent deflection of the anvil in the vertical direction. In other words, having a weld with a weld penetration equal to or greater than the length of the angled weld surface may increase the moment of inertia and overall stiffness of the anvil 3500. In other cases, the weld depth 3502 may be less than the length of the angled weld surface or the mating length. Suitable welding techniques are used to weld any of the anvils disclosed herein. In some cases, a gap exists between adjacent weld surfaces, the gap being configured to receive the weld material. In some cases, no gap is provided. In at least one such case, the angled weld surface is laser welded.

Fig. 78 is a photomicrograph of an anvil 3600 that includes an anvil body portion 3610 and an upper anvil portion 3620. Anvil body portion 3610 includes: a tissue-facing surface 3611 comprising a plurality of staple forming pockets 3612 defined therein; a longitudinal cavity 3613 configured to receive a firing member of a surgical instrument therein; and a tab 3615 configured to engage the firing member during a staple firing stroke. The anvil body portion 3610 and the upper anvil portion 3620 are welded to one another by welds 3601, each having a weld penetration length 3602. Notably, the weld 3601 does not penetrate the anvil 3600 to reach the horizontal surface 3617 of the upper boss 3616 of the anvil body portion 3610.

The anvil 3600 includes a larger non-welding width 3606 and also a larger slot cavity width 3605. The non-weld width 3606 is approximately 125% of the cavity width 3605. In practice, the width of the non-welding width 3606 is such that the middle forming pocket row 3612B and the inner forming pocket row 3612A are defined within the non-welding width 3606. Similarly, a portion of the inner forming pocket 3612A and the intermediate forming pocket 3612B are defined having a slot cavity width 3605. Further, an inner boundary axis 3619 of the middle row of forming pockets 3612B is defined within both the non-weld width 3606 and the pocket width 3605. Such an arrangement can significantly deflect the anvil 3600 as tissue is clamped and/or as the firing member is moved through its staple firing stroke. Such deflection may be due to lack of weld penetration and a relatively large non-weld width 3605 relative to the slot width 3606.

Fig. 79 depicts an anvil 3700 that includes an anvil body portion 3710 and an anvil cap 3720. The anvil body portion 3710 includes a planar tissue-facing surface 3711 that includes a plurality of forming staple pockets including an inner staple forming pocket 3712A, a middle staple forming pocket 3712B, and an outer staple forming pocket 3712C. The body portion 3710 further includes: a longitudinal cavity or slot 3713 configured to receive a firing member therein; anvil tab 3715 defining radial cam surfaces 3714 configured to be engaged by the firing member as the firing member moves through its staple firing stroke; and a boss 3716 configured to retain anvil cap 3730. Slot 3713 includes: a first portion 3713A configured to receive a cutting member of a firing member therein; and a second portion 3713B configured to receive an upper cam portion of the firing member therein. The width of the first portion 3713A is less than the width of the second portion 3713B.

Anvil cap 3720 includes a Y-shaped cross-section. Anvil cap 3720 includes; a lower portion 3721 configured to be received within a slot 3713 defining a first mating region; and an upper portion 3723 configured to be welded to the anvil body 3710. The upper portion 3723 includes a boss or shoulder 3724 that includes horizontal alignment surfaces configured to rest on corresponding horizontal alignment surfaces of the boss 3716. The interface defines a second mating region perpendicular, or at least substantially perpendicular, to the first mating region. The horizontal alignment surface is at least substantially parallel to the tissue facing surface 3711. The upper portion 3723 is flared relative to the lower portion 3721 and includes an angled weld surface 3725 configured to be welded to a corresponding angled weld surface 3717 of the anvil body 3710 defining a third mating region. The weld penetration length of the weld is equal to the length of the angled weld surfaces 3725, 3717.

Anvil 3700 includes a non-welding width 3706 and a slot width 3705. The non-weld width 3706 is not greater than about 105% of the slot width 3705. The center plane axis "CA" is defined as the geometric center of the anvil 3700. The non-weld width 3706 (i.e., the width between the welds) defines an outer boundary axis 3731, which is a first distance 3731D from the central axis CA. The inner staple forming pockets 3712A define a row axis 3732, which is a second distance 3732D from the central axis CA. Second distance 3732D is less than first distance 3731D. Thus, all or at least a portion of the inner staple forming pocket 3712A is defined within the non-weld width 3706. In other cases, the inner staple forming pocket 3712A is located entirely outside of the non-weld width 3706. In such cases, the first width 3731D is less than the second width 3732D. In some cases, the outer boundary axis 3731 does not extend beyond the inner boundary axis of the inner staple forming pocket 3712A. The inner staple forming pocket 3712A also defines an outer boundary axis 3733, which is a third distance 3733D from the central axis CA. Third distance 3733D is greater than first distance 3731D and second distance 3732D. In other cases, the inner staple forming pocket 3712A is located entirely within the non-weld width 3706. In such cases, the second distance 3732D and the third distance 3733D are less than the first distance 3731D.

The intermediate staple forming pocket 3712B defines an inner boundary axis 3734, which is a fourth distance 3734D from the central axis. Fourth distance 3734D is greater than first distance 3731D, second distance 3732D, and third distance 3733D. In other words, the non-weld width 3706 does not extend to the middle staple forming pocket 3712B. Minimizing the distance that first distance 3731D or outer boundary shaft 3731D extends from central axis CA may increase the overall stiffness of anvil 3700 to reduce longitudinal and rotational, or torsional, bending, or deflection of anvil 3700.

Fig. 80 is a chart 3800 showing four different surgical stapling anvil arrangements subjected to two different loading conditions. Model a is a one-piece or unitary anvil. Model B is a two-piece anvil comprising an anvil body and an anvil cap welded to the anvil body. The anvil cap includes an upper welded portion that includes a non-welded width that is wider than 105% of the slot width. Like model B, model C is a two-piece anvil comprising an anvil body and an anvil cap welded to the anvil body. The non-welding width of the anvil cap is about 105% of the slot width. However, the angle of the angled weld surface of model C defined between the anvil cap and anvil body prevents the formation of a weld depth extending along the entire length of the angled weld surface. In at least one instance, the weld depth is, for example, less than 0.03 inches. Model D represents anvil 3700. The anvil cap included a non-weld width of about 105% of the slot width, and the angle of the angled weld surface of model D allowed for creation of a weld depth that fused the entire length of the angled weld surface. In at least one instance, the weld depth is, for example, at least 0.03 inches. Thus, the distal tip deflection of anvil 3700 is less than the distal tip deflection of the anvils of model a, model B, and model C. Also, the total stress in the convex portions of the model B, the model C, and the model D is smaller than that of the model a.

Fig. 81-83 depict an anvil 3900 for use with a surgical stapling instrument. Anvil 3900 is configured to deform staples during a surgical stapling procedure. Anvil 3900 includes an anvil body 3910 and an anvil cap 3920. Anvil body 3910 and anvil cap 3920 are welded together. The anvil body 3910 includes a proximal portion 3912 that includes a coupling portion that is configured to be assembled to an end effector of a surgical stapling instrument to allow anvil jaw 3900 to rotate relative to a corresponding jaw (e.g., a staple cartridge jaw). Embodiments are contemplated in which the anvil jaw is fixed relative to the cartridge jaw, and in which case the cartridge jaw may rotate relative to the anvil jaw. Anvil body 3910 further includes a distal tip portion 3914 and a planar tissue-facing surface 3911. Tissue-facing surface 3911 includes staple forming pockets 3912 defined therein that are configured to deform staples during a surgical stapling procedure. The anvil body 3910 includes a longitudinal slot 3913 configured to receive a firing member of a surgical instrument therein. The anvil body 3910 further includes a cam feature 3914 that includes a radial cam surface 3915 configured to be engaged by an anvil cam portion of the firing member during a staple firing stroke of the firing member.

Referring to fig. 81, anvil cap 3920 includes a plurality of shallow lands 3930 each having a land length 3930L and a plurality of deep lands 3940 each having a land length 3940L.

Zone lengths

3930L, 3940L are equal; however, in other cases, the

zone lengths

3930L, 3940L are different. Each shallow land 3930 of cap 3920 includes an upper portion 3933 and a lower portion 3931. The upper portion 3933 includes a flared body portion 3934 with a welding surface 3935. The flared body portion 3934 is configured to rest on the alignment tab 3916 of the anvil body 3910, while the welding surface 3935 is configured to engage or mate with a corresponding angled welding surface 3917 of the anvil body 3910 (fig. 82). Each deep land 3940 includes an upper portion 3943 and a lower portion 3941. Lower portion 3941 is accessible via a window 3945 extending through upper portion 3943 of deep solder region 3940. Upper portion 3942 includes alignment tabs 3944 accessible via weld access zone 3945 that are configured to rest on corresponding alignment tabs 3418 of anvil body 3910. Alignment tab 3916 is a first distance from tissue-facing surface 3911 and alignment tab 3944 is a second distance from tissue-facing surface 3911. The first distance is greater than the second distance. In other cases, the first distance and the second distance are equal.

The welding surfaces 3935, 3917 discussed above are configured to be welded together to weld the shallow weld zone 3930 to the anvil body 3910 (fig. 83) via a weld 3936 that includes a root 3937. Root 3937 is configured to penetrate at least to the horizontal surface of male portion 3916. Deep weld zone 3940 is configured to be welded to anvil body 3910 by a weld 3946 that includes a root 3947 (fig. 83). The weld access region 3945 allows for deep welds to weld the lower portion 3941 to the anvil body 3910. During welding, the entire boss 3946 may fuse with the anvil body 3910. Although the

weld lengths

3938, 3948 may be similar, if not equal, the effective or net weld depth between the anvil cap 3920 and the anvil body 3910 may be increased by providing shallow welds 3930 and deep welds 3940. The depth of weld may be defined as the distance between the edge 3921 of the upper surface 3901 of the anvil to the root of the corresponding weld. Alternating shallow and

deep welds

3930, 3940 may allow for shallow and deep welds to exist on both sides of anvil 3900 along the longitudinal length of anvil 3900 and establish a secure connection between anvil cap 3920 and anvil body 3910.

Shallow welds 3930 and deep welds 3940 are configured to increase the total weld depth along the length of anvil 3900. The position, longitudinal length, and number of shallow welds 3930 and deep welds 3940 may be varied to vary or adjust the stiffness of anvil 3900 along the length of the anvil. For example, shallow land 3930 has a first stiffness and deep land 3940 has a second stiffness that is different than the first stiffness. Such an arrangement may also allow for the

welds

3936, 3946 to be manufactured using a single depth welder, which may simplify manufacturing. In addition to these welds, a filler weld may be applied to fill the ingress area 3945 after the weld 3946 has been formed in order to increase the stiffness of the anvil 3900 and reduce the likelihood of rotational deflection within the anvil 3900. An embodiment is contemplated wherein instead of having longitudinally alternating zones with deep welds on both sides of the anvil and zones with shallow welds on both sides of the anvil (fig. 81), the anvil comprises a plurality of zones extending along length L, wherein each zone comprises shallow welds and deep welds on opposite sides of the anvil. For example, each zone includes a shallow weld extending along the length L of the zone on one side of the anvil and a deep weld extending along the length L of the zone on the other side of the anvil. Further, the plurality of regions may alternate sides forming shallow welds and deep welds, in addition to having different lengths. Thus, such an anvil would include shallow welds and deep welds along the entire length of the anvil.

A variety of processes can be used to manufacture the various surgical stapling anvils disclosed herein. For example, the anvil body portion and/or anvil cap portion may be manufactured using a metal injection molding process. The anvil body portion and/or anvil cap portion may also be manufactured using a machining process. In at least one instance, one of the anvil body portion and anvil cap is manufactured using a metal injection molding process and the other of the anvil body portion and anvil cap is manufactured entirely using a machining process. In some cases, electrochemical machining processes may be used to form the anvil body portion, the anvil cap portion, or both the anvil body portion and the anvil cap portion. The molding process may allow the fillet to be easily incorporated into the geometry of the anvil cap and/or anvil body. Such rounded corners may reduce stress concentrations at locations where different vertices or corners might otherwise exist.

Methods for manufacturing surgical stapling anvils, such as those disclosed herein, may include various steps. One step in manufacturing the anvil includes manufacturing the anvil body portion and anvil cap member. Another step in manufacturing the anvil includes polishing the anvil cam surface of the anvil body portion. In various circumstances, any inner surface that may contact any portion of the firing member may be polished. Another step in manufacturing the anvil includes welding the anvil body portion and anvil cap member together. The welding step may comprise, for example, a laser welding process. Yet another step in manufacturing the anvil includes stamping staple forming pockets or fastener forming pockets into the tissue facing surface of the anvil body portion.

In addition to the above, the polishing step may include polishing various regions of the anvil cam surface or boss. The boss can include a first region and a second region, wherein the first region is configured to be contacted by an anvil cam of the firing member and the second region extends laterally beyond the first region. Under normal firing conditions, the firing member will contact only the first lobe region and not the second lobe region. However, in an abnormal firing condition, a portion of the firing member may contact the second zone. Thus, it may be advantageous to ensure that both the first and second regions of the boss are polished to reduce the likelihood of wear on the boss when contacted by the firing member.

Fig. 84 and 85 depict an anvil 4000 comprising an anvil body 4010 and an anvil cap 4020. The anvil body 4010 includes a tissue-facing surface 4011 and a plurality of staple forming pockets 4012 defined in the tissue-facing surface 4011. The anvil 4000 includes a longitudinal cavity 4013 that is configured to receive a firing member of a surgical instrument therein. Lumen 4013 includes an anvil cam surface 4015 defined by a boss 4014 of anvil body 4010. The firing member is configured to cam the boss 4014 as the firing member moves through the firing stroke. The anvil cap 4020 is welded to the anvil body 4010. A welder (such as a laser welder) is allowed to enter the anvil body 4010 and anvil cap 4020 via welder entry region 4005. The welder access area 4005 includes an opening or beveled edge to provide a welder with room to access the location to be welded. A larger welder entrance area may ensure deeper weld penetration.

Anvil 4000 includes a primary weld 4001 and a secondary filler weld 4003. Although only one secondary filler weld 4003 is shown, anvil 4000 may include a secondary filler weld on top of or over all existing primary welds. The filler welds 4003 provide additional stiffness to the anvil 4000 over the longitudinal length of the anvil 4000 and also help prevent rotational deflection or torsional bending or twisting of the anvil sides. In addition, the filler weld 4003 increases the overall weld penetration into the anvil 4000, which increases the stiffness of the anvil 4000. The primary weld 4001 fuses the corresponding beveled surfaces of the anvil body 4010 and anvil cap 4020. More specifically, the anvil body 4010 comprises: a first ramp 4019 configured to mate with the first ramp 4029 of the anvil cap 4020; a first horizontal surface 4018 configured to mate with the first horizontal surface 4028 of the anvil cap 4020; a second ramp 4017 configured to mate with the second ramp 4027 of the anvil cap 4020; and a second horizontal surface 4016 configured to mate with a second horizontal surface or bottom surface 4026 of anvil cap 4020. During manufacture, a welder may be selected and configured to fuse the

first ramps

4019, 4029 together.

The

additional ramps

4017, 4027 and

horizontal surfaces

4016, 4018, 4026, 4028 are configured to assist in assembly of the anvil body 4010 and anvil cap 4020 prior to welding during manufacture. For example, when preparing the anvil body 4010 and anvil cap 4020 for welding, the additional surfaces can help align the anvil body 4010 and anvil 4020 for welding. The second horizontal surface 4016 provides a defined depth for the anvil cap 4020. In other words, the second horizontal surface 4016 defines a lowest sewable position in which the bottom surface 4026 can be seated relative to the anvil body 4010.

Fig. 86 depicts an anvil 4100 comprising a first anvil member or anvil body portion 4110 and a second anvil member or anvil cap 4130. The first anvil member 4110 includes a tissue-facing surface 4111 that includes a plurality of staple forming pockets 4112 defined therein. The first anvil member 4110 further comprises a longitudinal cavity 4113 configured to receive a firing member of a surgical instrument therein. The first anvil member 4110 further includes an anvil cam lobe 4114 that defines an anvil cam surface 4115 that is configured to be engaged by the firing member as the firing member moves through a firing stroke.

The first anvil member 4110 and the second anvil member 4130 include interlocking features configured to increase the overall stiffness of the anvil 4100 and to reduce bending of the anvil 4100 away from the lateral tissue of the opposing staple cartridge when the anvil 4100 is clamped against the staple cartridge. The first anvil member 4110 includes a horizontally extending interlock feature 4117 that is received within a corresponding interlock bore 4137 of the second anvil member 4130. The first anvil member 4110 further includes vertically extending interlocking features 4116 that are received within corresponding apertures 4136 of the second anvil member 4130. In various circumstances, the interlocking features 4116, 4117 may require that the anvil 4100 be assembled only in the longitudinal direction before being welded together. For example, the second anvil member 4130 may be longitudinally slid in a longitudinal direction relative to the first anvil member to assemble the first anvil member 4110 and the second anvil member 4130.

The first anvil member 4110 and the second anvil member 4130 are welded to each other by an outer weld 4101 and an inner weld 4103. The

welds

4101, 4103 may comprise, for example, laser welds. The outer weld 4101 is located in an outer portion 4105 of the anvil 4100. The inner weld 4103 is located in a longitudinal cavity 4113 defined by a first anvil member 4110 and a second anvil member 4130. For example, a laser welder may access the longitudinal cavity 4113 through an opening or bore defined between the cam lobes 4114 to form an interior weld 4103. In various cases, the opening defined by the cam lobe 4114 is sized to allow access to a welder dedicated to the inner weld 4103. Such an arrangement with internal welds, external welds, and interlocking features may increase the overall strength of the anvil and reduce lateral deflection and/or torsional deflection. The interlocking feature may also provide a solid retention surface such that when one of the first anvil member and the second anvil member is grounded during weld preparation, the other of the first anvil member and the second anvil member is constrained to one plane of movement. Such an arrangement may ensure that the first anvil member and the second anvil member do not move relative to each other prior to and/or during the welding process.

Referring now to fig. 87, anvil 4200 includes an anvil body 4210 and an anvil cap 4220. The anvil body 4210 comprises a planar tissue contacting surface 4211 comprising a plurality of staple forming pockets 4212 defined therein. The anvil body 4210 further comprises a longitudinal cavity 4213 configured to receive a firing member of a surgical instrument therein. The anvil body 4210 further comprises an anvil cam lobe 4214 defining an anvil cam surface 4215 configured to be engaged by the firing member as the firing member moves through a firing stroke.

Anvil cap 4220 is positioned within longitudinal cavity 4213 and welded to anvil body 4210 by weld 4201. The weld 4201 may include, for example, a laser weld. The anvil cap 4220 comprises a lateral protrusion or interlocking feature 4221 configured to be received within the bore 4216 of the anvil body 4210. The weld 4201 includes a weld depth that does not penetrate into the tab 4221, however embodiments are contemplated in which the weld 4201 extends into the tab 4221 or into the tab 4221.

Fig. 88-92 illustrate a surgical stapling assembly 4300 including a welding anvil that employs another arrangement to help prevent and/or limit longitudinal bending of the welding anvil. The surgical stapling assembly 4300 includes: anvil jaw 4340, which comprises anvil body 4350 and anvil cap 4360; a cartridge channel jaw 4330 configured to receive a staple cartridge in a cartridge receiving aperture 4333 thereof; and a closure mechanism 4310 configured to pivot anvil jaw 4340 relative to cartridge channel jaw 4330 via a cam mechanism. That is, embodiments are contemplated in which the cartridge channel jaw 4330 pivots relative to the anvil jaw 4340. Anvil body 4350 includes a tissue-facing surface 4351 that includes a plurality of staple forming pockets defined therein that are configured to deform staples ejected from a surgical staple cartridge. The stapling assembly 4300 further includes a firing member 4370 configured to move longitudinally within the slot 4357 of the anvil jaw 4340 and within the slot 4331 of the cartridge channel jaw 4330 to deploy a plurality of staples stored within a staple cartridge and to cut tissue captured between the anvil jaw 4340 and the cartridge channel jaw 4330 during a firing stroke.

The surgical stapling assembly 4300 includes means for improving the overall stiffness and strength of the anvil jaw 4340 by reducing the stiffness of the cartridge channel jaw 4330. The cartridge channel comprises a channel wall 4334 comprising a proximal wall portion 4335 and a distal wall portion 4337. The anvil jaw 4340 is configured to abut or surround the cartridge channel jaw 4330, particularly the proximal wall portion 4335, when the anvil jaw 4340 is pivoted toward the cartridge channel jaw 4330. Anvil body 4350 comprises a proximal surrounding portion 4352 that is configured to cradle or surround proximal wall portion 4335 when anvil jaw 4340 is pivoted by closure mechanism 4310 from an open configuration (fig. 88) to a closed configuration (fig. 89). The proximal surrounding portion 4352 further comprises a tissue stop 4359 configured to limit proximal movement of tissue into the surgical stapling assembly 4300.

The proximal surrounding portion 4352 includes a lower portion 4354, an upper portion 4353, and a boss 4356 defined therebetween. When the suturing assembly 4300 is in a closed configuration (e.g., fig. 91), the lower portion 4354 is configured to overlap the proximal wall portion 4335. Upper portion 4353 is thicker or larger than lower portion 4354; however, upper portion 4353 and lower portion 4354 may have any suitable configuration. In general, the thicker upper and

lower portions

4353, 4354 are configured to increase the overall stiffness and moment of inertia of the anvil jaw 4340. When the suturing assembly 4300 is in the closed configuration, the boss 4336 of the channel jaw 4330 faces a corresponding boss 4356 of the proximal surrounding portion 4352.

Referring primarily to fig. 92, the proximal wall portion 4335 comprises a cutout having a wall thickness that is less than the wall thickness of the distal wall portion 4337. The proximal wall portion 4335 also includes a smaller height than the distal wall portion 4337 (fig. 91). Providing thinner and smaller walls in the proximal portion of the cartridge channel jaw 4330 allows for a greater space for the proximal peripheral portion 4352 of the anvil jaw 4340 to be thicker and generally larger, thereby increasing the stiffness of the anvil jaw 4340. In previous designs, the cartridge channel jaws of the stapling assembly have a substantially greater stiffness than the anvil of the stapling assembly. The present arrangement sacrifices some of the stiffness of the cartridge channel jaws to stiffen the anvil jaws by removing material from the cartridge channel jaws and adding material to the anvil jaws while maintaining the desired instrument diameter. In various cases, the desired instrument diameter may be, for example, 5mm, 8mm, or 12mm. Due to the above, the proximal surrounding portion 4352 comprises a volume of material configured to occupy a void defined beyond the proximal wall portion 4335, but within the instrument diameter.

In addition to the above, anvil jaw 4340 has a first stiffness and cartridge channel jaw 4330 has a second stiffness. The suturing assembly 4300 comprises structural means for reducing the second stiffness to increase the first stiffness. In various cases, the ratio of the first stiffness to the second stiffness is between about 1:3 and about 1:1. In some cases, the ratio of the first stiffness to the second stiffness is about 1:3. In other cases, the ratio of the first stiffness to the second stiffness is about 1:1.

Referring now to fig. 93-95, the cartridge channel jaw 4400 includes a main body portion 4410 and a cap portion 4430. The body portion 4410 includes a longitudinal cavity 4415 (fig. 94) configured to receive the cap portion 4430. Such an arrangement may allow for polishing of various inner surfaces of the channel jaw 4400 during manufacturing to reduce the force used to advance or fire the firing member through the surgical instrument. The cartridge channel jaw 4400 includes a cartridge receiving cavity 4401 (which is configured to receive a staple cartridge therein) defined by a channel wall 4411 of a main body portion 4410, a proximal portion 4405 configured to be coupled to an instrument shaft, and a distal portion 4407. The replaceable staple cartridge is configured to be inserted or mounted into the cartridge channel jaws 4400. Referring to fig. 95, the body portion 4410 further includes a longitudinal bore 4413 configured to receive a portion of the firing member of the surgical instrument therein as the firing member moves through the staple firing stroke.

The longitudinal cavity 4415 of the body portion 4410 defines a boss 4413 (fig. 95) configured to hold the cap portion 4430 in place relative to the body portion 4410 for welding. The cap portion 4430 includes a cap wall 4433 and is welded to the body portion 4410 by a weld 4409. The weld 4409 may include, for example, a laser weld. The boss 4413 of the cap portion 4430 and the body portion 4410 define a longitudinal slot 4403 configured to slidably receive a portion of the firing member. The longitudinal slot 4403 is polished prior to welding the cap portion 4430 to the body portion 4410. In each case, the entirety of the longitudinal slot 4403 is polished. For example, the inner surface of the cap portion 4430 and the convex portion 4413 are polished. The polished boss 4413 may be advantageous such that as the firing member moves through its staple firing stroke, the polished boss 4413 may reduce friction between the cartridge channel jaw 4400 and the firing member and thus reduce wear of the surfaces that would increase the force used to fire the surgical instrument. In other cases, only certain surfaces of cap portion 4430 are polished. In such a case, only the horizontal surface 4435 and the convex portion 4413 of the cap portion 4430 may be polished.

Fig. 96-107 compare two

different firing members

4500, 4600, respectively, for use with

surgical stapling systems

4800, 4700, respectively. Firing member 4500 (fig. 96) comprises: a body 4510 comprising a proximal connecting portion 4512; and a cutting member 4511 configured to cut tissue during a staple firing stroke. Firing member 4500 further includes a channel jaw coupling member 4520 and an anvil jaw coupling member 4530 that are configured to retain the anvil jaw and the channel jaw relative to each other during a staple firing stroke of firing member 4500. Similarly, the firing member 4600 (fig. 97) includes: a body 4610, the body comprising a proximal connection portion 4612; a cutting member 4611 configured to cut tissue during a staple firing stroke; and a latch feature 4615. The firing member 4600 further includes a channel jaw coupling member 4620 and an anvil jaw coupling member 4630 configured to retain the anvil jaw and the channel jaw relative to each other during a staple firing stroke of the firing member 4600.

Referring now to fig. 98 and 99, the anvil jaw coupling member 4530 of the firing member 4500 includes a lateral projection or anvil cam feature 4531 extending from a side of the main body 4510. The protrusion is rounded with a rounded corner 4532 relative to the body 4510. The tab 4531 also includes an outer rounded corner 4533. Anvil jaw coupling 4530 defines an upper planar surface 4534. Each tab 4531 includes a lateral width or thickness 4545 and a vertical thickness 4541. Lateral width 4545 is defined as the distance between main body 4510 and outer edge 4536 of tab 4531. The lateral protrusion 4531 defines a protrusion axis 4543 that is at an angle of about one degree relative to a horizontal surface of the firing member 4500 (e.g., the upper cam surface 4521 of the channel jaw coupling member 4520). Angling the tab 4531 may reduce wear of the contact surface. The lateral tab 4531 also has a longitudinal length 4542 (fig. 102) defined as the distance between the front edge 4535 of the tab 4531 and the rear edge 4537 of the tab 4531.

The longitudinal length 4542 and the vertical thickness 4541 of the lateral projection 4531, for example, have a ratio of about 2.5:1 to about 20:1. In some cases, the ratio of the longitudinal length 4542 to the vertical thickness 4541 is between about 5:1 and about 10:1. In some cases, the ratio of the longitudinal length 4542 to the vertical thickness 4541 is about 5:1. In various cases, the ratio of vertical thickness 4541 to lateral width 4545 is, for example, between about 1:2 and about 1:1. In some cases, the ratio of vertical thickness 4541 to lateral width 4545 is about 1:1. These arrangements reduce lobe deflection and in turn reduce deflection of the protrusion 4531 of the firing member 4500. These arrangements also encourage pure shear as the primary source of deflection, which increases the ability of the protrusions to resist deformation. An arrangement in which bending of the protrusion is the primary source of deflection may result in a greater likelihood of plastic deformation of the protrusion.

Referring now to fig. 100 and 101, anvil jaw coupling member 4630 includes a lateral projection or anvil cam feature 4631 extending from a side of body 4610. Each projection 4631 includes a lateral width or thickness 4645 and a vertical thickness 4641. The lateral width 4645 is defined as the distance between the main body 4610 and the outer edge 4636 of the protrusion 4631. Lateral projection 4631 also has a longitudinal length 4632 (fig. 103) defined as the distance between the front edge 4635 of projection 4631 and the rear edge 4637 of projection 4631. Longitudinal length 4542 is greater than longitudinal length 4642.

Turning now to fig. 104, the stapling system 4700 includes an end effector for use with a surgical instrument that comprises an anvil jaw 4750, a cartridge channel jaw 4780, and a staple cartridge 4710 mounted within the cartridge channel jaw 4780. The stapling system 4700 also includes a firing member 4600, as discussed above. Staple cartridge 4710 includes: a plurality of staples movably stored in staple cavities 4712 of staple cartridge 4710 configured to be fired by firing member 4600, cartridge deck, or tissue facing surface 4711; and a longitudinal slot 4713 configured to receive a firing member 4600 therein. Anvil jaw 4750 includes: a tissue facing surface 4751 comprising a plurality of staple forming pockets 4752 configured to deform staples; anvil slot 4753 configured to receive jaw coupling member 4630 of firing member 4600 therein; and cam lobe 4755 configured to be engaged by a protrusion 4631 of firing member 4600 as firing member 4600 moves through its staple firing stroke. The channel 4780 includes: channel wall 4781; a longitudinal slot or cavity 4785 configured to receive the jaw coupling member 4620 therein; and cam lobe 4783 configured to be engaged by jaw coupling member 4620 as firing member 4600 moves through its staple firing stroke. In this case, the protrusion 4631 acts as a cantilever beam, resulting in a much smaller force required to bend the protrusion 4631 than in the system described below.

Turning now to fig. 105, a stapling system 4800 includes an end effector for use with a surgical instrument that comprises an anvil jaw 3700, a cartridge channel jaw 4400, and a staple cartridge 4810 mounted within the cartridge channel jaw 4400. The system 4800 also includes a firing member 4500. The staple cartridge 4810 includes: a plurality of staples movably stored in staple cavities 4812 of staple cartridge 4810 and configured to be fired by firing member 4500, cartridge deck, or tissue facing surface 4811; and a longitudinal slot 4813 configured to receive the firing member 4500 therein. The anvil slot 3713 is configured to receive the jaw coupling member 4530 of the firing member 4500 therein, and the cam lobe 3715 is configured to engage the tab 4531 as the firing member 4500 moves through its staple firing stroke. In such cases, the rounded edge 4533 of the tab 4531 is configured to engage the rounded portion 3714 of the cam lobe 3715. The longitudinal slot 4403 of the channel jaw 4400 is configured to receive the jaw coupling member 4520 therein, and the cam lobe 4413 is configured to be engaged by the jaw coupling member 4520 as the firing member 4500 moves through its staple firing stroke. In this case, the primary source of deflection of the tab 4531 is caused by the shear stress that requires a much greater force to deform the tab 4531 than is required to deform the tab 4631 of the system 4700 shown in fig. 104.

Turning now to fig. 106 and 107, a comparison of the deflection of the lobes of each

suturing system

4700, 4800 is shown. The same firing load is applied to the

stapling systems

4700, 4800 shown in fig. 106 and 107. In fig. 106, a system 4800 with deflection 4801 is shown. In fig. 107, the system 4700 is shown as having a deflection 4701 that is greater than the deflection 4801. This difference may be due in part to lack of stiffness of protrusion 4631, lack of geometry of boss 4755 and its ability to resist bending, increased stiffness of protrusion 4531, and/or geometry of boss 3715 and its ability to resist bending, etc. For example, suturing system 4800 places protrusions 4531 and protrusions 3715 primarily in a shearing manner, thereby increasing its ability to resist deformation. Further, rounding the projections of the firing member and shortening the width of the projections of the firing member increases the stiffness of the corresponding jaw coupling member and anvil due to the fact that more material is allowed for the anvil.

In some instances, the stiffness of the balancing tab 3715 and tab 4531 will balance the deflection magnitude of the tab 3715 and the deflection magnitude of the tab 4531 during the firing stroke of the firing member. Because of such balanced deflection, neither the boss nor the protrusion dominate over each other in terms of deflection, and thus neither the boss nor the protrusion results in plastic deformation of one significantly greater than the other and possibly not at all during the firing stroke. In each case, the rigidity of the protrusion is equal to, substantially equal to, or less than the rigidity of the protrusion. In some cases, the height or vertical thickness of the protrusions is substantially similar to the height or vertical thickness of the protrusions. In addition to or instead of providing a balanced geometry of the protrusions and projections, the materials of the protrusions and projections may be selected based on, for example, yield strength and/or hardness values. Having materials with similar material yield strengths and/or hardness values may promote equal or balanced deflection of the protrusions and projections.

Fig. 108 is a stress and strain analysis 4900 of anvil 3700 including weld 3701 during advancement of firing member 4500. As can be seen in fig. 108, the combination of the application of distributed load 4903 by firing member 4500 to boss 3715 and the application of distributed load 4905 by tissue and cartridge 4810 to tissue facing human surface 3711 results in deflection 4901 and stress distribution as shown. Stress analysis shows low stress regions 4907, medium stress regions 4908, and high stress regions 4909. Notably, the stresses at and near the weld 3701 are evenly distributed and do not localize or concentrate at or near the weld 3701.

In various designs, a T-shaped cutter head is used to machine a slot in the anvil and/or channel that receives the jaw coupling member of the firing member. This machining method can cause bit chatter, which can roughen the surface of the slot cut using a T-shaped bit. In a two-piece anvil and channel design, standard tool tips may be used to eliminate this problem to provide a better surface finish and reduce the force used to fire the firing member.

Another method of reducing the force of impact may include coating at least the polished surfaces of the anvil with a material to reduce the coefficient of friction of those surfaces. Such a coating may comprise, for example, medcoat 2000.

During the manufacture of the various welded anvil designs disclosed herein, X-ray techniques may be employed to verify weld depth and/or weld integrity to reduce the passing of quality control tests lacking an X-ray step for a defective resulting weld. Another quality control step may include a batch destructive test, wherein the anvil is sliced and then analyzed to ensure proper weld depth and/or weld integrity.

Various materials may be used in the manufacture of the various two-piece anvil designs disclosed herein to increase strength and/or provide the desired welding materials. For example, tungsten-alloys may be used for anvil cap materials. In various cases, W-3, W-5, W-25 or W-26 tungsten-alloys may be used for the anvil cap material. In some cases, for example, silver nickel cladding may be used for the anvil cap and 416 stainless steel or 17-4 stainless steel may be used for the anvil body.

As discussed above, the anvil body and anvil cap may comprise different materials. For example, these materials may be selected based on weldability and/or strength. In addition to weldability and strength, another material selection process may affect hardness. This is particularly important for the anvil cam lobe of the anvil body. In some cases, the hardness value of the material selected for the anvil body may be greater than the hardness value of the anvil cap. The anvil cam lobe may have a lower wear resistance than if the anvil body and anvil cap were both fabricated using softer materials.

In some cases, the rows of forming pockets may be stamped into the tissue-facing surface of the anvil. In such cases, slits or cuts may be cut into the tissue-facing surface to provide space for the material to face or move into during the stamping process. This may allow all rows of forming pockets to include forming pockets having the same pocket depth, wherein stamping the pockets without pre-lancing may make equal pocket depths between rows difficult.

Examples

Example 1-a surgical stapling anvil for use with a surgical instrument wherein the surgical stapling anvil comprises an anvil body comprising a tissue-facing surface comprising a plurality of staple forming pockets defined therein and a longitudinal cavity defined therein. The longitudinal cavity comprises a first cavity portion having a first width, a second cavity portion having a second width greater than the first width, and a third cavity portion having a third width greater than the second width, wherein the first cavity portion is configured to receive at least a portion of a cutting edge of a firing member of a surgical instrument therein, wherein the second cavity portion is configured to receive an anvil engaging portion of the firing member therein, wherein the third cavity portion further comprises a first ramp flared outwardly relative to the second cavity portion. The anvil further comprises an anvil cap comprising a first segment positioned within a portion of the second cavity portion and a second segment positioned within the third cavity portion, wherein the second segment comprises a second ramp corresponding to the first ramp, and wherein the mating portion of the first ramp and the second ramp define a mating depth. The anvil further includes a weld that welds the first chamfer and the second chamfer together, wherein the weld includes a weld depth that is substantially equal to the mating depth.

Example 2-the surgical stapling anvil of example 1 wherein the anvil cap comprises a Y-shaped cross-section.

Example 3-the surgical stapling anvil of examples 1 or 2 wherein the depth of weld is between about 0.015 inches and about 0.040 inches.

Example 4-the surgical stapling anvil of example 3 wherein the depth of weld is 0.030 inches.

Embodiment 5-the surgical stapling anvil of embodiments 1, 2, 3, or 4, wherein the third cavity portion comprises a first lobe surface, wherein the second segment comprises a second lobe surface corresponding to the first lobe surface, and wherein the first lobe surface and the second lobe surface are at least substantially parallel to the tissue-facing surface.

Example 6-the surgical stapling anvil of example 5 wherein the weld extends into the lobe surface.

Example 7-the surgical stapling anvil of examples 1, 2, 3, 4, 5, or 6, wherein the weld comprises a laser weld.

Example 8-the surgical stapling anvil of examples 1, 2, 3, 4, 5, 6, or 7 wherein the depth of weld is less than the depth of fit.

Example 9-the surgical stapling anvil of examples 1, 2, 3, 4, 5, 6, or 7 wherein the depth of weld is greater than the depth of fit.

Example 10-a surgical stapling anvil for use with a surgical instrument wherein the surgical stapling anvil comprises a first anvil member comprising a tissue-facing surface comprising a plurality of staple forming pockets and longitudinal cavities defined therein. The longitudinal cavity includes a first cavity portion having a first width, a second cavity portion having a second width greater than the first width, and a third cavity portion having a third width greater than the second width, wherein the first cavity portion is configured to receive at least a portion of a cutting edge of a firing member of a surgical instrument therein, wherein the second cavity portion is configured to receive an anvil engaging portion of the firing member therein. The anvil further includes a second anvil member including a first segment positioned within the second cavity portion, a second segment positioned within the third cavity portion, wherein the second segment includes a fourth width that is greater than the second width and a transition edge, wherein the first segment and the second segment transition at the transition edge. The anvil further includes a weld joining the second segment and the first anvil member together, wherein the weld extends at least to the transition edge.

Example 11-the surgical stapling anvil of example 10 wherein the second segment flares outwardly relative to the first segment.

Example 12-the surgical stapling anvil of examples 10 or 11 wherein the second anvil member comprises a Y-shaped cross-section.

Example 13-the surgical stapling anvil of examples 10, 11, or 12 wherein the weld has a weld depth of between about 0.015 inches and about 0.040 inches.

Example 14-the surgical stapling anvil of examples 10, 11, 12, or 13 wherein the transition edge comprises a convex surface at least substantially parallel to the tissue-facing surface.

Example 15-the surgical stapling anvil of example 14 wherein the weld extends into the lobe surface.

Example 16-the surgical stapling anvil of examples 10, 11, 12, 13, 14, or 15, wherein the weld comprises a laser weld.

Example 17-a surgical stapling anvil comprising a first anvil member comprising a longitudinal slot and a tissue-facing surface, the longitudinal slot configured to receive a firing member of a surgical instrument therein, and the tissue-facing surface comprising a plurality of staple forming pockets defined therein. The anvil further comprises a second anvil member and a weld that welds the first anvil member and the second anvil member together, wherein the first anvil member and the second anvil member comprise a first mating surface that is at least substantially perpendicular to the tissue facing surface and a second mating surface that is angled relative to the tissue facing surface, wherein the weld joins the at least second mating surfaces together.

Example 18-the surgical stapling anvil of example 17, wherein the weld further joins at least a portion of the first mating surfaces together.

Example 19-the surgical stapling anvil of examples 17 or 18, wherein the first anvil member and the second anvil member further comprise a third mating surface that is at least substantially parallel to the tissue-facing surface.

Example 20-the surgical stapling anvil of example 19, wherein the second mating surface and the third mating surface are configured to assist in retaining the second anvil member relative to the first anvil member for welding.

Example 21-the surgical stapling anvil of examples 19 or 20, wherein the weld further welds at least a portion of the third mating surfaces together.

Example 22-the surgical stapling anvil of examples 17, 18, 19, or 20 or 21, wherein the second mating surface has a mating depth that at least substantially matches a predetermined welding depth of a welder used to weld the second mating surfaces together.

Example 23-the surgical stapling anvil of examples 17, 18, 19, 20, 21, or 22 wherein the weld has a weld depth of between about 0.015 inches and about 0.040 inches.

Example 24-a surgical stapling anvil comprising an anvil body comprising a tissue-facing surface, a plurality of staple forming pockets defined in the tissue-facing surface, and a longitudinal slot. The longitudinal slot includes a first portion having a first width and a second portion having a second width greater than the first width, wherein the first portion is configured to receive a cutting edge of the firing member therein, wherein the second portion is configured to receive an anvil cam portion of the firing member therein. The anvil further comprises an anvil cap welded to the anvil body, wherein the anvil cap comprises a welded portion and a non-welded portion, wherein the non-welded portion comprises a non-welded width, and wherein the non-welded width is less than or equal to about 105% of the second width.

Embodiment 25-the surgical stapling anvil of embodiment 24 wherein the non-welding portion comprises a first non-welding portion configured to be received within the second portion of the longitudinal slot and a second non-welding portion comprising an alignment surface configured to align the anvil cap and anvil body for welding.

Example 26-the surgical stapling anvil of example 25, wherein the tissue-facing surface defines a first plane, and wherein the alignment surface defines a second plane that is at least substantially parallel to the first plane.

Example 27-the surgical stapling anvil of examples 24, 25, or 26 wherein the welded portion flares in a horn shape relative to the non-welded portion.

Example 28-the surgical stapling anvil of examples 24, 25, 26, or 27 wherein the welded portion comprises a welded chamfer corresponding to a chamfer of the anvil body.

Example 29-the surgical stapling anvil of examples 24, 25, 26, 27, or 28 wherein the anvil cap comprises a Y-shaped cross-section.

Embodiment 30-a surgical stapling anvil comprising an anvil body comprising a longitudinal slot defining a slot axis and a tissue-facing surface, wherein the longitudinal slot comprises slot surfaces facing each other. The tissue facing surface includes a first side and a second side defined by a longitudinal slot, and a plurality of staple forming pockets arranged in a plurality of longitudinal rows of staple forming pockets, wherein the plurality of longitudinal rows of staple forming pockets includes an innermost row of staple forming pockets closest to the longitudinal slot, wherein the innermost row of staple forming pockets defines a row axis at a first distance from the slot axis and a first outer boundary axis at a second distance from the slot, the second distance being greater than the first distance. The anvil further includes an anvil cap welded to the anvil body. The anvil cap includes a welded portion and a non-welded portion, the non-welded portion including an outermost non-welded region defining a second outer boundary positioned a third distance from the slot axis, wherein the third distance is less than the second distance.

Example 31-the surgical stapling anvil of example 30, wherein the third distance is greater than the first distance.

Embodiment 32-the surgical stapling anvil of embodiment 30 wherein the third distance is less than the first distance.

Example 33-the surgical stapling anvil of examples 30, 31, or 32 wherein the anvil cap further comprises an alignment surface configured to align the anvil cap and the anvil body for welding.

Embodiment 34-the surgical stapling anvil of embodiment 33 wherein the tissue-facing surface defines a first plane and wherein the alignment surface defines a second plane that is at least substantially parallel to the first plane.

Example 35-the surgical stapling anvil of examples 30, 31, 32, 33, or 34, wherein the welded portion is flared relative to the non-welded portion.

Embodiment 36-the surgical stapling anvil of embodiments 30, 31, 32, 33, 34, or 35 wherein the welded portion comprises a welded bevel corresponding to a bevel of the anvil body.

Example 37-the surgical stapling anvil of examples 30, 31, 32, 33, 34, 35, or 36, wherein the anvil cap comprises a Y-shaped cross-section.

Example 38-an anvil for use with a surgical instrument wherein the anvil includes a first anvil member that includes a tissue-facing surface defining a datum plane and a plurality of staple forming pockets defined in the tissue-facing surface. The anvil further includes a second anvil member welded to the first anvil member by at least one weld. The first and second anvil members include first and second mating regions, the first mating region defining a first plane at least substantially parallel to the reference plane, the second mating region defining a second plane substantially perpendicular to the reference plane, and a third mating region defining a third plane angled relative to the reference plane, wherein the first and second anvil members are welded by the at least one weld at the third mating region.

Example 39-the anvil of example 38, wherein the third mating zone has a length, and wherein the at least one weld comprises a weld penetration that is at least about equal to the length.

Example 40-the anvil of example 39, wherein the weld penetration is greater than the length.

Embodiment 41-the anvil of embodiments 38, 39, or 40 wherein the first mating region comprises an alignment surface configured to align the first anvil member and the second anvil member for welding.

Embodiment 42-the anvil of embodiments 38, 39, 40, or 41 wherein the second anvil member comprises a Y-shaped cross-section.

Embodiment 43-the anvil of embodiments 38, 39, 40, 41, or 42, wherein the at least one weld comprises a laser weld.

Example 44-a surgical stapling anvil comprising an anvil body comprising a longitudinal slot configured to receive a firing member therein and a tissue-facing surface comprising a plurality of staple forming pockets defined therein. The anvil further includes an anvil cap and a plurality of welds that weld the anvil cap and anvil body together, the welds including a shallow weld region having a first weld depth and a deep weld region having a second weld depth different from the first weld depth, wherein the shallow weld region and the deep weld region are configured to increase a net weld depth of the plurality of welds.

Example 45-the surgical stapling anvil of example 44 wherein the anvil cap and anvil body include corresponding alignment features configured to assist in aligning the anvil body and anvil cap for welding.

Example 46-the surgical stapling anvil of example 45, wherein the corresponding alignment features comprise a first alignment feature on a first side of the longitudinal slot positioned a first distance from the tissue-facing surface and a second alignment feature on a second side of the longitudinal slot positioned a second distance from the tissue-facing surface, and wherein the first and second distances are different.

Embodiment 47-the surgical stapling anvil of embodiments 44, 45, or 46 wherein the deep lands have a first longitudinal length, wherein the shallow lands have a second longitudinal length, and wherein the first longitudinal length and the second longitudinal length are different.

Embodiment 48-the surgical stapling anvil of embodiments 44, 45, 46, or 47 wherein the deep lands have a first longitudinal length, wherein the shallow lands have a second longitudinal length, and wherein the first longitudinal length and the second longitudinal length overlap each other along the length of the surgical stapling anvil.

Example 49-the surgical stapling anvil of examples 44, 45, 46, 47, or 48, wherein the deep welds comprise welder access areas.

Example 50-the surgical stapling anvil of example 49, wherein the welder access area comprises a filler weld.

Example 51-the surgical stapling anvil of examples 44, 45, 46, 47, 48, 49, or 50, wherein the shallow weld zone has a first stiffness, wherein the deep weld zone has a second stiffness, and wherein the first stiffness and the second stiffness are different.

Example 52-the surgical stapling anvil of examples 44, 45, 46, 47, 48, 49, 50, or 51 wherein the anvil body and anvil cap are manufactured using a metal injection molding process.

Example 53-a surgical stapling anvil comprising a first anvil member comprising a longitudinal slot configured to receive a firing member therein, a tissue-facing surface comprising a plurality of staple forming pockets defined therein, and an upper anvil surface comprising an aperture defining an edge of the first anvil member. The anvil further includes a second anvil member and a welding configuration that welds the first anvil member and the second anvil member together. The weld configuration includes a first weld having a first weld depth including a first root, wherein the first weld depth is defined as a distance between the edge and the first root, and a second weld having a second weld depth including a second root, wherein the second weld depth is defined as a distance between the edge and the second root, wherein the second weld depth and the first weld depth are different, and wherein the first weld and the second weld are configured to increase a net weld depth of the weld configuration.

Embodiment 54-the surgical stapling anvil of embodiment 53 wherein the first anvil member and the second anvil member comprise corresponding alignment features configured to assist in aligning the first anvil member and the second anvil member for welding.

Embodiment 55-the surgical stapling anvil of embodiment 54, wherein the corresponding alignment features comprise a first alignment feature and a second alignment feature, the first alignment feature being located on a first side of the longitudinal slot positioned at a first distance from the tissue-facing surface, the second alignment feature being located on a second side of the longitudinal slot positioned at a second distance from the tissue-facing surface, and wherein the first distance and the second distance are different.

Example 56-the surgical stapling anvil of examples 53, 54, or 55, wherein the first weld has a first longitudinal length, wherein the second weld has a second longitudinal length, and wherein the first longitudinal length and the second longitudinal length are different.

Embodiment 57-the surgical stapling anvil of embodiments 53, 54, 55, or 56, wherein the first weld has a first longitudinal length, wherein the second weld has a second longitudinal length, and wherein the first longitudinal length and the second longitudinal length overlap each other along the length of the surgical stapling anvil.

Example 58-the surgical stapling anvil of examples 53, 54, 55, 56, or 57, further comprising a filler weld positioned on the first weld.

Example 59-the surgical stapling anvil of examples 53, 54, 55, 56, 57, or 58 further comprising a first stiffness along the first weld and a second stiffness along the second weld, wherein the first stiffness and the second stiffness are different.

Example 60-the surgical stapling anvil of examples 53, 54, 55, 56, 57, 58, or 59, wherein the first anvil member and the second anvil member are manufactured using a metal injection molding process.

Example 61-a surgical stapling anvil comprising an anvil body comprising a tissue-facing surface having a plurality of staple forming pockets and an interlocking aperture. The anvil further comprises an anvil cap, wherein the anvil body and anvil cap are welded together, and wherein the anvil cap comprises an interlocking feature configured to be received within the interlocking hole.

Embodiment 62-the surgical stapling anvil of embodiment 61 wherein the anvil body further comprises a longitudinal slot configured to receive a firing member of the surgical instrument therein, wherein the longitudinal slot defines a longitudinal axis, and wherein the anvil body and anvil cap are only assemblable along the longitudinal axis.

Example 63-the surgical stapling anvil of examples 61 or 62 wherein the anvil body and anvil cap are manufactured using a metal injection molding process.

Example 64-a surgical stapling assembly including a shaft defining a shaft axis, a first jaw including a cartridge channel, a cartridge including a plurality of staples removably stored therein, and an anvil configured to deform the staples. The anvil includes a tissue-facing surface, a plurality of staple forming pockets defined in the tissue-facing surface, and a longitudinal slot. The anvil further includes a firing member including a body portion including first and second sides, a cutting member, a channel engagement portion configured to slidably engage the first jaw as the firing member moves through the staple firing stroke, and an anvil engagement portion configured to slidably engage the anvil as the firing member moves through the staple firing stroke, wherein the anvil engagement portion includes a lateral portion extending from the body portion, wherein the lateral portion defines an anvil engagement portion axis that is angled relative to the shaft axis, wherein the lateral portion has a longitudinal length and a vertical thickness, and wherein a ratio of the longitudinal length and the vertical thickness is between about 2.5:1 and about 20:1.

Example 65-the surgical stapling assembly of example 64, wherein the ratio is between about 5:1 and about 10:1.

Example 66-the surgical stapling assembly of example 64, wherein the ratio is about 5:1.

Example 67-the surgical stapling assembly of examples 64, 65, or 66, wherein each lateral portion and the body portion include rounded corners therebetween.

Embodiment 68-the surgical stapling assembly of embodiments 64, 65, 66, or 67, wherein the lateral portion comprises a rounded outer end.

Example 69-the surgical stapling assembly of examples 64, 65, 66, 67, or 68, wherein the anvil engaging portion comprises a planar upper surface.

Embodiment 70-the surgical stapling assembly of embodiments 64, 65, 66, 67, 68, or 69, wherein each lateral portion comprises a rounded leading edge.

Example 71-the surgical stapling assembly of examples 64, 65, 66, 67, 68, 69, or 70, wherein the anvil engaging portion axis is at about a one-degree angle relative to the shaft axis.

Embodiment 72-a surgical stapling assembly comprising a shaft defining a shaft axis, a first jaw comprising a staple cartridge channel, a staple cartridge comprising a plurality of staples removably stored therein, and a second jaw comprising an anvil, wherein the anvil is configured to deform the staples. The anvil includes a tissue-facing surface, a plurality of staple forming pockets defined in the tissue-facing surface, and a longitudinal slot. The stapling assembly also includes a firing member comprising a vertically extending main body portion having two sides, a first jaw engagement member configured to slidably engage the first jaw as the firing member moves through the staple firing stroke, and a second jaw engagement member extending laterally from each side of the main body portion, wherein the second jaw engagement member is oriented at an angle relative to the shaft axis, wherein the second jaw engagement member is configured to slidably engage the second jaw as the firing member moves through the staple firing stroke. The second jaw engagement member includes a vertical thickness and a lateral width defined as a distance between the body portion and an outer edge of the second jaw engagement member, and wherein a ratio of the vertical thickness to the lateral width is between about 1:2 and about 1:1.

Example 73-the surgical stapling assembly of example 72, wherein the ratio is about 1:1.

Example 74-the surgical stapling assembly of examples 72 or 73, wherein the second jaw engagement member and the body portion comprise rounded corners therebetween.

Example 75-the surgical stapling assembly of examples 72, 73, or 74, wherein the second jaw engagement member comprises a rounded outer end.

Embodiment 76-the surgical stapling assembly of embodiments 72, 73, 74, or 75, wherein the second jaw engagement member comprises a planar upper surface.

Embodiment 77-the surgical stapling assembly of embodiments 72, 73, 74, 75, or 76, wherein the second jaw engagement member comprises a rounded leading edge.

Example 78-the surgical stapling assembly of examples 72, 73, 74, 75, 76, or 77, wherein the second jaw engagement member is oriented at about a one-degree angle relative to the shaft axis.

Example 79-a surgical stapling assembly comprising a shaft defining a shaft axis, a first jaw comprising a staple cartridge channel, a staple cartridge comprising a plurality of staples removably stored therein, and a second jaw comprising an anvil, wherein the anvil is configured to deform the staples. The anvil includes a tissue-facing surface, a plurality of staple forming pockets defined in the tissue-facing surface, and a longitudinal slot. The stapling assembly further includes a firing member comprising a body portion comprising first and second sides, a cutting member, a first jaw coupling member configured to slidably engage the first jaw as the firing member moves through the staple firing stroke, and a second jaw coupling member configured to slidably engage the anvil as the firing member moves through the staple firing stroke, wherein the second jaw coupling member comprises a lateral portion extending from the first and second sides and defining a planar upper surface, wherein the second jaw coupling member is angled relative to the shaft axis, wherein the lateral portion and the sides comprise rounded corners therebetween, and wherein the lateral portion comprises rounded outer ends.

Embodiment 80-the surgical stapling assembly of embodiment 79, wherein each lateral portion comprises a rounded leading edge.

Embodiment 81-the surgical stapling assembly of embodiment 79 or 80, wherein the longitudinal slot comprises a rounded slot edge defining an opening of the longitudinal slot, and wherein the rounded corners are configured to slidably engage the rounded slot edge.

Embodiment 82-the surgical stapling assembly of embodiments 79, 80, or 81, wherein the longitudinal slot comprises a circular lateral slot portion, and wherein the circular outer end is configured to slidably engage a corresponding circular slot portion.

Example 83-the surgical stapling assembly of examples 79, 80, 81, or 82, wherein the second jaw coupling member is at an angle of about one degree relative to the shaft axis.

Embodiment 84-a surgical instrument assembly comprising an anvil cam portion having a first stiffness, a staple cartridge having a plurality of staples configured to be ejected from the staple cartridge by a firing member, and an anvil. The anvil includes a tissue facing surface comprising a plurality of staple forming pockets configured to deform staples and an anvil tab configured to be engaged by an anvil cam portion of the firing member during a firing stroke, wherein the anvil tab has a second stiffness, and wherein the second stiffness is substantially equal to the first stiffness such that deflection of the anvil tab will be substantially equal to deflection of the anvil cam portion.

Embodiment 85-the surgical instrument assembly of embodiment 84, further comprising means for balancing the first stiffness and the second stiffness.

Embodiment 86-the surgical instrument assembly of embodiment 85 wherein the means comprises adjusting at least one of the first geometry of the anvil cam portion and the second geometry of the anvil lobe to provide a substantially similar stiffness.

Embodiment 87-the surgical instrument assembly of embodiments 85 or 86 wherein the means further comprises adjusting at least one of the first height of the anvil cam portion and the second height of the anvil lobe to provide a substantially similar stiffness.

Example 88-the surgical instrument assembly of examples 85, 86, or 87, wherein the means comprises substantially equalizing the yield strengths of the anvil cam portion and the anvil lobe.

Example 89-the surgical instrument assembly of examples 85, 86, 87, or 88, wherein the means comprises substantially equalizing the stiffness of the anvil cam portion and the anvil lobe.

Many of the surgical instrument systems described herein are actuated by electric motors; the surgical instrument systems described herein may be actuated in any suitable manner. In various examples, for example, the surgical instrument systems described herein can be actuated by a manually operated trigger. In certain examples, the motors disclosed herein may comprise a portion or portions of a robotic control system. Further, any of the end effector and/or tool assemblies disclosed herein may be used with robotic surgical instrument systems. For example, U.S. patent application Ser. No. 13/118,241, now U.S. Pat. No. 9,072,535, entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS," discloses several examples of robotic surgical instrument systems in greater detail.

The surgical instrument systems described herein have been described in connection with the deployment and modification of staples; however, the embodiments described herein are not limited thereto. For example, various embodiments are contemplated for deploying fasteners other than staples, such as clips or tacks. Further, various embodiments utilizing any suitable means for sealing tissue are also contemplated. For example, end effectors according to various embodiments may include electrodes configured to heat and seal tissue. Additionally, for example, end effectors in accordance with certain embodiments may apply vibrational energy to seal tissue.

The entire disclosures of the following patents are hereby incorporated by reference:

U.S. patent 5,403,312 entitled "ELECTROSURGICAL HEMOSTATIC DEVICE" issued 4/1995;

U.S. patent 7,000,818 entitled "SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS" published on month 21 of 2006;

U.S. patent 7,422,139 entitled "MOTOR-DRIVEN SURGICAL CUTTING AND FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK" published 9/2008;

U.S. patent 7,464,849 entitled "ELECTRO-MECHANICAL SURGICAL INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS" issued on 12/16/2008;

U.S. patent 7,670,334 entitled "SURGICAL INSTRUMENT HAVING AN ARTICULATING END EFFECTOR" issued on month 3 and 2 of 2010;

U.S. patent 7,753,245 entitled "SURGICAL STAPLING INSTRUMENTS" issued on the year 7, month 13 of 2010;

U.S. patent 8,393,514 entitled "SELECTIVELY ORIENTABLE IMPLANTABLE FASTENER CARTRIDGE" published on 3.3.12 of 2013;

U.S. patent application Ser. No. 11/343,803, entitled "SURGICAL INSTRUMENT HAVING RECORDING CAPABILITIES"; now us patent 7,845,537;

U.S. patent application Ser. No. 12/031,573, entitled "SURGICAL CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES," filed on month 2 and 14 of 2008;

U.S. patent application Ser. No. 12/031,873, entitled "END EFFECTORS FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT", filed on 2/15/2008 (now U.S. Pat. No. 7,980,443);

U.S. patent application Ser. No. 12/235,782, entitled "MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT," now U.S. Pat. No. 8,210,411;

U.S. patent application Ser. No. 12/249,117, entitled "POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM," now U.S. Pat. No. 8,608,045;

U.S. patent application Ser. No. 12/647,100, entitled "MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROL ASSEMBLY," filed 12/24/2009; now us patent 8,220,688;

U.S. patent application Ser. No. 12/893,461, now U.S. Pat. No. 8,733,613, entitled "STAPLE CARTRIDGE", filed 9/29/2012;

U.S. patent application Ser. No. 13/036,647, entitled "SURGICAL STAPLING INSTRUMENT", filed on 28/2/2011, now U.S. Pat. No. 8,561,870;

U.S. patent application Ser. No. 13/118,241, entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS," now U.S. Pat. No. 9,072,535;

U.S. patent application Ser. No. 13/524,049, entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE", filed 6/15/2012; now us patent 9,101,358;

U.S. patent application Ser. No. 13/800,025, now U.S. Pat. No. 9,345,481, entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM", filed on day 13 of 3.2013;

U.S. patent application Ser. No. 13/800,067, entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM", filed on day 13 of 3.3, now U.S. patent application publication 2014/0263552;

U.S. patent application publication 2007/0175955 entitled "SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM" filed on 1 month 31 2006; and

U.S. patent application publication 2010/0264194, entitled "SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR", filed on 4/22/2010, now U.S. patent 8,308,040.

While various devices have been described herein in connection with certain embodiments, many modifications and variations to these embodiments may be implemented. The particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, a particular feature, structure, or characteristic shown or described in connection with one embodiment may be combined, in whole or in part, with features, structures, or characteristics of one or more other embodiments without limitation. In addition, where materials for certain components are disclosed, other materials may be used. Furthermore, according to various embodiments, a single component may be replaced with multiple components, and multiple components may also be replaced with a single component, to perform a given function or functions. The above detailed description and the following claims are intended to cover all such modifications and variations.

The devices disclosed herein may be designed to be disposed of after a single use, or they may be designed for multiple uses. In either case, however, the device may be reconditioned for reuse after at least one use. Repair may include any combination of steps including, but not limited to, disassembly of the device, subsequent cleaning or replacement of specific components of the device, and subsequent reassembly of the device. In particular, the repair facility and/or surgical team may disassemble the device, and after cleaning and/or replacing particular components of the device, the device may be reassembled for subsequent use. Those skilled in the art will appreciate that the finishing assembly may be disassembled, cleaned/replaced, and reassembled using a variety of techniques. The use of such techniques and the resulting prosthetic devices are within the scope of the present application.

The devices disclosed herein may be treated prior to surgery. First, new or used instruments are available and cleaned as needed. The instrument may then be sterilized. In one sterilization technique, the instrument is placed in a closed and sealed container (such as a plastic or TYVEK bag). The container and instrument may then be placed in a radiation field, such as gamma radiation, X-rays, and/or energetic electrons, that may penetrate the container. The radiation may kill bacteria on the instrument and in the container. The sterilized instrument may then be stored in the sterile container. The sealed container may keep the instrument sterile until the container is opened in the medical facility. The device may also be sterilized using any other technique known in the art including, but not limited to, beta radiation, gamma radiation, ethylene oxide, plasma peroxide, and/or steam.

While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.

Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. Accordingly, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

Claims

1. A surgical stapling anvil comprising:

an anvil body, the anvil body comprising:

a longitudinal slot configured to receive a firing member therein; and

a tissue-facing surface comprising a plurality of staple forming pockets defined therein;

An anvil cap comprising an outer surface; and

a plurality of welds that weld the anvil cap and anvil body together, wherein the welds comprise:

a first weld comprising a first root, wherein the first weld is within a shallow weld zone having a first weld depth, wherein the first weld depth extends from the outer surface of the anvil cap to the first root; and

a second weld comprising a second root, wherein the second weld is within a deep weld zone having a second weld depth different from the first weld depth, wherein the second weld depth extends from an outer surface of the anvil cap to the second root, wherein the shallow weld zone and the deep weld zone are configured to increase a net weld depth of the plurality of welds;

wherein the first weld root is at a greater distance from the tissue facing surface than the second weld root is from the tissue facing surface in the direction of the central axis of the surgical stapling anvil.

2. The surgical stapling anvil of claim 1 wherein said anvil cap and said anvil body include corresponding alignment features configured to assist in aligning said anvil body and said anvil cap for welding.

3. The surgical stapling anvil of claim 2, wherein said corresponding alignment features comprise a first alignment feature on a first side of said longitudinal slot positioned at a first distance from said tissue-facing surface and a second alignment feature on a second side of said longitudinal slot positioned at a second distance from said tissue-facing surface, and wherein said first and second distances are different.

4. The surgical stapling anvil of claim 1, wherein said deep weld zone has a first longitudinal length, wherein said shallow weld zone has a second longitudinal length, and wherein said first longitudinal length and said second longitudinal length are different.

5. The surgical stapling anvil of claim 1 wherein said deep weld zone has a first longitudinal length, wherein said shallow weld zone has a second longitudinal length, and wherein said first longitudinal length and said second longitudinal length overlap one another along the length of said surgical stapling anvil.

6. The surgical stapling anvil of claim 1 wherein said deep weld zone comprises a welder access area.

7. The surgical stapling anvil of claim 6 wherein said welder access area comprises a filler weld.

8. The surgical stapling anvil of claim 1, wherein said shallow weld region has a first stiffness, wherein said deep weld region has a second stiffness, and wherein said first stiffness and said second stiffness are different.

9. The surgical stapling anvil of claim 1 wherein said anvil body and said anvil cap are manufactured using a metal injection molding process.