Articulation features for surgical end effector

[0001] The present invention relates to surgical instruments and, in various arrangements, to surgical stapling and cutting instruments and staple cartridges for use therewith that are designed to staple and cut tissue.

[0032] Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying 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 understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims.

[0033] The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a surgical system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, an element of a system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

[0034] The terms “proximal” and “distal” are used herein with reference to a clinician manipulating the handle portion of the 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 be further appreciated that, for convenience and clarity, spatial terms such as “vertical”, “horizontal”, “up”, and “down” 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.

[0035] 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 numerous surgical procedures and applications including, for example, in connection with open surgical procedures. As the present Detailed Description proceeds, the reader will further appreciate that the various instruments disclosed herein can be inserted into a body in any way, such as through a natural orifice, through an incision or puncture hole formed in tissue, etc. The working portions or end effector portions of the instruments can be inserted directly into a patient's body or can be inserted through an access device that has a working channel through which the end effector and elongate shaft of a surgical instrument can be advanced.

[0036] Although various aspects of the present disclosure have been described herein in connection with linear staplers, these aspects can be similarly implemented in other surgical staplers such as, for example, circular staplers and/or curved staplers. Also although various aspects of the present disclosure are described in connection with a hand-held instrument, these aspects can be similarly implemented in robotic surgical systems. Various suitable robotic surgical systems are disclosed in U.S. Patent No. 2012/0298719, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, filed May 27, 2011, now U.S. Pat. No. 9,072,535, the entire disclosure of which is incorporated by reference herein.

[0037] Referring primarily to FIG. 1-3, a surgical instrument 10 comprises a shaft 11 and an end effector 12 extending from the shaft 11. The end effector 12 comprises a first jaw 14 and a second jaw 15. The first jaw 14 comprises a staple cartridge 16. The staple cartridge 16 is insertable into and removable from a cartridge pan or channel 17 of the first jaw 14; however, other embodiments are envisioned in which the staple cartridge 16 is not removable from, or at least readily replaceable from, the first jaw 14. The second jaw 15 comprises an anvil 18 configured to deform staples ejected from the staple cartridge 16. The second jaw 15 is pivotable relative to the first jaw 14 about a closure axis; however, other embodiments are envisioned in which the first jaw 14 is pivotable relative to the second jaw 15.

[0038] Referring to FIG. 2, in various examples, the surgical instrument 10 includes a housing 8 that comprises a handle assembly 29 that is configured to be grasped, manipulated, and actuated by the clinician. The housing 8 is configured for operable attachment to an interchangeable shaft assembly 46, which includes the end effector 12 and at least a portion of the shaft 11. In accordance with the present disclosure, various forms of interchangeable shaft assemblies 46 may be effectively employed in connection with robotically controlled surgical systems as well hand-held instruments. The term “housing” may encompass a housing or similar portion of a robotic system that houses or otherwise operably supports at least one drive system configured to generate and apply at least one control motion that could be used to actuate interchangeable shaft assemblies. The term “frame” may refer to a portion of a hand-held surgical instrument. The term “frame” also may represent a portion of a robotically controlled surgical instrument and/or a portion of the robotic system that may be used to operably control a surgical instrument. Interchangeable shaft assemblies may be employed with various robotic systems, instruments, components, and methods disclosed in U.S. Pat. No. 9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which is herein incorporated by reference in its entirety.

[0039] Referring primarily to FIG. 3, the staple cartridge 16 comprises a cartridge body 21. The cartridge body 21 includes a proximal end 22, a distal end 23, and a deck 24 extending between the proximal end 22 and the distal end 23. In use, the staple cartridge 16 is positioned on a first side of the tissue to be stapled and the anvil 18 is positioned on a second side of the tissue. The anvil 18 is moved toward the staple cartridge 16 to compress and clamp the tissue against the deck 24. Thereafter, staples removably stored in the cartridge body 21 can be deployed into the tissue. The cartridge body 21 includes staple cavities 26 defined therein wherein staples are removably stored in the staple cavities 26. The staple cavities 26 are generally arranged in six longitudinal rows. Three rows of staple cavities 26 are positioned on a first side of a longitudinal slot 27 and three rows of staple cavities 26 are positioned on a second side of the longitudinal slot 27. Other arrangements of staple cavities 26 and staples may be possible.

[0040] As described in greater detail below, the surgical instrument 10 staples and cuts tissue by employing a firing mechanism carefully orchestrated to perform the tissue stapling ahead of the tissue cutting. To ensure avoidance of an instance where the tissue cutting occurs ahead of, or without, tissue stapling, the surgical instrument 10 is equipped with various safety features

[0041] The staples of the staple cartridge 16 are generally supported by staple drivers in the cartridge body 21. The drivers are movable between a first, or unfired position, and a second, or fired, position to eject the staples from the staple cavities 26. The drivers are retained in the cartridge body 21 by a pan or retainer which extends around the bottom of the cartridge body 21 and includes resilient members configured to grip the cartridge body 21 and hold the retainer to the cartridge body 21. The drivers are movable between their unfired positions and their fired positions by a sled. The sled is movable between a proximal position adjacent the proximal end 22 and a distal position adjacent the distal end 23. The sled comprises a plurality of ramped surfaces configured to slide under the drivers and lift the drivers, and the staples supported thereon, toward the anvil 18.

[0042] Further to the above, the sled is moved distally by a firing member. The firing member is configured to contact the sled and push the sled from a proximal position adjacent the proximal end 22 toward a distal position adjacent the distal end 23. The longitudinal slot 27 defined in the cartridge body 21 is configured to receive the firing member. The anvil 18 also includes a slot configured to receive the firing member. The firing member further comprises a first cam which engages the first jaw 14 and a second cam which engages the second jaw 15. As the firing member is advanced distally, the first cam and the second cam can control the distance, or tissue gap, between the deck 24 of the staple cartridge 16 and the anvil 18. The firing member also comprises a knife configured to incise the tissue captured intermediate the staple cartridge 16 and the anvil 18.

[0043] The shaft 11 encompasses and guides a firing motion from the housing 8 through a longitudinally-reciprocating laminated firing bar extending proximally from the firing member. In particular, the shaft 11 includes a longitudinal firing bar slot that receives the firing bar.

[0044] The housing 8 depicted in FIGS. 1-3 is shown in connection with an interchangeable shaft assembly 46 that includes an end effector 12 that comprises a surgical cutting and fastening device that is configured to operably support a surgical staple cartridge 16 therein. The housing 8 may be configured for use in connection with interchangeable shaft assemblies that include end effectors that are adapted to support different sizes and types of staple cartridges, have different shaft lengths, sizes, and types, etc. In addition, the housing 8 may also be effectively employed with a variety of other interchangeable shaft assemblies including those assemblies that are configured to apply other motions and forms of energy such as, for example, radio frequency (RF) energy, ultrasonic energy and/or motion to end effector arrangements adapted for use in connection with various surgical applications and procedures. Furthermore, the end effectors, shaft assemblies, handles, surgical instruments, and/or surgical instrument systems can utilize any suitable fastener, or fasteners, to fasten tissue. For instance, a fastener cartridge comprising a plurality of fasteners removably stored therein can be removably inserted into and/or attached to the end effector of a shaft assembly.

[0045] Referring to FIGS. 3-5, the surgical instrument 10 further comprises an articulation joint 20 configured to permit the end effector 12 to be rotated, or articulated, relative to the shaft 11. The end effector 12 is rotatable about a longitudinal articulation axis 19 extending through the articulation joint 20 between an unarticulated, or home, configuration (FIG. 4) and an articulated configuration (FIG. 5) where the end effector 12 defines an angle α with the longitudinal axis 19.

[0046] With regard to the articulation joint 20, in at least one example, the shaft 11 includes a pivot pin 30 which can be received within a pivot aperture 31 defined in a frame 32 of the end effector 12. The end effector frame 32 can further comprise a drive pin 33 extending therefrom which can be operably engaged with an articulation driver 34. The drive pin 33 can be received within a pin slot 35 defined in a distal end 36 of the articulation driver 34 such that the drive pin 33 can bear against a first sidewall 37 of the pin slot 35 in an unarticulated, or home, configuration (FIG. 4) and can bear against a second sidewall 38 of the pin slot 35 in an articulated configuration (FIG. 5).

[0047] The drive pin 33 can be configured to receive a force applied thereto and, depending on the direction in which the force is applied to the drive pin 33, rotate the end effector 12 in a first direction or a second, opposite, direction. More particularly, when a force is applied to the drive pin 33 in the distal direction by the articulation driver 34, the articulation driver 34 can push the drive pin 33 around the pivot pin 30 and, similarly, when a force is applied to the drive pin 33 in the proximal direction by the articulation driver 34, the articulation driver 34 can pull the drive pin 33 around the pivot pin 30 in the opposite direction, for example. To the extent that the drive pin 33 were to be placed on the opposite side of the articulation joint 20, for example, the distal and proximal movements of the articulation driver 34 would produce an opposite effect on the end effector 12.

[0048] In various examples, the surgical instrument 10 can be utilized in a minimally invasive surgical procedure such as, for example, a laparoscopic surgical procedure. In such examples, an access port such as a trocar can create an opening in a body wall to insert the end effector 12 of the surgical instrument 10 into a surgical site inside a patient. The remainder of the surgical instrument 10 remains outside the patient allowing a user of the surgical instrument 10 to remotely manipulate the end effector 12 at the surgical site.

[0049] It is desirable to insert the end effector 12 through the access port in an unarticulated configuration to maintain the opening at a small size. A high clearance between the drive pin 33 and the pin slot 35 facilitates the insertion of the end effector 12 through the access port by softening the connection between the end effector 12 and the shaft 11. A high clearance between the drive pin 33 and the pin slot 35 permits a limited range of passive or unintended motion of the end effector 12 relative to the shaft 11 in the unarticulated, or home, configuration. A high clearance permits the end effector 12 to be slightly wiggled relative to the shaft 11. The added flexibility facilitates insertion of the end effector 12 through a trocar.

[0050] Once inside the patient, the end effector 12 can be articulated to a desired orientation. A low clearance between the drive pin 33 and the pin slot 35 ensures a robust articulated configuration of the end effector 12 during operation by strengthening and/or stiffening the connection between the end effector 12 and the shaft 11. A low clearance between the drive pin 33 and the pin slot 35 reduces the passive or unintended motion of the end effector 12 relative to the shaft 11 in the articulated, or home, configuration.

[0051] In one example, as illustrated in FIGS. 6-8, the combined benefit of a high clearance in the unarticulated, or home, configuration and a low clearance in the articulated configuration can be achieved by utilizing the pin slot 35 that includes a first portion 35a that has a width (w₁) and a second portion 35b that has a width (w₂) smaller than the width (w₁). The drive pin 33 can be positioned at the first portion 35a in the unarticulated, or home, configuration, as illustrated in FIGS. 6 and 7, and at the second portion 35b in the articulated configuration, as illustrated in FIG. 8.

[0052] The greater width of the first portion 35a, relative to the second portion 35b, provides an additional clearance (w₃) at the first portion 35a, which is calculated by subtracting the diameter of the drive pin 33 from the width (w₁). As illustrated in FIGS. 6 and 7, the clearance (w₃) permits the drive pin 33 to move or reciprocate within the first portion 35a between a first position, where the drive pin 33 abuts against a distal wall 39 of the first portion 35a, and a second position, where the drive pin 33 abuts against a proximal wall 40, opposite the distal wall 39, of the first portion 35a. FIGS. 6 and 7 further illustrate a range of motion or reciprocating distance (θ) that the end effector 12 is permitted to move, or passively articulate, relative to the shaft 11 in the unarticulated, or home, configuration owing to the additional clearance (w₃).

[0053] Referring to FIG. 8, the drive pin 33 is moved laterally a distance (d) as the end effector 12 is transitioned by the articulation driver 34 from an unarticulated, or home, configuration (FIG. 7) to an articulated configuration (FIG. 8). Said another way, the drive pin 33 is moved from the first portion 35a of the pin slot 35 to the second portion 35b as the end effector 12 is articulated. In the articulated configuration, the drive pin 33 snuggly or tightly fits in the second portion 35b owing to the smaller width (w₂) of the second portion 35b, which yields a smaller clearance (w₄) at the second portion 35b. The clearance (w₄) is calculated by subtracting the diameter of the drive pin 33 from the width (w₂).

[0054] Snuggly fitted in the second portion 35b, the movement of the drive pin 33 within the second portion 35b is restricted while the end effector 12 remains in the articulated configuration. As the end effector 12 is returned to the unarticulated configuration, by the articulation driver 34, the drive pin 33 moves laterally to return to the first portion 35a where the additional clearance (w3) provides more space for drive pin 33 to move between the distal wall 39 and the proximal wall 40.

[0055] In various examples, the width (w₁) is greater than the width (w₂) by a value selected from a range of about 1% to about 200%. In certain examples, the width (w₁) is greater than the width (w₂) by a value selected from a range of about 1% to about 100%. In certain examples, the width (w₁) is greater than the width (w₂) by a value selected from a range of about 5% to about 50%. In certain examples, the width (w₁) is greater than the width (w₂) by a value selected from a range of about 5% to about 10%. In various examples, the clearance (w₃) is greater than the clearance (w4) by a value selected from a range of about 10% to about 100%, for example. In certain examples, the clearance (w₃) is greater than the clearance (w₄) by a value selected from a range of about 5% to about 50%, for example.

[0056] Referring now to FIGS. 9-11, a surgical instrument 50 is similar in many respects to the surgical instrument 10. For example, the surgical instrument 50 includes the shaft 11 and the end effector 12. The surgical instrument 50 utilizes a pin slot 55 in place of the pin slot 35, and a drive pin 53 in place of the drive pin 33. The drive pin 53 can be received within the pin slot 55 defined in the distal end 36 of the articulation driver 34 such that the drive pin 53 can bear against a first sidewall 57 of the pin slot 55 in an unarticulated, or home, configuration (FIG. 9) and can bear against a second sidewall 58 of the pin slot 55 in an articulated configuration (FIG. 11).

[0057] As the end effector 12 is articulated by the articulation driver 34, the drive pin 53 translates within the pin slot 55 toward the second sidewall 58. The drive pin 53 also rotates while translating changing its orientation from a first orientation (FIG. 9) defined in the unarticulated, or home, configuration to a second orientation (FIG. 11) defined in the articulated configuration. In the first orientation, the drive pin 53 comprises a width (w₆), and in the second orientation, the drive pin 53 comprises a width (w₈) greater than the width (w₆). The surgical instrument 50 achieves the combined benefit of a high clearance in the unarticulated, or home, configuration and a low clearance in the articulated configuration by utilizing the drive pin 53 that comprises different widths in different orientations.

[0058] The pin slot 55 further includes a distal wall 59 and a proximal wall 60 that are spaced apart defining a width (w₁₀) therebetween. The width (w₁₀) is greater than the width (w₆) of the pin slot 55 in the first orientation. As illustrated in FIGS. 9 and 10, a clearance (w₇), calculated by subtracting the width (w₆) of the drive pin 53 in the first orientation from the width (w₁₀) of the pin slot 55, permits the drive pin 53 to move or reciprocate between a first position and a second position. In the first position, as illustrated in FIG. 9, the drive pin 53 abuts against the distal wall 59. In the second position, as illustrated in FIG. 10, the drive pin 53 abuts against the proximal wall 60. FIGS. 9 and 10 further illustrate a range of motion or reciprocating distance (13) that the end effector 12 is permitted to move, or passively articulate, relative to the shaft 11 owing to the additional clearance (w₇).

[0059] Referring to FIG. 11, the drive pin 53 is moved laterally a distance (d) as the end effector 12 is transitioned by the articulation driver 34 from an unarticulated, or home, configuration (FIG. 9) to an articulated configuration (FIG. 11). Said another way, the drive pin 53 is moved laterally and radially from a first position and a first orientation in first portion 55a of the pin slot 55 to a second position and a second orientation in a second portion 55b of the pin slot 55 as the end effector 12 is articulated. In the articulated configuration, the drive pin 53 snuggly or tightly fits in the second portion 55b owing to the greater width (w₈) of the drive pin 53 in the second orientation. As illustrated in FIG. 11, a clearance (w₉) is calculated by subtracting the width (w₈) of the drive pin 53 in the second orientation from the width (w₁₀) of the pin slot 55.

[0060] Snuggly or tightly fitted in the second portion 55b, the movement of the drive pin 53 within the second portion 55b is restricted while the end effector 12 remains in the articulated configuration. As the end effector 12 is returned to the unarticulated configuration, by the articulation driver 34, the drive pin 53 moves laterally and radially to return to the first position and first orientation in the first portion 55a where the additional clearance (w7) provides more space for drive pin 53 to move between the proximal wall 60 and the distal wall 59.

[0061] In various examples, as illustrated in FIGS. 9-11, the drive pin 53 has an elliptical shape resulting in different widths in different orientations. Other irregular shapes capable of achieving different widths in different orientations are contemplated by the present disclosure. In certain examples, the drive pin 53 may comprise a protrusion, or an outwardly extending portion, where the protrusion would contribute to the width of the drive pin 53 in the second orientation in the second portion 55b but not the width of the drive pin 53 in the first orientation in the first portion 55a.

[0062] In various examples, the width (w₈) is greater than the width (w₆) by a value selected from a range of about 1% to about 200%. In certain examples, the width (w₈) is greater than the width (w₆) by a value selected from a range of about 1% to about 100%. In certain examples, the width (w₈) is greater than the width (w₆) by a value selected from a range of about 5% to about 50%. In certain examples, the width (w₈) is greater than the width (w₆) by a value selected from a range of about 5% to about 10%. In various examples, the clearance (w₇) is greater than the clearance (w₉) by a value selected from a range of about 10% to about 100%, for example. In certain examples, the clearance (w₇) is greater than the clearance (w₉) by a value selected from a range of about 5% to about 50%, for example.

[0063] In various examples, the surgical instrument 10 and/or the surgical instrument 50 can comprise an articulation driver system including a proximal articulation driver and a distal articulation driver. When a drive force is transmitted to the proximal articulation driver, whether it be in the proximal direction or the distal direction, the drive force can be transmitted to the distal articulation driver through an articulation lock. Furthermore, a firing member can be utilized to impart such a drive force to the proximal articulation driver. Examples of suitable articulation driver systems are disclosed in U.S. patent application Ser. No. 13/803,210, titled SENSOR ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS, and filed Mar. 14, 2014, now U.S. Patent Application Publication No. 2014/0263538, which is hereby incorporated by reference herein in its entirety.

[0064] Referring now to FIGS. 12-16, a surgical instrument 100 is similar in many respects to the surgical instrument 10. Like the surgical instrument 10, the surgical instrument 100 includes an articulation driver system including the articulation driver 34 movable to cause the end effector 12 to articulate relative to the shaft 11. In addition, the surgical instrument 100 includes an articulation joint 101 and an adaptive closure driver system 102 configured to maintain, or resist a change in, a jaw aperture 9 between the first jaw 14 and the second jaw 15 during articulation of the end effector 12 relative to the shaft 11.

[0065] A typical closure driver system causes at least one of the first jaw 14 and the second jaw 15 to move between an open configuration, defining the jaw aperture 9, and a closed or approximated configuration, as described above in greater detail. The offset nature of the articulation driver 34 with respect to the longitudinal axis 19, however, causes a typical closure driver system to move slightly during articulation of the end effector 12 due to a change in the closure length between the unarticulated and the articulated configurations.

[0066] The closure length is the distance occupied by the closure driver system. In an unarticulated configuration, the closure driver system follows a straight, or at least substantially straight, path. In an articulated configuration, however, the closure driver system follows an arcuate path. Unable to accommodate a change in the closure length, caused by the transition of the closure driver system from a straight path to an arcuate path, the typical closure driver system exerts an unwanted closure force on the end effector 12 reducing the jaw aperture 9 in the open configuration. The resulting reduction in the jaw aperture 9, caused by the articulation of the end effector 12, reduces the effectiveness of the end effector 12 in accommodating tissue between the first jaw 14 and the second jaw 15

[0067] The adaptive closure driver system 102 comprises one or more flexible components that allow for a lesser change in the closure length due to bending during articulation of the end effector 12. As illustrated in FIGS. 12-16, the adaptive closure driver system 102 includes a shaft closure tube section 103 having upper and lower distally projecting tangs 104, 104′. An end effector closure tube section 105 includes a horseshoe aperture 106 and a tab 107 for engaging an opening tab on the anvil 18. The horseshoe aperture 106 and the tab 107 engage an opening tab of the anvil 18 when the anvil 18 is opened. The closure tube section 105 is shown having upper and lower proximally projecting tangs 110, 110′.

[0068] Further to the above, the closure tube section 103 is coupled to the closure tube section 105 by flexible bands 111,111′ that allow for a lesser change in the closure length due to bending during articulation of the end effector 12. The flexible band 111 extends between the tangs 104 and 110. Likewise, the flexible band 111′ extends between the tangs 104′ and 110′.

[0069] In use, the adaptive closure driver system 102 is translated distally to close the anvil 18, for example, in response to the actuation of the handle assembly 29 (FIG. 1). The anvil 18 is closed by distally translating the closure tube section 103. The flexible bands 111, 111′ transmit the distal closure force of the closure tube section 103 to the closure tube section 105. In turn, the closure tube section 105 is translated distally, which closes the anvil 18. The anvil 18 is opened by proximally translating the closure tube section 103 and the closure tube section 105, causing the tab 107 and the horseshoe aperture 106 to contact and push against the opening tab of the anvil 18 to lift the anvil 18.

[0070] Although flexible, the bands 111, 111′ are capable of transmitting closure and/or opening forces between the closure tube section 103 and the closure tube section 105. In one example, as illustrated in FIGS. 13 and 14, the flexible bands 111, 111′ are comprised of a plurality of flexible members 112 that are attached together to form the bands 111, 111′. The distal ends of the flexible members 112 can be bent and/or welded together to form the bands 111, 111′. Distal portions 113, 113′ of the flexible bands 111, 111′ can be fixed to the tangs 110, 110′ of the closure tube section 105. Proximal portions 114, 114′ of the flexible bands 111, 111′ can be fixed to the tangs 104, 104′ of the closure tube section 103.

[0071] The attachment of the flexible members 112 to one another and/or the fixing of the bands 111, 111′ to the closure tube sections 103, 105 can be accomplished by any suitable technique including, but not limited to, bolting, screwing, crimping, gluing or any other suitable technique. In at least one example, the attachment of the flexible members 112 to one another and/or the fixing of the bands 111, 111′ to the closure tube sections 103, 105 can be accomplished by any suitable welding technique or appropriate apparatus to accomplish a weld seal including, but not limited to, gas tungsten arc welding, shielded metal arc welding, plasma arc welding, laser beam welding, electron beam welding, or a combination thereof.

[0072] Referring to FIG. 13, the flexible members 112 can be aligned and attached to one another side-to-side permitting a greater degree of flexibility in one direction over another. The number of flexible members 112 can determine the degree of flexibility of a flexible band. In at least one example, four flexible members 112 are used to create a flexible band 111, 111′. In at least one example, the number of flexible members used to create a flexible band ranges from 2 to 20. The thickness of a flexible member 112 can also affect the flexibility of a flexible band 111, 111′. In at least one example, the thickness (T1) of a flexible member 112 can be about 25% of the thickness (T2) of a flexible band 111, 111′.

[0073] In certain examples, the proximal portions 114, 114′ of the flexible bands 111, 111′ are not fixed to the tangs 104, 104′ of the closure tube section 103. Instead, as illustrated in FIGS. 15 and 16, a surgical instrument 100′, which similar in many respects to the surgical instrument 100, includes flexible bands 111, 111′ that have proximal portions 114, 114′ that are movably coupled to tangs 104, 104′, respectively.

[0074] In the example illustrated in FIGS. 15 and 16, the tang 104 is equipped with an enclosure 115 configured to movably accommodate the proximal portion 114 of the flexible band 111. The proximal portion 114 is permitted to move within the enclosure 115 to compensate for the change in closure length that occurs during articulation of the end effector 12. The proximal portion 114, however, includes laterally extended features that prevent the proximal portion from exiting the enclosure 115 by abutting against a distal wall 116 of the enclosure 115. The distal wall 116 includes an opening 117 sized to permit motion of the flexible band there through but not the proximal portion 114. During closure of the end effector 12, the proximal portion 114 abuts against a proximal wall 118 of the enclosure 115. In a similar fashion, the proximal portion 114′ of the flexible band 111′ can be movably accommodated in an enclosure of the tang 104′.

[0075] Referring to FIGS. 17-21, a surgical instrument 200 is similar in many respects to the surgical instrument 10. For example, the surgical instrument 200 includes an end effector 212 and a shaft 211. In addition, the surgical instrument 200 includes an articulation joint 220 and an adaptive closure driver system 202. Like the adaptive closure driver system 102, the adaptive closure driver system 202 is configured to accommodate a change in the closure length during articulation of the end effector 12. The adaptive closure driver system 202 is configured to maintain, or resist a change in, a jaw aperture 9 between the first jaw 14 and the second jaw 15 during articulation of the end effector 212 relative to the shaft 211.

[0076] Further to the above, the adaptive closure driver system 202 includes a shaft closure tube section 203 having upper and lower distally projecting tangs 204, 204′. An end effector closure tube section 205 includes a horseshoe aperture and a tab for engaging an opening tab on the anvil 18. The horseshoe aperture and the tab engage an opening tab of the anvil 18 when the anvil 18 is opened. The closure tube section 205 has upper and lower proximally projecting tangs 210, 210′.

[0077] Further to the above, the closure tube section 203 is coupled to the closure tube section 105 by double pivot links 230, 230′. An upper double pivot link 230 includes upwardly projecting distal and proximal pivot pins 234, 236 that engage respectively an upper distal pin hole 238 in the upper proximally projecting tang 210 and an upper proximal pin hole 240 in the upper distally projecting tang 204. The lower double pivot link 230′ includes downwardly projecting distal and proximal pivot pins 234′, 236′ that engage respectively a lower distal pin hole 238′ in the lower proximally projecting tang 210′ and a lower proximal pin hole 240′ in the lower distally projecting tang 204′.

[0078] In use, the adaptive closure driver system 202 is translated distally to close the anvil 18, for example, in response to the actuation of the handle assembly 29 (FIG. 17). The anvil 18 is closed by distally translating the closure tube section 203. The links 230, 230′ transmit the distal closure force of the closure tube section 203 to the closure tube section 205. In turn, the closure tube section 205 is translated distally, which closes the anvil 18. The anvil 18 is opened by proximally translating the closure tube section 203 and the closure tube section 205, causing the tab and the horseshoe aperture to contact and push against the opening tab of the anvil 18 to lift the anvil 18.

[0079] As illustrated in FIG. 18, the pin holes 238, 238′ are bigger in size than the pin holes 240, 240′ permitting the closure tube section 205 to move relative to the pin holes 238, 238′ in order to accommodate the change in closure length caused by articulation of the end effector 12. In the example illustrated in FIGS. 18 and 19, the pin holes 238, 238′ are stretched longitudinally into an elliptical shape. In the unarticulated position, as illustrated in FIG. 18, the pivot pins 234, 234′ abut against proximal ends 241 of the pin holes 238, 238′. In the articulated position, as illustrated in FIG. 19, the pivot pins 234, 234′ abut against distal ends 243 of the pin holes 238, 238′.

[0080] Referring now to FIGS. 22-25, a surgical instrument 300 is similar in many respects to the surgical instruments 10, 100, 200. For example, the surgical instrument 300 includes a shaft 311 and an end effector 312 articulatable relative to the shaft 311 between a home, or unarticulated, position and an articulated position. The surgical instrument 300 includes an articulation control system 302 which includes the articulation driver 34. Examples of suitable articulation control systems are disclosed in U.S. patent application Ser. No. 13/803,053, titled INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT, filed Mar. 14, 2014, now U.S. Patent Application Publication No. 2014/0263564, which is hereby incorporated by reference herein in its entirety.

[0081] A surgical operator may utilize the articulation control system 302 to articulate the end effector 312 relative to the shaft 311 between an articulation home state position and an articulated position. In addition, the surgical operator may utilize the articulation control system 302 to reset or return the articulated end effector 312 to the articulation home state position.

[0082] In addition, as illustrated in the exemplary schematic block diagram in FIG. 23, the articulation control system 302 may comprise a control circuit 301. The control circuit 301 includes a controller 306 which can be configured to receive an input signal and, in response, activate an electric motor 303 to cause the end effector 312 to articulate in accordance with such an input signal. The control circuit 301 also includes one or more sensors 305 configured to detect an articulation position of the end effector 312.

[0083] The controller 306 may comprise a processor 307 and/or one or more memory units 308. By executing instruction code stored in the memory 308, the processor 307 may control various components of the surgical instrument 300, such as the motor 303. The controller 306 may be implemented using integrated and/or discrete hardware elements, software elements, and/or a combination of both. The sensors 305 are in communication with the processor 307.

[0084] The surgical instrument 300 may include a motor controller 309 in operable communication with the controller 306. The motor controller 309 can be configured to control a direction of rotation of the motor 303. For example, the motor 303 can be powered by a battery such as, for example, the battery 304 and the motor controller 309 may be configured to determine the voltage polarity applied to the motor 303 by the battery 304 and, in turn, the direction of rotation of the motor 303 based on input from the controller 306. For example, the motor 303 may reverse the direction of its rotation from a clockwise direction to a counterclockwise direction when the voltage polarity applied to the motor 303 by the battery 304 is reversed by the motor controller 309 based on input from the controller 306.

[0085] To reset the end effector 312 from an articulated position to an articulation home state position, the end effector 312 needs to be positioned in sufficient alignment with the shaft 311 in the articulation home state position, also referred to herein as an unarticulated position such that the end effector 312 and at least a portion of the shaft 311 can be inserted into or retracted from a patient's internal cavity through an access port such as, for example, a trocar positioned in a wall of the internal cavity without damaging the axis port.

[0086] To accurately return the end effector 312 to the articulation home state position, the surgical instrument 300 is configured to divide the motion of the end effector 312 toward the articulation home state position into two separate stages: a motor-driven stage and a non-motor driven stage. The motor-driven stage is a high tolerance stage intended to bring the end effector 312 within a predetermined range of positions. On the other hand, the non-motor driven stage is low tolerance stage intended to accurately adjust, or fine-tune, the position of the end effector 312 within the predetermined range to precisely reach the articulation home state position.

[0087] In the motor-driven stage, the controller 306 is relied upon to direct the motor-driven movement of the end effector 312 toward the predetermined range. The controller 306, however, is not required to determine a precise location of the articulation home state position. Instead, the controller 306 need only bring the end effector 312 to any position within the predetermined range.

[0088] In at least one example, the predetermined range includes any angle up to and including 30°, for example, with the longitudinal axis on either side of the longitudinal axis. In at least one example, the predetermined range includes any angle up to and including 20°, for example, with the longitudinal axis on either side of the longitudinal axis. In at least one example, the predetermined range includes any angle up to and including 10°, for example, with the longitudinal axis on either side of the longitudinal axis. In at least one example, the predetermined range includes any angle up to and including 5°, for example, with the longitudinal axis on either side of the longitudinal axis. Other values for the predetermined range are contemplated by the present disclosure.

[0089] In the non-motor-driven stage, a mechanical centering system 313 is configured to passively guide the end effector 312 within the predetermined range to the articulation home state position with a lower tolerance than the controller 306. In some examples, as illustrated in FIGS. 24 and 25, the mechanical centering system 313 includes a notch 315 defined at a proximal portion 314 of the end effector 312. A mechanical alignment feature 316 is configured to capture the notch 315 at any position within the predetermined range. The predetermined range can be defined by the width and/or depth of the notch 315. The mechanical alignment feature 316 is configured to exert a force onto the proximal portion 314 of the end effector 312 to accurately drive the end effector 312 to the articulation home state position.

[0090] In some examples, as illustrated in FIGS. 24, 25 the mechanical alignment feature 316 is a spring-loaded pin. A spring 317 is configured to bias the mechanical alignment feature 316 against an outer surface 318 of the proximal portion 314 of the end effector 312. Once the mechanical alignment feature 316 engages the edge of the notch 315, the biasing force of the mechanical alignment feature 316 guides the end effector 312 to the articulation home state position. The spring 317 is supported in a housing 319 in the shaft 311. A distal portion 316a of the mechanical alignment feature 316 movably extends through an opening in a distal wall 320 of the housing 319. A stop 321 prevents a proximal portion 316b of the mechanical alignment feature 316 from exiting the housing through the opening of the distal wall 320.

[0091] In various examples, as illustrated in FIGS. 24 and 25, the mechanical centering system 313 can be configured to accurately drive the end effector 312 to a predetermined articulation position in a non-motor driven stage following an initial motor-driven stage, wherein the controller 306 directs the articulation of the end effector 312 toward a predetermined range encompassing the predetermined articulation position. To accurately bring the end effector 312 to a predetermined articulated position, the surgical instrument 300 is configured to divide the motion of the end effector 312 toward the predetermined articulation position into two separate stages: a motor-driven stage controlled by the controller 306 and a non-motor-driven stage controlled by the mechanical centering system 313.

[0092] Further to the above, the mechanical centering system 313 may include one or more notches 323, 324 in the proximal portion 314 at one or more predetermined articulation positions. For example, as illustrated in FIGS. 24 and 25, the proximal portion 314 includes the notch 323 at an articulation angle (α).

[0093] To articulate the end effector 312 to an articulation position at the articulation angle (α), for example, the controller 306 directs the motor 303 to motivate the articulation driver 34 to rotate the end effector 312 toward an articulation position at the articulation angle (α). The controller 306 need only bring the end effector 312 to any position within a predetermined range encompassing the articulation position at the articulation angle (α). The predetermined range can be defined by the width and/or depth of the notch 323.

[0094] Once the end effector 312 is in the predetermined range, the mechanical centering system 313 guides the end effector 312 to the articulation position at the articulation angle (α), as illustrated in FIG. 25. The mechanical alignment feature 316 is configured to capture the notch 315 at any position within the predetermined range, and exert a force onto the proximal portion 314 of the end effector 312 to accurately drive the end effector 312 to the articulation position at the articulation angle (α).

[0095] Referring now to FIGS. 26-29, a surgical instrument 400 is similar in many respects to the surgical instruments 10, 100, 200, 300. For example, the surgical instrument 400 includes a shaft 411 and an end effector 412 articulatable relative to the shaft 411 between a home, or unarticulated, position and an articulated position. The surgical instrument 400 includes an articulation control system 402 which includes the articulation driver 34.

[0096] The surgical instrument 400 further includes a mechanical centering system 413 which is similar in many respects to the mechanical centering system 313. For example, a proximal portion 414 of the end effector 412 includes notches 415, 423, 424, which are similar to the notches 315, 323, 324, of the proximal portion 314 of the end effector 312. The mechanical centering system 413 includes a mechanical alignment feature 416 that is similar in function, but different in structure, than the mechanical alignment feature 316. Like the mechanical alignment feature 316, the mechanical alignment feature 416 is configured to capture the notches 315, 323, 324, and guide the end effector 412 to a target position such as, for example, an articulation home state position or a predetermined articulation position.

[0097] Like the end effector 312, the end effector 412 can be guided by the controller 306 toward the articulation home state position in a high-tolerance motor-driven stage. The controller 306 is relied upon to bring the end effector 412 within a predetermined range of positions that can be defined by the depth and/or width of the notch 415. As described above in connection with the surgical instrument 300, the motor-driven stage is followed by a low-tolerance non-motor-driven stage, which is controlled by the mechanical centering system 413. Once the end effector 412 is within the predetermined range, the mechanical alignment feature 416 exerts a force onto the proximal portion 414 of the end effector 412 to accurately drive the end effector 412 from any position within the predetermined range to the articulation home state position.

[0098] As illustrated in FIGS. 28 and 29, the end effector 412, like the end effector 312, can also be articulated to a predetermined articulation position in a high-tolerance motor-driven stage followed by a low-tolerance non-motor-driven stage. The mechanical centering system 413, like the mechanical centering system 313, is configured to adjust, or fine-tune, the position of the end effector 412 within the predetermined range to precisely reach the predetermined articulation position.

[0099] Further to the above, the mechanical alignment feature 416 is in the form of a leaf spring that includes a generally arcuate frame including two ends 429, 430, which are movable position against a shaft frame portion 428. An arcuate portion 431 extends between the ends 429, 430. The arcuate portion 431 includes a distal pointed portion 432 extending distally from the center of the arcuate portion 431, as illustrated in FIG.

[0100] The mechanical alignment feature 416 is maintained in an unbiased configuration, or a first biased configuration, while the pointed portion 432 is received in one of the notches 415, 423, 424. While pressed against an outer surface 418 of the proximal portion 414 of the end effector 312, as illustrated in FIG. 28, the mechanical alignment feature 416 flexes to a second biased configuration greater than the first biased configuration.

[0101] Once the mechanical alignment feature 416 engages the edge of the notch 415, the biasing force of the mechanical alignment feature 416 guides the end effector 412 to the articulation home state position. Likewise, once the mechanical alignment feature 416 engages the edge of the notch 415, the biasing force of the mechanical alignment feature 416 guides the end effector 412 to a predetermined articulation position corresponding to the notch 424.

[0102] In various examples, a closure tube section 105 may include a mechanical alignment feature in the form of plastic or spring-loaded insert that is configured to center an end effector at an articulation home state position. A corresponding notch can be configured to receive the insert of the closure tube section 105 during closure of the end effector. The distal closure motion of the closure tube section 105 forces the insert of the closure tube section 105 into the notch, which guides the end effector to the articulation home state position.

[0103] Although various devices have been described herein in connection with certain embodiments, modifications and variations to those embodiments may be implemented. Particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined in whole or in part, with the features, structures or characteristics of one ore more other embodiments without limitation. Also, where materials are disclosed for certain components, other materials may be used. Furthermore, according to various embodiments, a single component may be replaced by multiple components, and multiple components may be replaced by a single component, to perform a given function or functions. The foregoing description and following claims are intended to cover all such modification and variations.

[0104] The devices disclosed herein can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either case, however, a device can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps including, but not limited to, the disassembly of the device, followed by cleaning or replacement of particular pieces of the device, and subsequent reassembly of the device. In particular, a reconditioning facility and/or surgical team can disassemble a device and, after cleaning and/or replacing particular parts of the device, the device can be reassembled for subsequent use. Those skilled in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

[0105] The devices disclosed herein may be processed before surgery. First, a new or used instrument may be obtained and, when necessary, cleaned. 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 field of radiation that can penetrate the container, such as gamma radiation, x-rays, and/or high-energy electrons. 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 it is opened in a medical facility. A 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.

[0106] While this invention has been described as having exemplary designs, the present invention may be further modified within the spirit and scope of the disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.

[0107] 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 materials do not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, 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.

[0108] A surgical instrument that comprises an articulation joint, an end effector extending distally from the articulation joint, a shaft extending proximally from the articulation joint, and an articulation driver. The end effector comprises a drive pin movable between a first position and a second position. The articulation driver is configured to move the drive pin from the first position to the second position to transition the end effector from an unarticulated configuration to an articulated configuration. The surgical instrument further comprises a pin slot extending from the articulation driver. The pin slot is configured to movably accommodate the drive pin in the unarticulated configuration. The pin slot is configured to tightly accommodate the drive pin in the articulated configuration.

[0109] The surgical instrument of Example 1, wherein the pin slot comprises a first portion configured to accommodate the drive pin in the first position and a second portion configured to accommodate the drive pin in the second position.

[0110] The surgical instrument of Example 2, wherein the first portion is greater in width than the second portion.

[0111] The surgical instrument of Example 2 or 3, wherein the drive pin is movable within the first portion independent of the articulation driver.

[0112] The surgical instrument of Example 1, 2, 3, or 4, wherein the drive pin comprises a first orientation defining a first width in the first position, wherein the drive pin comprises a second orientation defining a second width in the second position, and wherein the second width is greater than the first width.

[0113] The surgical instrument of Example 1, 2, 3, 4, or 5, wherein the pin slot comprises a proximal wall and a distal wall. The drive pin is movable between the proximal wall and the distal wall independent of the articulation driver.

[0114] The surgical instrument of Example 1, 2, 3, 4, 5, or 6, wherein the pin slot comprises a first lateral wall and a second lateral wall. The drive pin bears against the first lateral wall in the unarticulated configuration. The drive pin bears against the second lateral wall in the articulated configuration.

[0115] A surgical instrument that comprises an end effector, a shaft, and an adaptive closure driver system. The end effector extends distally from the shaft. The end effector is movable relative to the shaft between an unarticulated configuration and an articulated configuration. The adaptive closure driver system is configured to transition the end effector between an open configuration and a closed configuration. The adaptive closure driver system comprises a first closure length in the unarticulated configuration, and a second closure length in the articulated configuration. The first closure length is different than the second closure length.

[0116] The surgical instrument of Example 8, wherein the adaptive closure driver system comprises a distal closure tube section, a proximal closure tube section, and a flexible band configured to couple the distal closure tube section to the proximal closure tube section.

[0117] The surgical instrument of Example 9, wherein the flexible band comprises a distal portion fixed to the distal closure tube section and a proximal portion movably coupled to the proximal closure tube section.

[0118] The surgical instrument of Example 10, wherein the proximal closure tube section comprises an enclosure configured to movably accommodate the proximal portion of the flexible band.

[0119] The surgical instrument of Example 8, wherein the adaptive closure driver system comprises a distal closure tube section, a proximal closure tube section, and a link extending between the distal closure tube section and the proximal closure tube section.

[0120] The surgical instrument of Example 12, wherein the link comprises a first pivot pin and a second pivot pin.

[0121] The surgical instrument of Example 13, wherein the distal closure tube section comprises a first hole configured to receive the first pivot pin, wherein the proximal closure tube section comprises a second hole configured to receive the second pivot pin, and wherein the first hole is larger than the second hole.

[0122] A surgical instrument that comprises a shaft, an end effector extending distally from the shaft, a motor configured to generate at least one rotational motion, and an articulation driver operably coupled to the motor. The end effector is articulatable relative to the shaft between a home position and a predetermined articulated position. The articulation driver is configured to articulate the end effector from the home position in response to the at least one rotational motion of the motor. Articulation of the end effector between the home position and the predetermined articulated position comprises a predetermined motor-driven articulation motion and a predetermined non-motor-driven articulation motion.

[0123] The surgical instrument of Example 15, wherein a biasing member is configured to drive the predetermined non-motor-driven articulation motion independent of the motor.

[0124] The surgical instrument of Example 15, wherein an alignment feature is configured to drive the predetermined non-motor-driven articulation motion independent of the motor.

[0125] The surgical instrument of Example 15, 16, or 17, wherein the predetermined motor-driven articulation motion is configured to deliver the end effector to a first articulated position.

[0126] The surgical instrument of Example 15, 16, 17, or 18, wherein the predetermined non-motor-driven articulation motion is configured to deliver the end effector to a second articulated position.

[0127] The surgical instrument of Example 15, 16, 17, 18, or 19, wherein the second articulated position is closer to the predetermined articulated position than the first articulated position.