Surgical instrument and cartridge members for use therewith

[0001] 1. Technical Field

[0002] The present disclosure relates generally to instruments for surgically joining tissue and, more specifically, to a surgical kit including a surgical instrument having a replaceable cartridge member.

[0003] 2. Background of Related Art

[0004] Various types of surgical instruments used to surgically join tissue are known in the art, and are commonly used, for example, for closure of tissue or organs in transection, resection, anastomoses, for occlusion of organs in thoracic and abdominal procedures, and for electrosurgically fusing or sealing tissue.

[0005] One example of such a surgical instrument is a surgical stapling instrument, which may include an anvil assembly, a cartridge assembly for supporting an array of surgical fasteners, an approximation mechanism for approximating the cartridge and anvil assemblies, and a firing mechanism for ejecting the surgical fasteners from the cartridge assembly.

[0006] Using a surgical instrument, it is common for a surgeon to approximate the anvil and cartridge members. Next, the surgeon can fire the instrument to emplace fasteners in tissue. Additionally, the surgeon may use the same instrument or a separate instrument to cut the tissue adjacent or between the row(s) of fasteners.

[0007] Additionally, a single use loading (“SULU”) or a disposable loading unit (“DLU”) may be attached to an elongated or endoscopic portion of a surgical stapling instrument. Such loading units allow surgical stapling instruments to have greater versatility, for example. The loading units may be configured for a single use, and/or may be configured to be used more than once.

[0008] Further, surgical instrument and/or loading unit may include a cartridge member that is removable and replaceable. For example, after all of the fasteners in a first cartridge have been ejected, a user may remove the first cartridge and replace it with a second cartridge including fasteners.

[0009] The present disclosure relates to a surgical kit. The kit comprises a surgical instrument, a loading unit, and a plurality of cartridge members. The surgical instrument includes a handle assembly, and an elongated portion extending distally from the handle assembly and defining a longitudinal axis. The loading unit is configured for selective engagement with a distal portion of the elongated portion. The loading unit including an anvil assembly and a cartridge channel. Each cartridge member includes a plurality of retention slots with at least some of the slots including fasteners therein. Each cartridge member is configured for selective mechanical engagement with the cartridge channel, and includes a longitudinal length and a working length. The working length is the longitudinal distance along retention slots having fasteners therein. The longitudinal length of each cartridge member is substantially the same, and the working length of at least two of the plurality of cartridge members is different.

[0010] In disclosed embodiments, the working length of a first cartridge member is about 60 mm, the working length of a second cartridge member is about 45 mm, and the working length of a third cartridge member is about 30 mm. It is further disclosed that the longitudinal length of each cartridge member is about 65 mm in accordance with various embodiments.

[0011] In disclosed embodiments, the second cartridge member includes a tissue stop disposed adjacent a proximal end thereof, and the tissue stop is disposed proximally of the working length of the second cartridge member. Here, it is disclosed that the tissue stop is pivotable adjacent a proximal end thereof.

[0012] In disclosed embodiments, the third cartridge member includes a tissue stop disposed adjacent a proximal end thereof, and the tissue stop is disposed proximally of the working length of the second cartridge member.

[0013] In disclosed embodiments, each cartridge member is configured for a snap-fit connection with the cartridge channel.

[0014] The present disclosure also relates to a surgical kit comprising a surgical instrument, a first cartridge member, and a second cartridge member. The surgical instrument includes a handle assembly, an elongated portion extending distally from the handle assembly and defining a longitudinal axis, and an end effector disposed adjacent a distal portion of the elongated portion. The end effector includes an anvil assembly and a cartridge channel. The first cartridge member is configured for selective mechanical engagement with the cartridge channel and includes a plurality of retention slots, with at least some of the slots including fasteners therein. The first cartridge member has a longitudinal length and a working length. The working length is the longitudinal distance along retention slots having fasteners therein. The second cartridge member is configured for selective mechanical engagement with the cartridge channel and includes a plurality of retention slots, with at least some of the slots including fasteners therein. The second cartridge member has a longitudinal length and a working length. The working length is the longitudinal distance along retention slots having fasteners therein. The longitudinal length of the first cartridge member is substantially the same as the longitudinal length of the second cartridge member. The working length of the first cartridge member is different from the working length of the second cartridge member.

[0015] In disclosed embodiment, the kit also comprises a third cartridge member configured for selective mechanical engagement with the cartridge channel. The third cartridge member includes a plurality of retention slots, with at least some of the slots including fasteners therein. The third cartridge member has a longitudinal length and a working length. The working length is the longitudinal distance along retention slots having fasteners therein. The longitudinal length of the third cartridge member is substantially the same as the longitudinal length of the second cartridge member. The working length of the third cartridge member is different from the working length of the first cartridge member and is different from the working length of the second cartridge member.

[0016] In disclosed embodiments, the working length of the first cartridge member is about 60 mm, the working length of the second cartridge member is about 45 mm, and the working length of the third cartridge member is about 30 mm. Disclosed embodiments include the longitudinal length of each cartridge member being about 65 mm.

[0017] In disclosed embodiments, the second cartridge member includes a tissue stop disposed adjacent a proximal end thereof. The tissue stop is disposed proximally of the working length of the second cartridge member. Here, it is disclosed that the tissue stop is pivotable adjacent a proximal end thereof.

[0018] In disclosed embodiments, the third cartridge member includes a tissue stop disposed adjacent a proximal end thereof. The tissue stop is disposed proximally of the working length of the third cartridge member.

[0019] In disclosed embodiments, each cartridge member is configured for a snap-fit connection with the cartridge channel.

[0029] Embodiments of the presently disclosed surgical instrument, loading unit for use therewith, and cartridge members for use therewith, are described in detail with reference to the drawings, wherein like reference numerals designate corresponding elements in each of the several views. As is common in the art, the term “proximal” refers to that part or component closer to the user or operator, e.g., surgeon or physician, while the term “distal” refers to that part or component farther away from the user.

[0030] A surgical instrument having linear jaw members of the present disclosure is indicated as reference numeral 100a in FIG. 1A. A surgical instrument having curved jaw members of the present disclosure is indicated as reference numeral 100b in FIG. 1B. Collectively, surgical instruments 100a and 100b are referred to herein as reference numeral 100. Similarly, several features that are common to both surgical stapling instruments 100a and 100b are collectively referred to as the same reference number (e.g., handle portion 110, elongated portion 120, and jaw members 230).

[0031] Handle portion 110 of surgical instrument 100 is shown in FIG. 2, and an enlarged view of the distal end of handle portion 110, including a distal end of firing rod 130, is shown in FIG. 3. A single use loading unit (“SULU”) or a disposable loading unit (“DLU”) (collectively referred to as “loading unit 200”), which is mechanically engageable with handle portion 100 is shown in FIGS. 4 and 6. Loading unit 200 is attachable to elongated portion 120 of surgical instrument 100, e.g., to allow surgical instrument 100 to have greater versatility. Loading unit 200 may be configured for a single use, and/or may be configured to be used more than once. Additionally, the disclosed surgical instrument 100 (e.g., loading unit 200) is configured to accept a plurality of removable and replaceable cartridges members 518 (see FIG. 6).

[0032] Examples of loading units for use with a surgical stapling instrument are disclosed in commonly-owned U.S. Pat. No. 5,752,644 to Bolanos et al., the entire contents of which are hereby incorporated by reference herein. Further details of an endoscopic surgical stapling instrument are described in detail in commonly-owned U.S. Pat. No. 6,953,139 to Milliman et al., the entire contents of which are hereby incorporated by reference herein.

[0033] In a surgical instrument 100 in accordance with the present disclosure, a firing rod 130 is moved distally through actuation of a movable handle 132 to deploy the fasteners. For example, referring back to FIGS. 1A and 1B, at least a partial actuation of movable handle 132 with respect a stationary handle 134 translates firing rod 130 longitudinally, such that a dynamic clamping member 606 (FIG. 5) translates longitudinally, to approximate at least one jaw member with respect to the other. It is also envisioned that other types of handles can be used such as, for example, motor-driven, hydraulic, ratcheting, etc.

[0034] With reference to FIG. 4, loading unit 200 of the present disclosure is shown. Loading unit 200 includes a proximal body portion 210 defining a longitudinal axis “A-A,” and a tool assembly 220 including a pair of jaw members 230, which include an anvil assembly 506 and a cartridge assembly 508. Proximal body portion 210 is configured to removably attach to elongated portion 120 of surgical instrument 100. More particularly, an insertion tip 202 of loading unit 200 is linearly inserted into the distal end of elongated portion 120 (FIGS. 2 and 3) of surgical instrument 100. Nubs 204 of insertion tip 202 (FIG. 4) move linearly through slots (not shown) formed in the distal end of elongated portion 120. Subsequently, loading unit 200 is rotated about the longitudinal axis “A-A” such that nubs 204 move transversely through slots (not shown) within elongated portion 120. Additionally, during engagement of loading unit 200 and elongated portion 120, firing rod 130 of handle portion 110 engages a drive assembly 560 (FIG. 5) of loading unit 200.

[0035] With reference to FIG. 5, anvil assembly 506 includes an anvil cover 510 and an anvil plate 512, which includes a plurality of staple forming depressions. Anvil plate 512 is secured to an underside of anvil cover 510 and defines a channel between plate 512 and cover 510. When tool assembly 220 is in the approximated position, staple forming depressions are positioned in juxtaposed alignment with cartridge assembly 508.

[0036] Cartridge assembly 508 includes a channel or carrier 516 which removably receives and supports a cartridge member 518. The cartridge member 518 can be removably attached to the channel or carrier 516 by adhesives, a snap-fit connection, or other connections (as discussed below). Cartridge member 518 includes a pair of support struts 524 which rest on sidewalls 517 of carrier 516 to stabilize cartridge member 518 on carrier 516. Support struts 524 also set the height or location of cartridge member 518 with respect to anvil plate 512. An external surface of carrier 516 includes an angled cam surface 516a.

[0037] Cartridge member 518 defines a plurality of laterally spaced staple retention slots 528 (see FIGS. 7-9), which are configured as holes in its tissue contacting surface. Each slot 528 is configured to receive a fastener (e.g., staple) 530 therein. Cartridge member 518 also defines a plurality of cam wedge slots which accommodate pushers 532 and which are open on the bottom (i.e., away from tissue contacting surface 540) to allow an actuation sled 536 to pass therethrough.

[0038] In the illustrated embodiments, cartridge member 518 includes a central slot 526, and three rows of staple retention slots 528 positioned on each side of slot 526. Distal advancement of a dynamic clamping member 606 (discussed below) causes actuation sled 536 to pass through cam wedge slots and force pushers 532 towards respective fasteners 530. The fasteners 530 are then forced out of their respective staple retention slots 528 toward anvil plate 512.

[0039] With continued reference to FIG. 5, loading unit 200 includes dynamic clamping member 606 disposed adjacent a distal end of drive assembly 560. Dynamic clamping member 606 includes an I-shaped cross-section, the top portion of which is configured to engage the anvil assembly 506, and the bottom portion of which is configured to engage the cartridge assembly 508. More particularly, engagement between the top portion of the dynamic clamping member 606 and the anvil assembly 506 causes the anvil assembly 506 to pivot towards the cartridge assembly 508, e.g., to clamp tissue therebetween. Continued distal translation of dynamic clamping member 606 helps maintain the relative positions of cartridge assembly 508 and anvil assembly 506 with respect to each other and causes ejection of fasteners 530 from staple retention slots 528. Subsequent to the ejection of fasteners 530, a cutting edge, which may be included on a distal face of dynamic clamping member 606, severs the fastened tissue.

[0040] After dynamic clamping member 606 has been advanced a predetermined amount (e.g., corresponding to when all fasteners 530 have been ejected), a user may retract dynamic clamping member 606. Once dynamic clamping member 606 has been retracted a predetermined amount, a user may use the same cartridge member 518 an additional time (e.g., when cartridge assembly 508 includes a multi-use cartridge member 518, such as the cartridge disclosed in U.S. patent application Ser. No. 13/173,295 filed on Jun. 30, 2011, the entire contents of which being incorporated by reference herein) or may remove the cartridge member 518 and insert another cartridge member.

[0041] With reference to FIG. 6, jaw members 230 of loading unit 200 are shown including an anvil assembly 506 and a cartridge carrier 516. In the illustrated embodiments, cartridge carrier 516 is configured to releasably accept a cartridge member 518. As discussed above, cartridge member 518 includes a plurality of fasteners 530, a plurality of pushers 532, and actuation sled 536.

[0042] Cartridge member 518 is configured for reception at least partially within a cartridge channel 516 (e.g., a snap-fit connection) of loading unit 200. For example, in the embodiment illustrated in FIG. 6, cartridge member 518 includes a plurality of tabs 519, which are each configured to releasably engage a corresponding detent 521 of cartridge channel 516.

[0043] With specific reference to FIGS. 7-9, the present disclosure includes a plurality of cartridge members 518a, 518b and 518c (collectively referred to as “cartridge member 518”). Each cartridge member 518 is configured for selective insertion and removal from cartridge channel 516. As shown, each cartridge member 518a, 518b and 518c is the same length or substantially the length “L” and each is dimensioned to engage cartridge channel 516, e.g., via a snap-connection. However, while the overall length “L” of each cartridge member 518a, 518b and 518c is substantially the same, the working length “WL” of each cartridge member 518a, 518b and 518c is different from each other. The working length “WL” is defined as the longitudinal distance along staple retention slots 528 having fasteners 530 therein (and does not include the longitudinal distance along staple retention slots without fasteners therein). It is envisioned that the working length “WL_A” of cartridge member 518a is about 60 mm, the working length “WL_B” of cartridge member 518b is about 45 mm, and the working length “WL_C” of cartridge member 518c is about 30 mm. As can be appreciated, a particular working length “WL” of a cartridge member 518 may be desired for a particular surgical procedure. Other lengths “L” and working lengths “WL” of cartridge members 518 are also envisioned and within the scope of the disclosure.

[0044] In the portion of the cartridge members 518 where no fasteners 530 are present, a tissue stop 700 may be included. As shown in FIGS. 8 and 9, tissue stops 700 extend distally from a proximal portion of cartridge members 518b, 518c, respectively. Additionally, while tissue stops 700 are shown being pivotable adjacent their proximal ends and located adjacent the proximal end of cartridge members 518b, 518c, respectively, it is also envisioned that tissue stops 700 are pivotable adjacent their distal ends and located adjacent the distal end of respective cartridge members 518b, 518c (as shown in FIG. 5, for example). Further details of tissue stops are disclosed in U.S. patent application Ser. No. 13/208,447 filed on Aug. 12, 2011, the entire contents of which are incorporated by reference herein.

[0045] It is further envisioned that cartridge members 518a, 518b, and 518c include fasteners 530 of different heights. In such embodiments, working lengths “WL” of cartridge members 518 may be the same or different. Fasteners having different heights (i.e., different heights from other fasteners in the same cartridge member 518, or different heights from fasteners in other cartridge members 518), may be desirable for various surgical procedures and/or surgical locations within the body. This concept is further disclosed in U.S. Pat. No. 7,407,075 to Holsten et. al., the entire contents of which are incorporated herein by reference.

[0046] The present disclosure also includes a kit 1000. Kit 1000 includes a surgical instrument 100, a plurality of cartridge members 518, and/or a loading unit 200, such as those described above. As can be appreciated surgical instrument 100 and/or loading unit 200 includes anvil assembly 506 and cartridge channel 516.

[0047] The present disclosure also includes embodiments having other types of handles than the illustrated embodiment. For example, the present disclosure also includes a powered (e.g., electrically-powered, battery-powered, etc.) handle.

[0048] While the above description contains many specifics, these specifics should not be construed as limitations on the scope of the present disclosure, but merely as illustrations of various embodiments thereof. For example, the disclosed surgical instrument 100 may include tool assembly 220 attached thereto (i.e., without a loading unit 200) and may be configured to accept removable cartridge members 518. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.