CN110799107A - Surgical anvil arrangement - Google Patents

Abstract

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

Description

Surgical anvil placement

Background technique

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

Description of drawings

The various features of the embodiments described herein, along with their advantages, can be understood from the following description in conjunction with the accompanying drawings:

1 is a side elevational view of a surgical system including a handle assembly and a plurality of interchangeable surgical tool assemblies that can be used therewith;

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;

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

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

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

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

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

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

Figure 8 is an exploded assembled view of a portion of the interchangeable surgical tool assembly of Figures 4-7;

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

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

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

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

Figure 13 is a cross-sectional side elevation view of the anvil of Figure 12;

Figure 14 is a bottom view of the anvil of Figures 12 and 13;

15 is a cross-sectional side elevation view of a portion of the surgical end effector and shaft portion of the interchangeable surgical tool assembly of FIG. 4 with the unused surgical staple cartridge properly positioned within the elongated channel of the surgical end effector in place;

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

Figure 17 is another cross-sectional side elevation view of the surgical end effector and shaft portion of Figure 16 with the firing member fully retracted to its starting position;

Figure 18 is a top cross-sectional view of the surgical end effector and shaft portion depicted in Figure 15 with an unused surgical staple cartridge properly seated with the elongated channel of the surgical end effector;

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

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

Figure 21 is an exploded side elevation view of the anvil and portion of the elongated channel of Figure 20;

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

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

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

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

Figure 26 is an exploded perspective view of the anvil of Figure 25;

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

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

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

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

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

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

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

Figure 34 provides a comparison between the first embodiment of the anvil and the second embodiment of the anvil;

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

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;

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

Figure 38 is a diagram depicting stress concentrations in the first anvil embodiment of Figure 34 and the firing member of Figure 36;

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

68 is a schematic diagram depicting the energy required to propel a firing member disclosed herein through a spike firing stroke;

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

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

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

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

Figure 73 is an exploded view of the anvil of Figure 72;

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

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

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

77 is a cross-sectional view of an anvil including an anvil body and an anvil cap, wherein the anvil body and anvil cap are welded to each other;

78 is a photomicrograph of a surgical stapling anvil including a first anvil member and a second anvil member, wherein the first and second anvil members are welded to each other;

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

80 is a graph representing four different surgical stapling anvil arrangements subjected to two different loading conditions, including deflection and stress data for the first condition and stress data for the second condition;

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

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

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

84 is a cross-sectional view of a surgical stapling anvil including a first anvil member and a second anvil member welded to each other;

Figure 85 is a partial cutaway, partial exploded view of the surgical stapling anvil of Figure 84;

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

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

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

Figure 89 is a perspective view of the end effector assembly shown in Figure 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 in Fig. 88;

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

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

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

Figure 94 is an exploded view of the staple cartridge channel of Figure 93;

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

Figure 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;

Figure 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;

Figure 98 is a front view of the firing member of Figure 96;

Figure 99 is a front view of the firing member of Figure 96;

Figure 100 is a front view of the firing member of Figure 97;

Figure 101 is a front view of the firing member of Figure 97;

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

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

104 is a cross-sectional view of a suturing system including the firing member of FIG. 97;

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

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

Figure 107 is a partial cross-sectional view of the anvil and firing member of the stapling system of Figure 104; and

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

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications described herein illustrate various embodiments of the invention in one form, and such exemplifications should not be construed to limit the scope of the invention in any way.

Detailed ways

The applicant of the present application has the following US patent applications filed on the same date as the present application and each of which is incorporated herein by reference in its entirety:

-US Patent Application Serial No. ________ entitled "SURGICAL ANVIL MANUFACTURING METHODS"; Attorney's Docket No. END8165USNP/170079M;

- US Patent Application Serial No. __________ entitled "SURGICAL ANVIL ARRANGEMENTS"; Attorney Docket No. END8168USNP/170080;

- US Patent Application Serial No. __________ entitled "SURGICAL ANVIL ARRANGEMENTS"; Attorney Docket No. END8170USNP/170081;

- US Patent Application Serial No. __________ entitled "SURGICAL FIRING MEMBER ARRANGEMENTS"; Attorney Docket No. END8169USNP/170083;

- US Patent Application Serial No. __________ entitled "STAPLE FORMING POCKET ARRANGEMENTS"; Attorney's Docket No. END8167USNP/170085;

- US Patent Application Serial No. __________ entitled "STAPLE FORMING POCKET ARRANGEMENTS"; Attorney's Docket No. END8232USNP/170086;

- US Patent Application Serial No. __________ entitled "SURGICAL END EFFECTORS AND ANVILS"; Attorney's Docket No. END8166USNP/170087; and

-US Patent Application Serial No. __________ entitled "ARTICULATION SYSTEMS FOR SURGICAL INSTRUMENTS"; Attorney's Docket No. END8171USNP/170088.

The applicant of the present application has the following US patent applications filed on December 21, 2016, each of which is incorporated herein by reference in its entirety:

- US Patent Application Serial No. 15/386,185 entitled "SURGICAL STAPLING INSTRUMENTS AND REPLACEABLE TOOL ASSEMBLIESTHEREOF";

- US Patent Application Serial No. 15/386,230 entitled "ARTICULATABLE SURGICAL STAPLING INSTRUMENTS";

- US Patent Application Serial No. 15/386,221 entitled "LOCKOUT ARRANGEMENTS FOR SURGICAL END EFFECTORS";

- US Patent Application Serial No. 15/386,209 entitled "SURGICAL END EFFECTORS AND FIRING MEMBERS THEREOF";

- US Patent Application Serial No. 15/386,198 entitled "LOCKOUT ARRANGEMENTS FOR SURGICAL END EFFECTORS ANDREPLACEABLE TOOL ASSEMBLIES";

- US Patent Application Serial No. 15/386,240 entitled "SURGICAL END EFFECTORS AND ADAPTABLE FIRING MEMBERS THEREFOR";

- US Patent Application Serial No. 15/385,939 entitled "STAPLE CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLECAVITIES THEREIN";

- US Patent Application Serial No. 15/385,941 entitled "SURGICAL TOOL ASSEMBLIES WITH CLUTCHING ARRANGEMENTS FORSHIFTING BETWEEN CLOSURE SYSTEMS WITH CLOSURE STROKE REDUCTION FEATURES ANDARTICULATION AND FIRING SYSTEMS";

- US Patent Application Serial No. 15/385,943 entitled "SURGICAL STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS";

- US Patent Application Serial No. 15/385,950 entitled "SURGICAL TOOL ASSEMBLIES WITH CLOSURE STROKE REDUCTIONFEATURES";

- US Patent Application Serial No. 15/385,945 entitled "STAPLE CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLECAVITIES THEREIN";

- US Patent Application Serial No. 15/385,946 entitled "SURGICAL STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS";

- US Patent Application Serial No. 15/385,951 entitled "SURGICAL INSTRUMENTS WITH JAW OPENING FEATURES FOR INCREASINGA JAW OPENING DISTANCE";

- US Patent Application Serial No. 15/385,953 entitled "METHODS OF STAPLING TISSUE";

- US Patent Application Serial No. 15/385,954 entitled "FIRING MEMBERS WITH NON-PARALLEL JAW ENGAGEMENT FEATURES FORSURGICAL END EFFECTORS";

- US Patent Application Serial No. 15/385,955 entitled "SURGICAL END EFFECTORS WITH EXPANDABLE TISSUE STOPARRANGEMENTS";

- US Patent Application Serial No. 15/385,948 entitled "SURGICAL STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS";

- US Patent Application Serial No. 15/385,956 entitled "SURGICAL INSTRUMENTS WITH POSITIVE JAW OPENING FEATURES";

- US Patent Application Serial No. 15/385,958 entitled "SURGICAL INSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTINGFIRING SYSTEM ACTUATION UNLESS AN UNSPENT STAPLE CARTRIDGE IS PRESENT";

- US Patent Application Serial No. 15/385,947 entitled "STAPLE CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLECAVITIES THEREIN";

- US Patent Application Serial No. 15/385,896 entitled "METHOD FOR RESETTING A FUSE OF A SURGICAL INSTRUMENT SHAFT";

- US Patent Application Serial No. 15/385,898 entitled "STAPLE FORMING POCKET ARRANGEMENT TO ACCOMMODATE DIFFERENTTYPES OF STAPLES";

- US Patent Application Serial No. 15/385,899 entitled "SURGICAL INSTRUMENT COMPRISING IMPROVED JAW CONTROL";

- US Patent Application Serial No. 15/385,901 entitled "STAPLE CARTRIDGE AND STAPLE CARTRIDGE CHANNEL COMPRISING WINDOWS DEFINED THEREIN";

- US Patent Application Serial No. 15/385,902 entitled "SURGICAL INSTRUMENT COMPRISING A CUTTING MEMBER";

- US Patent Application Serial No. 15/385,904 entitled "STAPLE FIRING MEMBER COMPRISING A MISSING CARTRIDGE AND/ORSPENT CARTRIDGE LOCKOUT";

- US Patent Application Serial No. 15/385,905 entitled "FIRING ASSEMBLY COMPRISING A LOCKOUT";

- US Patent Application Serial No. 15/385,907 entitled "SURGICAL INSTRUMENT SYSTEM COMPRISING AN END EFFECTOR LOCKOUTAND A FIRING ASSEMBLY LOCKOUT";

- US Patent Application Serial No. 15/385,908 entitled "FIRING ASSEMBLY COMPRISING A FUSE";

- US Patent Application Serial No. 15/385,909 entitled "FIRING ASSEMBLY COMPRISING A MULTIPLE FAILED-STATE FUSE";

- US Patent Application Serial No. 15/385,920 entitled "STAPLE FORMING POCKET ARRANGEMENTS";

- US Patent Application Serial No. 15/385,913 entitled "ANVIL ARRANGEMENTS FOR SURGICAL STAPLE/FASTENERS";

- US Patent Application Serial No. 15/385,914 entitled "METHOD OF DEFORMING STAPLES FROM TWO DIFFERENT TYPES OFSTAPLE CARTRIDGES WITH THE SAME SURGICAL STAPLING INSTRUMENT";

- US Patent Application Serial No. 15/385,893 entitled "BILATERALLY ASYMMETRIC STAPLE FORMING POCKET PAIRS";

- US Patent Application Serial No. 15/385,929 entitled "CLOSURE MEMBERS WITH CAM SURFACE ARRANGEMENTS FOR SURGICALINSTRUMENTS WITH SEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS";

- US Patent Application Serial No. 15/385,911 entitled "SURGICAL STAPLE/FASTENERS WITH INDEPENDENTLY ACTUATABLECLOSING AND FIRING SYSTEMS";

- US Patent Application Serial No. 15/385,927 entitled "SURGICAL STAPLING INSTRUMENTS WITH SMART STAPLE CARTRIDGES";

- US Patent Application Serial No. 15/385,917 entitled "STAPLE CARTRIDGE COMPRISING STAPLES WITH DIFFERENT CLAMPINGBREADTHS";

- US Patent Application Serial No. 15/385,900 entitled "STAPLE FORMING POCKET ARRANGEMENTS COMPRISING PRIMARYSIDEWALLS AND POCKET SIDEWALLS";

- US Patent Application Serial No. 15/385,931 entitled "NO-CARTRIDGE AND SPENT CARTRIDGE LOCKOUT ARRANGEMENTS FORSURGICAL STAPLE/FASTENERS";

- US Patent Application Serial No. 15/385,915 entitled "FIRING MEMBER PIN ANGLE";

- US Patent Application Serial No. 15/385,897 entitled "STAPLE FORMING POCKET ARRANGEMENTS COMPRISING ZONED FORMINGSURFACE GROOVES";

- US Patent Application Serial No. 15/385,922 entitled "SURGICAL INSTRUMENT WITH MULTIPLE FAILURE RESPONSE MODES";

- US Patent Application Serial No. 15/385,924 entitled "SURGICAL INSTRUMENT WITH PRIMARY AND SAFETY PROCESSORS";

- US Patent Application Serial No. 15/385,912 entitled "SURGICAL INSTRUMENTS WITH JAWS THAT ARE PIVOTABLE ABOUT AFIXED AXIS AND INCLUDE SEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS";

- US Patent Application Serial No. 15/385,910 entitled "ANVIL HAVING A KNIFE SLOT WIDTH";

- US Patent Application Serial No. 15/385,906 entitled "FIRING MEMBER PIN CONFIGURATIONS";

- US Patent Application Serial No. 15/386,188 entitled "STEPPED STAPLE CARTRIDGE WITH ASYMMETRICAL STAPLES";

- US Patent Application Serial No. 15/386,192 entitled "STEPPED STAPLE CARTRIDGE WITH TISSUE RETENTION AND GAPSETTING FEATURES";

- US Patent Application Serial No. 15/386,206 entitled "STAPLE CARTRIDGE WITH DEFORMABLE DRIVER RETENTION FEATURES";

- US Patent Application Serial No. 15/386,226 entitled "DURABILITY FEATURES FOR END EFFECTORS AND FIRING ASSEMBLIESOF SURGICAL STAPLING INSTRUMENTS";

- US Patent Application Serial No. 15/386,222 entitled "SURGICAL STAPLING INSTRUMENTS HAVING END EFFECTORS WITHPOSITIVE OPENING FEATURES";

- US Patent Application Serial No. 15/386,236 entitled "CONNECTION PORTIONS FOR DEPOSABLE LOADING UNITS FOR SURGICALSTAPLING INSTRUMENTS".

- US Patent Application Serial No. 15/385,887 entitled "METHOD FOR ATTACHING A SHAFT ASSEMBLY TO A SURGICALINSTRUMENT AND, ALTERNATIVELY, TO A SURGICAL ROBOT";

- US Patent Application Serial No. 15/385,889 entitled "SHAFT ASSEMBLY COMPRISING A MANUALLY-OPERABLE RETRACTION SYSTEM FOR USE WITH A MOTORIZED SURGICAL INSTRUMENT SYSTEM";

- US Patent Application Serial No. 15/385,890 entitled "SHAFT ASSEMBLY COMPRISING SEPARATELY ACTUATABLE ANDRETRACTABLE SYSTEMS";

- US Patent Application Serial No. 15/385,891 entitled "SHAFT ASSEMBLY COMPRISING A CLUTCH CONFIGURED TO ADAPT THEOUTPUT OF A ROTARY FIRING MEMBER TO TWO DIFFERENT SYSTEMS";

- US Patent Application Serial No. 15/385,892 entitled "SURGICAL SYSTEM COMPRISING A FIRING MEMBER ROTATABLE INTO ANARTICULATION STATE TO ARTICULATE AN END EFFECTOR OF THE SURGICAL SYSTEM";

- US Patent Application Serial No. 15/385,894 entitled "SHAFT ASSEMBLY COMPRISING A LOCKOUT";

- US Patent Application Serial No. 15/385,895 entitled "SHAFT ASSEMBLY COMPRISING FIRST AND SECOND ARTICULATION LOCKOUTS";

- US Patent Application Serial No. 15/385,916 entitled "SURGICAL STAPLING SYSTEMS";

- US Patent Application Serial No. 15/385,918 entitled "SURGICAL STAPLING SYSTEMS";

- US Patent Application Serial No. 15/385,919 entitled "SURGICAL STAPLING SYSTEMS";

- US Patent Application Serial No. 15/385,921 entitled "SURGICAL STAPLE/FASTENER CARTRIDGE WITH MOVABLE CAMMINGMEMBER CONFIGURED TO DISENGAGE FIRING MEMBER LOCKOUT FEATURES";

- US Patent Application Serial No. 15/385,923 entitled "SURGICAL STAPLING SYSTEMS";

- US Patent Application Serial No. 15/385,925 entitled "JAW ACTUATED LOCK ARRANGEMENTS FOR PREVENTING ADVANCEMENT OFA FIRING MEMBER IN A SURGICAL END EFFECTOR UNLESS AN FIRED CARTRIDGE ISINSTALLED IN THE END EFFECTOR";

- US Patent Application Serial No. 15/385,926 entitled "AXIALLY MOVABLE CLOSURE SYSTEM ARRANGEMENTS FOR APPLYING CLOSURE MOTIONS TO JAWS OF SURGICAL INSTRUMENTS";

- US Patent Application Serial No. 15/385,928 entitled "PROTECTIVE COVER ARRANGEMENTS FOR A JOINT INTERFACE BETWEEN AMOVABLE JAW AND ACTUATOR SHAFT OF A SURGICAL INSTRUMENT";

- US Patent Application Serial No. 15/385,930 entitled "SURGICAL END EFFECTOR WITH TWO SEPARATE COOPERATING OPENINGFEATURES FOR OPENING AND CLOSING END EFFECTOR JAWS";

- US Patent Application Serial No. 15/385,932 entitled "ARTICULATABLE SURGICAL END EFFECTOR WITH ASYMMETRIC SHAFTARRANGEMENT";

- US Patent Application Serial No. 15/385,933 entitled "ARTICULATABLE SURGICAL INSTRUMENT WITH INDEPENDENT PIVOTABLELINKAGE DISTAL OF AN ARTICULATION LOCK";

- US Patent Application Serial No. 15/385,934 entitled "ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END EFFECTOR INAN ARTICULATED POSITION IN RESPONSE TO ACTUATION OF A JAW CLOSURE SYSTEM";

- US Patent Application Serial No. 15/385,935 entitled "LATERALLY ACTUATABLE ARTICULATION LOCK ARRANGEMENTS FORLOCKING AN END EFFECTOR OF A SURGICAL INSTRUMENT IN AN ARTICULATED CONFIGURATION"; and

- US Patent Application Serial No. 15/385,936 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH ARTICULATION STROKEAMPLIFICATION FEATURES".

The applicant of the present application has the following US patent applications filed on June 24, 2016, each of which is incorporated herein by reference in its entirety:

- US Patent Application Serial No. 15/191,775 entitled "STAPLE CARTRIDGE COMPRISING WIRE STAPLES AND STAMPED STAPLES";

- US Patent Application Serial No. 15/191,807 entitled "STAPLING SYSTEM FOR USE WITH WIRE STAPLES AND STAMPEDSTAPLES";

- US Patent Application Serial No. 15/191,834 entitled "STAMPED STAPLES AND STAPLE CARTRIDGES USING THE SAME";

- US Patent Application Serial No. 15/191,788 entitled "STAPLE CARTRIDGE COMPRISING OVERDRIVEN STAPLES"; and

- US Patent Application Serial No. 15/191,818 entitled "STAPLE CARTRIDGE COMPRISING OFFSET LONGITUDINAL STAPLE ROWS".

The applicant of the present application has the following US patent applications filed on June 24, 2016, each of which is incorporated herein by reference in its entirety:

- US Design Patent Application Serial No. 29/569,218 entitled "SURGICAL FASTENER";

- US Design Patent Application Serial No. 29/569,227 entitled "SURGICAL FASTENER";

- US Design Patent Application Serial No. 29/569,259 entitled "SURGICAL FASTENER CARTRIDGE"; and

- US Design Patent Application Serial No. 29/569,264 entitled "SURGICAL FASTENER CARTRIDGE".

The applicant of the present application has the following patent applications filed on April 1, 2016, each of which is incorporated herein by reference in its entirety:

- US Patent Application Serial No. 15/089,325 entitled "METHOD FOR OPERATING A SURGICAL STAPLING SYSTEM";

- US Patent Application Serial No. 15/089,321 entitled "MODULAR SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY";

- US Patent Application Serial No. 15/089,326 entitled "SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE DISPLAY FIELD";

- US Patent Application Serial No. 15/089,263 entitled "SURGICAL INSTRUMENT HANDLE ASSEMBLY WITH RECONFIGURABLE GRIPPORTION";

- US Patent Application Serial No. 15/089,262 entitled "ROTARY POWERED SURGICAL INSTRUMENT WITH MANUALLY ACTUATABLEBAILOUT SYSTEM";

- US Patent Application Serial No. 15/089,277 entitled "SURGICAL CUTTING AND STAPLING END EFFECTOR WITH ANVILCONCENTRIC DRIVE MEMBER";

- US Patent Application Serial No. 15/089,296 entitled "INTERCHANGEABLE SURGICAL TOOL ASSEMBLY WITH A SURGICAL ENDEFFECTOR THAT IS SELECTIVELY ROTATABLE ABOUT A SHAFT AXIS";

- US Patent Application Serial No. 15/089,258 entitled "SURGICAL STAPLING SYSTEM COMPRISING A SHIFTABLE TRANSMISSION";

- US Patent Application Serial No. 15/089,278 entitled "SURGICAL STAPLING SYSTEM CONFIGURED TO PROVIDE SELECTIVECUTTING OF TISSUE";

- US Patent Application Serial No. 15/089,284 entitled "SURGICAL STAPLING SYSTEM COMPRISING A CONTOURABLE SHAFT";

- US Patent Application Serial No. 15/089,295 entitled "SURGICAL STAPLING SYSTEM COMPRISING A TISSUE COMPRESSIONLOCKOUT";

- US Patent Application Serial No. 15/089,300 entitled "SURGICAL STAPLING SYSTEM COMPRISING AN UNCLAMPING LOCKOUT";

- US Patent Application Serial No. 15/089,196 entitled "SURGICAL STAPLING SYSTEM COMPRISING A JAW CLOSURE LOCKOUT";

- US Patent Application Serial No. 15/089,203 entitled "SURGICAL STAPLING SYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT";

- US Patent Application Serial No. 15/089,210 entitled "SURGICAL STAPLING SYSTEM COMPRISING A SPENT CARTRIDGELOCKOUT";

- US Patent Application Serial No. 15/089,324 entitled "SURGICAL INSTRUMENT COMPRISING A SHIFTING MECHANISM";

- US Patent Application Serial No. 15/089,335 entitled "SURGICAL STAPLING INSTRUMENT COMPRISING MULTIPLE LOCKOUTS";

- US Patent Application Serial No. 15/089,339 entitled "SURGICAL STAPLING INSTRUMENT";

- US Patent Application Serial No. 15/089,253 entitled "SURGICAL STAPLING SYSTEM CONFIGURED TO APPLY ANNULAR ROWS OFSTAPLES HAVING DIFFERENT HEIGHTS";

- US Patent Application Serial No. 15/089,304 entitled "SURGICAL STAPLING SYSTEM COMPRISING A GROOVED FORMING POCKET";

- US Patent Application Serial No. 15/089,331 entitled "ANVIL MODIFICATION MEMBERS FOR SURGICAL STAPLE/FASTENERS";

- US Patent Application Serial No. 15/089,336 entitled "STAPLE CARTRIDGES WITH ATRAUMATIC FEATURES";

- US Patent Application Serial No. 15/089,312 entitled "CIRCULAR STAPLING SYSTEM COMPRISING AN INCISABLE TISSUESUPPORT";

- US Patent Application Serial No. 15/089,309 entitled "CIRCULAR STAPLING SYSTEM COMPRISING ROTARY FIRING SYSTEM"; and

- US Patent Application Serial No. 15/089,349 entitled "CIRCULAR STAPLING SYSTEM COMPRISING LOAD CONTROL".

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

- US Patent Application Serial No. 14/984,488 entitled "MECHANISMS FOR COMPENSATING FOR BATTERY PACK FAILURE INPOWERED SURGICAL INSTRUMENTS";

- US Patent Application Serial No. 14/984,525 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWEREDSURGICAL INSTRUMENTS"; and

- US Patent Application Serial No. 14/984,552 entitled "SURGICAL INSTRUMENTS WITH SEPARABLE MOTORS AND MOTOR CONTROLCIRCUITS".

The applicant of the present application also owns the following identified US patent applications filed on February 9, 2016, each of which is incorporated herein by reference in its entirety:

- US Patent Application Serial No. 15/019,220 entitled "SURGICAL INSTRUMENT WITH ARTICULATING AND AXIALLYTRANSLATABLE END EFFECTOR";

- US Patent Application Serial No. 15/019,228 entitled "SURGICAL INSTRUMENTS WITH MULTIPLE LINK ARTICULATION ARRANGEMENTS";

- US Patent Application Serial No. 15/019,196 entitled "SURGICAL INSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY CONSTRAINT";

- US Patent Application Serial No. 15/019,206 entitled "SURGICAL INSTRUMENTS WITH AN END EFFECTOR THAT IS HIGHLYARTICULATABLE RELATIVE TO AN ELONGATE SHAFT ASSEMBLY";

- US Patent Application Serial No. 15/019,215 entitled "SURGICAL INSTRUMENTS WITH NON-SYMMETRICAL ARTICULATION ARRANGEMENTS";

- US Patent Application Serial No. 15/019,227 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH SINGLE ARTICULATIONLINK ARRANGEMENTS";

- US Patent Application Serial No. 15/019,235 entitled "SURGICAL INSTRUMENTS WITH TENSIONING ARRANGEMENTS FOR CABLEDRIVEN ARTICULATION SYSTEMS";

- US Patent Application Serial No. 15/019,230 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH OFF-AXIS FIRING BEAMARRANGEMENTS"; and

- US Patent Application Serial No. 15/019,245 entitled "SURGICAL INSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS".

The applicant of the present application also owns the following identified US patent applications filed on February 12, 2016, each of which is incorporated herein by reference in its entirety:

- US Patent Application Serial No. 15/043,254 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWEREDSURGICAL INSTRUMENTS";

- US Patent Application Serial No. 15/043,259 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWEREDSURGICAL INSTRUMENTS";

- US Patent Application Serial No. 15/043,275 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWEREDSURGICAL INSTRUMENTS"; and

- US Patent Application Serial No. 15/043,289 entitled "MECHANISMS FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWEREDSURGICAL INSTRUMENTS".

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

- US Patent Application Serial No. 14/742,925 entitled "SURGICAL END EFFECTORS WITH POSITIVE JAW OPENINGARRANGEMENTS", now US Patent Application Publication 2016/0367256;

- US Patent Application Serial No. 14/742,941 entitled "SURGICAL END EFFECTORS WITH DUAL CAM ACTUATED JAW CLOSINGFEATURES", now US Patent Application Publication 2016/0367248;

- US Patent Application Serial No. 14/742,914 entitled "MOVABLE FIRING BEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLESURGICAL INSTRUMENTS", now US Patent Application Publication 2016/0367255;

- US Patent Application Serial No. 14/742,900 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH COMPOSITE FIRING BEAMSTRUCTURES WITH CENTER FIRING SUPPORT MEMBER FOR ARTICULATION SUPPORT", now US Patent Application Publication 2016/0367254;

- US Patent Application Serial No. 14/742,885 entitled "DUAL ARTICULATION DRIVE SYSTEM ARRANGEMENTS FOR ARTICULATABLESURGICAL INSTRUMENTS", now US Patent Application Publication 2016/0367246; and

- US Patent Application Serial No. 14/742,876 entitled "PUSH/PULL ARTICULATION DRIVE SYSTEMS FOR ARTICULATABLESURGICAL INSTRUMENTS", now US Patent Application Publication 2016/0367245.

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

- US Patent Application Serial No. 14/640,746 entitled "POWERED SURGICAL INSTRUMENT", now US Patent Application Publication 2016/0256184;

- US Patent Application Serial No. 14/640,795 entitled "MULTIPLE LEVEL THRESHOLDS TO MODIFY OPERATION OF POWEREDSURGICAL INSTRUMENTS", now US Patent Application Publication 2016/02561185;

- US Patent Application Serial No. 14/640,832 entitled "ADAPTIVE TISSUE COMPRESSION TECHNIQUES TO ADJUST CLOSURERATES FOR MULTIPLE TISSUE TYPES", now US Patent Application Publication 2016/0256154;

- US Patent Application Serial No. 14/640,935 entitled "OVERLAID MULTI SENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TOMEASURE TISSUE COMPRESSION", now US Patent Application Publication 2016/0256071;

- US Patent Application Serial No. 14/640,831 entitled "MONITORING SPEED CONTROL AND PRECISION INCREMENTING OF MOTORFOR POWERED SURGICAL INSTRUMENTS", now US Patent Application Publication 2016/0256153;

- US Patent Application Serial No. 14/640,859 entitled "TIME DEPENDENT EVALUATION OF SENSOR DATA TO DETERMINESTABILITY, CREEP, AND VISCOELASTIC ELEMENTS OF MEASURES", now US Patent Application Publication 2016/0256187;

- US Patent Application Serial No. 14/640,817 entitled "INTERACTIVE FEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS", now US Patent Application Publication 2016/0256186;

- US Patent Application Serial No. 14/640,844 entitled "CONTROL TECHNIQUES AND SUB-PROCESSOR CONTAINED WITHIN MODULARSHAFT WITH SELECT CONTROL PROCESSING FROM HANDLE", now US Patent Application Publication 2016/0256155;

- US Patent Application Serial No. 14/640,837 entitled "SMART SENSORS WITH LOCAL SIGNAL PROCESSING", now US Patent Application Publication 2016/0256163;

- US Patent Application Serial No. 14/640,765 entitled "SYSTEM FOR DETECTING THE MIS-INSERTION OF ASTAPLE CARTRIDGEINTO A SURGICAL STAPLE/FASTENER", now US Patent Application Publication 2016/0256160;

- US Patent Application Serial No. 14/640,799 entitled "SIGNAL AND POWER COMMUNICATION SYSTEM POSITIONED ON AROTATABLE SHAFT", now US Patent Application Publication 2016/0256162; and

- US Patent Application Serial No. 14/640,780 entitled "SURGICAL INSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING", now US Patent Application Publication 2016/0256161.

The applicant of the present application has the following patent applications filed on February 27, 2015, each of which is incorporated herein by reference in its entirety:

- US Patent Application Serial No. 14/633,576 entitled "SURGICAL INSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION", now US Patent Application Publication 2016/0249919;

- US Patent Application Serial No. 14/633,546 entitled "SURGICAL APPARATUS CONFIGURED TO ASSESS WHETHER A PERFORMANCEPARAMETER OF THE SURGICAL APPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE BAND", now US Patent Application Publication 2016/0249915;

- US Patent Application Serial No. 14/633,560 entitled "SURGICAL CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONEOR MORE BATTERIES", now US Patent Application Publication 2016/0249910;

- US Patent Application Serial No. 14/633,566 entitled "CHARGING SYSTEM THAT ENABLES EMERGENCY RESOLUTIONS FORCHARGING A BATTERY", now US Patent Application Publication 2016/0249918;

- US Patent Application Serial No. 14/633,555 entitled "SYSTEM FOR MONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TOBE SERVICED", now US Patent Application Publication 2016/0249916;

- US Patent Application Serial No. 14/633,542 entitled "REINFORCED BATTERY FOR A SURGICAL INSTRUMENT", now US Patent Application Publication 2016/0249908;

- US Patent Application Serial No. 14/633,548 entitled "POWER ADAPTER FOR A SURGICAL INSTRUMENT", now US Patent Application Publication 2016/0249909;

- US Patent Application Serial No. 14/633,526 entitled "ADAPTABLE SURGICAL INSTRUMENT HANDLE", now US Patent Application Publication 2016/0249945;

- US Patent Application Serial No. 14/633,541 entitled "MODULAR STAPLING ASSEMBLY", now US Patent Application Publication 2016/0249927; and

- US Patent Application Serial No. 14/633,562 entitled "SURGICAL APPARATUS CONFIGURED TO TRACK AN END-OF-LIFEPARAMETER", now US Patent Application Publication 2016/0249917.

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

- US Patent Application Serial No. 14/574,478 entitled "SURGICAL INSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE ENDEFFECTOR AND MEANS FOR ADJUSTING THE FIRING STROKE OF A FIRING MEMBER", now US Patent Application Publication 2016/0174977;

- US Patent Application Serial No. 14/574,483 entitled "SURGICAL INSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS", now US Patent Application Publication 2016/0174969;

- US Patent Application Serial No. 14/575,139 entitled "DRIVE ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS", now US Patent Application Publication 2016/0174978;

- US Patent Application Serial No. 14/575,148 entitled "LOCKING ARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITHARTICULATABLE SURGICAL END EFFECTORS", now US Patent Application Publication 2016/0174976;

- US Patent Application Serial No. 14/575,130 entitled "SURGICAL INSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLEABOUT A DISCRETE NON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE, now US Patent Application Publication 2016/0174972;

- US Patent Application Serial No. 14/575,143 entitled "SURGICAL INSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS", now US Patent Application Publication 2016/0174983;

- US Patent Application Serial No. 14/575,117 entitled "SURGICAL INSTRUMENTS WITH ARTICULATABLE END EFFECTORS ANDMOVABLE FIRING BEAM SUPPORT ARRANGEMENTS", now US Patent Application Publication 2016/0174975;

- US Patent Application Serial No. 14/575,154 entitled "SURGICAL INSTRUMENTS WITH ARTICULATABLE END EFFECTORS ANDIMPROVED FIRING BEAM SUPPORT ARRANGEMENTS", now US Patent Application Publication 2016/0174973;

- US Patent Application Serial No. 14/574,493 entitled "SURGICAL INSTRUMENT ASSEMBLY COMPRISING A FLEXIBLEARTICULATION SYSTEM"; now US Patent Application Publication 2016/0174970; and

- US Patent Application Serial No. 14/574,500 entitled "SURGICAL INSTRUMENT ASSEMBLY COMPRISING A LOCKABLEARTICULATION SYSTEM", now US Patent Application Publication 2016/0174971.

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

- US Patent Application Serial No. 13/782,295 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYSFOR SIGNAL COMMUNICATION", now US Patent Application Publication 2014/0246471;

- US Patent Application Serial No. 13/782,323 entitled "ROTARY POWERED ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS", now US Patent Application Publication 2014/0246472;

- US Patent Application Serial No. 13/782,338 entitled "THUMBWHEEL SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS", now US Patent Application Publication 2014/0249557;

- US Patent Application Serial No. 13/782,499 entitled "ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAYARRANGEMENT", now US Patent Application Publication 9,358,003;

- US Patent Application Serial No. 13/782,460 entitled "MULTIPLE PROCESSOR MOTOR CONTROL FOR MODULAR SURGICALINSTRUMENTS", now US Patent No. 9,554,794;

- US Patent Application Serial No. 13/782,358 entitled "JOYSTICK SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS", now US Patent Application Publication 9,326,767;

- US Patent Application Serial No. 13/782,481 entitled "SENSOR STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGHTROCAR", now US Patent Application Publication 9,468,438;

- US Patent Application Serial No. 13/782,518 entitled "CONTROL METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLEIMPLEMENT PORTIONS", now US Patent Application Publication 2014/0246475;

- US Patent Application Serial No. 13/782,375 entitled "ROTARY POWERED SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OFFREEDOM", now US Patent Application Publication 9,398,911; and

- US Patent Application Serial No. 13/782,536 entitled "SURGICAL INSTRUMENT SOFT STOP", now US Patent Application Publication 9,307,986.

The applicant of the present application also owns the following patent applications filed on March 14, 2013, each of which is incorporated herein by reference in its entirety:

- US Patent Application Serial No. 13/803,097 entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE", now US Patent Application Publication 2014/0263542;

- US Patent Application Serial No. 13/803,193 entitled "CONTROL ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICALINSTRUMENT", now US Patent Application Publication 9,332,987;

- US Patent Application Serial No. 13/803,053 entitled "INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICALINSTRUMENT", now US Patent Application Publication 2014/0263564;

- US Patent Application Serial No. 13/803,086 entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK", now US Patent Application Publication 2014/0263541;

- US Patent Application Serial No. 13/803,210 entitled "SENSOR ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FORSURGICAL INSTRUMENTS", now US Patent Application Publication 2014/0263538;

- US Patent Application Serial No. 13/803,148 entitled "MULTI-FUNCTION MOTOR FOR A SURGICAL INSTRUMENT", now US Patent Application Publication 2014/0263554;

- US Patent Application Serial No. 13/803,066 entitled "DRIVE SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICALINSTRUMENTS", now US Patent Application Publication 9,629,623;

- US Patent Application Serial No. 13/803,117 entitled "ARTICULATION CONTROL SYSTEM FOR ARTICULATABLE SURGICALINSTRUMENTS", now US Patent Application Publication 9,351,726;

- US Patent Application Serial No. 13/803,130 entitled "DRIVE TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICALINSTRUMENTS", now US Patent Application Publication 9,351,727; and

- US Patent Application Serial No. 13/803,159 entitled "METHOD AND SYSTEM FOR OPERATING A SURGICAL INSTRUMENT", now US Patent Application Publication 2014/0277017.

The applicant of the present application also owns the following patent application filed on March 7, 2014 and incorporated herein by reference in its entirety:

- US Patent Application Serial No. 14/200,111 entitled "CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS", now US Patent 9,629,629;

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

- US Patent Application Serial No. 14/226,106 entitled "POWER MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS", now US Patent Application Publication 2015/0272582;

- US Patent Application Serial No. 14/226,099 entitled "STERILIZATION VERIFICATION CIRCUIT", now US Patent Application Publication 2015/0272581;

- US Patent Application Serial No. 14/226,094 entitled "VERIFICATION OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT", now US Patent Application Publication 2015/0272580;

- US Patent Application Serial No. 14/226,117 entitled "POWER MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUITAND WAKE UP CONTROL", now US Patent Application Publication 2015/0272574;

- US Patent Application Serial No. 14/226,075 entitled "MODULAR POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFTASSEMBLIES", now US Patent Application Publication 2015/0272579;

- US Patent Application Serial No. 14/226,093 entitled "FEEDBACK ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICALINSTRUMENTS", now US Patent Application Publication 2015/0272569;

- US Patent Application Serial No. 14/226,116 entitled "SURGICAL INSTRUMENT UTILIZING SENSOR ADAPTATION", now US Patent Application Publication 2015/0272571;

- US Patent Application Serial No. 14/226,071 entitled "SURGICAL INSTRUMENT CONTROL CIRCUIT HAVING A SAFETYPROCESSOR", now US Patent Application Publication 2015/0272578;

- US Patent Application Serial No. 14/226,097 entitled "SURGICAL INSTRUMENT COMPRISING INTERACTIVE SYSTEMS", now US Patent Application Publication 2015/0272570;

- US Patent Application Serial No. 14/226,126 entitled "INTERFACE SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS", now US Patent Application Publication 2015/0272572;

- US Patent Application Serial No. 14/226,133 entitled "MODULAR SURGICAL INSTRUMENT SYSTEM", now US Patent Application Publication 2015/0272557;

- US Patent Application Serial No. 14/226,081 entitled "SYSTEMS AND METHODS FOR CONTROLLING A SEGMENTED CIRCUIT", now US Patent Application Publication 2015/0277471;

- US Patent Application Serial No. 14/226,076 entitled "POWER MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLEVOLTAGE PROTECTION", now US Patent Application Publication 2015/0280424;

- US Patent Application Serial No. 14/226,111 entitled "SURGICAL STAPLING INSTRUMENT SYSTEM", now US Patent Application Publication 2015/0272583; and

- US Patent Application Serial No. 14/226,125 entitled "SURGICAL INSTRUMENT COMPRISING A ROTATABLE SHAFT", now US Patent Application Publication 2015/0280384.

The applicant of the present application also owns the following patent applications filed on September 5, 2014 and each of which is incorporated herein by reference in its entirety:

- US Patent Application Serial No. 14/479,103 entitled "CIRCUITRY AND SENSORS FOR POWERED MEDICAL DEVICE", now US Patent Application Publication 2016/0066912;

- US Patent Application Serial No. 14/479,119 entitled "ADJUNCT WITH INTEGRATED SENSORS TO QUANTIFY TISSUECOMPRESSION", now US Patent Application Publication 2016/0066914;

- US Patent Application Serial No. 14/478,908 entitled "MONITORING DEVICE DEGRADATION BASED ON COMPONENT EVALUATION", now US Patent Application Publication 2016/0066910;

- US Patent Application Serial No. 14/478,895 entitled "MULTIPLE SENSORS WITH ONE SENSOR AFFECTING A SECOND SENSOR'SOUTPUT OR INTERPRETATION", now US Patent Application Publication 2016/0066909;

- US Patent Application Serial No. 14/479,110 entitled "POLARITY OF HALL MAGNET TO DETECT MISLOADED CARTRIDGE", now US Patent Application Publication 2016/0066915;

- US Patent Application Serial No. 14/479,098 entitled "SMART CARTRIDGE WAKE UP OPERATION AND DATA RETENTION", now US Patent Application Publication 2016/0066911;

- US Patent Application Serial No. 14/479,115 entitled "MULTIPLE MOTOR CONTROL FOR POWERED MEDICAL DEVICE", now US Patent Application Publication 2016/0066916; and

- US Patent Application Serial No. 14/479,108 entitled "LOCAL DISPLAY OF TISSUE PARAMETER STABILIZATION", now US Patent Application Publication 2016/0066913.

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

- US Patent Application Serial No. 14/248,590 entitled "MOTOR DRIVEN SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVESHAFTS", now US Patent Application Publication 2014/0305987;

- US Patent Application Serial No. 14/248,581 entitled "SURGICAL INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRINGDRIVE OPERATED FROM THE SAME ROTATABLE OUTPUT", now US Patent 9,649,110;

- US Patent Application Serial No. 14/248,595 entitled "SURGICAL INSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLINGTHE OPERATION OF THE SURGICAL INSTRUMENT", now US Patent Application Publication 2014/0305988;

- US Patent Application Serial No. 14/248,588 entitled "POWERED LINEAR SURGICAL STAPLE/FASTENER", now US Patent Application Publication 2014/0309666;

- US Patent Application Serial No. 14/248,591 entitled "TRANSMISSION ARRANGEMENT FOR A SURGICAL INSTRUMENT", now US Patent Application Publication 2014/0305991;

- US Patent Application Serial No. 14/248,584 entitled "MODULAR MOTOR DRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENTFEATURES FOR ALIGNING ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS", now US Patent Application Publication 2014/0305994;

- US Patent Application Serial No. 14/248,587 entitled "POWERED SURGICAL STAPLE/FASTENER", now US Patent Application Publication 2014/0309665;

- US Patent Application Serial No. 14/248,586 entitled "DRIVE SYSTEM DECOUPLING ARRANGEMENT FOR A SURGICALINSTRUMENT", now US Patent Application Publication 2014/0305990; and

- US Patent Application Serial No. 14/248,607 entitled "MODULAR MOTOR DRIVEN SURGICAL INSTRUMENTS WITH STATUSINDICATION ARRANGEMENTS", now US Patent Application Publication 2014/0305992.

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

- US Provisional Patent Application Serial No. 61/812,365 entitled "SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY ASINGLE MOTOR";

- US Provisional Patent Application Serial No. 61/812,376 entitled "LINEAR CUTTER WITH POWER";

- US Provisional Patent Application Serial No. 61/812,382 entitled "LINEAR CUTTER WITH MOTOR AND PISTOL GRIP";

- U.S. Provisional Patent Application Serial No. 61/812,385 entitled "SURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION MOTORS ANDMOTOR CONTROL"; and

- US Provisional Patent Application Serial No. 61/812,372 entitled "SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY ASINGLE MOTOR".

Numerous specific details are set forth herein in order to provide a thorough understanding of the general structure, function, manufacture, and use of the embodiments described in the specification and shown 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 by way of non-limiting example, so that the specific structural and functional details disclosed herein may be representative and illustrative, and may be appreciated. Variations and changes may be made to these embodiments without departing from the scope of the claims.

The term "comprise" (and any form of "comprise" such as "comprises" and "comprising"), "have" (and "have" any form, 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 copulas. Thus, a surgical system, device, or device that "comprises," "has," "comprises," 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 characteristic structure.

The terms "proximal" and "distal" are used herein with respect to a clinician manipulating the 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 should also be understood that, for brevity and clarity, spatial terms such as "vertical," "horizontal," "upper," and "lower" may be used herein in connection with 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. The reader will readily appreciate, however, that the various methods and devices disclosed herein can be used in a variety of surgical procedures and applications, including, for example, in conjunction 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, and the like. The working or end effector portion of the instrument can be inserted directly into the patient or through an access device having a working channel through which the end effector and elongated shaft of the surgical instrument can 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 cannot be removed from the first jaw, or at least 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 the closing axis; however, other embodiments are contemplated in which the first jaw is pivotable relative to the second jaw. The surgical stapling system also includes an articulation joint configured to allow rotation or articulation of the end effector relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments are contemplated that do not include articulation joints.

The staple cartridge includes a cartridge body. The cartridge body includes a proximal end, a distal end, and a platform extending between the proximal and distal ends. 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 moves toward the staple cartridge to compress and clamp the tissue against the platform. The staples, which are removably stored in the cartridge body, can then be deployed into tissue. The cartridge body includes staple cavities defined therein, wherein the staples are removably stored in the staple cavities. The nail 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 staple cavities and staples are also possible.

The staples are supported by staple drivers in the cartridge body. The drive device is movable between a first or non-fired position and a second or fired position to fire 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 a resilient member configured to grip and retain the retainer to the cartridge body. The drive is movable between its non-fired position and its fired position by means of a slide. The slider is movable between a proximal position adjacent the proximal end and a distal position adjacent the distal end. The slider includes a plurality of ramp surfaces configured to slide under the drive device toward the anvil and to lift the drive device, and the staples are supported on the drive device.

In addition to the above, the slider can also be moved distally by the firing member. The firing member is configured to contact the slider and urge the slider toward the distal end. A longitudinal slot defined in the cartridge body is configured to receive a firing member. The anvil also includes a slot configured to receive the firing member. The firing member also includes a first cam engaging the first jaw and a second cam engaging the second jaw. The first and second cams may control the distance or tissue clearance between the platform of the staple cartridge and the anvil as the firing member is advanced distally. The firing member also includes a knife configured to cut through tissue captured between the staple cartridge and the anvil. It is desirable for the knife to be positioned at least partially proximate the ramp surface so that the nails are fired ahead of the knife.

FIG. 1 shows a motor-driven surgical system 10 that can be used to perform a variety of different surgical procedures. As can be seen in this figure, one example of surgical system 10 includes four interchangeable surgical tool assemblies 100 , 200 , 300 , and 1000 each adapted to be interchangeable with handle assembly 500 use together. Each interchangeable surgical tool assembly 100, 200, 300, and 1000 may be designed for use in conjunction 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 the tool drive assembly of a robotically controlled surgical system or an automated surgical system. For example, the surgical tool assemblies disclosed herein may be used with various robotic systems, instruments, components, and methods such as, but not limited to, those disclosed in US Pat. No. 9,072,535, entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLESTAPLE DEPLOYMENT ARRANGEMENTS," which patent application It is hereby incorporated by reference in its entirety.

FIG. 2 shows one form of interchangeable surgical tool assembly 100 operably coupled to handle assembly 500 . FIG. 3 shows the attachment of the interchangeable surgical tool assembly 100 to the handle assembly 500 . The attachment arrangement and method depicted in Figure 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 portion or tool drive housing of a robotic system. The handle assembly 500 can include a handle housing 502 that includes a pistol grip portion 504 that can be grasped and manipulated by a clinician. As will be discussed briefly below, the handle assembly 500 operably supports a plurality of drive systems configured to generate and apply various control motions to operably attached thereto. Corresponding portions of interchangeable surgical tool assemblies 100 , 200 , 300 and/or 1000 above.

Referring now to FIG. 3, the handle assembly 500 may also include a frame 506 that operably supports a plurality of drive systems. For example, frame 506 may operably support a "first" or closing drive system, generally designated 510, that may be used to apply closing and opening motion to the operatively attached or coupled Interchangeable surgical tool assemblies 100 , 200 , 300 and/or 1000 to 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 would allow the closure trigger 512 to be manipulated by the clinician such that when the clinician grasps the pistol grip portion 504 of the handle assembly 500, the closure trigger 512 can pivot from the activated or "unactuated" position Go to the "actuated" position and more specifically pivot to the fully compressed or fully actuated position. In various forms, the closure drive system 510 also includes a closure linkage assembly 514 that is pivotally coupled to or otherwise operably connected to the closure trigger 512 . As will be discussed in further detail below, the closure linkage assembly 514 includes a lateral attachment pin 516 that facilitates attachment to a corresponding drive system on the surgical tool assembly. To actuate the closure drive system, the clinician depresses the closure trigger 512 toward the pistol grip 504 . As described in further detail in U.S. Patent Application Serial No. 14/226,142 entitled "SURGICAL INSTRUMENT COMPRISING A SENSORSYSTEM," which is herein incorporated by reference in its entirety, now in U.S. Patent Application Publication 2015/0272575, when the clinician fully presses The closure drive system is configured to lock the closure trigger 512 into a fully depressed or fully actuated position when the trigger 512 is closed to achieve the full closure stroke. 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 the 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 close-release button assembly 518 can be found in US Patent Application Publication 2015/0272575.

In at least one form, handle assembly 500 and frame 506 may operably support another drive system, referred to herein as firing drive system 530, configured to apply firing action to a Corresponding portion of the interchangeable surgical tool assembly thereon. As described in detail in US Patent Application Publication 2015/0272575, the firing drive system 530 may employ an electric motor (not shown in FIGS. 1-3 ) located in the pistol grip portion 504 of the handle assembly 500 . In various forms, the motor may be, for example, a DC brush drive motor with a maximum speed of about 25,000 RPM. In other configurations, the motor may comprise 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 multiple lithium ion ("LI") or other suitable batteries therein. Multiple batteries connectable in series may be used as the power source 522 for the surgical system 10 . Additionally, power source 522 may be replaceable and/or rechargeable.

The electric motor is configured to axially drive the longitudinally movable drive member 540 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 is moved. Actuation of the motor may be controlled by firing trigger 532 ( FIG. 1 ) pivotally supported on 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 an 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 by the spring or biasing arrangement or otherwise Return to the unactuated position. In at least one form, the firing trigger 532 may be positioned "outside" the closure trigger 512 as described above. As discussed in US Patent Application Publication 2015/0272575, the handle assembly 500 may 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, the safety button is housed in the handle assembly 500, in which case the clinician cannot easily access the safety button and keep the safety button in a position that prevents actuation of the firing trigger 532. Movement between a safety position and a firing position in which the firing trigger 532 can 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 that interfaces with the motor. Further details on those features can be found in US Patent Application Publication 2015/0272575. In at least one form, handle assembly 500 also includes a manually actuatable "rescue" assembly configured to enable a clinician to manually activate longitudinally movable drive member 540 with the motor disabled retract. The rescue assembly may include a lever or rescue handle assembly that is stored within handle assembly 500 under 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". US Patent Application Serial No. 12/249,117 (now US Patent 8,608,045, the entire disclosure of which is hereby incorporated by reference), entitled "POWERED SURGICAL CUTTING AND STAPLING APPARATUSWITH MANUALLY RETRACTABLE FIRING SYSTEM", discloses a rescue arrangement and Salvage arrangements that can 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 elongated channel 112 configured to operably support a surgical staple cartridge 116 therein. The second jaw includes an anvil 114 pivotally supported relative to the elongated 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 constructions and operations of end effector 110, articulation joint 120 and articulation lock are set forth in US Patent Application Serial No. 13/803,086 entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK" (now US Pat. Application Publication 2014/0263541, which is hereby incorporated by reference in its entirety). As can be further seen in Figures 2 and 3, the interchangeable surgical tool assembly 100 may include a proximal housing or nozzle 130 and a closure tube assembly 140, which may be used to close and/or open an end effector Anvil 114 of 110 . As discussed in US 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 enable application of articulation motion to surgical end performance device 110. Ridge 145 is configured to: first, slidably support firing rod 170 therein; and second, slidably support closure tube assembly 140 extending around spine 145 . In each case, spine 145 includes a proximal end rotatably supported in base 150 . See Figure 3. In one arrangement, for example, the proximal end of spine 145 is attached to a spine bearing that is configured to be supported within base 150 . This arrangement facilitates the rotatable attachment of the spine 145 to the base 150 so that the spine 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 that is slidably supported within the base 150 such that the closure shuttle 160 can move axially relative to the base 150 . As can be seen in FIG. 3 , the closure shuttle 160 includes a pair of proximally protruding hooks 162 configured to attach to an attachment pin 516 that attaches to a closure link in the handle assembly 500 Component 514 . The proximal closure tube segment 146 of the closure tube assembly 140 is rotatably coupled to the closure shuttle 160 . Thus, when the hook 162 is hooked on the pin 516, actuation of the closure trigger 512 will cause the closure shuttle 160 to move axially and ultimately the closure tube assembly 140 on the spine 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 the proximal direction "PD", which may be used to enable the shaft assembly 100 when the shaft assembly 100 is operably coupled to the handle assembly 500. The closure trigger 512 pivots into an unactuated position. In use, the closure tube assembly 140 is translated distally (direction DD) to close the anvil 114 in response to actuation of the closure trigger 512 . 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 segment 142 is configured to move axially relative to the surgical end effector 110 with the proximal closure segment 146 . When the distal end of the distal closure tube segment 142 strikes the proximal surface or flange 115 on the anvil 114, the anvil 114 pivots closed. Further details regarding the closure of the anvil 114 can be found in the aforementioned US Patent Application Publication 2014/0263541 and will be discussed in further detail below. As also described in detail in US Patent Application Publication 2014/0263541, the anvil 114 is opened by translating the distal closure tube segment 142 proximally. The distal closure tube section 142 has therein a horseshoe shaped hole 143 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.

Also as described above, the interchangeable surgical tool assembly 100 also includes a firing rod 170 that is supported for axial travel within the spine 145 . The firing rod 170 includes an intermediate firing shaft portion configured to be attachable to a distal cutting portion or shank that is configured to travel axially through the surgical end for execution device 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 rod 170 . More details on the features and operation of the clutch assembly can be found in US Patent Application Publication 2014/0263541. As discussed in US Patent Application Publication 2014/0263541, when the clutch assembly is in its engaged position, distal movement of the firing rod 170 may move the articulation driver arrangement 147 distally and, accordingly, the The proximal movement may move the articulation driver arrangement 147 proximally. When the clutch assembly is in its disengaged position, movement of the firing rod 170 is not transmitted to the articulation driver arrangement 147 , and thus, the firing rod 170 can 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 transmit signals to the end effector 110. The end effector 110 and/or transmit signals from the end effector. More details on slip ring assemblies can be found in US Patent Application Publication 2014/0263541. US Patent Application Serial No. 13/800,067 entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSORSYSTEM", now US Patent Application Publication 2014/0263552, is incorporated by reference in its entirety. US 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 within 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 seating manner. As can be further seen in FIG. 3 , a shaft attachment lug 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 lugs 172 are received in the firing shaft attachment brackets 542 formed in the distal end of the longitudinally movable drive member 540 . The interchangeable surgical tool assembly 100 also employs a latch 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, latch system 180 includes a locking member or locking yoke 182 movably coupled to base 150 . The locking yoke 182 includes two proximally protruding locking lugs 184 that are configured for engagement with corresponding locking pawls or grooves 509 in the distal attachment flange of the frame 506. Releasably engage. In various forms, the locking yoke 182 is biased in the proximal direction by a spring or biasing member. Actuation of the locking 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 can be biased in a proximal direction relative to the locking yoke 182 . As will be discussed in further detail below, the locking yoke 182 may be moved to the unlocked position by biasing the latch button 186 in the distal direction DD, which also pivots the locking yoke 182 out of contact with the distal side of the frame 506 . The attachment flange remains engaged. The locking lugs 184 remain seated within corresponding locking pawls or grooves 509 in the distal end of the frame 506 when the locking yoke 182 is "retained" with the distal attachment flange of the frame 506 . More details on the latching system can be found in US Patent Application Publication 2014/0263541.

To attach the interchangeable surgical tool assembly 100 to the handle assembly 500A, the 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 The tapered attachment portion 152 is aligned with the dovetail-shaped slot 507 in the frame 506 . The clinician can then move the surgical tool assembly 100 along the mounting axis IA perpendicular to the shaft axis SA to seat the tapered attachment portion 152 into a corresponding dovetail-shaped receiving slot 507 in the distal end of the frame 506 operatively engaged. In doing so, the shaft attachment lugs 172 on the firing shaft 170 will also be seated in the brackets 542 in the longitudinally movable drive member 540, and the portion of the pin 516 on the closure link 514 will be seated in the closure shuttle into corresponding hooks 162 in member 160 . As used herein, the term "operably engaged" in the context of two components means that the two components are sufficiently engaged with each other such that once actuating motion is applied thereto, the components perform their intended actions, functions and/or program.

Returning now to FIG. 1, the surgical system 10 includes four interchangeable surgical tool assemblies 100, 200, 300, and 1000, each of which can be effectively used with the same handle assembly 500 to perform different of surgery. The construction of an exemplary form of the interchangeable surgical tool assembly 100 is discussed briefly above and is discussed in further detail in US Patent Application Publication 2014/0263541. Various details regarding interchangeable surgical tool assemblies 200 and 300 can be found in various US patent applications, which have been incorporated herein by reference. Various details regarding the interchangeable surgical tool assembly 1000 are discussed in further detail below.

As shown in FIG. 1, each of surgical tool assemblies 100, 200, 300, and 1000 includes a pair of jaws, at least one of which is movable to capture, manipulate and/or grip tissue between the two jaws . The movable jaws are moved between open and closed positions upon application of closing and opening motions thereto by a robotic or automated surgical system to which the handle assembly or surgical tool assembly is operatively coupled. In addition, each of the illustrated interchangeable surgical tool assemblies includes a firing member configured to cut tissue and fire staples from a staple cartridge that is responsive to being driven by a handle assembly or a robotic system. The applied firing action is supported in a jaw. Each surgical tool assembly can be uniquely designed to perform a specific procedure, eg, for cutting and securing a specific type and thickness of tissue in a specific area of the body. The closure, firing and articulation control system in the handle assembly 500 or robotic system can be configured to generate axial control motion and/or rotation depending on the type of closure, firing and articulation system configuration employed in the surgical tool assembly Control action. 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 is moved axially from the unactuated position to its fully actuated position. The axial distance the closed tube assembly travels as it moves from its unactuated position to its fully actuated position may be referred to herein as its "closed 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 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 articulating end effector arrangements, the handle assembly or robotic system may employ articulation control components that move 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. Accordingly, each of the surgical tool assemblies must be capable of accommodating the closure, firing, and/or controlled movement of the articulation components through each of all of its stroke lengths without undue stressing the surgical tool components because This may result in damage to surgical tool components.

Turning now to FIGS. 4-10 , the interchangeable surgical tool assembly 1000 includes a surgical end effector 1100 that includes an elongated channel 1102 configured to operably support a staple cartridge 1110 therein. The end effector 1100 may also include an anvil 1130 pivotally supported relative to the elongated channel 1102 . The interchangeable surgical tool assembly 1000 may also include an articulation joint 1200 and an articulation lock 1210 (FIGS. 5 and 8-10), which may be configured to enable the end effector 1100 to be positioned relative to the shaft axis SA Releasably held in the desired articulation position. Details regarding the construction and operation of articulation lock 1210 can be found in US Patent Application Serial No. 13/803,086 entitled "ARTICULATABLE SURGICALINSTRUMENT COMPRISING AN ARTICULATION LOCK", now US Patent Application Publication 2014/0263541, the entire disclosure of which is hereby Incorporated herein by reference. Additional details regarding this articulation lock can also be found in US Patent Application Serial No. 15/019,196, filed February 9, 2016, entitled "SURGICAL INSTRUMENTARTICULATION MECHANISM WITH SLOTTED SECONDARY CONSTRAINT," the entire disclosure of which is hereby incorporated by reference method is incorporated herein. As can be seen in FIG. 7, the interchangeable surgical tool assembly 1000 may also include a proximal housing or nozzle 1300 comprised of nozzle portions 1302, 1304 and an actuator wheel portion 1306 configured to ears and/or screws to couple to the assembled nozzle parts 1302, 1304. The interchangeable surgical tool assembly 1000 may also include a closure tube assembly 1400 that may 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 FIGS. 8 and 9 , interchangeable surgical tool assembly 1000 may include spine assembly 1500 that may be configured to support articulation lock 1210 . Ridge assembly 1500 includes "elastic" spine or frame members 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 seen in FIGS. 7 and 8 , spine assembly 1500 is configured to: first, slidably support firing member assembly 1600 therein; and second, slidably support closure tube assembly 1400 extending around spine assembly 1500 . The spine assembly 1500 may also be configured to slidably support the proximal articulation driver 1700 .

As shown in FIG. 10 , the distal frame segment 1560 is pivotally coupled to the elongated channel 1102 by the 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. The pivot pin 1564 is adapted to be pivotally received within a pivot hole 1234 formed in the pivot base portion 1232 of the end effector mounting assembly 1230. The end effector mounting assembly 1230 is attached to the proximal end 1103 of the elongated channel 1102 by a spring pin 1108 or other suitable member. The pivot pin 1564 defines an articulation axis B-B transverse to the shaft axis SA. See Figure 4. This arrangement facilitates pivotal travel (ie, articulation) of the end effector 1100 relative to the spine assembly 1500 about the articulation axis B-B.

Still referring to FIG. 10 , the articulation driver 1700 has a distal end 1702 configured to operably engage the articulation lock 1210 . Articulation lock 1210 includes articulation frame 1212 adapted to operably engage drive pins 1238 on pivot base portion 1232 of end effector mount assembly 1230 . Additionally, a cross-connect 1237 may be connected to the drive pins 1238 and the articulation frame 1212 to assist in articulation of the end effector 1100 . As noted above, more details regarding the operation of articulation lock 1210 and articulation frame 1212 can be found in US Patent Application Serial No. 13/803,086, now US Patent Application Publication 2014/0263541. Additional details regarding end effector mounting assemblies and cross-connects can be found in US Patent Application Serial No. 15/019,245, filed February 9, 2016, entitled "SURGICAL INSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS," The entire disclosure is hereby incorporated by reference herein. In various cases, the resilient spine member 1510 includes a proximal end 1514 that is rotatably supported in the base 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 supported within the base 1800 . Such an arrangement facilitates the rotatable attachment of the resilient spine member 1510 to the base 1800 such that the spine assembly 1500 can 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 base 1800 such that the closure shuttle 1420 can move circumferentially relative to the base 1800 . In one form, the closure shuttle 1420 includes a pair of proximally projecting hooks 1421 configured to attach to an attachment pin 516 that is attached to the handle The closing linkage assembly 514 of the section 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, U-shaped connector 1424 is inserted into annular slot 1414 in proximal end 1412 of proximal closure tube segment 1410 and retained within vertical slot 1422 in closure shuttle 1420. See Figure 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 relative to the closure shuttle 1420 about the shaft axis SA . 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 can be used to operably in the interchangeable surgical tool assembly 1000 When coupled to handle assembly 500, the closure trigger 512 on handle assembly 500 (FIG. 3) is pivoted to an unactuated position.

As described above, the illustrated interchangeable surgical tool assembly 1000 includes an articulation joint 1200 . However, other interchangeable surgical tool assemblies may not be able to articulate. As can be seen in FIG. 10, upper tang 1415 and lower tang 1416 protrude distally from the distal end of proximal closure tube segment 1410 for movably coupling to an end effector closure sleeve or end effector of closure tube assembly 1400. Section 1430 is closed distally. As can be seen in Figure 10, the distal closure segment 1430 includes an upper tang 1434 and a lower tang 1436 protruding proximally from its proximal end. The upper dual pivot connection 1220 includes proximal and distal pins that engage corresponding holes in the upper tangs 1415, 1434 of the proximal closure tube segment 1410 and the distal closure tube segment 1430, respectively. Similarly, lower dual pivot link 1222 includes proximal and distal pins that engage corresponding ones of lower tangs 1416 and 1436 of proximal closure tube section 1410 and distal closure tube section 1430, respectively hole. As will be discussed in further detail below, the distal and proximal axial translation of the closure tube assembly 1400 will cause the anvil 1130 to close and open relative to the elongated 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 attachable to the distal cutting portion or shank 1610 . The firing member assembly 1600 may also be referred to herein as the "second shaft" and/or the "second shaft assembly." As seen in FIGS. 7-10 , the intermediate firing shaft portion 1602 can include a longitudinal slot 1604 in its distal end that can be configured to receive a tab on the proximal end of the knife bar 1610 . The longitudinal slot 1604 and the proximal end of the shank 1610 may be sized and configured such that they allow relative movement therebetween and may include a sliding joint 1612. The sliding joint 1612 may allow movement of the intermediate firing shaft portion 1602 of the firing member assembly 1600 to articulate the end effector 1100 without moving, or at least substantially 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 sidewall of the longitudinal slot 1604 comes into contact with the tabs on the arbor 1610 to advance the arbor 1610 and The staple cartridge 1110 positioned within the elongated channel 1102 is fired. As can be further seen in FIGS. 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 engage the resilient spine member to enclose the intermediate firing shaft portion 1602 and the knife bar 1610 therein. Further description regarding the operation of the firing member assembly 1600 can be found in US Patent Application Serial No. 13/803,086 (now US Patent Application Publication 2014/0263541).

In addition to the above, interchangeable tool assembly 1000 can include clutch assembly 1620 that can be configured to selectively and releasably couple articulation driver 1700 to firing member assembly 1600 . In one form, the clutch assembly 1620 includes a locking collar or locking sleeve 1622 positioned about the firing member assembly 1600, wherein the locking sleeve 1622 is rotatable between an engaged position and a disengaged position in which the locking sleeve is 1622 couples the articulation driver 1700 to the firing member assembly 1600, in the disengaged position the articulation driver 1700 is not operatively coupled to the firing member assembly 1600. When the locking sleeve 1622 is in its engaged position, distal movement of the firing member assembly 1600 can move the articulation driver 1700 distally, and correspondingly, proximal movement of the firing member assembly 1600 can move the articulation driver 1700 proximally sports. When the locking sleeve 1622 is in its disengaged position, the motion of the firing member assembly 1600 is not transmitted to the articulation driver 1700 , and thus, the firing member assembly 1600 can move independently of the articulation driver 1700 . In various cases, 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 locking 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 locking 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 locking sleeve 1622 is in its engaged position, the locking tabs 1626, 1628 are positioned within the drive recess 1605 defined in the intermediate firing shaft portion 1602 such that the distal push and/or proximal pull can be Passed from the firing member assembly 1600 to the locking sleeve 1622. When locking sleeve 1622 is in its engaged position, second locking member 1629 is received within drive recess 1704 defined in articulation driver 1700 such that a distal push and/or proximal pull applied to locking sleeve 1622 can Passed to articulation driver 1700 . In effect, when locking sleeve 1622 is in its engaged position, firing member assembly 1600, locking sleeve 1622, and articulation driver 1700 will move together. On the other hand, when the locking sleeve 1622 is in its disengaged position, the locking 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 thus, the distal thrust and/or Or the proximal pulling force may not be transmitted from the firing member assembly 1600 to the locking sleeve 1622. Accordingly, distal push and/or proximal pull forces may not be transmitted to articulation driver 1700 . In such cases, the firing member assembly 1600 can slide proximally and/or distally relative to the locking sleeve 1622 and the proximal articulation driver 1700 . Clutch assembly 1620 also includes a switch barrel 1630 that engages locking sleeve 1622 . Additional details regarding the operation of the switching barrel and locking sleeve 1622 can be found in US Patent Application Serial No. 13/803,086 (now US Patent Application Publication 2014/0263541 and Serial No. 15/019,196). The switching cartridge 1630 can also include at least partially peripheral openings 1632, 1634 defined therein that can receive a perimeter mount 1305 extending from the nozzle halves 1302, 1304 and permit switching between the cartridge 1630 and the proximal nozzle 1300 relative rotation but not relative translation. See Figure 6. Rotation of the nozzle 1300 to the point where the mount 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 switching barrel 1630 will eventually cause the locking sleeve 1622 to move between its engaged and disengaged positions. Thus, in essence, the nozzle 1300 can be used to operatively engage and disengage the articulation drive system from the firing drive system in various manners as described in more detail in US Patent Application Serial No. 13/803,086, Now US Patent Application Publication 2014/0263541; and US Patent Application Serial No. 15/019,196; each of these patents are incorporated herein by reference in their entirety.

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

As also shown in FIGS. 7 and 8 , the interchangeable tool assembly 1000 can include a slip ring assembly 1640 that can be configured to conduct electrical power to and/or from the end effector 1100 Power is conducted and/or signals are transmitted to and/or from the end effector 1100 back to, for example, a microcontroller or robotic system controller in the handle assembly. Additional details regarding slip ring assembly 1640 and associated connectors can be found in US Patent Application Serial No. 13/803,086 (now US Patent Application Publication 2014/0263541) and US Patent Application Serial No. 15/019,196 (both patent application each of which is incorporated by reference in its entirety) and US Patent Application Serial No. 13/800,067 (now US Patent Application Publication 2014/0263552) entitled "STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM", which is hereby incorporated by reference in its entirety found in this article). Also as described in further detail in the aforementioned patent applications, which have been incorporated by reference herein, the interchangeable surgical tool assembly 1000 may also include at least one sensor configured to detect the position of the switching barrel 1630 .

Referring again to FIG. 7, the base 1800 includes one or more tapered attachment portions 1802 formed thereon adapted to be received within corresponding dovetail slots 507 that form Within the 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 lug 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 the firing shaft attachment bracket 542 formed in the In the distal end of longitudinal drive member 540 . See Figure 3.

Various interchangeable surgical tool assemblies employ a latch 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 latch system 1810 includes a locking member or locking yoke 1812 movably coupled to the base 1800 . The locking yoke 1812 is U-shaped with two spaced apart and downwardly extending legs 1814. The legs 1814 each have pivot lugs formed thereon adapted to be received in corresponding holes 1816 formed in the base 1800 . Such a configuration facilitates pivotal attachment of locking yoke 1812 to base 1800 . The locking yoke 1812 may include two proximally projecting locking lugs 1818 configured to engage corresponding locking pawls or grooves in the distal end of the frame 506 of the handle assembly 500 509 is releasably engaged. See Figure 3. In various forms, the locking yoke 1812 is biased in the proximal direction by a spring or biasing member 1819. Actuation of the locking yoke 1812 may be accomplished by a latch button 1820 slidably mounted on a latch actuator assembly 1822 mounted to the chassis 1800 . The latch button 1820 can be biased in a proximal direction relative to the locking yoke 1812 . The locking yoke 1812 can be moved to the unlocked position by biasing the latch button 1820 in the distal direction, which also pivots the locking yoke 1812 out of engagement 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 when the locking yoke 1812 remains engaged with 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 adapted to contact corresponding locking lug portions 1426 formed on the closure shuttle 1420 . When the closure shuttle 1420 is in the unactuated position, the locking yoke 1812 can pivot in the 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 lug portion 1426 on the closure shuttle 1420. However, when the closure shuttle 1420 is moved to the actuated position, the locking yoke 1812 is prevented from pivoting to the unlocked position. In other words, if the clinician attempts to pivot the locking yoke 1812 to the unlocked position, or, for example, the locking yoke 1812 is inadvertently bumped or contacted in a manner that might otherwise have caused it to pivot distally, the locking yoke 1812 is placed on the locking yoke 1812. The locking hooks 1824 of the will contact the locking lugs 1426 on the closure shuttle 1420 and prevent the locking yoke 1812 from moving to the unlocked position.

Still referring to FIG. 10, the cutter bar 1610 may include a laminated beam structure including at least two beam layers. The beam layers may comprise, for example, stainless steel strips interconnected at their proximal ends and/or elsewhere along the strip length by, for example, welding and/or pins. In an alternative embodiment, the distal ends of the straps are not connected together to allow the laminate or straps to unfold relative to each other when the end effector is articulated. Such an arrangement allows the knife bar 1610 to be flexible enough to accommodate articulation of the end effector. Various laminated cutter bar arrangements are disclosed in US Patent Application Serial No. 15/019,245. As also seen in FIG. 10 , the intermediate support member 1614 serves to provide lateral support for the knife rod 1610 as it flexes to accommodate the articulation of the surgical end effector 1100 . Further details regarding intermediate support members and alternative arbor support arrangements are disclosed in US Patent Application Serial 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 shaft 1610 .

FIG. 11 shows one form of firing member 1660 that can be used with 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 shank 1610 middle. See Figure 10. For example, the connector 1663 may be retained within the connector opening 1614 by friction, welding, and/or a suitable adhesive. Referring to FIGS. 15-17 , body portion 1662 protrudes through elongated slot 1104 in elongated channel 1102 and terminates in foot members 1664 extending laterally on each side of body portion 1662 . When the firing member 1660 is driven distally by the surgical staple cartridge 1110, the foot member 1664 straddles the elongated channel 1102 within a passageway positioned below the surgical staple cartridge 1110. As seen in FIG. 11 , the firing member 1660 may also include a laterally projecting central tab, pin or retainer feature 1680 . The central retainer feature 1680 rides on the inner surface 1106 of the elongated channel 1102 when the firing member 1660 is driven distally by the surgical staple cartridge 1110 . The body portion 1662 of the firing member 1660 also 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 may also include two laterally extending top tab, pin or anvil engagement features 1665 . See Figures 13 and 14. When the firing member 1660 is driven distally, the top portion of the body 1662 extends through the centrally positioned anvil slot 1138 ( FIG. 14 ), and the top anvil engagement feature 1672 straddles the surface of the anvil slot 1134 formed in the anvil slot 1134 . on corresponding protrusions 1136 on each side.

Returning to FIG. 10 , the firing member 1660 is configured to be operably connected to the slider 1120 supported within the body 1111 of the surgical staple cartridge 1110 . Slider 1120 is slidably displaceable within surgical staple cartridge body 1111 from a proximal end starting position adjacent proximal end 1112 of cartridge body 1111 to an ending position adjacent distal end 1113 of cartridge body 1111 . The cartridge body 1111 operably supports therein a plurality of staple drivers (not shown in FIG. 10 ) that are aligned in rows on each side of the centrally disposed slots 1114 . The centrally positioned slot 1114 enables the firing member 1660 to pass therethrough and cut tissue held between the anvil 1130 and the staple cartridge 1110. The drives are associated with corresponding pockets 1115 that pass through the upper platform 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 sloped or wedge-shaped cams 1122 , where 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 "dual" drivers each supporting two pegs or fasteners thereon, and the other cam 1122 is on the same side of the slot 1114 Aligned with another row of "single" drivers on the row, each of which supports 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 cutting line. However, other cartridge and driver configurations may also be employed to fire other staple/fastener arrangements. Slider 1120 has a central body portion 1124 that is configured to be engageable by shoulder 1665 of firing member 1660 . When the firing member 1660 is fired or driven distally, the firing member 1660 also drives the slider 1120 distally. As the firing member 1660 moves distally through the cartridge 1110, the tissue cutting features 1666 cut the tissue clamped between the anvil assembly 1130 and the cartridge 1110, and also the slider 1120 drives the driver in the cartridge upwardly The corresponding staples or fasteners are driven into contact with the anvil assembly 1130 .

In embodiments where the firing member includes a tissue cutting surface, it is desirable that the elongated shaft assembly can be configured in such a way that unless the unused staple cartridge is properly supported in the elongated channel 1102 of the surgical end effector 1100 , which would otherwise prevent accidental advancement of the firing member. 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 in the end effector (ie, a staple cartridge from which at least some staples have been fired), and the firing member is advanced, the tissue will be severed, but may not be completely stapled live. It will be appreciated that such conditions may lead to undesired results during a surgical procedure. US Patent 6,988,649 entitled "SURGICAL STAPLING INSTRUMENT HAVING A SPENT CARTRIDGE LOCKOUT" and US Patent 7,044,352 entitled "SURGICAL STAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISMFOR PREVENTION OF FIRING" entitled "SURGICAL STAPLING OF INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR PREVENTION" US Patent No. 7,380,695 to FIRING" and US Patent Application Serial No. 14/742,933 entitled "SURGICAL STAPLING INSTRUMENTS WITH LOCKOUTARRANGEMENTS FOR PREVENTING FIRING SYSTEM ACTUATION WHEN A CARTRIDGE IS SPENTOR MISSING" each disclose various firing member latching arrangements. Each of these US patents is incorporated herein by reference in its entirety.

An "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. The new cartridge 1110 is seated within the elongated channel 1102 and may be retained therein by snap features on the cartridge body that are configured to retain engagement with corresponding portions of the elongated channel 1102 . 15 and 18 illustrate a portion of a surgical end effector 1100 with a new or unfired surgical staple cartridge 1110 seated therein. As can be seen in Figures 15 and 18, the slider 1120 is in its starting position. To prevent activation of the firing system, and more precisely, to prevent the firing member 1660 from being driven distally through the end effector 1110 unless an unfired or new surgical staple cartridge has been properly seated within the elongated channel 1102 , otherwise interchangeable surgical tool assembly 1000 employs a firing member locking system commonly designated 1650.

Referring now to FIGS. 10 and 15-19 , the firing member lockout system 1650 includes a movable locking member 1652 configured to be able to seat a new surgical staple cartridge 1110 incorrectly within the elongated channel 1102 The firing member 1660 remains engaged. More specifically, locking member 1652 includes at least one laterally movable locking portion 1654 configured to remain engaged with a corresponding portion of firing member 1660 when slider 1120 is not present within cartridge 1110 in its starting position. In effect, the locking member 1652 employs two laterally moving locking portions 1654 that each engage a laterally extending portion of the firing member 1660 . Other latching arrangements can 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 configured to be capable of being designated by an "L" in FIGS. 18 and 19 . Move in a sideways direction. 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 similar materials. Central spring portion 1653 is seated within slot 1236 in end effector mounting assembly 1230. See Figure 10. As can be seen in Figures 15-17, the laterally movable legs or locking portions 1654 each have a distal end 1656 with a locking window 1658 therein. When locking member 1652 is in the locked position, central retainer features 1680 on each side of firing member 1660 extend into corresponding locking windows 1658 defined in locking portion 1654 to hold the firing member against distal or Advance axially.

The operation of the firing member lockout system will be described with reference to FIGS. 15-19 . 15 and 18 illustrate a portion of the surgical end effector 1100 with the new unfired cartridge 1110 properly installed in the portion. As seen in FIGS. 15 and 18 , the slider 1120 includes unlocking features 1126 that correspond to each of the laterally movable locking portions 1654 . An unlock feature 1126 is provided on or extends proximally from each central wedge cam 1122. In alternative arrangements, the unlocking features 1126 may include proximally projecting portions of corresponding wedge-shaped cams 1122 . As can be seen in Figure 18, when the slider 1120 is in its home position, the unlocking features 1124 engage the corresponding locking portions 1654 and bias them laterally in a direction transverse to the shaft axis SA (Figure 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 may be advanced (fired) distally or axially. However, when the cartridge is not present in the elongated channel 1102 or the slider 1120 has moved out of its starting position (which means the cartridge is partially or fully fired), the locking portion 1654 is resiliently held laterally in engagement with the firing member 1660 . In such a situation, referring to Figure 19, the firing member 1660 cannot move distally.

16 and 17 illustrate the retraction of the firing member 1660 to its starting or unfired position after performing the staple firing stroke as discussed above. 16 depicts the initial re-engagement of retention features 1680 with their corresponding locking windows 1658. Figure 17 shows the retention feature in its locked position when the firing member 1660 has been fully retracted to its starting position. To assist in locking lateral displacement of the locking portion 1654 when it contacts the proximally moving retention features 1680, each of the retention features 1680 may be provided with proximally facing, laterally tapered end part. Such a latching system prevents the firing member 1660 from being actuated when no new unfired cartridge is present or when a new unfired cartridge is present but not properly seated in the elongated channel 1102. Additionally, the lockout system may prevent the clinician from advancing the firing member distally if the spent or partially fired cartridge has inadvertently been properly seated within the elongated channel. Another advantage that the latching system 1650 can provide is that, unlike other firing member latching arrangements that require movement of the firing member to align and misalign with corresponding slots/passages in the staple cartridge, the firing member 1660 is in the locked and unlocked positions maintain alignment with the bin passage. The locking portion 1654 is designed to be laterally movable to engage and disengage corresponding sides of the firing member. Such lateral movement of one or more locking portions may distinguish it from other locking arrangements that move vertically to engage and disengage portions of the firing member.

Returning to FIGS. 13 and 14 , the anvil 1130 includes an elongated anvil body portion 1132 and a proximal anvil mounting portion 1150 . The elongated anvil body portion 1132 includes an outer surface 1134 that defines two downwardly extending tissue stop members 1136 adjacent the proximal anvil mounting portion 1150 . The elongated anvil body portion 1132 also includes an underside 1135 that defines an elongated anvil slot 1138 . In the exemplary arrangement shown in FIG. 14 , the anvil slot 1138 is centrally disposed in the 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 the anvil slot 1138 are two elongated anvil passages 1146 . Each passageway 1146 has a proximal ramp portion 1148 . See Figure 13. When the firing member 1660 is advanced distally, the top anvil engagement feature 1632 initially enters the corresponding proximal ramp portion 1148 and enters the corresponding elongated anvil passageway 1146 .

Turning to FIGS. 12 and 13 , the anvil slot 1138 and the proximal ramp portion 1148 extend into the anvil mounting portion 1150 . In other words, the anvil slot 1138 divides or divides the anvil mounting portion 1150 into two anvil attachment flanges 1151 . Anvil attachment flanges 1151 are coupled together at their proximal ends by connecting bridges 1153 . The connecting bridge 1153 supports the anvil attachment flange 1151 and can be used to make the anvil mounting portion 1150 more rigid than mounting portions of other anvil arrangements that are not connected together at their proximal ends. 12 and 14, the anvil slot 1138 has a wider portion 1139 to accommodate the 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 FIGS. 13 and 20-24, each of the anvil attachment flanges 1151 includes a lateral mounting hole 1156 configured to receive a pivot pin 1158 therein (FIG. 10 and Figure 20). Anvil mounting portion 1150 is pivotally pinned to proximal end 1103 of elongated channel 1102 by pivot pin 1158 that extends through mounting hole 1107 in proximal end 1103 of elongated channel 1102 and the anvil Mounting holes 1156 in seat mounting portion 1150. This arrangement pivotally attaches the anvil 1130 to the elongated channel 1102s such that the anvil 1130 can pivot about a fixed anvil axis A-A transverse to the shaft axis SA. See Figure 5. The anvil mounting portion 1150 also includes a cam surface 1152 that extends from the concentrated firing member parking area 1154 to the outer surface 1134 of the anvil body portion 1132 .

In addition to the above, the anvil 1130 can be moved between the open and closed positions by axially advancing and retracting the distal closure tube segment 1430, as discussed further below. The distal end portion of the distal closure segment 1430 has an internal cam surface formed thereon that is configured to engage the cam surface 1552 or a cam surface formed on the anvil mounting portion 1150 and move the anvil 1130 . 22 shows cam surface 1152a formed on anvil mounting portion 1150 to establish a single contact path 1155a with inner cam surface 1444, eg, on distal closure segment 1430. FIG. 23 shows the cam surface 1152b configured relative to the inner cam surface 1444 on the distal closure segment 1152 to the inner cam surface 1444 on the distal closure segment 1430 with the cam surface 1152 on the anvil mounting portion 1150 Two separate and distinct arcuate contact paths 1155b are established therebetween. This arrangement may better distribute the closing force from the distal closing segment 1430 to the anvil 1130, among other potential advantages discussed herein. FIG. 24 shows cam surface 1152c configured relative to inner cam surface 1444 of distal closure tube section 1430 to establish three distinct cam surfaces between anvil mounting portion 1150 and the cam surfaces on distal closure tube section 1430 Contact regions 1155c and 1155d. Regions 1155c, 1155d create a larger area of cam contact between the distal closure tube segment 1430 and one or more cam surfaces on the anvil mounting portion 1150, and may better distribute the closing force to the anvil 1130.

When the distal closure segment 1430 cams into engagement with the anvil mounting portion 1150 of the anvil 1130, the anvil 1130 pivots about the anvil axis AA (FIG. 5), which causes the end 1133 of the elongated anvil body portion 1132 to be distal The ends pivotally move toward the surgical staple cartridge 1110 and the distal end 1105 of the elongated channel 1102 . As the anvil body portion 1132 begins to pivot, the anvil body portion contacts the tissue to be cut and stapled, which is now positioned between the underside 1135 of the elongated 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 their point of application 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. Such bending may result in misalignment of the firing member 1660 with the passageways 1148 , 1146 within the anvil 1130 , for example. In the case of excessive bending, such bending can significantly increase the amount of firing force required to fire the instrument (ie, to drive the firing member 1660 through the tissue from its starting position to its ending position). Such excessive firing force may result in, for example, damage to the end effector, firing member, knife bar, and/or firing drive system components. Therefore, it may be advantageous to configure the anvil to resist such deflection.

Figures 25-27 illustrate anvil 1130' including features that improve the stiffness of the anvil body and its resistance to bending forces that may arise during the closing and/or firing process. Aside from the differences discussed herein, the anvil 1130' may be identical in construction to the anvil 1130 described above. As can be seen in Figures 25-27, the anvil 1130' has an elongated anvil body 1132' having an upper body portion 1165 and an anvil cap 1170 attached thereto. Anvil cap 1170 is generally rectangular in shape and has an outer cap perimeter 1172, although anvil cap 1170 may have any suitable shape. The perimeter 1172 of the anvil cap 1170 is configured to be insertable into corresponding shaped openings 1137 formed in the upper body portion 1165 and to be positioned against an axially extending inner boss portion 1139 formed therein. See Figure 27. The inner raised portion 1139 is configured to support the corresponding long side 1177 of the anvil cap 1170 . In an alternative embodiment, the anvil cap 1170 can 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 inner raised portion is provided. 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 position. The first weld 1178 may be continuous, or it may be discontinuous or discontinuous. In those embodiments where the first weld 1178 is discontinuous or discontinuous, the weld segments may be evenly distributed along the long side 1177 of the anvil cap 1170, more densely spaced closer to the distal end of the long side 1177, and /or nearer the proximal ends of the long sides 1177 are more closely spaced. In some arrangements, the weld segments may be more densely spaced in the central region of the long sides 1177 of the anvil cap 1170 .

FIGS. 28-30 show anvil cap 1170 ′ configured to mechanically interlock with anvil body 1132 ′ and to be welded to upper body portion 1165 . In this embodiment, a plurality of retention 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 regardless of the orientation of the elongated anvil body, the anvil cap will remain attached to the elongated anvil body and does not require any additional retention or fastening, such as welding and/or adhesive. Although any suitable arrangement may be used, retention structure 1182 may protrude inwardly from opening wall 1180 into opening 1137 . Retention structure 1182 may be integrally formed in wall 1180 or otherwise attached thereto. 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. Retention structures 1182 project inwardly into openings 1137 and are configured to be frictionally received within corresponding shaped engagement regions 1184 formed in outer perimeter 1172' of anvil cap 1170'. Retention structure 1182 corresponds only to long side 1177' of anvil cap 1170' and is not provided in the portion of wall 1180 that corresponds to distal end 1173 or proximal end 1175 of anvil cap 1170'. In an alternative arrangement, retention structure 1182 may also be provided in a portion of wall 1180 corresponding to distal ends 1173 and proximal ends 1175 of anvil cap 1170' and its long sides 1177'. In further arrangements, the retention structure 1182 may be provided only in a portion of the wall 1180 that corresponds to one or both of the distal end 1173 and the proximal end 1175 of the anvil cap 1170'. In further arrangements, retention structure 1182 may be provided in a portion of wall 1180 that corresponds to long edge 1177' and to only one of proximal end 1173 and distal end 1175 of anvil cover 1170'. It should also be understood that the retention tabs of all of the foregoing embodiments may alternatively be formed on the anvil cap, with the engagement region formed in the elongated anvil body.

In the embodiment shown in FIGS. 28-30, the retention structures 1182 are equally spaced or evenly distributed along the wall portion 1180 of the anvil cap 1170'. In alternative embodiments, the retention structures 1182 may be more closely spaced apart from the distal ends of the long sides 1177', or more closely spaced from the proximal ends of the long sides 1177'. In other words, the spacing between those retention structures adjacent to the distal end, adjacent to the proximal end, or adjacent to both the distal and proximal ends may be smaller than those positioned in the central portion of the anvil cover 1170'. spacing between the structures. In further arrangements, the retention structures 1182 may be more densely spaced in the central region of the long sides 1177' of the anvil cap 1170'. In some alternative embodiments, the correspondingly shaped engagement region 1184 may not be provided in the outer periphery 1172' or may not be provided in a portion of the outer periphery 1172' of the anvil cap 1170'. In other embodiments, the retention structures and correspondingly shaped engagement regions may be provided with different shapes and sizes. In an alternative arrangement, the retention structure may be sized relative to the engagement area such that there is no interference fit between the retention structure and the engagement area. In such arrangements, the anvil cap may be held in place, eg, 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 its distal end 1173 and/or proximal end 1175. The weld 1178' may be continuous, or it may be discontinuous or discontinuous. In those embodiments where the weld 1178' is discontinuous or discontinuous, the weld segments may be evenly distributed along the long side 1177' of the anvil cover 1170', or the weld segments may be closer to the distal end of the long side 1177' It may be more closely spaced, or closer to the proximal end of the long side 1177'. In further arrangements, the weld sections may be more closely spaced in the central region of the long side 1177' of the anvil cap 1170'.

31 and 32 illustrate another anvil arrangement 1130" with an anvil cap 1170" attached thereto. Anvil cap 1170" is generally rectangular in shape and has an outer cap perimeter 1172"; however, anvil cap 1170" may comprise any suitable configuration. Outer cap perimeter 1172" is configured to be insertable into anvil body 1132" in the correspondingly shaped opening 1137" in the upper body portion 1165 of and can be received on axially extending inner boss portions 1139" and 1190" formed therein. See Figure 32. Raised portions 1139" and 1190" are configured to support corresponding long sides 1177" of anvil cap 1170". In an alternative embodiment, the anvil cap 1170" slides over the inner bosses 1139" and 1190" through an opening in the distal end 1133" of the anvil body 1132'. Anvil body 1132" and anvil cap 1170" may be made of a metal 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 Proximal end positioning. The weld 1178" may be continuous, or it may be discontinuous or discontinuous. It will be appreciated that, compared to embodiments with straight peripheral sides, such as the anvil cover shown in FIG. 26, due to the The cover 1170" has an irregularly shaped perimeter, and the continuous weld embodiment has a larger weld surface area. In those embodiments where the weld 1178" is discontinuous or discontinuous, the weld segments may be evenly distributed along the long side 1177" of the anvil cover 1170", or the weld segments may be closer to the distal end of the long side 1177" It may be more closely spaced, or closer to the proximal end of the long side 1177". In other arrangements, the weld section may be centered on the long side 1177" of the anvil cap 1170" more densely spaced in regions.

Still referring to Figures 31 and 32, anvil cover 1170" may be additionally welded to anvil body 1132" by a plurality of second discrete "deep" welds 1192". For example, each weld 1192" may be placed through Anvil cover 1170" is provided at the bottom of corresponding holes or openings 1194" such that discrete welds 1192" may be formed along the portion of anvil body 1132" between projections 1190" and 1139". See Figure 32. The welds 1192" may be evenly distributed along the long side 1177" of the anvil cover 1170", or the welds 1192" may be more closely spaced closer to the distal end of the long side 1177", or closer to the long side 1177" The proximal ends of the can then be more closely spaced. In further arrangements, the welds 1192" may be more densely spaced in the central region of the long sides 1177" of the anvil cap 1170".

FIG. 33 shows 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"'. Specifically, laterally extending continuous or interrupted tabs 1195"' protrude from each long side 1177"' of the anvil cover 1170"'. Each tab 1195" is associated with a Axial slots 1197"' correspond. Anvil cap 1170"' slides in through an opening in the distal end of anvil body 1132"' to "mechanically" attach the anvil cap to anvil body 1132"'. Tabs 1195"' and slits The grooves 1197"' can be sized relative to each other to create a sliding friction fit therebetween. Additionally, the anvil cap 1170"' can be welded to the anvil body 1132"'. The anvil body 1132"' and the anvil cap 1170''' may 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 only be along the long side 1177''' of the anvil cap 1170''' position. The weld 1178"' may be continuous, or it may be discontinuous or discontinuous. In those embodiments where the weld 1178"' is discontinuous or discontinuous, the weld section may be along the length of the anvil cover 1170"' The long sides 1177"' are evenly spaced, or the welded sections can be more closely spaced closer to the distal end of the long sides 1177"', or closer to the proximal end of the long sides 1177"' spaced apart. In further arrangements, the weld sections may be more densely spaced in the central region of the long sides 1177"' of the anvil cap 1170"'.

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 elongated channel, the firing member can be installed through the opening in the anvil body. Another advantage is that the upper cover can improve the stiffness of the anvil and its resistance to the aforementioned bending forces that may be encountered when gripping tissue. By resisting such bending, the frictional forces normally encountered by the firing member 1660 may be reduced. Accordingly, the amount of firing force required to drive the firing member from its starting position in the surgical staple cartridge to its ending position may also be reduced.

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

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

Anvil 2030 includes a tissue engaging surface 2031 that is flat or at least substantially flat. Formed pockets 2032a, 2032b, and 2032c are defined in the flat surface 2031 . The flat surface 2031 has no steps defined therein; however, embodiments are envisioned in which the anvil 2030 may include a stepped tissue engaging surface. For example, the anvil 2030' includes a stepped tissue engaging surface 2031'. In this embodiment, shaped pockets 2032a and 2032b are defined in the lower step, and shaped pocket 2032c is defined in the upper step.

The firing member 2040 ′ includes a coupling member 2042 ′ that includes the cutting portion 2041 . Cutting portion 2041 is constructed and arranged to cut into tissue captured, for example, between anvil 2030' and staple cartridge 2010 (FIG. 35). The firing member 2040' is configured to push the slider with the sloped surface distally during the staple firing stroke. The sloped surface is configured to lift the staple drivers within the staple cartridge 2010 to form the staples 2020 against the anvil 2030 ′ and eject the staples 2020 from the 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 the staple firing stroke. Referring to Figure 37, protrusion 2043' is formed by a longitudinally elongated shoulder extending from coupling member 2042'. In other embodiments, the protrusion 2043' includes a barrel pin extending through the coupling member 2042'. In any event, the protrusions 2043' have flat sides or ends 2047'.

Longitudinal slot 2033' includes lateral portions 2033l' extending laterally from central portion 2033c', the lateral portions being configured to receive protrusions 2043'. As shown in Figure 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' that is configured to engage the protrusion 2043' during the staple firing stroke. Each longitudinal cam surface 2035' is defined on the upper side of a projection 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 comprise a cantilever beam.

The coupling member 2042' also includes a foot or cam 2044 (FIG. 35) configured to engage the staple cartridge 2010 or the jaws supporting the staple cartridge 2010 during the staple firing stroke. Additionally, the protrusions 2043' and the feet 2044 cooperate to position the anvil 2030' and the staple cartridge 2010 relative to each other. 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 into position 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 . The cutting portion 2041 is constructed and arranged to cut into tissue captured between the anvil 2030 and the staple cartridge 2010 (FIG. 35). The firing member 2040 is configured to push the slider with the sloped surface distally during the staple firing stroke. The sloped surface is configured to lift the staple drivers within the staple cartridge 2010 to form the staples 2020 against the anvil 2030 and eject the staples 2020 from the 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 the staple firing stroke. The protrusions 2043 have curved or rounded sides or ends 2047 . Lateral ends 2047 of protrusions 2043 are fully curved or fully rounded. Each lateral end 2047 includes an arcuate profile extending between the top surface of the protrusion 2043 and the bottom surface of the protrusion 2043 . In other embodiments, the lateral ends 2047 of the protrusions 2043 are only partially curved.

Longitudinal slot 2033 includes lateral portions 2033l extending laterally from central portion 2033c, the lateral portions being configured to receive protrusions 2043. Each lateral portion 2033l of the slot 2033 includes a longitudinal cam surface 2035 configured to engage the protrusion 2043 during the staple firing stroke. Each longitudinal cam surface 2035 is defined on the upper side of a projection 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 comprise 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 the jaws that support the staple cartridge 2010 during the staple firing stroke. Additionally, the protrusions 2043 and the feet 2044 cooperate to position the anvil 2030 and the staple cartridge 2010 relative to each other. 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 into position relative to the anvil 2030.

Referring again to Figure 34, the lateral portion 2033l' of the longitudinal slot 2033' extends a distance 2034' from the centerline CL of the anvil 2030'. The lateral portions 2033l' extend above or behind the shaped pockets 2032a in the anvil 2030'. As shown in Figure 34, the lateral ends of the lateral portions 2033l' are aligned with the outer edges of the forming pockets 2032a. Other embodiments are contemplated in which, for example, the lateral portions 20331' extend laterally beyond the forming pockets 2032a. That is, referring to Fig. 36, the projection 2037' of the anvil 2030' is very long, and in some cases the projection 2037' can deflect significantly under load. In some cases, the protrusions 2037' may be deflected downwardly such that the majority of the drive surfaces 2045' defined on the bottom of the protrusions 2043' are not in contact with the cam surfaces 2035'. In this case, the contact between the protrusion 2043' and the cam surface 2035' can be reduced to a point, such as point 2047'. In some cases, the contact between the protrusion 2043' and the cam surface 2035' can be reduced to a longitudinally extending line that, when viewed from the distal end of the end effector, can appear to be A point, as shown in Figure 36.

Furthermore, referring again to Fig. 34, protrusions 2043' extend above or behind the shaped pockets 2032a in the anvil 2030'. The lateral ends of the protrusions 2043' extend above the longitudinal centerline 2062a of the forming pocket 2032a. Other embodiments are contemplated in which the lateral ends of the protrusions 2043' are aligned with the longitudinal centerlines 2062a of the forming pockets 2032a. Certain embodiments are contemplated in which the lateral ends of the protrusions 2043' do not extend to the longitudinal centerline 2062a of the forming pocket 2032a. In any event, referring again to Figure 36, the protrusion 2043' can be deflected upward (especially when the protrusion 2043' is long) so that the 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 shaped pocket 2032a, the protrusion 2043' can be better controlled within the shaped pocket 2032a and/or the shaped pocket 2032b and The staple forming process that takes place in 2032c.

In addition to the above, the projections 2037' and protrusions 2043' may be deflected 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 projections 2037'. As shown in Figure 36, the contact point 2048' is positioned at or near the inner end of the protrusion 2037'. The deflection of the protrusions 2037' and protrusions 2043' is the same as or similar to the deflection of the cantilever beam. As the reader should understand, when a load is applied at the ends of a cantilever beam, the deflection of the cantilever beam is proportional to the cube of the beam length. In any event, when the protrusions 2037' and/or the protrusions 2043' are deflected, a gap may be formed between the protrusions 2037' and the protrusions 2043'. This gap between the parts of the protrusion 2037' and the protrusion 2043' means that the force flowing between them will flow through a very small area, which will increase the amount of space between the protrusion 2037' and the protrusion 2043'. Stress and strain experienced. This interaction is represented by stress risers or stress concentrations 2039' and 2049' in Figures 38 and 39, where stress riser 2039' exists in protrusion 2037' and stress riser 2049' exists in protrusion 2043' and the interconnection between the coupling member 2042'. Other stress risers or concentrations may be present, but as discussed below, it is desirable to reduce or eliminate such stress risers.

Referring again to FIGS. 34 and 35 , the lateral portions 20331 of the longitudinal slots 2033 each extend a distance 2034 from the centerline CL of the anvil 2030 . Distance 2034 is shorter than distance 2034'. Nonetheless, the lateral portion 2033l extends above or behind the shaped pocket 2032a in the anvil 2030. As shown in Figure 34, the lateral ends of the lateral portions 2033l are not aligned with the outer edges of the forming pockets 2032a. Furthermore, the lateral ends of the lateral portions 2033l do not extend beyond the outer edges of the shaped pockets 2032a. However, the lateral portion 2033l extends above the longitudinal centerline 2062a of the forming pocket 2032a. In addition to the above, the convex portion 2037 is shorter than the convex portion 2037'. Thus, for a given force applied to it, the protrusions 2037 will experience less deflection, stress and strain than the protrusions 2037'.

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

In addition to the above, the cross-sectional thickness of the convex portion 2037 is not constant, unlike the convex portion 2037' which has a constant cross-sectional thickness. 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 2033l. This configuration can be used to strengthen or strengthen the protrusion 2037 and reduce deflection, stress and strain of the protrusion 2037 compared to the protrusion 2037'. In at least one instance, a portion of the protrusion 2037 is tapered and 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 nowhere the cross-sectional thickness is constant.

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

In addition to the above, the bosses 2037 and protrusions 2043 may be applied laterally along the length of the bosses 2037 in such a way that the load flowing between the firing member 2040 and the anvil 2030 is not at a single point and/or at the bosses 2037 Deflection in the manner applied at the ends. Thus, the forces flowing therebetween will flow over a larger area, which in turn will reduce the stress and strain experienced by the protrusions 2037 and protrusions 2043, which in turn may reduce or eliminate, for example, above in conjunction with protrusions 2037' and protrusions The stress riser discussed in section 2043'.

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

As mentioned above, the end effector may include, for example, an anvil that is movable between an open position and a closed position. In some cases, 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 the 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 be progressively closed due to the capture of thicker tissue between the anvil and the staple cartridge. In some cases, the anvil may actually deflect or deform during the staple firing stroke of the firing member. However, this is generally controlled by the upper projection and foot of the firing member.

Turning now to FIG. 37, the drive surface 2045' defined on the protrusion 2043' is flat or at least substantially flat. Additionally, the drive surface 2045' is configured to punch-type engagement with 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 a face-to-face relationship. The flat orientation of the anvil 2030' is depicted in phantom in FIG. 37 . In this case, the drive surface 2045' is parallel, or at least substantially parallel, to the longitudinal path of the firing member 2040' during the staple firing stroke. However, as discussed 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. Therefore, the drive surface 2045' may not always be aligned with the cam surface 2035', and in this case, the protrusions 2043' may gouge into the protrusions 2037' of the anvil 2030. Figure 37 depicts such an example with 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 projection 2043' and/or the cam surface 2035 defined on the boss 2037' ' can be deformed plastically. In some cases, the cam surface 2035', for example, may wear out, which may increase the force required to complete the nail firing stroke. More specifically, when the metal deforms beyond the plastic limit, the plastic strain of the protrusions 2043' and/or the anvil protrusions 2037' may cause energy loss. At this point, wear occurs and the coefficient of friction 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%. Furthermore, in this case, if the end effector 2000' is used again, the force required to complete a subsequent staple firing stroke with the end effector 2000' may increase.

Turning now to Figures 40-42, the firing member 2140 includes a firing rod and a coupling member 2142 attached to the firing rod. The coupling member 2142 includes a connector 2148 that connects the coupling member 2142 to the firing rod. The coupling member 2142 also includes a cutting member 2041 that is configured to cut into the patient's tissue during the staple firing stroke. The coupling member 2142 also includes a protrusion 2143 configured to engage an anvil such as anvil 2030 or 2030', and a foot 2144 configured to engage the staple cartridge jaws during the staple firing stroke . Each protrusion 2143 includes a drive surface 2145 defined on an underside thereof. Each protrusion 2143 also includes a proximally extending cam transition 2147 and a radiused transition 2149 extending around the perimeter of the protrusion 2143 . The coupling member 2142 also includes an intermediate protrusion 2146 extending laterally therefrom that is configured to prevent the firing member 2140 from performing a staple firing stroke when the staple cartridge is not in use and not positioned in front of the firing member 2140 at the beginning of the 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 . Rather, 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 further away from the longitudinal path 2160 than the proximal end. Such an arrangement may reduce or eliminate the problems described above in connection with the progressive closure of the anvil 2130. More specifically, in at least one instance, if the anvil 2130 is to move through the range of motion at an angle between about 4 degrees and about 0 degrees relative to the longitudinal path 2160 during progressive closure, the drive surface 2145 may For example, oriented at about 2 degrees relative to the longitudinal path 2160, which represents the midpoint of the progressively closed range. Other implementations are also possible. For example, if the anvil 2130 is to move through the range of motion at an angle of between about 1 degree and about 0 degrees relative to the longitudinal path 2160 during progressive closure, the drive surface 2145 may, for example, be at an angle of about 1 degree relative to the longitudinal path 2160 . degree orientation, which represents the upper limit of the progressively closed 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 cases, for example, the firing member 2140 may be required to progressively close the anvil 2130 through a range of motion of 10 degrees. 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, the drive surfaces 2145 of the protrusions 2143 are not parallel to the drive surfaces of the feet 2144 . Referring primarily to FIG. 41 , the 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, the drive surface 2145 is oriented at an angle of about 0.5 degrees relative to the drive surface of the foot 2144 . Examples are contemplated in which, for example, the drive surface 2145 is oriented at an angle of about 1 degree relative to the drive surface of the foot 2144 . Certain examples are contemplated in which, for example, the drive surface 2145 is oriented at an angle of between about 0.5 degrees to about 5 degrees relative to the drive surface of the foot 2144 . The drive surfaces of the feet 2144 are parallel to the longitudinal path 2160; however, other embodiments in which the drive surfaces of the feet 2144 are not parallel to the longitudinal path 2160 are also contemplated.

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

Turning now to Figures 43-45, the firing member 2240 includes a firing rod and a coupling member 2242 attached to the firing rod. The coupling member 2242 includes a connector 2148 that connects the coupling member 2242 to the firing rod. The coupling member 2242 also includes a cutting member 2041 that is configured to cut into the patient's tissue during the staple firing stroke. The coupling member 2242 also includes a protrusion 2243 configured to engage an anvil such as anvil 2030 or 2030', and a foot 2144 configured to engage the staple cartridge jaws during the staple firing stroke . Each protrusion 2243 includes a drive surface 2245 defined on an underside thereof. Each protrusion 2243 also includes a rounded transition 2249 extending around its perimeter. The coupling member 2242 also includes an intermediate protrusion 2146 extending laterally therefrom that is configured to prevent the firing member 2240 from performing a staple firing stroke when the staple cartridge is not in use and not positioned in front of the firing member 2240 at the beginning of the staple firing stroke .

In addition to the above, each protrusion 2243 includes a forward or proximal end 2251 configured to engage an anvil and a rearward end. The front end of each protrusion 2243 is different from the trailing or rear end of the protrusion 2243 . The front end 2251 includes a radius extending from the bottom drive surface 2245 of the protrusion 2243 to a location positioned above the longitudinal centerline 2250 of the protrusion 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 protrusion 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 bias the force or load transmitted between the firing member 2240 and the anvil away from the front end 2251 toward the rear end of the protrusion 2243 . In other words, the configuration of the leading end 2251 may prevent the leading end 2251 from becoming the focal point of forces transmitted between the firing member 2240 and the anvil. This arrangement can prevent or reduce the likelihood of the firing member 2240 sticking to the anvil, and can reduce the force required to move the firing member 2240 distally.

Turning now to Figures 46-48, the firing member 2340 includes a firing rod and a coupling member 2342 attached to the firing rod. 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 that is configured to cut into the patient's tissue during the staple firing stroke. The coupling member 2342 also includes a protrusion 2343 configured to engage an anvil such as anvil 2030 or 2030', and a foot 2144 configured to engage the staple cartridge jaws during the staple firing stroke . Each protrusion 2343 includes a drive surface defined on an underside thereof. Each protrusion 2343 also includes a rounded transition 2349 extending around its perimeter. The coupling member 2342 also includes an intermediate protrusion 2146 extending laterally therefrom that is configured to prevent the firing member 2340 from performing a staple firing stroke when the staple cartridge is not in use and not positioned in front of the firing member 2340 at the beginning of the staple firing stroke .

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

Turning now to Figures 49-51, the firing member 2440 includes a firing rod and a coupling member 2442 attached to the firing rod. The coupling member 2442 includes a connector 2148 that connects the coupling member 2442 to the firing rod. The coupling member 2442 also includes a cutting member 2041 that is configured to cut into the patient's tissue during the staple firing stroke. The coupling member 2442 also includes a protrusion 2443 configured to engage an anvil such as anvil 2030 or 2030', and a foot 2144 configured to engage the staple cartridge jaws during the staple firing stroke . Each protrusion 2443 includes a drive surface 2445 defined on an underside thereof. Each protrusion 2443 also includes a rounded transition extending around its perimeter. The coupling member 2442 also includes an intermediate protrusion 2146 extending laterally therefrom that is configured to prevent the firing member 2440 from performing a staple firing stroke when the staple cartridge is not in use and not positioned in front of the firing member 2440 at the beginning of the staple firing stroke .

In addition to the above, the sides or lateral ends of each protrusion 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 . The first radius of curvature 2447a is different from the second radius of curvature 2447b. For example, the first radius of curvature 2447a is greater than the second radius of curvature 2447b. However, the curvatures 2447a and 2447b may comprise any suitable configuration. Referring primarily to FIG. 51 , the first radius of curvature 2447a extends upwardly past the centerline 2450 of the protrusion 2443 .

Turning now to Figures 52-54, the firing member 2540 includes a firing rod and a coupling member 2542 attached to the firing rod. The coupling member 2542 includes a connector 2148 that connects the coupling member 2542 to the firing rod. The coupling member 2542 also includes a cutting member 2041 that is configured to cut into the patient's tissue during the staple firing stroke. The coupling member 2542 also includes a protrusion 2543 configured to engage an anvil such as anvil 2030 or 2030' and a foot 2144 configured to engage the staple cartridge jaws during the staple firing stroke . Each protrusion 2543 includes a drive surface defined on an underside thereof. Each protrusion 2543 also includes a rounded transition extending around its perimeter. The coupling member 2542 also includes an intermediate protrusion 2146 extending laterally therefrom that is configured to prevent the firing member 2540 from performing a staple firing stroke when the staple cartridge is not in use and not positioned in front 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 flat or at least substantially flat. Each protrusion 2543 also includes a rounded transition 2547 extending around the lateral ends 2552. Each protrusion 2543 is symmetrical, or at least substantially symmetrical, about a longitudinal centerline extending through the lateral end 2552 . Also, the top and bottom surfaces of each protrusion 2543 are parallel to each other.

Referring primarily to FIG. 53 , the forward end 2551 of each protrusion 2543 is positioned distally relative to the cutting edge 2042 of the cutting portion 2041 . The rear end 2559 of each protrusion 2543 is positioned proximally relative to the cutting edge 2042. Thus, the protrusion 2043 spans the cutting edge 2042 longitudinally. In this case, the firing member 2540 may hold the anvil together with the staple cartridge directly at the location where the tissue is being cut.

Turning now to Figures 55-57, the firing member 2640 includes a firing rod and a coupling member 2642 attached to the firing rod. 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 that is configured to cut into the patient's tissue during the staple firing stroke. The coupling member 2642 also includes a protrusion 2643 configured to engage an anvil such as anvil 2030 or 2030', and a foot 2144 configured to engage the staple cartridge jaws during the staple firing stroke . Each protrusion 2643 includes a drive surface 2645 defined on an underside thereof. Each protrusion 2643 also includes a rounded transition 2649 extending around its perimeter. The coupling member 2642 also includes an intermediate protrusion 2146 extending laterally therefrom that is configured to prevent the firing member 2640 from performing a staple firing stroke when the staple cartridge is not in use and not positioned in front of the firing member 2640 at the beginning of the staple firing stroke .

In addition to the above, each protrusion 2643 includes a lateral end 2652, a bottom drive surface 2645, and a top surface 2647. Bottom drive surface 2645 is flat and parallel to longitudinal firing path 2660 of firing member 2640. Referring primarily to FIG. 57, the top surface 2647 is flat, but not parallel to the longitudinal firing path 2660. Additionally, the top surface 2647 is not parallel to the bottom surface 2645. Therefore, each protrusion 2643 is asymmetrical. In effect, the orientation of the top surface 2647 offsets the moment of inertia of the protrusion 2643 over the lateral end 2652. This arrangement can increase the bending stiffness of the protrusions 2643, which can reduce deflection of the protrusions 2643.

Turning now to Figures 58-60, the firing member 2740 includes a firing rod and a coupling member 2742 attached to the firing rod. 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 that is configured to cut into the patient's tissue during the staple firing stroke. The coupling member 2742 also includes a protrusion 2743 configured to engage an anvil such as anvil 2030 or 2030' and a foot 2144 configured to engage the staple cartridge jaws during the staple firing stroke . Each protrusion 2743 includes a drive surface defined on an underside thereof. The coupling member 2742 also includes an intermediate protrusion 2146 extending laterally therefrom that is configured to prevent the firing member 2740 from performing a staple firing stroke when the staple cartridge is not in use and not positioned in front of the firing member 2740 at the beginning of the staple firing stroke .

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

As the firing member 2740 is advanced distally, in addition to the above, the drive surfaces 2745a and 2745b may cooperate to engage and position the anvil. In certain embodiments, the drive surfaces 2745a and 2745b define a drive plane that is parallel, or at least substantially parallel, to the longitudinal path 2760 of the firing member 2740 during the staple firing stroke. However, in some cases, only the front drive surface 2745a may engage the cam surface defined on the anvil. This may occur, for example, when the firing member 2740 progressively closes the anvil.

In other embodiments, referring to Figures 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 further away 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, drive surfaces 2745a and 2745b can define a drive plane transverse to 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, front drive surface 2745a is positioned vertically above rear drive surface 2745b by a distance of, for example, about 0.001". In other embodiments, front drive surface 2745a is positioned vertically above, for example, by a distance of about 0.002" Above rear drive surface 2745b. In some cases, the front drive surface 2745a is positioned above the rear drive surface 2745b by a distance between about 0.001" and about 0.002".

In some cases, referring again to Figure 70, when 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 protrusions 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 flex due to the staple forming load applied to the anvil, in some cases, the anvil can flex upwardly into contact with the front drive surface 2745a, as shown in FIG. 71 .

The front portion 2753a is thicker than the rear portion 2753b. 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 protrusion 2743. Thus, the rear portion 2753b can be deflected upward more than the front portion 2753a. In this case, even though the firing member 2740 is used to progressively close the anvil, the two portions 2753a and 2753b of the protrusion 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 can 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 can withstand greater shear forces than the front protrusion 2753a, for example, the rear portion 2753b can have a greater shear thickness than the front portion 2753a.

Turning now to Figures 61-63, the firing member 2840 includes a firing rod and a coupling member 2842 attached to the firing rod. 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 that is configured to cut into the patient's tissue during the staple firing stroke. The coupling member 2842 also includes a protrusion configured to engage an anvil such as anvil 2030 or 2030', and a foot 2144 configured to engage the cartridge jaws during the staple firing stroke. As described in more detail below, each protrusion includes a drive surface defined on an underside thereof. The coupling member 2842 also includes an intermediate protrusion 2146 extending laterally therefrom that is configured to prevent the firing member 2840 from performing a staple firing stroke when the staple cartridge is not in use and not positioned in front 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 protrusion 2843d and a second or rear protrusion 2843p positioned behind the front protrusion 2843d. The front protrusion 2843d includes a curved lead-in surface 2851d defined on its distal end that is configured to initially engage the anvil. Front protrusion 2843d also includes a first drive surface or front drive surface 2845d defined on an underside thereof. Similarly, rear protrusion 2843p includes a curved lead-in surface 2851p defined on its distal end that is configured to engage the anvil. The rear protrusion 2843p also includes a second or rear drive surface 2845p defined on the bottom side thereof.

In addition to the above, the drive surfaces 2845d and 2845p may cooperate to engage and position the anvil as the firing member 2840 is advanced distally. In certain embodiments, 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 during the staple firing stroke. In other embodiments, the front drive surface 2845d is positioned above the rear drive surface 2845p. In other words, the front drive surface 2845d is positioned further away from the longitudinal path 2860 than the rear drive surface 2845p. In at least one instance, drive surfaces 2845d and 2845p can define a drive plane transverse to 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 protrusion 2843d and the rear protrusion 2843p may move relative to each other. In each case, the front protrusion 2843d and the rear protrusion 2843p on one side of the coupling member 2842 can move independently of each other. This arrangement may allow the projections 2843d and 2843p to independently adapt to the orientation of the anvil, especially when the firing member 2840 is used to progressively close the anvil. Accordingly, both protrusions 2843d and 2843p may remain engaged with the anvil, allowing force to flow between the firing member 2840 and the anvil at various locations and reducing plastic deformation of the protrusions.

FIG. 68 depicts the energy required by the first firing member to complete the firing stroke marked 2090 ′ and the energy required by the second firing member to complete the firing stroke marked 3090 . The firing stroke 2090' represents a condition in which significant plastic deformation and wear have occurred. The firing stroke 3090 represents an improvement over the firing stroke 2090' in which the deformation of the firing member and anvil lug is mostly elastic. It is believed that under certain circumstances, for example, by employing the teachings disclosed herein, the plastic strain experienced by the firing member and/or the anvil can be reduced by about 40% to 60%.

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

In addition to the above, referring now to FIGS. 64-67 , the firing member 2940 includes a lateral protrusion 2943 . Each protrusion 2943 includes a longitudinal ridge 2945 extending from its base. Ridges 2945 are configured to plastically deform and/or smear as firing member 2940 is advanced distally to engage the anvil. The ridges 2945 are configured to quickly break in or establish a cornering posture in order to increase the contact area between the protrusions 2943 and the anvil and provide better load balance 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 foregoing, one or more wearable pads may be attached to the protrusions of the firing member that may be configured to be plastically deformable.

72 and 73 depict a surgical stapling anvil or anvil jaw 3100 for use with a surgical stapling instrument. Anvil 3100 is configured to deform staples during a surgical stapling procedure. Anvil 3100 includes anvil body 3101 and anvil cap 3110 . Anvil body 3101 and anvil cap 3110 are welded together. Anvil body 3101 includes proximal portion 3102 that includes coupling portion 3103 . The coupling portion 3103 is configured to be assembled to an end effector of a surgical stapling instrument to allow rotation of the anvil jaws 3000 relative to corresponding jaws (eg, cartridge jaws). Embodiments are envisioned in which the anvil jaws are fixed relative to the cartridge jaws, and in such cases the cartridge jaws can be rotated relative to the anvil jaws. Anvil body 3101 also includes a distal tip portion 3104, an outer edge 3107, and a planar tissue-facing surface 3106. The tissue-facing surface 3106 includes staple-forming pockets defined therein that are configured to deform the staples during a surgical stapling procedure. Anvil body 3101 also includes 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. Certain surfaces may be configured for welding, while other surfaces may only be configured for alignment during assembly.

Anvil cap 3110 includes a proximal end 3111 , a distal end 3112 and a continuous perimeter or edge 3113 . When anvil body 3101 and anvil cap 3110 are assembled and/or welded together, edge 3113 may be flush or substantially flush with top surface 3108 of anvil body 3101 to provide a smooth upper surface of surgical stapling anvil 3100, although Steps in the seams in between may be possible. In addition to the above, the anvil cap 3110 also includes a rounded upper surface 3114. The upper surface 3114 may be shaped and/or rounded, eg, 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 may allow polishing of the interior surfaces within the anvil 3100 during manufacture. Manufacturing these parts can include processes that result in a less than desired surface finish for various surfaces within the anvil. Improving the finish of the various inner surfaces can reduce the internal friction between the anvil and the staple firing member passing therethrough. Reducing the internal friction force can reduce the force required to move the firing member through its spike firing stroke. Reducing the force required to move the firing member through its staple firing stroke can result in a reduction in the size of certain components, resulting in a desired reduction in overall instrument size. This arrangement may also reduce the number of instrument failures. That said, the two-piece welding anvil presents challenges. For example, in some cases a two-piece welding anvil may deflect more than a one-piece anvil. In other words, a two-piece anvil may be less rigid than a one-piece anvil, and less resistant to bending. Furthermore, lateral deflection or rotation of the side of the anvil away from the firing member or longitudinal instrument axis can cause the staples to deform inappropriately. This deflection can result in a vertical expansion of the entire system, resulting in a forming height of the forming staple that is not the intended forming height. Furthermore, this deflection may allow the firing member to tear vertically through the anvil of 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 tissue induced pressure. Minimizing this deflection is important to create properly formed nails. As mentioned above, the presence of lateral and lateral deflection can have a combined effect. In effect, lateral deflection can cause lateral deflection of the anvil.

74 depicts a portion of a surgical stapling anvil 3200 that includes an anvil body 3210 and an anvil cap 3220 welded to the anvil body 3210 by a weld 3201. Although only a portion of the surgical staple 3200 is shown, it should be understood that there are mirrored portions of the portion shown to complete the surgical staple 3200. The illustrated and mirrored portions will be discussed concurrently. Anvil body 3210 includes a tissue facing surface 3211 that includes a plurality of staple-forming pockets 3212 defined therein, a projection 3215 that includes cam surfaces 3216 configured to be capable of being fired by a surgical stapling instrument The member's anvil cam feature contacts, as well as a longitudinal slot 3213 configured to receive a firing member therein. Anvil body 3210 also includes an outer edge 3214. The protrusions 3215 are configured to withstand or support the distributed load force 3231 exerted by the firing member as the firing member moves through the staple firing stroke. Anvil body 3210 also includes protrusions 3217 configured to retain anvil cap 3220 during welding. The protrusions 3217 can aid in assembly and can ensure proper alignment of the anvil cap 3220 and the anvil body 3210. The protrusions 3217 may also serve as features to improve overall anvil stiffness. Anvil cap 3220 includes upper portion 3223, lower portion 3221, and boss 3224 configured to rest on 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 the welding portion 3201 . A chamfered edge on one or both of the anvil body 3210 and the anvil cap 3220 provides a welding channel. In this case, the welding portion surfaces of the anvil body 3210 and the anvil cap 3220 are vertical, and thus, the welding portion 3201 is vertical. Weld 3201 has a weld length or depth marked by 3202. For example, the weld depth 3202 is approximately 0.030 inches. Notably, the weld 3201 does not penetrate the anvil 3200 to reach the horizontal surfaces of the bosses 3217, 3224. With this arrangement, the anvil body 3210 will tend to be rotationally deflected about the pivot axis P due to the combination of forces exerted by the firing member and tissue on the anvil body 3210 . When the firing member cams the surface 3216 by pressing on the boss 3215 (represented by the distributed load force 3231), and the tissue and cartridge push on the tissue facing surface 3211 (represented by the distributed load force 3232), the anvil Both sides of seat 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 (indicated by deflection 3233) is allowed due to the lack of weld penetration of the provided welding device. In some cases, the anvil body 3210 and the anvil cap 3220 may be fanned out at a non-welded portion or seam 3204 having a length 3203.

75 depicts a portion of a surgical stapling anvil 3300 that includes an anvil body 3310 and an anvil cap 3320 welded to the 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 are mirror image portions of the portions shown to complete the surgical stapling anvil 3300. The illustrated and mirrored portions will be discussed concurrently. Anvil body 3310 includes a tissue-facing surface 3311 that includes a plurality of staple-forming pockets 3312 defined therein, a projection 3315 that includes cam surfaces 3316 configured to be capable of being fired by a surgical stapling instrument The member's anvil cam feature contacts, as well as a longitudinal slot 3313 configured to receive a firing member therein. Anvil body 3310 also includes an outer edge 3314. The protrusions 3315 are configured to withstand or support the distributed load force 3331 exerted by the firing member as the firing member moves through the staple firing stroke. Anvil body 3310 also includes an upper portion 3317 extending from slot 3313 to outer edge 3314. Anvil cap 3320 includes an upper portion 3323, a lower portion 3321, and a boss 3224 configured to rest on upper portion 3317 before, during, and after welding.

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

76 depicts a portion of a surgical stapling anvil 3400 that includes an anvil body 3410 and an anvil cap 3420 welded to the anvil body 3410 by a weld 3401. Although only a portion of the surgical stapling anvil 3400 is shown, it should be understood that there are mirror image portions of the portions shown to complete the surgical stapling anvil 3400. The illustrated and mirrored portions will be discussed concurrently. Anvil body 3410 includes a tissue-facing surface 3411 that includes a plurality of staple-forming pockets 3412 defined therein, a projection 3415 that includes cam surfaces 3416 that are configured to be configured to be slidable by a surgical stapling instrument. The anvil cam feature of the firing member contacts; and a longitudinal slot 3413 configured to receive the firing member therein. Anvil body 3410 also includes an outer edge 3414. The protrusions 3415 are configured to withstand or support the distributed load force 3431 exerted by the firing member as the firing member moves through the staple firing stroke. Anvil body 3410 also includes protrusions 3417 configured to retain anvil cap 3420 during welding. The protrusions 3417 can aid in the assembly of the cap 3420 and the body 3410 and can ensure proper alignment of the anvil cap 3420 and the anvil body 3410. The protrusions 3417 may also improve the overall anvil stiffness of the anvil 3400. Anvil cap 3420 includes upper portion 3423, lower portion 3421, and 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 the welding portion 3401 . The weld channel is provided by the chamfered edge of one or both of the anvil body 3410 and the anvil cap 3420. In this case, the weld surfaces of the anvil body 3410 and the anvil cap 3420 are angled, and thus, the weld 3401 is angled. 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 bosses 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 on 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 the distributed load force 3431 ), and when the tissue and staple pushes on the tissue-facing surface 3411 (represented by the distributed load force 3431 ) distributed load force 3432), both sides of the anvil body 3410 (only one side is shown in FIG. 76) may tend to rotate about the pivot axis P. However, as the sides of the anvil body 3410 are rotated, the angled weld surfaces will tend to compress, which may limit the amount of deflection experienced by the anvil 3400. Anvil body 3410 and anvil cap 3420 may tend to compress at non-welded portion 3404 having length 3403, resulting in a very strong interconnection between cap 3420 and body 3410.

Figure 77 depicts a surgical stapling anvil 3500 for use with a surgical stapling instrument. Anvil 3500 includes anvil body 3510 and anvil cap 3520 . Anvil body 3510 includes a tissue-facing surface 3511 that includes a plurality of staple-forming pockets 3512 defined therein, a protrusion 3515 that includes cam surfaces 3516 configured to be The anvil cam feature of the firing member of the surgical stapling instrument engages; and the longitudinal slot 3513 configured to receive the firing member therein. The protrusions 3415 are configured to withstand or support the distributed load force applied by the firing member as the firing member moves through the staple firing stroke. Anvil body 3510 also includes protrusions 3517 configured to hold anvil cap 3520 in place during welding. The protrusions 3517 can aid in the assembly of the cap 3520 and the anvil body 3510 and can ensure proper alignment of the anvil cap 3520 and the anvil body 3510. The protrusions 3517 may also improve the overall stiffness of the anvil 3500. Anvil cap 3520 includes upper portion 3523, lower portion 3521, and 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 the welding portion 3501 . Only one weld 3501 is shown to provide clarity of the relationship of the anvil body 3510 and the anvil cap 3520 before and after welding. In this case, the weld surfaces of the anvil body 3510 and the anvil cap 3520 are angled, and thus, the weld 3501 is angled. 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 bosses 3517, 3524. Providing an angled weld surface configured to match weld penetration can aid in rotation as well as prevent deflection of the anvil in the vertical direction. In other words, having welds with 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 length of the fit. Suitable welding techniques are used to weld any of the anvils disclosed herein. In some cases, there is a gap between adjacent weld surfaces that is configured to receive weld material. In some cases, no clearance is provided. In at least one such case, the angled weld surface is laser welded.

78 is a photomicrograph of anvil 3600 including anvil body portion 3610 and upper anvil portion 3620. Anvil body portion 3610 includes: a tissue-facing surface 3611 including 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 boss 3615, The protrusion is configured to engage the firing member during the firing stroke of the staple. Anvil body portion 3610 and upper anvil portion 3620 are welded to each other by welds 3601, each weld 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.

Anvil 3600 includes a larger non-welded width 3606, and also a larger slot cavity width 3605. The non-welded width 3606 is about 125% of the cavity width 3605. In effect, the width of the non-weld width 3606 is such that the middle forming dimple row 3612B and the inner forming dimple row 3612A are defined within the non-welding width 3606 . Similarly, a portion of the inner forming pocket 3612A and the middle forming pocket 3612B are defined with a slot cavity width 3605 . In addition, the inner boundary axis 3619 of the middle row of shaped pockets 3612B is defined within both the non-welded width 3606 and the cavity width 3605. This arrangement can significantly deflect the anvil 3600 when gripping tissue and/or when the firing member is moved through its staple firing stroke. Such deflection may be due to the lack of weld penetration and the relatively large non-weld width 3605 relative to the slot width 3606 .

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

Anvil cap 3720 includes a Y-shaped cross-section. Anvil cap 3720 includes; lower portion 3721 configured to be received within slot 3713 defining a first mating region; and upper portion 3723 configured to be welded to anvil body 3710. The upper portion 3723 includes protrusions or shoulders 3724 that include horizontal alignment surfaces configured to rest on corresponding horizontal alignment surfaces of the protrusions 3716. The interface defines a second mating region that is 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 weldable to a corresponding angled weld surface of the anvil body 3710 defining the third mating area 3717. The weld penetration length of the weld is equal to the length of the angled weld surfaces 3725, 3717.

Anvil 3700 includes non-welded width 3706 and slot width 3705 . The non-welded width 3706 is no 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-welded width 3706 (ie, 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 that is a second distance 3732D from the central axis CA. The second distance 3732D is less than the first distance 3731D. Accordingly, all or at least a portion of the inner staple forming pocket 3712A is defined within the non-welded width 3706 . In other cases, the inner nail forming pockets 3712A are completely outside of the non-welded width 3706. In such cases, the first width 3731D is smaller 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. The third distance 3733D is greater than the first distance 3731D and the second distance 3732D. In other cases, the inner staple forming pockets 3712A lie completely within the non-welded width 3706. In such a case, 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. The fourth distance 3734D is greater than the first distance 3731D, the second distance 3732D, and the third distance 3733D. In other words, the non-welded width 3706 does not extend to the intermediate staple forming pocket 3712B. Minimizing the distance by which the first distance 3731D or outer boundary axis 3731D extends from the central axis CA may increase the overall stiffness of the anvil 3700 to reduce longitudinal and rotational, or torsion, bending, or deflection of the anvil 3700 .

Figure 80 is a graph 3800 representing four different surgical stapling anvil arrangements subjected to two different loading conditions. Model A is a one-piece or one-piece anvil. Model B is a two-piece anvil that includes an anvil body and an anvil cap welded to the anvil body. The anvil cap includes an upper weld portion that includes a non-weld width that is wider than 105% of the slot width. Like Model B, Model C is a two-piece anvil that includes an anvil body and an anvil cap welded to the anvil body. The non-welded 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 the anvil body prevents the formation of a weld depth extending 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 the anvil 3700 . The anvil cap includes a non-weld width of about 105% of the slot width, and the angle of the angled weld surface of Model D allows the creation of a weld depth that blends 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 the anvil 3700 is less than the distal tip deflection of the anvils of Model A, Model B, and Model C. Likewise, the total stress in the convex portions of Model B, Model C, and Model D is smaller than that of Model A.

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

81, the anvil cap 3920 includes a plurality of shallow weld lands 3930 each having a zone length 3930L, and a plurality of deep weld lands 3940 each having a zone length 3940L. The zone lengths 3930L, 3940L are equal; however, in other cases, the zone lengths 3930L, 3940L are different. Each shallow pad 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 projections 3916 of the anvil body 3910, while the welding surface 3935 is configured to engage or mate with the corresponding angled welding surface 3917 of the anvil body 3910 (FIG. 82 ). Each deep weld 3940 includes an upper portion 3943 and a lower portion 3941 . Lower portion 3941 is accessible via window 3945 extending through upper portion 3943 of deep bond 3940. The upper portion 3942 includes alignment tabs 3944 accessible via the weld access region 3945 that are configured to rest on corresponding alignment tabs 3418 of the anvil body 3910. Alignment protrusions 3916 are a first distance from tissue-facing surface 3911 and alignment protrusions 3944 are 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 via the weld 3936 including the weld root 3937 (FIG. 83). The weld root 3937 is configured to penetrate at least to the horizontal surface of the boss 3916. Deep weld 3940 is configured to be welded to anvil body 3910 by weld 3946 including root 3947 (FIG. 83). Weld entry area 3945 allows deep welds to weld lower portion 3941 to anvil body 3910. During welding, the entire protrusion 3946 may be fused with the anvil body 3910. Although weld lengths 3938, 3948 may be similar, if not equal, the effective or net weld depth between anvil cap 3920 and anvil body 3910 may be increased by providing shallow 3930 and deep 3940 welds Increase. The weld depth can be defined as the distance from the edge 3921 of the upper surface 3901 of the anvil to the root of the corresponding weld. Alternating shallow welds 3930 and deep welds 3940 may allow for shallow and deep welds on both sides of anvil 3900 along the longitudinal length of anvil 3900, and between anvil cap 3920 and anvil body 3910 establish a strong connection between them.

Shallow weld 3930 and deep weld 3940 are configured to increase the overall weld depth along the length of anvil 3900. The location, longitudinal length, and number of shallow welds 3930 and deep welds 3940 can be varied to vary or adjust the stiffness of the anvil 3900 along the length of the anvil. For example, the shallow weld zone 3930 has a first stiffness and the deep weld zone 3940 has a second stiffness that is different from the first stiffness. This arrangement may also allow the use of a single depth welder to manufacture the welds 3936, 3946, which may simplify manufacturing. In addition to these welds, filler welds may be applied to fill the entry region 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 envisaged in which 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 includes extending along length L a plurality of zones, wherein each zone includes a shallow weld and a deep weld 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. Furthermore, in addition to having different lengths, multiple zones may alternate sides forming shallow and deep welds. Thus, such an anvil would include shallow and deep welds along the entire length of the anvil.

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

Methods for making surgical stapling anvils, such as those disclosed herein, can include various steps. One step of manufacturing an anvil includes manufacturing an anvil body portion and an anvil cap member. Another step of manufacturing the anvil includes polishing the anvil cam surface of the anvil body portion. In various cases, any inner surface of any portion of the firing member that is accessible may be polished. Another step of manufacturing the anvil includes welding the anvil body portion and the anvil cap member together. The welding step may include, for example, a laser welding process. Yet another step of 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 projection. The boss may include a first region and a second region, wherein the first region is configured to be contactable by the anvil cam of the firing member, and the second region extends laterally beyond the first region. Under normal firing conditions, the firing member will only contact the first boss region and not the second boss region. However, under abnormal firing conditions, 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.

84 and 85 depict an anvil 4000 including an anvil body 4010 and an anvil cap 4020. Anvil body 4010 includes a tissue facing surface 4011 and a plurality of staple forming pockets 4012 defined in tissue facing surface 4011. Anvil 4000 includes longitudinal lumen 4013 configured to receive a firing member of a surgical instrument therein. Cavity 4013 includes an anvil cam surface 4015 defined by protrusion 4014 of anvil body 4010. The firing member is configured to cam tilt the boss 4014 as the firing member moves through the firing stroke. Anvil cap 4020 is welded to anvil body 4010. A welder, such as a laser welder, is allowed to enter anvil body 4010 and anvil cap 4020 via welder access area 4005 . The welder access area 4005 includes an opening or chamfered edge to provide the welder with room to access the location to be welded. Larger welder entry area ensures deep weld penetration.

Anvil 4000 includes a primary weld 4001 and an auxiliary filler weld 4003 . Although only one auxiliary filler weld 4003 is shown, the anvil 4000 may include auxiliary filler welds on top of or over all existing primary welds. The filler weld 4003 provides additional stiffness to the anvil 4000 over its longitudinal length and also helps prevent rotational deflection or torsional bending or twisting of the anvil sides. Additionally, the filler weld 4003 increases the overall weld penetration in the anvil 4000 , which increases the stiffness of the anvil 4000 . The main weld 4001 fuses the corresponding slopes of the anvil body 4010 and the anvil cap 4020 . More specifically, the anvil body 4010 includes: a first sloped surface 4019 configured to mate with the first sloped surface 4029 of the anvil cap 4020; a horizontal surface 4028 to mate; 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 engage the second horizontal surface of the anvil cap 4020 or bottom surface 4026 to mate. During manufacture, a welding machine may be selected and configured to fuse the first bevels 4019, 4029 together.

Additional ramps 4017, 4027 and horizontal surfaces 4016, 4018, 4026, 4028 are configured to assist in assembly of anvil body 4010 and anvil cap 4020 prior to welding during manufacture. For example, when preparing the anvil body 4010 and the anvil cap 4020 for welding, the additional surfaces can help align the anvil body 4010 and the anvil 4020 for welding. The second horizontal surface 4016 provides the anvil cap 4020 with a defined depth. In other words, the second horizontal surface 4016 defines the lowest seatable position at which the bottom surface 4026 can sit relative to the anvil body 4010 .

86 depicts an anvil 4100 that includes 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 also includes a longitudinal lumen 4113 configured to receive a firing member of a surgical instrument therein. The first anvil member 4110 also includes an anvil cam protrusion 4114 that defines an anvil cam surface 4115 that is configured to be engaged by the firing member as the firing member moves through the 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 reduce the distance of the anvil 4100 from relative to each other when the anvil 4100 is clamped against the staple cartridge. Bending caused by the transverse tissue of the cartridge. The first anvil member 4110 includes horizontally extending interlocking features 4117 that are received within corresponding interlocking holes 4137 of the second anvil member 4130 . The first anvil member 4110 also includes vertically extending interlocking features 4116 that are received within corresponding holes 4136 of the second anvil member 4130. In various cases, the interlocking features 4116, 4117 may require that the anvil 4100 be assembled in the longitudinal direction only before being welded together. For example, the second anvil member 4130 can slide longitudinally relative to the first anvil member in a longitudinal direction to assemble the first and second anvil members 4110 and 4130 .

The first anvil member 4110 and the second anvil member 4130 are welded to each other by the outer welding portion 4101 and the inner welding portion 4103 . The welds 4101, 4103 may comprise, for example, laser welds. The outer weld 4101 is located in the outer portion 4105 of the anvil 4100 . The inner weld 4103 is located in the longitudinal cavity 4113 defined by the first anvil member 4110 and the second anvil member 4130 . For example, a laser welder may enter longitudinal cavity 4113 through openings or holes defined between cam lobes 4114 to form internal weld 4103. In each case, the opening defined by the cam lobe 4114 is sized to allow access by a welding machine dedicated to the inner weld 4103. Such an arrangement with inner welds, outer welds, and interlocking features can increase the overall strength of the anvil and reduce lateral and/or torsional deflection. The interlocking features can also provide a solid retention surface so that when one of the first and second anvil members is grounded during preparation for welding, the other of the first and second anvil members is grounded. One is restricted to one plane of motion. This arrangement can ensure that the first and second anvil members do not move relative to each other before and/or during the welding process.

Referring now to FIG. 87 , an anvil 4200 includes an anvil body 4210 and an anvil cap 4220 . Anvil body 4210 includes a planar tissue-contacting surface 4211 that includes a plurality of staple-forming pockets 4212 defined therein. Anvil body 4210 also includes longitudinal lumen 4213 configured to receive a firing member of a surgical instrument therein. The anvil body 4210 also includes an anvil cam projection 4214 that defines an anvil cam surface 4215 that is configured to be engaged by the firing member as the firing member moves through the firing stroke.

Anvil cap 4220 is positioned within longitudinal cavity 4213 and welded to anvil body 4210 by weld 4201 . Welds 4201 may include, for example, laser welds. Anvil cap 4220 includes lateral projections or interlocking features 4221 configured to be received within bore 4216 of anvil body 4210. Welds 4201 include weld depths that do not penetrate into protrusions 4221 , however embodiments in which welds 4201 extend into or into protrusions 4221 are contemplated.

88-92 illustrate a surgical stapling assembly 4300 including a welding anvil in another arrangement to help prevent and/or limit longitudinal flexing of the welding anvil. Surgical stapling assembly 4300 includes: anvil jaw 4340 including anvil body 4350 and anvil cap 4360; cartridge channel jaw 4330 configured to receive a staple cartridge in its cartridge receiving hole 4333; and a closure mechanism 4310, which is configured to pivot the anvil jaw 4340 relative to the cartridge channel jaw 4330 by a cam mechanism. That is, embodiments in which the cartridge channel jaws 4330 pivot relative to the anvil jaws 4340 are contemplated. 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 that are ejected from a surgical staple cartridge. The stapling assembly 4300 also includes a firing member 4370 configured to be longitudinally movable 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 the staple cartridge, and is configured to cut tissue captured between the anvil jaws 4340 and the cartridge channel jaws 4330 during the firing stroke.

Surgical stapling assembly 4300 includes means for improving the overall stiffness and strength of anvil jaws 4340 by reducing the stiffness of cartridge channel jaws 4330. The cartridge channel includes a channel wall 4334 that includes a proximal wall portion 4335 and a distal wall portion 4337. The anvil jaw 4340 is configured to abut against 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 includes a proximal surrounding portion 4352 that is configured to subsidize or surround proximally when anvil jaws 4340 are pivoted from an open configuration ( FIG. 88 ) to a closed configuration ( FIG. 89 ) by closure mechanism 4310 Wall portion 4335. The proximal surrounding portion 4352 also includes 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. Lower portion 4354 is configured to overlap proximal wall portion 4335 when suturing assembly 4300 is in a closed configuration (eg, FIG. 91 ). Upper portion 4353 is thicker or larger than lower portion 4354; however, upper portion 4353 and lower portion 4354 may have any suitable configuration. Generally, the thicker upper portion 4353 and lower portion 4354 are configured to increase the overall stiffness and moment of inertia of the anvil jaw 4340. The protrusions 4336 of the channel jaws 4330 face the corresponding protrusions 4356 of the proximal surrounding portion 4352 when the suturing assembly 4300 is in the closed configuration.

Referring primarily to FIG. 92, the proximal wall portion 4335 includes a cutout having a wall thickness that is less than the wall thickness of the distal wall portion 4337. Proximal wall portion 4335 also includes a smaller height than distal wall portion 4337 (FIG. 91). Providing thinner and smaller walls in the proximal portion of the cartridge channel jaw 4330 allows more space for the proximal peripheral portion 4352 of the anvil jaw 4340 to be thicker and generally larger, thereby increasing the size of the anvil The stiffness of the jaws 4340. In previous designs, the cartridge channel jaws of the stapling assembly had substantially greater stiffness than the anvil of the stapling assembly. This arrangement sacrifices some 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 each case, the desired instrument diameter may be, for example, 5mm, 8mm or 12mm. As a result of the above, the proximal surrounding portion 4352 includes a volume of material configured to occupy a void defined as a space beyond the proximal wall portion 4335 but within the diameter of the instrument.

In addition to the above, the anvil jaws 4340 have a first stiffness and the cartridge channel jaws 4330 have a second stiffness. The suture assembly 4300 includes structural means for reducing the second stiffness to increase the first stiffness. In each case, the ratio of the first stiffness to the second stiffness is between about 1:3 to 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 FIGS. 93-95 , the cartridge channel jaw 4400 includes a 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 . This arrangement may allow polishing of various inner surfaces of the channel jaw 4400 during manufacture to reduce the force used to advance or fire the firing member through the surgical instrument. Cartridge channel jaw 4400 includes a staple cartridge receiving cavity 4401 defined by channel walls 4411 of body portion 4410 (which is configured to receive a staple cartridge therein), a proximal portion 4405 configured to be coupled to an instrument shaft, and a distal Side section 4407. The replaceable staple cartridge is configured to be inserted or installed into the cartridge channel jaw 4400. Referring to Figure 95, the body portion 4410 also includes a longitudinal hole 4413 configured to receive a portion of the firing member of a 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) that is configured to hold the cap portion 4430 in place relative to the body portion 4410 for welding. Cap portion 4430 includes cap wall 4433 and is welded to body portion 4410 by weld 4409 . Welds 4409 may include, for example, laser welds. The cap portion 4430 and the protrusion 4413 of the body portion 4410 define a longitudinal slot 4403 configured to slidably receive a portion of the firing member. Before welding the cap portion 4430 to the body portion 4410, the longitudinal slot 4403 is polished. In each case, the entirety of longitudinal slot 4403 is polished. For example, the inner surface of the cap portion 4430 and the convex portion 4413 are polished. Polished projections 4413 may be advantageous such that as the firing member moves through its staple firing stroke, the polished projections 4413 may reduce friction between the cartridge channel jaw 4400 and the firing member and thus reduce surface wear, surface The wear will increase the force used to fire the surgical instrument. In other cases, only certain surfaces of the 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.

Figures 96-107 compare two different firing members 4500, 4600 for use with surgical stapling systems 4800, 4700, respectively. Firing member 4500 (FIG. 96) includes a body 4510 that includes a proximal connecting portion 4512, and a cutting member 4511 configured to cut tissue during a staple firing stroke. The firing member 4500 also includes a channel jaw coupling member 4520 and an anvil jaw coupling member 4530 that are configured to retain the anvil and channel jaws relative to each other during the staple firing stroke of the firing member 4500. Similarly, firing member 4600 ( FIG. 97 ) includes a body 4610 including a proximal connecting portion 4612 ; a cutting member 4611 configured to cut tissue during a staple firing stroke; and a locking feature 4615 . The firing member 4600 also includes a channel jaw coupling member 4620 and an anvil jaw coupling member 4630 that are configured to enable the anvil jaws to be activated during the staple firing stroke of the firing member 4600. The mouth and channel jaws are held relative to each other.

Referring now to FIGS. 98 and 99 , the anvil jaw coupling member 4530 of the firing member 4500 includes a lateral protrusion or anvil cam feature 4531 extending from the side of the body 4510 . With respect to the main body 4510, the projections are rounded with rounded corners 4532. The protrusions 4531 also include rounded corners 4533 . Anvil jaw coupling member 4530 defines an upper flat surface 4534. Each protrusion 4531 includes a lateral width or thickness 4545 and a vertical thickness 4541 . Lateral width 4545 is defined as the distance between body 4510 and outer edge 4536 of protrusion 4531 . The lateral protrusions 4531 define a protrusion axis 4543 that is at an angle of about one degree relative to the horizontal surface of the firing member 4500 (eg, the upper cam surface 4521 of the channel jaw coupling member 4520). Angled protrusions 4531 may reduce wear on the contact surfaces. The lateral protrusion 4531 also has a longitudinal length 4542 ( FIG. 102 ), which is defined as the distance between the front edge 4535 of the protrusion 4531 and the rear edge 4537 of the protrusion 4531 .

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

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

Turning now to FIG. 104 , a stapling system 4700 includes an end effector for use with a surgical instrument, the end effector including an anvil jaw 4750 , a cartridge channel jaw 4780 , and a cartridge channel jaw 4780 mounted within the end effector. Nail Cartridge 4710. Suture system 4700 also includes firing member 4600, as discussed above. The staple cartridge 4710 includes: a plurality of staples movably stored in the staple cavity 4712 of the staple cartridge 4710, configured to be fireable by the firing member 4600, the cartridge deck, or the tissue facing surface 4711; and a longitudinal slot 4713, The longitudinal slot is configured to receive a firing member 4600 therein. Anvil jaw 4750 includes a tissue-facing surface 4751 that includes a plurality of staple-forming pockets 4752 configured to deform staples, and anvil slot 4753 configured to receive the jaws of firing member 4600 therein mouth coupling member 4630; and cam boss 4755 configured to be engaged by protrusion 4631 of firing member 4600 as firing member 4600 moves through its staple firing stroke. Channel 4780 includes: channel wall 4781; longitudinal slot or cavity 4785 configured to receive jaw coupling member 4620 therein; and cam boss 4783 configured to move firing member 4600 through its staple firing stroke is engaged by the jaw coupling member 4620. In this case, the protrusions 4631 act as cantilever beams, resulting in much less force required to bend the protrusions 4631 than in the system described below.

Turning now to FIG. 105 , stapling system 4800 includes an end effector for use with a surgical instrument, the end effector including anvil jaw 3700 , cartridge channel jaw 4400 , and a cartridge channel jaw 4400 mounted within the end effector Nail Cartridge 4810. System 4800 also includes firing member 4500 . The staple cartridge 4810 includes: a plurality of staples movably stored in the staple cavity 4812 of the staple cartridge 4810, configured to be fireable by the firing member 4500, the cartridge deck, or the tissue-facing surface 4811; and a longitudinal direction Slot 4813, the longitudinal slot configured to receive firing member 4500 therein. Anvil slot 3713 is configured to receive jaw coupling member 4530 of firing member 4500 therein, and cam boss 3715 is configured to engage protrusion 4531 as firing member 4500 moves through its staple firing stroke. In such cases, the rounded edge 4533 of the protrusion 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 boss 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 protrusions 4531 is caused by shear stress that requires much greater force than is required to deform the protrusions 4631 of the system 4700 shown in FIG. 104 . The protrusion 4531 is deformed.

Turning now to Figures 106 and 107, a comparison of the deflection of the protrusions of each suture system 4700, 4800 is shown. The same firing loads are applied to the suture systems 4700, 4800 shown in FIGS. 106 and 107 . In Figure 106, a system 4800 with deflection 4801 is shown. In FIG. 107 , system 4700 is shown with deflection 4701 greater than deflection 4801 . This difference may be due in part to the lack of stiffness of the protrusion 4631, the geometry of the protrusion 4755 and its lack of resistance to bending, the increased stiffness of the protrusion 4531, and/or the geometry of the protrusion 3715 and its resistance to bending ability etc. For example, suture system 4800 places protrusions 4531 and protrusions 3715 primarily in shear to increase their resistance to deformation. Furthermore, rounding and shortening the width of the projection of the firing member increases the stiffness of the corresponding jaw coupling member as well as the anvil due to the fact that more material is allowed for the anvil.

In some cases, the stiffness of balancing boss 3715 and protrusion 4531 will balance the amount of deflection of boss 3715 and the amount of deflection of protrusion 4531 during the firing stroke of the firing member. Due to such balanced deflection, neither the lug nor the lug will dominate each other in deflection, and thus neither will cause plastic deformation of one to be significantly greater than the other during the firing stroke and may No plastic deformation at all. In each case, the stiffness of the protrusions is equal to, substantially equal to, or less than the stiffness of the protrusions. In some cases, the height or vertical thickness of the protrusion is substantially similar to the height or vertical thickness of the protrusion. In addition to or instead of providing a balanced geometry of the protrusions and protrusions, for example, the materials of the protrusions and protrusions may be selected based on yield strength and/or hardness values. Materials with similar material yield strength and/or hardness values may promote equal or balanced deflection of the protrusions and protrusions.

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 Figure 108, the combination of distributed load 4903 applied by firing member 4500 to protrusion 3715 and distributed load 4905 applied by tissue and cartridge 4810 to tissue-facing surface 3711 results in deflection 4901 and stress as shown distributed. The stress analysis shows a low stress region 4907, a medium stress region 4908, and a high stress region 4909. Notably, the stress at and near the weld 3701 is uniformly distributed and not localized or concentrated at or near the weld 3701 .

In various designs, a T-shaped bit 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 tip chatter, which can roughen the surface of the slot cut with the T-tip. In a two-piece anvil and channel design, a standard bit can 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 firing force 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 Medcoat 2000, for example.

During manufacture of the various welding anvil designs disclosed herein, X-ray techniques may be employed to verify weld depth and/or weld integrity to reduce defective resulting welds through quality control testing lacking an X-ray step. Another quality control step may include batch destructive testing, where 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 desired weld materials. For example, tungsten-alloys can be used for the anvil cap material. In various cases, W-3, W-5, W-25 or W-26 tungsten-alloys can be used for the anvil cap material. In some cases, for example, silver nickel cladding can be used for the anvil cap and 416 stainless steel or 17-4 stainless steel can be used for the anvil body.

As discussed above, the anvil body and the 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 especially 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 wear resistance of the anvil cam lobes may be lower than when both the anvil body and the anvil cap were made of softer materials.

In some cases, rows of shaped 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 room for material to move towards or into it during the stamping process. This may allow all forming dimple rows to include forming dimples with the same dimple depth, where punching the dimples without a pre-slit may make equal dimple depths between rows difficult.

Example

Embodiment 1 - A surgical stapling anvil for use with a surgical instrument, wherein the surgical stapling anvil includes an anvil body that includes a tissue-facing surface that includes a plurality of A staple forming pocket and a longitudinal cavity 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 at least a portion of a cutting edge of a firing member configured to receive a surgical instrument therein, wherein the second lumen portion is configured to receive an anvil engagement portion of the firing member therein, wherein the third lumen portion further includes a relative length relative to the second lumen The first slope is flared partially outwards. The anvil also includes an anvil cap including 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 includes a portion corresponding to the first cavity portion. A second bevel of a bevel, and wherein the mating portion of the first bevel and the second bevel define a mating depth. The anvil also includes a weld that welds the first bevel and the second bevel together, wherein the weld includes a weld depth substantially equal to the mating depth.

Embodiment 2—The surgical stapling anvil of Embodiment 1, wherein the anvil cap includes a Y-shaped cross-section.

Embodiment 3—The surgical stapling anvil of Embodiment 1 or 2, wherein the weld depth is between about 0.015 inches and about 0.040 inches.

Embodiment 4—The surgical stapling anvil of Embodiment 3, wherein the weld depth is 0.030 inches.

Embodiment 5—The surgical stapling anvil of Embodiment 1, 2, 3, or 4, wherein the third lumen portion includes a first convex surface, and wherein the second segment includes a first convex surface corresponding to the first convex surface. Two convex surfaces, and wherein the first convex surface and the second convex surface are at least substantially parallel to the tissue facing surface.

Embodiment 6—The surgical stapling anvil of Embodiment 5, wherein the weld extends into the convex surface.

Embodiment 7—The surgical stapling anvil of Embodiment 1, 2, 3, 4, 5, or 6, wherein the weld comprises a laser weld.

Embodiment 8—The surgical stapling anvil of Embodiment 1, 2, 3, 4, 5, 6, or 7, wherein the weld depth is less than the mating depth.

Embodiment 9—The surgical stapling anvil of Embodiment 1, 2, 3, 4, 5, 6, or 7, wherein the weld depth is greater than the mating depth.

Embodiment 10 - A surgical stapling anvil for use with a surgical instrument, wherein the surgical stapling anvil includes a first anvil member, the first anvil member including a tissue-facing surface, the tissue-facing surface including a defined A plurality of staples therein form pockets and longitudinal cavities. 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 At least a portion of a cutting edge of a firing member configured to receive a surgical instrument therein, wherein the second lumen portion is configured to receive an anvil engagement portion of the firing member therein. The anvil also 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 greater than A fourth width of the second width and a transition edge where the first segment and the second segment transition at the transition edge. The anvil also includes a weld connecting the second segment and the first anvil member together, wherein the weld extends at least to the transition edge.

Embodiment 11 - The surgical stapling anvil of Embodiment 10, wherein the second segment flares outwardly relative to the first segment.

Embodiment 12—The surgical stapling anvil of Embodiment 10 or 11, wherein the second anvil member includes a Y-shaped cross-section.

Embodiment 13—The surgical stapling anvil of Embodiment 10, 11, or 12, wherein the weld has a weld depth of between about 0.015 inches and about 0.040 inches.

Embodiment 14—The surgical stapling anvil of Embodiments 10, 11, 12, or 13, wherein the transition edge includes a convex surface that is at least substantially parallel to the tissue-facing surface.

Embodiment 15—The surgical stapling anvil of Embodiment 14, wherein the weld extends into the convex surface.

Embodiment 16—The surgical stapling anvil of Embodiments 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 be received therein A firing member of a surgical instrument, and the tissue-facing surface includes a plurality of staple-forming pockets defined therein. The anvil also includes a second anvil member and a weld that welds the first and second anvil members together, wherein the first and second anvil members include at least substantially perpendicular tissue-facing A first mating surface of the surfaces and a second mating surface angled relative to the tissue facing surface, wherein the weld connects at least the second mating surfaces together.

Embodiment 18—The surgical stapling anvil of Embodiment 17, wherein the weld also joins together at least a portion of the first mating surfaces.

Embodiment 19—The surgical stapling anvil of Embodiment 17 or 18, wherein the first and second anvil members further comprise a third mating surface at least substantially parallel to the tissue-facing surface.

Embodiment 20—The surgical stapling anvil of Embodiment 19, wherein the second and third mating surfaces are configured to help retain the second anvil member relative to the first anvil member for welding.

Embodiment 21 - The surgical stapling anvil of Embodiment 19 or 20, wherein the weld also welds together at least a portion of the third mating surface.

Embodiment 22—The surgical stapling anvil of Embodiment 17, 18, 19, or 20 or 21, wherein the second mating surface has a mating depth that at least substantially matches for welding the second mating surface Pre-determined welding depth of the welding machine together.

Embodiment 23—The surgical stapling anvil of Embodiments 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 including a tissue facing surface, a plurality of staple forming pockets and longitudinal slots defined in the tissue facing surface. 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 the cutting edge of the firing member therein The anvil cam portion receives the firing member therein. The anvil also includes an anvil cap welded to the anvil body, wherein the anvil cap includes a welded portion and a non-welded portion, wherein the non-welded portion includes 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 includes a first non-welding portion and a second non-welding portion, the first non-welding portion being configured to be received in the longitudinal slot Within the second portion, the second non-welding portion includes an alignment surface configured to align the anvil cap and the anvil body for welding.

Embodiment 26—The surgical stapling anvil of Embodiment 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.

Embodiment 27—The surgical stapling anvil of Embodiment 24, 25, or 26, wherein the welded portion is flared relative to the non-welded portion.

Embodiment 28—The surgical stapling anvil of Embodiment 24, 25, 26, or 27, wherein the welding portion includes a welding bevel corresponding to the bevel of the anvil body.

Embodiment 29—The surgical stapling anvil of Embodiment 24, 25, 26, 27, or 28, wherein the anvil cap includes a Y-shaped cross-section.

Embodiment 30 - A surgical stapling anvil comprising an anvil body including a longitudinal slot defining a slot axis and a tissue facing surface, wherein the longitudinal slot includes slot surfaces facing each other. The tissue-facing surface includes first and second sides defined by longitudinal slots, and a plurality of staple-forming pockets arranged in a plurality of longitudinal rows of staple-forming pockets, wherein the plurality of staple-forming pockets The longitudinal row includes an innermost row of staple forming pockets closest to the longitudinal slot, wherein the innermost row of staple forming pockets defines the row axis at a first distance from the slot axis and defines the first outer boundary axis at a second distance from the slot, the second distance being greater than the first distance. The anvil also 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, the 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.

Embodiment 31 - The surgical stapling anvil of Embodiment 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.

Embodiment 33—The surgical stapling anvil of Embodiment 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.

Embodiment 35—The surgical stapling anvil of Embodiment 30, 31, 32, 33, or 34, wherein the welded portion flares in a flare relative to the non-welded portion.

Embodiment 36—The surgical stapling anvil of Embodiments 30, 31, 32, 33, 34, or 35, wherein the welding portion includes a welding bevel corresponding to the bevel of the anvil body.

Embodiment 37—The surgical stapling anvil of Embodiments 30, 31, 32, 33, 34, 35, or 36, wherein the anvil cap includes a Y-shaped cross-section.

Embodiment 38 - An anvil for use with a surgical instrument, wherein the anvil includes a first anvil member including a tissue-facing surface defining a reference plane and defined in the tissue-facing surface of multiple nail forming pockets. The anvil also includes a second anvil member welded to the first anvil member by at least one weld. The first and second anvil members include a first mating region, a second mating region, and a third mating region, the first mating region defining a first plane at least substantially parallel to the reference plane, and the second mating region defining a substantially a second plane perpendicular to the reference plane, the third mating region defines a third plane angled relative to the reference plane, wherein the first and second anvil members are welded by the at least one at the third mating region Welding.

Embodiment 39—The anvil of Embodiment 38, wherein the third mating region has a length, and wherein the at least one weld includes a weld penetration at least approximately equal to the length.

Embodiment 40—The anvil of Embodiment 39, wherein the weld penetration is greater than the length.

Embodiment 41—The anvil of Embodiment 38, 39, or 40, wherein the first mating region includes an alignment configured to align the first and second anvil members for welding surface.

Embodiment 42—The anvil of Embodiments 38, 39, 40, or 41, wherein the second anvil member includes a Y-shaped cross-section.

Embodiment 43—The anvil of Embodiment 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 and a tissue-facing surface, the longitudinal slot being configured to receive a firing member therein, the The tissue-facing surface includes a plurality of staple-forming pockets defined therein. The anvil also includes an anvil cap and a plurality of welds that weld the anvil cap and the anvil body together, the welds including a shallow weld zone having a first weld depth and a second weld having a different depth than the first weld depth A deep weld zone, wherein the shallow weld zone and the deep weld zone are configured to increase the net weld depth of the plurality of welds.

Embodiment 45—The surgical stapling anvil of Embodiment 44, wherein the anvil cap and the anvil body include corresponding alignments configured to assist in aligning the anvil body and the anvil cap for welding feature structure.

Embodiment 46—The surgical stapling anvil of Embodiment 45, wherein the corresponding alignment features include a first alignment feature and a second alignment feature, the first alignment feature positioned at a distance from the surface on a first side of the longitudinal slot positioned at a first distance from the surface of the tissue, a second alignment feature is positioned on a second side of the longitudinal slot positioned at a second distance from the tissue facing surface, and wherein the first distance different from the second distance.

Embodiment 47—The surgical stapling anvil of Embodiment 44, 45, or 46, wherein the deep weld zone has a first longitudinal length, wherein the shallow weld zone has a second longitudinal length, and wherein the first longitudinal length and the second longitudinal length Vertical lengths vary.

Embodiment 48—The surgical stapling anvil of Embodiment 44, 45, 46, or 47, wherein the deep weld zone has a first longitudinal length, wherein the shallow weld zone has a second longitudinal length, and wherein the first longitudinal length and The second longitudinal lengths overlap each other along the length of the surgical stapling anvil.

Embodiment 49—The surgical stapling anvil of Embodiment 44, 45, 46, 47, or 48, wherein the deep weld zone includes a welder entry zone.

Embodiment 50—The surgical stapling anvil of Embodiment 49, wherein the welder access region includes a filler weld.

Embodiment 51 - The surgical stapling anvil of Embodiments 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 third The first stiffness and the second stiffness are different.

Embodiment 52—The surgical stapling anvil of Embodiments 44, 45, 46, 47, 48, 49, 50, or 51, wherein the anvil body and anvil cap are fabricated using a metal injection molding process.

Example 53 - A surgical stapling anvil comprising a first anvil member comprising a longitudinal slot, a tissue facing surface and an upper anvil surface, the longitudinal slot being configured to A firing member can be received therein, the tissue-facing surface includes a plurality of staple forming pockets defined therein, wherein the upper anvil surface includes apertures that define an edge of the first anvil member. The anvil also includes a second anvil member, and a welding configuration that welds the first and second anvil members together. The weld configuration includes a first weld and a second weld, the first weld having a first weld depth including a first weld root, wherein the first weld depth is defined as the distance between the edge and the first weld root, the first weld The second weld has a second weld depth including a second weld root, wherein the second weld depth is defined as the distance between the edge and the second weld root, wherein the second weld depth and the first weld depth are different, and wherein the first weld depth The weld and the second weld are configured to increase the 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 include components configured to assist in aligning the first and second anvil members to Corresponding alignment features for soldering.

Embodiment 55—The surgical stapling anvil of Embodiment 54, wherein the corresponding alignment features include a first alignment feature and a second alignment feature, the first alignment feature positioned at a distance from the surface on a first side of the longitudinal slot positioned at a first distance from the surface of the tissue, a second alignment feature is positioned on a second side of the longitudinal slot positioned at a second distance from the tissue facing surface, and wherein the first distance different from the second distance.

Embodiment 56—The surgical stapling anvil of Embodiment 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 is different.

Embodiment 57—The surgical stapling anvil of Embodiment 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 The length and the second longitudinal length overlap each other along the length of the surgical stapling anvil.

Embodiment 58—The surgical stapling anvil of Embodiment 53, 54, 55, 56, or 57, further comprising a filler weld positioned on the first weld.

Embodiment 59—The surgical stapling anvil of Embodiments 53, 54, 55, 56, 57, or 58, further having a first stiffness along the first weld and a second stiffness along the second weld, wherein the first The first stiffness and the second stiffness are different.

Embodiment 60—The surgical stapling anvil of Embodiments 53, 54, 55, 56, 57, 58, or 59, wherein the first and second anvil members are fabricated using a metal injection molding process.

Example 61 - A surgical stapling anvil comprising an anvil body including a tissue facing surface having a plurality of staple forming pockets and interlocking apertures. The anvil also includes an anvil cap, wherein the anvil body and the anvil cap are welded together, and wherein the anvil cap includes 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 a surgical instrument therein, wherein the longitudinal slot defines longitudinal axis, and wherein the anvil body and anvil cap can only be assembled along the longitudinal axis.

Embodiment 63—The surgical stapling anvil of Embodiment 61 or 62, wherein the anvil body and the anvil cap are fabricated using a metal injection molding process.

Example 64 - 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 configured into an anvil capable of deforming the nail. The anvil includes a tissue-facing surface, a plurality of staple-forming pockets and longitudinal slots defined in the tissue-facing surface. The anvil also includes a firing member including a body portion including first and second sides, a cutting member, and a cutting member configured to slidably engage the first jaw as the firing member moves through the staple firing stroke and an anvil engaging portion configured to slidably engage the anvil as the firing member moves through the staple firing stroke, wherein the anvil engaging portion includes a lateral portion extending from the body portion, wherein the lateral portion An anvil engagement portion axis is defined that is angled relative to the shaft axis, wherein the lateral portion has a longitudinal length and a vertical thickness, and wherein the ratio of the longitudinal length to the vertical thickness is between about 2.5:1 and about 20:1.

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

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

Embodiment 67—The surgical stapling assembly of Embodiments 64, 65, or 66, wherein each of the lateral portion and the body portion includes a fillet therebetween.

Embodiment 68—The surgical stapling assembly of Embodiments 64, 65, 66, or 67, wherein the lateral portion includes a rounded outer end.

Embodiment 69—The surgical stapling assembly of Embodiments 64, 65, 66, 67, or 68, wherein the anvil engagement portion includes a planar upper surface.

Embodiment 70—The surgical stapling assembly of Embodiments 64, 65, 66, 67, 68, or 69, wherein each lateral portion includes a rounded anterior edge.

Embodiment 71 - The surgical stapling assembly of Embodiments 64, 65, 66, 67, 68, 69 or 70, wherein the anvil engaging portion axis is at about a degree angle with respect to the shaft axis.

Example 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 comprising an anvil a second jaw of the seat, wherein the anvil is configured to deform the staples. The anvil includes a tissue-facing surface, a plurality of staple-forming pockets and longitudinal slots defined in the tissue-facing surface. The suturing assembly further includes a firing member including a vertically extending 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 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 be movable at the firing member The second jaw is slidably engaged upon firing stroke through the staple. The second jaw engaging member includes a vertical thickness and a lateral width, the lateral width being defined as the distance between the body portion and the outer edge of the second jaw engaging member, and wherein the ratio of the vertical thickness and the lateral width is Between about 1:2 and about 1:1.

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

Embodiment 74—The surgical stapling assembly of Embodiment 72 or 73, wherein the second jaw engaging member and the body portion include fillets therebetween.

Embodiment 75—The surgical stapling assembly of Embodiments 72, 73, or 74, wherein the second jaw engagement member includes a rounded outer end.

Embodiment 76—The surgical stapling assembly of Embodiments 72, 73, 74, or 75, wherein the second jaw engagement member includes a planar upper surface.

Embodiment 77—The surgical stapling assembly of Embodiments 72, 73, 74, 75, or 76, wherein the second jaw engaging member includes a rounded leading edge.

Embodiment 78—The surgical stapling assembly of Embodiments 72, 73, 74, 75, 76, or 77, wherein the second jaw engaging member is oriented at about a 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 comprising an anvil a second jaw of the seat, wherein the anvil is configured to deform the staples. The anvil includes a tissue-facing surface, a plurality of staple-forming pockets and longitudinal slots defined in the tissue-facing surface. The suturing assembly also includes a firing member including a body portion including first and second sides, a cutting member, and a cutting member configured to slidably engage the first jaw as the firing member moves through the staple firing stroke a first jaw coupling member, 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 includes a Two sides extend and define a lateral portion of the planar upper surface, wherein the second jaw coupling member is angled relative to the shaft axis, wherein the lateral portion and the side include a rounded corner therebetween, and wherein the lateral portion includes a rounded outer end.

Embodiment 80 - The surgical stapling assembly of Embodiment 79, wherein each lateral portion includes a rounded leading edge.

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

Embodiment 83—The surgical stapling assembly of Embodiments 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 including a plurality of staple-forming pockets configured to deform the staples and an anvil projection configured to be engaged by the anvil cam portion of the firing member during the firing stroke portion, wherein the anvil lobe has a second stiffness, and wherein the second stiffness is substantially equal to the first stiffness, such that the deflection of the anvil lobe will be substantially equal to the 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 includes adjusting at least one of the first geometry of the cam portion of the anvil and the second geometry of the cam portion of the anvil to provide a basic similar stiffness.

Embodiment 87—The surgical instrument assembly of Embodiment 85 or 86, wherein the apparatus 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 Basically similar stiffness.

Embodiment 88—The surgical instrument assembly of Embodiments 85, 86, or 87, wherein the means comprises substantially equalizing the yield strengths of the anvil cam portion and the anvil lug.

Embodiment 89—The surgical instrument assembly of Embodiments 85, 86, 87, or 88, wherein the means comprises substantially equalizing the durometers of the anvil cam portion and the anvil lug.

Many of the surgical instrument systems described herein are actuated by electric motors; however, the surgical instrument systems described herein may be actuated in any suitable manner. In various instances, for example, the surgical instrument systems described herein may be actuated by manually operated triggers. In some instances, the motors disclosed herein may include part or parts of a robotic control system. Furthermore, any end effector and/or tool assembly disclosed herein may be used with a robotic surgical instrument system. For example, US Patent Application Serial No. 13/118,241 (now US Patent 9,072,535) entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS" discloses several examples of robotic surgical instrument systems in greater detail.

The surgical instrument systems described herein have been described in conjunction with deployment and deformation of the staples; however, the embodiments described herein are not so limited. For example, various embodiments are contemplated that deploy fasteners other than nails, such as clips or tacks. In addition, various embodiments are contemplated that utilize any suitable device for sealing tissue. For example, end effectors according to various embodiments may include electrodes configured to heat and seal tissue. Additionally, for example, end effectors according to certain embodiments may apply vibrational energy to seal tissue.

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

- US Patent 5,403,312 entitled "ELECTROSURGICAL HEMOSTATIC DEVICE", issued April 4, 1995;

- US Patent 7,000,818 entitled "SURGICAL STAPLING INSTRUMENT HAVINGSEPARATE DISTINCT CLOSING AND FIRING SYSTEMS" issued on February 21, 2006;

- US Patent 7,422,139 entitled "MOTOR-DRIVEN SURGICAL CUTTING ANDFASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK" issued on September 9, 2008;

- US Patent 7,464,849 entitled "ELECTRO-MECHANICAL SURGICAL INSTRUMENTWITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS" issued on December 16, 2008;

- US Patent 7,670,334 entitled "SURGICAL INSTRUMENT HAVING ANARTICULATING END EFFECTOR" issued on March 2, 2010;

- US Patent 7,753,245 entitled "SURGICAL STAPLING INSTRUMENTS" issued on July 13, 2010;

- US Patent 8,393,514 entitled "SELECTIVELY ORIENTABLE IMPLANTABLEFASTENER CARTRIDGE" issued March 12, 2013;

- US Patent Application Serial No. 11/343,803 entitled "SURGICAL INSTRUMENT HAVING RECORDING CAPABILITIES"; now US Patent 7,845,537;

- US Patent Application Serial No. 12/031,573, filed February 14, 2008, entitled "SURGICAL CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES";

- US Patent Application Serial No. 12/031,873 (now US Patent 7,980,443), filed February 15, 2008, entitled "END EFFECTORS FOR A SURGICAL CUTTING ANDSTAPLING INSTRUMENT";

- US Patent Application Serial No. 12/235,782 entitled "MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT", now US Patent 8,210,411;

- US Patent Application Serial No. 12/249,117 entitled "POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM", now US Patent 8,608,045;

- US Patent Application Serial No. 12/647,100, entitled "MOTOR-DRIVEN SURGICAL CUTTINGINSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROL ASSEMBLY," filed December 24, 2009; now US Patent 8,220,688;

- US Patent Application Serial No. 12/893,461, entitled "STAPLE CARTRIDGE", filed September 29, 2012, now US Patent 8,733,613;

- US Patent Application Serial No. 13/036,647, entitled "SURGICAL STAPLING INSTRUMENT", filed February 28, 2011, now US Patent 8,561,870;

- US Patent Application Serial No. 13/118,241 entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS", now US Patent 9,072,535;

- US Patent Application Serial No. 13/524,049, entitled "ARTICULATABLE SURGICAL INSTRUMENTCOMPRISING A FIRING DRIVE," filed June 15, 2012; now US Patent 9,101,358;

- US Patent Application Serial No. 13/800,025, entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSORSYSTEM", filed March 13, 2013, now US Patent 9,345,481;

- US Patent Application Serial No. 13/800,067, entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSORSYSTEM", filed March 13, 2013, now US Patent Application Publication 2014/0263552;

- US Patent Application Publication 2007/0175955, filed January 31, 2006, entitled "SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM"; and

- US Patent Application Publication 2010/0264194, entitled "SURGICAL STAPLING INSTRUMENT WITH ANARTICULATABLE END EFFECTOR", filed April 22, 2010, now US Patent 8,308,040.

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

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, the device can be reconditioned after at least one use. Repair may include any combination of steps including, but not limited to, disassembly of the device, followed by cleaning or replacement of specific components of the device, and subsequent reassembly of the device. Specifically, the repair facility and/or surgical team may disassemble the device, and after cleaning and/or replacing certain components of the device, the device may be reassembled for subsequent use. Those skilled in the art will appreciate that the trimming device can 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 this application.

The devices disclosed herein can be processed prior to surgery. First, new or used instruments are available and cleaned as needed. The instruments can 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 device can then be exposed to a radiation field that penetrates the container, such as gamma radiation, X-rays, and/or high-energy electrons. Radiation kills bacteria on instruments and in containers. The sterilized instruments can then be stored in sterile containers. The sealed container keeps 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, this invention can be further modified within the spirit and scope of this disclosure. Accordingly, this application is intended to cover any adaptations, uses, or adaptations of the invention using the general principles of the invention.

Any patent, publication or other disclosure material incorporated herein by reference, in whole or in part, is incorporated only to the extent that the incorporated material does not conflict with existing definitions, statements or other disclosure material described herein This article. Accordingly, and to the extent necessary, the disclosure expressly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated herein by reference but which conflicts with existing definitions, statements, or other disclosed material set forth herein will only not arise between the incorporated material and the existing disclosed material merged to the extent of conflict.

Claims (20)

1. A surgical suture anvil, comprising: an anvil body comprising: a longitudinal slot configured to receive a firing member therein; and a tissue-facing surface, the tissue-facing surface including a plurality of staple-forming pockets defined therein; anvil cap; and a plurality of welds that weld the anvil cap and the anvil body together, wherein the welds include: a shallow weld zone having a first weld depth; and a deep weld zone having a second weld depth different from the first weld depth, wherein the shallow weld zone and the deep weld zone are configured to increase the net weld of the plurality of welds depth. 2. The surgical stapling anvil of claim 1 , wherein the anvil cap and the anvil body include components configured to assist in aligning the anvil body and the anvil cap for use in Soldered corresponding alignment features. 3. The surgical stapling anvil of claim 2, wherein the corresponding alignment features include a first alignment feature and a second alignment feature, the first alignment feature positioned at the On a first side of the longitudinal slot at a first distance from the tissue-facing surface, the second alignment feature is located on the longitudinal slot positioned at a second distance from the tissue-facing surface on the second side of the slot, and wherein the first distance and the second distance are different. 4. The surgical stapling anvil of claim 1, wherein the deep weld zone has a first longitudinal length, wherein the shallow weld zone has a second longitudinal length, and wherein the first longitudinal length and the The second longitudinal length is different. 5. The surgical stapling anvil of claim 1, wherein the deep weld zone has a first longitudinal length, wherein the shallow weld zone has a second longitudinal length, and wherein the first longitudinal length and the The second longitudinal lengths overlap each other along the length of the surgical stapling anvil. 6. The surgical stapling anvil of claim 1, wherein the deep weld zone comprises a welder entry zone. 7. The surgical stapling anvil of claim 6, wherein the welder access region includes a filler weld. 8. The surgical stapling anvil of claim 1, 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 different. 9. The surgical stapling anvil of claim 1, wherein the anvil body and the anvil cap are fabricated using a metal injection molding process. 10. A surgical suture anvil, comprising: a first anvil member comprising: 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; and an upper anvil surface, wherein the upper anvil surface includes a hole defining an edge of the first anvil member; a second anvil member; and a welding configuration that welds the first anvil member and the second anvil member together, wherein the welding configuration includes: a first weld having a first weld depth including a first weld root, wherein the first weld depth is defined as a distance between the edge and the first weld root; and A second weld having a second weld depth including a second weld root, wherein the second weld depth is defined as the distance between the edge and the second weld root, wherein the The second weld depth and the first weld depth are different, and wherein the first weld and the second weld are configured to increase the net weld depth of the weld configuration. 11. The surgical stapling anvil of claim 10, wherein the first anvil member and the second anvil member comprise components configured to assist in aligning the first anvil member and the second anvil member The anvil members are aligned for welding with corresponding alignment features. 12. The surgical stapling anvil of claim 11, wherein the corresponding alignment features include a first alignment feature and a second alignment feature, the first alignment feature positioned at the On a first side of the longitudinal slot at a first distance from the tissue-facing surface, the second alignment feature is located on the longitudinal slot positioned at a second distance from the tissue-facing surface on the second side of the slot, and wherein the first distance and the second distance are different. 13. The surgical stapling anvil of claim 10, 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 lengths are different. 14. The surgical stapling anvil of claim 10, 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 lengths overlap each other along the length of the surgical stapling anvil. 15. The surgical stapling anvil of claim 10, further comprising a filler weld positioned on the first weld. 16. The surgical stapling anvil of claim 10, further having a first stiffness along the first weld and a second stiffness along the second weld, wherein the first stiffness and the first stiffness The two stiffnesses are different. 17. The surgical stapling anvil of claim 10, wherein the first and second anvil members are fabricated using a metal injection molding process. 18. A surgical stapling anvil, comprising: an anvil body comprising: a tissue-facing surface that includes a plurality of staple-forming pockets; and interlocking holes; and an anvil cap, wherein the anvil body and the anvil cap are welded together, and wherein the anvil cap includes an interlocking feature configured to be received within the interlocking hole. 19. The surgical stapling anvil of claim 18, wherein the anvil body further comprises a longitudinal slot configured to receive a firing member of a surgical instrument therein, wherein the longitudinal slot The slot defines a longitudinal axis, and wherein the anvil body and the anvil cap can only be assembled along the longitudinal axis. 20. The surgical stapling anvil of claim 18, wherein the anvil body and the anvil cap are fabricated using a metal injection molding process.

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