CN109310419B - Rotary powered surgical instrument with manually actuatable emergency system - Google Patents

Abstract

A motor driven surgical instrument is disclosed. The surgical instrument includes a motor supported in a housing and includes at least one rotary drive system configured to be selectively, operably engaged and disengaged with the motor assembly. An emergency drive mechanism is supported by the housing assembly and is configured to be selectively, operably engaged and disengaged with the at least one rotary drive system. The emergency handle assembly is selectively movable between a storage position and an actuated position within the housing assembly such that when the emergency handle assembly is in the storage position, the at least one rotary drive system remains operably engaged with the motor assembly, and when the emergency handle assembly is in the actuated position, the emergency drive mechanism is operably engaged with the at least one rotary drive system.

Description

Rotary powered surgical instrument with manually actuatable emergency system

Background

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

Drawings

Various features of the embodiments described herein, along with their advantages, may be understood from the following description in conjunction with the following drawings:

FIG. 1 is a perspective view of a surgical instrument including an interchangeable surgical tool assembly according to at least one embodiment;

FIG. 2 is another perspective view of the handle assembly of the surgical instrument of FIG. 1 with a portion of the handle housing omitted to expose components housed therein;

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

FIG. 4 is a cut-away perspective view of the handle assembly of FIGS. 2 and 3;

fig. 5 is a partial cross-sectional side view of the handle assembly of fig. 2-4, with the clamping portion of the handle assembly shown in solid lines in one position relative to the main housing portion and shown in phantom lines in another position relative to the main housing portion of the handle assembly;

FIG. 6 is an end cross-sectional view of the handle assembly of FIGS. 2-5 taken along line 6-6 of FIG. 5;

FIG. 7 is another end sectional view of the handle assembly of FIGS. 2-6 taken along line 7-7 in FIG. 5;

FIG. 8 is another end cross-sectional view of the handle assembly of FIGS. 2-7, showing the shifter gear engaged with the drive gear on the rotary drive socket;

FIG. 9 is another end cross-sectional view of the handle assembly of FIGS. 2-8, showing the position of the shifter solenoid when the shifter gear is engaged with the drive gear on the rotary drive socket;

fig. 10 is another perspective view of the handle assembly of fig. 2-9, with portions of the handle assembly shown in cross-section and the access panel portion of the handle assembly shown in phantom;

fig. 11 is a top view of the handle assembly of fig. 2-11 with the bailout system shown in an actuatable position;

fig. 12 is a perspective view of the bailout handle of the bailout system shown in fig. 2-11;

fig. 13 is an exploded assembly view of portions of the bailout handle of fig. 12, with portions of the bailout handle shown in cross-section;

FIG. 14 is a cross-sectional elevation view of the handle assembly of FIG. 11;

fig. 15 is a perspective view of the tool attachment module portion of the handle assembly of fig. 2-11 and the interchangeable surgical tool assembly of fig. 1;

FIG. 16 is a perspective view, partially in section, of the tool attachment module portion of FIG. 15;

FIG. 17 is an exploded assembly view of portions of the interchangeable surgical tool assembly of FIG. 16;

FIG. 18 is an exploded assembly view of the tool attachment module of FIG. 16;

FIG. 19 is a perspective view of one form of a shaft coupler release assembly;

FIG. 20 is a side cross-sectional view of the tool attachment module of FIGS. 16 and 18 aligned for mounting on the tool mounting portion of the handle assembly of FIG. 1;

FIG. 21 is another side cross-sectional view of the tool attachment module of FIG. 20 first inserted into the tool mounting portion of the handle assembly of FIG. 1;

FIG. 22 is another side cross-sectional view of the tool connection module of FIGS. 20 and 21 attached to the tool mounting portion of the handle assembly of FIG. 1;

FIG. 23 is a perspective view of the interchangeable surgical tool assembly of FIG. 1;

FIG. 24 is a cutaway perspective view of the interchangeable surgical tool assembly of FIG. 23;

FIG. 25 is a perspective view of a surgical end effector portion of the interchangeable surgical tool assembly of FIG. 23;

FIG. 26 is a cut-away perspective view of the surgical end effector of FIG. 25;

FIG. 27 is an exploded assembly view of the surgical end effector of FIG. 25;

FIG. 28 is a partial rear cross-sectional view of the surgical end effector of FIG. 25;

FIG. 29 is a cut-away perspective view of a firing member or cutting member in accordance with at least one embodiment;

FIG. 30 is a cross-sectional elevation view of an articulation joint in accordance with at least one embodiment;

FIG. 31 is a cross-sectional view of the surgical end effector of FIG. 25 with the firing member of FIG. 29 in a fired position;

FIG. 32 is another cross-sectional view of the surgical end effector of FIG. 25 with the firing member of FIG. 29 in an end position;

FIG. 33 is another cross-sectional view of a portion of the surgical end effector of FIG. 25 with the anvil assembly in an open position;

FIG. 34 is another cross-sectional view of a portion of the surgical end effector of FIG. 25 with the firing member of FIG. 29 in a pre-firing position;

FIG. 35 is another cross-sectional view of a portion of the surgical end effector of FIG. 34 with the firing member having been returned to a starting position to thereby cause the internally threaded closure nut to threadedly engage the closure threaded segment on the distal power shaft;

FIG. 36 is a perspective view of a bearing spring according to at least one embodiment;

FIG. 37 is an exploded assembly view of the articulation joint of FIG. 30;

FIG. 38 is a top view of the articulation joint of FIG. 30 with the surgical end effector of FIG. 25 in a non-articulated orientation;

FIG. 39 is another top view of the articulation joint of FIG. 30 with the surgical end effector in a maximum articulation orientation;

FIG. 40 is a perspective view of a portion of the elongate shaft assembly of FIG. 23 showing a portion of the articulation joint and surgical end effector rotation locking system embodiment of FIG. 30;

FIG. 40A is a partially exploded perspective view of an articulation joint and an end effector showing an arrangement for facilitating the supply of electrical signals to the end effector about the articulation joint in accordance with at least one embodiment.

FIG. 40B is a side elevational view of the articulation joint and end effector of FIG. 40A, with some components of the articulation joint and end effector shown in cross-section;

FIG. 41 is a perspective view, partially in section, of the surgical end effector rotation locking system of FIG. 40 in an unlocked orientation;

FIG. 42 is another perspective view, partially in section, of the surgical end effector rotation locking system of FIGS. 40 and 41 in an unlocked orientation;

FIG. 43 is a top view of the surgical end effector rotation locking system of FIGS. 40-42 in a locked orientation; and is

Fig. 44 is a top view of the surgical end effector rotation locking system of fig. 40-43 in an unlocked orientation.

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

Detailed Description

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

-U.S. patent application serial No. 15/089,325 entitled "METHOD FOR CREATING A flexibale STAPLE LINE";

-U.S. patent application serial No. 15/089,321 entitled "MODULAR minor injection SYSTEM";

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

-U.S. patent application serial No. 15/089,263 entitled "minor entering HANDLE association WITH robust GRIP support";

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

-U.S. patent application serial No. 15/089,283 entitled "close SYSTEM ARRANGEMENTS FOR SURGICAL curing AND STAPLING DEVICES WITH SEPARATE AND DISTINCT FIRING SHAFTS";

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

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

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

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

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

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

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

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

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

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

-U.S. patent application Ser. No. 15/089,335 entitled "SURGICAL STAPLING INSTRUMENTS COMPLEMENTING MULTIPLE LOCKOUTS";

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

-U.S. patent application serial No. 15/089,253 entitled "SURGICAL STAPLING SYSTEM CONFIGURED TO applied annual ROWS OF STAPLES HAVING DIFFERENT HEIGHTS";

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

-U.S. patent application serial No. 15/089,331 entitled "artificial MODIFICATION machinery FOR minor platform";

-U.S. patent application serial No. 15/089,336 entitled "STAPLE CARTRIDGES WITH atraumatc featurs";

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

-U.S. patent application serial No. 15/089,309 entitled "CIRCULAR STAPLING SYSTEM comprisingrotary FIRING SYSTEM"; and

-U.S. patent application serial No. 15/089,349 entitled "CIRCULAR STAPLING SYSTEM comprisingload CONTROL";

the applicant of the present application also has the following U.S. patent applications filed on 31/12/2015, each of which is hereby incorporated by reference in its entirety:

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

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

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

The applicant of the present application also has the following U.S. patent applications filed on 9/2/2016, each of which is hereby incorporated by reference in its entirety:

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

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

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

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

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

-U.S. patent application serial No. 15/019,227 entitled "article minor filing WITH SINGLE article LINK ARRANGEMENTS";

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

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

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

The applicant of the present application also has the following U.S. patent applications filed on 12.2.2016, each of which is hereby incorporated by reference in its entirety:

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

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

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

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

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

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

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

-U.S. patent application serial No. 14/742,914 entitled "MOVABLE filing bed SUPPORT FOR easy maintenance letters";

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

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

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

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

-U.S. patent application serial No. 14/640,746 entitled "POWERED minor instroment";

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

-U.S. patent application Ser. No. 14/640,832 entitled "ADAPTIVE TISSUE COMPRESSION TECHNIQUES TO ADAJUST CLOSURE RATES FOR MULTIPLE TISSUE TYPE"; attorney docket number END7557 USNP/140482;

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

U.S. patent application Ser. No. 14/640,831 entitled "MONITORING SPEED CONTROL AND PRECISION INCREASING OF MOTOR FOR POWER SURGICAL INSTRUMENTS";

-U.S. patent application Ser. No. 14/640,859 entitled "TIME DEPENDENT EVALTION OF SENSOR DATA TO DETERMINE STATIONITY, CREPE, AND VISCELATIC ELEMENTS OF MEASURES";

-U.S. patent application serial No. 14/640,817 entitled "INTERACTIVE FEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS";

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

-U.S. patent application serial No. 14/640,837 entitled "SMART SENSORS WITH LOCAL SIGNAL PROCESSING";

-U.S. patent application Ser. No. 14/640,765 entitled "SYSTEM FOR DETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A SURGICAL STAPLER";

-U.S. patent application Ser. No. 14/640,799 entitled "SIGNAL AND Power COMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT"; and

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

The applicant of the present application owns the following patent applications filed 2015 on day 2, 27 and each of which is incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/633,576 entitled "SURGICAL INSTRUMENT SYSTEM COMPLISING AN INSPECTION STATION";

-U.S. patent application serial No. 14/633,546 entitled "minor applied configuration TO ASSESS WHETHER A minor PARAMETER OF THE minor applied PARAMETER IS WITHIN AN ACCEPTABLE minor PARAMETER BAND";

U.S. patent application Ser. No. 14/633,576 entitled "SURGICAL CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE BATTERIES";

-U.S. patent application serial No. 14/633,566 entitled "CHARGING SYSTEM THAT energy EMERGENCY resolution FOR CHARGING A BATTERY";

-U.S. patent application Ser. No. 14/633,555 entitled "SYSTEM FOR MONITORING WHETHER A SURGICAL INSTRUMENTS NEEDS TO BE SERVICED";

-U.S. patent application serial No. 14/633,542 entitled "related BATTERY FOR a SURGICAL INSTRUMENT";

-U.S. patent application serial No. 14/633,548 entitled "POWER ADAPTER FOR a SURGICAL insert";

-U.S. patent application serial No. 14/633,526 entitled "adaptive minor insert HANDLE";

-U.S. patent application serial No. 14/633,541 entitled "MODULAR station association"; and

-U.S. patent application serial No. 14/633,562 entitled "SURGICAL APPATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER";

the applicant of the present application owns the following patent applications filed 2014, 12, 18 and each incorporated herein by reference in its entirety:

U.S. patent application Ser. No. 14/574,478 entitled "SURGICAL INSTRUMENT SYSTEM COMPLEMENTS A ARTICULATED END EFFECTOR AND MEANS FOR ADJUSE THE FIRING STROKE OF A FIRING";

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

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

-U.S. patent application serial No. 14/575,148 entitled "LOCKING argemenets FOR DETACHABLE SHAFT association WITH article END effects";

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

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

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

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

-U.S. patent application Ser. No. 14/574,493 entitled "SURGICAL INSTRUMENT ASSEMBLY COMPLEMENTING A FLEXIBLE ARTICULATION SYSTEM"; and

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

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

U.S. patent application Ser. No. 13/782,295 entitled "ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL COMMUNICATION", now U.S. patent application publication 2014/0246471;

U.S. patent application Ser. No. 13/782,323 entitled "Rolling Power operated vibration FOR minor Instrument," now U.S. patent application publication 2014/0246472;

-U.S. patent application serial No. 13/782,338 entitled "thumb wheel SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS," now U.S. patent application publication 2014/0249557;

-U.S. patent application serial No. 13/782,499 entitled "ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT," now U.S. patent application publication 2014/0246474;

U.S. patent application Ser. No. 13/782,460 entitled "MULTIPLE PROCESSOR MOTORS CONTROL FOR MODULAR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0246478;

U.S. patent application Ser. No. 13/782,358 entitled "JOYSTICK SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0246477;

U.S. patent application Ser. No. 13/782,481 entitled "SENSOR STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR," now U.S. patent application publication 2014/0246479;

U.S. patent application Ser. No. 13/782,518 entitled "CONTROL METHOD FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS", now U.S. patent application publication 2014/0246475;

U.S. patent application Ser. No. 13/782,375 entitled "Rolling Power weighted accumulation INSTRUMENTS WITH MULTIPLE layers OF FREEDOM", now U.S. patent application publication 2014/0246473; and

U.S. patent application Ser. No. 13/782,536 entitled "SURGICAL INSTRUMENT SOFT STOP", now U.S. patent application publication 2014/0246476.

The applicant of the present application also owns the following patent applications filed 2013, month 3, day 14 and each of which is incorporated herein by reference in its entirety:

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

U.S. patent application Ser. No. 13/803,193 entitled "CONTROL ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT", now U.S. patent application publication 2014/0263537;

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

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

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

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

U.S. patent application Ser. No. 13/803,066 entitled "DRIVE SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0263565;

U.S. patent application Ser. No. 13/803,117 entitled "ARTICULATION CONTROL FOR ARTICULATE SURGICAL INSTRUMENTS," now U.S. patent application publication 2014/0263553;

U.S. patent application Ser. No. 13/803,130 entitled "DRIVE TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0263543; and

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

The applicant of the present application also owns the following patent applications filed 3/7 2014 and incorporated herein by reference in their entirety:

U.S. patent application Ser. No. 14/200,111 entitled "CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS", now U.S. patent application publication 2014/0263539.

The applicant of the present application also owns the following patent applications filed 3/26 2014 and each incorporated herein by reference in its entirety:

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

-U.S. patent application serial No. 14/226,099 entitled "serilization version CIRCUIT", now U.S. patent application publication 2015/0272581;

-U.S. patent application Ser. No. 14/226,094 entitled "VERIFICATION OF NUMBER OF Battery improvements/Process COUNT", now U.S. patent application publication 2015/0272580;

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

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

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

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

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

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

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

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

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

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

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

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

The applicant of the present application also owns the following patent applications filed 2014, 9, 5 and each of which is incorporated herein by reference in its entirety:

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

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

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

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

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

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

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

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

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

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

U.S. patent application Ser. No. 14/248,581 entitled "SURGICAL INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE OPERATED FROM THE SAME ROTATABLE OUTPUT", now U.S. patent application publication 2014/0305989;

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

U.S. patent application serial No. 14/248,588 entitled "POWERED LINEAR minor stable", now U.S. patent application publication 2014/0309666;

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

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

U.S. patent application serial No. 14/248,587 entitled "POWERED minor platform," now U.S. patent application publication 2014/0309665;

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

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

The applicant of the present application also owns the following patent applications filed 2013 on 16.4.2013 and each of which is incorporated herein by reference in its entirety:

U.S. provisional patent application serial No. 61/812,365 entitled "minor entering WITH MULTIPLE functional electronic BY a SINGLE MOTOR";

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

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

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

U.S. provisional patent application serial No. 61/812,372 entitled "minor entering WITH MULTIPLE functional PERFORMED BY A SINGLE MOTOR".

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

The terms "comprising" (and any form of "including", such as "comprising"), "having" (and any form of "having", such as "with"), "including" (and any form of "including", such as "including"), and "containing" (and any form of "containing", such as "containing") are open-ended linking verbs. Thus, a surgical system, device, or apparatus that "comprises," "has," "contains," or "contains" one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, a system, apparatus, or device that "comprises," "has," "includes," or "contains" one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

The terms "proximal" and "distal" are used herein with respect to a clinician manipulating a handle portion of a surgical instrument. The term "proximal" refers to the portion closest to the clinician and the term "distal" refers to the portion located away from the clinician. It will be further appreciated that for simplicity and clarity, spatial terms such as "vertical," "horizontal," "up," and "down" may be used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily appreciate that the various methods and devices disclosed herein may 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 portion or end effector portion of the instrument may be inserted directly into a patient or may be inserted through an access device having a working channel through which the end effector and elongate shaft of the surgical instrument may be advanced.

A surgical stapling system may 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. A staple cartridge is insertable into and removable from the first jaw; however, other embodiments are contemplated in which the staple cartridge is not removable 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 a closure axis; however, other embodiments are envisioned in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises 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 an articulation joint.

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

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

In addition to the above, the sled can be moved distally by the firing member. The firing member is configured to contact the sled and urge the sled 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 that engages the first jaw and a second cam that engages the second jaw. The first and second cams can control a distance or tissue gap between a deck of the staple cartridge and the anvil as the firing member is advanced distally. The firing member also includes a knife configured to incise tissue captured intermediate the staple cartridge and the anvil. It is desirable that the knife be positioned at least partially adjacent to the ramp surface so that the staples are ejected prior to the knife.

Handle assembly

Fig. 1 illustrates a motor driven surgical system 10 that may be used to perform a variety of different surgical procedures. In the illustrated embodiment, the motor driven surgical system 10 includes a selectively reconfigurable housing or handle assembly 20 that is attached to one form of interchangeable surgical tool assembly 1000. For example, the system 10 depicted in fig. 1 includes an interchangeable surgical tool assembly 1000 that includes a surgical cutting and fastening instrument, which may be referred to as an endocutter. As will be discussed in further detail below, the interchangeable surgical tool assemblies may include end effectors adapted to support different sizes and types of staple cartridges, and have different shaft lengths, sizes, types, and the like. Such an arrangement may, for example, utilize any suitable fastener or fasteners to fasten tissue. For example, a fastener cartridge including a plurality of fasteners removably stored therein can be removably inserted into and/or attached to an end effector of a surgical tool assembly. Other surgical tool assemblies may be used interchangeably with the handle assembly 20. For example, the interchangeable surgical tool assembly 1000 may be detached from the handle assembly 20 and replaced with a different surgical tool assembly configured to perform other surgical procedures. In other arrangements, the surgical tool assembly may not be interchangeable with other surgical tool assemblies and basically includes a dedicated shaft that is, for example, non-removably attached or coupled to the handle assembly 20. The surgical tool assembly may also be referred to as an elongate shaft assembly. The surgical tool assembly may be reusable, or in other configurations, the surgical tool assembly may be designed to be disposed after a single use.

With continued reference to the present detailed description, it should be understood that the various forms of interchangeable surgical tool assemblies disclosed herein may also be effectively used in conjunction with robotically controlled surgical systems. Thus, the terms "housing" and "housing assembly" may also encompass a housing or similar portion of a robotic system that houses or otherwise operatively supports at least one drive system configured to generate and apply at least one control motion that may be used to actuate the elongate shaft assemblies disclosed herein and their respective equivalents. The term "frame" may refer to a portion of a hand-held surgical instrument. The term "frame" may also refer to a portion of a robotically-controlled surgical instrument and/or a portion of a robotic system that may be used to operably control a surgical instrument. 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 U.S. patent application serial No. 13/118,241, now U.S. patent application publication 2012/0298719, entitled "SURGICAL station inserting INSTRUMENTS WITH robotic tool assemblies," which is hereby incorporated by reference in its entirety.

Referring now to fig. 1 and 2, the housing assembly or handle assembly 20 includes a main housing portion 30, the main housing portion 30 may be formed from a pair of housing segments 40,70, the housing segments 40,70 may be made of plastic, polymeric material, metal, or the like, and joined together by a suitable fastener arrangement such as, for example, adhesive, screws, press-fit features, snap-fit features, latches, or the like. As will be discussed in further detail below, the main housing portion 30 operably supports a plurality of drive systems therein that are configured to generate and apply various control motions to corresponding portions of an interchangeable surgical tool assembly operably attached to the drive systems. The handle assembly 20 further includes a clamping portion 100, the clamping portion 100 being movably coupled to the main housing portion 30 and configured to be clamped and manipulated by a clinician in various positions relative to the main housing portion 30. The clamp portion 100 may be made of a pair of clamp segments 110,120, and the clamp portions 110,120 may be made of plastic, polymeric material, metal, etc., and joined together by a suitable fastener arrangement such as, for example, adhesive, screws, press-fit features, snap-fit features, latches, etc., for assembly and maintenance purposes.

As can be seen in fig. 2, the clamp portion 100 includes a clamp housing 130, the clamp housing 130 defining a hollow cavity 132, the hollow cavity 132 configured to operably support a drive motor and a gearbox, which will be discussed in further detail below. The upper portion 134 of the clamp housing 130 is configured to extend through the opening 80 in the main housing portion 30 and is pivotally journaled on a pivot shaft 180. The pivot axis 180 defines a pivot axis designated "PA". See fig. 3. For reference purposes, the handle assembly 20 defines a handle axis designated "HA" which may be parallel to the axis "SA" of the elongated shaft assembly of the interchangeable surgical tool which is operably attached to the handle assembly 20. The pivot axis PA is transverse to the handle axis HA. See fig. 1. Such an arrangement enables the clamp portion 100 to pivot relative to the main housing portion 30 about the pivot axis PA to a position that is most suitable for the type of interchangeable surgical tool assembly that is coupled to the handle assembly 20. The clamp housing 130 defines a clamp axis, generally designated "GA". See fig. 2. When the interchangeable surgical tool assembly coupled to the handle assembly 20 comprises, for example, an endocutter, the clinician may want to position the clamp portion 100 relative to the main housing portion 30 such that the clamp axis GA is perpendicular or approximately perpendicular (angle "H1") to the handle axis HA (referred to herein as the "first clamp position"). See fig. 5. However, if the handle assembly 20 is used to control an interchangeable surgical tool assembly, including, for example, a circular stapler, the clinician may wish to pivot the clamp portion 100 relative to the main housing portion 30 to a position in which the clamp axis GA is at or about 45 degrees or other suitable acute angle (angle "H2") relative to the handle axis HA. This position is referred to herein as the "second clamping position". Fig. 5 shows the clamping portion 100 in a second clamping position shown in phantom.

Referring now to fig. 3-5, the handle assembly 20 also includes a handle locking system, generally designated 150, for selectively locking the handle section 100 in a desired orientation relative to the main housing section 30. In one arrangement, the clamp locking system 150 includes an arcuate sequence 152 of tines 154. The teeth 154 are spaced apart from one another and form a locking groove 156 therebetween. Each locking groove 156 corresponds to a particular angular locking position of the clip portion 100. For example, in at least one arrangement, the teeth 154 and locking groove or "locking position" 156 are arranged to permit the clamp portion 100 to be locked at 10 to 15 degree intervals between the first and second clamp positions. The arrangement may employ two stop positions that are tailored to the type of instrument employed (shaft arrangement). For example, for an end cutter shaft arrangement, which may be about 90 degrees from the shaft and for a circular stapler arrangement, the angle may be about 45 degrees from the shaft while sweeping forward toward the surgeon. The clamp locking system 150 further includes a lock button 160, the lock button 160 having a locking portion configured to lockingly engage the lock groove 156. For example, the locking buttons 160 are pivotally mounted in the main handle portion 30 on the pivot pins 131 to permit the locking buttons 160 to pivot into engagement with the corresponding locking recesses 156. The locking spring 164 serves to bias the locking button 160 into engagement with the corresponding locking groove 156 or into a locked position. The locking portion and tooth configuration serves to enable the teeth 154 to slide through the locking portion when the clinician presses the lock button 160. Thus, to adjust the angular position of the clamp portion 100 relative to the main housing portion 30, the clinician depresses the lock button 160 and then pivots the clamp portion 100 to the desired angular position. Once the clip portion 100 has been moved to the desired position, the clinician releases the lock button 160. The locking spring 164 will then bias the locking button 160 toward the series of teeth 154 such that the locking portion enters the corresponding locking groove 156 to retain the clip portion 100 in this position during use.

Drive system

The handle assembly 20 operably supports a first rotary drive system 300, a second rotary drive system 320, and a third axial drive system 400. The rotary drive systems 300,320 are each powered by a motor 200, the motor 200 being operably supported in the clamp portion 100. As seen in fig. 2, for example, a motor 200 is supported within the cavity 132 in the clamp portion 100 and has a gearbox assembly 202, the gearbox assembly 202 having an output drive shaft 204 projecting therefrom. In various forms, the motor 200 may be, for example, a DC brushed driving motor having a maximum rotation of about 25,000 RPM. In other arrangements, the motor may comprise a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The motor 200 may be powered by a power supply 210, which in one form may include a removable power pack 212. The power source 210 may include, for example, any of the various power source arrangements disclosed in further detail in U.S. patent application publication 2015/0272575 entitled SURGICAL INSTRUMENT including a SENSOR SYSTEM (SURGICAL INSTRUMENT SENSOR SYSTEM), the entire disclosure of which is hereby incorporated by reference. In the arrangement shown, for example, the power pack 212 may include a proximal housing portion 214 configured for attachment to a distal housing portion 216. The proximal housing portion 214 and the distal housing portion 216 are configured to operably support a plurality of batteries 218 therein. The batteries 218 may each include, for example, a lithium ion ("LI") or other suitable battery. Distal housing portion 216 is configured to be removably operably attached to a handle circuit board assembly 220 that is also operably coupled to motor 200. The handle circuit board assembly 220 may also be generally referred to herein as a "control system or CPU 224". A plurality of batteries 218 connected in series may be used as a power source for the handle assembly 20. In addition, the power supply 210 may be replaceable and/or rechargeable. In other embodiments, the surgical instrument 10 may be powered by, for example, Alternating Current (AC). The motor 200 may be controlled by a rocker switch 206 mounted to the clamp portion 100.

As outlined above, the motor 200 is operably coupled to a gearbox assembly 202, the gearbox assembly 202 including an output drive shaft 204. A drive bevel gear 230 is attached to the output drive shaft 204. The motor 200, gearbox assembly 202, output drive shaft 204, and drive bevel gear 230 may also be collectively referred to herein as a "motor assembly 231". The drive bevel gear 230 interfaces with a driven bevel gear 234, the driven bevel gear 234 being attached to a system drive shaft 232 and a pivot bevel gear 238, the pivot bevel gear 238 being journaled on a pivot shaft 180. The driven bevel gear 234 is axially movable on the system drive shaft 232 between an engaged position in which the driven bevel gear 234 is in engagement with the drive bevel gear 230 (fig. 5) and a disengaged position in which the driven bevel gear 234 is out of engagement with the drive bevel gear 230 (fig. 14). A drive system spring 235 is journaled between the driven bevel gear 234 and a proximal end flange 236, the proximal end flange 236 being formed on a proximal portion of the system drive shaft 232. See fig. 4 and 14. The drive system spring 235 serves to bias the driven bevel gear 234 out of engagement with the drive bevel gear 230, as will be discussed in further detail below. The pivot bevel gear 238 facilitates pivotal travel of the output drive shaft 204 and the drive bevel gear 230 with the handle section 100 relative to the main handle section 30.

In the example shown, the system drive shaft 232 interfaces with a rotary drive selector system, generally designated 240. In at least one form, for example, the rotary drive selector system 240 includes a shifter gear 250 that is selectively movable between the first rotary drive system 300 and the second rotary drive system 320. As seen in fig. 6-9, for example, the drive selector system 240 includes a shifter mounting plate 242, the shifter mounting plate 242 being non-movably mounted within the main handle portion 30. For example, the shifter mounting plates 242 may be frictionally retained between mounting lugs (not shown) formed in the housing segments 40,70 or otherwise retained therein by screws, adhesives, or the like. Still referring to fig. 6-9, the system drive shaft 232 extends through an aperture in the shifter mounting plate 242 and has a central or system drive gear 237 non-rotatably attached thereto. For example, the central drive gear 237 may be attached to the system drive shaft 232 by a keyway arrangement 233. See fig. 6-9. In other arrangements, the system drive shaft 232 may be rotatably supported in the shifter mounting plate 242 by corresponding bearings (not shown) mounted thereto. In any event, rotation of the system drive shaft 232 will result in rotation of the central drive gear 234.

As seen in fig. 3, the first drive system 300 includes a first drive socket 302, the first drive socket 302 being rotatably supported in the distal wall 32 formed in the main handle portion 30. The first drive socket 302 may include a first body portion 304 having an elongated socket formed therein. The first driven gear 306 is formed on the first body portion 304 or non-movably attached to the first body portion 304. The first body portion 304 may be rotatably supported in a corresponding hole or channel provided in the distal wall 32, or it may be rotatably supported in a corresponding bearing (not shown) mounted in the distal wall 32. Similarly, the second rotary drive system 320 includes a second drive socket 322, the second drive socket 322 also being rotatably supported in the distal wall 32 of the main handle section 30. The second drive socket 322 may include a second body portion 324, the second body portion 324 having an elongated socket formed therein. The second driven gear 326 is formed on the second body portion 324 or is non-rotatably mounted to the second body portion 324. The second body portion 324 may be rotatably supported in a corresponding hole or channel provided in the distal wall 32, or it may be rotatably supported in a corresponding bearing (not shown) mounted in the distal wall 32. The first and second drive sockets 302, 322 are spaced apart from one another on each lateral side of the handle axis HA. See, for example, fig. 4.

As noted above, in the example shown, the rotary drive selector system 240 includes a shifter gear 250. As can be seen in fig. 6-9, the shifter gear 250 is rotatably mounted on an idler shaft 252, the idler shaft 252 being movably supported in an arcuate slot 244 in the shifter mounting plate 242. The mounting shifter gear 250 is free to rotate on an idler shaft 252 throughout and remains meshed with the center drive gear 234. The idler shaft 252 is coupled to the end of the shaft 262 of the displacer solenoid 260. The shifter solenoid 260 is pinned or otherwise mounted with the main handle housing 30 such that when the shifter solenoid 260 is actuated, the shifter gear 250 moves into engagement with one of the first driven gear 306 or the second driven gear 326. For example, in one arrangement, when the solenoid shaft 262 is retracted (fig. 6 and 7), the shifter gear 250 meshes with the center drive gear 234 and the first driven gear 306 such that actuation of the motor 200 will result in rotation of the first drive socket 302. As can be seen in fig. 6 and 7, a shifter spring 266 may be employed to bias the shifter gear 250 into this first actuated position. Thus, if the surgical instrument 10 loses power, the shifter spring 266 will automatically bias the shifter gear 250 into the first position. When the shifter gear 250 is in this position, subsequent actuation of the motor 200 will result in rotation of the first drive socket 302 of the first rotary drive system 300. When the shifter solenoid is actuated, the shifter gear 250 moves into engagement with the second driven gear 326 on the second drive socket 322. Thereafter, actuation of the motor 200 will result in actuation or rotation of the second drive socket 322 of the second rotary drive system 320.

Emergency system

As will be discussed in further detail below, the first and second rotary drive systems 300,320 may be used to power various component parts of the interchangeable surgical tool assembly coupled thereto. As noted above, in at least one arrangement, if the motor loses power during actuation of the interchangeable surgical tool assembly, the shifter spring 266 will bias the shifter gear 250 into the first position. Depending on which component part of the interchangeable surgical tool assembly is being operated, it may be necessary to reverse the application of the rotary drive motion to the first drive system 300 to enable the interchangeable surgical tool assembly to be removed from the patient. The handle assembly 20 of the illustrated example employs a "panic" system, generally designated 330, that can be manually actuated for manually imparting rotary drive motion to the first rotary drive system 300, such as in the scenario described above.

Referring now to fig. 3, 10 and 11, the illustrated emergency system 330 includes an emergency drive mechanism 332, the emergency drive mechanism 332 including a planetary gear assembly 334. In at least one form, the planetary gear assembly 334 includes a planetary gear housing 336, the planetary gear housing 336 housing a planetary gear arrangement (not shown) that includes a planetary bevel gear 338. The planetary gear assembly 334 includes an emergency drive shaft 340, the emergency drive shaft 340 being operatively coupled to the planetary gear arrangement within the planetary gear housing 336. Rotation of the planetary bevel gear 338 rotates the planetary gear arrangement which ultimately rotates the emergency drive shaft 340. The emergency drive gear 342 is journaled on the emergency drive shaft 340 such that the emergency drive gear 342 can move axially on the emergency drive shaft 340 and then rotate therewith. Emergency drive gear 342 is movable between a spring stop flange 344 formed on emergency drive shaft 340 and a shaft end stop 346 formed on the distal end of emergency drive shaft 340. An emergency shaft spring 348 is journaled on the emergency drive shaft 340 between the emergency drive gear 342 and the spring stop flange 344. An emergency shaft spring 348 biases emergency drive gear 342 distally on emergency drive shaft 340. When the emergency drive gear 342 is in a distal-most position on the emergency drive shaft 340, it meshes with an emergency driven gear 350, which emergency driven gear 350 is non-rotatably mounted to the system drive shaft 232. See fig. 14.

Referring now to fig. 12 and 13, the bailout system 330 includes a bailout actuator assembly or bailout handle assembly 360 that facilitates manual application of a bailout drive motion to the bailout drive mechanism 332. As can be seen in these figures, the emergency handle assembly 360 includes an emergency bevel gear assembly 362 including an emergency bevel gear 364 and a ratchet gear 366. The bailout handle assembly 360 further includes a bailout handle 370 movably coupled to the bailout bevel gear assembly 362 by a pivoting yoke 372, the pivoting yoke 372 being pivotally mounted on the ratchet gear 366. The emergency handle 370 is pivotally coupled to a pivot yoke 372 by a pin 374 for selective pivotal travel between a storage position "SP" and an actuation position "AP". See fig. 12. The handle spring 376 is used to bias the emergency handle 370 into the actuated position AP. In at least one arrangement, for example, the angle between the axis SP representing the storage position and the axis AP representing the actuation position may be about 30 degrees. See fig. 13. As also seen in fig. 13, the emergency handle assembly 360 further includes a ratchet pawl 378, the ratchet pawl 378 being rotatably mounted in a cavity or bore 377 in the pivot yoke 372. Ratchet pawl 378 is configured to engage ratchet gear 366 when rotated in an actuation direction "AD" and then rotate out of engagement when rotated in the opposite direction. The ratchet spring 384 and the spherical member 386 are movably supported in a cavity 379 in the pivot yoke 372 and are used to lockingly engage the detents 380,382 in the ratchet pawl 378 when the emergency handle 370 is actuated (ratchet installed).

Referring now to fig. 3 and 10, the emergency system 330 further includes an emergency access panel 390 that is operable between an open position and a closed position. In the arrangement shown, the emergency access panel 390 is configured to be removably coupled to the housing segment 70 of the main housing portion 30. Thus, in at least this embodiment, when the emergency access panel 390 is removed or detached from the main housing portion 30, it is said to be in an "open" position and when the emergency access panel 390 is attached to the main housing portion 30 as shown, it is said to be in a "closed" position. However, other embodiments are contemplated in which the access panel is movably coupled to the main housing portion such that it remains attached to the main housing portion when the access panel is in the open position. For example, in such embodiments, the access panel is pivotally or slidably attached to the main housing portion and is capable of being manipulated between an open position and a closed position. In the example shown, the emergency access panel 390 is configured to snapably engage a corresponding portion of the housing segment 70 to removably retain it in a "closed" position. Other forms of mechanical fasteners, such as screws, pins, etc., may also be used.

Regardless of whether the emergency access panel 390 is detachable from or remains movably attached to the main housing portion 30, the emergency access panel 390 includes a drive system locking member or yoke 392 and an emergency locking member or yoke 396, each of which project from or are otherwise formed on a back side thereof. The drive system locking yoke 392 includes a drive shaft notch 394, the drive shaft notch 394 being configured to receive a portion of the system drive shaft 232 therein when the emergency access panel 390 is installed in the main housing portion 30 (i.e., the emergency access panel is in a "closed" position). The drive system lock yoke 392 is used to bias the driven bevel gear 234 into engagement with the drive bevel gear 230 (against the bias of the drive system spring 235) when the emergency access panel 390 is positioned or installed in the closed position. Further, emergency locking yoke 396 includes an emergency drive shaft notch 397 configured to receive a portion of emergency drive shaft 340 therein when emergency access panel 390 is installed or positioned in the closed position. As seen in fig. 5 and 10, the emergency locking yoke 396 also serves to bias the emergency drive gear 342 out of engagement with the emergency driven gear 350 (against the bias of the emergency shaft spring 348). Thus, when the emergency access panel 390 or the emergency access panel 390 is in the closed position, the emergency locking yoke 396 prevents the emergency drive gear 342 from interfering with the rotation of the system drive shaft 232. In addition, the emergency locking yoke 396 includes a handle recess 398 for engaging and retaining the emergency handle 370 in the storage position SP.

Fig. 4,5 and 10 illustrate the configuration of the drive system components and emergency system components when the emergency access panel 390 is installed or in a closed position. As can be seen in these figures, the drive system locking member 392 biases the driven bevel gear 234 into engagement with the drive bevel gear 230. Thus, when the emergency access panel 390 is installed or in a closed position, actuation of the motor 200 will cause the drive bevel gear 230 and ultimately the system drive shaft 232 to rotate. Additionally, when in this position, the emergency locking yoke 396 is used to bias the emergency drive gear 342 out of engagement with the emergency driven gear 350 on the system drive shaft 232. Thus, when the emergency access panel 390 is installed or in a closed position, the drive system may be actuated by the motor 200 and the emergency system 330 is disconnected or prevented from applying any actuating motion to the system drive shaft 232. To activate the emergency system 330, the clinician first removes the emergency access panel 390 or otherwise moves the emergency access panel 390 to the open position. This action removes the engagement of the drive system locking member 392 with the driven bevel gear 234, permitting the drive system spring 235 to bias the driven bevel gear 234 out of engagement with the drive bevel gear 230. In addition, removal of emergency access panel 390 or movement of emergency access panel to an open position also causes emergency lock yoke 396 to disengage from emergency drive gear 342, permitting emergency shaft spring 348 to bias emergency drive gear 342 into engagement with emergency driven gear 350 on system drive shaft 232. Thus, rotation of the emergency drive gear 342 will result in rotation of the emergency driven gear 350 and the system drive shaft 232. Removing emergency access panel 390 or otherwise moving emergency access panel 390 to the open position also permits handle spring 376 to bias emergency handle 370 to the actuated position shown in fig. 11 and 14. When in this position, the clinician may manually install the ratchet to the emergency handle 370 in the ratchet direction RD, which results in rotation of the ratchet bevel gear 364 (e.g., clockwise in fig. 14), which ultimately results in applying a retracting rotational motion to the system drive shaft 232 through the emergency drive train 332. The clinician may ratchet to the bailout handle 370 multiple times until the system drive shaft 232 has been rotated multiple times sufficiently to retract the components of the surgical end effector portion of the surgical tool assembly attached to the handle assembly 20. Once the emergency system 330 has been sufficiently manually actuated, the clinician may then replace the emergency access panel 390 (i.e., return the emergency access panel 390 to the closed position), causing the drive system locking member 392 to bias the driven bevel gear 234 into engagement with the drive bevel gear 230 and the emergency locking yoke 396 to bias the emergency drive gear 342 out of engagement with the emergency driven gear 350. As discussed above, if power is lost or interrupted, the shifter spring 266 will bias the shifter solenoid 260 into the first actuated position. In this manner, actuation of the bailout system 330 will cause a reverse or retraction motion to be applied to the first rotary drive system 300.

As discussed above, the surgical stapling instrument can include a manually actuated emergency system configured to retract, for example, the staple firing drive. In many instances, the bailout system may need to be operated and/or flexed more than once to fully retract the staple firing drive. In such a case, the user of the stapling instrument may not have a grasp of how many times the emergency system has rocked and/or to otherwise confuse how many times the firing drive still needs to be retracted. Various embodiments are contemplated wherein the stapling instrument includes a system configured to detect the position of a firing member of a firing drive, determine the distance the firing member needs to be retracted, and display the distance from a user of the surgical instrument.

In at least one embodiment, a surgical stapling instrument comprises one or more sensors configured to detect a position of a firing member. In at least one instance, the sensor can comprise, for example, a hall effect sensor, and can be positioned in the shaft and/or end effector of the stapling instrument. The sensor is in signal communication with a controller of the surgical stapling instrument, which in turn is in signal communication with a display on the surgical stapling instrument. The controller includes a microprocessor configured to compare the actual position of the firing member to a baseline or reference position (which includes a fully retracted position of the firing member) and calculate a distance between the actual position of the firing member and the reference position, i.e., a remaining distance.

In addition to the above, the display includes, for example, an electronic display, and the controller is configured to display the remaining distance on the electronic display in any suitable manner. In at least one case, the controller displays a progress bar on the display. In such a case, for example, an empty progress bar may indicate that the firing member is at the end of its firing stroke, and a full progress bar may indicate that the firing member has been fully retracted. In at least one instance, for example, 0% can indicate that the firing member is at the end of its firing stroke, and 100% can indicate that the firing member has been fully retracted. In some instances, the controller is configured to display how many actuations of the bailout mechanism are required to retract the firing member to its fully retracted position on the display.

In addition to the above, actuation of the arming mechanism operably disconnects the battery or power source of the surgical stapling instrument from the electric motor of the firing drive. In at least one embodiment, actuation of the emergency mechanism flips a switch that electrically disconnects the battery from the electric motor. This system will prevent manual retraction of the electric motor against the firing member.

The illustrated handle assembly 20 also supports a third axial drive system, generally designated 400. As can be seen in fig. 3 and 4, in at least one form, the third axial drive system 400 includes a solenoid 402, the solenoid 402 having a third drive actuator member or rod 410 protruding therefrom. The distal end 412 of the third drive actuator member 410 has a third drive bracket or socket 414 formed therein for receiving a corresponding portion of the drive system components of the interchangeable surgical tool assembly operably attached thereto. Solenoid 402 is wired to or otherwise in communication with handle circuit board assembly 220 and control system or CPU 224. In at least one arrangement, the solenoid 402 is "spring loaded" such that when the solenoid 402 is unactuated, its spring member biases the third drive actuator 410 back into the unactuated, starting position.

As noted above, the reconfigurable handle assembly 20 can be advantageously used to actuate a variety of different interchangeable surgical tool assemblies. To this end, the handle assembly 20 includes a tool mounting portion, generally designated 500, for operably coupling an interchangeable surgical tool assembly to the handle assembly. In the example shown, the tool mounting portion 500 includes two inward facing dovetail receiving slots 502 configured to engage corresponding portions of a tool attachment module portion of an interchangeable surgical tool assembly. Each dovetail receiving slot 502 may be tapered, or in other words, slightly V-shaped. The dovetail receiving slot 502 is configured to releasably receive a corresponding tapered attachment or lug portion formed on a portion of the tool attachment nozzle portion of the interchangeable surgical tool assembly. Each interchangeable surgical tool assembly may also be equipped with a latch system configured to releasably engage a corresponding retention pocket 504 formed in the tool mounting portion 500 of the handle assembly 20.

Various interchangeable surgical tool assemblies may have a "primary" rotary drive system configured to be operatively coupled to or interface with the first rotary drive system 310 and a "secondary" rotary drive system configured to be operatively coupled to or interface with the second rotary drive system 320. The primary and secondary rotary drive systems can be configured to provide various rotary motions to portions of a particular type of surgical end effector, including portions of an interchangeable surgical tool assembly. To facilitate operably coupling the primary rotary drive system to the first rotary drive system and the secondary rotary drive system to the second rotary drive system 320, the tool mounting portion 500 of the handle assembly 20 also includes a pair of insertion ramps 506 configured to bias portions of the primary and secondary rotary drive systems of the interchangeable surgical tool assembly distally during the coupling process to facilitate aligning and operably coupling the primary rotary drive system with the first rotary drive system 300 on the handle assembly 20 and the secondary rotary drive system with the second rotary drive system 320 on the handle assembly 20.

The interchangeable surgical tool assembly may also include a "three stage" axial drive system for applying axial motion(s) to corresponding portions of a surgical end effector of the interchangeable surgical tool assembly. To facilitate operably coupling the three-stage axial drive system to the third axial drive system 400 on the handle assembly 20, the third drive actuator member 410 is provided with a socket 414, the socket 414 being configured to operably receive therein a lug or other portion of the three-stage axial drive system.

Interchangeable surgical tool assembly

Fig. 15 illustrates the use of an interchangeable surgical tool assembly 1000 that can be used in conjunction with the handle assembly 20. As can be seen in this figure, for example, the interchangeable surgical tool assembly 1000 includes a tool attachment module 1010 configured for operable and removable attachment to the tool mounting portion 500 of the handle assembly 20. In the arrangement shown, the tool attachment module 1010 includes a nozzle frame 1020. In the arrangement shown, the interchangeable surgical tool assembly 1000 includes a primary rotary drive system 1100 and a secondary rotary drive system 1200. The main rotary drive system 1100 is configured to operably interface with the first rotary drive system 300 on the handle assembly 20 and apply rotary firing motions to a surgical end effector 1500 attached thereto, as will be discussed in further detail below. The auxiliary rotary drive system 1200 is configured to operably interface with the second rotary drive system 320 on the handle assembly 20 and apply articulation control motions to the articulation system 1700. The articulation system 1700 couples the surgical end effector 1500 to the elongate shaft assembly 1400, and the elongate shaft assembly 1400 is coupled to the nozzle frame 1020. The interchangeable surgical tool assembly 1000 further includes a tertiary drive system 1300, the tertiary drive system 1300 configured to operably interface with the third axial drive system 400 in the handle assembly 20. The tertiary axial drive system 1300 of the surgical tool assembly includes a tertiary actuation shaft 1302 having shaft attachment ears 1306 formed on a proximal end 1304 of the tertiary actuation shaft 1302. As will be discussed in further detail below, when the interchangeable surgical tool assembly 1000 is coupled to the handle assembly 20, the shaft attachment lug 1306 is received in the shaft attachment socket 414 on the distal end 412 of the third drive actuator member 410.

Still referring to fig. 15, the reader will observe that the tool mounting portion 500 of the handle assembly 20 includes two inward facing dovetail receiving slots 502. Each dovetail receiving slot 502 may be tapered, or in other words, slightly V-shaped. Dovetail receiving slot 502 is configured to releasably receive a corresponding tapered attachment or lug portion 1022 formed on nozzle frame 1020. Turning next to fig. 18, in at least one form, the tool attachment module 1010 is removably latched to the tool mounting portion 500 of the handle assembly 20 by a latching system generally designated 1030. In the illustrated embodiment, the latch system 1030 includes a lock yoke 1032, the lock yoke 1032 including a pair of inwardly extending pivot pins 1034 (only one shown in fig. 18), the pivot pins 1034 being received in corresponding pivot holes (not shown) in the nozzle frame 1020. This arrangement serves to pivotally or movably couple the lock yoke 1032 to the nozzle frame 1020. The lock yoke 1032 further includes a pair of retention ears or hook formations 1036 (only one visible in fig. 18) that are configured to be hooked or otherwise retainingly received in corresponding retention pockets 504 formed in the tool mounting portion 500 of the handle assembly 20. The lock yoke 1032 is pivotable out of retaining engagement by applying an unlocking motion (represented by arrow 1041 in fig. 18, 20, and 21) to the release button 1038, the release button 1038 being attached to the lock yoke 1032. The lock yoke springs 1040 are received on spring ears 1039 formed on the lock yoke 1032 and spring mounting ears 1021 formed on the nozzle frame 1020. The locking yoke spring 1040 is used to bias the locking yoke 1032 into the locked position.

The illustrated exemplary latching system 1030 further includes a shaft connector release assembly 1031 for releasably engaging the primary rotary drive system 1100 to the first rotary drive system 300 and coupling the secondary rotary drive system 1200 to the second rotary drive system 320 on the handle assembly 20. Referring now to fig. 18 and 19, the primary rotary drive system 1100 includes a primary drive key 1102, the primary drive key 1102 being configured to be axially received within the first drive socket 302 of the first rotary drive system 300. The main drive key 1102 is slidably received on a main transfer shaft 1104, the main transfer shaft 1104 being rotatably supported by a bulkhead 1023 formed in the nozzle frame 1020. Primary drive key 1102 also movably extends through an aperture 1025 formed in another bulkhead 1024 in nozzle frame 1020. See fig. 18. The main transfer shaft 1104 is rack-toothed such that the main drive key 1102 is free to move axially on the main transfer shaft 1104 but does not rotate relative to the main transfer shaft 1104 such that rotation of the main drive key 1102 causes rotation of the main transfer shaft 1104. As further seen in fig. 18, primary drive key 1102 includes an attachment flange 1106 that is received within a cavity 1044 in coupler release tab 1042. Thus, the main drive key 1102 and the coupler release tab 1042 move as a unit. A main transfer spring 1108 is journaled on the main transfer shaft 1104 and extends between the bulkhead 1023 and the coupler release tab 1042 to bias the coupler release tab 1042 and the main drive key 1102 in the proximal direction "PD" on the main transfer shaft 1104.

Still referring to fig. 18 and 19, the auxiliary rotary drive system 1200 includes an auxiliary drive key 1202, the auxiliary drive key 1202 configured to be axially received within the second drive socket 322 of the second rotary drive system 320. The secondary drive key 1202 is slidably received on a secondary transfer shaft 1204, the secondary transfer shaft 1204 being rotatably supported by a spacer 1023. The auxiliary drive key 1202 also movably extends through the aperture 1026 in the spacer 1024. The secondary transfer shaft 1204 is rack-toothed such that the secondary drive key 1202 is free to move axially on the secondary transfer shaft 1204 but not rotate relative to the secondary transfer shaft 1204 such that rotation of the secondary drive key 1202 causes rotation of the secondary transfer shaft 1204. The secondary drive key 1202 includes an attachment flange (not shown) that is received within a cavity (not shown) in the coupler release tab 1042. Thus, the auxiliary drive key 1202 and the coupler release tab 1042 move as a unit. A secondary transfer spring 1208 is journaled on the secondary transfer shaft 1204 and extends between the spacer 1023 and the coupler release tab 1042 to bias the coupler release tab 1042 and the secondary drive key 1202 on the secondary transfer shaft 1204 in the proximal direction PD. As can be seen in fig. 18, the coupler release tab 1042 is formed with two upstanding actuator portions 1046 that correspond to inwardly extending coupler release tabs 1048 formed on the lock yoke 1032.

The operation of the latch system 1030 may be understood with reference to fig. 20-22. Fig. 20 illustrates the beginning of the coupling process, wherein the interchangeable surgical tool assembly 1000 is moved in the mounting direction "ID" relative to the handle assembly 20. To begin the installation process, the clinician aligns the tapered attachment ears 1022 on the nozzle frame 1020 with their corresponding dovetail slots 502 on the tool mounting portion 500 of the handle assembly 20 and moves the interchangeable surgical tool assembly 1000 relative to the handle assembly 20 in the insertion direction ID. Insertion and movement of the tapered attachment ears 1022 in their respective dovetail slots 502 serves to align the shaft attachment ears 1306 on the tertiary actuation shaft 1302 with the shaft attachment sockets 414 on the distal end 412 of the third drive actuator member 410. Likewise, the primary drive key 1102 and the secondary drive key 1202 are each aligned to contact a corresponding insertion ramp 506 formed on the tool mounting portion 500 of the handle assembly 20.

Fig. 21 shows the contact between the primary drive key 1102 and the corresponding insertion ramp 506, where it is understood that the secondary drive key 1202 will be in a similar position to its corresponding insertion ramp 506. As can be seen in this figure, primary drive key 1102 has contacted insertion ramp 506 and continued advancement of replaceable surgical tool assembly 1000 in the installation direction ID causes insertion ramp 506 to bias primary drive key 1102 in a distal direction on primary transmission shaft 1104. The secondary drive key 1202 will similarly move on the secondary transfer shaft 1204 in the distal direction DD. This movement may be further achieved by pushing the release button 1038 in the direction indicated by arrow 1041, which causes the lock yoke 1032 to contact the coupler release tab 1042 and move it in the distal direction DD against the biasing force of the first and second transfer springs 1108 and 1208. The clinician may maintain pressure on the release button 1038 such that once the primary drive key 1102 and the secondary drive key 1202 clear their corresponding insertion ramps 506, the primary drive key 1102 and the secondary drive key 1202 may be moved into alignment with the corresponding first drive socket 302 and second drive socket 322, respectively. When the tapered attachment ears 1022 are seated in their respective dovetail slots 502, the primary drive key 1102 is axially aligned with the first drive socket 302 and the secondary drive key 1202 is axially aligned with the second drive socket 322 such that when the clinician releases the release button 1038, the primary drive key 1102 enters the first drive socket 302 and the secondary drive key 1202 enters the second drive socket 322. See fig. 22. Thus, rotation of the first drive socket 302 will result in rotation of the primary drive key 1102 and the primary transfer shaft 1104, and rotation of the second drive socket 322 will result in rotation of the secondary drive key 1202 and the secondary transfer shaft 1204. Additionally, a shaft attachment lug 1306 is received within a shaft attachment socket 414 on the distal end 412 of the third drive actuator member 410. Thus, axial movement of the third drive actuator member 410 will result in axial movement of the tertiary drive shaft 1302. As can also be seen in fig. 20-22, the interchangeable surgical tool assembly 1000 further includes an on-board "tool" circuit board 1060, the on-board "tool" circuit board 1060 having a connector portion 1062, the connector portion 1062 being configured to mate with a corresponding connector 222 on the handle circuit board 220. When the tool circuit board 1060 is coupled to the handle circuit board 220, the tool circuit board provides an identification signal to the control system or CPU224 so that the control system or CPU224 can select the appropriate control action for the type of interchangeable surgical tool assembly being used.

End effector

The interchangeable surgical tool assembly 1000 includes a surgical end effector 1500, the surgical end effector 1500 being configured to cut and fasten tissue. As can be seen in fig. 23 and 24, the surgical end effector 1500 is operably coupled to the elongate shaft assembly 1400 by an articulation joint 1702. As will be discussed in further detail below, the elongate shaft assembly 1400 is operably coupled to the tool attachment module 1010 and includes portions of the primary rotary drive system 1100, the secondary rotary drive system 1200, and the tertiary axial drive system 1300. Referring now to fig. 25-28, a surgical end effector 1500 includes an elongate channel 1520, the elongate channel 1520 configured to operably support a surgical staple cartridge 1550 therein. The surgical staple cartridge 1550 may comprise a compressible or implantable staple cartridge having a body portion 1552, the body portion 1552 being comprised of a compressible hemostatic material, such as, for example, oxidized regenerated cellulose ("ORC") or bioabsorbable foam, in which unformed rows of metal staples or other forms of fasteners are supported. In at least certain embodiments, to protect the staples from being affected and to prevent the hemostatic material from being activated during the introduction and positioning process, the entire cartridge can be coated and/or wrapped with a biodegradable film, such as that sold under the trade name

Polydioxanone membranes are sold or coated or wrapped with polyglycerol sebacate (PGS) and/or other biodegradable membranes formed of PGA (polyglycolic acid), PCL (polycaprolactone), PLA or PLLA (polylactic acid), PHA (polyhydroxyalkanoate), PGCL (poliglecaprone), and/or composites of PGA, PCL, PLA, PDS, for example, which are permeable only when ruptured. Various different implantable cartridge arrangements are known and may be employed. Various implantable/compressible cartridge arrangements are disclosed in further detail, for example, in a number of patent applications and patents, which are incorporated herein by reference in their respective entireties. In the illustrated example, the cartridge body portion of the surgical staple cartridge 1550The portion 1552 is sized to be removably supported within the elongate channel 1520.

The elongate channel 1520 and the surgical staple cartridge 1550 mounted therein may also be referred to herein as a "first clamp" 1502. The surgical end effector 1500 also includes a second clamp 1504 in the form of an anvil assembly 1560 that is supported for movable travel relative to the first clamp. In other words, the first clamp 1502 and the second clamp 1504 may be configured to be movable moveable relative to each other between an open position and a closed position. In the illustrated arrangement, the anvil assembly 1560 includes an anvil body portion or anvil frame 1562. The anvil frame 1562 includes a proximal anvil portion 1570 having a pair of trunnion pins 1572 extending laterally therefrom 1570. The trunnion pin 1572 is movably received in a pivot slot 1526, the pivot slot 1526 being formed in a corresponding upstanding wall 1524 of the channel mounting portion 1522 of the elongate channel 1520. See fig. 27 and 28. In at least one form, the anvil frame 1562 includes a pair of downwardly extending tissue stops 1564 for limiting the distance that the target tissue can extend proximally between the first and second clips 1502, 1504 such that when the target tissue is severed, the fasteners are properly positioned to fasten the severed tissue. When the first and second clamps 1502, 1504 are in the closed position, the tissue stop 1564 is located outside of the upstanding walls 1524 of the channel mounting portion 1522 and the proximal anvil portion 1570 is located between the upstanding walls 1524. See fig. 28.

Anvil concentric drive member

The anvil assembly 1560 operably supports an anvil concentric drive member 1600 for operably driving a firing member 1620 through the end effector 1500. The anvil concentric drive member 1600 may be, for example, centrally disposed within the anvil frame 1562 and extend substantially the length thereof. In the illustrated embodiment, the anvil concentric drive member 1600 includes an anvil drive shaft 1610, the anvil drive shaft 1610 including a distal bearing ear 1611 and a proximal bearing ear 1612. The distal bearing ears 1611 are rotatably received in a distal bearing housing 1580, which housing 1580 is supported within a bearing housing in an anvil frame 1562. The proximal bearing ears 1612 are rotatably supported in the anvil assembly 1560 by a floating bearing housing 1582, which floating bearing housing 1582 is movably supported in a bearing pocket 1574 formed in the proximal anvil portion 1570. See fig. 27. The proximal and distal bearing housing arrangements may serve to prevent or at least minimize the occurrence of compressive forces on the anvil drive shaft 1610 that may otherwise cause the anvil drive shaft 1610 to bend under high force conditions. The anvil drive shaft 1610 also includes a driven firing gear 1614, a proximal threaded or helical portion 1616, and a distal threaded or helical portion 1618. In the arrangement shown, the proximal threaded section 1616 has a first length "FL", and the distal threaded section 1618 has a distal length "DL" that is greater than the first length FL. In at least one arrangement, for example, the first length FL can be only about 3 to 5 threads per inch, using only one acme thread lead, and the distal length DL can be about 9 to 15 threads per inch, with 2 to 4 tip thread leads for more power. However, the proximal and distal threaded sections 1616, 1618 may have other lengths. See fig. 31. As can be seen in fig. 26, the pitch of the distal threaded section 1618 is greater than the pitch of the proximal threaded section 1616. In other words, the lead of distal threaded section 1618 is greater than the lead of proximal threaded section 1616. In one arrangement, the lead of the distal threaded section 1618 may be about twice the lead of the proximal threaded section 1616. As can also be seen in fig. 31, a dead space 1617 may be provided between the proximal and distal threaded sections 1616, 1618. In at least one example, the anvil drive shaft 1610 can be made as a single piece from an extruded gear element.

To facilitate assembly of the various anvil components, the anvil assembly 1560 includes an anvil cover 1563, which anvil cover 1563 may be attached to the anvil frame 1562 by welding, snap features, or the like. Further, the anvil assembly 1560 includes a pair of anvil plates or staple forming plates 1568 that may contain various patterns of staple forming pockets or forming pockets on the bottom surface thereof that correspond to the arrangement of staples in the surgical staple cartridge 1550 supported in the elongate channel 1520. The staple forming plate 1568 may be made of metal or similar material and welded or otherwise attached to the anvil frame 1562. In other arrangements, a single anvil having a slot therein to receive a firing member may also be employed. Such an anvil plate or combination of plates may be used to improve the overall stiffness of the anvil assembly. For example, the anvil(s) may be flat and have "cast" staple-forming pockets or forming pockets therein.

Fig. 29 illustrates one form of the firing member 1620, which includes a body portion 1622 having a knife nut portion 1624 formed thereon or otherwise attached thereto. The knife nut portion 1624 is configured to be received on the anvil drive shaft 1610. Formed in the knife nut portion 1624 are a distal threaded knot 1626 and a proximal threaded knot 1628, the distal and proximal threaded knots 1626, 1628 configured to engage the proximal and distal threaded sections 1616, 1618. The distal threaded nodule 1626 is spaced apart from the proximal threaded nodule 1628 relative to the length of the dead space 1617 such that when the knife nut portion 1624 spans the dead space 1617, the distal threaded nodule 1626 is threadedly engaged with the distal threaded section 1618 and the proximal threaded nodule 1628 is threadedly engaged with the proximal threaded section 1616. In addition, anvil engagement tabs 1630 project laterally from opposite lateral portions of the knife nut 1624 and are oriented to engage corresponding staple forming plates 1568 that are attached to the anvil frame 1562. The firing member 1620 also includes channel engagement tabs 1632 that protrude from each side of the body portion 1622 to engage portions of the elongate channel 1520, as will be discussed in further detail below. The firing member 1620 also includes a tissue cutting surface 1634.

Rotation of the anvil drive shaft 1610 in a first rotational direction will cause the firing member 1620 to move axially from a starting position (fig. 35) to an ending position (fig. 32). Similarly, rotation of the anvil drive shaft 1610 in a second rotational direction will cause the firing member 1620 to retract axially from the end position back to the starting position. The anvil drive shaft 1610 ultimately obtains rotational motion from the proximal drive shaft 1120, which proximal drive shaft 1120 operably interfaces with the main transfer shaft 1104. Referring again to fig. 16-18, the proximal drive gear 1110 is mounted to the main transfer shaft 1104 and is supported in meshing engagement with a power driven gear 1122 that is mounted to the proximal end of the proximal drive shaft 1120. The proximal drive shaft 1120 is rotatably supported within the power shaft support tube 1124 and has a power bevel gear 1126 attached to its distal end. See fig. 30. As noted above, the illustrated interchangeable surgical tool assembly 1000 includes an articulation joint 1702 that facilitates articulation of the surgical end effector 1500. In at least one embodiment as shown in fig. 30, the articulation joint 1702 includes an articulation shaft 1704 that is mounted to the distal end of the outer spine 1402 of the elongate shaft assembly. Specifically, the outer spine tube 1402 includes a pair of distally projecting pivot tabs 1404,1406, the pivot tabs 1404,1406 being attached to corresponding ends of the articulation shaft 1704 such that the articulation shaft 1704 defines an articulation axis "AA" that is transverse to a shaft axis "SA-SA" defined by the elongate shaft assembly 1400.

Still referring to FIG. 30, a power bevel gear 1126 meshes with a centrally disposed power transfer gear 1128, the power transfer gear 1128 being rotatably journaled on the articulation shaft 1704. The primary rotary drive system 1100 of the illustrated embodiment also includes a distal power shaft 1130, the distal power shaft 1130 having a distal driven gear 1132 attached to its proximal end by a screw or other fastener 1133. The distal power shaft 1130 may also be referred to herein as a rotary output drive shaft. The distal driven gear 1132 is meshed with a centrally disposed power transmission gear 1128. Turning next to fig. 31 and 32, a distal drive gear 1134 is attached to the distal end of the distal power shaft 1130. The distal drive gear 1134 is configured to engage the driven firing gear 1614 on the anvil drive shaft 1610 when the anvil assembly 1560 is in the closed position, as shown in fig. 31 and 32. Anvil drive shaft 1610 is said to be "separate and distinct" from distal power shaft 1130. That is, for example, at least in the arrangement shown, the anvil drive shaft 1610 is not coaxially aligned with the distal power shaft 1130 and does not form a part of the distal power shaft 1130. Additionally, for example, anvil drive shaft 1610 is movable relative to distal power shaft 1130 as anvil assembly 1560 is moved between an open position and a closed position. Fig. 31 illustrates the anvil assembly 1560 in a closed position and the firing member 1620 in a pre-fired position. As can be seen in this figure, the distal threaded nodule 1626 in the knife nut 1624 of the firing member 1620 is engaged with the distal threaded portion 1618 such that rotation of the anvil drive shaft 1610 drives (fires) the firing member 1620 to the end position shown in fig. 32. Further details regarding the operation of the firing member 1620 are provided below.

Opening and closing system

In the illustrated arrangement, the anvil assembly 1560 is closed by distally advancing a closure tube 1410 that is part of the elongate shaft assembly 1400. As seen in fig. 27 and 31-35, the closure tube 1410 includes an internally threaded closure nut 1412, the internally threaded closure nut 1412 configured for threaded engagement with a closure threaded segment 1136 formed on the distal power shaft 1130. Fig. 33 illustrates the anvil assembly 1560 in an open position. As discussed above, the proximal bearing ears 1612 are rotatably supported in the anvil assembly 1560 by the floating bearing housing 1582, which floating bearing housing 1582 is movably supported in the bearing pockets 1574 in the proximal anvil portion 1570. A bearing spring 1584 is journaled on the distal power shaft 1130 and is configured to apply a biasing force to the bearing housing 1582 during opening and closing of the anvil assembly 1560. Such biasing forces serve to force the anvil assembly 1560 into the open position. In at least one arrangement, the bearing spring 1584 includes an assembly of plates 1586 made of, for example, 17-4, 416, or 304 stainless steel, laminated together by a more annealed stainless steel material and having a bore 1588 for receiving the distal power shaft 1130 therethrough. See fig. 36.

As noted above, the anvil trunnion pins 1572 are received in vertically oriented pivot slots 1526, the pivot slots 1526 being formed in the upstanding walls 1524 of the elongate channel 1520 to provide the anvil assembly 1560 with the ability to move vertically relative to the elongate channel 1520 and relative to the surgical staple cartridge 1550 supported therein. This movement of the anvil assembly 1560 relative to the elongate channel 1520 may be used to accommodate different thicknesses of tissue clamped therebetween. To this end, in the example shown, the surgical end effector 1500 also includes an anvil spring assembly 1590 for managing the amount of tissue gap between the staple forming plate 1568 and the upper surface of the surgical staple cartridge 1550. As can be most particularly seen in fig. 27, in the example shown, the anvil spring assembly 1590 includes a bearing seat 1592, the bearing seat 1592 being mounted between upstanding walls 1524 of the elongate channel 1520. As can be seen in fig. 27 and 33, the bearing housing 1592 has a slightly U-shaped bearing cavity 1594 therein (the bearing cavity 1594 being configured to operably receive a bearing 1138 therein) and a bearing stop flange 1140 formed on or otherwise attached to the distal power shaft 1130. This arrangement serves to rotatably support the distal power shaft 1130 within the proximal end portion or channel mounting portion 1522 of the elongate channel 1520. Two spring tabs 1596 extend from the bearing seat 1592 and are oriented to apply a downward biasing force to the proximal anvil portion 1570. See fig. 32. This biasing force acts to bias the proximal anvil portion 1570 downwardly such that the anvil trunnion pins 1572 are biased downwardly within their corresponding vertical pivot slots 1526 and such that the anvil assembly 1560 is able to move vertically to accommodate tissues of different thicknesses. When the anvil assembly 1560 is closed, the targeted tissue captured between the anvil assembly 1560 and the surgical staple cartridge 1550 will cause compression of the cartridge body 1552 and the staples or fasteners supported therein will be pressed through the tissue into contact with the staple forming plate 1568 on the underside of the anvil assembly 1560. Depending on the arrangement of the staples of the fasteners in the staple cartridge 1550, the staples can be formed in several discrete rows through the cartridge body and the clamped tissue. For example, there may be a total of six rows of staples (three rows of staples on each side of the central region through which the firing member 1620 may pass). In at least one arrangement, for example, the staples in one row may be offset or staggered from the staples in an adjacent row.

As can be seen in fig. 33, the closure threaded section 1136 on the distal power shaft 1130 remains in threaded engagement with the closure nut 1412 when the anvil assembly 1560 is in the open position. When in the open position, the firing member 1620 is located at a most proximal or starting position on the proximal threaded portion 1616 of the anvil drive shaft 1610. As can be seen in fig. 33, when in this proximal starting position, the channel engagement tab 1632 on the firing member can clear the channel protrusion 1528 formed in the elongate channel 1520 such that the firing member 1620 can pivot with the anvil assembly 1560 to the open position. When in this position (which may also be referred to as a "fully open position"), drive device firing gear 1614 may remain in contact with, but not meshed with, distal drive gear 1134. Thus, rotation of the distal power shaft 1130 will not result in rotation of the anvil drive shaft 1610.

To begin the closing process, the distal power shaft 1130 is rotated in a first rotational direction. This initial rotation of the distal power shaft 1130 causes the closure tube 1410 to move in the distal direction DD by virtue of the threaded engagement between the closure threaded section 1136 on the distal power shaft 1130 and the internally threaded closure nut 1412. As the closure tube 1410 is moved distally, a closure tab 1414 formed on the distal end of the closure tube 1410 contacts the proximal anvil portion 1570 and moves into camming contact therewith to pivot the anvil assembly 1560 to an initial closed position. Further rotation of the distal power shaft 1130 will cause distal movement of the closure tube 1410 until the closure tube reaches a "fully closed" position wherein the internally threaded closure nut 1412 is threadably disengaged from the closure thread segments 1136. For example, when in this position, the internally threaded closure nut 1412 is distal of the closure threaded segment 1136 and further rotation of the distal power shaft 1130 in the first rotational direction will not affect movement of the closure tube 1410. A closure spring 1416 is used to bias the closure tube 1410 distally to hold the internally threaded closure nut 1412 out of threaded engagement with the closure thread segments 1136.

Once the anvil assembly 1560 has been moved to the closed position, the driven firing gear 1614 on the anvil drive shaft 1610 will now engage the distal drive gear 1134 on the distal power shaft 1130. Accordingly, further rotation of the distal power shaft 1130 in a first rotational direction will cause rotation of the anvil drive shaft 1610 and cause the firing member 1620 to move distally on the proximal threaded portion 1616. Continued rotation of the anvil drive shaft 1610 in the first rotational direction will result in distal movement of the firing member 1620. FIG. 34 illustrates the position of the firing member 1620 just prior to engagement between the distal threaded nodule 1626 and the distal threaded portion 1618 of the firing drive shaft. Fig. 31 illustrates the position of the firing member 1620 after the distal threaded nodule 1626 initially threadingly engages the distal threaded portion 1618 of the anvil drive shaft 1610. When in this position, the anvil engagement tab 1630 on the firing member 1620 has engaged the corresponding staple forming plate 1568 attached to the anvil frame 1562 and the channel engagement tab 1632 has engaged the corresponding protrusion 1528 on the elongate channel 1520 to maintain the desired spacing between the anvil assembly 1560 and the elongate channel 1520.

Continued rotation of the distal power shaft 1130 in the first rotational direction causes the anvil drive shaft 1610 to also rotate. Now that the distal threaded nodule 1626 has engaged the distal threaded portion 1618 of the anvil drive shaft 1610, the firing member 1620 will move at a "firing rate" that is faster than the "pre-firing rate" at which the firing member 1620 moves when threadedly engaged with the proximal threaded portion 1616 of the anvil drive shaft 1610. This difference in velocity is due to the difference in thread leads of the proximal threaded portion 1616 and the distal threaded portion 1618. As the firing member 1620 is moved distally through the end effector 1500, the tissue cutting surface 1634 passes between the staple forming plates 1568 and cuts through tissue that has been clamped between the anvil assembly 1560 and the surgical staple cartridge 1550. Thus, when the anvil assembly 1560 is moved to the fully closed position, tissue is stapled first. Thereafter, as the firing member is advanced distally through the end effector 1500, tissue is cut. Thus, the staple forming process can be "separated and differentiated" from the tissue cutting process.

FIG. 32 illustrates the position of the firing member 1620 at or near the end firing position. Once the firing member 1620 has reached an end firing position (which may be determined, for example, by sensors, encoders, etc. (not shown)), the distal power shaft 1130 may be rotated in a second rotational direction, or "retraction direction," which also causes the anvil drive shaft 1610 to be rotated in the opposite direction. Rotation of the anvil drive shaft 1610 in a second rotational direction will cause the firing member 1620 to move proximally to the position shown in fig. 35. As can be seen in fig. 35, the closure tube 1410 is fitted with a closure tube return spring 1418, the closure tube return spring 1418 extending distally from ears 1413 on the closure nut 1412. The firing member 1620 is formed with a proximally extending reset tab 1636, the reset tab 1636 configured to contact the closure tube return spring 1418 and apply a proximal compression force to the closure tube return spring 1418 when the firing member 1620 is returned to the starting position. This proximal compressive force acts to force the closure tube 1410, and more specifically, the internally threaded closure nut 1412, against the closure threaded section 1136 on the distal power shaft 1130 such that the closure nut threads threadingly re-engage the closure threaded section 1136 on the distal power shaft 1130. As the distal power shaft 1130 continues to rotate in the second rotational direction, the interaction between the closure threaded section 1136 and the closure nut 1412 causes the closure tube 1410 to move proximally such that the closure tabs 1414 move out of camming contact with the proximal anvil portion 1570, thereby permitting the bearing springs 1584 to force the anvil assembly 1560 to an open position (fig. 33). Tissue contained between the anvil assembly 1560 and the elongate channel 1520 may also be used to force the anvil assembly 1560 to an open position, wherein the tissue may be removed from the open position.

Joint movement system

As noted above, the illustrated example includes an articulation system 1700 that facilitates articulation of the surgical end effector 1500 about an articulation axis AA that is transverse to the shaft axis SA. In the example shown, the surgical end effector 1500 is also selectively rotatable about a shaft axis SA distal of the articulation joint 1702, as shown by arrow 1703 in fig. 24. In the example shown, the articulation system 1700 is actuated by the second rotary drive system 320 in the handle assembly 20. As discussed above, the interchangeable surgical tool assembly 1000 includes an auxiliary rotary drive system 1220, the auxiliary rotary drive system 1220 configured to operably interface with the second rotary drive system 320 on the handle assembly. In the arrangement shown, the auxiliary rotary drive 1220 comprises a portion of the articulation system 1700. In the example shown, the articulation system 1700 includes an articulation drive shaft 1706 that is rotatably supported on a power shaft support tube 1124. As noted above, the proximal drive shaft 1120 rotatably extends through the power shaft support tube 1124. In the arrangement shown, the proximal drive shaft 1120 is coaxially aligned on the shaft axis SA. The power shaft support tube 1124 is configured to enable the articulation drive shaft 1706 to be not coaxially aligned on the shaft axis SA. In other words, the articulation drive shaft 1706 has an articulation drive shaft axis "ADA" that is offset from the axis SA when the articulation drive shaft 1706 is mounted on the power shaft support tube 1124. See fig. 30. This arrangement facilitates a relatively compact nested gear arrangement adjacent to articulation joint 1702, as seen in fig. 38-42. In the arrangement shown, for example, a proximal articulation driven gear 1708 is mounted to a proximal end of an articulation drive shaft 1706. See fig. 19. The proximal articulation driven gear 1708 is arranged to mesh with an auxiliary drive gear 1206, the auxiliary drive gear 1206 being mounted to a distal end of the auxiliary drive shaft 1204. Rotation of the auxiliary transfer shaft 1204 and the auxiliary drive gear 1206 will result in rotation of the proximal articulation driven gear 1708 and rotation of the articulation drive shaft 1706. A distal articulation drive gear 1710 is attached to the distal end of the articulation drive shaft 1706. Distal articulation drive gear 1710 is supported in meshing engagement with channel articulation gear 1538, and channel articulation gear 1538 is formed on channel mount fixture 1530.

More specifically and with reference to fig. 30 and 37, in the example shown, the channel-mounting fixture 1530 includes a disc-shaped body portion 1532, the disc-shaped body portion 1532 having a lower shaft attachment tab 1534 and an upper shaft attachment tab 1536 formed thereon. The articulation shaft 1704 extends through corresponding holes in the lower and upper shaft attachment tabs 1536 and 1534 to attach to the pivot tab 1404,1406 in the outer spine tube 1402. This arrangement serves to permit the channel mount fixture 1530 to rotate relative to the outer spine tube 1402 about the articulation axis AA. A channel articulation gear 1538 is formed on the lower shaft attachment tab 1534 and remains engaged with the distal articulation drive gear 1710. Referring now to fig. 27, in the example shown, the channel mounting portion 1522 of the elongate channel 1520 includes an upstanding proximal wall 1523, the upstanding proximal wall 1523 having a mounting hub 1525 projecting proximally therefrom. An axial bore 1527 extends through the mounting hub 1525 and an upstanding proximal wall 1523, the upstanding proximal wall 1523 being configured to permit the distal power shaft 1130 to extend therethrough. In the example shown, the channel mounting clamp 1530 is frictionally mounted to the mounting hub 1525 to complete the coupling of the end effector 1500 to the articulation joint 1702. See fig. 30.

The operation of the articulation joint 1702 is best illustrated in fig. 30, 38 and 39. Rotating the articulation drive shaft 1704 in the first rotational direction by the second rotary drive system 320 will cause the surgical end effector 1500 to rotate or articulate at an articulation angle 1711 (fig. 39) relative to the shaft axis SA. In at least one example, the articulation angle 1711 may be between 0 ° and 90 °, for example. Rotation of the articulation drive shaft 1704 in the opposite rotational direction will result in articulation of the surgical end effector 1500 in the opposite articulation direction. Once the surgical end effector 1500 has been articulated to the desired orientation, power to the second rotary drive system 320 (and ultimately to the auxiliary rotary drive system 1200) is discontinued. Friction between components of the auxiliary rotary drive system 1200 (i.e., gears) and components of the articulation system 1700 (i.e., gears) serves to maintain the surgical end effector 1500 in the articulated orientation. However, in an alternative arrangement, gears 306 and 326 may be locked in place. For example, when gear 252 engages these gears, the shifting mechanism that engages gear 252 with gear 306 may be unlocked. This may be achieved with a simple cam surface which disengages the locking means when the gear 252 is moved into engagement.

End effector rotation

The illustrated interchangeable surgical tool assembly 1000 is configured to employ the primary rotary drive system 1100 to selectively rotate the surgical end effector 1500 about the axis SA. Additionally, in the example shown, the third axial drive system 1300 is configured to selectively lock the surgical end effector 1500 in a desired rotational orientation. As seen in fig. 37 and 42, for example, the elongate shaft assembly 1400 includes an elongate shaft support tube 1420 that extends from the tool mounting portion 1010 to proximal of the articulation joint 1702. The elongate shaft support tube 1420 includes an "off-axis" channel 1422 for rotatably supporting the articulation drive shaft 1706 therethrough. The elongate shaft support tube 1420 further includes a distal end 1424, the distal end 1424 having a gear cavity 1426 and a gear shaft 1428 formed therein for receiving the locking gear assembly 1430 therein. See fig. 37. The locking gear assembly 1430 includes a drive gear 1432, the drive gear 1432 being received within a gear cavity 1426 in the elongate shaft support tube 1420. In addition, the locking gear assembly 1430 has a smaller driven gear 1434 attached thereto. As briefly discussed above, the third axial drive system 1300 includes a third actuation shaft 1302, also referred to herein as a locking lever 1302. The locking lever 1302 has shaft attachment ears 1306 formed on its proximal end 1304. When the interchangeable surgical tool assembly 1000 is coupled to the handle assembly 20, the shaft attachment lug 1306 is received in the shaft attachment socket 414 on the distal end 412 of the third drive actuator member 410. Thus, actuation of the third axial drive 400 will result in axial movement of the locking lever 1302. In the arrangement shown, the axially movable locking lever 1302 has a gear rack 1308 formed in a distal end thereof, the gear rack 1308 being configured to engage with a driven gear 1434. Axial movement of the lock control rod 1302 will cause the lock gear assembly 1430 to rotate about the gear shaft 1428 in a first rotational direction, and axial movement of the lock control rod 1302 in a proximal direction will cause the lock gear assembly 1430 to rotate in a second rotational direction.

In the example shown, the tertiary drive system 1300 is configured to operably interface with the end effector rotation lock system 1310. In at least one embodiment, end effector rotational lock system 1310 includes a rotational lock disk 1320, rotational lock disk 1320 including a disk-shaped body 1322 having a hollow mounting stem 1324 protruding therefrom. As can be seen in fig. 30, the mounting stem 1324 extends through an axial hole 1527 in the mounting hub 1525. The distal end of the mounting stem 1324 includes an annular recess 1326, the annular recess 1326 configured to receive an inwardly extending fastener flange 1598, the fastener flange 1598 formed on a bearing housing 1592 of the anvil spring assembly 1590. The proximally facing surface of the disc-shaped body 1322 of the rotational locking disc 1320 has a plurality of locking detents 1328 radially disposed thereon. The locking detent 1328 is arranged to be frictionally engaged by a locking member that, in at least one form, includes a locking lug 1332, the locking lug 1332 being formed on a locking gear 1330 journaled on the articulation shaft 1704. See fig. 43 and 44. As can be seen in these figures, the locking gear 1330 is supported in meshing engagement with the drive gear 1432 of the locking gear assembly 1430. Actuation of the tertiary actuation shaft 1302 by the tertiary drive system 1300 will result in rotation of the locking gear assembly 1430. Actuation of the lock gear assembly 1430 will cause rotation of the lock gear 1330 about the articulation axis 1704. When the lock ears 1332 on the lock gear 1330 are engaged with the lock detents 1328, the rotating lock plate 1320 and thus the end effector 1500 are prevented from rotating about the axis SA. For example, the locking ears 1332 frictionally engage corresponding locking detents 1328 and serve to force the rotating locking disk 1320 into further frictional engagement with the body portion 1532 of the channel mount fixture 1530. This frictional engagement between the two components serves to prevent the locking disk 1320 and the elongate channel 1520 from rotating about the axis SA. Fig. 43 shows the locking lug 1332 in locking engagement with one of the locking detents 1328, and fig. 44 shows the locking lug 1332 in an unlocked orientation whereby the locking disk 1320 is free to rotate about the axis SA of the shaft.

In the illustrated embodiment of the interchangeable surgical tool assembly 1000, rotation of the end effector 1500 about the axis SA is controlled by a remote rotary dial 1340, the remote rotary dial 1340 being rotatably supported on the nozzle frame 1020. The remote rotary dial 1340 operably interfaces with a varistor mounting assembly 1350 mounted within the nozzle frame 1020. As seen in fig. 23, for example, the remote rotary dial 1340 includes a plurality of sectors 1341 around its perimeter and accessible on both sides of the nozzle frame 1020. Such an arrangement may enable a user to engage and rotate the remote rotary dial 1340 with the fingers of the same hand that holds the handle assembly 20, or the remote rotary dial may also be engaged with the user's other hand. Referring to fig. 18, 20 and 21, the varistor mounting assembly 1350 includes a hollow mounting hub 1352, the hollow mounting hub 1352 having an annular groove 1354 for receiving a corresponding mounting bulkhead 1028 formed in the nozzle frame 1020. In at least one arrangement, the mounting hub 1352 includes an annular retaining detent 1356, the annular retaining detent 1356 configured to retain the remote rotary dial 1340 on the hollow mounting hub 1352 while permitting rotation of the remote rotary dial 1340 relative thereto. The varistor mounting assembly 1350 includes a radially extending flange portion 1358 that supports a collection of stationary contacts 1360 thereon. See fig. 18. The flange portion 1358 is received within a varistor cavity 1342 in the remote rotary dial 1340. The rotating contact assembly 1344 is mounted within the varistor cavity 1342 and is configured to interface with the stationary contact 1360 as the remote rotary dial 1340 rotates on the varistor mounting assembly 1350. The varistor mounting assembly is wired to or otherwise in communication with the tool circuit board 1060.

In at least one arrangement, rotation of the surgical end effector 1500 about the axis SA is initiated by rotating the distal rotation dial 1340. In at least one arrangement, the control system or CPU224 is configured to rotate the surgical end effector 1500 in the same rotational direction that the remote rotary dial 1340 is rotated. Initial rotation of the remote rotary dial 1340 would cause the control system or CPU224 in the handle assembly 20 to activate the third axial drive system 400 in the handle assembly 20. Specifically, the control system or CPU224 actuates the solenoid 402, which results in axial movement of the third actuator member 410. Axial movement of the third actuator member 410 results in axial movement of a tertiary actuation shaft or locking control rod 1302 operably coupled thereto. Axial movement of the lock control lever 1302 causes rotation of the lock gear assembly 1430. Rotation of the lock gear assembly 1430 will rotate the lock gear 1330 to the unlocked position (fig. 44). The control system or CPU224 will then activate the first rotary drive system 300. The reader will appreciate that the rotary lock disk 1320 is now able to rotate about the axis SA because the lock ears 1332 have rotated out of engagement with the corresponding lock detents 1328 on the rotary lock disk 1320. However, friction between the rotating lock plate 1320 and the mounting hub 1525 on the channel mounting portion 1522 can temporarily prevent the surgical end effector 1500 from rotating.

Actuation of the first rotary drive system 300 will cause a rotary drive motion to be applied to the first drive socket 302 because the shifter solenoid 260 has not been actuated and the shifter spring 166 has biased the shifter gear 250 into engagement with the first driven gear 306 on the first drive socket 302. See fig. 6 and 7. Rotation of the first drive socket 302 will result in rotation of the primary transfer shaft 1104, the primary transfer shaft 1104 being operably engageable with the first drive socket 302. Rotation of the main transfer shaft 1104 will result in rotation of a proximal drive gear 1110 attached to the main transfer shaft 1104. Since the proximal drive gear 1110 meshes with the power driven gear 1122 attached to the proximal drive shaft 1120, the proximal drive shaft 1120 also rotates. See fig. 19.

Referring now to fig. 30, rotation of the proximal drive shaft 1120 will ultimately result in rotation of a distal driven gear 1132, which distal driven gear 1132 is attached to a distal power shaft 1130. Rotation of distal driven gear 1132 will result in rotation of distal power shaft 1130. The combined friction between the distal power shaft 1130 and the rotary locking disk 1320, and the friction between the bearing housing 1592 and the distal power shaft 1130 and the rotary locking disk 1320, and the friction between the closure nut 1412 of the closure tube 1410 and the closure threaded segment 1136 on the distal power shaft 1130 ("second amount of friction") is greater than the combined friction between the mounting hub portion 1525 of the elongate channel 1520 and the channel mounting fixture 1530, and the friction between the rotary locking disk 1320 and the channel mounting fixture 1530 ("first amount of friction") in order to permit the elongate channel 1520 and the closure tube 1410 and the distal power shaft 1130 to rotate about the shaft axis SA relative to the channel mounting fixture 1530. In one arrangement, for example, the rotational position of the remote rotary dial 1340 would be determined by the control system or CPU224 to the distal power shaft 1130 and ultimately the rotational position of the surgical end effector 1500. Once the user has positioned the surgical end effector 1500 in the desired rotational position about the shaft axis SA and has terminated rotation of the remote rotary dial 1340, the control system or CPU224 will terminate power to the first rotary drive system 300 and to the third axial drive system 400. In at least one embodiment, solenoid 402 is "spring loaded" such that when deactivated, its spring component will bias third drive actuator member 410 distally, which will cause locking lever 1302 to move proximally. Such axial movement of the lock lever 1302 will cause rotation of the lock gear 1330, thereby maintaining the lock ears 1332 in engagement with corresponding lock detents 1328 on the rotating lock disk 1320, thereby locking the surgical end effector 1500 into a rotational orientation. Thus, if the handle assembly 20, and more specifically the third drive system 400, loses power, the solenoid spring will urge the end effector rotation locking system 1310 to move to the locked orientation, thereby preventing the surgical end effector 1500 from rotating relative to the elongate shaft assembly 1400. As can be appreciated from the foregoing discussion, when the interchangeable surgical tool assembly 1000 is operably coupled to the handle assembly 20, the third axial drive system 400 is used to unlock the end effector lock system 1310 and the first rotary drive system 300 is used to rotate the surgical end effector 1500 relative to the elongate shaft assembly 1400. The reader will appreciate that this rotation of the surgical end effector 1500 is entirely distal of the articulation joint 1702. Thus, the outer spine tube 1402 as well as the articulation joint 1702 remain stationary during the rotation process.

One general method of operating and controlling the surgical instrument 10 will now be described. Fig. 1 shows the surgical instrument 10 after the interchangeable surgical tool assembly 1000 has been operably attached to the handle assembly 20. As noted above, coupling the tool attachment module portion 1010 of the interchangeable surgical tool assembly 1000 to the tool attachment portion 500 of the handle assembly 20 causes the tool circuit board 1060 to couple to or otherwise communicate with the handle circuit board 220, the handle circuit board 220 including the control system or CPU 224. Once connected or in communication with the control system or CPU224, the tool circuit board 1060 can provide the control system or CPU224 with specific software that is unique to that particular interchangeable surgical tool assembly. The clinician may also position the clamping portion 100 of the handle assembly 20 in a desired position relative to the main housing portion 30, which may be most appropriate for the type of interchangeable surgical tool assembly to be used.

As can be seen in fig. 3, the illustrated handle assembly 20 includes a right control button assembly 270R and a left control button assembly 270L that interface with the control system or CPU 224. In one exemplary arrangement, each control button assembly 270R,270L includes a first button 272, a second button 274, and a third button 276, each of which interfaces with the control system or CPU 224. It should be appreciated that, in at least one embodiment, the control buttons 272 on the right control button assembly 270a may perform the same control functions as the control buttons 272 on the left control button assembly 270 a. Similarly, the control buttons 274 on the right control button assembly 270R may perform the same control functions as the control buttons 274 on the left control button assembly 270L. Likewise, the control buttons 276 on the right control button assembly 270R may perform the same control functions as the control buttons 276 on the left control button assembly 270L. Such an arrangement enables the clinician to control the surgical instrument from both sides of the handle assembly 20. In at least one arrangement, the control buttons 272, 274, 276 comprise "hall effect" sensors or linear sensors, so that actuation of the buttons can indicate, for example, the intensity of the user request and the desired speed.

In one arrangement, the first control button 272 and the second control button 274 may be used to control the operation of the articulation system 1700. For example, the control buttons 272 may be used to initiate articulation of the surgical end effector 1500 to the right (arrow "R" in fig. 1) about an articulation axis AA. Upon actuation of the first control button 272, the control system or CPU224 activates the shifter solenoid 260 of the rotary drive selector system 240 to engage the shifter gear 250 with the second driven gear 326 on the second drive socket 322. Thereafter, the control system 224 or CPU actuates the motor 200 to apply rotational motion to the second rotary drive system 320 in the rotational direction necessary for the articulation system 1700 to articulate the surgical end effector to the right (arrow R). In one arrangement, the amount of depression or actuation force applied to the control button may be indicative of the speed at which the motor is rotating. Additionally, or in the alternative, the clinician may also depress the rocker switch 206 to affect the motor rotational speed. Once the surgical end effector 1500 has been articulated to the desired position, the user discontinues actuation of the first control button 270 (and rocker switch 206). Once the control button 270 is deactivated, the control system or CPU224 deactivates the shifter solenoid 260. The spring member of the shifter solenoid 260 moves the shifter gear 250 into engagement with the first driven gear 306 on the first drive socket 302. Thus, further actuation of the motor 200 will result in actuation of the first rotary drive device 300. Actuation of the second control button 274 will operate in the same manner, but will result in rotation of the motor 200 to cause the articulation system 1700 to articulate the surgical end effector 1500 to the left (arrow L in FIG. 1).

As discussed above, the surgical end effector 1500 may also rotate about the axis relative to the articulation joint 1702. To begin rotation of the surgical end effector 1500, the clinician rotates the remote rotary dial 1340 in the direction of rotation in which he or she intends to rotate the surgical end effector 1500. Rotation of the remote rotary dial 1340 causes the control system or CPU224 to actuate the third axial drive system 400. In particular, solenoid 402 is actuated to axially move third drive actuator member 410 and locking control rod 1302 in a proximal direction. As the locking lever 1302 moves proximally, the gear rack 1308 causes the locking gear assembly 1430 to rotate the locking gear 1330 so as to disengage the locking ears 1332 from the corresponding locking detents 1328 in the rotary locking disk 1320. See fig. 41 and 42. The control system or CPU maintains the solenoid 402 in this actuated orientation and then activates the motor 200 to impart rotational motion to the first rotary drive system 300 in the direction required to rotate the surgical end effector 1500 in the desired rotational direction. Actuation of the first rotary drive system 300 will cause rotation of the distal drive shaft 1130, which will cause rotation of the surgical end effector 1500 about the axis SA. Once the surgical end effector 1500 has been rotated to the desired position, the clinician discontinues rotation of the remote rotary dial 1340. Thereafter, the control system or CPU224 will deactivate the motor 200 and solenoid 402. The spring component of solenoid 402 then biases third drive actuator member 410 and locking lever 1302 in a distal position, causing locking gear 1330 to rotate in an opposite direction so as to cause locking lug 1332 to engage a corresponding locking detent 1328 in rotary locking disk 1320. The surgical end effector 1500 is locked in this rotational position.

In at least one arrangement, the third button 276 can comprise a "master state" button that communicates with the control system or CPU224 to return the surgical end effector 1500 to a master state, wherein the surgical end effector is unarticulated and also rotates back to the initial rotational orientation. For example, when the third button 276 is actuated, the CPU can unlock the end effector rotation locking system 1310 by actuating the solenoid 402 to cause the locking ears 1332 to disengage from the rotation locking disk 1320, and then actuate the first rotary drive system 300 to cause the surgical end effector to rotate back to the starting rotational position. Thereafter, the solenoid 402 is deactivated to cause the locking ears 1332 to re-engage the rotary locking disk to lock the surgical end effector 1500 in this rotational orientation. The control system or CPU224 may then actuate the shifter solenoid 260 to bring the shifter gear 250 into meshing engagement with the second driven gear 326 on the second drive socket 322. After the second rotary drive system 320 is ready to be actuated, the control system or CPU224 can then actuate the motor 200 to return the surgical end effector 1500 to the unarticulated position.

Once the surgical end effector 1500 has been rotated and/or articulated to the desired configuration, discontinuing actuation of the articulation system 1700 and discontinuing rotation of the remote rotary dial 1340 will cause the motor 200 to operably engage the first rotary drive system 300 in the manner discussed herein. The clinician may then manipulate the surgical end effector 1500 to position the target tissue between the anvil assembly 1560 and the surgical staple cartridge 1550. The clinician may begin the closing and firing process by actuating the rocker switch 206. Actuation of the rocker switch 206 will cause the control system or CPU224 to actuate the motor 200 to cause the motor to apply rotary control motion to the first rotary drive system 300 in a first rotational direction. Rotation of the first rotary drive system 300 will cause the distal power shaft 1130 to rotate and begin the closing process in the manner described above. Once the anvil assembly 1560 is fully closed, the control system or CPU224 may stop the motor 200 and provide an indication (audio, vibration, notification on a display screen, etc.) to the clinician that the anvil is fully closed. This may occur whether or not rocker switch 206 remains actuated. Then, when the clinician desires the firing member to cut the target tissue stapled during the closure procedure, the clinician may then re-actuate the rocker switch 206 to start the motor and cause the firing member to be driven distally through the end effector in the manner described above. The rocker switch 206 may be configured such that the speed at which the motor rotates is proportional to the distance the rocker switch is depressed or otherwise actuated. In other arrangements, the control system or CPU224 may not stop the motor between the closing and firing sequences. Various forms of sensors and/or encoders may be used to monitor the position of the firing member during the firing process. Once the firing member reaches the end position, the rotational direction of the motor is reversed by the control system or CPU224 until the firing member returns to the starting position, wherein the anvil assembly 1560 is biased to the open position in the manner described above.

Fig. 40A and 40B illustrate one example arrangement for supplying electrical signals from a circuit board 1060 in the tool attachment module portion 1010 to an end effector attached thereto, while enabling the end effector to be selectively articulated and rotated in the various manners described herein. As can be seen in these figures, conductors (wires) 1401A,1401B extend along the exterior of the outer spine 1402 of the elongate shaft assembly. Conductors 1401A,1401B extend from the tool attachment module 1010 along the spine tube 1402 and into holes 1531 in the channel mounting fixture 1530. To accommodate articulation of the end effector about the articulation joint 1702, a loop 1403 may be provided in the conductors 1401A,1401B to provide a sufficient amount of slack therein. Conductor 1401A extends into channel mounting fixture 1530 and has a proximally facing contact 1405A attached thereto. Similarly, conductor 1401B extends into channel mounting fixture 1530 and has a proximally facing contact 1405B attached thereto. These contacts 1405A,1405B correspond to electrically conductive traces 1325A,1325B, respectively, mounted on the distal surface 1323 of the disk-shaped body 1322 of the rotating locking disk 1320. When assembled together, contact 1405A is in rotational electrical contact with trace 1325A, and contact 1405B is in rotational electrical contact with trace 1325B. This arrangement permits relative rotation of the channel mount fixture 1530 and the rotating locking disk 1320 while facilitating electrical contact between the conductors 1401A,1401B and the tracks 1325A, 1325B. End effector wires 1327A,1327B are attached to traces 1325A,1325B, respectively, and extend through a hollow mounting stem 1324 of the rotating locking disk 1320. The end effector wires 1327A,1327B may then be attached to sensors, lights, etc. in the end effector. Such an arrangement serves to supply power to the end effector from the tool attachment module 1010 while facilitating articulation and rotation of the end effector.

Many of the surgical instrument systems described herein are actuated by an electric motor; however, the surgical instrument systems described herein may be actuated in any suitable manner. In various circumstances, for example, the surgical instrument systems described herein can be actuated by a manually operated trigger. In certain instances, the motors disclosed herein may comprise one or more portions of a robotic control system. Further, any of the end effectors and/or tool assemblies disclosed herein may be used with a robotic surgical instrument system. U.S. patent application serial No. 13/118,241 (now U.S. patent application publication 2012/0298719), entitled "SURGICAL INSTRUMENTS WITH robotic SURGICAL INSTRUMENTS," discloses several examples of robotic SURGICAL instrument systems in more detail.

The surgical instrument systems described herein have been described in connection with the deployment and deformation of staples; however, the embodiments described herein are not so limited. For example, various embodiments are contemplated in which fasteners other than staples, such as clamps or tacks, are deployed. Moreover, various embodiments are also contemplated that utilize any suitable means for sealing tissue. For example, an end effector according to various embodiments may include an electrode configured to heat and seal tissue. In addition, for example, an end effector according to certain embodiments may apply vibrational energy to seal tissue.

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

U.S. patent 5,403,312 entitled "ELECTROSURURGICAL HEMOSTATIC DEVICE" published on 4.4.1995;

U.S. patent 7,000,818 entitled "SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS" published on 21.2.2006;

U.S. Pat. No. 7,422,139 entitled "MOTOR-DRIVEN SURGICAL CUTTING AND FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK" published on 9.9.2008;

U.S. patent 7,464,849 entitled "ELECTRO-MECHANICAL SURGICAL INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS" published on 16.12.2008;

U.S. patent 7,670,334 entitled "SURGICAL INSTRUMENT HAVATING AN ARTICULATING END EFFECTOR" published on 3, 2/2010;

U.S. patent 7,753,245 entitled "SURGICAL STAPLING INSTRUMENTS" published on 13.7.2010;

U.S. patent 8,393,514 entitled "SELECTIVELY ORIENTABLE IMPLANTABLE FASTENER CARTRIDGE" published on 12.3.2013;

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

U.S. patent application Ser. No. 12/031,573 entitled "SURGICAL CUTTING AND FASTENING INSTRUMENTT HAVAGING RF ELECTRODES" filed on 14.2.2008;

U.S. patent application Ser. No. 12/031,873 (now U.S. Pat. No. 7,980,443), entitled "END EFFECTORS FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT", filed on 15.2.2008;

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

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

U.S. patent application Ser. No. 12/647,100 entitled "MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROL ASSEMBLY" filed 24.12.2009; now us patent 8,220,688;

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

U.S. patent application serial No. 13/036,647 entitled "SURGICAL STAPLING INSTRUMENT" filed on 28.2.2011, now U.S. patent No. 8,561,870;

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

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

U.S. patent application serial No. 13/800,025 entitled "STAPLE CARTRIDGE TISSUE thickingsenser SYSTEM" filed on 13/3/2013, now U.S. patent application publication 2014/0263551;

U.S. patent application serial No. 13/800,067 entitled "STAPLE CARTRIDGE TISSUE thickingsenser SYSTEM" filed on 13/3/2013, now U.S. patent application publication 2014/0263552;

U.S. patent application publication 2007/0175955 entitled "SURGICAL CUTTING AND FASTENING INSTRUMENTT WITH CLOSURE TRIGGER LOCKING MECHANISM" filed on 31.1.2006; and

U.S. patent application publication 2010/0264194 entitled "SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR" filed on 22.4.2010, now U.S. Pat. No. 8,308,040.

While various devices have been described herein in connection with certain embodiments, many modifications and variations to these embodiments may be implemented. In addition, where materials for certain components are disclosed, other materials may also be used. Further, according to various embodiments, a single component may be replaced with multiple components, and multiple components may also be replaced with a single component, to perform a given function or functions. The foregoing detailed description and the following claims are intended to cover all such modifications and variations.

The device disclosed herein may be designed to be disposed of after a single use, or it may be designed to be used multiple times. In either case, however, the device may be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular pieces of the device, and subsequent reassembly of the device. Specifically, the repair facility and/or surgical team may remove the device and, after cleaning and/or replacing certain components of the device, may reassemble the device for subsequent use. Those skilled in the art will appreciate that the finishing assembly may be disassembled, cleaned/replaced, and reassembled using a variety of techniques. The use of such techniques and the resulting prosthetic devices are within the scope of the present application.

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

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

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

Claims (7)

1. A surgical instrument, comprising:

a housing assembly;

a motor assembly operably supported in the housing assembly; at least one rotary drive system configured to be selectively, operably engaged and disengaged with the motor assembly;

an emergency system, the emergency system comprising:

an emergency drive mechanism supported by the housing assembly and configured to be selectively, operably engaged and disengaged with the at least one rotary drive system; and

an emergency handle assembly selectively movable between a storage position and an actuated position within the housing assembly such that the at least one rotary drive system remains operably engaged with the motor assembly when the emergency handle assembly is in the storage position and the emergency drive mechanism is operably engaged with the at least one rotary drive system when the emergency handle assembly is in the actuated position;

wherein the housing assembly further comprises an emergency access panel manipulable between a closed position in which the emergency handle assembly is fully enclosed within the housing assembly in the storage position and an open position in which the emergency handle assembly is actuatable;

wherein the at least one rotary drive system comprises:

a system drive shaft rotatably supported by the housing assembly; a driven bevel gear axially movable on the system drive shaft between a first position in which the driven bevel gear is engaged with the drive bevel gear of the motor assembly and a second position in which the driven bevel gear is disengaged from the drive bevel gear; and

a drive system biasing member for biasing the driven bevel gear to the second position, and wherein a portion of the emergency access panel is configured to bias the driven bevel gear to the first position when the emergency access panel is in the closed position.

2. The surgical instrument of claim 1, wherein the emergency access panel is removably attachable to the housing assembly.

3. The surgical instrument of claim 1, wherein the emergency access panel securely retains the at least one rotary drive system in operable engagement with the motor assembly and prevents the emergency drive mechanism from being in operable engagement with the motor assembly when the emergency access panel is in the closed position.

4. The surgical instrument of claim 1, wherein the emergency drive mechanism comprises:

an emergency drive shaft operably interfacing with the emergency handle assembly such that manual actuation of the emergency handle assembly imparts a rotational motion to the emergency drive shaft;

an emergency driven gear located on the system drive shaft;

an emergency drive gear axially movable on the emergency drive shaft between an unactuated position in which the emergency drive gear is not meshed with the emergency driven gear and an actuated position in which the emergency drive gear is meshed with the emergency driven gear; and

an emergency biasing member configured to bias the emergency drive gear into engagement with the emergency driven gear when the emergency access panel is in the open position.

5. The surgical instrument of claim 4, wherein the emergency access panel is configured to bias the emergency drive gear out of engagement with the emergency driven gear when the emergency access panel is in the open position.

6. The surgical instrument of claim 1, further comprising a bailout handle biasing member for biasing the bailout handle assembly to an actuated position when the bailout access panel is in the open position.

7. The surgical instrument of claim 6, wherein the bailout handle assembly is configured to apply a rotational motion to a bailout drive shaft upon application of a manually generated ratcheting motion to the bailout handle assembly.

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