Abstract: Methods for fabricating an anvil for a surgical stapling device. Various methods include forming an anvil body from a first material and a deformable anvil tip from a second material and attaching the deformable anvil tip to a distal end of the anvil body with a deformable second attachment member. Other methods include molding a deformable anvil tip to a distal end of an anvil body.

Abstract: A surgical instrument and method of controlling the surgical instrument are disclosed. The surgical instrument includes a housing and an elongated shaft that extends distally from the housing and defines a first longitudinal axis. The surgical instrument also includes a firing rod disposed in the elongated shaft and a drive mechanism disposed at least partially within the housing. The drive mechanism mechanically cooperates with the firing rod to move the firing rod. A sensor senses a parameter of light reflected from the surface of the firing rod, which includes markings that change the reflectivity of the firing rod. The measurement unit determines a parameter of the motion of the firing rod, such as the position and speed of the firing rod, based on the sensed parameter of the light reflected from the surface of the firing rod.

Abstract: A surgical instrument system can comprise, one, a surgical instrument including a handle, a shaft comprising a distal end, and a trigger and, two, an end effector attachable to the shaft. The instrument can further include a firing member and a motor configured to move the firing member toward the distal end, wherein the trigger is configured to operate the motor. The surgical instrument system can further include a plurality of sensors configured to detect one or more error conditions, a plurality of indicators, and a controller in communication with the plurality of sensors and the indicators, wherein the controller is configured to selectively activate the indicators to indicate the error conditions detected. A surgical instrument can comprise a plurality of actuators and a plurality of actuator locks, wherein the controller can actuate one or more of the actuator locks to indicate the error condition detected.

Abstract: A surgical instrument and method of controlling the surgical instrument are disclosed. The surgical instrument includes a housing and an elongated shaft that extends distally from the housing and defines a first longitudinal axis. The surgical instrument also includes a firing rod disposed in the elongated shaft and a drive mechanism disposed at least partially within the housing. The drive mechanism mechanically cooperates with the firing rod to move the firing rod. A motion sensor senses a change in the electric field (e.g., capacitance, impedance, or admittance) between the firing rod and the elongated shaft. The measurement unit determines a parameter of the motion of the firing rod, such as the position, speed, and direction of the firing rod, based on the sensed change in the electric field. A controller uses the measured parameter of the motion of the firing rod to control the drive mechanism.

Abstract: A handle assembly for use with a surgical instrument having an operative distal end portion is disclosed. The handle assembly includes a housing, a drive element, an actuator, a spring arm, and a biasing element. At least a partial actuation of the actuator distally translates the drive element from a proximal position where a portion of the drive element is in contact with the spring arm to a distal position where the drive element is not in contact with the spring arm.

Abstract: A safety handle assembly for use with a surgical instrument having an operative distal end portion is disclosed. The handle assembly includes a handle housing and a drive element movably mounted within the handle housing and connected to an associated operative distal end portion. A drive assembly is positioned within the handle housing and is engageable with the drive element to move the drive element within the handle housing. An actuator is movably mounted on the handle housing and an adjustable force-limiting mechanism is interposed between the drive assembly and the actuator. A force-limiting mechanism releasably connects the actuator to the drive assembly. The force-limiting mechanism is adjustable to preset the force at which the actuator separates or breaks away from the drive assembly.

Abstract: A surgical cutting and fastening instrument. The instrument comprises an end effector, a shaft connected to the end effector, and a handle connected to the shaft. The handle comprises an electric, DC motor connected to a drive train in the shaft for powering the drive train. The handle also comprises a power pack that comprises at least one charge-accumulating device connected to the DC motor for powering the DC motor.

Abstract: An OTC surgical device includes a handle having therein a compression controller and thereat an end effector, which has an electrically controlled tissue-compressor coupled to the controller and powered thereby to selectively control tissue compression. A mechanical binary-output electrical switch is disposed in-line with the compressor to place a compressing force directed upon the compressed tissue proportionally upon the switch. The switch has two switching states initiated and changed only by mechanical movement. The switch includes a biasing device retaining the switch in a first switching state until a force imparted thereupon overcomes the bias force to change to the second switching state. A switching-state-status output provides information identifying a current state and communicates with the compression controller to selectively control compression of tissue based upon the information. With appropriate feedback, the controller can keep the tissue at OTC while the surgical procedure is carried out.

Abstract: A surgical stapler including one or more visual indicators is provided. The surgical stapler includes a body and a stapling assembly positioned at a distal portion of the body. The stapling assembly includes a cartridge assembly and an anvil assembly. An alignment pin is mounted on the stapling assembly and configured to engage the anvil assembly. A visual indicator of engagement of the alignment pin with the anvil assembly, clamping and/or stapling can be provided.

Abstract: A motor-driven surgical instrument having a control assembly for controlling a switch of the instrument. The surgical instrument may comprise a motor control circuit, a drive member, and a slider. The drive member comprises a first shoulder at a first position and a second shoulder at a second position. A first portion of the slider interfaces the drive member such that the slider is moveable in a direction of movement of the drive member when either the first shoulder or the second shoulder of the drive member engages the first portion of the slider. A second portion of the slider actuates a switch of the motor control circuit when the drive member moves the slider to a first position relative to the first switch. In various embodiments, the switches of the control circuit are not embodied as a part of an IC.

Abstract: A surgical instrument. The surgical instrument has an end effector and a trigger in communication with the end effector. The surgical instrument also has a first sensor and an externally accessible memory device in communication with the first sensor. The first sensor has an output that represents a first condition of either the trigger or the end effector. The memory device is configured to record the output of the first sensor. In various embodiments, memory device may include an output port and/or a removable storage medium.

Abstract: A surgical stapling device is disclosed for performing circular anastomoses. The surgical stapling device includes a handle portion, an elongated body portion and a head portion including an anvil assembly and a shell assembly. The head portion includes an anvil assembly including a tiltable anvil which will tilt automatically after the device has been fired and unapproximated. The tiltable anvil provides a reduced anvil profile to reduce trauma during removal of the device after the anastomoses procedure has been performed. The stapling device includes an approximation mechanism including a rotatable knob, a screw having a helical channel and an anvil retainer. The helical channel includes a dwell portion for providing a tactile indication to a surgeon that the anvil retainer has been advanced to a position wherein the anvil assembly can be removed from the anvil retainer.

Abstract: A medical device includes a control handle, an end effector, and a passive articulating joint connecting the end effector to the handle. The handle has a stapling actuator, an articulation joint actuator different from the stapling actuator, and a body through which the stapling and articulation joint actuators traverse. The end effector has an anvil, a stapler cartridge with staples, and an anvil-cartridge control device connected thereto and to the stapling actuator and staples when the stapling actuator is actuated. The stapling actuator passes through the articulating joint and flexes correspondingly to articulation of the articulating joint. The articulation joint actuator, when unactuated, holds the articulation joint and, thereby, the end effector, in a substantially fixed articulation position, and, when actuated, releases the articulation joint into its freely articulating state to permit free articulation of the end effector dependent upon external forces acting upon the end effector.

Abstract: A surgical stapling apparatus comprises a handle assembly, an actuation shaft having a connector, and a retraction mechanism positioned within the handle assembly. The retraction mechanism includes a motor coupled to a transmission shaft, a first gear rotatably mounted on the transmission shaft, the first gear configured to engage a second gear, a clutch operatively attached to the second gear, a main shaft rotatably connected to the clutch, and a pulley coupled to the main shaft, the pulley being operatively attached to the connector. The connector and the pulley may be attached via a cable. The retraction mechanism may include a spring motor for maintaining the cable in tension. The spring motor may have a spring element wrapped around and interconnecting at least two arbors.

Abstract: The present disclosure relates to surgical fastener applying apparatus for sequentially applying a plurality of surgical fasteners to body tissue. The surgical fastener applying apparatus includes a replaceable cartridge assembly receivable in a distal end portion of a cartridge receiving half-section, the cartridge assembly including a safety lockout pivotably disposed along the upper surface of the cartridge assembly and movable from an unlocked orientation permitting assembly of an anvil half-section to the cartridge receiving half-section, to a locked orientation preventing assembly of the anvil half-section to the cartridge receiving-half section.

Abstract: Circular stapling instruments for cutting and applying one or more surgical staples to tissue are disclosed. The instruments include various forms of anvil locking systems designed to selectively prevent the anvil from moving axially relative to the stapling head of the stapling instrument. One embodiment employs an elongated gear rack that is selectively engagable with locking gears to prevent axial motion of the elongated gear rack and an adjustment shaft used to axially position the anvil. Other embodiments employ a gear assembly that cooperates with the elongated gear rack. A locking member is movably supported by a handle assembly that houses the gear assembly and elongated gear rack. The locking member is configured for selective meshing engagement with the gear assembly to ultimately prevent axial movement of the gear rack and adjustment shaft.

Abstract: A retraction mechanism allows the full distal retraction of the firing drive from various positions. The retraction mechanism has been developed for use with a hand held surgical apparatus. An embodiment of the retraction mechanism includes a drive member, a first pulley, a second pulley, and a firing drive. The drive mechanism is configured to be driven by a motor. The first pulley is configured to rotate when the motor drives the drive mechanism. The second pulley is movable relative to the first pulley between a proximal position and a distal position. The firing drive is movable relative to the first pulley between proximal and distal positions. In operation, the first pulley rotates in a first direction in response to a distal translation of the firing drive and wherein the firing drive moves proximally upon rotation of the first pulley in a second direction.

Abstract: An assembly including a component of a surgical instrument, such as an endoscopic or laparoscopic instrument. The assembly may comprise a package; a surgical instrument component within the package; and a power source within the package. The power source may be configured to be placed in electrical communication with the surgical instrument component. The assembly may also comprise an auxiliary power source within the package and a circuit element, where the circuit element is in electrical communication with the power source and the auxiliary power source.

Abstract: The present disclosure provides for a surgical instrument which includes a housing and an endoscopic portion extending distally from the housing and defining a first longitudinal axis. The surgical instrument also includes an end effector disposed adjacent a distal portion of the endoscopic portion. The end effector includes an anvil assembly and a cartridge assembly. The anvil assembly is pivotally coupled to the cartridge assembly to be movable from a first actuation position to at least one other second actuation position. The surgical instrument further includes a firing rod having a shaft defining a second longitudinal axis, the shaft having a cam member which is in mechanical cooperation with the anvil assembly and is configured to move the anvil assembly from the first actuation position to the at least one other second actuation position upon rotation of the firing rod about the second longitudinal axis.

Abstract: An articulating surgical stapler having a proximal end and a distal end includes a handle at the proximal end and an end effector at the distal end for selective articulation to improve access to tissue requiring treatment and ease of use of the present linear surgical stapler. A support shaft connects the handle to the end effector. An articulation mechanism is positioned between the support shaft and the end effector permitting selective movement of the end effector relative to the support shaft.

Abstract: The present disclosure provides for a loading unit for use with and/or supportable on a distal end of a surgical stapling apparatus. The loading unit includes a housing portion including a distal end and a proximal end, a drive assembly slidably supported within the housing portion of the loading unit, and a locking mechanism pivotally supported on the housing portion of the loading unit, the locking mechanism having a first position wherein the locking mechanism engages a portion of the drive assembly and maintains the position, preferably the axial position, of the drive assembly relative to the housing portion of the loading unit, and the locking mechanism having a second position wherein the locking mechanism disengages the drive assembly and enables the drive assembly to move relative to the housing portion.

Abstract: A surgical cutting and stapling instrument is disclosed. The instrument includes an end effector and a handle. The end effector includes a channel, an anvil pivotally attached to the channel, a moveable cutting instrument for cutting an object positioned between the anvil and the channel, and a staple cartridge configured for removable receipt by the channel. The staple cartridge includes a sled that is engaged by the cutting instrument during a cutting stoke. The handle includes a motor for actuating the cutting instrument via a main drive shaft assembly. The instrument further includes a first interlock circuit for enabling initiation of motor operation based upon a position of the staple cartridge.

Abstract: A surgical instrument includes an E-beam firing bar engages the channel and selectively engages the anvil during distal firing movements, wherein the tissue is severed and stapled driven upward from the staple cartridge to form against the anvil. In particular, a wedge integral to the staple cartridge is driven distally by a middle pin of the firing bar to effect stapling. A single lockout of the staple channel responds to the presence of the wedge sled in its unfired position to allow the firing bar to fire. Otherwise, the single lockout prevents firing when the staple cartridge is missing or spent. Further, some versions include an Electroactive Polymer (EAP) actuator that presents an abutting surface, or acts as a trapdoor to a ramped recess in a staple channel to block the firing bar, as an active approach to preventing firing for one or more conditions.

Abstract: A surgical stapling device including a self-righting anvil assembly includes an anvil center rod and a pivotable anvil head. The surgical stapling device includes an anvil retainer assembly having a locking member. A cam member is provided to retain the locking member in a locked position and, thus, the anvil head in the operative position until after firing. In another embodiment, a tiltable anvil assembly includes a center rod and a head assembly pivotally secured to the center rod. The head assembly includes a housing, a post, an anvil plate and a backup member. The backup member is movably positioned from a first to a second position. A retainer member is positioned between the backup member and the housing. In another embodiment, a passive lockout mechanism is operably associated with a trigger lock on the handle assembly of the surgical stapling device.

Abstract: A septal stapling apparatus includes an instrument body having proximal and distal end portions. A handle at the distal end portion enables a user to hold and manipulate the instrument body. A pair of spaced apart arms are extending from the handle and include a staple arm and a tensioning arm. The body provides a trigger that moves between resting and firing positions. An actuator link moves between first and second positions, the actuator link being moved by the trigger, wherein the actuator link includes a staple moving member that is attached to the staple arm. The staple arm has a staple bank that includes multiple staples. The trigger, actuator link, staple bank, and staple moving member are configured to move a staple to a stapling position when the trigger is pulled. The staple arm and tensioning arm move together when the trigger is pulled.

Abstract: A surgical stapling and severing instrument particularly suited to endoscopic procedures incorporates a handle that produces separate closing and firing motions to actuate an end effector. In particular, the handle produces multiple firing strokes in order to reduce the required amount of force required to fire (i.e., staple and sever) the end effector. A linked transmission reduces the required handle longitudinal length, yet achieves a rigid, strong configuration when straightened for firing. A traction biased firing mechanism avoids binding in driving this straightened linked rack in cooperation with an anti-backup mechanism, with a lockout mechanism that prevents releasing the closure trigger during firing. Furthermore, an external indicator gives feedback to the surgeon as to how far firing has progressed, as well as providing a manual retraction capability.

Abstract: The present disclosure provides for a loading unit for use with and/or supportable on a distal end of a surgical stapling apparatus. The loading unit includes a housing portion including a distal end and a proximal end, a drive assembly slidably supported within the housing portion of the loading unit, and a locking mechanism pivotally supported on the housing portion of the loading unit, the locking mechanism having a first position wherein the locking mechanism engages a portion of the drive assembly and maintains the position, preferably the axial position, of the drive assembly relative to the housing portion of the loading unit, and the locking mechanism having a second position wherein the locking mechanism disengages the drive assembly and enables the drive assembly to move relative to the housing portion.

Abstract: A surgical instrument is adapted for stapling tissue in a highly controlled manner. The surgical instrument includes a frame having a proximal end and a distal end, with a handle positioned at the proximal end and an end effector positioned at the distal end. The end effector is shaped and dimensioned for selectively receiving a cartridge module containing a plurality of surgical fasteners. A firing mechanism is associated with the end effector and the cartridge module for selective actuation of the surgical fasteners. The cartridge module includes a cartridge housing in which the surgical fasteners are housed and an anvil shaped and dimensioned for engagement with the surgical fasteners to facilitate stapling. The cartridge housing and anvil are relatively movable between a first spaced apart position and a second position in close approximation with one another.

Abstract: A surgical instrument is adapted for applying a plurality of surgical fasteners to body tissue. The surgical instrument includes an anvil and a cartridge housing containing a plurality of surgical fasteners. The cartridge housing and anvil are relatively movable between a first spaced apart position and a second closed position. A firing mechanism is associated with the cartridge housing for ejecting the surgical fasteners from the cartridge housing to be driven against the anvil. A lockout mechanism interacts with the cartridge housing for activation and deactivation; the lockout mechanism preventing movement of the cartridge housing to its second closed position but permitting relative reapproximation movement of the cartridge housing and anvil, whereby reapproximation provides an indicator that the instrument is not malfunctioning.

Abstract: The present disclosure provides for a loading unit for use with a surgical stapling apparatus. The loading unit includes a housing portion having a distal end and a proximal end, a drive assembly slidably supported within the housing portion of the loading unit, and a locking member supported on the housing portion of the loading unit. The locking member is movable from a first position wherein the locking member engages the drive assembly and maintains the drive assembly in a ready-to-load position to a second position wherein the locking member permits movement of the drive assembly relative to the housing portion.

Abstract: A surgical stapling and severing instrument particularly suited to endoscopic procedures incorporates a handle that produces separate closing and firing motions to actuate an end effector. The handle produces multiple firing strokes to reduce the required amount of force required to fire (i.e., staple and sever) the end effector. A linked transmission reduces the required handle longitudinal length, yet achieves a rigid, strong configuration when straightened for firing. One or more electrically activated lockout mechanisms, such as electroactive polymer (EAP) actuators, are biased to prevent firing unless activated. One lockout is a spring-biased side pawl firing mechanism enabled by an EAP block actuator. Another is a firing trigger EAP lock. Yet another is a closure yoke EAP lock. Yet a further one is a manual retraction EAP lock that locks the firing mechanism. Thereby, various sensed or commanded inputs may be incorporated to prevent inadvertent firing.

Abstract: A surgical instrument includes an E-beam firing bar engages the channel and selectively engages the anvil during distal firing movements, wherein the tissue is severed and stapled driven upward from the staple cartridge to form against the anvil. In particular, a wedge integral to the staple cartridge is driven distally by a middle pin of the firing bar to effect stapling. A single lockout of the staple channel responds to the presence of the wedge sled in its unfired position to allow the firing bar to fire. Otherwise, the single lockout prevents firing when the staple cartridge is missing or spent. Further, some versions include an Electroactive Polymer (EAP) actuator that presents an abutting surface, or acts as a trapdoor to a ramped recess in a staple channel to block the firing bar, as an active approach to preventing firing for one or more conditions.

Abstract: The present disclosure provides for a loading unit for use with and/or supportable on a distal end of a surgical stapling apparatus. The loading unit includes a housing portion including a distal end and a proximal end, a drive assembly slidably supported within the housing portion of the loading unit, and a locking mechanism supported on the housing portion of the loading unit. The locking mechanism has a first position wherein the locking mechanism engages the drive assembly and maintains the position of the drive assembly in a ready-to-load position relative to the housing portion of the loading unit. The locking mechanism is pivotable to a second position wherein the locking mechanism disengages the drive assembly and enables the drive assembly to move relative to the housing portion.

Abstract: A surgical stapling and severing instrument particularly suited to endoscopic procedures incorporates a handle that produces separate closing and firing motions to actuate an end effector. In particular, the handle produces multiple firing strokes in order to reduce the required amount of force required to fire (i.e., staple and sever) the end effector. A linked transmission reduces the required handle longitudinal length, yet achieves a rigid, strong configuration when straightened for firing. A traction biased firing mechanism avoids binding in driving this straightened linked rack in cooperation with an anti-backup mechanism, with a lockout mechanism that prevents releasing the closure trigger during firing. Furthermore, an external indicator gives feedback to the surgeon as to how far firing has progressed, as well as providing a manual retraction capability.

Abstract: An improved surgical stapler including a digital counter to facilitate easy accounting of the number of staples consumed during a procedure. The surgical stapler also includes audible feedback including a first audible sound to indicate when an individual staple has been formed and a second audible sound to indicate that the stapler is ready to begin another staple forming process. The surgical stapler is of simple construction that lends itself to low cost production and mass assembly techniques thereby enabling it to be a disposable device.