United States Patent (19
`Knodel et al.
`
`SURGICAL STAPLER INSTRUMENT
`
`Inventors: Bryan D. Knodel, Cincinnati; Richard
`P. Nuchols; Warren P. Williamson,
`IV, both of Loveland, all of Ohio
`Assignee: Ethicon Endo-Surgery, Inc.,
`Cincinnati, Ohio
`
`Appl. No.: 191412
`Filed:
`Feb. 3, 1994
`Int. Cl. .................................. A61B 17/068
`U.S. Cl. ............................ 227/176; 227/180; 227/19
`Field of Search .............................. 227/19,902, 175,
`227/176, 178, 180
`
`54)
`
`(75)
`
`73)
`
`21
`22)
`51)
`52)
`58)
`
`56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
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`5/1986
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`5/1991
`8/1991
`10/1992
`10/1992
`12/1992
`1/1993
`
`Green .
`Green .
`Green et al. .
`Bilotti.
`Fedotov et al. .
`Rothfuss et al. .
`Kula et al. .
`Chow et al. .
`Chow et al. .
`Green ...................................... 227/178
`Green.
`Presty et al..
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`Green et al. .
`Madden et al. .
`Crainich.
`
`4,530,453
`4,568,009
`4,573,622
`4,589,582
`4,596,351
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`4,978,049
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`5,040,715
`5,156,315
`5,156,614
`5,170,925
`5,180,092
`
`
`
`IIIHIIII
`US005465895A
`5,465.895
`Patent Number:
`Nov. 14, 1995
`Date of Patent:
`
`11
`45)
`
`5,263,629
`11/1993 Trumbullet al. .
`5,275,323
`1/1994 Schulze et al. .
`5,307,976
`5/1994 Olson et al. .
`7/1994 Green et al. .............................. 227/19
`5,318,221
`5,350,400 9/1994 Esposito et al. ........................ 227/902
`FOREIGN PATENT DOCUMENTS
`728848 4f1980 U.S.S.R.
`Primary Examiner-Scott A. Smith
`57
`ABSTRACT
`A surgical stapler instrument is provided for applying lateral
`lines of staples to tissue while cutting the tissue between
`those staple lines. The instrument includes a handle portion,
`an implement portion, a reciprocating section, a drive mem
`ber and a movable actuator. The implement portion includes
`a staple cartridge and an anvil. The reciprocating section is
`adapted to move back and forth along an axis of the
`implement portion. The movable actuator is associated with
`the handle portion and is engaged with the drive member
`such that motion of the actuator causes the drive member to
`move back and forth between first and second drive posi
`tions separated by a first distance. A multiplier is further
`provided and is associated with the reciprocating section and
`the drive member for causing the reciprocating section to
`move back and forth between first and second reciprocating
`positions in response to movement of the drive member. The
`reciprocating section includes a work portion which, when
`moved distally, effects the firing of staples in the staple
`cartridge toward the anvil. The workportion is also provided
`with a reciprocating knife. The first and second reciprocating
`positions are separated by a second distance which differs
`from the first distance.
`
`15 Claims, 16 Drawing Sheets
`
`Ethicon Exhibit 2010.001
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 1 of 16
`
`5,465,895
`
`
`
`Ethicon Exhibit 2010.002
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 2 of 16
`
`5,465,895
`
`
`
`Ethicon Exhibit 2010.003
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 3 of 16
`
`5,465,895
`
`
`
`
`
`
`
`SS
`M 32S -V7
`
`s
`
`Ethicon Exhibit 2010.004
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 4 of 16
`
`5,465,895
`
`
`
`S
`
`S
`
`S
`
`Ethicon Exhibit 2010.005
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`
`
`Nov. 14, 1995
`
`Sheet 5 of 16
`
`5,465,895
`
`99/-/
`
`Ethicon Exhibit 2010.006
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`
`
`Nov. 14, 1995
`
`Sheet 6 of 16
`
`5,465,895
`
`
`
`q2II 29, D19||
`
`
`
`
`
`Ethicon Exhibit 2010.007
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 7 of 16
`
`5,465,895
`
`
`
`
`
`W799/-/
`
`8799/-/
`
`Ethicon Exhibit 2010.008
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 8 of 16
`
`
`
`5,465,895
`
`Ethicon Exhibit 2010.009
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 9 of 16
`
`5,465,895
`
`
`
`R***<<<<<=<
`
`5:7 z zrae)
`
`
`
`
`
`O/ 9/-/
`
`<!~~~~~No. SJ
`
`Ethicon Exhibit 2010.010
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 10 of 16
`
`5,465,895
`
`
`
`
`
`
`
`
`
`
`
`D061 og jozi 191· O2/
`
`// $)/-/
`
`Ethicon Exhibit 2010.011
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 11 of 16
`
`5,465,895
`
`F/G 11A
`
`F/G1 IB
`
`Ethicon Exhibit 2010.012
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 12 of 16
`
`5,465,895
`
`
`
`s
`
`|
`
`Ethicon Exhibit 2010.013
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 13 of 16
`
`5,465,895
`
`
`
`Ethicon Exhibit 2010.014
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 14 of 16
`
`5,465,895
`
`F/G15A
`
`I65
`
`I62b
`
`I62C
`
`1
`
`162d
`
`F/G15E9
`
`
`
`22
`
`I65b.
`
`I62b'
`
`Ethicon Exhibit 2010.015
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 15 of 16
`
`5,465,895
`
`
`
`Ethicon Exhibit 2010.016
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`U.S. Patent
`
`Nov. 14, 1995
`
`Sheet 16 of 16
`
`5,465,895
`
`
`
`.
`
`V2/93
`
`
`
`87// 5)/-/
`
`Ethicon Exhibit 2010.017
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`1.
`SURGICAL STAPLER INSTRUMENT
`
`5,465,895
`
`2
`SUMMARY OF THE INVENTION
`In accordance with the present invention, an improved
`surgical stapler instrument is provided. The improved instru
`ment includes a plurality of wedges and a pusher block
`which are integrally formed as a single wedge work member.
`The wedge work member is formed from a liquid crystal
`polymer, which material results in a reduced coefficient of
`friction between the wedges and the drivers during staple
`firing over that found in the prior art. An improved cam
`surface profile on the wedges is also provided. The instru
`ment also includes a multiplier to vary the motion generated
`by the firing trigger to impart either increased or decreased
`motion to the wedges. The multiplier of the present inven
`tion is easily modifiable for use in stapler instruments having
`different staple line lengths and/or staple firing force require
`ments so as to permit, for a given instrument, the length of
`the stroke of the firing trigger and the force required to move
`it to be set at ergonomically preferred values. An improved
`method for forming a staple instrument anvil is also pro
`vided.
`In accordance with a first aspect of the present invention,
`a surgical instrument is provided and comprises: a handle
`portion; an implement portion including first and second
`implements capable of performing a function during a
`surgical procedure; a reciprocating section adapted to move
`back and forth along an axis of the implement portion; a
`drive member; a movable actuator associated with the
`handle portion and engaged with the drive member such that
`motion of the actuator causes the drive member to move
`back and forth between first and second drive positions
`separated by a first distance; and, a multiplier associated
`with the reciprocating section and the drive member for
`causing the reciprocating section to move back and forth
`between first and second reciprocating positions in response
`to movement of the drive member. The reciprocating section
`includes a work portion which, when moved distally, is
`capable of causing the first and second implements to
`perform the function. The first and second reciprocating
`positions are separated by a second distance which differs
`from the first distance.
`The multiplier may comprise first and second integral
`pinion gears. The first pinion gear is engaged with the
`reciprocating section and the second pinion gear is engaged
`with the drive member. The first pinion gear has a first
`diameter and the second pinion gear has a second diameter
`which is smaller than the first diameter. Alternatively, the
`first diameter of the first pinion may be smaller than the
`second diameter of the second pinion.
`The implement portion comprises: a staple cartridge hav
`ing a plurality of staples and at least one slot for receiving
`a distal end of the work portion; an elongated channel
`extending from the handle portion and having a distal end
`which is adapted to receive the staple cartridge; an anvil
`mounted on the elongated channel for pivotable movement
`toward and away from the cartridge; and means for effecting
`pivotable movement of the anvil. The staple cartridge
`defines the first implement. The anvil defines the second
`implement. The work portion causes the staples to fire
`toward the anvil upon movement of the distal end of the
`work portion into the cartridge.
`The means for effecting pivotable movement of the anvil
`comprises: a closure tube having distal and proximal ends;
`a closure trigger having a handle section and a gear segment
`section; and, a closure yoke having distal and proximal ends.
`The distal end of the closure tube is adapted to engage the
`anvil for effecting pivotable movement of the anvil. The
`
`O
`
`15
`
`20
`
`25
`
`BACKGROUND OF THE INVENTION
`The present invention relates in general to surgical stapler
`instruments which are capable of applying lines of staples to
`tissue while cutting the tissue between those staple lines and,
`more particularly, to improvements relating to stapler instru
`ments and improvements in processes for forming various
`components of such stapler instruments.
`Surgical staplers have been used in the prior art to
`simultaneously make a longitudinal incision in tissue and
`apply lines of staples on opposing sides of the incision. Such
`instruments commonly include a pair of cooperating jaw
`members which, if the instrument is intended for endoscopic
`or laparoscopic applications, are capable of passing through
`a cannula passageway. One of the jaw members receives a
`staple cartridge having at least two laterally spaced rows of
`staples. The other jaw member defines an anvil having
`staple-forming pockets aligned with the rows of staples in
`the cartridge. The instrument includes a plurality of recip
`rocating wedges which, when driven distally, pass through
`openings in the staple cartridge and engage drivers support
`ing the staples to effect the firing of the staples toward the
`anvil.
`The wedges are commonly formed from metal and
`assembled in a pusher block to form a single component.
`Since a number of individual parts must be assembled to
`form this component, it is costly to manufacture. Also, such
`30
`components, because they are comprised of a number of
`individual parts, oftentimes have less than optimum stability.
`Further, it has been found that use of metal wedges results
`in a high coefficient of friction between the wedges and the
`drivers during staple firing.
`The prior art wedges generally include a straight, single
`angle cam surface. The cam surface is designed to provide
`sufficient force for bending over ends of the staples. While
`the cam design performs the desired operation, it also results
`in an undesirable increase in the overall length of the
`instrument.
`Prior art mechanisms for driving wedges distally into a
`staple cartridge commonly include a firing mechanism and
`a motion transfer mechanism. The firing mechanism is
`engaged by a surgeon to effect staple firing. Most currently
`available motion transfer mechanisms, which are interposed
`between the firing mechanism and the pusher block, are not
`easily modifiable for use in stapler instruments having
`different staple line lengths and/or staple firing force require
`ments so as to permit, for a given instrument, the length of
`the stroke of the firing mechanism and the force required to
`move it to be set at ergonomically preferred values.
`Accordingly, there is a need for an improved stapler
`instrument. Preferably, such an instrument would have
`wedges integrally formed as a single unit. Also, the
`improved stapler instrument would have wedges which are
`formed from an improved material such that the coefficient
`of friction between the wedges and the drivers during staple
`firing is reduced over that found in the prior art. The
`improved stapler would also have wedges provided with a
`more efficient cam surface profile. There is further a need for
`an improved motion transfer mechanism which is easily
`adaptable for use in various stapler instruments having
`different staple line lengths and/or staple firing force require
`ments so as to permit, for a given instrument, the length of
`the stroke of the firing mechanism and the force required to
`move it to be set at ergonomically preferred values.
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`Ethicon Exhibit 2010.018
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`25
`
`3
`distal end of the yoke is connected to the proximal end of the
`closure tube and the proximal end of the yoke has a gear rack
`which is adapted to engage the gear segment section, such
`that movement of the closure trigger effects movement of the
`closure tube.
`The anvil is provided with a stop and the distal end of the
`closure tube is provided with a tab engageable with the stop,
`such that movement of the closure trigger away from the
`handle portion causes the tab to engage the stop and pivot
`the anvil away from the cartridge.
`The workportion comprises: a pusher block; a plurality of
`wedges connected to the pusher block; and a reciprocating
`knife. The wedges define the distal end of the work portion.
`The knife includes a boss at its proximal end and the pusher
`block is provided with a recess for receiving the boss. The
`recess is defined by front, rear and side surfaces formed in
`the pusher block. The pusher block effects movement of the
`knife upon engagement of the boss with one of the front and
`rear surfaces. Preferably, the pusher block and the plurality
`of wedges are integrally molded from a liquid crystal
`polymer.
`In accordance with a second aspect of the present inven
`tion, a surgical instrument is provided and comprises: a
`handle portion; an implement portion having first and sec
`ond implements adapted to perform a function during a
`surgical procedure; a reciprocating section adapted to move
`back and forth along an axis of the implement portion; a
`movable actuating mechanism associated with the handle
`portion; and, a multiplier engaged with the actuating mecha
`nism and the reciprocating section such that motion of the
`actuating mechanism causes the multiplier to effect multi
`plied motion of the reciprocating section. The reciprocating
`section includes a work portion capable of causing the first
`and second implements to perform the function. The recip
`rocating section further includes a first drive member.
`35
`The actuating mechanism comprises a second drive mem
`ber and an actuator associated with the second drive member
`for causing the second drive member to reciprocate back and
`forth between first and second drive positions.
`The multiplier comprises first and second integral pinion
`gears. The first pinion gear is engaged with the first drive
`member and the second pinion gear is engaged with the
`second drive member. The first pinion gear has a first
`diameter and the second pinion gear has a second diameter
`which is smaller than the first diameter.
`In accordance with a third aspect of the present invention,
`a wedge work member is provided for use in a surgical
`stapler having a staple cartridge provided with drivers
`supporting staples. The wedge work member comprises: a
`pusher block and a plurality of wedges formed from a liquid
`crystal polymer. The wedges are adapted to pass through
`openings in the staple cartridge to engage the drivers to
`effect the firing of the staples. Preferably, the wedges and the
`pusher block are integrally formed as a single unit. The
`liquid crystal polymer may comprise a fiber reinforced
`liquid crystal polymer. The fiber reinforced liquid crystal
`polymer is preferably selected from the group consisting of
`carbon fiber reinforced copolyesters and carbon fiber rein
`forced copolyester-amides.
`In accordance with a fourth aspect of the present inven
`tion, a wedge work member is provided for use in a surgical
`stapler having a staple cartridge provided with at least one
`driver supporting at least one staple. The wedge work
`member comprises: a pusher block and at least one wedge
`having an elongated portion and a camming portion. The
`camming portion has first and second cam surfaces which
`
`4
`sequentially engage the driver supporting the staple to effect
`the firing of the staple. The first cam surface forms a first
`angle with a first plane and the second cam surface forms a
`second angle with a second plane. The first plane is generally
`parallel with the second plane and the first angle is different
`from the second angle. Preferably, the first angle is greater
`than the second angle.
`In accordance with a fifth aspect of the present invention,
`a method is provided for forming an anvil adapted for use in
`a surgical stapler. The method comprises the steps of
`forming a wax pattern having an anvil shape and including
`a plurality of pockets therein; dipping the wax pattern into
`a slurry of material to form an outer shell about the wax
`pattern; heating the outer shell causing the wax in the outer
`shell to melt and leave the outer shell; filling the outer shell
`with molten metal to form a metal casting of the anvil within
`the outer shell; removing the outer shell from the metal
`casting; and removing surface irregularities from within
`each of the plurality of pockets in the casting to form a
`finished casting. The finished casting defines the anvil.
`Accordingly, it is an object of the present invention to
`provide an improved surgical stapler instrument. It is further
`an object of the present invention to provide a wedge work
`member for use in a surgical stapler instrument which
`comprises a plurality of wedges and a pusher block which
`are integrally formed as a single unit. It is another object of
`the present invention to provide wedges for use in a stapler
`instrument which are formed from a liquid crystal polymer.
`It is still further an object of the present invention to provide
`wedges for use in a stapler instrument which are provided
`with an improved cam surface profile. It is still another
`object of the present invention to provide a multiplier for use
`in an instrument to effect multiplied motion of a work
`portion of the instrument. It is yet further an object of the
`present invention to provide an improved method for form
`ing a surgical instrument anvil. These and other objects and
`advantages of the present invention will be apparent from
`the following description, the accompanying drawings and
`the appended claims.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a perspective view of a surgical stapler instru
`ment of the present invention;
`FIG. 2 is an exploded view of an implement portion of the
`instrument shown in FIG. 1;
`FIG. 3 is an exploded view showing the handle portion,
`the firing trigger, the closure trigger, the spring, the motion
`transfer mechanism, the yoke and the release button of the
`instrument in FIG. 1;
`FIG. 4 is a side view of the instrument shown in FIG. 1
`with the anvil in its tissue-clamping position;
`FIG. 5 is a side view of the instrument shown in FIG. 1
`with the firing trigger positioned directly adjacent to the
`closure trigger,
`FIG. 6 is a side view, partially in cross-section, of a
`proximal portion of the instrument shown in FIG. 1 prior to
`tissue clamping;
`FIG. 7 is a side view, partially in cross-section, of the
`implement portion prior to tissue clamping;
`FIG. 7a is a view taken along line 7a-7a in FIG. 7;
`FIG. 8a is a side view of the anvil of the instrument in
`FIG. 1;
`FIG. 8b is a view of the lower surface of the anvil shown
`in FIG. 8a,
`
`5,465,895
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`20
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`30
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`65
`
`Ethicon Exhibit 2010.019
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`5,465,895
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`5
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`5
`FIG. 9 is a side view, partially in cross-section, of the
`implement portion with the anvil shown in its tissue-clamp
`ing position;
`FIG. 10 is a front side view, partially in cross-section, of
`a proximal portion of the instrument shown in FIG. 1 with
`the closure trigger moved to its tissue-clamping position;
`FIG. 10a is a back side view of the closure trigger, the
`firing trigger, the spring, a portion of the yoke, a portion of
`the closure tube and a portion of the channel with those
`elements positioned as shown in FIG. 10;
`FIG. 11 is a cross-sectional view of the implement portion
`with the wedge work member and the knife in their distal
`most positions;
`FIG.11a is an enlarged top view of a portion of the staple
`cartridge of the instrument shown in FIG. 1;
`FIG.11b is a view taken along section line 11b-11b in
`FIG. 11a,
`FIG. 12 is a side view, partially in cross-section, of a
`proximal portion of the instrument with the firing trigger
`shown positioned adjacent to the closure trigger;
`FIG. 13 is a side view of the knife of the instrument shown
`in FIG. 1;
`FIG. 14a is a side view, partially in cross-section, of a
`portion of the staple cartridge including the lockout member
`and a portion of the knife;
`FIG. 14b is a view similar to FIG. 14a with the lockout
`member pushed downward beneath a guide member of the
`cartridge;
`FIG. 15a is a side view of a camming portion of a wedge
`formed in accordance with a first embodiment of the present
`invention;
`FIG. 15b is a side view of a camming portion of a wedge
`formed in accordance with a second embodiment of the
`present invention;
`FIG. 16a is a top view of the wedge guide of the
`instrument shown in FIG. 1;
`FIG. 16b is a side view of the wedge guide shown in FIG.
`6a,
`FIG.16c is an end view of the wedge guide shown in FIG.
`16a,
`FIG. 17a is a side view of the first channel section of the
`instrument shown in FIG. 1; and,
`FIG. 17b is a plan view of the first channel section shown
`in FIG. T.
`
`6
`130, see FIG. 4, the anvil 114 is caused to pivot to a
`tissue-clamping position, such that it is essentially parallel to
`and spaced from an upper surface 120a of the staple car
`tridge 120. A pin 121 is provided on the cartridge 120 and
`is engaged by the anvil 114 when the anvil 114 is in its
`tissue-clamping position. After tissue clamping has
`occurred, the firing trigger 140 can then be moved toward
`the base section 130a, see FIG. 5, to cause stapling and
`severing of tissue 200 engaged between the anvil 114 and the
`staple cartridge 120.
`The handle portion 130 is comprised of first and second
`base sections 132 and 134, see FIG. 3, which are molded
`from a polymeric material such as a glass-filled polycarbon
`ate. The first section 132 is provided with a plurality of
`cylindrical-shaped pins (not shown). The second section 134
`includes a plurality of extending members 134a, each hav
`ing a hexagonal-shaped opening 134b, see also FIG. 6. The
`pins are received within the openings 134b and are friction
`ally held therein for maintaining the first and second sections
`132 and 134 in assembly.
`The staple cartridge 120 is divided by a central, elongated
`slot 125 which extends from the proximal end 120b of the
`cartridge 120 towards its tapered outer tip 120c, see FIGS.
`2 and 7a. A plurality of staple receiving pockets 126a-126f
`are formed within the staple cartridge 120 and are arranged
`in six laterally spaced longitudinal rows, see FIGS. 11a and
`11b. An opening 126g extends between every two adjacent
`pockets 126a and 126b. An opening 126g also extends
`between every two adjacent pockets 126e and 126f Posi
`tioned within the pockets 126a-126fare the staples 124.
`The cartridge 120 further includes four laterally spaced
`longitudinal rows of staple drivers 122a-122d. Drivers 122a
`are slidably mounted within the pockets 126a and 12.6b such
`that each driver 122a supports two staples 124, one in a
`pocket 126a and one in a pocket 126b. The drivers 122b are
`slidably received within the pockets 126c. The drivers 122c
`are slidably received within the pockets 126d. Each of the
`drivers 122b and 122c supports a single staple 124. Each of
`the drivers 122b and 122c is provided with a lateral rib 123
`for guiding and stabilizing the driver as it moves within its
`respective pocket. The drivers 122d are slidably mounted
`within the pockets 126e and 126f such that each driver 122d
`supports two staples 124, one in a pocket 126e and one in a
`pocket 126f
`The cartridge 120 further includes four longitudinal slots
`129 extending from its proximal end 120b to its tapered
`outer tip 120c, see FIG. 7a. Wedges 162b provided at the
`distal end of a wedge work member 162 pass through the
`slots 129 and engage the drivers 122a-122d to effect the
`firing of the staples 124 toward the anvil 114, see FIG.11b.
`Grooves 112a' are provided in the distal end 112a of the
`elongated channel 112 for receiving, guiding and stabilizing
`the wedges 162b as they move through the slots 129, see
`FIG. 17b.
`As shown in FIG. 2, the elongated channel 112 is com
`prised of first and second channel sections 112b and 112c. In
`the illustrated embodiment, the first channel section 112b is
`formed from metal and the second section 112c is formed
`from a polymeric material, such as a carbon-fiber filled
`polycarbonate. The staple cartridge 120 is snapped in place
`at the distal end of the first section 112b, which end defines
`the distal end 112a of the elongated channel 112. Alignment
`tabs 120d provided on the staple cartridge 120 are received
`in slots 112b' in the first section 112b, see FIGS. 7 and 17a.
`The distal end 112d of the second section 112c snaps onto
`the proximal end 112e of the first section 112b. The proximal
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`DETALED DESCRIPTION OF THE
`INVENTION
`Reference is now made to FIG. 1, which illustrates a
`surgical stapler and severing instrument 100 formed in
`accordance with the present invention. The stapler instru
`ment 100 includes an implement portion 110 having an
`elongated channel 112 and an anvil 114, see also FIGS. 2 and
`3. A distal end 112a of the elongated channel 112 releasably
`receives a staple cartridge 120. Housed within the staple
`cartridge 120 are a plurality of drivers 122a-122d, each
`supporting one or more staples 124, see FIGS. 11a and 11b.
`The anvil 114 is mounted on the channel 112 for pivotable
`movement toward and away from the distal end 112a of the
`channel 112. The instrument 100 further includes a handle
`portion 130, a firing trigger 140, a closure trigger 150, and
`a knife 161. As will be discussed more explicitly below, by
`grasping the closure trigger 150 and moving it to a position
`directly adjacent to a base section 130a of the handle portion
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`Ethicon Exhibit 2010.020
`Intuitive v. Ethicon
`IPR2019-00880
`
`

`

`7
`end 112f of the second section 112c is provided with a
`circumferential notch 112g which is engaged by opposing
`channel securement members extending from the base sec
`tions 132 and 134. Only channel securement member 134c
`of section 134 is shown, see FIG. 3. The channel securement
`members extending from the base sections 132 and 134
`serve to secure the channel 112 to the handle portion 130
`such that the channel 112 does not move longitudinally
`relative to the handle portion 130.
`The anvil 114 includes first and second laterally posi
`tioned pins 114a and 114b, see FIGS. 2,8A and 8B. The pins
`114a and 114b are received respectively within slots 113a
`and 13b provided in the first channel section 112b.
`Referring again to FIG. 2, a closure tube 152 is provided
`which moves longitudinally with respect to the handle
`portion 130 to effect pivotal movement of the anvil 114. The
`closure tube 152 has the first and second channel sections
`112b and 112c extending through it. The closure tube 152 is
`also capable of rotating with respect to the handle portion
`130 via a rotating knob 135.
`20
`The rotating knob 135 has a bore 135a extending com
`pletely through it, see FIG. 3. The knob 135 includes a
`protruding boss 135b extending from its inner sidewall
`135c. The boss 135b is received within a slot 152fprovided
`in the closure tube 152 such that rotation of the knob 135
`effects rotation of the closure tube 152. The elongated
`channel 112, the cartridge 120 and the anvil 114 rotate with
`the closure tube 152.
`An external tube 156, shown only in FIGS. 2 and 4, is
`received over the closure tube 152 and seals with a sealing
`member (not shown) provided within a trocar cannula (not
`shown) through which the instrument 100 passes when used
`during an endoscopic procedure. In the illustrated embodi
`ment, the external tube 156 is formed from a polymeric
`material, such as polypropylene. The closure tube 152 is
`permitted to rotate with respect to the external tube 156.
`Provided at the distal end 52a of the closure tube 152 is
`a tab 152b, see FIGS. 2 and 7. A stop 114c is provided at the
`proximal end of the anvil 114, see FIG. 8A. Upon proximal
`movement of the closure tube 152, the tab 152b engages the
`stop 114c to pivot the anvil 114 away from the distal end
`112a of the channel 112, see FIG. 7. The outer distal edge
`152c of the closure tube 152 defines a camming surface.
`When the closure tube 152 moves distally, the distal edge
`152c engages an upper portion 114d of the anvil 114 causing
`the anvil 114 to pivot toward the distal end 112a of the
`channel 112 to its tissue-clamping position, see FIGS. 4 and
`9.
`Referring again to FIG. 3, the closure trigger 150 has a
`handle section 150a, a gear segment section 150b, and an
`intermediate section 150c. Abore 150d extends through the
`intermediate section 150c. A cylindrical support member
`134d extending from the second base section 134 passes
`through the bore 150d for pivotably mounting the closure
`trigger 150 on the handle portion 130. A hexagonal opening
`134e is provided in the support member 134d for receiving
`a securement pin (not shown) extending from the first base
`section 132. A closure yoke 154 is housed within the housing
`portion 130 for reciprocating movement therein and serves
`to transfer motion from the closure trigger 150 to the closure
`tube 152. Support members 134f extending from the second
`base section 134 and securement member 134c, which
`extends through a recess 154g (see also FIG. 6) in the yoke
`154, support the yoke 154 within the housing portion 130.
`The proximal end 152d of the closure tube 152 is provided
`with a flange 152e which is snap-fitted into a receiving
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`recess 154a formed in the distal end 154b of the yoke 154,
`see FIGS. 3 and 6. The proximal end 154c of the yoke 154
`has a gear rack 154d which is engaged by the gear segment
`section 150b of the closure trigger 150, see also FIG. 10a.
`When the closure trigger 150 is moved toward the base
`section 130a of the handle portion 130, the yoke 154 and,
`hence, the closure tube 152 move distally. Distal movement
`of the closure tube 152 effects pivotal movement of the anvil
`114 toward the distal end 112a of the channel 112, see FIGS.
`4 and 9. Movement of the closure trigger 150 away from the
`base section 130a effects proximal movement of the closure
`tube 152 causing the tab. 152b on the tube 152 to engage the
`stop 114c on the anvil 114 and pivot the anvil 114 away from
`the distal end 112a of the channel 112, see FIG. 7.
`The yoke 154 is provided with a second recess 154e, see
`FIGS. 3 and 6, which is capable of receiving a flange of a
`closure tube (not shown) having a size that differs from the
`one illustrated in FIG. 2. Thus, the yoke 154 shown in FIG.
`3 can be used in the manufacture of the illustrated stapler
`instrument or a stapler instrument (not shown) having a
`closure tube with a flange of a different size.
`A firing trigger return spring 136 is located within the
`handle portion 130. The spring 136 has opposed ends
`attached to a pin 134g extending from the second base
`section 134 and a pin 140a on the firing trigger 140. The
`spring 136 applies a return force to the pin 140a for biasing
`the firing trigger 140 in a direction away from the base
`section 130a of the handle portion 130.
`The firing trigger 140 has an engaging surface 140b which
`is adapted to engage with a front surface 150e on the closure
`trigger 150, see FIGS. 3 and 10a. As the closure trigger 150
`is moved toward the base section 130a, its front surface 150e
`engages wi