USO10780539B2

( 12 ) United States Patent ( 10) Patent No .: US 10,780,539 B2

Shelton , IV et al. (45 ) Date of Patent : Sep. 22 , 2020
( 54 ) STAPLING INSTRUMENT FOR USE WITH A ( 56 ) References Cited
ROBOTIC SYSTEM
U.S. PATENT DOCUMENTS
( 71 ) Applicant: Ethicon LLC , Guaynabo , PR (US ) 66,052 A 6/1867 Smith
662,587 A 11/1900 Blake
( 72 ) Inventors: Frederick E. Shelton , IV , Hillsboro , (Continued )
OH (US ); James R. Giordano ,
Milford, OH (US ) ; Jeffrey S. Swayze, FOREIGN PATENT DOCUMENTS
West Chester, OH (US )
( 73 ) Assignee : Ethicon LLC , Guaynabo, PR ( US ) AU 2012200594 Al 2/2012
AU 2011218702 B2 6/2013
(*) Notice: Subject to any disclaimer, the term of this (Continued )
patent is extended or adjusted under 35
U.S.C. 154 ( b ) by 285 days . OTHER PUBLICATIONS
( 21 ) Appl . No .: 15 /814,345 ASTM procedure D2240-00 , “ Standard Test Method for Rubber
Property -Durometer Hardness, ” (Published Aug. 2000 ) .
(22 ) Filed : Nov. 15 , 2017 (Continued )
( 65 ) Prior Publication Data Primary Examiner — Andrew M Tecco
US 2018/0133856 A1 May 17 , 2018
( 57 ) ABSTRACT
Related U.S. Application Data
A stapling instrument for use with a robotic surgical system
( 63 ) Continuation of application No. 14/ 459,485 , filed on is disclosed . The stapling instrument comprises a housing , a
Aug. 14 , 2014 , now Pat . No. 10,058,963 , which is a shaft, a loading unit, a firing drive , an articulation drive, and
(Continued ) a rotation drive. The housing comprises a first, second , and
(51 ) Int. Ci . third rotatable members . The loading unit comprises a staple
A61B 17/068 ( 2006.01 ) cartridge and a firing drive . The firing drive is operably
B23Q 3/155 ( 2006.01 ) coupled to the first rotatable member and configured to
(Continued ) convert rotary motion of the first rotatable member to linear
( 52) U.S. Ci .
motion to eject staples from the staple cartridge. The articu
CPC B23Q 3/1554 ( 2013.01 ) ; A61B 17/068 lation drive is operably coupled to the second rotatable
(2013.01 ) ; A61B 17/072 ( 2013.01 ) ; member and configured to convert rotary motion of the
second rotatable member to linear motion to articulate a first
( Continued ) jaw and a second jaw of the loading unit . The rotation drive
( 58 ) Field of Classification Search is configured to rotate the shaft about a longitudinal axis and
CPC .... A61B 17/07207 ; A61B 2017/00398 ; A61B is operably coupled to the third rotatable member.
2017/00477; A61B 2017/07278;
(Continued ) 4 Claims, 139 Drawing Sheets
LT
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3600

3751
3700

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3662 3676
3677
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 US 10,780,539 B2
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Related U.S. Application Data 2,318,379 A 5/1943 Davis et al.

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Iaccarino
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2017/2946 (2013.01 ) ; A61B 2017/320094 3,377,893 A 4/1968 Shorb
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-

T -134
142
Begin g Sof-troke

1324
Stroke
of
-
End
130
U.S. Patent Sep. 22 , 2020 Sheet 13 of 139 US 10,780,539 B2

78
80
72
122 84
48 -70
74 1116 68
114 1142
-124
130

250
0918 65

64

20

18

FIG . 12
U.S. Patent Sep. 22 , 2020 Sheet 14 of 139 US 10,780,539 B2

6
128
142 126
130 80
-72
78
0_122 -70
48
68
90
-124 -74
1 65
250

64
1

20

18

FIG . 13
U.S. Patent Sep. 22 , 2020 Sheet 15 of 139 US 10,780,539 B2

160

no -151 152
64

150 158
26 156

-154
18
14
.
FIG
U.S. Patent Sep. 22 , 2020 Sheet 16 of 139 US 10,780,539 B2

26

64

18

150 --152
160
156
154 151

FIG . 15
U.S. Patent Sep. 22 , 2020 Sheet 17 of 139 US 10,780,539 B2

LI

64 -26

18

164
162
160
172
?. -161
-166
170
168
FIG . 16
U.S. Patent Sep. 22 , 2020 Sheet 18 of 139 US 10,780,539 B2

-26

18

180
-176 188
186
178
182
184

FIG . 17
U.S. Patent Sep. 22 , 2020 Sheet 19 of 139 US 10,780,539 B2

26
18

180

176
184
182
OW
188
-186
-178

FIG . 18
U.S. Patent Sep. 22 , 2020 Sheet 20 of 139 US 10,780,539 B2

26

18

180
184 -188

178
1176

FIG . 19
U.S. Patent Sep. 22 , 2020 Sheet 21 of 139 US 10,780,539 B2

26
18
-

178
1188

190
182

FIG . 20
U.S. Patent Sep. 22 , 2020 Sheet 22 of 139 US 10,780,539 B2

192

182 188 178

-190

FIG . 21
U.S. Patent Sep. 22 , 2020 Sheet 23 of 139 US 10,780,539 B2

178
192 188

182 -190
176
180

FIG . 22
U.S. Patent Sep. 22 , 2020 Sheet 24 of 139 US 10,780,539 B2

195-1

23B
.
FIG
195

195-1 195-2

195-2
23A
.
FIG
195
U.S. Patent Sep. 22 , 2020 Sheet 25 of 139
.
US 10,780,539 B2

197
24B
.
FIG

197

C
24A
.
FIG
U.S. Patent Sep. 22 , 2020 Sheet 26 of 139 US 10,780,539 B2

26

68 65 207
64
3
18

256
72

124
76
122 20 STROKE
40

25
.
FIG
U.S. Patent Sep. 22 , 2020 Sheet 27 of 139 US 10,780,539 B2

-62

-60
64

68 65
18

70 -206 207
72 -208 202
lot

200 STROKE
224 204 20 250 254
-261
-256
59

263 260
/
26
.
FIG
61 258 267
U.S. Patent Sep. 22 , 2020 Sheet 28 of 139 US 10,780,539 B2

72 20

201
124
76

122

214
212 218
216
48
210
27
FIG
.
U.S. Patent Sep. 22 , 2020 Sheet 29 of 139 US 10,780,539 B2

26

68
th
222
70 64
65

72 18

207
124
48 20

122

101 6
28
.
FIG
U.S. Patent Sep. 22 , 2020 Sheet 30 of 139 US 10,780,539 B2

64
68 65
-70
222
-72

18

210 214 207

76 218 -124 250
20
122 48

256
40

29
.
FIG
U.S. Patent Sep. 22 , 2020 Sheet 31 of 139 US 10,780,539 B2

-256 48
-20
-124
216
122 214
218 212 210 208 2 4 207 18
206cco
76

72
70
68 65 222 30
.
FIG
U.S. Patent Sep. 22 , 2020 Sheet 32 of 139 US 10,780,539 B2

68 65
70
72

18
218 210
122 -76 220 214 207
20
250
124
48

31
.
FIG
U.S. Patent Sep. 22 , 2020 Sheet 33 of 139 US 10,780,539 B2

232 -72
122 210
-70

68
O 230
124
65
200 130 242 E222
142
230 238 234
207
110
228 234
236
3

-26

20 18

FIG . 32
U.S. Patent Sep. 22 , 2020 Sheet 34 of 139 US 10,780,539 B2

124 72
122 200
70

68

O 130 65

230
E H222
142 110
228

26

18
20

160

FIG . 33
U.S. Patent Sep. 22 , 2020 Sheet 35 of 139 US 10,780,539 B2

230 232
O

242
kommun 65

130
E
142
110
Wam
230

5 ° rotation

FIG . 34
232 230
lo

65

130
142 M
110
228

FIG . 35
U.S. Patent Sep. 22 , 2020 Sheet 36 of 139 US 10,780,539 B2

230 232
IO

65

130 222
142
110

228

FIG . 36
U.S. Patent Sep. 22 , 2020 Sheet 37 of 139 US 10,780,539 B2

72
122 76 -70

48

124
268 242
270
230
TH o

65
68

265 266

110

1
1

64 -26
228 +

18
20

FIG . 37
U.S. Patent Sep. 22 , 2020 Sheet 38 of 139 US 10,780,539 B2

72
122 76 -70

48
Mo -66
268 IO
242 -230
265 65
266 E
110
228

64

18
-20

FIG . 38
U.S. Patent Sep. 22 , 2020 Sheet 39 of 139 US 10,780,539 B2

242 OL
230
265 65

266

110

5 ° rotation

FIG . 39

Io
-230
265 MMODOOD 65
266
242
E

228

FIG . 40
U.S. Patent Sep. 22 , 2020 Sheet 40 of 139 US 10,780,539 B2

-10 8
10 5
1014 1016 45
-10 2 -10 8
62
1010 -- -10 6 10 7
1024 -22
102 1028
1027 ***

-12
1026 -33 1036
27 25
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a
1031 34
1030 1034 FIG
.
41
10 4 10 2 24
U.S. Patent Sep. 22 , 2020 Sheet 41 of 139 US 10,780,539 B2

10 30
1 0 222 1040 -1058 1062 -1063
11052 094 -1054 -1050 -1056 -106 -1072d
59

-1090-1098
AvaviVITTAE.
108 1084 1048 1 0 6 4 1 0 6 7
26

1086 1092 1074 106

1072a 1078 252
1082 1068 104696
1070 1080 104 164 228 18

109 1 0461 250

1 02 1 08
1097106 1 12 1 10
1 14 20

1010 1016
42
.
FIG
10 5 8
U.S. Patent Sep. 22 , 2020 Sheet 42 of 139 US 10,780,539 B2

-1090 1054 1058 1056 30

-1096 59 1052 004484 -1040 26
10641062 -1063
1074
1124 1076V 1116 -1 20 -1072b 1072c 1072d -1067
96 11078 072a
12 1 18
6

-1 0 107
1097 1082 1070 1050 1060 106
10 1098 1075222-1 26 1068
-1 04 -109
20
1 06
1094
108
1 02 1 08 1046 18
-1 14 104 1042
-61 10841086 1092
250 1080
-1010
-1 10 1097
8

-1012 1 121016 1018

1014 43
.
FIG
10 5
U.S. Patent Sep. 22 , 2020 Sheet 43 of 139 US 10,780,539 B2

C2012 ARTIDGE CONDIT SENOR

C2010 ARTIDGE PRESNT SENOR
20 8 KPONSITFOEN SENOR C2018 ONVERT
D
/
A

2020
POUTR
110
TFRIGNER SENOR CONVERT DMEVIOCREY
2016
D
/
A

20 6
ACLNOVSUIRLE SLEONADR 2014 CONVERT
D
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E M O V A B L
2021
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20 0 20 2 CLOSUR STREINGOR 44
.
FIG
U.S. Patent Sep. 22 , 2020 Sheet 44 of 139 US 10,780,539 B2

30
59

10

26

20 2
252
110

96
45
.
FIG
U.S. Patent Sep. 22 , 2020 Sheet 45 of 139 US 10,780,539 B2

??
59

10

26
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252

nator 110

96

le 20

46
FIG
.
U.S. Patent Sep. 22 , 2020 Sheet 46 of 139 US 10,780,539 B2

-20 9
20 8 10 6 -25

20 4
201 20 5
24

102 (22
22

48
.
FIG 47
.
FIG
U.S. Patent Sep. 22 , 2020 Sheet 47 of 139 US 10,780,539 B2

INTLUNTENTILTALTUNVEILTON

-20 9
201
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49
.
FIG
www

blit 102
22

-
U.S. Patent Sep. 22 , 2020 Sheet 48 of 139 US 10,780,539 B2

2012
==

2013
2010 201201
-22

-22
2012
2013
50
.
FIG 202 51
.
FIG
201 2010
-1028
U.S. Patent Sep. 22 , 2020 Sheet 49 of 139 US 10,780,539 B2

-2200

2202 2203
CLOSE ANVIL RECORD STATE
2204
INSERT INTO PATIENT
2206 2205
OPEN /CLOSE ANVIL RECORD STATE
2208
CLAMP TISSUE

2210
SENSOR : NO
IS ANVIL
CLOSED ?
2211
YES RECORD STATE
2212 2213
CUT / STAPLE RECORD STATE

2214
NO IS CUT
COMPLETE ?

YES

B D

FIG . 52A
U.S. Patent Sep. 22 , 2020 Sheet 50 of 139 US 10,780,539 B2

B A?.

2216 2215
KNIFE RETURNS RECORD STATE
2218 2217
OPEN ANVIL : CLEAR TISSUE RECORD STATE
2220 2219
CLOSE ANVIL RECORD STATE
2222
REMOVE FROM PATIENT
2224 2223
OPEN ANVIL RECORD STATE
2226 2225
REMOVE CARTRIDGE RECORD STATE

2228 2227)
INSERT CARTRIDGE RECORD STATE

2230
IS 2229
NO
CARTRIDGE RECORD STATE
NEW ?

YES 2231
RECORD STATE

FIG . 52 B
U.S. Patent Sep. 22 , 2020 Sheet 51 of 139 US 10,780,539 B2

2316
230 YES OFF
-
ON
1 NO
O
-
CARTIDGE PRESNT YES
/
NO 1 1 1 1 1 1 1 1

2314 S
P RLE N
D T
LOCKUTSISMLOECKRUYT C/OPENYESNOLOSED
1 1 1 1 0 0 0 0 0

ANVL 0 0 0 1 1 1 1 1 1

2RE3V1CO2NRTD
M-2310 EORY KNIFE % .33 .66 .75
POFSIRTONG LOAD )
MAX
(
250 400 200
2308
2306
STROKE 1
2 3

ECFLVIORSUNTEGLOAD 10 12 15 50 25 100 120 50 50

2304 # 1
2 3 .
4

25 26 27 55 56
2302 53
FIG
.
EXAMPLE :
3 STEP FIRING
U.S. Patent Sep. 22 , 2020 Sheet 52 of 139 US 10,780,539 B2

10
101

102 103
105
54
.
FIG