CA2117744A1

CA2117744A1 - Gas powered apparatus for applying surgical fasteners to body tissue

Info

Publication number: CA2117744A1
Application number: CA002117744A
Authority: CA
Inventors: David T. Green; Henry Bolanos; Lisa W. Heaton; Thomas A. Pelletier
Original assignee: Individual
Current assignee: United States Surgical Corp
Priority date: 1993-10-14
Filing date: 1994-10-07
Publication date: 1995-04-15
Also published as: US5862972A; EP0649630A1

Abstract

ABSTRACT OF THE DISCLOSURE

An endoscopic surgical stapling apparatus is disclosed. The apparatus comprises a frame and a generally elongated endoscopic section connected to the frame and extending distally therefrom. The endoscopic section includes a mechanism for storing a plurality of staples, a mechanism for advancing the staples for positioning adjacent body tissue and a mechanism for at least partially closing each staple. A low pressure pneumatic system disposed in the frame provides the forces to at least partially activate the staple advancing mechanism. The apparatus has particular application in attaching mesh to body tissue as in laparoscopic hernia repair.

Description

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1438 CANAD~

GAS POWERED APPARATUS FOR APPLYING
SURG CAL FASTENERS TO BODY TISSUE

BACKGROUND OF THE INVENTION
l. Field of the Invention The present invention relates to an apparatus and method for applying suryical staples to body tissue. More particularly, this invention relates to a laparoscopic or endoscopic surgical stapling apparatus which is at least partîally powered by a low pressure pneumatic system.

-2. Back~round of the Invention In laparoscopic procedures, surgery is performed in the interior of the abdomen through a small incision. In endoscopic procedures, surgery is performed in any hollow viscus of the body through narrow endossopic tubes inserted through small entrance wounds in the skin. Laparoscopic and endoscopic procedures generally require that any instrumentation inserted into the body be sealed, i.e., provisions must be made to ensure th~t gases do not enter or exit the body through the laparoscopic or endoscopic incision as, for example, in surgical procedures in which the surgical region is insufflated. Moreover, laparoscopic and endoscopic procedures often require the surgeon to act on organs, tissues and vessels ~ar removed from the incision, thereby requiring that any instruments being used in such procedures be long and narrow while being ~unctionally controllable from one end of ~he instrument, i.e. the proximal end.
Examples of surgical instruments having laparoscopic and/or endoscopic application are disclosed in commonly assigned U.SO Patent Nos. 5,040,715 to Green et al., 5,071,430 to de Salis et al., 5,084,057 to Green et al.
and 5,100,420 to Green et al.. The instrument disclosed in the '715 patent to Green et al. is adapted to place one or more rows of staples endoscopically to perform gastrointestinal anastomosis. The instrument disclosed in the '430 patent to de Salis et al. endoscopically drives fasteners into body tissue for ablation of organs. The instruments disclosed in the '057 and '420 patents to Green et al. are adapted to surgically apply clips to body tissue in endoscopic procedures.
- While the above developments represent major advances in endoscopic and laparoscopic instrumentation, the present invention is directed to further improvements whereby the handle section incorporates a pneumatic system to alleviate the degree of manually applied force required to actuate the instrument.
Surgical instruments having handle mechanisms which incorporate pneumatic systems or self contained ~-powered units are described in U.S. Patent Nos. 3,61~,842,

3,643,851, 3,662,939, 3,717,294, 3,815,476 and 3,837,555.
Typically, the pneumatic system in these instruments include a replaceable cylinder which supplies gas (s.g., carbon dioxide or nitrogen) at relatively high pressure te.g., 800 psig.) to power the instrument. The high pressure gas used in these inskruments requires the instruments to be o~
~ relatively heavy construction in order to solely acco~modate the high pressure involved. Consequently, these design requirements preclude the incorporation of such high pressure gas units in endoscopic instrumentation vhich typically is more delicate in construction and is not .".",,~..,..' s~

capable of withstanding the high pressure delivered by these units.
Therefore, there is a need for a pneumatic system or self~powered gas unit of relatively low pressure that can be incorporated in an actuating or handIe mechanism of an endoscopic or laparoscopic instrument, and which is capable of generating the substantial forces required to operate the instrument. Also, although it may be desirable to perform ~ most of the functions of the endoscopic apparatus using the self-powering elements in the apparatus, it may also be -desirable for the initial function to be at least partly manual. For example, if the initial function is to aclvance the ~taple for pre-positioning, it is preferably initiated manually so that it can be performed slowly and precisely and the results inspected and corrected if necessary before the automatic self-powered portion of the operating sequence begins. See, for example, U.S. Patent Nos. ~,349,02~ and

4,331,277 to Green.
One embodiment of the present invention contemplates an endoscopic apparatus adaptèd to endoscopically apply staples to attach a surgical mesh to body tissue to reinforce a surgical repair of the body tissue, as in hernia repair.
In hernia surgery a suitable mesh material is generally sutured over the opening in the tissue. The mesh ~~ material i5 often also attached by sutures and left within the opening to act as a reinforcing agent for tissue regrowth in the area of the surgery. One example of a mesh material currently utilized in hernia surgery includes a polypropylene material marketed by the Ethicon Division of Johnson ~ Johnson, New Brunswick, New Jersey, under th2 ,....

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trademark MARLEX. Another example of a mesh material is a tri-fluoroethylene material marketed by W.L. Gore &
Associates, Newark, Delaware, under the tradename GORE-TEX.
Another example is a polypropylene mesh marketed by the assignee under the trademark SURGIPRO~.
U.S. Patent No. 4,944,443 to Oddsen et al.
discloses an i~strument and method for applying and forming staples into body tissue to suture a hernial opening. The staple is applied to two pieces of body tissue on opposite sides of the opening which are gripped, approximated and -held together by a tissue positioning assembly. U.S. Patent No. 4,919,152 to Ger relates to a surgical instrument for placing a single clip which is proposed for use in direct hernia repair ~or closing sacs having narrow neck openings.
Commonly assigned U.S. patent application Serial No. 07/782,290, filed October 18, 1991, discloses a novel apparatus adapted to éndoscopically apply staples for attaching objects such as surgical mesh in a manner which positively secures the object to body tissue without danger of separation thereof after the attachment is completed.
This apparatus has proven to be highly effective in performing endoscopic surgical procedures, particularly, hernia repair.
The present invention is related to a novel endoscopic stapler incorporating a low pressure pneumatic system to provide the necessary forces to per~orm the stapling ~unction. In accordance with the preferred embodiment of the present invention, the apparatus incorporates an initial or a staple-prepositioning function to facilitate proper placement o~ tha staple relative to :`

surgical mesh and body tissue prior to completion of the staple firing stroke.

SUMMARY OF THE INVENTION
An endoscopic surgical stapling apparatus comprises a frame and a generally elongated endoscopic portion connected to the frame and 0xtending distally therefrom. The endoscopic portion includes means for storing a plurality of staples, means for individually advancing the staples for positioning adjacent body tissue -and means for a~ least partially closing each staple. The apparatus further comprises pneumatic means which are disposed within the frame for at laast partially activating the staple advancing means. The pneumatic means comprises a pressurized gas supply and pneumatic actuator means including a cylinder in fluid communication with the pressurized gas supply and defining an opening at a distal end thereof, and a piston disposed within the opening and adapted to advance in response to admisslon of gas therewithin.
The apparatus also comprises ~irst operable means disposed within the rame for distally advancing the staple pusher of the staple advancing meanis from an initial unadvanced position to a first predetermined pOsitioll.
Preferably, the first operable means i5 adapted tM
selectiYely advance the staple pusher between the initial position and the first predetermined position. The first operable means includes a ratchet and an associated pawl which is adapted to pre~ent proximal movement o* the staple pusher except wh~n the staple pusher iis advanced to the first predetermined position whereby the pawl is '` ~ :, :: .
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released so as to permit return of the staple pusher to the initial position. The first operable means may be manually operated by a trigger or a lever mechanism.
The apparatus also comprises second operable means for actuating the pneumatic means to distally drive the staple pusher beyond the first pred~termined position to a second advanced position corresponding to at least partially closing each staple by the staple closing means.
The second operable means is manually operated by an actuating mechanism which includes a firing button pivotally -mounted to the frame and operativPly connectPd to a firing link of the second operable means. The firing link is engageable with the piston of the pneumatic means, whgitudinal movement of the firing link and corresponding distal movement o~ the piston. Such distal movement of the piston causes release of pressurized gas from the pressurized gas supply in an amount sufficient to establish the force to distally drive the piston to advance the staple pusher means to the second advanced position.
In an alternative preferred embodiment of the apparatu of the present invention, the first operable means is operatively connected to the pneumatic means such that actuation of the first operable means activates the pneumatic means to distally drive the piston and the s1:aple pusher~ Upon actuation of the first operable means the ~~ staple pusher is advanced to the first predete~mined position and prevented ~rom advanciny beyond this position hy engaging means located within the frame. The second operable means is adapted to release the engaging means to permit continued distal movement of the staple pusher ~yond the ~irst predetermined position to a second advanced :.:

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position corresponding to at least partially closing the staple by the staple closing means.
The present invention is also directed to an apparatus for endoscopic application of surgical staples adapted to attach an object to body tissue. Th~ apparatus comprises a handle member adapted to be gripped by hand and a generally elcngated endoscopic portion connected to the handle member and extending distally therefrom. The Pndoscopic portion includes at least one staple, a staple pusher for individually advancing the one staple distally -for positioning adjacent the body tissue and an anvil for closing the staple. The handle member comprises a pneumatic system including a supply of low pressure sas. The pneumatic system is adapted to convert the low pressure gas into a force to advance the staple pusher. The apparatus further comprises a first transmission for distally advancing the staple pusher from an initial position to a first predetermined position and a second transmission connected to the pneumatic system to actuate the pneumatic system to distally drive th~ staple pusher beyond the first predetermined position to a second advanced position to close the staple about the anvil.
In accordance with an alternative preferred embodiment, the apparatus for endoscopic application oE
surgical staples adapted to attach an object to body t:issue comprises a handle member and a g nerally elongated endoscopic portion connected to the handle member ~nd extending distally therefromO The endoscopic portion includes means for storing a plurality of staples, means for individually ad~ancing the staples distally for positioning adjacent the body tissue and anvil means for closing the ''~ : ;~ ..

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staple in a manner to encompass at least a portion of the object and to penetrate the body tissue to attach the portion of the object to the body tissue. The handle member comprises a pneumatic system including a supply of low pressure gas. The pneumatic system is adapt~d to convert the low pressure gas into a force to activate the staple advancing means. The apparatus further comprises transmission means for actuating the pneumatic means to ~ distally advance the staple advancing means, engaging means associated with the staple advancing means for selectiv~ly -preventing distal movement of the staple advancing means beyond a first predetermined position and release means for releas~ng the engaging means to permit further advancing movement of the staple advancing means beyond the first predetermined position to a second fully advanced position to close the staple about the anvil means.

BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described hereinbelow with reference to the drawinys wherein:
Fig. 1 is a perspective view of an apparatus incorporatiny the novel handle and pneumatic system of the present invention and adapted to apply surgical staples to attach objects to body tissue;
Fig. lA is a perspective view of the distal end portion of the apparatus of Fig. 1 illustrating an alternative embodiment for pivoting the staple storage magazine;

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Fig. 2 is an exploded perspective view with parts separated of the handle and pneumatic system of the apparatus of Fig. ~;
Fig. 3 is a cross-sectional view taken along lines 3-3 of Fig. 1, illustrating the handle system of the apparatus in the initial position;
Fig. 4 is a cross-sectional view taken along lines 4-4 of Fig. 3 illustrating the mechanism for providing distal movement to advance and to close staples at the distal end;
Fig. 5 is a cross-sectional view similar to Fig. 3 with the staple advancing trigger in the full proxima~
position to selectively partially advance a s~aple prior to firing;
Fig. 6 is an enlarged cross-seckional view of the pawl and ratchet system in the handle, illustrating the positioning of the system after proximal movement of the staple advancing trigger;
Fig. 7 is a cross-sectional view similar to Fig. 5 with the staple firing button in the depressed ad~anced position corresponding to firing of the staple;
Fig. 8 is a perspective view of an alternative embodiment of the handle and pneumatic system to be used with the apparatus of Fig. l;
Fig. 9 is an exploded perspectivP Yiew with parts separated of the handle and pneumatic system o~ Fig. 8;
Fig. 10 is a cross-sectional view taken along the lines 10-10 of Fig. 8 illustrating the initial position of the handle system;
Fig. 11 is a cross-sectional vi~w taken along lines 11-11 of FigO 10 illustrating the positioning of the , ~ , ~i77~
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pawl and ratchet system prior to pivotal movement of the staple advancing lever;
Fig. 12 is a cross-sectional view similar to Fig.
10 with the staple advancing lever in the fully pivoted position to selectively partially advance the staple prior to firing;
Fig. 13 is a cross-sectional view taken along lines 13-13 of Fig. 12 illustrating the positioning of the pawl and ratchet system after the initial advancement of the staple;
- Fig. 14 is a cross-sectional view similar to Fig.
12 with the staple firing button in the depressed advanced position corresponding to firing of a staple;
Fig. 15 is a cross-sectional view taken along 15 lines 15-15 of Fig. 14 illustrating the relationship of the pivoting lever with the staple advancing mechanism;
Fig. 16 is a perspective view o~ another embodiment of the handle and pneumatic system of the present invention;
Fig. 17 is a perspective view with parts separated of the handle and pneumatic system of Fig. 16;
Fig. 18 is a cross-sectional view taken along the lines 18-18 of Fig. 16 illustrating the handle in the initial position;
Fig~ 19 is a cross-sectional view similar to Fig.
18 with the staple firing button in an advanced position to actuate the pneumatic system to initially advance the staple;
Fig. 20 is a cross-sectional view taken along the 30 lines 20-20 of Fig. 19 illustrating the abutting 7 7 `~

relationship of the piston and piston stop prior to pivotal movement of the piston stop release button;
Fig. 21 is a cross-sectional view similar to Fig.
l9 illustrating the stop release button in the depressed position corresponding to release of the piston to complete the firing of the staple;
Fig. 22 is an enlarged cross-sectional view taken along lines 22-22 of Fig. 21 illustrating the piston in ~ alignment with the piston stop to permit :Eurther advancing movement of the piston;
- Fig. 23 is a perspective view of another alternative embodiment of the handle and pneumatic system of the present invention;
Fig. 24 i~ an exploded perspective view with parts separated of the handle and pneumatic system of Fig, 23;
Fig. 25 is a cross-sectional view taken along lines 25-25 of Fig. 23 illustrating the handle of the apparatus in the initial condition; ~
Fig. 26 is a cross-sectional view taken alony .:: :
lines 26-26 of Fig. 25 illustrating the piston of the pneumatic system received within the piston stop and the relative positioning of the piston stop prior to pivotal movement of the firing button; :
Fig. 27 is a cross-sectional view taken along~ :n lines 27-27 of Fig~ 25 illustrating the firing link operatively connected to the piston of the pneumatic system;
Fig. 28 is a cross-sectional view similar to Fig.
25 illustrating the staple firing button in an advanced- .
depressed position corresponding to firing of the staple;
Fig. 29 is a cross-sectional view taken along lines 29-29 of Fig. 28 illustrating the abutting ~:

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relationship of ~he piston and piston stop prior to pivotal movement of the stop release trigger;
Fig. 30 is a cross-sectional view similar to Fig.
28 illustrating the stop release trigger in a pivoted proximal position corresponding to release of the piston from the piston stop to complete firing of the staple;
Fig. 31 is an enlarged cross-sectional view taken along lines 31-31 of Fig. 30 illustrating the piston in ~ alignmenk with the piston stop to permit advancing movement of the piston;
- Fig. 32 is a cross-sectional view of another alternative embodiment of the handle of the present invention illustrating th initial unadvanced position of the apparatus;
Fig. 33 is a cross-sectional view taken along the lines 33-33 of Fig. 32 illustrating the mechanisms for advancing and closing the staples;
Fig. 34 is a cross-sectional view similar to Fig.
32 illustrating the actuating button in a first depressed position corresponding to the partially advanced position of the staple;
Fig. 35 is a cross-sectional view similar to Fig.
34 illustrating the actuating button in a second depressed position corresponding to firing of the staple;
Fig. 36 is a cross-sectional view of an alternative two-part pneumatic piston which may be incorporated with the handle systems of Figs. 3, 8, 16~ 23 and 32, illustrating the piston in an initial unadvanced position;
Fig. 37 is a cross-sectional view of the pneumatic piston of FigO 36, illustrating the p.iston in a ~irst . . .
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advanced position corresponding to at least partially advancing the staple;
Fig. 38 is an enlarged cross-sectional view taken along lines 38-38 of Fig. 1 illustrating ihe rotating mechanism for the endoscopic portion and the system for pivoting the staple storage magazine from the proximal end;
Fig. 39 is a cross-sectional view taken along lines 39-39 of Fig. 38;
Fig. 40 is a cross-sectional view taken along lines 40-40 of Fig. 38 illustrating the system for providing -pivotal motion of the staple storage magazine located at the distal end;
Fig. 41 is a cross-sectional view taken along lines 41 41 of Fig. 39 illustrating further details of the system for providing pivotal motion to the staple magazine at the distal end;
Fig. 42 is a view of the interior surface oE the inner sleeve of the manually operable collar of Figs. 38-41, projected as a flat surface to illustrate the helical groove provided for coaction with a pin to provide pivotal motion for the staple magazine at the distal end;
Fig~ 43 is a perspective view of an internal sleeve and pin which coacts with the inner sleeve shown in Figs. 41 and 42 which forms part of the system for pivc~ting the staple magazine at the distal end;
Fig. 44 is an exploded perspective view with parts separated, of the endoscopic section o~ the instrument o~
the invention, illustrating the staple advancing system and components thereoE;
Fig. 45 is an exploded perspectivP view with parts separated, o~ the staple storage magazine which is 2~ i77i~
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controllably pivotally mounted at the distal end portion of the endoscopic section;
Fig. 46 is a cross-sectional view taken along lines 46-46 of Fig. 1 illustrating the distal end of the instrumPnt including the pivotal staple magazine at three positions;
Fig. 47 is a cross-sectional view taken along lines 47-47 of Fig. 46 illustrating the staple next in line ~ and the pusher plate provided for advancing the staple toward a stapie closing anvil;
- Fig. 48 is a cross-sectional view of the distal end of the instrument shown in engagement with a surgical mesh positioned against body tissue prior to firing the staple;
Fig. 49 is a cross-sectional view taken along lines 49-49 of Fig. 48;
Fig. 50 is a cross-sectional view similar to Fig.
48 of the distal end of the instrument during the firing of the staple and after penetration into the mesh and body ~0 tissue, but prior to closure;
Fig. 51 is a view similar to Fig. 49, taken along lines 51-51 of Fig. 50;
Fig. 52 is a cross-sectional view of the distal end o~ the instxument after closure of the staple to attach the surgical mesh to the body tissue;
~ Fig. 53 is a cross-sectional view taken along lines 53-53 of Fig. 52 illustrating the staple ejection system for releasing the closed staple ~rom the anvils ,after firing;
Fig. 54 is a cross-sectional view similar to Fig.
52 illustrating the staple after closure about the surgical ~ ~ 7~ ~ ~
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mesh and body tissue and the distal end of the instrument withdrawn from the surgical mesh;
Fig. 55 is a cross-sectional view taken along lines 55-55 o~ Fig. 54;
Fig. 56 is a cross-sectional view o~ the distal end portion of the staple storing magazin2 of the instrument after firing a staple;
Fig. 57 is a frontal view of a repair in body ~ tissue illustrating one example of an arrangement of staples of the invention for attachment of reinforcing ~urgical mesh -to the tissue;
Fig. 58 is a perspective ~iew of a staple constructed according to the invention for attaching surgical reinforcing mesh to body tissue over a surgical repair; and Fig. 59 is another example of arranging the staples for attachment of the reinforcing surgical mesh to the body tissue in the area of a hernia repair.

2 0 DETAILED DESCRIPTION O:F THE PREFERRED ~:MBOD MENTS
Although the principles of the invention are applicable to various types of surgical fastener instruments, the invention will be fully understood from the follswing illustration of its applic~tion in a surgical ~astener instrument for hernia repair disclosed in commonly assigned U.S. patent application Serial No. 07/782,290, filed October 18, 1991, applicati3n Serial No. 07~861,065, filed March 31, 1992, which is a continuation-in-part o~
application Serial No. 7/782,290 and application Serial No.
07/950,425, filed September 23, 1991, which is a continuation-in~part o~ application Serial No. 07/861,065, , ,., , :: :. ~, -::

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the contents of each application being incorporated herein by reference.

GENERAL
Following a general description of the instrument, the description will be divided into separate sections to describe the structure and the desired movements produced thereby. Those sections include the handle system, the staple storage magazine pivoting system, the endoscopic section and staple firing system, the staple storage -magazine, the staple closing system and the staple. Also a kit ~or attaching objects such as surgical mesh is described.

THE INSTRUMENT
Referring initially to Fig. 1, there is illustrated in perspective view the apparatus 10 incorporating the novel handle system of the present invention and particulaxly adapted for endoscopic application of surgical staples to attach surgical mesh to body tissue during hernia repair. Except where noted otherwisa, the materials utilized in the ~omponents of the apparatus generally include such materials as polycarbonate for housing sections and related components, and ~tainless steel for such components which transmit forc~s. One preferred polycarbonate material is LEXAN brand polycarbonate available from General Electric Company. Other specific preferred materials such as nylon or glass filled nylon (for stxength) are also utilized. However, e~uivalent alternative materials will readily come to the mind o~ those skilled in the art.

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Apparatus 10 includes a handle portion 12 and an endoscopic section 14 having at its distal end portion a staple storage magazine 16 which pivots with respect to at least one side of the longitudinal axis extending centrally through the endoscopic section as shown in Fiq. lA.
Generally, staple storage magazine 16 will selectively pivot up to about 45 degrees with respect to the aforesaid longitudinal axis. In the illustration of Fig. 1 the staple ~ storage magazine ~6 is shown in general alignment with the longitudinal axis of the endoscopic section and in phantom -to illustrate a range of movement. The total range o-f pivotal motion of the staple storage magazine 16 as shown is approximately 90 degrees, i.e. 45 degrees to each side of neutral.
Referring generally to Fig. l, the handle 12 of instrument 10 includes frame 18, staple prepositioning trigger 20 which is slidably mounted to the frame and firing button 22 which is pivotally mount2d to an upper portion of the frame. Trigger 20 is proximally moved towards the main portion of frame 18 to initially selectiveiy position the staple in a slightly advanced position prior to firing.
Firing button 22 is pivoted towards frame 12 to actuate a pneumatic system to fire the staple.
A double knurled finger operative collar 2~ :is rotatable and adapted to rotatP the entire endoscopic ~ section 14 a full 360 degrees as will be described hereinbelow, while proximal movement of the operative collar 24 produces pivotal motion o~ the staple storage magazine to one of the positions shown in phantom in Fig. 1. To achieve the other position shown in phantom in Fig. 1, the collar 24 may be simply rotated 180 degrees thereby rotating the .: ~ ; : .. : . ~ .

entire endoscopic section and causing the position of the magazine 16 to be reversed as shown to the other position shown in phantom. Thus, it can be seen that the combination of full rotation of the endoscopic section and the pivotal movement of the staple storing magazine facilitates a wide range of articulation of the distal end of the staple magazine 16, thus facilitating application of staples over a wide range of locations ~ 180 degrees~ and in any of a ~ plurality of orientations. In the embodiment of the invention shown in the Figs., when the collar 24 is moved to -its proximalmost position the staple magazine is in one of the positions shown in phantom in ~ig. 1, i.e. at an angle with respect to the longitudinal axis of the instrument.
When the collar 24 is advanced to the distalmost position the staple magazine assumes the position shown in Fig. 1, i.e. in alignment with the longitudinal axis of the instrument.
Thus, in the preferred embodiment of Fig. 1, it can be seen that the full 90 degrees of movement of the magazine may be achieved simply by longitudinal movement sf collar 24 in combination with full rotation of the endoscopic section. The longitudinal movement of collar 24 causes pivotal movement of the staple storing magazine to ~5 degrees in one direction and rotation of the endoscopic section provides completion of the articulation of the ~~ magazine. Both of these movements in combination, facilitate a wide range of maneuvera~ility of the distal end of the staple magazine 16, thus facilitating application of staples over a wide range of locations (+ 180 degrees) and in any of a plurality of orientations.

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Alternatively, the positions of the staple storing magazine 16 may be achieved as shown in Fig. lA, i.~. by movement of the magazine between zero degrees and about 45 degrees on either side of the longitudinal axis. In such arrangement, to achieve the positions shown in phantom in Fig. lA, the collar 24 is moved distally and proximally, equal distances on either side of a neutral detent. Movement in one direction would pivot the magazine to one side and ~ movement in the other direction would cause pivotal movement o~ the magazine in the opposite direction. The directions -selected would be arbitrary. However, in this last described embodiment the orientation of the magazine would be the same throughout the 90 degree pivoting range, whereas in the preferred embodiment of Fig. 1, the orientation of the magazine when on one side is opposite the orientation when on the other. Further, in this embodiment the endoscopic section will be somewhat longer to accommoda~e the additional movement of collar 24.

THE HANDLE SECTION
Referring to Fig. 2, ther2 is shown an exploded perspective view with parts separated, of the novel handle system 12 of the instrument with associated components. The handle system 12 incorporates a pneumatic system which powers the staple firing stroke of th~ instrument. As previously noted, the handle is comprised o~ an outer fram2 or housing 18 preferably ~ormed of separate sections as shown, of polycarbonate material. The separate parts shown are attached by welding, adhesives, etcO Fig. 3 illustrates a cross sectisnal view o~ the handle mechanism taken along lines 3-3 of Fig. 1.

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The ultimate purpose of the handle system 12 is to provide distal movement to the pusher rod 26 which extends through the endoscopic section 14 and ultimately fires the staples. In the embodiment shown, the endoscopic section i5 intended to be permanently and rotatably attached to the instrument via rim 28 formed on a proximal end of endoscopic section 14 which is received within correspondingly positioned and dimensioned arcuate recesses 30 formed in ~ each part of frame 18 during assembly. 4ther conventional means for rotatably connecting endoscopic section 14 to -handle 12 can readily be determined by one skilled in the art.
Handle 12 is contemplated to be entirely disposable. However, it is also contemplated and within the scope of the invention to construct the endoscopic section to be selectively detachable whereby the handle may be sterilized and reused, or the endoscopic section can be sterilized, and the staple storage magazine re-loaded with staples for re-use. Alternatively a replacement staple magazine, and optionally a replacement endoscopic section, may be detachably secured to a disposable handle for multiple use during a single surgical procedure. Thus, any combination of alternatives may be incorporated within the scope of the present invention.
Referring now to Fiy. 2 in conjunction with Fig.
~~ 3, the novel handl~ system 12 will be described in detail.
Handle 12 includes a staple positioning mechanism operable by single finger trigger 20 which initially advances or "prepositions" a staple prior to firing and a firing mechanism operable by firing button 22 which actuates the pneumatic system to fire the staple~ The staple positioning .. . . .

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mechanism enables the operator to selectively advance a staple so that the staple legs protrude from the staple magazine. This initial advancement of th staple facilitates attachment of the mesh to the staple and positioning of the staple relative to the body tissue.
Trigger 20 is mounted for longitudinal movement within channel 32 of frame 18 and is operatively connected to pusher rod 26 through a linkage mechanism, identified ~ generally as reference numeral 34, to produce corresponding longitudinal movement to the pusher rod 26. Linkage -mechanism 34 includes trigger link 36, U-shaped driving link 38 connected to the trigger link and pusher housing 40.
U-shaped driving link 38 includes a pair of upwardly extending members 42 which are received within correspondingly dimensioned and positioned elongated apertures 44 formed in pusher housing 40 to operatively connect the two components.
Pusher housing 40 includes a pusher rod receiving portion 40a which receives the proximal end portion of pusher rod 26 to connect the housing to the rod. Pusher housing 40 advances distally in response to proximal movement of trigger 20 to advance pusher rod 2~ towards staple cartridge 16 to position the staple in an advanced position partially exposed from the distal end of staple magazine 16. Fig. 5 illustrates the corresponding movement ~~ o~ push~r housing 40 and pusher rod 26 when trigger 20 is moved proximally.
Referring now to Figs. 2, 4 and 6, the structure and function of the uni-motion clutch mechanism will be described. This clutch mechanism prevents proximal movement o~ pusher housing 40 in the event trigger 20 is released .. , . ~,, . . ~ , . . . .

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after squeezing motion of the trigger has begun but before the full stroke is completed. The clutch mechanism is self-releasing when pusher housing 40 reaches the distalmost position, thus permitting the entire pusher housing to return to the pre-advanced, or proximalmost conditionl and trigger 20 to also return to the initial position.
A ratchet plate 46 i5 fixed to frame 18 and possesses a surface defined by a pluralit~y of triangular ~ shaped parallel ridges 48 as best shown in Fig. 6. Pawl 50 is rockably mounted ~or distal and proximal movement with -pusher housing 40 through frame 18, and is biased toward ratchet plate 46 by a resilient wire spring or the like. The location o~ pawl 50 shown in Fig. 4 corresponds to the initial condition of the apparatus prior to proximal movement of trigger 20 with the pawl 50 located proximal of ratchet plate 46. Pawl 50 is pre~erably of stainless steel while ratchet plate 46 is made of brass or other compatible material.
While trigger 20 is squeezed or moved proximally producing distal motion to pusher rod 2~, pawl 50 engagably slides distally past the ratchet surface 48 of ratchet plate 46 as shown in Fig. 6 such that one corner of the tip 52 of the pawl 50 sequentially engages each right angled ridge o~
ratchet plate 46 to thereby prevent proximal movement of the pusher rod 26 in the even trigger 20 is released by the ~~ operator. The engagement of pawl 50 with ratchet plate 46 provides audible confirmation that pusher housing 40 and pusher rod 26 are moving distally since the user will hear a series of progressive audible click5. This action continues with the tip 52 of pawl 50 sliding past the ratchet surface of the ratchet plate 46 until the pawl is positioned .
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distally of the distalmost tooth. Preferably, trigger 20 is in its distalmost position as shown in Fig. 6 when pawl 50 clears ratchet surface 48.
Upon clearing ratchet surface 48, the pawl 50 moves proximally with pusher rod 26 as dlescribed under the action of negator spring 54 which is attached to pusher housing 40. The end portion 52 of pawl 50 which is now free, engages the distal end of the ratchet plate 4~ causing the pawl to rock to a reverse direction so as to slide proximally past ratchet surface 48 of ratchet plate 46 -without interference to the proximal movement of the pusher rod 25. Thusr it can be seen that the clutch mechanism as described will e~fectively permit squeezing trigger 20 while maintaining all positions midway through the stroke, and while permitting return motion thereof after the trigger has moved to its distalmost position or upon complation of the firing stroke as will be appreciated from the description ~elow. The clutch mechanism allows the operator to selectively advance the staple beyond the distal end of staple magazine. The operator may then turn full attention to locating the prepositioned staple in the d~sired target location, at which point the pivoting of the trigger mechanism may be resumed and the cycle completed or the pneumatic system actuated to ~ire the staple. This staple prepositioning feature greatly facilitates staple placement within the surgical mesh and body tissue.
Referring now to Figs. 2~ 3 and 5, negator spring 54 is formed of a resilient flat spring material and is coil2d about rotational bar 55. The free end of negator spriny 54 is attached to pusher housing 40 via anchor pin 57 as shown, while the spring 54 is normally biased toward the ~i7~ 1 ~

coiled configuration shown in Fig. 3. It can therefore be appreciated that upon firing the instrument negator spring 54 assumes control and returns pusher rocl 26 to the initial proximal location by the automatic winding action of the negator spring to its original unloade~ configuration. The constant force of negator spring 54 uniquely prevents the natural tendency of the user to rotate the hand as with springs which increase in force when progressing through a ~ ~ull spring cycle.
Referring again to Figs. 2 and 3, the staple -firing mechanism will now be described. The staple firing mechanism provides the power stroke to ultimately fire the staple for attachment to the body tissue and incorporates a pneumatic system having a container 56 of relatively low pressure gas and a pneumatic actuator identified generally by reference numeral ~8. Container 56 is adapted for slight reciprocal longitudinal movement within frame 18 and includes a stem valve ~0 at one end which releases the gas during proximal movement of the container 56. Container 56 is normally distally biased by spring 62 which is positioned about valve 6U between the container and a bearing wall of gas tube 64. Container 56 dispenses the relatively low pressure gas through stem valve 60 and tubP 64 when firing button 22 is depressed.
The pressure o~ the gas in container 56 during ~ operation of the apparatus is typically less than about 200 psig and preferably in the rang~ ~rom about 80 psig to about 160 psig. Any suitable non~toxic gas can be used including but not limited to halogenated hydrocarbons which are gaseous at room temperature, e.y., fluorinated hydrocarbons r ,~

'` :~ '` ' ' ` :

; ~ '~ ~" '` ' : ' 1' `~`" ~ ' ~

7 7 .` ~

such as Freon 12 or chlorinated hydrocarbons such as Freon 15234.
Pneumatic actuator 58 includes pneumatic cylinder 66 and pneumatic piston 68 disposed within the cylinder 66.
Cylinder 66 receives the gas emitted from container 56.
Piston ~8 is pneumatically sealed to cyl:inder 56 by "O" ring 70 and is mounted for reciprocal motion :in the cylinder in response to admission of gas therewithin. Distal longitudinal movement of piston 68 advances pusher rod 26 as will be described in greater detail below.
- Referring still to Figs. 2 and 3, firing button 22 of the staple firing mechanism is opera~ively connected to a firing rod 74 via intermediate link 72, which rod 74 extends longitudinally from the firing button towards the proximal end of the apparatus. Firing rod 74 includes a transverse portion 76 on its proximal end which is received within a correspondingly positioned channel 78 formed in piston 68.
Channel 78 is sufficient in length to accommodate transverse portion 76 of firing rod 6~ during the full power stroke of piston 68.
A coiled spring ~0 affixed to the proximal end of firing rod 74 normally biases the firing rod in the proximal direction. It can therefore be appreciated that after the pivotal motion of firing button 22 towards frame 18 from the position shown in Figs. 3 or 5 to the position shown in Fig.
7 to advance firing rod 74, coiled spring ~0 will return the firing rod 74 and the firing button 22 to its initial position of Fig. 3.
Referring again to Figs. 2 and 3, a rocking lever 82 is pivotally mounted about pin 84 in the general midportion of frame 18. The upper portion of the rocking 7 7 ~ ~

lever 82 is in engaging contact with bearing surface 88 of piston 68 while the lower portion of the rockiny lever is in engaging contact with pusher disk 86 affixed to the distal end surface of container ~6. Rocking lever 82 pivots in response to distal movement of piston 68.
Referring now to Fig. 7, depression of firing button 22 towards frame 18 advances firing rod 74 distally whereby the transverse portion 76 of the firing rod engages ~ forward bearing surface 87 defined by recess 78 of piston 68 (Fig. 5~ to cause corresponding advancing movement of the -piston. Distal longitudinal movement of piston 68 causes counterclockwise pivotal movement of rocking lever 82 which causes the lower portion of rocking lever 82 to move gas container 56 in the proximal direction. Proximal movement of container 56 effects depression of valve 60 to thereby cause release of gas from container 56 and into cylinder 66 to drive piston 68 distally. Container 56 continues to release gas into cylinder 66 until the upper portion of rocking lever 82 clears bearing surface 89 defined on the lower side of piston 68. It is to be appreciated that the gas released by container 56 during the power stroke is sufficient to drive piston 68 into pusher housing 40 and to advance housing 40 and pusher rod 26 to fire a staple :Erom staple magazine 16. The dimension or length of beariny surface 89 may be adjusted to control th~ amount of gases released by container 56.
After completion of the power stroke, piston 68 returns to its initial position under the influence of spring 54O 3uring the return movement of piston 68, cal~miny surface 90 formed in piston 68 causes the upper portion of rocking lever 82 tu move transversely out of engagement with .~; .. .. . . .
.".... ,.~: ,, ~ .
,. . .

i 7 7 1 ~

the piston to permit the piston 68 to assume its initial position.
Referring now to Fig. 8, there is illustrated an alternative embodiment of the handle system of the present invention. Handle 92 is simila~ in m~st respects to the handle of Fig. 1 except that the staple positioning mechanism has been modified. In particul~r, elongated lever 94 replaces the trigger 20 of the embodiment of Fig. 1~
~ Lever 94 facilitates manipulation by the user by reducing the amount o~ force required to preposition the staple.
- Referring now to Figs. 9 and 10, lever 94 is pivotally mounted to frame 96 by mounting pin 98 and is operatively connected to driving link 100 by connecting link 102. Driving link 100 is pivotally mounted about pin 104 and pivots fxom the position shown in Fig. 10 to the position shown in Fig. 12 in response to movement of lever 94 towards frame 96. Driving link 100 includes an upstanding projection 106 which operatively enga~es a bearing wall defined within the interior of pusher housing 108 (See Fig. 15) to cause corresponding advancing movement of the housing and pusher rod 26 to initially advan~e or preposition the staple. Fig. 12 illustrates lever 94 in a pivoted position adjacent frame 96, which position corresponds to the staple prepositioning stroke of the apparatus.
~~ Referring now to Fig. 14, the staple is ultimately fired by depressing firing button 110 to actuate the pneumatic system to provide the required force and des:ixed movements of the staple firing mechanism. The components of the staple firing mechanism and pneumatic system 112 are structurally and functionally equivalent to their ~ ~ ~ 7 ~ ~ ~

corresponding components described in the embodiment of Fig.
1.
Handle 92 also includes a clutch mechanism, identified generally as reference numeral 114, including pawl 116 and ratchet plate 118 as shown in Figs. 11 and 13.
Clutch mechanism 114 is structurally and functionally similar to the clutch mechanism described in the embodiment of Fig. 1 and serves in preventing proximal movement of pusher housing 108 in the event lever 94 is released after squeezing motion of the lever has began but before the full -stroke is completed. Fig. 11 shows pawl 116 in its proximalmost position relative to ratchet plate 118 pr:ior to squeezing of lever 94 towards frame 96. Fig. 13 shows pawl 116 in its distalmost position after movement of lever 94 towards frame ~6.
Referring now to Fig. 16, there is illustrated in pPrspective view another alternative embodiment of the handle system of the present invention. In accordance with this embodiment, the staple prepositioning stroke or function is powered by the pneumatic system.
Referring initially to Figs. 16, 17 and 1~, handle 120 includes frame 122 having firing button 124 pivotably mounted to the upper surface portion of the frame about pin 126 and release button 128 pivotally mounted about pin 130.
As will be appreciated from the description below, firing button 124 initiates the power stroke provided by the pneumatic system and functions in positioning the staple in a slightly advanced position to f~cilitate attachment to the surgical mesh and subsequent placemPnt of the staple in the body tissue. Release button 128 releases the pneumatic ..... ":, ~ 7 ~

piston o~ the pneumatic system to permit full completion of the power stroke to fire the staple.
Firing button 124 is biased to its upward pre-actuated position by spring 132 which is wrapped about mounting pin 126. Firing button 124 is operatively connected to firing link 134 via intermediate link 136.
Firing link 134 extends longitudinally wit:hin frame 122 and includes a downwardly extending projection 136 at its d.istal end which is operatively connected to the pneumatic system, identified generally as reference numeral 138, as will be described.
Pneumatic system 138 is substantially similar in structure and function to the pneumatic system described in connection with the two previous embodiments and includes piston 140 reciprocally mova~le in cylinder 142 in response to release of gas from container 144. Piston 140 includes a partial channel 146 formed in its upper surface to receive downwardly extending projection 136 of firing link 134 to connect the firing link with the pneumatic system. Partial channel 146 defines a forward bearing surface 148 which is engaged by downwardly projecting membar 136 of firing link 134 during distal longitudinal movement of the ~iring link 134 to thereby cause corresponding longitudinal movement of piston 140 as shown in Fig. 19. Piston 140 is directly connected to pusher rod 26 at its distal end portion by conventional means.
Referring particularly to Figs. 17 and 18, rocking lever 150 mounted about pin 152 operatively engages piston 140 at an upper end portion of the lever and engages pusher disk 154 affixed to container 144 at a lower portion of the r~

.: ~. . .
~ 7~ ~

lever. Rocking lever 150 pivots in response to longitudinal movement of piston 140.
Release button 128 is biased in the proximal direction by spring 156 and is operatively connected to release rod 158 which extends longitudinally within frame 122 beneath piston 140. Release rod 158 is adapted for reciprocal longitudinal movement in response to corresponding pivotal movement of release button 128. The distal end portion of release rod 158 includes a sloped portion 160 which defines a lower bearing surface portion -162 on which a rectangular piston stop 164 rests.
Piston stop 164 defines a genPrally rectangular aperture 166 which receives the distal end portion of piston 140. Piston stop 164 is reciprocally vertically movable between a lower piston engaging position (Figs. 19 and 20) and an upper piston non-engaging position (Figs. 21 and 22)o As shown in Figs. 19 and 20, in the engaging position, piston 140 and aperture 166 of piston stop 164 are misaligned such that an upper transverse bearing surface 168 of the piston 140 engages an upper surface of piston stop 164. In the non-engaging position shown in Figs. 21 and 22 piston 140 and aperture 166 of piston stop 164 ars in general alignment to permit continual distal advancement of the piston. Piston stop 164 is normally bi~sed in the lower engaging position by resilient lever 170.
In use, firing hutton 124 is depressed as shown in Fig~ 19 which effects longitudinal distal mov~ment of firing link 134. During longitudinal movement of firlng link 134, projecting member 136 of the firing link engages forward beariny surface 14~ defined by channel 146 in piston 140 to advance the piston. Advancing movement of piston 140 causss ~ , :
: ~-D '~

rotation of rocking lever 150 about pin 152, which causes proximal movement of container 144 and, accordingly, release of gases from the container. The released gases drive piston 140 in the distal direction. Piston 140 continues in the distal direction until outer bearing sur~ace 168 of the piston engages piston stop 164 as shown. In this position of piston 140, the pusher rod 26 is advanced sufficiently to partially expose a staple from staple magazine 16 to thereby preposition the staple to facilitate staple placement in the surgical mesh and/or body tissue.
- As piston 140 moves distally, rocking lever 150 remains in a pivoted engaged position with container 144 by contact with lower bearing surface 172 of the piston.
Accordingly, this ensures movement of container 144 to its proximalmost position, thus ensuring sufficient release of gas from the container and sufficient gas build-up in the cylinder to complete the firing stroke. It is to be appreciated that the dimension of bearing surface 172 may be varied to control the amount of rotational movement of rocking lever 150, and, thus the amount of gases released by container 144. Once the piston 140 advances to a position where lower bearing surface 172 clears rocking lever 150, tha release of gas from container 144 is stopped.
Referring now to Fig. 21, release button 128 is depressed which effectuates correspsnding distal movemlent of releas~ link 158. As release link 158 ad~ances distally, piston stop 164 slides along sloped portion 160 sf the release link to assume an elevated position as shown. In this position, aperture 166 of piston stop 164 is in alignment with piston 140 ~See also Fiy. 22) to permit continued distal movemant of the piston and corresponding . , . ~ ,; :, : : : : :

7 ~
.~

movement of pusher rod 26 to thereby fire a staple from staple magazine. As previously mentioned, the gas build-up in cylinder 142 is sufficient to drive piston 140 to fire a staple once the piston is disengaged from piston stop 164.
Referring again to Fig. 21, release of release button 128 upon completion of the power stroke effects return of piston 140 to its initial position under the influence o~ negator spring 174. During the return movement of piston 140, camming surface 176 formed in piston 140 causes the upper portion of rocking lever 150 to move -transversely out of engagement with the piston to permit the piston to assume its initial position.
Referring now to Figs. 23, 24 and 25, there is illustrated another embodiment of the handle system of the present invention. Handle system 178 is similar in most respects to the embodiment of Fig. 16 and includes fir:ing button 180 pivotally mounted about pin 182 in the forward portion of frame 184 and release trigger 186 pivotally mounted to the lower surface portion of the frame. Firing 20 button 180 is operatively connected to firing link 188, which linX 188 is operatively connected to piston 190 of the pneumatic system. In particular, downward extending pxojection 192 of firing link 188 is received within channel 194 ~ormed in piston 190.
Release trigger 186 includes a horizontal bearing surface 196 at its proximal portion on which piston stop 193 rests. Piston stop 198 is adapted for transverse movement between a downward piston engaging position (Figs. 28 and 29~ and an upward piston disengaged position ~Fig. 30 and 30 31) in response to pivotal movement o~ release trigger 186.
Piston stop 198 is normally biased to the downward piston ". ~

~ ~ i 7 7 ~ ~

engaging position by coil spring 200 which is in engaging contact with the upper surface of the piston stop 198 as shown in Fig. 26.
In use, depression of firing ~utton 180 causes advancing movement of firing link 188 ancl piston 190 and rotation of rocking lever 202 to thereby effect release of gases from container 204 to drive piston 190 to the advanced position shown in Fig. 28 in engagement with piston stop 198. In this position, a staple is slightly advanced from cartridge 16 to pre-position the staple for subse~uent -placement to the surgical mesh and/or body tissue.
Therea~ter, trigger 186 is squeezed to elevate piston stop 198 and align the aperture of the piston stop with piston 190 as shown in Figs. 30 and 31. Accordingly, piston 190 is released from its engagement with the piston stop 198 so as to be driven by the gaseous build up in the cylinder to complete the power stroke and fire the staple. It is to be appreciated that in the alternative, the apparatus may be adapted such that further advancing movement of piston 190 after release of piston stop 198 may cause further rotational movement o~ rocking lever 202 and release of additional gases from the gas container to assist in driving the piston.
Upon completion of the power stroke, firing link 188 is returned to its initial unadvanced position by coil spring 209 which is affixed to the proximal end of the link.
Similarly, piston 190 is returned to its initial position by negator spring 199 (Fig. 27) and piston stop 198 is ret:urned to its downward piston engaging position by coil spring 200.
Referring now to Figs. 32 and 33, there is illustrated another alternative embodiment of the handle ;",`,; , ~ ' , -, , , 7 ?~ ~

system of the present invention. Handle system 206 is similar to the handle system described in connection with the embodiments of Figs. 16 and 23 except that the current handle 206 is provided with a single actuating button 208 to perform both the staple prepositioning function, i.e., to actuate the pneumatic system to initially advance the staple, and the release function, i.e., t:o release tha pneumatic piston to permit full completion of tha power stroke to fire the staple.
Actuating button 208 of handle 206 is operatively -connected to two link members namely, firing link 210 and release link 212, which extend longitudinally within the handle section. The firing link 210 is operatively connected at its forward end portion to a reciprocating slide 214 which is mounted for reciprocal movement on a lower ~urface portion of an actuating rod 216 and moves independently relative to the rod. Reciprocating slide 214 moves in a distal direction in response to distal movement of firing link 210, which linX 210 moves distally by initial depression of actuating button 208. A recess 218 is formed in reciprocating slide 214 and is dimensioned to receive the forward end portion of rockin~ lever 220.
Piston 222 of the pneumatic system includes a forward camming portion 224 defining camming surface 226.
Camming sur~ace 226 contacts pin 228 which connects rear and forward link members 23~, 232 respectively. A portion of ca~ming pin 228 extends beyond one o~ the front link members 232 in position to be engaged by camming surface 226. Rear link 230 is mounted at its lower portion to the frame of handle 206 by stationary mounting pin 233~ Front link 232 is oparatively connected to actuating rod 216 via connecting ' '' ' '' . ~ ' ' ` ' -~ 4~~ ~ 77~

~35-pin 234. As will be appreciated from the description provided below, distal movement of piston 222 advances actuating rod 216 in the distal direction due to coordinating movement of front and rear links 230, 232.
Release link 212 includes a sloped portion 236 at its distal end which defines a lower bearing surface portion 238 on which rectangular piston stop 240 rests.
Handle 206 also includes a coiled spring 242 disposed adjacent the distal bearing surfaca 244 of release link 212. As will be appreciated from the description -provided hereinbelow, spring 242 provides a tactile feel to the user that the prepositioning stage of the stapler has been obtained.
In use, actuating button 208 is depressed a first distance as shown in Fig. 34 which effects lonsitudinal distal movement of both firing link 210 and release link 212. Focusing initially on firing link 210, longitudinal movement of the firing link causes reciprocating slide 214 to move distally due to its interconnection with the firing link. Distal movement of reciprocating slide 214 effects rotation of rocking lever 220, due to the engagement of the rocking lever with recess 218 of the slide, which thereby releases gas from the container in the same manner described in connection with the embodiments of Figs. 16 and 23. Fig.
34 shows the condition o~ handle 206 upon completion of the first or prepositioning stage. As shown in Fig. 34, after release of slide 214 with rocking lever 220, slid 214 returns to an initial proximal position relative to actuating rod 216. Such return of sllde 2~4 is effected by a return spring (not shown~ disposed within the body o~ the slide 214.

~ ~ .. . .

~ ~ 77 ~

It is to be appreciated that during initial movement of reciprocating slide 214 actuating rod 216 remains stationary. The released gases drive piston 222 in the distal direction which causes camming surface 226 of camming portion 224 to engage camming pin 228 and force ~he pin 2~8 to move along the camming surface 226. A5 camming pin 228 moves along camming sur~ace 226, the front link members 232 move distally, which drives actuating rod 216 ~ distally where bearing surface 246 (Fig. 32) of the actuating rod engages actuating stop 240 as shown in Fig.
-34. Such advanced position of piston 222 and actuating rod 216 corresponds to khe prepositioned stage of the apparatus where the staple is slightly advanced for positioning adjacent the body tissue.
During the initial depression o~ actuating button 208, release link 212 also advances as previously mentioned.
In particular, release link 212 moves distally until d:istal bearing surface 244 of the release link 212 engages coiled spring 242. It is to be noted that in this position of release link 212, firing link 210 has been advanced to the posltion where it actuates the pneumatic system to preposition the staple. Upon engagement with spring 242, the surgeon is tactilely made aware that the prepositioning stage o~ the apparatus has been achieved due to the restraining force pro~ided by spring on release linX 212.
To complete the firing o~ the staple, the surgeon further depresses button 208 against the resisting force provided by coil spring 242 to the position shown in Fig.
35, which causes release link 212 to further advance distally. The distal movement of release link 212 is resisted by coil spring 242 which indicates to the surgeon . . .
.:- . :, . .

~ ~ 7~

that firing of the staple is imminent. As release link 212 advances, actuating stop 240 slides along sloped portion 236 of the release link 212 to assume the elevated position shown in the Fig. In this position~ the aperture of actuating stop 240 is in alignment with actuating rod 216 to permit continued movement of the actuating rod 216 and the pusher rod to complete the firing of the staple in a similar manner described in connection with the embodiments of Figs.
~ 16 and 23. After the firing cycle is completed, actuating button 208 is returned to its initial proximalmost position -by return spring 247.
Referring now to Fig. 36, there is illustrated in cross-section an alternative embodiment of a pneumatic piston which may be readily incorporated in the pneumatic systems of the prior handle systems of Figs. 3, 8, 16 and 23. Piston 248 includes an inner rod 250 concentrically received within a bore defined in outer tubular member 252 as shown. Inner rod 250 includes two separate sections, namely, proximal section 250a and distal section 250b.
During the prepositio~ing stage of the instrument, gas is xeleased into inlet 251 and ~irected against surfac~ 253 of proximal section 250a, which drives the proximal and distal sections o~ inner rod 250 distally to the position shown in Fig. 37. During such distal movement of inner rod 250, outer tubular member 252 remains stationary. This position ~~ of inner rod 250 corresponds to the prepositioning stage of the apparatus where the staple is slightly advanced and exposed from the staple cartridge. Also; in such position of inner rod 250, the distal section 250b of inner rod 250 becomes engagingly connected to outer tubular member 252 via -.~, . -;;:.-. .

2 ~ ~ 7 ~

an engaging mechanism identified generally as reference numeral 254.
~eferring again to Fig. 36, in conjunction with Fig. 37, engaging mechanism 254 includes transverse member 256 which is securely mounted at one end portion to distal section 250b of inner rod 250. The second end portion of transverse member 256 is received within a groove 258 formed in tubular member 252 where it is connected by conventional means to a hollow cylindrical sleeve 260 disposed about the outer tubular member 252. Also provided as part o~ the -engaging mechanism is a pair of outwardly biased oppos,ed springs 262 connected to outer tubular member 252 as shown.
Springs 262 each have a transverse connecting member 2163 which is received within a correspondingly dimensioned slot 264 formed in the distal section 250b to connect the outer tubular member to the distal section of the inner rod. In particular, during the prepositioning stage of the apparatus, cylindrical sleeve 260 advances with inner rod 250 and engages springs 262 to collapse the springs. The transverse connecting member 263 aligns with the correspondingly dimensioned slots 2~4 formed in distal section 250b and are received thPrewithin as shown in Fig.
37 to connec-t the distal section 250b o~ inner rod 250 with outer tubular member 252.
A significant advantage o~ having inner rod 250 move independently from outer tubular member 252 during the prepositioning stage of the apparatus is to reduce the gas requirements during this stage. In particular, minimal force is required to move the pusher rod to initially advance the staple during the prepositioning stageO
Therefore, in an effort to consexve the amount of gas . ~ . , .
~ . . .
:~ - .

~77~

released by the gas container, only the inner rod 250 is required to advance so as to longitudinally move the pusher rod. The inner rod provides sufficient mass to move the pusher rod to initially preposition the staple. However, increased mass is required to create the forces sufficient to close the staple about the anvil. Therefore, in accordance with this ambodiment, the inner rod 250 is connected to the outer tubular member 252 after the prepositioning stage of the apparatus to satisfy the mass requirements to close the staple.
- Referring again to Fig. 37, once the piston 248 is advanced to the position corresponding to the prepositioned stage of the apparatus and the locking mechanism 254 is engaged to connect the distal portion 250b of the inner rod 250 with the outer tubular member 252, a second gaseous release is directed into inlet 265 and through channel 267 formed in proximal section 250a of rod 250. Channel 267 directs the gases into an inlet opening 269 and against a bearing surface (not shown) of distal section 250b, which drives the distal section 250b and connectèd outer tubular membPr 252 distally to advance the pusher rod to close the staple.
It is envisioned that on~ skilled in the art could readily modify the pneumatic systems and linkage mechanisms disclosed in the prior embodiments to operative with piston 248. For example, it is possible to incorporate a ~alve mechanism to control the direction of the gas flow from the gas container between the inlet opening 251 and the inlet opening 265. Further, the piston 248 may be interconn~cted to the rocking lever in a manner readily determinad by one . ~. , .

77 ` ~

skilled in the art to ause the first and second gaseous releases from the pneumatic container.

THE STAPLE STORAGE MAGAZINE PIVOTING SYSTEM
Referring to Figs. 38-44, the system for pivoting the staple storage magazine located at the distal end o~ the endoscopic section 14 will now be described. Fig. 38 illustrates double knurled finger operablle collar 24 which i5 mounted for rotation with the endoscopic section 14 by ~0 inwardly extending pin 266 which is slidably positioned -within longitudinal groove 268 in the outer housing half section 14a of endoscopic section 14, as shown in further detail in Fig. 38. Thus, collar 24 is readily slidable distally and proximally while pin 266 slides within groove ~5 268. Thus while permitting slidable movement of collar 24, pin 266 prevents independent rotation of collar 24 relative to the endoscopic section 14. Accordingly, when collar 24 is gripped between the user's fingers and rotated, the endoscopic section 14 rotates with the collar.
Positioned within finger opsrable collar 24 is helically grooved inner sleeve ~70 fabricated of a suikable plastic material such as nylon, glass filled ~or strength.
Helically grooved inner sleeve 270 is generally cylindrical in shape and includes a helical groove 272 shown in phantom lines in FigO 3B and illustrated schematically in the projected ~rontal view of the sleev~ shown in Fig~ 42. The sleeve 270 is fixedly at-tached to outer collar 24 for rotation therewith. In the projected view of Fig. ~2, the helical groove appears as a diagonal groove having a linear shi~pe. In Fig. 41, ~inger operabl collar 24 is shown in cross--section and the inner helically grooved sleeve 270 is ,i .. , : ~. :: : .

shown whereby helical groove 272 is represen-ted at two locations as viewed in Fig. 41. In Fig. 41, the cross-section of groove 272 at the 10 o'clock position (where lines 41-41 are located in Fig. 39) is just distal o~ the cross-section of groove 272 shown in phantom at the 12 o'clock position.
Referring now to Fig. 38 in conjunction with Figs.
39-43, elongated internal cylindrical sleeve 274 is positioned partially within inner helically grooved sleeve 270 and collar 24 when collar 24 i5 in the distalmost -position, as shown in Fig. 38; however, when collar 24 is withdrawn to the proximalmost position as shown in phantom lines in Fig. 38, the major portion o~ internal cylindrical sleeve 274 is positioned within collar 24 as shown. Internal sleeve 274 is preferably of nylon (preferably glass filled ~or strength~ and defines a distal face 276 which is generally oriented at an acute angle with respect to the longitudinal axis of the instrument as shown clearly in Figs. 38 and 43. The sleeve 274 contains pin 278 extending radially outwardly ~rom the outer surface as shown. Pin 278 is preferably o steel or it may be formed of nylon integral with sleeve 274. Pin 278 is positioned for slidable movement within the helical groove 272 o~ inner sleeve 270 of collar 24 such that proximal moYement o~ collar 2~ will cause pin 278 to follow the groove 272 causing slesve 27~ to rotate in one direction. Similarly, distal movement o~
collar 24 to the position shown in phantom lines in Fiy. 38 will cause pin 278 to traverse groove 272 in the cpposite direction thereby causing sleeve ~74 to rotate in the opposite d.irection~

.: - . .
:, . `
::.............. .. .

The significance of the rotational motion of sleeve 274 as it pertains to the pivotal motion o~ staple storing magazine 16 will be described in further detail hereinbelow. At this stage, however, it is sufficient to state that the obliquely oriented distal face 276 of sleeve 274 engages the proximal ends of a pair of longitudinally extending push rods 280, 282 shown in phantom lines in Fig.
43 and more clearly in Fig. 44 such that when collar 24 is ~ moved distally or proximally, inner sleeve 274 also rotates ~o and tha rods 280, 282 respectively move in e~ual and -opposite directions by the engagement with different portions of oblique distal face 276 with these rods. In ~ssence, one rod is enyaged by a surface portion distal of the surfa~e portion on the side of face 276 which engages the other rod. Thus, when the sleeve 274 is rotatPd in one direction, rod 282 moves in the distal direction while rod 280 withdraws proximally the same distance, and when sleeve 274 is rotated in the opposite direction, rod 280 moves in the distal direction and rod 282 moves proximally the same di~tance.
Collar 24 contains rotary ridges 24a in th~ distal hal~ and longitudinal ridges 24b in the proximal half, and is thus conveniently movable longitudinally and rotatably by the user when the appropriate knurled portion is gripped between the user's ~ingers. Howe~er, the operator need not grip th2 collar 24 at any specigic locations. The ridges may be formed integral by molding procedures or alternatively may be in the form of knurled surfaces. The rotary ridges respectively permit collar 24 to be finger movable distally and proximally, while the longitudinal ridges assist in rotation o~ collar 24 by hand. Rotational . .; ~ , ,; , ,: : . : : :

i .: i :,. . : .

it~

motion of the collar causes the endoscopic portion 14 to rotate while proximal movement of the collar in a preferred embodiment causes staple storing magazine 16 to pivot up to about 45 degrees in one direction with respect to the longitudinal axis o~ the instrument as shown in Fig. 1.
Distal movement of the collar 24 to the distalmost position shown in Fig. 38, caus~s staple storing magazine 16 to withdraw to the original orientation shown in Fig. 1 which ~ is generally in line with the endoscopic section. Thus, by pivoting the staple storing magazine up to 45 degrees and by -rotating the endoscopic portion 14, the total range of movement o~ the staple storing magazine is 45 degrees to either side o~ the endoscopic section traversing a total of 9o degrees of effective pivotal movement. With respect to movements of collar 24, the direction which produces pivotal motion of staple storage magazine 16 away from the longitudinal axis or toward the axis is clearly a matter of choice and would be determined by the respective configurations of the coacting components.
In the alternative embodiment shown in Fig. lA, the internal sleeve 274 and forward face 276 are configured such that collar 24 may be positioned midway between proximal and distal positions~ The mid-position will correspond to the staple storage magazine being at zero degrees with respect to the longitudinal axis. Collar movement in one direction from neutral will produce up to 45 degrees o~ pivotal movement of magazine 16 and collar movement in the other direction on the side of neutral will produce pivotal movement of the magazine 16 up to 45 degrees in the other direction. A major distinction in this embodiment is that the actual orientation of the magazine .:,.:::. ,....... :
:..,: . ~.;:

~ rl 7 i ~L

with respect to the longitudinal axis will di~fer on either side of neutral.
Referring now to Figs. 45 and 46, the system for providing pivotal motion to the staple storing magazine 16 is illustrated at the distal end of the instrument. In Fig.
46 the staple storage magazine 16 is shown in the position ~enerally in alignment with the endoscopic section and is shown in phantom lines at the pivoted locations corresponding to plus or minus 45 degrees. The staple storage magazine is formed of an outer housing of a suitable -plastic material such as polycarbonate and is ~omprised of upper housing half section 16a and lower housing hal~
section 16b attached by welding, adhesives, etc. The upper housing half section 16a contains an indentation 284 at tAe proximal end having a "V-shaped" cross section and the lower housing half section 16b contains a similar indentation 286 also having a "V-shaped" cross section as shown. Both indentations 284, 286 are adapted -to respectively Pngagably receive the distal ends of rods 280,282 (which are rounded) such that when the rods are respectively and alternately moved in the proximal and distal directions as described hereinabovet one rod may ad~ance distally to cause the upper housing to rotate and the other rod withdraws to permit the pivotal mo-tion of the staple magazine. For example, as shown in Fig. 46, when rod 282 moves distally, engagemerlt of the tip of the rod 282 with indentation 284 in upper housing 16a of staple storing magazine causes the staple magazine to pivot downwardly as shown in phantom.
Similarly, equal and oppositely wi-thdrawing rod 280 will accommodate the downward movement of the staple storing magazine 16. In a similar ~ashiorl when the collar ~ 7~ 1 ~

24 is moved in the opposite distal direction the movement of each rod is respectively reversed causing rod 280 to move distally and to engage the lower housing 16b of staple storing magazine 16 and rod 282 withdraws to accommodate the pivotal movement of staple storing magazine back to the original (or neutral) position in general alignment with the endoscopic section as shown in Fig. 46.
Alternatively one rod may be provided and connected to the staple storage magazine and adapted to pivot the magazine by causing such rod to move proximally -and distally thereby actually pivoting the magazine about the pivot point.
In the alternative, as disclosed in commonly-assigned U.S. patent application Serial No. 07/950/425, filed September 23, 1992, which is previously incorporated herein by reference, the staple storage magazine may be pivotally movable to positions 32.5 n and 65u respectively relative to the longitudinal axis defined by the endoscopic ~e~tion via a double knurled collar which is similar to collar 24 shown in Figs. 38-430 Dual detent mechanisms are provided to positively establish the o a J 32.5 or the 65 positions. Further, in accordance with this embodiment, the staple storaga magazine is capable of rotating indepenclent about its own central axis.
THE ENDOSCOPIC SECTION AND STAPLE FTRING SYSTEM
The endoscopic section 14 is shown clearly in FigO
44 and is mounted for rotation relative to the handle section 12. As noted above, the endoscopic section may be permanently attached to the handl as shown in a disposable instrumen~; alternatively as noted above, it may be :
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removably attached to a re-usable handle, or a variety of other combinations or configurations.
Referring again to Fig. 44 the endosropic section is shown in exploded view with parts separ~ted for convenience of illustration and includes upper housing Aalf section 14a and lower housing half section 14b. The housing half sections are preferably of a polycarbonate material such as LEXAN brand material mentioned preYiously, and are ~ attached by welding, adhesives, etc. Pssitioned within the upper and lower housing half sections is the pusher assembly -300 as described in more detail below and anvil extension 285, formed of stainless steel and having a pair of elongated legs 287, 289 which are joined at 291 at the distal end. As shown in Fig. 45, anvil extension 285 is attached at the distal end 291 to the staple storing magazin~ 16 by pivot pins 293 where the staple storing magazine is pivotally attached. The proximal end of anvil extension 285 is fixedly attached to handle 12 hy conventional means.
Anvil extension 285 is ~abricated of stainless steel and its purpose is to stahilize the dimension of the endoscopic section 14 to prevent the forces acting on the compon~nts from stretching or compressing th~ upper and lower housing half sections 14a,14b of the endoscspic section which are constructed of a polycarbonate material ~~ such as LEXAN brand material. Thus, the steel anvil extension provides dimensional stability to the endos~opic siPction while the endoscopic section is supporting the components being subjected to forces for supporting, advancing and forming the surgical staples as will be described.

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Referring further to Fig. 44, the steel pusher assembly 300 is formed of firing rod 26 connected to flexible elongated firing wire 288 which is in turn connected to pusher plate assembly 290 as shown. The connection between firing rod 26 and firing wire 288 is a crimped or swaged connection at 292, whereas the connection between firing wire 288 and pusher 290 is accomplished by an interference fit between the firing wire 288 and collar 294 which is attached to pusher plate 290. Firing rod 26 and pusher plate 290 are preferably made of stainless steel -whereas firing wire 288 is made to be resiliently flexihle to accommodate the pivotal movement of the staple storing magazine 16 since firing wire 288 is located within the instrument at the location of staple magazine 16. In particular, firing wire ~88 is preferably made of a super elastic metal. One example of such super elastic metal is TINEL brand metal available from Raychem Corporation, Menlo Park, California. This material has a reduced tendency to Eatigue after a substantial number of cycles of deflection caused by pivoting the staple storage magazine. Other resilient materials are also contemplated for firiny wire 288.
An alternative embodiment o~ the stapl~- storage magazine, which is disclosed in commonly assigned U.S~
patent application Serial No. 07/861,065, flled ~arch 31, ~~ 1992, previously incorporated herein by reference, includes a cartridge which is self contained and which is readi3y insertable at the distal end portion of the endoscopic section. The staple storage cartridge is removably supportPd on a pivotecl support system at the distal encl portion of the endoscopic section.

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THE STAPLE STORAGE MAGAZ INE
Referring now to Figs. 45-48 there is illustrated further details of the staple storing magazine 16. As noted previously, the staple storing magazine 16 is comprised of upper housing half 16a and lower housing half 16b suitably ~ attached by welding,adhesives, etc. The magazine is adapted to contain a plurality of surgical staples 298 which axe -particularly shaped to penetrate and to attach surgica:L mesh to body tissue. For particular details of the shape of the staples constructed according to the invention~ reference is made to Fig. 58.
Referring once again to Figs. 45-48, a particular feature of the present invention resides in the systam of storage of the staples 298 which are positioned in adjacent stacked relation whereby the stack of staples forms an angle with the longitudinal axis of the instrument of approximately 45 degrees as shown in Fig. 48. One purpose of stacking the staples as shown is to provide greater visibility to the user by the fact that the outer suxface of the upper housing half section adjacent the stack of staples forms a similar angle and provides visibility to the user at the distal end of the staple storage magazine. Angular ~~ stacking of the staples as shown greatly facilitates storage of a plurality of staples in a structure configured and dimensioned for use in endoscopic applications, e.g., for use through a trocar guide tube of diam~ter of about 36 mm for example. The stack of staples 298 as shown in Fig. 48 is positioned and retained in such position by a resilient 7-~ 1 ....

spring member 300 having dual resilient legs and whose side profile is curved as shown in Fig. 48.
The distal end of each leg engages the uppermost staple follower 302 in the form of a nylon insert having a general "H-shaped" configuration and dimensioned sufficient to cover the staples as best shown in Fig. 45. The nylon follower is intended to transmit the downwarcl force of the staplP retainer spring 300 so as to distribute the force on ~ the stack of staples in a manner to facilitate a constant and uni-directional downward force on the lowermost Gtaple -which is positioned for advancement and deformation. It also functions to advance the stack of staples downwardly when the lowermost staple is fired. Steel anvil plate 304 is shown in Fig. 45 and includes upwardly extending feet 306 and 308 which form anvils at the distal end as shown in Fiy.
45, for forming the staple therearound.
Thus, as seen in Fig. 48, the lowermost staple is identified by numeral 298L and is in a position for engagement by pusher plate 290 when the pusher assembly is advanced distallyO The push~r plate 290 is shown clearly in Figs. 45 and 48 and contains distally advancing lands 290R
and 290L shown clearly in Figs. 45 and 49 at the distal end to facilitate transmission of advancing force to the two rounded or arcuate bridge portions of the staple. This relative complementary configuration of the pusher plate 290 ~~ and the staple 298 facilitates efficient a~d uniform distribution of force to the staple when it is deformed about the anvil members as will be described.

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THE STAPLE CLOSING SYSTEM

Referring now to Figs. 47-54 there is illustrated the sequential views of the staple advancing and closing system between the initial and fired condition of the staple. In particular, the staple and pusher mechanism are shown in Fig. 47 in the initial condition while the staple sho~n in Fig. 54 is embedded within the body tissue in a manner to retain the surgical mesh to the body tissue.
In~Fig. 47, the staple pusher assembly is positioned proximal of the lowermost staple 298L and pusher plate 290 is correspondingly posikioned proximal of the lowermost staple 298L. In Figs. 48 and 49 the pusher plate 290 has been partially advanced distally by, e.g., the staple prepositioning stroke of the apparatus, and the lowe~most staple 298L has been advanced distally o~ the stack o~ staples 298 in a manner such that the pusher plate 290 has now replaced lowermost staple 298L thereby preserving the integrity and position o~ the stack of 20 staples 298. The preservation of the stac~ of staplas 298 is provided by the fact that the thickness of the staple pusher plate 290 is eithex identical to or slightly less than the thickness of the staples to assume that the plate 290 will engage only one staple at a tim~.
Referring further to Figs. 50 and 51, the push2r ~- plate 290 has now advanced distally suffi~ient to cause the staple to penetrate the surgical mesh 305 and the body tissue 310. As shown in Figs. ~8 and 51, it can be seen that an~il members 306 and 308 are positioned for engagement by th2 straight sections of bridge portions 298BR and 298BL
o~ the back rib of the staple 298L such that engagement o~

~ 5 the staple by pusher plate 290 with the arcuate end corner portions of the staple as shown will cause the staple to deform in a predetermined manner as will be described.
In Figs. 52-54 the staple 298L .is now shown in the deformed condition about the anvil members 306 and 308 and the straight portions 298S of the back rib of the s-taple 298 are still in engagement with the anvils 3()6,308. In Fig.
52, the staple has penetrated into the body tissue 310 and ~ has been deformed and in Fig. 54 the staple deformation is completed in a manner to substantially retain the surgical -mesh 305 in attached position with respect to the ~ody tissue as shown in Fig. 52. The inwardly projecting central portion or bight, 298C, of staple 298 is shown gripping the mesh and tissue in cooperation with the staple legs as shown in Fig. 54. However, release o~ the staples from the anvil members 306,308 has not yet been completed.
Release of the staple from the anvil members 306,308 is read'ly accomplished ~y ejector spring 312 which is a "U-shaped" resilient spring having upwardly biased legs 310R and 312L each positioned respectively as shown in Fig.
45~ When the pusher plate 290 is in the position shown in Fig. 50, the legs 252R and 252L of staple ejector spring 312 are retained in a downward position by lands 290R and 290L
of the pusher plate 290. However, when the pusher plate 290 is moved to th2 distalmost position shown in Fig. 53, khe absence of the pusher plate permits staple ejector legs 312R
and 312L to resiliently deflPct upwardly to their natural configuration ~hereby creating a vertical separation between the anvil members 306,308 and the deformed staple, thus releasing the ~e~ormed staple from the anvil members as shown in Fig. 53. Continued proximal movem~nt of the pusher ~, . . .

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plate 290 causes withdrawal of the pusher plate to a position entirely proximal of the stack of staples 298 as shown in Fig. 56, causing the stack of staples to move downwardly due to the downward force of resilient staple retainer spring 300 to advance the lowermost staple to the firing position.
Once the staple 298 is applied to the mesh 305 and tissue 310 as shown in Figs. 52 and 54, the distal end of ~ staple storing magazine 16 is withdrawn as shown in Fig. 54 and preparation is made for application of the next staple.
-Fig. 55 is a cross-sectional view taken along lines 55-55 of Fig. 54 with the staple storing magazine withdrawn ~rom the surgical mesh 305 and body tissue. Thereafter, the apparatus may be repositioned to apply another staple, or even an array of staples as shown in Figs. 57 and 59.
Referring once again to Fig. 57 , there is illustrated one form of surgical mesh repair of an opening in the body utilizing the apparatus and staple. In the application shown in Fig. 57, a surgical mesh is attached to the body tissue over the opening as illustrated schematically at 310c in Tig. 57 , and staples 298 have been applied in a circ~lar array as shown to rein~orce the repair. Beneath the mesh 305, the opening 310c may have previously been repaired as wellO In Fig. 59 an alternative array o~ staples to apply mesh material to body tissue is ~ shown. In this embodiment, the mesh material 305 is essentially formed as a circular patch and staples 298 are oriented in ia radial direction and are attached around the periphery o~ the patch such that one ley o~ the staple pierces the mesh and the other leg pierces body tissue 310 Essentially the staple bridges the periphery o~ the mesh ' ""' "".' ' ` ' ' ~ ~ . ~ . , '', ` ~ ' , :'~' ; ' '. .' ' .
., .. ,, ,.~ ........... . , , , ,, , . . . . ~ ' , S~ 7 1 4 material as shown. Clearly, alternative forms and arrangements are available to attach mesh or other surgery related objects or prostheses to body tissue as may come to the mind of persons skilled in the art.
It should be further noted that the repair of body tissue utilizing surgical mesh as shown in Figs. 56 and 58 are exemplary, and that other applications of mesh and staples may be utilized in a manner to either reinforce a ~ surgical repair or to encourage tissue growth. Such mesh materials are~typically disclosed in U.S. Patent NosO
-4,838,884, 4,665,221, 4,~52,245, and 4,347,847. It is noted that the staple as shown in Fig. 59 is particularly adapted for attachment of such mesh material to body tissue according to any number of techniques which may readily come to the mind of those skilled in the art. In fact, in some instances the mesh may be formed as a plug for insertion into a surgical opening and then stapled. Moreover, the apparatus and staple may be applied to attach other objects to body tissue as may come to the mind of those skilled in the art.

THE STAPLE
Referring now once again to Fig. 59, there is illustrated staple 298. The staple 298 is particularly shaped as shown, and is preferably formed of a length of ~~ wire of titanium. Stainless steel or equivalent material is also contemplated and the staple preferably has a rectangular cross-section as shown. Other cross-sections may be used. Typically, the wire will be ahout .38mm in width (dimension w) and .51 mm in thickness (dim~nsion T).
The initial width of the staple before closure (dimension A) , , ".,',`.~. ` '', ', '`~ ., ' '' ' " ' '.' .!.',','~'. : .. . ..

~ ~L ~. I~-is about 4.4mm and the thickness dimansion between the back rib and legs after closure (i.e. dimension B in Fig. 54) is about 3mm. The staple 298 has a central bight portion 298C
and a wire leg member 298R and 298L extending generally perpendicular to the central portion as shown. Each leg member 298R, 298L is connected to the central portion 298C
by a bridge portion 298BR, 298BL having an arcuate corner portion as shown. Each leg member has a sharp tip for ~ penetrating mesh and body tissue. Right leg member 298R
further possesses a tapered surface 298TR at the tip which -is opposite the position of the tapered surface 298TL at the tip of the other leg member 298L as shown in Fig. 58.
When the staple shown in Fig. 58 is advanced toward dual spaced anvils 306,308 as shown in Fig. 52 for example, and staple pusher plat~ 290 as shown, engages the arcuate portions of the bridge portions 298BR and 298BL, the legs of the staples are made to fold inwardly toward each other as shown for example in Fig. 52, with one leg crossing over the other~ The cross-over configuration is automatically assumed by the legs bPcause of the presence of tapered surfaces 298TR and 298TL which act as camming surfaces tending to bias each leg away from the other thereby tending to cross the legs in the manner shown. This structurs also prevents interference of the legs when ~olded toward each other.
~~ Thus, it can be seen that the particular shape of the staple as shown, promotes a unique foldlng pattern for the legs which achieves the configuration shown in the bent staples of Figs. 52 and 54. Note in particular that inwardly bent central portion 298C promotPs positive attachment of the mesh to the tissue by providing a gripping :,-"-,r,~ ,", , ,~ " ~ " ~ "~ ,- , , ~ ,, ", ~" , ~,r. ~., . : ', , ' ~, ' .`,.. . , '~

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system between inwardly projecting bight portion 238C and ley members 298R and 298L with mesh and tissue gripped therebetween. This staple shape combines with the arrangement of the anvils and the particularly configured pusher plate 290 to cause the staple to pierce mesh and body tissue up to a predetermined extent. At this point, continued application of force to the staple causes the staple legs to fold upon themselves as shown in the drawings ~ while encompassing a sufficient portion of the mesh to attach the mesh to the body tissue. Thus the staple pieces -folds and grips in substantially a single movement.
In practice, the laparoscopic procedures to repair tissue in hernia repair using surgical mesh is similar in some respects to the surgical procedures to gall bladders, appendix, lungs, etc. In particular, the endoscopic tubular section of the apparatus is inserted into the cannula which is positioned within the opening in the body. Provision i5 made between the cannula and the endoscopic section to seal the connection therebetween and provision may also be provided to seal the actual endoscopic apparatus from leakage of fluids or insufflatiny gaseous media. An exemplary cannula assembly including seal means is disclosed for example in commonly assigned U.S. Patent No. 4,943,224, issued July 24, 1990, the disclosure of which is incorporated herein by reference.

THE KIT
The present invention is readily adaptable to bs provided to suryeons in the form of a kit in which all necessary equlpment and accessories are provided in s~erile form ready for use in surgery. For exampl , an apparatus `.. ,.,.. ~ :

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constructed according to the invention can be readily packaged with a supply of stapl~s (i.e. up to 36 or more staples) and sufficient mesh material for completing the hernial repair. The mesh material is typically a~out 1 mm in thickness. The components may be provided separately as a matched kit, or in a blister type or other package, suitable and ready for use by the surgeon and the surgeon's assistants. The apparatus and staples can be provided in ~ any size matched to meet the apparatus and mesh material in accordance wi~h the particular needs of a contemplat~d hernial surgical procedure. In addition, the kit can include a matching trocar assembly with appropriate va:Lve assembly to prevent loss of the insufflating gas fro-,n the peritoneum between the trocar and the outside surface o~ the endoscopic section. Since the outer housing of the endoscopic se~tion is substantially closed at the point of attachment of the staple magazine, release o~ insufflating gases through the staple magazine and the endoscopic section housing is either non existent or minimal. Su~h trocax assembly is available from United States Surgical Corporation, Norwalk, Connecticut, under the trademark SURGIPORT brand ~rocar assembly.
A typical endoscopic section may be a 36mm diameter with a staple magazine capable of holding up to 10 staples of appropriate size. The length of the endoscopic ~~ section is typically 14 to 15 înches. An ~ndoscopic section in the embodiment shown will be about 14 inches. Howe~er, if pivotal movement o~ the staple storage magazin~ is ~o be provided between plus 45 degrees and minus 45 degrees solely by distal and proximal movement of collar 24, ~he endoscopic section will be structurPd to greater in length, i.e~ about .:, , ; . . :: : ::
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15 inches. The trocar assembly will be of matching size, i.e., 36mm, to accommodate the endoscopic section and to prevent release of gases thereby. The mesh material provided with the kit will be of mesh siza comparable for use with the size of the staples provided in the kit.
Thus by structuring the apparatus to provide such sealing, the endoscopic application of staples to attach objects such as surgical mesh to body tissue can be readily accomplished. Accordingly, the present invention is not only directed to the apparatus for applying such staples to body tissua, but also to a kit in which the apparatus is uniquely combined with a supply of staples, surgical mesh, cannula assembly etc. whereby the surgeon may readily perform the necessary procedures.

. .. .

... . .. . .

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. An endoscopic surgical stapling apparatus, which comprises:
a) frame;
b) generally elongated endoscopic portion connected to said frame and extending distally therefrom;
said endoscopic portion including:
i) means for storing a plurality of staples;
ii) means for individually advancing said staples distally for positioning adjacent body tissue; and iii) means for at least partially closing each said staple;
c) pneumatic means disposed within said frame for at least partially activating said staple advancing means;
and d) means for sealing said endoscopic portion.

2. Apparatus according to claim 1 wherein said advancing means comprises a staple pusher.

3. Apparatus according to claim 2 further comprising first operable means disposed within said frame for distally advancing said staple pusher from an initial unadvanced position to a first predetermined position.

4. Apparatus according to claim 3 wherein said first operable means is adapted to selectively advance said staple pusher between said initial position and said first predetermined position.

5. Apparatus according to claim 4 wherein said first operable means includes a ratchet and associated pawl adapted to prevent proximal movement of said staple pusher except when said staple pusher is advanced at least beyond said first predetermined position whereby said pawl is released so as to permit return of said staple pusher to said initial position.

6. Apparatus according to claim 4 wherein said first operable means is manually operated by a trigger mechanism.

7. Apparatus according to claim 6 wherein said trigger mechanism is mounted for longitudinal movement relative to said frame, whereby proximal longitudinal movement of said trigger mechanism actuates said first operable means to distally advance said staple pusher.

8. Apparatus according to claim 4 wherein said first operable means is manually operated by a lever mechanism.

9. Apparatus according to claim 8 wherein said lever mechanism is pivotally mounted for pivotal movement towards said frame to a position corresponding to advancing said staple pusher distally.

10. Apparatus according to claim 3 wherein said staple pusher is biased to said initial position by constant force resilient means.

11. Apparatus according to claim 10 wherein said constant force resilient means is a spring.

12. Apparatus according to claim 11 wherein said constant force spring is a negator spring.

13. Apparatus according to claim 3 further comprising second operable means for actuating said pneumatic means to distally drive said staple pusher beyond said first predetermined position to a second advanced position corresponding to at least partially closing each said staple by said staple closing means.

14. Apparatus according to claim 13 wherein said pneumatic means comprises a pressurized gas supply and pneumatic actuator means including a cylinder in fluid communication with said pressurized gas supply and defining an opening at a distal end thereof, and a piston disposed within said opening and adapted to advance in response to admission of gas therewithin.

15. Apparatus according to claim 14 wherein said piston is operatively connected to said pressurized gas supply by a linkage, whereby initial distal longitudinal movement of said piston causes release of pressurized gas from said pressurized gas supply to distally drive said piston to advance said staple pusher to said second advanced position.

16. Apparatus according to claim 15 wherein said second operable means is operatively connected to said piston of said pneumatic means.

17. Apparatus according to claim 16 wherein said second operable means is manually operated by an actuating mechanism.

18. Apparatus according to claim 17 wherein said actuating mechanism includes a firing button pivotally mounted to said frame and operatively connected to a firing link of said second operable means, said firing link engageable with said piston of said pneumatic means, whereby pivotal movement of said firing button in one direction causes distal longitudinal movement of said firing link and corresponding distal movement of said piston to thereby cause release of the pressurized gas from said gas supply.

19. Apparatus according to claim 18 wherein said firing link is biased to a proximalmost position by constant force resilient means.

20. Apparatus according to claim 19 wherein said constant force resilient means is a spring.

21. Apparatus according to claim 3 wherein said first operable means is operatively connected to said pneumatic means such that actuation of said first operable means activates said pneumatic means to distally drive said staple pusher.

22. Apparatus according to claim 21 wherein engaging means is provided to selectively prevent said staple pusher from advancing beyond said first predetermined position upon actuation of said first operable means and said pneumatic means.

23. Apparatus according to claim 22 further comprising second operable means for releasing said engaging means to permit continued distal movement of said staple pusher beyond said first predetermined position to a second advanced position corresponding to at least partially closing each said staple by said staple closing means.

24. Apparatus according to claim 23 wherein said pneumatic means comprises a pressurized gas supply and pneumatic actuator means including a cylinder in fluid communication with said pressurized gas supply and defining an opening at a distal end thereof, and a piston disposed within said opening and adapted to advance in response to admission of gas therewithin, said piston being operatively connected to said staple pusher.

25. Apparatus according to claim 24 wherein said piston is operatively connected to said pressurized gas supply by a linkage, whereby distal longitudinal movement of said piston causes release of pressurized gas from said pressurized gas supply to distally drive said piston and said staple pusher.

26. Apparatus according to claim 25 wherein said first operable means is manually operated by an actuating mechanism.

27. Apparatus according to claim 26 wherein said actuating mechanism includes a firing button pivotally mounted to said frame and operatively connected to a firing link of said first operable means, said firing link engageable with said piston of said pneumatic means, whereby pivotal movement of said firing button in one direction causes distal longitudinal movement of said firing link and corresponding distal movement of said piston to thereby cause release of pressurized gas from a gas supply to distally drive said piston and to advance said staple pusher.

28. Apparatus according to claim 24 wherein said engaging means comprises a piston stop.

29. Apparatus according to claim 28 wherein said piston stop is movable between an engaged position wherein said piston stop engages said piston at said first predetermined position and a disengaged position wherein said piston stop is disengaged from said piston to permit further distal movement of said piston and said staple pusher to a second advanced position of said staple pusher.

30. Apparatus according to claim 29 wherein said piston stop defines an aperture therethrough for reception of a distal end portion of said piston.

31. Apparatus according to claim 30 wherein said piston includes a transverse bearing surface which engages said piston stop when said piston stop is in said engaged position and said piston is advanced to said first predetermined position.

32. Apparatus according to claim 31 wherein said second operable means is adapted to move said piston stop between said engaged and said disengaged positions.

33. Apparatus according to claim 32 wherein said second operable means is actuated by an actuating mechanism.

34. Apparatus according to claim 33 wherein said actuating mechanism comprises a release button pivotally mounted to said frame and operatively connected to a release link of said second operable means, said release link adapted for longitudinal movement in response to pivotal movement of said release button, said release link dimensioned and configured at a distal end portion thereof to support said piston stop and to move said piston stop to said disengaged position when said release link is longitudinally distally moved.

35. Apparatus according to claim 34 wherein said release link comprises a longitudinally offset portion at its distal end and a tapered portion interconnecting said offset portion with the remaining portion of said release link, said piston stop being positioned on said offset portion when in said engaged position.

36. Apparatus according to claim 35 wherein said release button is biased to a pre-pivoted position by a spring.

37. Apparatus according to claim 32 wherein said second operable means comprises a release trigger pivotally mounted to said frame and defining a support surface for supporting said piston stop, said release trigger moving said piston stop to said disengaged position when pivoted proximally.

38. Apparatus according to claim 29 wherein said piston stop is normally biased to said engaged position by a spring.

39. Apparatus according to claim 1 wherein said stapler storing means is located at the distal end portion of said endoscopic portion.

40. Apparatus according to claim 39 wherein said staple storing means is pivotally attached at the distal end portion of said endoscopic portion.

41. Apparatus according to claim 40 wherein pivotal control means is provided to pivot said staple storing means from a proximal location.

42. Apparatus according to claim 41 wherein said pivotal control means is located at the proximal end portion of said endoscopic portion.

43. Apparatus according to claim 42 wherein said pivotal control means of said staple storing means comprises a member movable with respect to said endoscopic portion in proximal and distal directions and adapted to position said staple storing means at substantially zero degrees with respect to a longitudinal axis defined by said endoscopic portion when said pivotal control means is in a first position and said staple storing means forms and angle of up to about 45 degrees when said pivotal control means is in a second position.

44. Apparatus according to claim 43 wherein said staple storing means is adapted to be pivoted up to about 45 degrees with respect to each side of said longitudinal axis whereby full pivotal articulation thereof is provided of about 90 degrees.

45. Apparatus according to claim 41 wherein said pivotal control means is adapted to rotate said staple storing means to predetermined angles with respect to a longitudinal axis defined by said endoscopic portion.

46. Apparatus according to claim 41 wherein said endoscopic portion is rotatable about a longitudinal axis defined thereby.

470 Apparatus according to claim 46 wherein said pivotal control means of said staple storing means is connected for rotation with said endoscopic portion such that distal and proximal movement of said pivotal control means produces pivotal movement of said staple storing means and rotation thereof produces corresponding rotation of said endoscopic portion.

48. Apparatus according to claim 1, wherein said staple storing means comprises a cartridge removably positioned at a distal end portion of said endoscopic portion.

49. Apparatus according to claim 48 further comprising means for producing a perceptible tactile indicator to the user when each stapler has been advanced to a predetermined position at the distal end of said cartridge.

50. Apparatus for endoscopic application of surgical staples to body tissue, which comprises:
a) a handle member adapted to be gripped by hand;
b) a generally elongated endoscopic portion connected to said handle member and extending distally therefrom, said endoscopic portion including:
i) at least one staple positioned therein;
ii) a staple pusher for individually advancing said at least one staple distally for positioning adjacent the body tissue; and iii) an anvil for closing said staple;
c) said handle member including:
i) a pneumatic system including a supply of low pressure gas and adapted to convert said low pressure gas into a force to advance said staple pusher;

ii) a first transmission for distally advancing said staple pusher from an initial position to a first predetermined position; and iii) a second transmission connected to said pneumatic system to actuate said pneumatic system to distally drive said staple pusher beyond said first predetermined position to a second advanced position to close said staple about said anvil.

51. Apparatus according to claim 50 wherein said first transmission is adapted to selectively advance said staple pusher from said initial position to said first predetermined position.

52. Apparatus according to claim 51 wherein said first transmission is actuable by a trigger mechanism.

53. Apparatus according to claim 51 wherein said first transmission is actuable by a lever mechanism.

54. Apparatus according to claim 50 wherein said second transmission is actuated by an actuating mechanism.

55. Apparatus for endoscopic application of surgical staples to body tussue, which comprises:
a) a handle member;
b) a generally elongated endoscopic portion connected to said handle member and extending distally therefrom, said endoscopic portion including:
means for storing a plurality of staples;

means for individually advancing said staples distally for positioning adjacent the body tissue; and anvil means for closing said staple in a manner to encompass at least a portion of the object and to penetrate the body tissue to attach the portion of the object to the body tissue; and c) said handle member including:
i) a pneumatic system including a supply of low pressure gas and adapted to convert said low pressure gas into a force to activate said staple advancing means;
ii) transmission means for actuating said pneumatic means to distally advance said staple advancing means;
iii) engaging means associated with said staple advancing means for selectively preventing distal movement of said staple advancing means beyond a first predetermined position; and iv) release means for releasing said engaging means to permit further advancing movement of said staple advancing means beyond said first predetermined position to a second fully advanced position to close said staple about said anvil means.

56. Apparatus according to claim 55 wherein said transmission means is actuable by an actuating mechanism.

57. Apparatus according to claim 56 wherein said release means is actuated by a trigger mechanism.

58. Apparatus according to claim 56 wherein said release means is actuated by an actuating mechanism.

/

59. Apparatus for endoscopic application of surgical staples to body tissue, which comprises:
a) a handle;
b) an endoscopic section of generally elongated configuration and extending distally from said handle, said endoscopic section including:
i) a cartridge for storing a plurality of surgical staples;
ii) a staple pusher for at least partially ejecting said staples individually from said cartridge; and iii) an anvil for at least partially closing said staples at least sufficient to engage the body tissue;
and c) a self-contained pneumatic system mounted in said handle for generating forces sufficient to actuate said staple pusher.

60. Apparatus according to claim 59 wherein said pneumatic system comprises a pressurized gas supply and a pneumatic actuator including a cylinder in fluid communication with said pressurized gas supply and defining an opening at a distal end thereof, and a piston disposed within said opening and adapted to advance in response to admission of gas therewithin.

61. Apparatus according to claim 60 wherein said piston is operatively engageable with said staple pusher such that advancing movement of said piston causes corresponding movement of said staple pusher.

62. Apparatus according to claim 61 wherein said cartridge is supported by a support member pivotally attached at the distal end portion of said endoscopic section.

63. Apparatus according to claim 62 wherein said cartridge is selectively pivotal by the user such that said cartridge is pivotal therewith.

64, Apparatus according to claim 63 further comprising gaseous seal means.

65. Apparatus according to claim 64 wherein said gaseous seal means comprises silicone grease.

66. Apparatus for endoscopic application of a surgical staple adapted to attach an object to body tissue, which comprises:
a) a frame;
b) a generally elongated endoscopic tubular portion connected to said frame and extending distally therefrom, said endoscopic tubular portion having a generally longitudinal axis, a proximal end portion and a distal end portion;
c) means for storing a plurality of staples, said staple storing means pivotally attached at said distal end portion of said endoscopic tubular portion;
d) means for individually advancing said staples distally for positioning adjacent body tissue;

e) pneumatic means associated with said staple advancing means for at least partially activating said staple advancing means;
f) means for at least partially closing each said staple; and g) control means remote from said distal end portion of said endoscopic tubular portion for selectively pivoting said staple storage means.

67; Apparatus according to claim 66 wherein said control means is selectively manually controllable from a proximal location.

68. An endoscopic surgical stapling apparatus, which comprises.
a) a handle adapted to be gripped by hand;
b) an endoscopic tubular portion connected to said handle and extending distally from said handle, said endoscopic section including:
i) means for storing at least one surgical staple;
ii) a staple pusher for individually advancing said at least one staple distally for positioning adjacent the body tissue; and iii) an anvil for closing at least one staple;
c) said handle including:
i) a pneumatic system including a supply of low pressure gas and adapted to convert said low pressure gas into a force to distally advance said staple pusher to close said staple about said anvil;

ii) first means for distally advancing said stapler pusher from an initial position to a first predetermined position;
iii) second means for distally advancing said staple pusher beyond said first predetermined position to a second position wherein said staple is substantially closed about said anvil; and iv) at least one of said first and second means being operatively connected to said pneumatic system.

69. Apparatus according to claim 68 wherein actuating means is provided for selectively activating said first and second means.

70. Apparatus according to claim 69 wherein said actuating means comprises an actuating button whereby movement of said actuating button a first distance activates said first means and whereby movement of said actuating button a second distance activates said second means.

71. Apparatus according to claim 70 further comprising means for providing a perceptible tactile indicator to the user when said staple pusher has been advanced to said first position.

72. Apparatus according to claim 71 wherein said tactile indicator means comprises means to alter the manual feel to the user when said staple pusher has been advanced to said first position.

73. Apparatus according to claim 72 wherein said means to alter the manual feel to the user comprises resilient spring means.

74. Apparatus according to claim 73 wherein said resilient spring means is engaged by said actuating mechanism upon movement of said actuating button said first distance whereby movement of said actuating button said second distance is resisted by said resilient spring means.

75. An endoscopic surgical stapling apparatus, which comprises:
a) handle;
b) generally elongated endoscopic portion connected to said handle and extending distally therefrom, said endoscopic portion including:
i) means for storing a plurality of staples;
ii) staple pusher for individually advancing said staples distally for positioning adjacent body tissue;
iii) anvil for closing each staple; and c) pneumatic means comprising a pneumatic piston advanceable in response to release of gas by said pneumatic means, said piston comprising.
i) a first inner rod connected to said staple pusher and adapted to distally advance said staple pusher to a first position in response to a first release of pneumatic gases by said pneumatic means;
ii) a second outer rod having a longitudinal bore for at least partially receiving said first inner rod;
iii) means for connecting said first inner rod upon advancement of said first inner rod and said staple pusher to said first position of said staple pusher such that a second release of pneumatic gases by said pneumatic means distally advances both said first inner rod and said second outer rod to drive said staple pusher to a second position corresponding to closing said staple about said anvil.