(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2014/0252071 A1
`Sep. 11, 2014
`(43) Pub. Date:
`M00re et al.
`
`US 20140252071A1
`
`DETACHABLE MOTOR POWERED
`SURGICAL INSTRUMENT
`
`Applicant: Ethicon Endo-Surgery, Inc., Cincinnati,
`OH (US)
`Inventors: Kyle P. Moore, Mason, OH (US);
`Frederick E. Shelton, IV, Hillsboro,
`OH (US); William B. Weisenburgh, II,
`Maineville, OH (US); Jerome R.
`Morgan, Cincinnati, OH (US); Mark H.
`Ransick, West Chester, OH (US);
`Eugene L. Timperman, Cincinnati, OH
`(US)
`Assignee: Ethicon Endo-Surgery, Inc., Cincinnati,
`OH (US)
`Appl. No.: 14/283.729
`Filed:
`May 21, 2014
`
`Related U.S. Application Data
`Continuation of application No. 13/832,522, filed on
`Mar. 15, 2013, which is a continuation of application
`No. 13/118,210, filed on May 27, 2011, now Pat. No.
`
`8,752,749, which is a continuation-in-part of applica
`tion No. 12/856,099, filed on Aug. 13, 2010, now Pat.
`No. 8,196,795, which is a continuation of application
`No. 12/031,628, filed on Feb. 14, 2008, now Pat. No.
`7,793,812.
`
`Publication Classification
`
`(51)
`
`(52)
`
`(2006.01)
`
`Int. C.
`A6B I7/068
`U.S. C.
`CPC ....... A61B 17068 (2013.01); A61B 2017/0688
`(2013.01)
`USPC ..................................... 227/180.1; 227/175.1
`
`(57)
`ABSTRACT
`A detachable motor-powered Surgical instrument. The instru
`ment may include a housing that includes at least one engage
`ment member for removably attaching the housing to an
`actuator arrangement. A motor is Supported within the hous
`ing for Supplying actuation motions to various portions of a
`Surgical end effector coupled to the housing. The housing
`may include a contact arrangement that is configured to per
`mit power to be supplied to the motor only when the housing
`is operably attached to the actuator arrangement.
`
`(54)
`
`(71)
`
`(72)
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`(73)
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`(21)
`(22)
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`(63)
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`Patent Application Publication
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`Patent Application Publication
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`Ethicon Exhibit 2009.066
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 66 of 95
`
`US 2014/0252071 A1
`
`
`
`Ethicon Exhibit 2009.067
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 67 of 95
`
`US 2014/0252071 A1
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`Ethicon Exhibit 2009.068
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 68 of 95
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`US 2014/0252071 A1
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`
`
`Ethicon Exhibit 2009.069
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 69 of 95
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`US 2014/0252071 A1
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`Intuitive v. Ethicon
`IPR2018-00935
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`

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`Patent Application Publication
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`Sep. 11, 2014 Sheet 70 of 95
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`US 2014/0252071 A1
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`Intuitive v. Ethicon
`IPR2018-00935
`
`

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`Patent Application Publication
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`Sep. 11, 2014 Sheet 71 of 95
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`US 2014/0252071 A1
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`Intuitive v. Ethicon
`IPR2018-00935
`
`

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`Patent Application Publication
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`Sep. 11, 2014 Sheet 72 of 95
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`US 2014/0252071 A1
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`Ethicon Exhibit 2009.073
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 73 of 95
`
`US 2014/0252071 A1
`
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`Ethicon Exhibit 2009.074
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 74 of 95
`
`US 2014/0252071 A1
`
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`Ethicon Exhibit 2009.075
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 75 of 95
`
`US 2014/0252071 A1
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`Intuitive v. Ethicon
`IPR2018-00935
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`Sep. 11, 2014 Sheet 76 of 95
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`US 2014/0252071 A1
`
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`Ethicon Exhibit 2009.077
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
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`Sep. 11, 2014 Sheet 77 of 95
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`US 2014/0252071 A1
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`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 78 of 95
`
`US 2014/0252071 A1
`
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`Ethicon Exhibit 2009.079
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11,2014 Sheet 79 of 95
`
`US 2014/0252071 Al
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`Ethicon Exhibit 2009.080
`Intuitive v. Ethicon
`IPR2018-00935
`
`Ethicon Exhibit 2009.080
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 80 of 95
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`US 2014/0252071 A1
`
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`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 81 of 95
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`US 2014/0252071 A1
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`Ethicon Exhibit 2009.082
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 82 of 95
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`US 2014/0252071 A1
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`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 83 of 95
`
`US 2014/0252071 A1
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`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 84 of 95
`
`US 2014/0252071 A1
`
`
`
`Ethicon Exhibit 2009.085
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 85 of 95
`
`US 2014/0252071 A1
`
`
`
`Ethicon Exhibit 2009.086
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 86 of 95
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`US 2014/0252071 A1
`
`
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`Ethicon Exhibit 2009.087
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 87 of 95
`
`US 2014/0252071 A1
`
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`Ethicon Exhibit 2009.088
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 88 of 95
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`US 2014/0252071 A1
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`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 89 of 95
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`US 2014/0252071 A1
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`
`
`Ethicon Exhibit 2009.090
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 90 of 95
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`US 2014/0252071 A1
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`
`
`Ethicon Exhibit 2009.091
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 91 of 95
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`US 2014/0252071 A1
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`
`
`Ethicon Exhibit 2009.092
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 92 of 95
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`US 2014/0252071 A1
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`
`
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`
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`L-0309L-0009
`
`Ethicon Exhibit 2009.093
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 93 of 95
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`US 2014/0252071 A1
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`
`
`23 N
`
`Ethicon Exhibit 2009.094
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 94 of 95
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`US 2014/0252071 A1
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`
`
`3.
`
`Ethicon Exhibit 2009.095
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`Patent Application Publication
`
`Sep. 11, 2014 Sheet 95 of 95
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`US 2014/0252071 A1
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`
`
`Ethicon Exhibit 2009.096
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`US 2014/025.2071 A1
`
`Sep. 11, 2014
`
`DETACHABLE MOTOR POWERED
`SURGICAL INSTRUMENT
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`0001. This application is a continuation application claim
`ing priority under 35 U.S.C. S 120 to U.S. patent application
`Ser. No. 13/832,522, entitled DETACHABLE MOTOR
`POWERED SURGICAL INSTRUMENT, filed on Mar. 15,
`2013, now U.S. Patent Publication No. 2013/0200132, which
`is a continuation application claiming priority under 35 U.S.
`C. S 120 of U.S. patent application Ser. No. 13/118,210,
`entitled ROBOTICALLY CONTROLLED DISPOSABLE
`MOTOR-DRIVEN LOADING UNIT, filed on May 27, 2011,
`now U.S. Patent Publication No. 2011/0290855, which is a
`continuation-in-part application claiming priority under 35
`U.S.C. S 120 of U.S. patent application Ser. No. 12/856,099,
`entitled DISPOSABLE MOTOR-DRIVEN LOADING
`UNIT FOR USE WITH A SURGICAL CUTTING AND
`STAPLINGAPPARATUS, filed on Aug. 13, 2010, now U.S.
`Pat. No. 8,196,795, which is a continuation application claim
`ing priority under 35 U.S.C. S 120 of U.S. patent application
`Ser. No. 12/031,628, entitled DISPOSABLE MOTOR
`DRIVEN LOADING UNIT FOR USE WITHA SURGICAL
`CUTTING AND STAPLINGAPPARATUS, filed on Feb. 14,
`2008, now U.S. Pat. No. 7,793,812, the entire disclosures of
`which are hereby incorporated by reference herein.
`
`FIELD OF THE INVENTION
`0002 The present invention relates in general to endo
`scopic Surgical instruments including, but not limited to, Sur
`gical cutting and stapling apparatuses that have disposable
`loading units that are capable of applying lines of Staples to
`tissue while cutting the tissue between those staple lines and,
`more particularly, to improvements relating to such dispos
`able loading units.
`
`BACKGROUND
`0003 Endoscopic surgical instruments are often preferred
`over traditional open Surgical devices since a smaller incision
`tends to reduce the post-operative recovery time and compli
`cations. Consequently, significant development has gone into
`a range of endoscopic Surgical instruments that are Suitable
`for precise placement of a distal end effector at a desired
`Surgical site through a cannula of a trocar. These distal end
`effectors engage the tissue in a number of ways to achieve a
`diagnostic ortherapeutic effect (e.g., endocutter, grasper, cut
`ter, Staplers, clip applier, access device, drug/gene therapy
`delivery device, and energy device using ultrasound, RF,
`laser, etc.).
`0004 Known surgical staplers include an end effector that
`simultaneously makes a longitudinal incision in tissue and
`applies lines of staples on opposing sides of the incision. The
`end effector includes a pair of cooperating jaw members that,
`if the instrument is intended for endoscopic or laparoscopic
`applications, are capable of passing through a cannula pas
`sageway. One of the jaw members Supports a Staple cartridge
`that has at least two laterally spaced rows of staples. The other
`jaw member defines an anvil having staple-forming pockets
`aligned with the rows of staples in the cartridge. The instru
`ment commonly includes a plurality of reciprocating wedges
`which, when driven distally, pass through openings in the
`
`Staple cartridge and engage drivers Supporting the staples to
`effect the firing of the staples toward the anvil.
`0005 One type of Surgical stapling apparatus is config
`ured to operate with disposable loading units (DLU's) that are
`constructed to Support a staple cartridge and knife assembly
`therein. Once the procedure is completed, the entire DLU is
`discarded. Such instruments that are designed to accommo
`date DLU's purport to offer the advantage of a “fresh' knife
`blade for each firing of the instrument. Examples of such
`Surgical staplingapparatuses and DLU's are disclosed in U.S.
`Pat. No. 5,865,361, entitled SURGICAL STAPLINGAPPA
`RATUS, which issued on Feb. 2, 1999, the disclosure of
`which is herein incorporated by reference in its entirety.
`0006 Such prior disposable loading units, however,
`require the clinician to continuously ratchet the handle to fire
`the staples and cut the tissue. There is a need for a Surgical
`Stapling apparatus configured for use with a disposable load
`ing unit that is driven by a motor contained in the disposable
`loading unit.
`
`SUMMARY
`0007. In one general aspect of various embodiments of the
`present invention, there is provided a disposable loading unit
`for attachment to a Surgical cutting and Stapling apparatus. In
`various embodiments, the disposable loading unit may com
`prise a carrier that Supports a staple cartridgetherein. An anvil
`assembly may be movably coupled to the carrier for selective
`movable travel between open and closed positions relative to
`the staple cartridge. An axial drive assembly may be Sup
`ported within the carrier such that it can move in a distal
`direction from a start position to an end position through the
`carrier and the staple cartridge. The axial drive assembly may
`also be retracted in a proximal direction from the end position
`back to the start position. A motor may be Supported within
`the carrier and constructed to drive the axial drive assembly in
`the distal and proximal directions. A battery may be Sup
`ported within the carrier and be coupled to the motor for
`Supplying power thereto.
`0008. In still another general aspect of various embodi
`ments of the present invention, there is provided a disposable
`loading unit for attachment to a Surgical cutting and Stapling
`apparatus. In various embodiments, the disposable loading
`unit includes a carrier that Supports a staple cartridge therein.
`An anvil assembly may be movably coupled to the carrier for
`selective movable travel between open and closed positions
`relative to the staple cartridge. A housing may be coupled to
`the carrier and be configured for removable operable attach
`ment to the Surgical stapling apparatus. An axial drive assem
`bly may be Supported within the carrier and the housing to
`move in a distal direction from a start position to an end
`position through the carrier and the Staple cartridge. The axial
`drive assembly may also be retracted in a proximal direction
`from the end position to the start position. A motor may be
`supported within the carrier and configured to interface with
`the axial drive assembly to drive the axial drive assembly in
`the distal and proximal directions. A battery may be Sup
`ported within the carrier and be coupled to the motor for
`supplying power thereto. The battery may be selectively mov
`able between a disconnected position and connected posi
`tions in response to motions applied thereto by a portion of the
`Surgical stapling apparatus.
`0009. In another general aspect of various embodiments of
`the present invention, there is provided a Surgical cutting and
`Stapling apparatus. Various embodiments of the instrument
`
`Ethicon Exhibit 2009.097
`Intuitive v. Ethicon
`IPR2018-00935
`
`

`

`US 2014/025.2071 A1
`
`Sep. 11, 2014
`
`may include a handle assembly that operably Supports a drive
`assembly therein that is constructed to impart drive motions
`and a retraction motion. A movable handle portion may be
`operably Supported on the handle assembly and configured to
`interface with the drive system such that manipulation of the
`movable handle causes the drive system to impart the drive
`motions. An elongated body may protrude from the handle
`assembly and have a distal end that is couplable to a dispos
`able loading unit. In various embodiments, the disposable
`loading unit may comprise a carrier that has a staple cartridge
`Supported therein. An anvil assembly may be movably
`coupled to the carrier for selective movable travel between
`open and closed positions relative to the staple cartridge. An
`axial drive assembly may be supported within the carrier such
`that the axial drive assembly may move in a distal direction
`from a start position to an end position through the carrier and
`the staple cartridge and also in a proximal direction from the
`end position to the start position. A motor may be Supported
`within the carrier and configured to interface with the axial
`drive assembly to drive the axial drive assembly in the distal
`and proximal directions. A battery may be supported within
`the carrier and be coupled to the motor for Supplying power
`thereto. The battery may be configured to interface with a
`portion of the elongated body to receive the drive motions
`therefrom upon manipulation of the moveable handle.
`0010. In accordance with other general aspects of various
`embodiments of the present invention, there is provided a
`disposable loading unit for use with a remotely controllable
`system. In various embodiments, the disposable loading unit
`comprises a cartridge assembly that has an elongated housing
`coupled thereto that is configured for operable attachment to
`an elongated shaft assembly for transmitting control motions
`from a control portion of the remotely controllable system.
`The disposable loading unit further comprises an axial drive
`assembly that is supported for selective axial travel through
`the cartridge assembly from a start position to an end position
`upon application of a rotary control motion thereto from the
`elongated shaft assembly. A motor is Supported within the
`housing and operably interfaces with the axial drive assembly
`to selectively apply the rotary motion thereto. A power Source
`is axially movable within the housing from a disconnected
`position wherein the power source is disconnected from the
`motor to at least one connected position wherein the power
`Source provides power to said motor.
`0011. In accordance with yet other general aspects of vari
`ous embodiments of the present invention, there is provided a
`Surgical instrument that includes a tool drive portion that is
`configured for operable attachment to a portion of a robotic
`system for receiving control motions therefrom. An elongated
`shaft is coupled to the tool drive portion. An axially movable
`control member is operably supported within the elongated
`shaft and is axially movable in response to actuation motions
`applied thereto from the robotic system. The surgical instru
`ment further includes a disposable loading unit that has a
`housing that is coupled to the elongated shaft. A staple car
`tridge is Supported by the housing assembly and an axial drive
`assembly is supported for selective axial travel through the
`cartridge assembly from a start position to an end position
`upon application of a rotary motion thereto. A motor is Sup
`ported within the housing and operably interfaces with the
`axial drive assembly to selectively apply the rotary motion
`thereto. A power source is axially movable within the housing
`from a disconnected position wherein the power source is
`disconnected from the motor to a first connected position
`
`wherein the power source provides power to the motor upon
`attachment to the control member.
`0012. In accordance with still other general aspects of
`various embodiments of the present invention, there is pro
`vided a Surgical instrument that includes a tool drive portion
`that is configured for operable attachment to a portion of a
`robotic system for receiving control motions therefrom. An
`elongated shaft is coupled to the tool drive portion. Anaxially
`movable control member is operably supported within the
`elongated shaft and is axially movable in response to actua
`tion motions applied thereto from the robotic system. The
`Surgical instrument further includes a disposable loading unit
`that has a housing that is coupled to the elongated shaft. A
`Staple cartridge is supported by the housing assembly and an
`axial drive assembly is supported for selective axial travel
`through the cartridge assembly from a start position to an end
`position upon application of a rotary motion thereto. A motor
`is Supported within the housing and operably interfaces with
`the axial drive assembly to selectively apply the rotary motion
`thereto. A movable battery holder is coupleable to the control
`member and is axially movable within the housing in
`response to motions applied thereto by a control rod. A bat
`tery is Supported within the battery housing and is configured
`for selective axial communication with a series of axially
`spaced contact arrangements in the housing for controlling
`supply of power from the battery to the motor.