Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS FOR ENDOSCOPIC PROCEDURES
BACKGROUND
1. Technical Field
[0001] The present disclosure relates to surgical apparatus, devices
and/or systems for
performing endoscopic surgical procedures and methods of use thereof. More
specifically, the
present disclosure relates to electromechanical, hand-held surgical apparatus,
devices and/or
systems configured for use with removable disposable loading units and/or
single use loading
units for clamping, cutting and/or stapling tissue.
2. Background of Related Art
[0002] A number of surgical device manufacturers have developed product
lines with
proprietary drive systems for operating and/or manipulating electromechanical
surgical devices.
In many instances the electromechanical surgical devices include a handle
assembly, which is
reusable, and disposable loading units and/or single use loading units or the
like that are
selectively connected to the handle assembly prior to use and then
disconnected from the handle
assembly following use in order to be disposed of or in some instances
sterilized for re-use.
[0003] Many of these electromechanical surgical devices are relatively
expensive to
manufacture, purchase and/or operate. There is a constant desire by
manufactures and end users
to develop electromechanical surgical devices that are relatively inexpensive
to manufacture,
purchase and/or operate yet still provide a large degree of operability.
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[0004] Accordingly, a need exists for electromechanical surgical
apparatus, devices
and/or systems that are relatively economical from the development and
manufacturing stages, to
the selling/purchase stages, to the storing/shipping stages, to the
use/operation stages, and on to
the disposal and/or re-use stages while still providing an end user with a
high degree of
operability.
SUMMARY
[0005] The present disclosure relates to electromechanical, hand-held
surgical apparatus,
devices and/or systems configured for use with removable disposable loading
units and/or single
use loading units for clamping, cutting and/or stapling tissue.
[0006] According to an aspect of the present disclosure, an
electromechanical surgical
device is provided and includes an end effector configured to perform at least
one function, the
end effector including an input drive axle projecting therefrom; and a shaft
assembly. The shaft
assembly includes an outer tube; a rotatable drive shaft supported therein; a
proximal neck
housing supported at a distal end of the outer tube; a distal neck housing
pivotally connected to
the proximal neck housing, wherein a distal end of the distal neck housing is
configured and
adapted for operative connection with the end effector; a pivot pin
interconnecting the proximal
neck housing and the distal neck housing; and a gear train supported in the
proximal neck
housing, on the pivot pin, and in the distal neck housing.
[0007] The gear train includes a proximal gear rotatably supported in the
proximal neck
housing and being coupled to a distal end of the rotatable drive shaft; an
intermediate gear
rotatably supported on the pivot pin and being in operative engagement with
the proximal gear; a
distal gear rotatably supported in the distal neck housing and being in
operative engagement with
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the intermediate gear; and a pair of output gears rotatably supported in the
distal neck housing
and each being in operative engagement with the distal gear, wherein each
output gear defines a
coupling socket each configured to selectively receive the drive axle of the
end effector.
[0008] The end effector may include an upper jaw and a lower jaw movable
with respect
to one another between open and closed positions, wherein tissue contacting
surfaces of the
upper jaw and the lower jaw define a plane therebetween, and wherein the end
effector is
selectively connectable to the distal neck housing of the shaft assembly in
one of a first
orientation and a second orientation.
[0009] In the first orientation, the plane defined by the end effector may
be oriented
substantially orthogonal to a pivot axis defined by the pivot pin. In the
second orientation, the
plane defined by the end effector may be oriented substantially parallel to a
pivot axis defined by
the pivot pin.
[0010] In use, when the end effector is connected to the distal neck
housing of the shaft
assembly in the first orientation, the drive axle of the end effector may be
coupled to the
coupling socket of a first of the pair of output gears. Also in use, when the
end effector is
connected to the distal neck housing of the shaft assembly in the second
orientation, the drive
axle of the end effector may be coupled to the coupling socket of a second of
the pair of output
gears.
[0011] In an embodiment, a rotation of the drive shaft of the shaft
assembly may result in
rotation of both output gears.
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[0012] The shaft assembly may have a straight configuration, and an angled
configuration wherein the distal neck housing is pivoted about the pivot pin
to a desired angled
configuration. The gear train may transmit rotation from the drive shaft to
both output gears
when the shaft assembly is in either the straight configuration or the angled
configuration.
[0013] An axis of rotation of the proximal gear may be co-axial with an
axis of rotation
of the drive shaft, wherein an axis of rotation of the distal gear may be co-
axial with the axis of
rotation of the drive shaft when the shaft assembly is in a straight
configuration, and wherein an
axis of rotation of each of the output gears may be parallel to the axis of
rotation of the distal
gear.
[0014] The axis of rotation of the distal gear may be oriented orthogonal
to a pivot axis
defined by the pivot pin.
[0015] The axis of rotation of each of the output gears may be disposed at
approximately
90 to one another, relative to the axis of rotation of the distal gear.
[0016] The shaft assembly may include a release assembly configured for
selective
engagement with the end effector at a distal end of the shaft assembly, and
may be actuatable
from a proximal end of the shaft assembly.
[0017] The release assembly of the shaft assembly may include a pair of
diametrically
opposed connection pins supported in the distal neck housing. The release
assembly may
include an actuated condition in which the connection pins are retracted
radially inward; and a
non-actuated condition in which the connection pins project radially outward.
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100181 The end effector may include a coupling member defined by an annular
wall, and
wherein the coupling member may define a first pair of diametrically opposed
attachment holes
and a second pair of diametrically opposed attachment holes, wherein the first
pair and the
second pair of attachment holes may be offset approximately 900 relative to
one another.
[00191 Each of the first pair and second pair of attachment holes may be
configured to
receive the pair of connection pins of the release assembly when the end
effector is connected to
the shaft assembly in one of the first orientation and the second orientation.
[00201 The release assembly of the shaft assembly may include a release
button
supported near a proximal end of the outer tube, and a release cable
interconnecting the release
button and the connection pins. In use, an actuation of the release button may
exert a force on
the release cable to actuate the connection pins from the non-actuated
condition to the actuated
condition.
[00211 The shaft assembly may further include an articulation rod at least
partially
slidably supported in the distal neck housing. The articulation rod may
include a distal end; and
a proximal end operatively connected to a rotatable drive shaft; wherein the
articulation rod is off
set a radial distance from a central longitudinal axis of the shaft assembly.
The shaft assembly
may further include an articulation link having a proximal end pivotally
connected to the distal
end of the articulation rod, and a distal end pivotally connected to the
distal neck housing. In
use, actuation of a rotatable drive shaft of the electromechanical surgical
device that is connected
to the articulation rod may cause the articulation rod to axially translate.
Also in use, axial
translation of the articulation rod may cause the distal neck housing to pivot
off axis relative to
the proximal neck housing.
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=
100221 According to another aspect of the present disclosure, an
electromechanical
surgical device is provided and comprises an end effector configured to
perform at least one
function, the end effector including an input drive axle projecting therefrom;
and a shaft
assembly. The shaft assembly includes an outer tube; a rotatable drive shaft
supported therein; a
proximal neck housing supported at a distal end of the outer tube; a distal
neck housing pivotally
connected to the proximal neck housing, wherein a distal end of the distal
neck housing is
configured and adapted for operative connection with the end effector; a pivot
pin
interconnecting the proximal neck housing and the distal neck housing; and a
release assembly
configured for selective engagement with the end effector at a distal end of
the shaft assembly,
and being actuatable from a proximal end of the shaft assembly, wherein the
release assembly of
the shaft assembly includes a pair of diametrically opposed connection pins
supported in the
distal neck housing. The release assembly includes an actuated condition in
which the
connection pins are retracted radially inward; and a non-actuated condition in
which the
connection pins project radially outward.
[00231 The end effector may include a coupling member defined by an
annular wall, and
wherein the coupling member may define a first pair of diametrically opposed
attachment holes
and a second pair of diametrically opposed attachment holes, wherein the first
pair and the
second pair of attachment holes are offset approximately 900 relative to one
another.
[0024] Each of the first pair and second pair of attachment holes may be
configured to
receive the pair of connection pins of the release assembly when the end
effector is connected to
the shaft assembly in one of a first orientation and a second orientation
oriented approximately
900 about a longitudinal axis thereof, relative to the first orientation.
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[0025] The release assembly of the shaft assembly may include a release
button
supported near a proximal end of the outer tube, and a release cable
interconnecting the release
button and the connection pins. In use, an actuation of the release button may
exert a force on
the release cable to actuate the connection pins from the non-actuated
condition to the actuated
condition.
[0026] The shaft assembly may further include a gear train supported in
the proximal
neck housing, on the pivot pin, and in the distal neck housing. The gear train
may include a
proximal gear rotatably supported in the proximal neck housing and being
coupled to a distal end
of the rotatable drive shaft; an intermediate gear rotatably supported on the
pivot pin and being in
operative engagement with the proximal gear; a distal gear rotatably supported
in the distal neck
housing and being in operative engagement with the intermediate gear; and a
pair of output gears
rotatably supported in the distal neck housing and each being in operative
engagement with the
distal gear, wherein each output gear defines a coupling socket each
configured to selectively
receive the drive axle of the end effector.
[0027] The end effector may include an upper jaw and a lower jaw movable
with respect
to one another between open and closed positions, wherein tissue contacting
surfaces of the
upper jaw and the lower jaw defines a plane therebetween. The end effector may
be selectively
connectable to the distal neck housing of the shaft assembly in one of a first
orientation and a
second orientation.
[0028] In the first orientation, the plane defined by the end effector may
be oriented
substantially orthogonal to a pivot axis defined by the pivot pin. In the
second orientation, the
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plane defined by the end effector may be oriented substantially parallel to a
pivot axis defined by
the pivot pin.
[0029] In use, when the end effector is connected to the distal neck
housing of the shaft
assembly in the first orientation, the drive axle of the end effector may be
coupled to the
coupling socket of a first of the pair of output gears. Also in use, when the
end effector is
connected to the distal neck housing of the shaft assembly in the second
orientation, the drive
axle of the end effector may be coupled to the coupling socket of a second of
the pair of output
gears.
[0030] A rotation of the drive shaft of the shaft assembly may result in
rotation of both
output gears.
[0031] The shaft assembly may have a straight configuration, and an angled
configuration wherein the distal neck housing is pivoted about the pivot pin
to a desired angled
configuration between about 00 to about 900.
[0032] The gear train may transmit rotation from the drive shaft to both
output gears
when the shaft assembly is in either the straight configuration or the angled
configuration.
[0033] An axis of rotation of the proximal gear may be co-axial with an
axis of rotation
of the drive shaft, wherein an axis of rotation of the distal gear may be co-
axial with the axis of
rotation of the drive shaft when the shaft assembly is in a straight
configuration, and wherein an
axis of rotation of each of the output gears may be parallel to the axis of
rotation of the distal
gear.
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[0034] The axis of rotation of the distal gear may be oriented orthogonal
to a pivot axis
defined by the pivot pin. The axis of rotation of each of the output gears may
be disposed at
approximately 900 to one another, relative to the axis of rotation of the
distal gear.
[0035] The shaft assembly may further comprise an articulation rod at
least partially
slidably supported in the distal neck housing. The articulation rod may
include a distal end; and
a proximal end operatively connected to a rotatable drive shaft; wherein the
articulation rod is off
set a radial distance from a central longitudinal axis of the shaft assembly.
The shaft assembly
may include an articulation link having a proximal end pivotally connected to
the distal end of
the articulation rod, and a distal end pivotally connected to the distal neck
housing. Actuation of
a rotatable drive shaft of the electromechanical surgical device that is
connected to the
articulation rod may cause the articulation rod to axially translate. Axial
translation of the
articulation rod may cause the distal neck housing to pivot off axis relative
to the proximal neck
housing.
[0036] According to yet another embodiment of the present disclosure, an
end effector
for performing a surgical function and being connectable to an
electromechanical power source
is provided. The end effector comprises an upper jaw and a lower jaw, at least
one of the upper
jaw and the lower jaw being movable in relation to the other of the upper jaw
and the lower jaw,
wherein the lower jaw of the end effector is configured to selectively receive
a cartridge
assembly; a drive beam slidably supported in the lower jaw and being
translatable through each
of the upper jaw and the lower jaw to move the lower jaw relative to the
upper; a cartridge
assembly configured for loading into the lower jaw, the cartridge assembly
including an
actuation sled slidably supported therein body and being configured to expel
at least a portion of
a plurality of staples loaded in the cartridge assembly upon a distal movement
of the actuation
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sled from a proximal-most position; a drive screw rotatably supported in the
lower jaw, wherein
the drive beam is threadably supported on the drive screw, whereby rotation of
the drive screw
results in axial translation of the drive beam; and a proximal coupling member
defined by a
proximally extending annular wall defining a proximal facing opening, wherein
a first pair of
diametrically opposed attachment holes are formed in the annular wall, and a
second pair of
diametrically opposed attachment holes are formed in the annular wall, wherein
the first pair and
the second pair of attachment holes are offset approximately 900 relative to
one another.
[0037] The annular wall of the coupling member may be angled radially
inwardly and
distally from a proximal-most edge thereof.
[00381 According to still another embodiment of the present disclosure, a
shaft assembly
for selectively interconnecting an end effector and an electromechanical power
source is
provided. The shaft assembly comprises an outer tube; a rotatable drive shaft
supported therein;
a proximal neck housing supported at a distal end of the outer tube; a distal
neck housing
pivotally connected to the proximal neck housing, wherein a distal end of the
distal neck housing
is configured and adapted for operative connection with the end effector; a
pivot pin
interconnecting the proximal neck housing and the distal neck housing; and a
gear train
supported in the proximal neck housing, on the pivot pin, and in the distal
neck housing. The
gear train includes a proximal gear rotatably supported in the proximal neck
housing and being
coupled to a distal end of the rotatable drive shaft; an intermediate gear
rotatably supported on
the pivot pin and being in operative engagement with the proximal gear; a
distal gear rotatably
supported in the distal neck housing and being in operative engagement with
the intermediate
gear; and a pair of output gears rotatably supported in the distal neck
housing and each being in
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operative engagement with the distal gear, wherein each output gear defines a
coupling socket
each configured to selectively receive the drive axle of the end effector.
[0039] In use, a rotation of the drive shaft of the shaft assembly may
result in rotation of
both output gears.
[0040] The shaft assembly may have a straight configuration, and an angled
configuration, between about 00 to about 900, wherein the distal neck housing
is pivoted about
the pivot pin to a desired angled configuration.
[0041] The gear train may transmit rotation from the drive shaft to both
output gears
when the shaft assembly is in either the straight configuration or the angled
configuration.
[0042] An axis of rotation of the proximal gear may be co-axial with an
axis of rotation
of the drive shaft, wherein an axis of rotation of the distal gear may be co-
axial with the axis of
rotation of the drive shaft when the shaft assembly is in a straight
configuration, and wherein an
axis of rotation of each of the output gears may be parallel to the axis of
rotation of the distal
gear.
[0043] The axis of rotation of the distal gear may be oriented orthogonal
to a pivot axis
defmed by the pivot pin. The axis of rotation of each of the output gears may
be disposed at
approximately 90 to one another, relative to the axis of rotation of the
distal gear.
[0044] The shaft assembly may further include a release assembly
configured for
selective engagement with the end effector at a distal end of the shaft
assembly, and may be
actuatable from a proximal end of the shaft assembly.
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[0045] The release assembly may include a pair of diametrically opposed
connection pins
supported in the distal neck housing. The release assembly may include an
actuated condition in
which the connection pins are retracted radially inward; and a non-actuated
condition in which
the connection pins project radially outward.
[0046] The release assembly may include a release button supported near a
proximal end
of the outer tube, and a release cable interconnecting the release button and
the connection pins.
[0047] In use, an actuation of the release button may exert a force on the
release cable to
actuate the connection pins from the non-actuated condition to the actuated
condition.
[0048] The shaft assembly may further include an articulation rod at least
partially
slidably supported in the distal neck housing. The articulation rod may
include a distal end; and
a proximal end operatively connected to a rotatable drive shaft; wherein the
articulation rod is off
set a radial distance from a central longitudinal axis of the shaft assembly.
The shaft assembly
may include an articulation link having a proximal end pivotally connected to
the distal end of
the articulation rod, and a distal end pivotally connected to the distal neck
housing. In use,
actuation of a rotatable drive shaft of the electromechanical surgical device
that is connected to
the articulation rod may cause the articulation rod to axially translate. Also
in use, axial
translation of the articulation rod may cause the distal neck housing to pivot
off axis relative to
the proximal neck housing.
[0049] Further details and aspects of exemplary embodiments of the present
invention
are described in more detail below with reference to the appended figures.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0050] Embodiments of the present disclosure are described herein with
reference to the
accompanying drawings, wherein:
[0051] FIG. 1 is a perspective view, with parts separated, of an
electromechanical
surgical system according to an embodiment of the present disclosure;
[0052] FIG. 2 is a perspective view of a powered surgical instrument of
the
electromechanical surgical system of FIG. 1;
[0053] FIG. 3 is a rear, perspective view of a shaft assembly and a
powered surgical
instrument, of the electromechanical surgical system of FIG. 1, illustrating a
connection
therebetween;
[0054] FIG. 4 is a side, elevational view of the shaft assembly of FIGS. 1
and 3;
[0055] FIG. 5 is a rear, perspective view of the shaft assembly of FIGS.
1, 3 and 4, with
outer covers or housing removed therefrom;
[0056] FIG. 6 is a rear, perspective view of the shaft assembly
illustrated in FIG. 5, with
an outer cover or housing of a proximal coupling member removed therefrom;
[0057] FIG. 7 is an enlarged, left-side, perspective view of a proximal
end portion of the
shaft assembly illustrated in FIG. 6;
[0058] FIG. 8 is an enlarged, right-side, perspective view of a proximal
end portion of
the shaft assembly illustrated in FIG. 6;
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[0059] FIG. 9 is an enlarged, perspective view of a distal end portion of
the shaft
assembly illustrated in FIG. 6;
[0060] FIG. 10A is an enlarged, front, perspective view of the shaft
assembly of FIGS. 1
and 3-9, illustrating a release assembly thereof;
[0061] FIG. 10 B is a perspective view of a release assembly according to
another
embodiment of the present disclosure;
[0062] FIG. 10C is another perspective view of the release assembly of FIG.
10A;
[0063] FIG. 10D is a perspective view of a release assembly according to
yet another
embodiment of the present disclosure;
[0064] FIG. 11 is a side, elevational view of an articulating neck assembly
of the shaft
assembly of FIGS. 1 and 3-9;
[0065] FIG. 12 is a rear, perspective view of the articulating neck
assembly of FIG. 11
with housing portions removed therefrom;
[0066] FIG. 13 is a front, perspective view of the articulating neck
assembly of FIG. 11
with housing portions removed therefrom;
[0067] FIG. 14 is a rear, perspective view, partially broken away, of the
shaft assembly
of FIGS. 1, 3 and 4, with outer covers or housing removed therefrom;
[0068] FIG. 15 is a cross-sectional view as taken and viewed along 15-15 of
FIG. 14;
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[0069] FIG. 15A is an enlarged, perspective view, with parts separated, of
a release
button of the release assembly;
[0070] FIG. 16 is an enlarged, rear perspective view of a distal end
portion of the shaft
assembly of FIG. 4;
[0071] FIG. 16A is a cross-sectional view as taken and viewed along 16A-16A
of FIG.
16;
[0072] FIG. 17 is an enlarged, rear perspective view of a distal-most end
portion of the
shaft assembly of FIG. 4;
[0073] FIGS. 17A-17C are perspective views (with FIG. 17B being a cross-
sectional
perspective view taken along 17B-17B of FIG. 17A), illustrating an actuation
of the release
assembly from a locking position to a release position;
[0074] FIG. 18 is a side, elevational view of an end effector according to
an embodiment
of the present disclosure;
[0075] FIG. 19 is a longitudinal, cross-sectional view of the end effector
of FIG. 18;
[0076] FIG. 20 is a rear, perspective view of the end effector of FIG. 18;
[0077] FIG. 21 is an enlarged, rear, perspective view of a proximal end of
the end
effector of FIGS. 18-20;
[0078] FIG. 22 is a perspective view illustrating the end effector and
shaft assembly
connected to one another;
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[0079] FIG.
23 is a perspective view, illustrating the distal end of the shaft assembly in
an articulated condition and the end effector being connected thereto while in
a first angular
orientation; and
[0080] FIG.
24 is a perspective view, illustrating the distal end of the shaft assembly in
an articulated condition and the end effector being connected thereto while in
a second angular
orientation.
DETAILED DESCRIPTION OF EMBODIMENTS
[0081]
Embodiments of the presently disclosed electromechanical surgical system,
apparatus and/or device are described in detail with reference to the
drawings, in which like
reference numerals designate identical or corresponding elements in each of
the several views.
As used herein the term "distal" refers to that portion of the
electromechanical surgical system,
apparatus and/or device, or component thereof, that are farther from the user,
while the term
"proximal" refers to that portion of the electromechanical surgical system,
apparatus and/or
device, or component thereof, that are closer to the user.
[0082]
Referring initially to FIGS. 1-3, an electromechanical, hand-held, powered
surgical system, in accordance with an embodiment of the present disclosure is
shown and
generally designated 10. Electromechanical surgical system 10 includes a
surgical apparatus or
device in the form of an electromechanical, hand-held, powered surgical
instrument 100 that is
configured for selective attachment thereto of a plurality of different end
effectors 400, via an
adapter or shaft assembly 200, that are each configured for actuation and
manipulation by the
electromechanical, hand-held, powered surgical instrument 100. In
particular, surgical
instrument 100 is configured for selective connection with shaft assembly 200,
and, in turn, shaft
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assembly 200 is configured for selective connection with any one of a
plurality of different end
effectors 400.
[0083] Reference may be made to International Application No.
PCT/US2008/077249,
filed September 22, 2008 (Inter. Pub. No. WO 2009/039506) and U.S. Patent
Application Serial
No. 12/622,827, filed on November 20, 2009, the entire content of each of
which being
incorporated herein by reference, for a detailed description of the
construction and operation of
exemplary electromechanical, hand-held, powered surgical instrument 100.
[0084] Generally, as illustrated in FIGS. 1-3, surgical instrument 100
includes a handle
housing 102 having a lower housing portion 104, an intermediate housing
portion 106 extending
from and/or supported on lower housing portion 104, and an upper housing
portion 108
extending from and/or supported on intermediate housing portion 106. Handle
housing 102
defines a cavity therein in which a circuit board (not shown) and a drive
mechanism (not shown)
are situated.
[00851 The circuit board is configured to control the various operations
of surgical
instrument 100, as will be set forth in additional detail below. In accordance
with the present
disclosure, handle housing 102 provides a housing in which a rechargeable
battery (not shown),
is removably situated. The battery is configured to supply power to any of the
electrical
components of surgical instrument 100.
[00861 Upper housing portion 108 of handle housing 102 defines a nose or
connecting
portion 108a configured to accept a corresponding shaft coupling assembly 208a
of transmission
housing 208 of shaft assembly 200. As seen in FIGS. 2 and 3, connecting
portion 108a of upper
housing portion 108 of surgical instrument 100 has a cylindrical recess 108b
that receives shaft
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coupling assembly 208a of transmission housing 208 of shaft assembly 200 when
shaft assembly
200 is mated to surgical instrument 100. Connecting portion 108a houses three
rotatable drive
connectors 118, 120, 122, each independently actuatable and rotatable by the
drive mechanism
(not shown) housed within handle housing 102.
[0087] Upper housing portion 108 of handle housing 102 provides a housing
in which the
drive mechanism (not shown) is situated. The drive mechanism is configured to
drive shafts
and/or gear components in order to perform the various operations of surgical
instrument 100. In
particular, the drive mechanism is configured to drive shafts and/or gear
components in order to
selectively move end effector 400 relative to shaft assembly 200; to rotate
anvil assembly 200
and/or end effector 400, about a longitudinal axis "X" (see FIG. 4), relative
to handle housing
102; to move an upper jaw or anvil assembly 442 of end effector 400 relative
to a lower jaw or
cartridge assembly 432 of end effector 400, and/or to fire a stapling and
cutting cartridge within
cartridge assembly 432 of end effector 400.
[0088] In use, when shaft assembly 200 is mated to surgical instrument 100,
each of
rotatable drive connectors 118, 120, 122 of surgical instrument 100 couples
with a corresponding
rotatable connector sleeve 218, 220, 222 of shaft assembly 200 (see FIGS. 3, 7
and 8). In this
regard, the interface between corresponding first drive connector 118 and
first connector sleeve
218, the interface between corresponding second drive connector 120 and second
connector
sleeve 220, and the interface between corresponding third drive connector 122
and third
connector sleeve 222 are keyed such that rotation of each of drive connectors
118, 120, 122 of
surgical instrument 100 causes a corresponding rotation of the corresponding
connector sleeve
218, 220, 222 of shaft assembly 200.
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[0089] The mating of drive connectors 118, 120, 122 of surgical instrument
100 with
connector sleeves 218, 220, 222 of shaft assembly 200 allows rotational forces
to be
independently transmitted via each of the three respective connector
interfaces. The drive
connectors 118, 120, 122 of surgical instrument 100 are configured to be
independently rotated
by the drive mechanism. In this regard, a function selection module (not
shown) of the drive
mechanism selects which drive connector or connectors 118, 120, 122 of
surgical instrument 100
is to be driven by an input drive component (not shown) of the drive
mechanism.
[0090] Since each of drive connectors 118, 120, 122 of surgical instrument
100 has a
keyed and/or substantially non-rotatable interface with respective connector
sleeves 218, 220,
222 of shaft assembly 200, when shaft assembly 200 is coupled to surgical
instrument 100,
rotational force(s) are selectively transferred from the drive mechanism of
surgical instrument
100 to shaft assembly 200, and on to end effector 400, as will be discussed in
greater detail
below.
[0091] The selective rotation of drive connector(s) 118, 120 and/or 122 of
surgical
instrument 100 allows surgical instrument 100 to selectively actuate different
functions of end
effector 400. As will be discussed in greater detail below, selective and
independent rotation of
first drive connector 118 of surgical instrument 100 corresponds to the
selective and independent
rotation of end effector 400 about longitudinal axis "X" (see FIG. 4) relative
to handle housing
102 of surgical instrument 100. Also, the selective and independent rotation
of second drive
connector 120 of surgical instrument 100 corresponds to the selective and
independent opening
and closing of end effector 400, and driving of a stapling/cutting component
of end effector 400.
Additionally, the selective and independent rotation of third drive connector
122 of surgical
19
CA 02842338 2014-02-06
instrument 100 corresponds to the selective and independent articulation of
end effector 400
transverse to longitudinal axis "X" (see FIG. 4).
[0092] In accordance with the present disclosure, the drive mechanism may
include a
selector gearbox assembly (not shown); a function selection module (not
shown), located
proximal to the selector gearbox assembly, that functions to selectively move
gear elements
within the selector gearbox assembly into engagement with a second motor (not
shown). The
drive mechanism may be configured to selectively drive one of drive connectors
118, 120, 122 of
surgical instrument 100, at a given time. Alternatively, the drive mechanism
may be configured
and capable of simultaneously driving all drive connectors 118, 120, 122, or
any selected two of
the drive connectors 118, 120, 122.
[0093] As illustrated in FIGS. 1 and 2, handle housing 102 supports a pair
of finger-
actuated control buttons 124, 126 and/or rocker device(s) 130 (only one rocker
device being
shown). Each one of the control buttons 124, 126 and rocker device(s) 130
includes a respective
magnet (not shown) that is moved by the actuation of an operator.
[0094] As illustrated in FIGS. 1-3, surgical device 100 is configured for
selective
connection with shaft assembly 200, and, in turn, shaft assembly 200 is
configured for selective
connection with end effector 400. Turning now to FIGS. 1 and 3-17C, shaft
assembly 200 will
be shown in detail and described. Shaft assembly 200 is configured to
communicate the
rotational forces of first, second and third rotatable drive connectors 118,
120, and 122 of
surgical instrument 100 to end effector 400. As mentioned above, shaft
assembly 200 is
configured for selective connection to surgical instrument 100.
CA 02842338 2014-02-06
[0095] As seen in FIGS. 1 and 3-9, shaft assembly 200 includes an
elongate, substantially
rigid, tubular body 210 having a proximal end 210a and a distal end 210b; a
transmission
housing 208 connected to proximal end 2I0a of tubular body 210 and being
configured for
selective connection to surgical instrument 100; and an articulating neck
assembly 230 connected
to distal end 210b of elongate body portion 210.
[0096] Transmission housing 208 and tubular body 210 are configured and
dimensioned
to house the components of shaft assembly 200. Tubular body 210 is dimensioned
for
endoscopic insertion, in particular, that outer tube is passable through a
typical trocar port,
cannula or the like. Transmission housing 208 is dimensioned to not enter the
trocar port,
cannula of the like.
[0097] Transmission housing 208 of shaft assembly 200 is configured and
adapted to
connect to connecting portion 108a of upper housing portion 108 of surgical
instrument 100. As
seen in FIGS. 1, 3-5, 14 and 22, transmission housing 208 of shaft assembly
200 includes a shaft
coupling assembly 208a supported at a proximal end thereof. Shaft coupling
assembly 208a is
configured and adapted to connect to connecting portion 108a of upper housing
portion 108 of
distal half-section 110a of surgical device 100.
[0098] Transmission housing 208, and particularly shaft coupling assembly
208a,
rotatably supports a first rotatable proximal drive shaft 212, a second
rotatable proximal drive
shaft 214, and a third rotatable proximal drive shaft 216 therein.
[0099] Shaft coupling assembly 208a is also configured to rotatably
support first, second
and third connector sleeves 218, 220 and 222, respectively. Each of connector
sleeves 218, 220,
222 is configured to mate with respective first, second and third drive
connectors 118, 120, 122
21
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of surgical device 100, as described above. Each of connector sleeves 218,
220, 222 is further
configured to mate with a proximal end of respective first, second and third
proximal drive shafts
212, 214, 216.
[00100] Shaft coupling assembly 208a of transmission housing 208 also
includes a first, a
second and a third biasing member 224, 226 and 228 disposed distally of
respective first, second
and third connector sleeves 218, 220, 222. Each of biasing members 224, 226
and 228 is
disposed about respective first, second and third rotatable proximal drive
shaft 212, 214 and 216.
Biasing members 224, 226 and 228 act on respective connector sleeves 218, 220
and 222 to help
maintain connector sleeves 218, 220 and 222 engaged with the distal end of
respective drive
rotatable drive connectors 118, 120, 122 of surgical device 100 when shaft
assembly 200 is
connected to surgical device 100.
[001011 In particular, first, second and third biasing members 224, 226 and
228 function to
bias respective connector sleeves 218, 220 and 222 in a proximal direction. In
this manner,
during assembly of shaft assembly 200 to surgical device 100, if first, second
and or third
connector sleeves 218, 220 and/or 222 is/are misaligned with the drive
connectors 118, 120, 122
of surgical device 100, first, second and/or third biasing member(s) 224, 226
and/or 228 are
compressed. Thus, when surgical device 100 is operated, drive connectors 118,
120, 122 of
surgical device 100 will rotate and first, second and/or third biasing
member(s) 224, 226 and/or
228 will cause respective first, second and/or third connector sleeve(s) 218,
220 and/or 222 to
slide back proximally, effectively coupling drive connectors 118, 120, 122 of
surgical device 100
to first, second and/or third proximal drive shaft(s) 212, 214 and 216 of
shaft coupling assembly
208a of transmission housing 208.
22
CA 02842338 2014-02-06
[00102] Shaft assembly 200 includes a plurality of force/rotation
transmitting/converting
assemblies, each disposed within transmission housing 208 and tubular body
210. Each
force/rotation transmitting/converting assembly is configured and adapted to
transmit/convert a
speed/force of rotation (e.g., increase or decrease) of first, second and
third rotatable drive
connectors 118, 120 and 122 of surgical instrument 100 before transmission of
such rotational
speed/force to end effector 400.
[00103] Specifically, shaft assembly 200 includes a first, a second and a
third
force/rotation transmitting/converting assembly 240, 250, 260, respectively,
disposed within
transmission housing 208 and tubular body 210. Each force/rotation
transmitting/converting
assembly 240, 250, 260 is configured and adapted to transmit or convert a
rotation of a first,
second and third drive connector 118, 120, 122 of surgical device 100 into
axial translation of
articulation bar 248 of shaft assembly 200, to effectuate articulating of end
effector 400; a
rotation of a ring gear 266 of shaft assembly 200, to effectuate rotation of
shaft assembly 200; or
a second proximal drive shaft 214 of shaft assembly 200 to effectuate closing,
opening and firing
of end effector 400.
[00104] As seen in FIGS. 5-8, first force/rotation transmitting/converting
assembly 240
includes first rotatable proximal drive shaft 212, which, as described above,
is rotatably
supported within transmission housing 208. First rotatable proximal drive
shaft 212 includes a
non-circular or shaped proximal end portion configured for connection with
first connector 218
which is connected to respective first connector 118 of surgical device 100.
First rotatable
proximal drive shaft 212 includes a distal end portion 212b having a threaded
outer profile or
surface.
23
CA 02842338 2014-02-06
[00105] First
force/rotation transmitting/converting assembly 240 further includes a drive
coupling nut 244 rotatably coupled to threaded distal end portion 212b of
first rotatable proximal
drive shaft 212, and which is slidably disposed within transmission housing
208. Drive coupling
nut 244 is slidably keyed within transmission housing 208 so as to be
prevented from rotation as
first rotatable proximal drive shaft 212 is rotated. In this manner, as first
rotatable proximal
drive shaft 212 is rotated, drive coupling nut 244 is translated along
threaded distal end portion
212b of first rotatable proximal drive shaft 212 and, in turn, through and/or
along transmission
housing 208.
[00106] First
force/rotation transmitting/converting assembly 240 further includes a thrust
bearing assembly 246 having a first bearing 246a secured to drive coupling nut
244, and a
second bearing 246b rotatably connected to first bearing 246a. First
force/rotation
transmitting/converting assembly 240 also includes an articulation bar 248
having a proximal
end 248a secured or connected to second bearing 246b. A distal end 248b of
articulation bar 248
extends through tubular body 210.
[00107] In
operation, as first rotatable proximal drive shaft 212 is rotated, due to a
rotation
of first connector sleeve 218, as a result of the rotation of the first
respective drive connector 118
of surgical device 100, threaded distal end portion 212b of first rotatable
proximal drive shaft
212 is rotated. Thus, as first rotatable proximal drive shaft 212 is rotated,
drive coupling nut 244
is caused to be translated axially along threaded distal portion 212b of first
rotatable proximal
drive shaft 212.
[00108] As
drive coupling nut 244 is caused to be translated axially along first
rotatable
proximal drive shaft 212, thrust bearing 246 and, in turn, articulation bar
248, are caused to be
24
CA 02842338 2014-02-06
translated axially relative to tubular body 210. As will be described in
greater detail below, as
articulation bar 248 is axially translated, articulation bar 248 causes
articulating neck assembly
230 of shaft assembly 200 to articulate and, in turn, causes end effector 400
to articulate when
end effector 400 is connected to shaft assembly 200.
[00109] With reference to FIGS. 5-8, second force/rotation
transmitting/converting
assembly 250 of shaft assembly 200 includes second rotatable proximal drive
shaft 214 rotatably
supported within transmission housing 208 and tubular body 210. Second
rotatable proximal
drive shaft 214 includes a non-circular or shaped proximal end portion
configured for connection
with second connector 220 which is connected to respective second connector
120 of surgical
device 100. Second rotatable proximal drive shaft 214 further includes a
distal end portion 214b
(see FIGS. 11-13) having a non-circular or shaped transverse cross-sectional
profile. Distal end
portion 214b of second rotatable proximal drive shaft 214 extends to proximal
neck housing 232
of articulating neck assembly 230. In accordance with the present disclosure,
second rotatable
proximal drive shaft 214 defmes an axis of rotation that is substantially co-
incident or co-axial
with a central longitudinal axis of tubular body 210.
[00110] In operation, as illustrated in FIGS. 5-8, as second rotatable
proximal drive shaft
214 is rotated due to a rotation of second connector sleeve 220, as a result
of the rotation of the
second drive connector 120 of surgical device 100, said rotation is
transmitted directly to first or
proximal bevel gear 238a of articulating neck assembly 230 of shaft assembly
200, to effectuate
a closure and a firing of end effector 400, as will be discussed in greater
detail below.
1001111 As also seen in FIGS. 5-8 and as mentioned above, shaft assembly
200 includes a
third force/rotation transmitting/converting assembly 260 supported in
transmission housing 208.
CA 02842338 2014-02-06
Third force/rotation transmitting/converting assembly 260 includes a rotation
ring gear 266
fixedly supported in transmission housing 208. Ring gear 266 defines an
internal array of gear
teeth 266a. Ring gear 266 includes a pair of diametrically opposed, radially
extending
protrusions 266b projecting from an outer edge thereof. Protrusions 266b are
disposed within
recesses (not shown) defined in an inner surface of transmission housing 208,
such that rotation
of ring gear 266 results in rotation of transmission housing 208.
[00112] Third force/rotation transmitting/converting assembly 260 further
includes third
rotatable proximal drive shaft 216 which, as described above, is rotatably
supported within
transmission housing 208. Third rotatable proximal drive shaft 216 includes a
non-circular or
shaped proximal end portion configured for connection with third connector 222
which is
connected to respective third connector 122 of surgical device 100. Third
rotatable proximal
drive shaft 216 includes a spur gear 216a keyed to a distal end thereof. A
reversing spur gear
264 inter-engages spur gear 216a of third rotatable proximal drive shaft 216
to gear teeth 266a of
ring gear 266.
[00113] In operation, as illustrated in FIGS. 5-8, as third rotatable
proximal drive shaft
216 is rotated, due to a rotation of third connector sleeve 222, as a result
of the rotation of the
first drive connector 118 of surgical device 100, spur gear 216a of third
rotatable proximal drive
shaft 216 engages reversing gear 264 causing reversing gear 264 to rotate. As
reversing gear 264
rotates, ring gear 266 also rotates thereby causing transmission housing 208
to rotate. As
transmission housing 208 is rotated, tubular body 210 is caused to be rotated
about longitudinal
axis "X" of shaft assembly 200. As tubular body 210 is rotated, end effector
400, that is
connected to distal neck housing 236 of articulating neck assembly 230 of
shaft assembly 200, is
also caused to be rotated about a longitudinal axis of shaft assembly 200.
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CA 02842338 2014-02-06
[00114] Turning now to FIGS. 5, 6, 9 and 10A-13, articulating neck assembly
230 is
shown and described. Articulating neck assembly 230 includes a proximal neck
housing 232;
and a distal neck housing 236 pivotally connected to and extending distally
from proximal neck
housing 232 by a pivot pin 234. Pivot pin 234 defines a pivot axis "P" (see
FIGS. 9 and 11-13)
that is oriented orthogonal to the longitudinal axis "X" and extends through
the longitudinal axis
CLX59.
[00115] Articulating neck assembly 230 includes a gear train 238 having a
first or
proximal bevel gear 238a rotatably supported in proximal neck housing 232, a
second or
intermediate bevel gear 238b supported on pivot pin 234 and enmeshed with
first bevel gear
238a, and a third or distal bevel gear 238c rotatably supported in distal neck
housing 236 and
enmeshed with second or intermediate bevel gear 238b. It is contemplated that
each of first or
proximal bevel gear 238a and third or distal bevel gear 238c share a common
axis of rotation
which is co-incident or co-axial with the central longitudinal axis "X" of
shaft assembly 200,
when articulating neck assembly 230 is in a non-articulated condition.
[00116] First or proximal bevel gear 238a is non-rotatably coupled to
distal end portion
214b of second rotatable proximal drive shaft 214. In this manner, as second
rotatable proximal
drive shaft 214 is rotated, as described above, said rotation is transmitted
to first or proximal
bevel gear 238a.
[00117] Third or distal bevel gear 238c includes a spur gear 238d non-
rotatably connected
thereto via a rotation shaft or pin 238e. In this manner, as first or proximal
bevel gear 238a is
rotated, as described above, said rotation is transmitted to second or
intermediate bevel gear 238b
and, in turn, on to third or distal bevel gear 238c. As third or distal bevel
gear 238c is rotated,
27
CA 02842338 2014-02-06
said rotation is transmitted to spur gear 238d due to the non-rotatably inter-
connection by shaft
or pin 238e.
[00118] While gear train 238 has been shown and described using bevel
gears, it is
contemplated that gear train 238 may include at least one face gear or the
like to achieve the
intended purpose of transferring rotation across a pivot point.
[00119] As seen in FIGS. 5, 6, 9 and 10A-13, distal neck portion 236 of
articulating neck
assembly 230 rotatably supports a pair of output gears 239a, 239b, each
enmeshed with spur gear
238d. Each output gear 239a, 239b defines a respective coupling socket 239a1,
239b1. In this
manner, as spur gear 238d is rotated, as described above, said rotation is
transmitted to both
output gears 239a, 239b. Each coupling socket 239a1, 239b1 is configured and
dimensioned to
selectively receive a proximal head 426a of a drive axle 426 of end effector
400, as will be
discussed in greater detail below. Moreover, output gears 239a, 239b are
arranged to have axes
of rotation which are parallel to the longitudinal axis "X" and which are
disposed substantially at
90 relative to one another, or any other appropriate or desired angular
separation from one
another.
[00120] Articulating neck assembly 230 includes an articulation link 241
having a
proximal end 241a pivotally connected to distal end 248b of articulation bar
248. A distal end
241b of articulation link 241 is pivotally connected to distal neck housing
236, at a location
offset a transverse distance from the longitudinal axis "X".
[00121] Proximal neck housing 232 defines a chamfered distal surface 232a,
and distal
neck housing 236 defines a chamfered proximal surface 236a. In an embodiment,
chamfered
surfaces 232a, 236a are in juxtaposed relation to one another. In use, when
end effector 400 is
28
CA 02842338 2014-02-06
actuated to an off-axis orientation, as will be discussed in greater detail
below, chamfered
surfaces 232a, 236a of proximal neck housing 232 and distal neck housing 236
are approximated
toward one another. Desirably, each chamfered surface 232a, 236a is angled at
about 45
relative to the longitudinal axis "X". Specifically, chamfered surface 232a of
proximal neck
housing 232 is angled at about (-)45 relative to the longitudinal axis "X",
while chamfered
surface 236a of distal neck housing 236 is angled at about (+)45 relative to
the longitudinal axis
"X". In this manner, when end effector 400 is actuated to a maximum off-axis
orientation, as
seen in FIGS. 17, 23 and 24, end effector 400 is oriented at about 90
relative to the longitudinal
axis "X". In use, end effector 400 may be oriented at any angular orientation
from about 0 to
about 90 relative to the longitudinal axis "X", as needed or desired, such
as, for example, about
45 .
[00122] In accordance with the present disclosure, distal neck housing 236
is pivotable in
a single direction relative to proximal neck housing 232.
[00123] As seen in FIGS. 4-6 and 9, articulating neck assembly 230 includes
a shield 243
secured to articulation link 240. Shield 243 functions to protect the user and
patient from gear
train 238.
[00124] Articulating neck assembly 230 further includes, as seen in FIGS.
5, 6, 9, 10A and
17A-17C, a distal connection hub 250 supported and/or coupled in a distal end
of distal neck
housing 236. Connection hub 250 rotatably supports both output gears 239a,
239b. In an
embodiment, as seen in FIGS. 17A-17C, connection hub 250 defines a pair of
diametrically
opposed angled surfaces 252a, 252b. Each angled surface 252a, 252b extends in
a radially
29
CA 02842338 2014-02-06
outward direction and in a transverse distal direction relative to a central
axis of shaft assembly
200.
[00125] Shaft assembly 200, as seen in FIGS. 4-8, 10A-10D and 14-17C,
includes a
release assembly 280 at least partially supported in/on connection hub 250.
Release assembly
280 includes a pair of cam blocks 281a, 281b, each operatively associated with
a respective
angled surface 252a, 252b of connection hub 250. Release assembly 280 further
includes a pair
of connection pins 282a, 282b, each connected to and secured to respective cam
blocks 281a,
281b. Each connection pin 282a, 282b is dimensioned to extend from respective
cam block
281a, 281b and radially through connection hub 250. Specifically, each
connection pin 282a,
282b includes a tip which projects radially outward from connection hub 250,
when release
assembly 280 is in a non-actuated condition.
[00126] Release assembly 280 further includes a release lever 285 in the
form of a leaf
spring defining a biasing member interposed between cam blocks 281a, 281b and
functioning to
maintain or urge cam blocks 281a, 281b into engagement or contact with
respective angled
surface 252a, 252b of connection hub 250. Release lever 285 includes a pair of
ends 285a, 285b
secured to a respective cam block 281a, 281b, and a free end 285c projecting
radially from the
axis defined by connection pins 282a, 282b.
[00127] Release assembly 280 includes a first or connecting configuration
wherein a tip of
each connection pin 282a, 282b projects radially outward from connection hub
250, and a second
or release configuration wherein the tip of each connection pin 282a, 282b is
at least partially
withdrawn or retracted into connection hub 250.
CA 02842338 2014-02-06
[00128] In use, as seen in FIGS. 17A-17C, in order to actuate release
assembly 280 from
the first configuration to the second configuration, release lever 285 is
actuated to rotate release
lever 285 about the axis defmed by connection pins 282a, 282b. As release
lever 285 is actuated,
cam blocks 281a, 281b are rotated relative to respective angled surface 252a,
252b of connection
hub 250 thereby urging respective connection pins 282a, 282b radially inward,
and biasing or
compressing the leaf spring portion of release lever 285. Following actuation
of release lever
285, upon a release thereof, the leafspring un-compresses and urges cam blocks
281a, 281b
against respective angled surface 252a, 252b of connection hub 250 causing cam
blocks 281a,
281b to return to an un-rotated position and resulting in connection pins
282a, 282b re-extending
radially outward from connection hub 250.
[00129] In an alternate embodiment of a release assembly 280a, as seen in
FIG. 10A, leaf
spring release lever 285 of release assembly 280 may be replaced with a
separate biasing
member 284a and release lever 284b.
[00130] Release assembly 280 also includes a release lever 285 connected to
at least one
cam block 281a, 281b. In the present embodiment, release lever 285 extends in
a direction
transverse to an axis defined by connection pins 282a, 282b.
[00131] In yet another alternate embodiment, as seen in FIG. 10D, another
alternate
release assembly 280b may include a resilient wire-like release lever 284c
including a pair of
arms 284c1, 284c2 arranged in a substantial V-shape or S2-shape, and a pair of
connection pins
282a1, 282b1 extending from a respective arm 284c1, 284c2. Release lever 284c
of release
assembly 280b cooperates with particularly shaped camming surfaces 252a1,
252b1 of connection
hub 250.
31
CA 02842338 2014-02-06
[00132] In use, in order to actuate release assembly 280b from a first
configuration to a
second configuration, release lever 284c is actuated to rotate arms 284c1,
284c2 about an axis
defined by connection pins 282a1, 282b1. As release lever 284c is actuated,
arms 284c1, 284c2
engage respective angled surfaces 252a1, 252b1 of connection hub 250 thereby
urging respective
arms 284c1, 284c2 and thus connection pins 282a1, 282b1 radially inward, and
biasing or
compressing arms 284c1, 284c2 toward one another. Following actuation of
release lever 284c,
upon a release thereof, arms 284c1, 284c2 un-compress and urge connection pins
282a1, 282b1
radially outward from connection hub 250.
[00133] Turning now to FIGS. 14-17, release assembly 280 includes a release
cable 286
extending through articulation neck assembly 230 and tubular body 210 of shaft
assembly 200.
Specifically, release cable 286 includes a distal end connected to a free end
285c of release lever
285. Release cable 286 also includes a proximal end connected to a release
button 287 which is
slidably supported on transmission housing 208. Release button 287 includes a
first position
wherein release assembly 280 is un-actuated, as described above, and at least
a second position
wherein release button 287 pulls release cable 286 in a proximal direction to
actuate release
assembly 280.
[00134] Release assembly 280 further includes a slack removal assembly 288
including a
spring 288a, or the like, associated with release cable 286. Slack removal
spring 288a functions
to compensate for any slack or stretching that may occur in release cable 286
over time and after
any number of uses, or when articulation neck assembly 230 is in an articulate
configuration. In
particular, slack removal assembly 288 further includes a cylinder 288b into
which a proximal
end of release cable 286 extends. Release button 287 is connected to cylinder
288b such that
axial movement of release button 287 results in concomitant axial movement of
cylinder 288b.
32
CA 02842338 2014-02-06
Slack removal spring 288a is supported in cylinder 288b. The proximal end of
release cable 286
extends through slack removal spring 288a and is capped by a plug 288c fixedly
connected
thereto. Desirably, slack removal spring 288a is a coil spring or the like.
[001351 As seen in FIGS. 3 and 8, shaft assembly 200 includes a pair of
electrical contact
pins 290a, 290b for electrical connection to a corresponding electrical plug
190a, 190b disposed
in connecting portion 108a of surgical device 100. Electrical contacts 290a,
290b serve to allow
for calibration and communication of necessary life-cycle information to
circuit board 150 of
surgical device 100 via electrical plugs 190a, 190b that are electrically
connected to circuit board
150. Shaft assembly 200 further includes a circuit board 292 supported in knob
housing 202 and
which is in electrical communication with electrical contact pins 290a, 290b.
In accordance with
the present disclosure, shaft assembly 200 or circuit board 292 include a
button 294 (see FIGS. 7
and 8), which functions in the manner of a gyroscope, Hall-Effect sensors or
the like, to
communicate with surgical instrument 100 and provide surgical instrument 100
with an
indication of when shaft assembly is not rotated (i.e., in a home or straight
position or
configuration). In this manner, button 294 functions to inhibit instances of
excessive rotation of
shaft assembly 100.
[001361 Turning now to FIGS. 18-24, a detailed discussion of the
construction and
operation of end effector 400 is provided. End effector 400 is constructed
substantially in
accordance with end effector 400 disclosed in U.S. Provisional Patent
Application Serial No.
61/659,116, filed on June 13, 2012, entitled "Apparatus for Endoscopic
Procedures", the entire
content of which being incorporated herein by reference, and thus will only be
discussed in detail
herein to the extent necessary to describe differences in construction and
operation thereof. End
effector 400 may be configured and adapted to apply a plurality of linear rows
of fasteners,
33
CA 02842338 2014-02-06
which in embodiments may be of various sizes, and which, in certain
embodiments may have
various lengths or rows, e.g., about 30, 45 and 60 mm in length.
[00137] As seen in FIGS. 1 and 18-24, end effector 400 includes a mounting
portion 420
having a coupling member 422 configured for selective connection to distal
neck housing 236 of
shaft assembly 200. End effector 400 further includes a jaw assembly 430
connected to and
extending distally from mounting portion 420. Jaw assembly 430 includes a
lower jaw 432
pivotally connected to mounting portion 420 and being configured to
selectively support a
cartridge assembly therein, and an upper jaw 442 secured to mounting portion
420 and being
movable, relative to lower jaw 432, between approximated and spaced apart
positions.
1001381 As seen in FIGS. 20 and 21, coupling member 422 is substantially
cylindrical and
includes a rear or proximal annular wall 422a defining a central opening 422b
therein. Annular
wall 422a defines an angled inner surface 422c extending radially inwardly and
distally from a
proximal-most edge. Annular wall 422a further defines two pair of
diametrically opposed
attachment holes 422d1, 422d2 oriented orthogonally to one another. Central
opening 422b is
configured and dimensioned to receive connection hub 250 of shaft assembly 200
therein.
[00139] In use, when end effector 400 is connected to attached to shaft
assembly 200, end
effector 400 is oriented in either a first orientation, or a second
orientation rotated approximately
90 , along a longitudinal axis thereof, relative to the first orientation.
[00140] As seen in FIG. 23, in the first orientation, attachment holes
422d3 are aligned
with connection pins 282a, 282b of release assembly 280 of shaft assembly, and
a proximal head
426a of a drive axle 426 of end effector 400 is aligned with coupling socket
239a1. As so
oriented, end effector 400 is approximated toward shaft assembly 200 wherein
connection pins
34
CA 02842338 2014-02-06
282a, 282b of release assembly 280 are cammed radially inwardly as connection
pins 282a, 282b
engage angled inner surface 422c of coupling member until connection pins
282a, 282b align
with attachment holes 422d1 whereby connection pins 282a, 282b are free to
spring radially
outward into attachment holes 422d1 to secure end effector 400 to shaft
assembly 200. Also, as
so oriented, when end effector 400 is connected to shaft assembly 200,
proximal head 426a of
drive axle 426 of end effector 400 operatively couples with coupling socket
239a1.
[001411 In this first orientation, as seen in FIG. 23, a plane defined
between tissue
contacting surfaces of upper jaw 442 and lower jaw 432 of jaw assembly 430 is
substantially
parallel to the pivot axis "P" defined by pivot pin 234.
[001421 As seen in FIGS. 21 and 24, in the second orientation, attachment
holes 422d2 are
aligned with connection pins 282a, 282b of release assembly 280 of shaft
assembly, and
proximal head 426a of drive axle 426 of end effector 400 is aligned with
coupling socket 239b1.
As so oriented, end effector 400 is approximated toward shaft assembly 200
wherein connection
pins 282a, 282b of release assembly 280 are cammed radially inwardly as
connection pins 282a,
282b engage angled inner surface 422c of coupling member until connection pins
282a, 282b
align with attachment holes 422d2 whereby connection pins 282a, 282b are free
to spring radially
outward into attachment holes 422d2 to secure end effector 400 to shaft
assembly 200. Also, as
so oriented, when end effector 400 is connected to shaft assembly 200,
proximal head 426a of
drive axle 426 of end effector 400 operatively couples with coupling socket
239b1.
[001431 In this second orientation, as seen in FIG. 24, a plane defined
between tissue
contacting surfaces of upper jaw 442 and lower jaw 432 of jaw assembly 430 is
substantially
orthogonal to the pivot axis "P" defined by pivot pin 234.
CA 02842338 2014-02-06
[00144] As seen in FIG. 19, lower jaw 432 of jaw assembly 430 includes a
drive screw
464 rotatably supported therein and extending substantially an entire length
thereof. Drive screw
464 includes a female coupling member 464a supported on a proximal end thereof
and being
configured for receipt of multi-faceted, distal head 426b of drive axle 426.
Drive screw 464 is
axially and laterally fixed within lower jaw 432 of jaw assembly 430. In
operation, rotation of
drive axle 426 results in concomitant rotation of drive screw 464.
[00145) End effector 400 includes a drive beam 466 slidably supported in
lower jaw 432
of jaw assembly 430. Drive beam 466 includes a substantially I-shaped cross-
sectional profile
and is configured to approximate lower jaw 432 and upper jaw 442, and to
axially displace an
actuation sled 418 through lower jaw 432. Drive beam 466 includes a vertically
oriented support
strut; a lateral projecting member formed atop the support strut and being
configured to engage
and translate with respect to an exterior camming surface of upper jaw 442 to
progressively close
jaw assembly 430; and a retention foot having an internally threaded bore for
threadable
connection to threaded drive screw 464. Since drive beam 466 is prevented from
rotation by the
engagement of the strut and/or the cam member with upper jaw 442, as drive
screw 464 is
rotated, the retention foot, and in turn, drive beam 466 is axially translated
relative to lower jaw
432.
[00146] In operation, as drive screw 464 is rotated, in a first direction,
to advance drive
beam 466, as described above, drive beam 466 is advanced into contact with a
knife sled 450 and
an actuation sled 418 to distally advance or push knife sled 450 and actuation
sled 418 through
staple cartridge assembly 410 and lower jaw 432. Knife sled 450, actuation
sled 418 and drive
beam 466 travel through cartridge body 412 thereby fastening and severing
tissue. Drive screw
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464 is rotated until actuation sled 418, knife sled 450 and drive beam 466
reach a distal-most end
of cartridge body 412 and/or lower jaw 432, for a complete firing.
[00147] Following a complete or partial firing, drive screw 464 is rotated
in an opposite
direction to retract drive beam 466. Drive screw 464 is rotated until drive
beam 466 and knife
sled 450 are returned to the proximal-most position. Once drive beam 466 and
knife sled 450 are
returned to the proximal-most position, drive beam 466 is disengaged from
knife sled 450, and
staple cartridge assembly 410 is free to be removed from lower jaw 432.
[00148] Upper jaw 442 of jaw assembly 430 functions as an anvil against
which the
staples form when actuation sled 418 is advanced during a firing of surgical
instrument 100. In
particular, upper jaw 442 includes an anvil plate 443, secured to a cover
housing 444, in
juxtaposed relation to staple cartridge assembly 410. Anvil plate 443 defines
a plurality of staple
forming pockets (not shown), arranged in longitudinally extending rows that
cooperate with the
rows of staple retaining slots (not shown) of staple cartridge assembly 410,
when staple cartridge
assembly 410 is disposed in lower jaw 432.
[00149] Further aspects of the present disclosure are described in the
following numbered
paragraphs:
1. An electromechanical surgical device, comprising:
an end effector configured to perform at least one function, the end effector
including an
input drive axle projecting therefrom; and
a shaft assembly including:
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an outer tube;
a rotatable drive shaft supported therein;
a proximal neck housing supported at a distal end of the outer tube;
a distal neck housing pivotally connected to the proximal neck housing,
wherein a
distal end of the distal neck housing is configured and adapted for operative
connection with the
end effector;
a pivot pin interconnecting the proximal neck housing and the distal neck
housing; and
a release assembly configured for selective engagement with the end effector
at a
distal end of the shaft assembly, and being actuatable from a proximal end of
the shaft assembly,
wherein the release assembly of the shaft assembly includes a pair of
diametrically opposed
connection pins supported in the distal neck housing, wherein the release
assembly includes:
an actuated condition in which the connection pins are retracted radially
inward; and
a non-actuated condition in which the connection pins project radially
outward.
2. The
electromechanical surgical device according to claim 1, wherein the end
effector includes a coupling member defined by an annular wall, and wherein
the coupling
member defines a first pair of diametrically opposed attachment holes and a
second pair of
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diametrically opposed attachment holes, wherein the first pair and the second
pair of attachment
holes are offset approximately 900 relative to one another.
3. The electromechanical surgical device according to claim 2, wherein each
of the
first pair and second pair of attachment holes are configured to receive the
pair of connection
pins of the release assembly when the end effector is connected to the shaft
assembly in one of a
first orientation and a second orientation oriented approximately 90 about a
longitudinal axis
thereof, relative to the first orientation.
4. The electromechanical surgical device according to claim 1, wherein the
release
assembly of the shaft assembly includes a release button supported near a
proximal end of the
outer tube, and a release cable interconnecting the release button and the
connection pins.
5. The electromechanical surgical device according to claim 4, wherein an
actuation
of the release button exerts a force on the release cable to actuate the
connection pins from the
non-actuated condition to the actuated condition.
6. The electromechanical surgical device according to claim 3, wherein the
shaft
assembly further includes a gear train supported in the proximal neck housing,
on the pivot pin,
and in the distal neck housing, wherein the gear train includes:
a proximal gear rotatably supported in the proximal neck housing and being
coupled to a
distal end of the rotatable drive shaft;
an intermediate gear rotatably supported on the pivot pin and being in
operative
engagement with the proximal gear;
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a distal gear rotatably supported in the distal neck housing and being in
operative
engagement with the intermediate gear; and
a pair of output gears rotatably supported in the distal neck housing and each
being in
operative engagement with the distal gear, wherein each output gear defines a
coupling socket
each configured to selectively receive the drive axle of the end effector.
7. The electromechanical surgical device according to claim 6, wherein the
end
effector includes an upper jaw and a lower jaw movable with respect to one
another between
open and closed positions, wherein tissue contacting surfaces of the upper jaw
and the lower jaw
defines a plane therebetween, and wherein the end effector is selectively
connectable to the distal
neck housing of the shaft assembly in one of a first orientation and a second
orientation.
8. The electromechanical surgical device according to claim 7, wherein in
the first
orientation the plane defined by the end effector is oriented substantially
orthogonal to a pivot
axis defined by the pivot pin.
9. The electromechanical surgical device according to claim 8, wherein in
the
second orientation the plane defined by the end effector is oriented
substantially parallel to a
pivot axis defined by the pivot pin.
10. The electromechanical surgical device according to claim 9, wherein
when the
end effector is connected to the distal neck housing of the shaft assembly in
the first orientation,
the drive axle of the end effector is coupled to the coupling socket of a
first of the pair of output
gears.
CA 02842338 2014-02-06
11. The electromechanical surgical device according to claim 10, wherein
when the
end effector is connected to the distal neck housing of the shaft assembly in
the second
orientation, the drive axle of the end effector is coupled to the coupling
socket of a second of the
pair of output gears.
12. The electromechanical surgical device according to claim 11, wherein a
rotation
of the drive shaft of the shaft assembly results in rotation of both output
gears.
13. The electromechanical surgical device according to claim 12, wherein
the shaft
assembly has a straight configuration, and an angled configuration wherein the
distal neck
housing is pivoted about the pivot pin to a desired angled configuration
between about 00 to
about 90 .
14. The electromechanical surgical device according to claim 13, wherein
the gear
train transmits rotation from the drive shaft to both output gears when the
shaft assembly is in
either the straight configuration or the angled configuration.
15. The electromechanical surgical device according to claim 6, wherein an
axis of
rotation of the proximal gear is co-axial with an axis of rotation of the
drive shaft, wherein an
axis of rotation of the distal gear is co-axial with the axis of rotation of
the drive shaft when the
shaft assembly is in a straight configuration, and wherein an axis of rotation
of each of the output
gears is parallel to the axis of rotation of the distal gear.
16. The electromechanical surgical device according to claim 15, wherein
the axis of
rotation of the distal gear is oriented orthogonal to a pivot axis defined by
the pivot pin.
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17. The electromechanical surgical device according to claim 15, wherein
the axis of
rotation of each of the output gears is disposed at approximately 900 to one
another, relative to
the axis of rotation of the distal gear.
18. The electromechanical surgical device according to claim 6, wherein the
shaft
assembly further comprises:
an articulation rod at least partially slidably supported in the distal neck
housing, the
articulation rod including:
a distal end; and
a proximal end operatively connected to a rotatable drive shaft; wherein the
articulation rod is off set a radial distance from a central longitudinal axis
of the shaft assembly;
and
an articulation link having a proximal end pivotally connected to the distal
end of the
articulation rod, and a distal end pivotally connected to the distal neck
housing;
wherein actuation of a rotatable drive shaft of the electromechanical surgical
device that
is connected to the articulation rod causes the articulation rod to axially
translate; and
wherein axial translation of the articulation rod causes the distal neck
housing to pivot off
axis relative to the proximal neck housing.
19. An end effector for performing a surgical function and being
connectable to an
electromechanical power source, the end effector comprising:
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an upper jaw and a lower jaw, at least one of the upper jaw and the lower jaw
being
movable in relation to the other of the upper jaw and the lower jaw, wherein
the lower jaw of the
end effector is configured to selectively receive a cartridge assembly;
a drive beam slidably supported in the lower jaw and being translatable
through each of
the upper jaw and the lower jaw to move the lower jaw relative to the upper;
a cartridge assembly configured for loading into the lower jaw, the cartridge
assembly
including an actuation sled slidably supported therein body and being
configured to expel at least
a portion of a plurality of staples loaded in the cartridge assembly upon a
distal movement of the
actuation sled from a proximal-most position;
a drive screw rotatably supported in the lower jaw, wherein the drive beam is
threadably
supported on the drive screw, whereby rotation of the drive screw results in
axial translation of
the drive beam; and
a proximal coupling member defined by a proximally extending annular wall
defining a
proximal facing opening, wherein a first pair of diametrically opposed
attachment holes are
formed in the annular wall, and a second pair of diametrically opposed
attachment holes are
formed in the annular wall, wherein the first pair and the second pair of
attachment holes are
offset approximately 900 relative to one another.
20. The end effector according to claim 19, wherein the annular wall of
the coupling
member is angled radially inwardly and distally from a proximal-most edge
thereof.
[00150] It will be understood that various modifications may be made to the
embodiments
disclosed herein. For example, surgical instrument 100 and/or cartridge
assembly 410 need not
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apply staples but rather may apply two part fasteners as is known in the art.
Further, the length
of the linear row of staples or fasteners may be modified to meet the
requirements of a particular
surgical procedure. Thus, the length of the linear row of staples and/or
fasteners within a staple
cartridge assembly may be varied accordingly. Therefore, the above description
should not be
construed as limiting, but merely as exemplifications of preferred
embodiments. Those skilled in
the art will envision other modifications within the scope and spirit of the
claims appended
thereto.
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