Simplified spring-loaded mechanism for delivering shaft force of a surgical instrument

• US 10,245,100 B2
• Filed: 09/18/2015
• Issued: 04/02/2019
• Est. Priority Date: 05/01/2012
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Sims, Grant T., Lyons, Michael B.
• Primary Examiner(s): Yabut, Diane D
• Assistant Examiner(s): Jamialahmadi, Majid
• Application Number:
  US14/858,308
• Publication Number:
  US 20160008054A1
• Time in Patent Office: 1,292 Days
• CPC Class Codes: A61B 17/2812 with a single pivotal connection A61B17/29 takes precedence
• CPC Class Codes: A61B 18/1445 at the distal end of a shaft, e.g. forceps or scissors at the end of a rigid rod
• CPC Class Codes: A61B 18/1482 having a long rigid shaft for accessing the inner body transcutaneously in minimal invasive surgery, e.g. laparoscopy
• CPC Class Codes: A61B 2017/00367 Details of actuation of instruments, e.g. relations between pushing buttons, or the like, and activation of the tool, working tip, or the like
• CPC Class Codes: A61B 2017/0046 with a releasable handle; with handle and operating part separable for prosthetic joint-implanting tools A61F2/4603
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/2902 characterized by features of the actuating rod
• CPC Class Codes: A61B 2017/292 connection of actuating rod to handle, e.g. ball end in recess
• CPC Class Codes: A61B 2017/2929 with a head rotatable about the longitudinal axis of the shaft
• CPC Class Codes: A61B 2017/293 with means preventing relative rotation between the shaft and the actuating rod
• CPC Class Codes: A61B 2017/2936 Pins in guiding slots
• CPC Class Codes: A61B 2017/2946 Locking means
• CPC Class Codes: A61B 2018/00601 Cutting
• CPC Class Codes: A61B 2018/00607 Coagulation and cutting with the same instrument
• CPC Class Codes: A61B 2018/00619 Welding
• CPC Class Codes: A61B 2018/0063 Sealing
• CPC Class Codes: A61B 2018/00952 rotatable
• CPC Class Codes: A61B 2018/1455 having a moving blade for cutting tissue grasped by the jaws
• CPC Class Codes: A61B 2090/031 torque limiting
• CPC Class Codes: A61B 2090/033 : Abutting means, stops, e.g. abutting on tissue or skin
• CPC Class Codes: A61B 2090/034 : abutting on parts of the device itself
• CPC Class Codes: A61B 90/03 : Automatic limiting or abutting means, e.g. for safety
• CPC Class Codes: Y10T 29/49002 : Electrical device making
• CPC Class Codes: Y10T 29/49826 : Assembling or joining
• CPC Class Codes: Y10T 403/32549 : including limit means

Abstract

A connection mechanism and manufacturing method for a surgical instrument includes an inner shaft member that extends at least partially through an elongated shaft member of the instrument and defines proximal and distal ends and is selectively movable in a longitudinal direction with respect to the elongated shaft member and includes at least one aperture that extends partially along the longitudinal direction and disposed distally from the proximal end. The inner shaft member enables a drive collar member to slide on the inner shaft member and reciprocate along the longitudinal direction. A drive collar stop member slides on the inner shaft member and moves along the longitudinal direction. The drive collar stop member then moves in a direction relative to the longitudinal axis to engage the aperture and limit further longitudinal motion of the drive collar member. An inner shaft stop member limits movement of the inner shaft.

Claims

1. A method of assembling a surgical instrument, comprising:

inserting a knife into a knife guide;

positioning a pair of flags extending from a tissue engaging portion of a first jaw member with a pair of flags extending from a tissue engaging portion of a second jaw member in an offset configuration such that one flag of the first jaw member is disposed on a laterally exterior side of a corresponding flag of the second jaw member and the other flag of the first jaw member is disposed on a laterally interior side of the other flag of the second jaw member;

operably coupling the first and second jaw members to the knife guide;

positioning the knife and the knife guide into an inner shaft;

moving a drive collar stop along the inner shaft;

engaging the drive collar stop within at least one aperture defined in the inner shaft to limit movement of the drive collar stop along the inner shaft; and

moving a drive collar having a cylindrical portion extending distally from a proximal rim along the inner shaft to abut a distal end of the cylindrical portion with the drive collar stop and limit distal movement of the drive collar along the inner shaft, the cylindrical portion having a reduced diameter relative to the proximal rim.

2. The method according to claim 1, further comprising engaging the knife guide to the inner shaft.

3. The method according to claim 1, wherein operably coupling the first and second jaw members to the knife guide includes disposing a cam pin through a through bore defined by the knife guide and a cam slot defined through the pair of flags of each of the first and second jaw members.

4. A method of assembling a surgical instrument, comprising:

inserting a knife into a knife guide;

positioning a pair of flags extending from a tissue engaging portion of a first jaw member with a pair of flags extending from a tissue engaging portion of a second jaw member in an offset configuration such that one flag of the first jaw member is disposed on a laterally exterior side of a corresponding flag of the second jaw member and the other flag of the first jaw member is disposed on a laterally interior side of the other flag of the second jaw member;

operably coupling the first and second jaw members to the knife guide;

positioning the knife and the knife guide into an inner shaft;

moving a drive collar stop along the inner shaft;

engaging the drive collar stop within at least one aperture defined in the inner shaft;

moving a drive collar along the inner shaft to abut the drive collar stop and limit distal movement of the drive collar along the inner shaft;

moving a spring along the inner shaft to engage the drive collar and limit distal movement of the spring;

compressing the spring;

engaging an inner shaft stop within at least one additional aperture defined in the inner shaft to limit proximal movement of the inner shaft and retain the spring between the inner shaft stop and the drive collar in a compressed condition; and

engaging a projection extending distally from the inner shaft stop with an aperture defined in the spring.

5. The method according to claim 4, further comprising engaging the knife guide to the inner shaft.

6. The method according to claim 4, wherein operably coupling the first and second jaw members to the knife guide includes disposing a cam pin through a through bore defined by the knife guide and a cam slot defined through the pair of flags of each of the first and second jaw members.

7. A method of assembling a surgical instrument, comprising:

inserting a knife into a knife guide;

positioning a pair of flags extending from a tissue engaging portion of a first jaw member with a pair of flags extending from a tissue engaging portion of a second jaw member in an offset configuration such that one flag of the first jaw member is disposed on a laterally exterior side of a corresponding flag of the second jaw member and the other flag of the first jaw member is disposed on a laterally interior side of the other flag of the second jaw member;

operably coupling the first and second jaw members to the knife guide;

positioning the knife and the knife guide into an inner shaft;

moving a drive collar stop along a longitudinal axis defined through the inner shaft;

moving the drive collar stop transverse to the longitudinal axis to engage the drive collar stop within a proximal section of a slot defined in the inner shaft;

moving the drive collar stop distally within the slot to engage the drive collar stop within a distal section of the slot and limit further longitudinal movement of the drive collar stop;

moving a drive collar along the inner shaft to abut the drive collar stop and limit distal movement of the drive collar along the inner shaft;

moving a spring along the inner shaft to engage the drive collar and limit distal movement of the spring;

compressing the spring;

moving an inner shaft stop transverse to the longitudinal axis defined through the inner shaft to engage the inner shaft stop within a distal section of an additional slot defined in the inner shaft;

moving the inner shaft stop proximally within the additional slot to engage the inner shaft stop within a proximal section of the additional slot to limit proximal movement of the inner shaft stop and retain the spring between the inner shaft stop and the drive collar in a compressed condition; and

engaging a projection extending distally from the inner shaft stop with an aperture defined in the spring.

8. The method according to claim 7, further comprising engaging the knife guide to the inner shaft.

9. The method according to claim 7, wherein operably coupling the first and second jaw members to the knife guide includes disposing a cam pin through a through bore defined by the knife guide and a cam slot defined through the pair of flags of each of the first and second jaw members.