Modular battery powered handheld surgical instrument with multi-function motor via shifting gear assembly

• US 10,251,664 B2
• Filed: 12/16/2016
• Issued: 04/09/2019
• Est. Priority Date: 01/15/2016
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Shelton, IV, Frederick E., Yates, David C., Houser, Kevin L.
• Primary Examiner(s): Islam, Muhammad S
• Application Number:
  US15/382,274
• Publication Number:
  US 20170202570A1
• Time in Patent Office: 844 Days
• CPC Class Codes: A61B 17/320068 using mechanical vibrations, e.g. ultrasonic A61B17/22012 takes precedence; dental tooth drilling devices operated by vibration A61C3/03; removing intra-ocular material using mechanical vibrations A61F9/00745
• CPC Class Codes: A61B 17/320092 with additional movable means for clamping or cutting tissue, e.g. with a pivoting jaw
• CPC Class Codes: A61B 18/1206 Generators therefor
• 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 18/1447 wherein sliding surfaces cause opening/closing of the end effectors
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00026 Conductivity or impedance, e.g. of tissue
• CPC Class Codes: A61B 2017/00039 Electric or electromagnetic phenomena other than conductivity, e.g. capacity, inductivity, Hall effect
• CPC Class Codes: A61B 2017/00084 Temperature
• CPC Class Codes: A61B 2017/00119 alarm; indicating an abnormal situation
• CPC Class Codes: A61B 2017/00123 and automatic shutdown
• CPC Class Codes: A61B 2017/0023 disposable
• CPC Class Codes: A61B 2017/003 Steerable
• CPC Class Codes: A61B 2017/00323 Cables or rods
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/0046 with a releasable handle; with handle and operating part separable
• CPC Class Codes: A61B 2017/00464 for use with different instruments
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/00876 magnetic
• CPC Class Codes: A61B 2017/320072 : Working tips with special features, e.g. extending parts
• CPC Class Codes: A61B 2017/320073 : probe
• CPC Class Codes: A61B 2017/320074 : blade
• CPC Class Codes: A61B 2017/320078 : Tissue manipulating surface
• CPC Class Codes: A61B 2017/320094 : additional movable means performing clamping operation
• CPC Class Codes: A61B 2017/320095 : with sealing or cauterizing means
• CPC Class Codes: A61B 2018/00297 : Means for providing haptic feedback
• CPC Class Codes: A61B 2018/00601 : Cutting
• CPC Class Codes: A61B 2018/00607 : Coagulation and cutting with the same instrument
• CPC Class Codes: A61B 2018/0063 : Sealing
• CPC Class Codes: A61B 2018/00684 : using lookup tables
• CPC Class Codes: A61B 2018/00767 : Voltage
• CPC Class Codes: A61B 2018/00791 : Temperature
• CPC Class Codes: A61B 2018/00827 : Current
• CPC Class Codes: A61B 2018/00875 : Resistance or impedance
• CPC Class Codes: A61B 2018/00898 : Alarms or notifications created in response to an abnormal condition
• CPC Class Codes: A61B 2018/00904 : Automatic detection of target tissue
• CPC Class Codes: A61B 2018/00946 : slidable
• CPC Class Codes: A61B 2018/00988 : Means for storing information, e.g. calibration constants, or for preventing excessive use, e.g. usage, service life counter
• CPC Class Codes: A61B 2018/00994 : combining two or more different kinds of non-mechanical energy or combining one or more non-mechanical energies with ultrasound
• CPC Class Codes: A61B 2018/1226 : powered by a battery
• CPC Class Codes: A61B 2018/1455 : having a moving blade for cutting tissue grasped by the jaws
• CPC Class Codes: A61B 2034/252 : indicating steps of a surgical procedure
• CPC Class Codes: A61B 2090/061 : for measuring dimensions, e.g. length
• CPC Class Codes: A61B 2560/0209 : adapted for power saving
• CPC Class Codes: A61B 2560/0475 : Special features of memory means, e.g. removable memory cards
• CPC Class Codes: A61B 2562/0219 : Inertial sensors, e.g. accelerometers, gyroscopes, tilt switches
• CPC Class Codes: H01M 10/425 : Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/46 : Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/48 : Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 2220/30 : Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/213 : adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/247 : specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
• CPC Class Codes: H01M 6/02 : Details of electrodes H01M4/00; of non-active parts H01M50/00
• CPC Class Codes: H01M 6/5044 : Cells or batteries structurally combined with cell condition indicating means
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries

Abstract

A modular handheld surgical instrument including a modular handle assembly, a modular ultrasonic transducer assembly and a modular shaft assembly is disclosed. The modular handle assembly includes a shift gear translatable between a first position and a second position, wherein when the shift gear is translated to the first position, the surgical instrument is configured to rotate a drive gear of a first shaft of the modular shaft assembly to perform at least one shaft actuation function and when the shift gear is translated to the second position, the surgical instrument is configured to rotate a torque gear of a second shaft of the modular shaft assembly to controllably torque an ultrasonic waveguide of the modular shaft assembly to an ultrasonic transducer of the modular ultrasonic transducer assembly to a predefined torque.

Claims

1. A surgical instrument, comprising:

a modular handle assembly, comprising;

a motor assembly comprising a motor and a motor gear; and

a shift gear translatable between a first position and a second position;

a modular ultrasonic transducer assembly coupled to the modular handle assembly, wherein the modular ultrasonic transducer assembly comprises;

an ultrasonic transducer; and

an ultrasonic transducer shaft extending distally from the ultrasonic transducer; and

a modular shaft assembly coupled to the modular ultrasonic transducer assembly and the modular handle assembly, wherein the modular shaft assembly comprises;

a first rotatable shaft extending distally along a shaft axis, wherein the first rotatable shaft comprises a drive gear;

an ultrasonic waveguide coaxially aligned with the first rotatable shaft about the shaft axis; and

a second rotatable shaft coaxially aligned with the first rotatable shaft and the ultrasonic waveguide about the shaft axis, wherein the second rotatable shaft comprises a torque gear; and

an ultrasonic generator;

wherein when the shift gear is translated to the first position, the motor gear is configured to rotate the drive gear via the shift gear, and wherein when the shift gear is translated to the second position, the motor gear is configured to rotate the torque gear via the shift gear, and wherein rotation of the torque gear causes rotation of the ultrasonic transducer shaft relative to the ultrasonic waveguide.

2. The surgical instrument of claim 1, wherein the drive gear, upon rotation, is operable to perform at least one shaft actuation function comprising one or more than one of clamping, rotating, or articulating an actuation device.

3. The surgical instrument of claim 1, wherein the torque gear, upon rotation, is operable to couple the ultrasonic waveguide to the ultrasonic transducer shaft or decouple the ultrasonic waveguide from the ultrasonic transducer shaft.

4. The surgical instrument of claim 1, wherein the torque gear, upon rotation, is operable to controllably torque the ultrasonic waveguide to the ultrasonic transducer shaft.

5. The surgical instrument of claim 4, wherein the torque gear is coupled to the second rotatable shaft via a slip-clutch subsystem, wherein the slip-clutch subsystem is configured such that the torque gear and the second rotatable shaft remain fixedly coupled until a predefined torque is reached and such that the torque gear slips about the second rotatable shaft after the predefined torque is reached to controllably torque the ultrasonic waveguide to the ultrasonic transducer shaft.

6. The surgical instrument of claim 5, wherein the slip-clutch subsystem is further configured such that the torque gear slips about the second rotatable shaft at a higher predefined torque when decoupling the ultrasonic waveguide from the ultrasonic transducer shaft.

7. The surgical instrument of claim 4, further comprising a motor circuit, wherein the motor circuit is configured to alter current supplied to the motor to controllably torque the ultrasonic waveguide to the ultrasonic transducer shaft.

8. The surgical instrument of claim 7, further comprising a strain gauge configured to measure torque applied by the motor, and wherein the motor circuit is configured to limit current supplied to the motor based on the torque measured by the strain gauge.

9. The surgical instrument of claim 1, wherein the shift gear is manually or electronically translatable between the first position and the second position.

10. A modular handheld surgical instrument, comprising:

a motor assembly comprising a motor and a motor gear;

a shift gear translatable distally and proximally between a first position and a second position;

a transducer assembly comprising an ultrasonic transducer shaft; and

a shaft assembly, comprising;

a first shaft extending distally along a shaft axis, wherein the first shaft comprises a drive gear;

an ultrasonic waveguide coaxially aligned inside the first shaft about the shaft axis; and

a second shaft coaxially aligned outside the first shaft and the ultrasonic waveguide about the shaft axis, wherein the second shaft comprises a torque gear coupled to the second shaft via a slip-clutch subsystem, wherein the slip-clutch subsystem is configured such that the torque gear does not slip about the second shaft until a predefined torque is reached to controllably torque the ultrasonic waveguide to the ultrasonic transducer shaft;

wherein when the shift gear is translated to the first position, the motor gear is configured to rotate the drive gear via the shift gear, and wherein when the shift gear is translated to the second position, the motor gear is configured to rotate the torque gear via the shift gear, and wherein rotation of the torque gear causes rotation of the ultrasonic transducer shaft relative to the ultrasonic waveguide.

11. The modular handheld surgical instrument of claim 10, wherein the drive gear, upon rotation, is operable to perform at least one shaft actuation function comprising one or more than one of clamping, rotating, or articulating an actuation device.

12. The modular handheld surgical instrument of claim 10, wherein the torque gear, upon rotation, is operable to couple the ultrasonic waveguide to the ultrasonic transducer shaft or decouple the ultrasonic waveguide from the ultrasonic transducer shaft.

13. The modular handheld surgical instrument of claim 10, wherein the slip-clutch subsystem is further configured such that the torque gear slips about the second shaft at a higher predefined torque when decoupling the ultrasonic waveguide from the ultrasonic transducer shaft.

14. The modular handheld surgical instrument of claim 10, wherein the slip-clutch subsystem is further configured such that the torque gear does not slip about the second shaft when decoupling the ultrasonic waveguide from the ultrasonic transducer shaft.

15. The modular handheld surgical instrument of claim 10, wherein the shift gear is manually or electronically translatable between the first position and the second position.

16. A modular handheld surgical instrument, comprising:

a motor assembly comprising a motor and a motor gear;

a shift gear translatable distally and proximally between a first position and a second position;

a transducer assembly comprising an ultrasonic transducer shaft;

a shaft assembly, comprising;

a first shaft extending distally along a shaft axis, wherein the first shaft comprises a drive gear;

an ultrasonic waveguide coaxially aligned inside the first shaft about the shaft axis; and

a second shaft coaxially aligned outside the first shaft and the ultrasonic waveguide about the shaft axis, wherein the second shaft comprises a torque gear; and

a motor circuit, wherein the motor circuit is configured to alter current supplied to the motor to controllably torque the ultrasonic waveguide to the ultrasonic transducer shaft via the torque gear;

wherein when the shift gear is translated to the first position, the motor gear is configured to rotate the drive gear via the shift gear, and wherein when the shift gear is translated to the second position, the motor gear is configured to rotate the torque gear via the shift gear, and wherein rotation of the torque gear causes rotation of the ultrasonic transducer shaft relative to the ultrasonic waveguide.

17. The modular handheld surgical instrument of claim 16, wherein the first shaft is selectively coupleable to at least two independent actuation devices, and wherein the drive gear, upon rotation, is operable to actuate the at least two independent actuation devices.

18. The modular handheld surgical instrument of claim 16, further comprising a strain gauge configured to measure torque applied by the motor, and wherein the motor circuit is configured to limit current supplied to the motor based on the torque measured by the strain gauge.

19. The modular handheld surgical instrument of claim 16, wherein the motor circuit is configured to alter current supplied to the motor such that the torque when coupling the ultrasonic waveguide to the ultrasonic transducer shaft, does not exceed a predefined torque.

20. The modular handheld surgical instrument of claim 19, wherein the motor circuit is configured to alter current supplied to the motor such that the torque, when decoupling the ultrasonic waveguide from the ultrasonic transducer shaft, is a higher predefined torque.