Shaft assembly arrangements for surgical instruments

• US 10,413,294 B2
• Filed: 09/19/2016
• Issued: 09/17/2019
• Est. Priority Date: 06/28/2012
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Shelton, IV, Frederick E., Swayze, Jeffrey S., Morgan, Jerome R., Baxter, III, Chester O.
• Primary Examiner(s): Valvis, Alexander M
• Assistant Examiner(s): Hibbert-Copeland, Mary C
• Application Number:
  US15/269,154
• Publication Number:
  US 20170000485A1
• Time in Patent Office: 1,093 Days
• Field of Search: 2271751-1771
• CPC Class Codes: A61B 17/00234 for minimally invasive surgery A61B17/0218, A61B17/0469, A61B17/12013, A61B17/1285, A61B17/29, A61B17/320016 take precedence
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/105 Wound clamp magazines for packaging sharps A61B50/3001
• CPC Class Codes: A61B 17/29 Forceps for use in minimally invasive surgery
• CPC Class Codes: A61B 2017/00309 Cut-outs or slits
• CPC Class Codes: A61B 2017/00314 Separate linked members
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/07214 Stapler heads
• CPC Class Codes: A61B 2017/07271 characterised by its cartridge
• CPC Class Codes: A61B 2017/07278 characterised by its sled or its staple holder
• CPC Class Codes: A61B 2017/2903 transferring rotary motion
• CPC Class Codes: A61B 2017/2908 Multiple segments connected by articulations
• CPC Class Codes: A61B 2017/2929 with a head rotatable about the longitudinal axis of the shaft
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/35 for telesurgery
• CPC Class Codes: A61B 34/37 Master-slave robots A61B34/35 takes precedence
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms

Abstract

Shaft assembly arrangements for surgical instruments are disclosed. A surgical instrument assembly can comprise a proximal shaft assembly comprising a distal coupling portion. The surgical instrument assembly can also comprise a distal shaft assembly comprising a proximal coupling portion configured to be releasably coupled to the distal coupling portion. The distal shaft assembly can also include an articulation joint and an end effector configured to articulate about the articulation joint.

Claims

1. A stapling assembly, comprising:

a first source of first rotary drive motions;

a second source of second rotary drive motions;

a proximal shaft assembly, comprising;

a first rotary actuator configured to receive said first rotary drive motions;

a second rotary actuator configured to receive said second rotary drive motions;

a first linear actuator operably interfacing with said second rotary actuator, wherein said first linear actuator is configured to convert said second rotary drive motions to linear drive motions; and

a distal coupler, wherein said distal coupler comprises a proximal articulation ball portion; and

a distal shaft assembly, comprising;

a third rotary actuator;

a second linear actuator;

an articulation joint;

a proximal coupler configured to be releasably coupled to said distal coupler so as to operably couple said first rotary actuator to said third rotary actuator and said first linear actuator to said second linear actuator, wherein said proximal coupler comprises a distal articulation ball portion, and wherein said proximal articulation ball portion and said distal articulation ball portion form an internal articulation ball when said distal shaft assembly and said proximal shaft assembly are coupled to each other; and

an end effector attached to said distal shaft assembly by way of said articulation joint, wherein said second linear actuator is configured to articulate said end effector about said articulation joint, and wherein said end effector comprises;

a first jaw;

a second jaw, wherein one of said first and second jaws is configured to operably support a surgical staple cartridge therein; and

a firing member operably interfacing with said third rotary actuator so as to axially move said firing member through said end effector upon rotary actuation of said third rotary actuator, said firing member configured to move one of said first and second jaws relative to the other one of said first and second jaws between an open position and closed positions and eject staples from said surgical staple cartridge.

2. The stapling assembly of claim 1, wherein said end effector further comprises an anvil configured to deform said staples.

3. The stapling assembly of claim 1, wherein said firing member comprises:

a first jaw engaging portion configured to engage said first jaw; and

a second jaw engaging portion configured to engage said second jaw, wherein said first jaw engaging portion and said second jaw engaging portion are configured to hold said first jaw and said second jaw relative to each other during a firing stroke.

4. The stapling assembly of claim 1, wherein said distal coupler comprises a proximal ball joint segment and said proximal coupler comprises a distal ball joint segment, wherein said proximal ball joint segment is supported on said proximal articulation ball portion and said distal ball joint segment is supported on said distal articulation ball portion, and wherein said proximal ball joint segment and said distal ball joint segment are movable about said internal articulation ball when said distal shaft assembly and said proximal shaft assembly are coupled to each other.

5. The stapling assembly of claim 4, wherein said first linear actuator comprises a pair of cooperating proximal articulation members attached to said distal ball joint segment, and wherein said second linear actuator comprises a pair of cooperating distal articulation members attached to said proximal ball joint segment.

6. The stapling assembly of claim 5, wherein said linear drive motions are configured to be transferred between said distal shaft assembly and said proximal shaft assembly through said proximal articulation ball portion and said distal articulation ball portion.

7. A surgical instrument assembly, comprising:

a first source of first rotary drive motions;

a second source of second rotary drive motions;

a proximal shaft assembly, comprising;

a first rotary drive configured to receive said first rotary drive motions;

a second rotary drive configured to receive said second rotary drive motions;

a first linear articulation drive member operably interfacing with said second rotary drive, wherein said first linear articulation drive member is configured to convert said second rotary drive motions to linear articulation drive motions; and

a distal coupling portion, wherein said distal coupling portion comprises a proximal articulation ball portion; and

a distal shaft assembly, comprising;

a third rotary drive;

a second linear articulation drive member;

an articulation joint;

a proximal coupling portion configured to be releasably coupled to said distal coupling portion so as to operably couple said first rotary drive to said third rotary drive and said first linear articulation drive member to said second linear articulation drive member, wherein said proximal coupling portion comprises a distal articulation ball portion, and wherein said proximal articulation ball portion and said distal articulation ball portion form an internal articulation ball when said distal shaft assembly and said proximal shaft assembly are coupled to each other; and

an end effector attached to said distal shaft assembly by way of said articulation joint, wherein said second linear articulation drive member is configured to articulate said end effector about said articulation joint, and wherein said end effector comprises;

a first jaw;

a second jaw; and

a firing member operably interfacing with said third rotary drive so as to axially move said firing member through said end effector upon rotary actuation of said third rotary drive, said firing member configured to move one of said first and second jaws relative to the other one of said first and second jaws between an open position and closed positions.

8. The surgical instrument assembly of claim 7, wherein one of said first and second jaws is configured to operably support a surgical staple cartridge therein, wherein said firing member is configured to eject staples from said surgical staple cartridge when driven therethrough, and wherein the other of said first and second jaws comprises an anvil configured to deform said staples.

9. The surgical instrument assembly of claim 7, wherein said firing member comprises:

a first jaw engaging portion configured to engage said first jaw; and

a second jaw engaging portion configured to engage said second jaw, wherein said first jaw engaging portion and said second jaw engaging portion are configured to hold said first jaw and said second jaw relative to each other during a firing stroke.

10. The surgical instrument assembly of claim 7, wherein said distal coupling portion comprises a proximal ball joint segment and said proximal coupling portion comprises a distal ball joint segment, wherein said proximal ball joint segment is supported on said proximal articulation ball portion and said distal ball joint segment is supported on said distal articulation ball portion, and wherein said proximal ball joint segment and said distal ball joint segment are movable about said internal articulation ball when said distal shaft assembly and said proximal shaft assembly are coupled to each other.

11. The surgical instrument assembly of claim 10, wherein said first linear articulation drive member comprises a pair of cooperating proximal articulation members attached to said distal ball joint segment, and wherein said second linear articulation drive member comprises a pair of cooperating distal articulation members attached to said proximal ball joint segment.

12. The surgical instrument assembly of claim 11, wherein said linear articulation drive motions are configured to be transferred between said distal shaft assembly and said proximal shaft assembly through said proximal articulation ball portion and said distal articulation ball portion.

13. A surgical fastening assembly, configured to be attached to a surgical robot, wherein said surgical fastening assembly comprises:

a proximal shaft assembly, comprising;

a first rotary drive configured to receive first rotary drive motions from the surgical robot;

a second rotary drive configured to receive second rotary drive motions from the surgical robot;

a first linear articulation drive operably interfacing with said second rotary drive, wherein said first linear articulation drive is configured to convert said second rotary drive motions to linear articulation drive motions; and

a distal coupling portion, wherein said distal coupling portion comprises a proximal articulation ball portion; and

a distal shaft assembly configured to be operably attached to said proximal shaft assembly, wherein said distal shaft assembly comprises;

a third rotary drive;

a second linear articulation drive;

an articulation joint;

a proximal coupling portion configured to be releasably coupled to said distal coupling portion so as to operably couple said first rotary drive to said third rotary drive and said first linear articulation drive to said second linear articulation drive, wherein said proximal coupling portion comprises a distal articulation ball portion, and wherein said proximal articulation ball portion and said distal articulation ball portion form an internal articulation ball when said distal shaft assembly and said proximal shaft assembly are coupled to each other; and

an end effector attached to said distal shaft assembly by way of said articulation joint, wherein said second linear articulation drive is configured to articulate said end effector about said articulation joint, and wherein said end effector comprises;

a first jaw;

a second jaw, wherein one of said first and second jaws is configured to operably support a surgical fastener cartridge therein; and

a firing member operably interfacing with said third rotary drive so as to axially move said firing member through said end effector upon rotary actuation of said third rotary drive, said firing member configured to move one of said first and second jaws relative to the other one of said first and second jaws between an open position and closed positions and eject fasteners from said surgical fastener cartridge.

14. The surgical fastening assembly of claim 13, wherein said end effector further comprises an anvil configured to deform said fasteners.

15. The surgical fastening assembly of claim 13, wherein said firing member comprises:

a first jaw engaging portion configured to engage said first jaw; and

a second jaw engaging portion configured to engage said second jaw, wherein said first jaw engaging portion and said second jaw engaging portion are configured to hold said first jaw and said second jaw relative to each other during a firing stroke.

16. The surgical fastening assembly of claim 13, wherein said distal coupling portion comprises a proximal ball joint segment and said proximal coupling portion comprises a distal ball joint segment, wherein said proximal ball joint segment is supported on said proximal articulation ball portion and said distal ball joint segment is supported on said distal articulation ball portion, and wherein said proximal ball joint segment and said distal ball joint segment are movable about said internal articulation ball when said distal shaft assembly and said proximal shaft assembly are coupled to each other.

17. The surgical fastening assembly of claim 16, wherein said first linear articulation drive comprises a pair of cooperating proximal articulation members attached to said distal ball joint segment, and wherein said second linear articulation drive comprises a pair of cooperating distal articulation members attached to said proximal ball joint segment.

18. The surgical fastening assembly of claim 17, wherein said linear articulation drive motions are configured to be transferred between said distal shaft assembly and said proximal shaft assembly through said proximal articulation ball portion and said distal articulation ball portion.

19. A surgical instrument assembly, comprising:

a proximal shaft assembly, comprising;

a first rotary drive;

a second rotary drive;

a first linear drive operably interfacing with said second rotary drive; and

a distal coupling portion comprising a proximal articulation ball portion; and

a distal shaft assembly, comprising;

a third rotary drive;

a second linear drive;

an articulation joint;

a proximal coupling portion configured to be releasably coupled to said distal coupling portion so as to operably couple said first rotary drive to said third rotary drive and said first linear drive to said second linear drive, wherein said proximal coupling portion comprises a distal articulation ball portion, and wherein said proximal articulation ball portion and said distal articulation ball portion form an articulation ball when said distal shaft assembly and said proximal shaft assembly are coupled to each other; and

an end effector configured to articulate about said articulation joint, wherein said end effector comprises a first jaw, a second jaw, and a firing member, and wherein said firing member operably interfaces with said third rotary drive.

20. The surgical instrument assembly of claim 19, wherein said end effector is configured to support a fastener cartridge, and wherein said firing member is configured to eject fasteners from said fastener cartridge when driven relative to said fastener cartridge.

21. The surgical instrument assembly of claim 20, wherein said end effector further comprises an anvil configured to deform said fasteners.

22. The surgical instrument assembly of claim 19, wherein said firing member comprises:

a first jaw engaging portion configured to engage said first jaw; and

a second jaw engaging portion configured to engage said second jaw, wherein said first jaw engaging portion and said second jaw engaging portion are configured to hold said first jaw and said second jaw relative to each other during a firing stroke.

23. The surgical instrument assembly of claim 19, further comprising a quick disconnect arrangement between said proximal coupling portion and said distal coupling portion.

24. The surgical instrument assembly of claim 23, wherein said quick disconnect arrangement comprises a plurality of dovetail joints.