Powered surgical instrument

• US 20080251568A1
• Filed: 04/13/2007
• Published: 10/16/2008
• Est. Priority Date: 04/13/2007
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Tyco Healthcare Group LP (Medtronic Plc)
• Inventors: Racenet, David C., Zemlok, Michael
• Granted Patent: US 7,950,560 B2
• Time in Patent Office: Days
• US Class Current: 227/175.1
• 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 17/068 Surgical staplers , e.g. containing multiple staples or clampsstaplers containing only one staple A61B17/10; magazines or containers for staples A61B17/105; for performing anastomosis A61B17/115; staplers in general B25C5/00
• CPC Class Codes: A61B 17/072 for applying a row of staples in a single action , e.g. the staples being applied simultaneously
• 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 2017/00084 Temperature
• CPC Class Codes: A61B 2017/00115 with audible or visual output with imaging means A61B90/37, A61B34/20
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/2905 flexible
• CPC Class Codes: A61B 2090/065 for measuring contact or contact pressure
• CPC Class Codes: A61B 90/98 using electromagnetic means, e.g. transponders

Abstract

A surgical instrument including a housing, an endoscopic portion, a drive gear, a drive motor, a shift motor and an end effector is disclosed. The endoscopic portion extends distally from the housing and defines a longitudinal axis. The drive gear is disposed at least partially within the housing and is rotatable about a drive gear axis which extends therethrough. The drive gear is selectively movable along the drive gear axis. The drive motor is disposed in mechanical cooperation with the drive gear and is configured to rotate the drive gear. The shift motor is disposed in mechanical cooperation with the drive gear and is configured to move the drive gear along the drive gear axis. The end effector is disposed adjacent a distal portion of the endoscopic portion.

Claims

1. A surgical instrument, comprising:

a housing;

an endoscopic portion extending distally from the housing and defining a longitudinal axis;

a drive gear disposed at least partially within the housing, the drive gear rotatable about a drive gear axis extending therethrough and being selectively movable along the drive gear axis;

a drive motor disposed in mechanical cooperation with the drive gear and being configured to rotate the drive gear;

a shift motor disposed in mechanical cooperation with the drive gear and being configured to move the drive gear along the drive gear axis; and

an end effector disposed adjacent a distal portion of the endoscopic portion.

2. The surgical instrument of claim 1, further including a ring gear disposed at least partially within the housing, wherein the drive gear is movable to a position along the drive gear axis to matingly engage the ring gear and wherein rotation of the ring gear rotates the end effector about the longitudinal axis.

3. The surgical instrument of claim 1, further including an actuator gear disposed at least partially within the housing, wherein the drive gear is movable to a position along the drive gear axis to matingly engage the actuator gear and wherein rotation of the actuator gear causes at least a partial actuation of the end effector.

4. The surgical instrument of claim 1, wherein the end effector defines a second longitudinal axis, the end effector being movable from a first position where the second longitudinal axis is substantially aligned with the first longitudinal axis to at least a second position where the second longitudinal axis is disposed at an angle to the first longitudinal axis.

5. The surgical instrument of claim 4, further including an articulation gear disposed at least partially within the housing, wherein the drive gear is movable to a position along the drive gear axis to matingly engage the articulation gear and wherein rotation of the articulation gear causes the end effector to move from its first position towards its second position.

6. The surgical instrument of claim 1, wherein the longitudinal axis and the drive gear axis are substantially parallel.

7. The surgical instrument of claim 1, further comprising a user interface, the user interface including a screen that displays readable information.

8. The surgical instrument of claim 1, further comprising a user interface including at least one switch that controls the position of the drive gear along the drive gear axis.

9. The surgical instrument of claim 1, further comprising a user interface including at least one switch that controls the rotation speed of the drive gear.

10. The surgical instrument of claim 1, wherein the housing further includes a distal housing portion and a proximal housing portion, the distal housing portion being rotatable about the longitudinal axis relative to the proximal housing portion.

11. The surgical instrument of claim 10, wherein the distal housing portion includes a plurality of detents thereon and the proximal housing portion includes a tab thereon, the tab being distally biased and in mechanical cooperation with a detent disposed on the distal housing portion.

12. The surgical instrument of claim 1, wherein the housing includes a handle portion, the handle portion being disposed along a handle axis, the handle axis being substantially parallel to the drive gear axis.

13. The surgical instrument of claim 1, wherein the drive gear is selectively movable along the drive gear axis between three distinct positions.

41. The surgical instrument according to claim 1, further including a clutch disposed between the drive motor and the drive tube, the clutch including a clutch plate and a spring.

42. The surgical instrument according to claim 41, wherein the clutch plate is arranged to mate with an interface at a proximal end of the drive tube.

43. The surgical instrument according to claim 1, wherein the end effector defines a second longitudinal axis, the end effector being movable from a first position where the second longitudinal axis is substantially aligned with the first longitudinal axis to at least a second position where the second longitudinal axis is disposed at an angle to the first longitudinal axis.

14. A method of applying surgical fasteners to tissue, comprising the steps of:

providing a powered surgical instrument, including;

a housing;

an endoscopic portion extending distally from the housing and defining a longitudinal axis;

a drive gear disposed at least partially within the housing, the drive gear rotatable about a drive gear axis extending therethrough and being selectively movable along the drive gear axis; and

an end effector disposed adjacent a distal portion of the endoscopic portion;

moving the drive gear along the drive gear axis; and

rotating the drive gear about the drive gear axis.

15. The method of claim 14, further including rotating the end effector about the longitudinal axis.

16. The method of claim 14, wherein the end effector defines a second longitudinal axis, the end effector being movable from a first position where the second longitudinal axis is substantially aligned with the first longitudinal axis to at least a second position where the second longitudinal axis is disposed at an angle to the first longitudinal axis.

17. The method of claim 16, further including moving the end effector from its first position towards its second position.

18. The method of claim 14, wherein the drive gear is selectively movable along the drive gear axis between three distinct positions.

19. The method of claim 18, wherein two of the three positions correspond to rotating the end effector and actuating the powered surgical instrument.

20. The method of claim 14, furthering including a user interface disposed on the powered surgical instrument.

21. A surgical stapling instrument, comprising:

a housing;

an endoscopic portion extending distally from the housing and defining a longitudinal axis;

an end effector adjacent a distal end of the endoscopic portion and being pivotably mounted for articulation with respect to the endoscopic portion;

a drive assembly for deploying surgical staples from the end effector into tissue;

a drive motor having a drive member, the drive member being movable from a first position to at least a second position;

an articulation member arranged for engagement by the drive member in the first position, the articulation member being connected to the end effector so that movement of the articulation member by the drive member articulates the end effector with respect to the endoscopic portion; and

an actuation member arranged for engagement by the drive member in the second position, the actuation member being connected to the drive assembly so that movement of the actuation member by the drive member deploys the surgical staples.

22. The surgical stapling instrument according to claim 21, further comprising a rotation member connected to the endoscopic portion and arranged for engagement by the drive member so that movement of the drive member rotates the endoscopic portion around the longitudinal axis.

23. The surgical stapling instrument according to claim 21, wherein the end effector has a cartridge assembly, surgical staples disposed in the cartridge assembly, and an anvil assembly disposed adjacent the cartridge assembly.

24. The surgical stapling instrument according to claim 23, wherein the cartridge assembly and anvil assembly are movable from an open position to an approximated position with respect to one another for engaging tissue between the cartridge assembly and anvil assembly

25. The surgical stapling instrument according to claim 24, wherein the movement of the actuation member approximates the cartridge assembly and anvil assembly with respect to one another before deploying the surgical staples.

26. A surgical stapling instrument, comprising:

a housing;

an endoscopic portion extending distally from the housing and defining a longitudinal axis;

an end effector disposed adjacent a distal end of the endoscopic portion;

a drive assembly for deploying surgical staples from the end effector into tissue;

a drive motor having a drive member, the drive member being movable from a first position to at least a second position;

a rotation member arranged for engagement by the drive member in the first position, the rotation member being connected to the endoscopic portion so that movement of the rotation member by the drive member rotates the endoscopic portion; and

an actuation member arranged for engagement by the drive member in the second position, the actuation member being connected to the drive assembly so that movement of the actuation member by the drive member deploys the surgical staples.

27. The surgical stapling instrument according to claim 26, further comprising an articulation member arranged for engagement by the drive member, the articulation member being connected to the end effector so that movement of the articulation member by the drive member articulates the end effector with respect to the endoscopic portion.

28. The surgical stapling instrument according to claim 26, wherein the end effector has a cartridge assembly, surgical staples disposed in the cartridge assembly, and an anvil assembly disposed adjacent the cartridge assembly.

29. The surgical stapling instrument according to claim 28, wherein the cartridge assembly and anvil assembly are movable from an open position to an approximated position with respect to one another for engaging tissue between the cartridge assembly and anvil assembly

30. The surgical stapling instrument according to claim 29, wherein the movement of the actuation member approximates the cartridge assembly and anvil assembly with respect to one another before deploying the surgical staples.

33. The surgical stapling instrument of claim 30, wherein the endoscopic portion has a distal end configured for connection with a first type of loading unit and at least a second type of loading unit having a second surgical function, the first type being an articulating surgical stapling loading unit and the second type being a non-articulating surgical stapling loading unit.

31. A surgical stapling instrument, comprising:

a housing;

an endoscopic portion extending distally from the housing;

a drive motor disposed at least partially within the housing and having a drive member;

an end effector connected adjacent a distal end of the endoscopic portion for articulation with respect to the endoscopic portion, the end effector being connected to an articulation member driven by the drive motor, the end effector having surgical staples arranged to be deployed in tissue; and

a power source disposed at least partially within the housing and arranged to provide power to the drive motor.

32. The surgical stapling instrument according to claim 31, wherein the end effector forms the distal end of a loading unit, the loading unit having a proximal body portion configured for connection to the endoscopic portion.

34. A surgical instrument comprising:

a housing;

an endoscopic portion extending distally from the housing and defining a longitudinal axis;

an end effector at a distal end of the endoscopic portion and arranged for articulation with respect to the endoscopic portion;

a drive shaft arranged for translation along the longitudinal axis and for engaging the end effector;

a motor assembly arranged to selectively drive one or more functions of the end effector; and

a display component for displaying a condition of the end effector.

35. The surgical instrument according to claim 34, wherein the display component is an operating room monitor.

36. The surgical instrument according to claim 34, wherein the function of the end effector is selected from the group consisting of:

rotation of the endoscopic portion about the longitudinal axis,

movement of the drive shaft along the longitudinal axis, and

articulation of the end effector.

37. The surgical instrument according to claim 34, further comprising a digital control module in the housing.

38. The surgical instrument according to claim 37, wherein the digital control module transmits information concerning the operation of the end effector to the display component.

39. The surgical instrument according to claim 34, wherein the display component is disposed at least partially in the housing.

40. A surgical instrument, comprising:

a housing;

an endoscopic portion extending distally from the housing and defining at longitudinal axis;

a drive tube rotatable about a drive tube axis extending therethrough;

a drive motor disposed at least partially within the housing, the drive motor being movable into engagement with the drive tube;

a rod disposed in mechanical cooperation with the drive tube, at least a portion of the rod being translatable with respect to the drive tube; and

an end effector disposed adjacent a distal portion of the endoscopic portion, the end effector being arranged to be actuated by rod so that the firing rod drives a surgical function of the end effector.

44. The surgical instrument according to claim 40, wherein the end effector is rotatable about the first longitudinal axis with respect to the housing.

45. The surgical instrument according to claim 40, further comprising a user interface including at least one switch that controls the translation of the rod.

46. The surgical instrument according to claim 40, wherein at least a portion of the rod is disposed at least partially within the drive tube.

47. The surgical instrument according to claim 40, wherein the drive tube includes a threaded portion on an interior surface thereof.

48. The surgical instrument according to claim 47, wherein the rod includes a threaded portion thereon, the threaded portion of the firing rod being engagable with the threaded portion of the drive tube.

49. The surgical instrument according to claim 40, wherein at least a portion of the rod extends through an aperture of a plate, the aperture including a non-round cross-section for preventing rotation of the firing rod with respect to the plate.

50. The surgical instrument according to claim 40, further comprising a power source disposed at least partially within the housing and arranged to provide power to the drive motor.

51. The surgical instrument according to claim 40, wherein the end effector is part of a disposable loading unit.