POWERED SURGICAL STAPLING DEVICE

• US 20090090763A1
• Filed: 08/12/2008
• Published: 04/09/2009
• Est. Priority Date: 10/05/2007
• Status: Abandoned Application

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Tyco Healthcare Group LP (Medtronic Plc)
• Inventors: Zemlok, Michael A., Ross, Adam J.
• Application Number:
  US12/189,834
• Publication Number:
  US 20090090763A1
• Time in Patent Office: Days
• US Class Current: 227/175.2
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• 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 2017/00734 battery operated
• CPC Class Codes: A61B 2090/067 for measuring angles
• CPC Class Codes: A61B 90/98 using electromagnetic means, e.g. transponders
• CPC Class Codes: H01M 10/637 characterised by the use of reversible temperature-sensitive devices, e.g. NTC, PTC or bimetal devices; characterised by control of the internal current flowing through the cells, e.g. by switching means for preventing undesired use or discharge H01M50/572
• 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 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A powered surgical stapler is disclosed. The stapler includes a housing, an endoscopic portion extending distally from the housing and defining a first longitudinal axis, a drive motor disposed at least partially within a housing and a firing rod disposed in mechanical cooperation with the drive motor. The firing rod is rotatable by the motor about the first longitudinal axis extending therethrough. The stapler also includes an end effector disposed adjacent a distal portion of the endoscopic portion. The end effector is in mechanical cooperation with the firing rod so that the firing rod drives a surgical function of the end effector. The stapler further includes a control system having a plurality of sensors coupled to the drive motor, the firing rod, the loading unit and the end effector, the plurality of sensors configured to detect operating parameters thereof. The control system also includes a microcontroller coupled to the plurality of sensors and being configured to determine operating status of the powered surgical stapler as a function of the detected operating parameters.

Claims

1. A powered surgical stapler comprising:

a housing;

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

a drive motor disposed at least partially within a housing;

a firing rod disposed in mechanical cooperation with the drive motor;

an end effector disposed adjacent a distal portion of the endoscopic portion, the end effector being in mechanical cooperation with the firing rod so that the firing rod drives a surgical function of the end effector; and

a main drive switch including first and second switches formed together as a toggle switch, wherein the first switch is adapted to activate the drive motor in a first direction to facilitate a first surgical function of the end effector and the second switch is adapted to activate the drive motor in a second direction to facilitate a second surgical function of the end effector.

2. A powered surgical stapler according to claim 1, wherein the first and second switches are coupled to a non-linear speed control circuit adapted to control the rate of rotation of the drive motor as a function of depression of the first and second switches.

3. A powered surgical stapler according to claim 2, wherein the non-linear speed control circuit is selected from the group consisting of a voltage regulation circuit, a variable resistance circuit, and a microelectronic pulse width modulation circuit.

4. A powered surgical stapler according to claim 2, wherein the first and second switches and the non-linear speed control circuit are coupled to a variable control device.

5. A powered surgical stapler according to claim 4, wherein the variable control device is selected from the group consisting of a rheostat, a multiple position switch, a linear variable displacement transducer, a rotary variable displacement transducer, a linear potentiometer, a rotary potentiometer, an optical encoder, a ferromagnetic sensor, and a Hall Effect sensor.

6. A powered surgical stapler according to claim 1, wherein the end effector includes a pair of opposing tissue engaging surfaces for deforming a plurality of surgical fasteners through and fastening tissue, the tissue engaging surfaces being movable in relation to one another between an open position and an approximated position in which the tissue engaging surfaces are juxtaposed with each other.

7. A powered surgical stapler according to claim 6, wherein the first surgical function of the end effector includes advancing the firing rod in a distal direction to move the pair of opposing tissue engaging surfaces into the approximated position and the second surgical function of the end effector includes retracting the firing rod in a proximal direction to move the pair of opposing tissue engaging surfaces into an approximated position.

8. A powered surgical stapler according to claim 6, further comprising:

a third switch adapted activate the drive motor to drive the firing rod to deploy and deform the surgical fasteners.

9. A powered surgical stapler according to claim 1, further comprising:

a loading unit configured to be removably attached to the endoscopic portion, the loading unit including an end effector being in mechanical cooperation with the firing rod so that the firing rod drives a surgical function of the end effector; and

a load switch disposed within the endoscopic portion and coupled to the main drive switch, wherein the main drive switch is disabled until actuation of the load switch upon attachment of the loading unit to the endoscopic portion.

10. A powered surgical stapler according to claim 1, further comprising:

a lock-out switch disposed on the top surface of a handle portion of the housing and coupled to the main drive switch, wherein the main drive switch is disabled until actuation of the lock-out switch upon grasping of the handle portion.

11. A powered surgical stapler according to claim 10, wherein the lock-out switch is selected from the group consisting of a bioimpedance sensor, a capacitance sensor and a pressure sensor.

12. A powered surgical stapler comprising:

a housing;

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

a drive motor disposed at least partially within a housing;

a firing rod disposed in mechanical cooperation with the drive motor;

a loading unit configured to be removably attached to the endoscopic portion, the loading unit including an end effector being in mechanical cooperation with the firing rod so that the firing rod drives a surgical function of the end effector; and

a loading unit identification system including an identifier identifying the loading unit and being disposed thereon and an interrogator configured to interface with the identifier to obtain an identifying code uniquely associated with the loading unit.

13. A powered surgical stapler according to claim 12, wherein the identifier and the interrogator are wireless transceivers configured to communicate with each other wirelessly.

14. A powered surgical stapler according to claim 12, wherein the identifier is an electrical identifier having at least one of a resistor, a capacitor and an inductor, the electrical identifier having at least one electrical property uniquely associated with an identifying code.

15. A powered surgical stapler according to claim 14, wherein the interrogator includes at least one contact adapted to interface with the electrical identifier and to determine the identifying code based on the at least one electrical property.

16. A powered surgical stapler according to claim 12, wherein the identifier is a magnetic device having at least one of an identifier coded magnets and a ferrous node disposed in a predetermined magnetic pattern uniquely associated with an identifying code.

17. A powered surgical stapler according to claim 16, wherein the interrogator is a magnetic sensor adapted to interface with the magnetic identifier and to determine the identifying code based on predetermined magnetic patterns.

18. A powered surgical stapler according to claim 17, wherein the magnetic sensor is selected from the group consisting of a ferromagnetic sensor and a Hall Effect sensor.

19. A powered surgical stapler according to claim 12, wherein the identifier includes a plurality of protrusions configured to interface with a displacement sensor such that the displacement pattern corresponds to the identifying code.

20. A powered surgical stapler according to claim 12, further comprising:

a user interface including a plurality of visual outputs configured to convey an operational status of at least one of the loading unit and the powered surgical stapler based on a combination of at least a portion of the plurality of visual outputs being activated.

21. A powered surgical stapler according to claim 20, wherein the user interface further includes a haptic feedback mechanism having an asynchronous motor disposed within the housing and configured to provide vibrational feedback varying in intensity as a function of force being exerted on the powered surgical stapler.

22. A powered surgical stapler according to claim 12, wherein the interrogator determines whether the loading unit has been previously fired.

23. A powered surgical stapler according to claim 12, wherein the end effector includes a pair of opposing tissue engaging surfaces for deforming a plurality of surgical fasteners through and fastening tissue, the tissue engaging surfaces being movable in relation to one another between an open position and an approximated position in which the tissue engaging surfaces are juxtaposed with each other.

24. A powered surgical stapler according to claim 23, wherein end effector includes a first tissue sensor and a second tissue sensor disposed in each of the tissue engaging surfaces respectively, the first and second tissue sensors configured to generate a field therebetween and to detect variations in the field indicative of foreign tissue.

25. A powered surgical stapler according to claim 24, wherein the first and second tissue sensors are calibrated to ignore at least one of air, bodily fluids and tissue.

26. A powered surgical stapler comprising:

a housing;

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

a drive motor disposed at least partially within a housing;

a firing rod disposed in mechanical cooperation with the drive motor;

an end effector disposed adjacent a distal portion of the endoscopic portion, the end effector being in mechanical cooperation with the firing rod so that the firing rod drives a surgical function of the end effector; and

a power source coupled to the drive motor, the power source including at least one cell and at least one ultracapacitor enclosed within an insulating shield formed from an absorbent and flame retardant material.

27. A powered surgical stapler according to claim 26, further comprising:

a power adapter further configured to couple to an electrosurgical generator to provide power to charge the power source.

28. A powered surgical stapler according to claim 26, further comprising:

an inductive charging interface including an inductive coil disposed within the housing, wherein upon placement of the housing and the inductive coil disposed therein within an electromagnetic field, the inductive coil converts the electromagnetic field energy into direct current to charge the power source.

29. A powered surgical stapler according to claim 26, further comprising:

a discharge circuit having a switch and a resistive load coupled to the power source, wherein upon activation of the switch the power source is discharged into the resistive load.

30. A powered surgical stapler according to claim 26, further comprising:

a motor and battery operating module coupled to at least one thermal sensor, the motor and battery operating module being configured to monitor temperature of at least one of the drive motor and the power source.

31. A powered surgical stapler according to claim 30, wherein the at least one thermal sensor is selected from the group consisting of a thermistor, a thermopile, a thermocouple and a thermal infrared sensor.

32. A powered surgical stapler according to claim 26, wherein the power source further includes a temperature sensor for measuring temperature therein and an embedded microcontroller for storing a unique identifier associated with the power source.

33. A powered surgical stapler according to claim 32, further comprising:

a microcontroller configured to interface with the embedded microcontroller to interrogate the microcontroller and to obtain the temperature and the unique identifier of the power source therefrom, wherein the microcontroller authenticates the power source if the temperature is within a predetermined operational range and the unique identifier is valid.

41. A powered surgical stapler according to claim 31, wherein the speed calculator is coupled to a rotation speed detecting apparatus having at least one encoder for transmitting pulses corresponding to speed of rotation of the drive motor.

43. A powered surgical stapler according to claim 31, further comprising a current sensor coupled to a shunt resistor which is connected to the drive motor, the current sensor being configured to measure current draw of the drive motor, the speed calculator being coupled to the current sensor and being configured to determine at least one of a linear speed of the firing rod and rotational speed of the drive motor based on the current draw.

44. A powered surgical stapler according to claim 43, wherein the speed calculator is configured to compare the linear speed of the firing rod and the current draw of the drive motor to determine whether rotation of the drive motor is being sufficiently translated to the firing rod.

46. A powered surgical stapler according to claim 31, wherein the position calculator and the speed calculator are coupled to a control system which includes a microcontroller.

34. A powered surgical stapler comprising:

a housing;

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

a drive motor disposed at least partially within a housing;

a firing rod disposed in mechanical cooperation with the drive motor;

a position calculator for determining the linear position of the firing rod, the position calculator coupled to a linear displacement sensor disposed adjacent to the firing rod and configured to detect linear movement of the firing rod; and

a speed calculator for determining at least one of a linear speed of the firing rod and rotational speed of the drive motor.

35. A powered surgical stapler according to claim 34, wherein the firing rod includes a first indicator and a second indicator disposed thereon.

37. A powered surgical stapler according to claim 34, wherein at least a portion of the firing rod is magnetized or the firing rod includes a magnetic material disposed therein and the linear displacement sensor is configured to detect variations in the magnetic field corresponding to movement of the firing rod.

38. A powered surgical stapler according to claim 37, wherein the linear displacement sensor is selected from the group consisting of a ferromagnetic sensor and a Hall Effect sensor.

39. A powered surgical stapler according to claim 34, wherein the linear displacement sensor is selected from the group consisting of a potentiometer and a rheostat and the firing rod includes a contact in electromechanical contact with the linear displacement sensors, wherein linear displacement sensor is configured to detect movement of the firing rod based on a change of at least one electrical property thereof.

40. A powered surgical stapler according to claim 34, wherein the speed calculator is coupled to the linear displacement sensor, the speed calculator being configured to determine the linear speed of the firing rod based on rate of change of displacement thereof.

42. A powered surgical stapler according to claim 34, further comprising a voltage sensor connected to the drive motor which measures back electromotive force thereof, the speed calculator being coupled to the voltage sensor and being configured to determine at least one of a linear speed of the firing rod and rotational speed of the drive motor based on the measured electromotive force.

45. A powered surgical stapler according to claim 34, wherein the speed calculator is configured to compare the linear speed of the firing rod and the rotational speed of the drive motor to determine whether rotation of the drive motor is being sufficiently translated to the firing rod.

36. A powered surgical stapler according to claim 36, further comprising:

a shaft start position sensor configured to signal the position calculator when the first indicator interfaces therewith, wherein position of the first indicator denotes commencement of the firing rod being moved; and

a clamp position sensor configured to signal the position calculator when the second indicator interfaces therewith, wherein position of the second indicator denotes clamping of the end effector.

47. A powered surgical stapler comprising:

a housing;

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

a drive motor disposed at least partially within a housing;

a firing rod disposed in mechanical cooperation with the drive motor;

an end effector disposed adjacent a distal portion of the endoscopic portion, the end effector defining a second longitudinal axis and being in mechanical cooperation with the firing rod so that the firing rod drives a surgical function of the end effector;

an articulation mechanism including an articulation motor configured to move the end effector between a first articulation position wherein the second longitudinal axis is substantially aligned with the first longitudinal axis toward a second articulation position in which the second longitudinal axis is disposed at an angle to the first longitudinal axis; and

an articulation sensor configured to determine during articulation when the end effector is in the first position, the articulation sensor being coupled to the articulation motor and configured to signal the articulation motor to cease articulation when the end effector is in the first position.

49. A powered surgical stapler according to claim 47, wherein the control system is adapted to couple to an external feedback controller configured to process the operating status of the powered surgical stapler to generate an output.

51. A powered surgical stapler according to claim 49, wherein the feedback controller includes:

an on-screen-display module configured to overlay the output of the feedback controller over the video display; and

a heads-up-display module configured to overlay the output of the feedback controller over the heads-up-display.

48. A powered surgical stapler comprising:

a housing;

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

a drive motor disposed at least partially within a housing;

a firing rod disposed in mechanical cooperation with the drive motor;

a loading unit configured to be removably attached to the endoscopic portion, the loading unit including an end effector being in mechanical cooperation with the firing rod so that the firing rod drives a surgical function of the end effector;

a control system including;

a plurality of sensors coupled to the drive motor, the firing rod, and the loading unit, the plurality of sensors configured to detect operating parameters thereof; and

a microcontroller coupled to the plurality of sensors, the microcontroller configured to determine the operating status of the powered surgical stapler as a function of the detected operating parameters.

50. A powered surgical stapler according to claim 48, wherein the feedback controller is adapted to couple to a video processor, a video display, a heads-up-display and a computing device.