POWERED SURGICAL INSTRUMENT

• US 20160256184A1
• Filed: 03/06/2015
• Published: 09/08/2016
• Est. Priority Date: 03/06/2015
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery LLC (Johnson & Johnson)
• Inventors: Shelton, Frederick E. IV, Yates, David C., Harris, Jason L., Morgan, Jerome R.
• Granted Patent: US 9,808,246 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/295 combined with cutting implements
• 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 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00022 Sensing or detecting at the treatment site
• CPC Class Codes: A61B 2017/00026 Conductivity or impedance, e.g. of tissue
• CPC Class Codes: A61B 2017/00119 alarm; indicating an abnormal situation
• CPC Class Codes: A61B 2017/0019 Means for setting or varying the pulse width
• 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 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00411 actuated by application of energy from an energy source outside the body
• 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 2017/00734 battery operated
• CPC Class Codes: A61B 2017/07257 characterised by its anvil
• 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 2017/07285 characterised by its cutter
• CPC Class Codes: A61B 2017/2927 the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2018/00607 : Coagulation and cutting with the same instrument
• CPC Class Codes: A61B 2018/1455 : having a moving blade for cutting tissue grasped by the jaws
• CPC Class Codes: A61B 2090/034 : abutting on parts of the device itself
• CPC Class Codes: A61B 2090/065 : for measuring contact or contact pressure
• CPC Class Codes: A61B 2090/066 : for measuring torque
• CPC Class Codes: A61B 2090/0803 : Counting the number of times an instrument is used
• CPC Class Codes: A61B 2090/0807 : Indication means
• CPC Class Codes: A61B 2090/0808 : for indicating correct assembly of components, e.g. of the surgical apparatus
• CPC Class Codes: A61B 2090/0814 : Preventing re-use
• CPC Class Codes: A61B 2090/0818 : Redundant systems, e.g. using two independent measuring systems and comparing the signals
• CPC Class Codes: A61B 2560/0475 : Special features of memory means, e.g. removable memory cards
• CPC Class Codes: A61B 90/98 : using electromagnetic means, e.g. transponders

Abstract

A method of operating a surgical instrument is disclosed. The surgical instrument includes an electronic system comprising an electric motor coupled to the end effector; a motor controller coupled to the motor; a parameter threshold detection module configured to monitor multiple parameter thresholds; a sensing module configured to sense tissue compression; a processor coupled to the parameter threshold detection module and the motor controller; and a memory coupled to the processor. The memory stores executable instructions that when executed by the processor cause the processor to monitor multiple levels of action thresholds and monitor speed of the motor and increment a drive unit of the motor, sense tissue compression, and provide rate and control feedback to the user of the surgical instrument.

Claims

1. A method of operating a surgical instrument, the surgical instrument comprising an electric motor coupled to an end effector, a motor controller coupled to the motor, a parameter threshold detection module, a sensing module, a processor, and a memory coupled to the processor, the memory storing executable instructions that when executed by the processor cause the processor to execute the method, the method comprising:

monitoring multiple parameter thresholds by the parameter threshold detection module;

sensing tissue compression by a sensing module;

monitoring multiple levels of action thresholds by the processor;

monitoring speed of the motor by the processor;

incrementing a drive unit of the motor by the processor;

sensing tissue compression by the processor; and

providing rate and control feedback by the processor to the user of the surgical instrument.

2. The method of claim 1, comprising automatically compensating by the processor for motor load when thresholds detected by the parameter threshold detection module are within acceptable limits.

3. The method of claim 2, comprising:

detecting battery current and speed of the motor by the parameter threshold detection module; and

increasing by the motor controller a pulse width or frequency modulation to maintain the speed of the motor constant when the battery current increases or the speed of the motor decreases.

4. The method of claim 1, comprising detecting minimum and maximum threshold limits by the parameter threshold detection module to control operation of the surgical instrument.

5. The method of claim 4, comprising detecting end effector closing force, end effector opening force, and speed of the motor by the parameter threshold detection module.

6. The method of claim 5, comprising controlling the speed of the motor by the processor when the end effector closing force decreases while a knife is translating through a knife channel in the end effector.

7. The method of claim 5, comprising activating an alarm by the processor when the end effector closing force decreases while a knife is translating through a knife channel.

8. The method of claim 4, comprising activating the motor by the processor only after a minimum parameter threshold is detected.

9. The method of claim 1, comprising detecting an ultimate threshold associated with current draw, end effector pressure applied to tissue, firing load, or torque, by the parameter threshold detection module, when the ultimate threshold is exceeded, the processor is configured to shut down the motor or cause the motor to retract the knife.

10. The method of claim 9, comprising:

detecting a secondary threshold which is less than the ultimate threshold by the parameter threshold detection module; and

adapting, by the processor, control parameters to accommodate the change in operation.

11. The method of claim 9, comprising detecting, by the parameter threshold detection module, a marginal threshold in the form of either a step function or ramp function based on a proportional response to another input to the parameter threshold detection module.

12. A method of operating a surgical instrument, the surgical instrument comprising an electric motor coupled to an end effector, a motor controller coupled to the motor, a sensing module, a processor, and a memory coupled to the processor, and a memory coupled to the processor, the memory storing executable instructions that when executed by the processor cause the processor to execute the method, the method comprising:

sensing tissue compression by a sensing module;

monitoring the sensing module by the processor; and

sensing multiple tissue parameters by the sensing module.

13. The method of claim 12, comprising sensing tissue impedance by the sensing module.

14. The method of claim 13, comprising measuring tissue impedance via sub-therapeutic RF energy by the sensing module coupled to electrodes.

15. The method of claim 14, comprising:

reading overlaid multiple frequency signals by the sensing module; and

measuring impedance in different locations simultaneously.

16. The method of claim 14, comprising measuring tissue impedance at variable RF frequencies sequentially by the sensing module with a multiplexor.

17. The method of claim 12, wherein the sensing module is configured to sense tissue pressure.

18. The method of claim 12, sensing tissue contact by the sensing module.

19. The method system of claim 12, comprising sensing viscoelasticity rate of change by the sensing module.

20. A method of operating a surgical instrument, the surgical instrument comprising an electric motor coupled to an end effector, a motor controller coupled to the motor, a sensing module configured to sense tissue compression, a feedback module configured to provide rate and control feedback to a user of the surgical instrument, a processor coupled to the parameter threshold detection module and the motor controller, and a memory coupled to the processor, the memory storing executable instructions that when executed by the processor cause the processor to execute the method, the method comprising:

monitoring multiple tissue parameters by the sensing module, wherein the sensing module is configured to sense multiple tissue parameters; and

providing feedback over the feedback module to a user of the instrument.