Surgical instrument system including replaceable end effectors

• US 9,226,751 B2
• Filed: 06/28/2012
• Issued: 01/05/2016
• Est. Priority Date: 06/28/2012
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery, Inc. (Johnson & Johnson)
• Inventors: Shelton, Frederick E. IV, Morgan, Jerome R.
• Primary Examiner(s): Holwerda, Kathleen
• Assistant Examiner(s): SIMPSON, SARAH A
• Application Number:
  US13/536,360
• Publication Number:
  US 20140005679A1
• Time in Patent Office: 1,286 Days
• Field of Search: 606/130, 227/176.1, 227/175.1, 227/180.1
• 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 17/320016 Endoscopic cutting instruments, e.g. arthroscopes, resectoscopes A61B10/0233, A61B17/29, A61B17/3207 take precedence
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/003 Steerable
• CPC Class Codes: A61B 2017/00309 Cut-outs or slits
• CPC Class Codes: A61B 2017/00314 Separate linked members
• CPC Class Codes: A61B 2017/00323 Cables or rods
• CPC Class Codes: A61B 2017/00327 with actuating members moving in opposite directions
• 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 2017/00473 Distal part, e.g. tip or head A61B2017/00464 takes precedence
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00685 Archimedes screw
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/00876 magnetic
• 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 2017/2903 : transferring rotary motion
• CPC Class Codes: A61B 2017/2905 : flexible
• CPC Class Codes: A61B 2017/2908 : Multiple segments connected by articulations
• CPC Class Codes: A61B 2017/2923 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/2927 : the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2929 : with a head rotatable about the longitudinal axis of the shaft
• CPC Class Codes: A61B 2017/2931 : with releasable head
• CPC Class Codes: A61B 2017/2939 : Details of linkages or pivot points
• CPC Class Codes: A61B 2017/2943 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/2946 : Locking means
• CPC Class Codes: A61B 2034/306 : Wrists with multiple vertebrae
• CPC Class Codes: A61B 2090/0811 : for the position of a particular part of an instrument with respect to the rest of the instrument, e.g. position of the anvil of a stapling instrument
• CPC Class Codes: A61B 2090/0812 : indicating loosening or shifting of parts of an instrument, signaling maladjustment of parts
• CPC Class Codes: A61B 2090/0814 : Preventing re-use
• CPC Class Codes: A61B 34/30 : Surgical robots
• CPC Class Codes: A61B 34/37 : Master-slave robots A61B34/35 takes precedence
• CPC Class Codes: A61B 34/70 : Manipulators specially adapted for use in surgery
• CPC Class Codes: A61B 34/71 : Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 34/74 : Manipulators with manual electric input means
• CPC Class Codes: A61M 2039/1061 : Break-apart tubing connectors or couplings
• CPC Class Codes: A61M 39/00 : Tubes, tube connectors, tube couplings, valves, access sites or the like, specially adapted for medical use for respiratory devices, e.g. tracheal tubes A61M16/00; artificial heart valves A61F2/24
• CPC Class Codes: A61M 39/1055 : Rotating or swivel joints in general F16L27/00
• CPC Class Codes: Y10T 29/49826 : Assembling or joining
• CPC Class Codes: Y10T 74/18056 : Rotary to or from reciprocating or oscillating
• CPC Class Codes: Y10T 74/20329 : Joint between elements

Abstract

A surgical instrument system that includes a housing and a rotatable drive shaft, a motor operably coupled to the drive shaft, and a plurality of replaceable end effectors that can be connected to the housing. Each replaceable end effector includes a drive screw that is turned a fixed number of revolutions by the motor-driven rotatable drive shaft when the end effector is connected to the housing. Each end effector further comprises a firing member operably coupled with the drive screw of the end effector. The drive screw is configured to displace the firing member over a firing length as a result of the fixed number of revolutions. In certain embodiments, each replaceable end effector can include a drive screw with a thread pitch set to the firing length divided by the fixed number of revolutions.

Claims

1. A surgical instrument system, comprising:

a housing including a motor-driven drive shaft, wherein said motor-driven drive shaft is configured to turn a set number of revolutions during a firing actuation;

a first end effector assembly configured to be coupled to and decoupled from said housing, wherein said first end effector assembly defines a first firing path having a first firing length, said first end effector assembly comprising;

a first firing member configured to travel along said first firing path; and

a first drive screw configured to be operably coupled to and operably decoupled from said motor-driven drive shaft, wherein said first drive screw is configured to engage said first firing member such that rotation of said first drive screw causes said first firing member to travel along said first firing path, and wherein said first drive screw is configured to cause said first firing member to travel said first firing length when said motor-driven drive shaft turns said set number of revolutions; and

a second end effector assembly configured to be coupled to and decoupled from said housing, wherein said second end effector assembly defines a second firing path having a second firing length, and wherein said second firing length is different than said first firing length, said second end effector assembly comprising;

a second firing member configured to travel along said second firing path; and

a second drive screw configured to be operably coupled to and operably decoupled from said motor-driven drive shaft, wherein said second drive screw is configured to engage said second firing member such that rotation of said second drive screw causes said second firing member to travel along said second firing path, and wherein said second drive screw is configured to cause said second firing member to travel said second firing length when said motor-driven drive shaft turns said set number of revolutions.

2. The surgical instrument system of claim 1, wherein the first drive screw comprises a first thread that defines a first thread lead, wherein the second drive screw comprises a second thread that defines a second thread lead, and wherein said first thread lead is different than said second thread lead.

3. The surgical instrument system of claim 1, wherein said first drive screw comprises a first thread arranged at a first angle relative to a longitudinal axis of said first drive screw, wherein said first angle defines a first thread lead, wherein said second drive screw comprises a second thread arranged at a second angle relative to a longitudinal axis of said second drive screw, wherein said second angle defines a second thread lead, wherein said first angle is greater than said second angle, and wherein said second thread lead is greater than said first thread lead.

4. A surgical instrument system, comprising:

a housing including a motor-driven drive shaft, wherein said motor-driven drive shaft is configured to turn a fixed number of revolutions during a firing actuation;

a first end effector assembly configured to be coupled to and decoupled from said housing, wherein said first end effector assembly defines a first firing path having a first firing length, said first end effector assembly comprising;

a first firing member configured to travel along said first firing path; and

a first drive screw configured to be operably coupled to and operably decoupled from said motor-driven drive shaft, wherein said first drive screw is configured to engage said first firing member such that rotation of said first drive screw causes said first firing member to travel along said first firing path, and wherein said first drive screw is configured to cause said first firing member to travel said first firing length when said motor-driven drive shaft turns said fixed number of revolutions; and

a second end effector assembly configured to be coupled to and decoupled from said housing, wherein said second end effector assembly defines a second firing path having a second firing length, and wherein said second firing length is different than said first firing length, said second end effector assembly comprising;

a second firing member configured to travel along said second firing path; and

a second drive screw configured to be operably coupled to and operably decoupled from said motor-driven drive shaft, wherein said second drive screw is configured to engage said second firing member such that rotation of said second drive screw causes said second firing member to travel along said second firing path, and wherein said second drive screw is configured to cause said second firing member to travel said second firing length when said motor-driven drive shaft turns said fixed number of revolutions.

5. The surgical instrument system of claim 4, wherein said fixed number of revolutions turned by said motor-driven drive shaft is a first fixed number of revolutions, wherein said first drive screw turns a second fixed number of revolutions when said motor-driven drive shaft turns said first fixed number of revolutions, wherein said first drive screw includes at least one thread, and wherein said thread on said first drive screw defines a thread lead equal to said first firing length of said first firing member divided by said second fixed number of revolutions.

6. The surgical instrument system of claim 5, wherein said second fixed number of revolutions is the same as said first fixed number of revolutions.

7. The surgical instrument system of claim 5, wherein said second fixed number of revolutions is different than said first fixed number of revolutions.

8. The surgical instrument system of claim 5, wherein said second drive screw turns a third fixed number of revolutions when said motor-driven drive shaft turns said first fixed number of revolutions, wherein said second drive screw includes at least one thread, and wherein said thread on said second drive screw defines a thread lead equal to the second firing length of said second firing member divided by said third fixed number of revolutions.

9. The surgical instrument system of claim 8, wherein said third fixed number of revolutions is the same as said second fixed number of revolutions.

10. The surgical instrument system of claim 8, wherein said third fixed number of revolutions is different than said second fixed number of revolutions.

11. The surgical instrument system of claim 8, wherein said at least one thread of said second drive screw comprises a first thread and a second thread, and wherein said first thread and said second thread are arranged on said second drive screw 180°

out of phase from each other.

12. The surgical instrument system of claim 8, wherein said at least one thread of second drive screw comprises a first thread, a second thread, and a third thread, and wherein said first thread, said second thread, and said third thread are arranged on said second drive screw 120°

out of phase from each other.

13. The surgical instrument system of claim 8, wherein said at least one thread of second drive screw comprises a first thread, a second thread, a third thread, and a fourth thread, and wherein said first thread, said second thread, said third thread, and said fourth thread are arranged on said second drive screw 90°

out of phase from each other.

14. An interchangeable end effector for use with a surgical instrument system, wherein the surgical instrument system includes a motor, wherein the motor is configured to turn a set number of revolutions, wherein the surgical instrument system also includes a drive shaft operably coupled to the motor, and wherein a replaceable end effector is configured to be attached to the surgical instrument system such that, when the motor turns the set number of revolutions, a first firing member of the replaceable end effector travels a first full firing length, said interchangeable end effector comprising:

a body configured to be coupled to and decoupled from the surgical instrument system;

a second firing member configured to travel along a second firing path of said interchangeable end effector, wherein said second firing path defines a second full firing length, and wherein said second full firing length is different than the first full firing length; and

a drive screw configured to be operably coupled to and operably decoupled from the drive shaft of the surgical instrument system, wherein said drive screw is configured to engage said second firing member such that rotation of said drive screw causes said second firing member to travel along said second firing path, and wherein said drive screw is configured to cause said second firing member to travel said second full firing length when the drive shaft turns the set number of revolutions.

15. A replaceable end effector for use with a surgical instrument system, wherein the surgical instrument system includes a motor, wherein the motor is configured to turn a first set number of revolutions, and wherein the surgical instrument system also includes a drive shaft operably coupled to the motor such that the drive shaft turns a second set number of revolutions, said replaceable end effector comprising:

a body configured to be coupled to and decoupled from the surgical instrument system;

a firing member configured to travel along a firing path of said replaceable end effector, wherein said firing path defines a firing length; and

a drive screw configured to be operably coupled to and operably decoupled from the drive shaft of the surgical instrument system, wherein said drive screw is configured to engage said firing member such that rotation of said drive screw causes said firing member to travel along said firing path, and wherein said drive screw is configured to cause said firing member to travel said firing length when the drive shaft in the surgical instrument system turns the second set number of revolutions;

wherein said drive screw comprises a thread that defines a thread lead, and wherein said thread lead is set to a distance equal to said firing length divided by the second set number of revolutions which the drive shaft turns.

16. A surgical kit for use with a surgical instrument system, wherein the surgical instrument system includes a motor configured to turn a drive shaft a set number of revolutions during a firing actuation, said surgical kit comprising:

a first end effector assembly configured to be coupled to and decoupled from the surgical instrument system, wherein said first end effector assembly defines a first firing path having a first firing length, said first end effector assembly comprising;

a first firing member configured to travel along said first firing path; and

a first drive screw configured to be operably coupled to and operably decoupled from said motor-driven drive shaft, wherein said first drive screw is configured to engage said first firing member such that rotation of said first drive screw causes said first firing member to travel along said first firing path, and wherein said first drive screw is configured to cause said first firing member to travel said first firing length when said drive shaft turns said set number of revolutions; and

a second end effector assembly configured to be coupled to and decoupled from said surgical instrument system, wherein said second end effector assembly defines a second firing path having a second firing length, and wherein said second firing length is different than said first firing length, said second end effector assembly comprising;

a second firing member configured to travel along said second firing path; and

a second drive screw configured to be operably coupled to and operably decoupled from said motor-driven drive shaft, wherein said second drive screw is configured to engage said second firing member such that rotation of said second drive screw causes said second firing member to travel along said second firing path, and wherein said second drive screw is configured to cause said second firing member to travel said second firing length when said drive shaft turns said set number of revolutions.