Firing member retraction devices for powered surgical instruments

• US 9,700,310 B2
• Filed: 08/23/2013
• Issued: 07/11/2017
• Est. Priority Date: 08/23/2013
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Morgan, Jerome R., Shelton, IV, Frederick E., Schellin, Emily A., Hall, Steven G., Swayze, Jeffrey S.
• Primary Examiner(s): Weeks, Gloria R
• Application Number:
  US13/974,166
• Publication Number:
  US 20150053739A1
• Time in Patent Office: 1,418 Days
• Field of Search: 2271752
• 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 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 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00084 Temperature
• CPC Class Codes: A61B 2017/00115 with audible or visual output
• CPC Class Codes: A61B 2017/00119 alarm; indicating an abnormal situation
• CPC Class Codes: A61B 2017/00123 and automatic shutdown
• CPC Class Codes: A61B 2017/00137 Details of operation mode
• CPC Class Codes: A61B 2017/00154 pulsed
• CPC Class Codes: A61B 2017/0019 Means for setting or varying the pulse width
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/00221 with wireless transmission of data, e.g. by infrared radiation or radiowaves
• 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 2017/00402 Piezo electric actuators
• CPC Class Codes: A61B 2017/00407 Ratchet means
• 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 2017/00482 : with a code
• CPC Class Codes: A61B 2017/00486 : Adaptors for coupling parts with incompatible geometries
• CPC Class Codes: A61B 2017/00734 : battery operated
• CPC Class Codes: A61B 2017/07214 : Stapler heads
• CPC Class Codes: A61B 2017/07228 : Arrangement of the staples
• 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 2017/2901 : Details of shaft
• CPC Class Codes: A61B 2017/291 : the position of the handle being adjustable with respect to the shaft
• 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 2017/2941 : Toggle linkages
• CPC Class Codes: A61B 2017/2946 : Locking means
• CPC Class Codes: A61B 2034/252 : indicating steps of a surgical procedure
• CPC Class Codes: A61B 2034/254 : being adapted depending on the stage of the surgical procedure
• CPC Class Codes: A61B 2034/256 : having a database of accessory information, e.g. including context sensitive help or scientific articles
• CPC Class Codes: A61B 2090/035 : preventing further rotation
• CPC Class Codes: A61B 2090/037 : with a frangible part, e.g. by reduced diameter
• CPC Class Codes: A61B 2090/0803 : Counting the number of times an instrument is used
• CPC Class Codes: A61B 2090/0804 : Counting number of instruments used; Instrument detectors
• 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 2090/0811 : 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 2090/0814 : Preventing re-use
• CPC Class Codes: A61B 2090/372 : Details of monitor hardware
• CPC Class Codes: A61B 2560/0214 : of power generation or supply
• CPC Class Codes: A61B 34/10 : Computer-aided planning, simulation or modelling of surgical operations
• CPC Class Codes: A61B 34/25 : User interfaces for surgical systems
• CPC Class Codes: A61B 34/30 : Surgical robots
• CPC Class Codes: A61B 34/74 : Manipulators with manual electric input means
• CPC Class Codes: A61B 34/76 : Manipulators having means for providing feel, e.g. force or tactile feedback
• CPC Class Codes: A61B 90/03 : Automatic limiting or abutting means, e.g. for safety
• CPC Class Codes: A61B 90/37 : Surgical systems with images on a monitor during operation
• CPC Class Codes: A61B 90/90 : Identification means for patients or instruments, e.g. tags
• CPC Class Codes: A61B 90/96 : using barcodes
• CPC Class Codes: A61B 90/98 : using electromagnetic means, e.g. transponders
• CPC Class Codes: G06F 21/60 : Protecting data
• CPC Class Codes: G06F 3/016 : Input arrangements with force or tactile feedback as computer generated output to the user
• CPC Class Codes: G06F 3/0416 : Control or interface arrangements specially adapted for digitisers
• CPC Class Codes: G06F 3/04817 : using icons graphical or visual programming using iconic symbols G06F8/34
• CPC Class Codes: G06F 3/0482 : Interaction with lists of selectable items, e.g. menus
• CPC Class Codes: G06F 3/04845 : for image manipulation, e.g. dragging, rotation, expansion or change of colour
• CPC Class Codes: G06F 3/0488 : using a touch-screen or digitiser, e.g. input of commands through traced gestures
• CPC Class Codes: G06T 11/60 : Editing figures and text; Combining figures or text
• CPC Class Codes: G09G 5/14 : Display of multiple viewports
• CPC Class Codes: G16H 20/40 : relating to mechanical, radiation or invasive therapies, e.g. surgery, laser therapy, dialysis or acupuncture
• CPC Class Codes: G16H 40/63 : for local operation
• CPC Class Codes: G16Z 99/00 : Subject matter not provided for in other main groups of this subclass
• CPC Class Codes: H01M 10/425 : Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/48 : Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 2220/30 : Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H02J 2310/23 : The load being a medical device, a medical implant, or a life supporting device
• CPC Class Codes: H02J 7/00 : Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/0068 : Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/342 : The other DC source being a battery actively interacting with the first one, i.e. battery to battery charging with circuits for polarity protection H02J7/0034
• CPC Class Codes: H02J 9/061 : for DC powered loads
• CPC Class Codes: H03K 2217/96062 : with tactile or haptic feedback
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries

Abstract

A surgical instrument that includes a motor-powered drive unit that drives a portion of a firing member assembly in an axial direction to actuate a surgical end effector coupled to the instrument. The instrument may further include a retraction system configured to interact with the firing member assembly to permit a clinician to manually retract the portion of the firing member assembly should it become jammed or inadvertently stopped during a firing process. The surgical instrument includes a locking arrangement that interfaces with the retraction system and the motor-powered drive unit to prevent the transfer of the retraction forces generated by the retraction system to the motor shaft without physically separating portions of the motorized drive unit.

Claims

1. A surgical instrument, comprising:

a firing member assembly including a portion supported for selective axial movement in a distal direction and a proximal direction;

a drive unit, comprising;

a motor including a motor shaft; and

a gear assembly drivingly coupled to the motor shaft and including an output shaft assembly configured to interface with the firing member assembly such that upon rotation of the motor shaft in a first rotary direction, the portion of the firing member assembly is axially driven in the distal direction and upon rotation of the motor shaft in a second rotary direction, the portion of the firing member assembly is axially driven in the proximal direction;

a retraction assembly interfacing with the firing member assembly for manually applying other rotary motions to the firing member assembly in the second rotary direction when the motor is deactivated; and

locking means interfacing with the retraction assembly and the drive unit for preventing transfer of the other rotary motions to the motor shaft during operation of the retraction assembly and while the gear assembly remains drivingly coupled to the motor shaft;

wherein the surgical instrument further comprises a housing and wherein the motor includes a motor housing and wherein the gear assembly includes a gear box housing non-movably coupled to the motor housing, the motor housing and the gear box housing being supported within the housing for rotation relative thereto as a unit upon application of the other rotary motions to the firing member assembly.

2. The surgical instrument of claim 1 wherein the locking means comprises a movable locking pawl assembly being movable from a locked position wherein said locking pawl assembly lockingly engages a portion of the gear box housing to prevent rotation thereof relative to the housing to an unlocked position wherein the gear box housing is free to rotate relative to the housing.

3. The surgical instrument of claim 2 wherein the movable locking pawl assembly is configured to interface with the retraction assembly such that actuation of the retraction assembly causes the locking pawl assembly to move from the locked position to the unlocked position.

4. A surgical instrument, comprising:

a firing member assembly including a portion supported for selective axial movement in a distal direction and a proximal direction;

a drive unit, comprising;

a motor including a motor shaft; and

a gear assembly drivingly coupled to the motor shaft and including an output shaft assembly configured to interface with the firing member assembly such that upon rotation of the motor shaft in a first rotary direction, the portion of the firing member assembly is axially driven in the distal direction and upon rotation of the motor shaft in a second rotary direction, the portion of the firing member assembly is axially driven in the proximal direction;

a retraction assembly interfacing with the firing member assembly for manually applying other rotary motions to the firing member assembly in the second rotary direction when the motor is deactivated; and

locking means interfacing with the retraction assembly and the drive unit for preventing transfer of the other rotary motions to the motor shaft during operation of the retraction assembly and while the gear assembly remains drivingly coupled to the motor shaft;

further comprising a housing and wherein the motor includes a motor housing that is non-movably supported within the housing and wherein the gear assembly comprises;

a gear box housing coupled to the motor housing;

a gear train assembly operably supported within the gear box housing in driving engagement with the motor shaft; and

a lockable ring gear rotatably supported by the gear box housing and in driving engagement with the gear train assembly and the output shaft assembly and wherein said locking means comprises a movable shift ring assembly being movable from a locked position wherein said shift ring assembly lockingly engages the lockable ring gear to prevent rotation thereof relative to the gear box housing to an unlocked position wherein the lockable ring gear is free to rotate relative to the gear box housing.

5. The surgical instrument of claim 4 wherein the movable shift ring assembly is configured to interface with the retraction assembly such that actuation of the retraction assembly causes the shift ring assembly to move from the locked position to the unlocked position.

6. The surgical instrument of claim 4 wherein the movable shift ring assembly comprises:

a shift ring operably coupled to a portion of the retraction assembly, the shift ring being supported for axial movement relative to the drive unit in response to movement of the portion of the retraction assembly; and

at least one locking member coupled to said shift ring and configured for locking engagement with the lockable ring gear.

7. The surgical instrument of claim 4 wherein the locking means comprises at least one ring gear locking member supported for locking engagement with the lockable ring gear to prevent rotation thereof and wherein the movable shift ring assembly comprises:

a shift ring operably coupled to a portion of the retraction assembly, the shift ring being supported for axial movement relative to the drive unit in response to movement of the portion of the retraction assembly; and

at least one shift ring actuator portion coupled to the shift ring for travel therewith such that when the shift ring is in the locked position, the at least one shift ring actuator portion moves the at least one ring gear locking member into locking engagement with the lockable ring gear and when the shift ring is in the unlocked position, the at least one ring gear locking member is configured to disengage the lockable ring gear.

8. The surgical instrument of claim 7 wherein the at least one ring gear locking member comprises at least one biasing member configured to bias the at least one ring gear locking member out of locking engagement with the lockable ring gear when the shift ring is in the unlocked position.

9. A surgical instrument, comprising:

a housing;

a firing member assembly comprising a portion supported for selective axial movement;

a drive unit, comprising;

a motor comprising a motor shaft and a motor housing; and

a gear box, comprising;

a gear box housing non-movably coupled to the motor housing; and

a gear assembly drivingly coupled to the motor shaft, wherein the gear assembly is configured to interface with the firing member assembly such that a rotation of the motor shaft is configured to drive the portion of the firing member assembly;

a retraction assembly interfacing with the firing member assembly for retracting the portion of the firing member assembly when the motor is inactive; and

locking means interfacing with the retraction assembly and the drive unit for preventing the transmission of torque between the firing member assembly and the motor shaft during operation of the retraction assembly and while maintaining an operable connection between the firing member assembly and the motor shaft, wherein the motor housing and the gear box housing are supported within the housing for rotation relative thereto as a unit during operation of the retraction assembly.

10. The surgical instrument of claim 9, further comprising a loading unit configured to cut and staple tissue.

11. The surgical instrument of claim 9, further comprising a loading unit comprising a plurality of staples.

12. A surgical instrument, comprising:

a housing;

a firing member assembly comprising a firing rod;

a drive unit rotatably supported within the housing, wherein the drive unit comprises;

a motor comprising a motor shaft and a motor housing; and

a gear box, comprising;

a gear box housing non-movably coupled to the motor housing; and

a gear assembly drivingly positioned intermediate the motor shaft and the firing member assembly;

a retraction assembly configured to selectively retract the firing rod without the assistance of the motor; and

a locking assembly movable between a locked position and an unlocked position upon actuation of the retraction assembly, wherein the locking assembly is configured to permit rotation of the motor housing and the gear box housing relative to the housing when in the unlocked position, and wherein the locking assembly is configured to prevent rotation of the motor housing and the gear box housing relative to the housing when in the locked position.

13. The surgical instrument of claim 12, further comprising a plurality of bearings intermediate the drive unit and the housing.

14. The surgical instrument of claim 12, further comprising a loading unit configured to cut and staple tissue.

15. The surgical instrument of claim 12, further comprising a loading unit comprising a plurality of staples.

16. The surgical instrument of claim 12, wherein the locking assembly comprises a movable locking pawl configured to lockingly engage the gear box housing when the locking assembly is in the locked position.

17. A surgical instrument, comprising:

a housing;

a firing member assembly comprising a firing rod;

a drive unit rotatably supported within the housing, wherein the drive unit comprises;

a motor comprising a motor shaft and a motor housing;

a gear box, comprising;

a gear box housing non-movably coupled to the motor housing;

a gear assembly drivingly positioned intermediate the motor shaft and the firing member assembly;

retraction means for retracting the firing rod without the assistance of the motor; and

locking means for preventing rotation of the motor housing and the gear box housing relative to the housing when the locking means is in a locked position, wherein actuation of the retraction means is configured to move the locking means from the locked position to an unlocked position.

18. The surgical instrument of claim 17, further comprising:

a first bearing intermediate the housing and the motor housing; and

a second bearing intermediate the housing and the gear box housing.

19. The surgical instrument of claim 17, further comprising means for cutting and stapling tissue.