System and method for performing surgical procedures with a reusable instrument module

• US 9,867,675 B2
• Filed: 10/03/2016
• Issued: 01/16/2018
• Est. Priority Date: 01/13/2012
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Beardsley, John, Chowaniec, Matthew, Pribanic, Russell
• Primary Examiner(s): Wieland, Robert N
• Application Number:
  US15/283,489
• Publication Number:
  US 20170020632A1
• Time in Patent Office: 470 Days
• CPC Class Codes: A61B 17/00 Surgical instruments, devices or methods, e.g. tourniquets A61B18/00 takes precedence; contraceptive devices, pessaries, or applicators therefor A61F6/00; eye surgery A61F9/007; ear surgery A61F11/00
• 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 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/32 Surgical cutting instruments A61B18/042 takes precedence; suture cutters A61B17/0467; instruments for ligaturing or cutting A61B17/128; instruments for rupturing the amniotic membrane A61B17/4208; specially adapted knives for eye surgery A61F9/0133
• CPC Class Codes: A61B 17/3201 Scissors for biopsy A61B10/02
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00115 with audible or visual output with imaging means A61B90/37, A61B34/20
• 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 for prosthetic joint-implanting tools A61F2/4603
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/00907 for light
• CPC Class Codes: A61B 2017/2925 Pistol grips
• CPC Class Codes: A61B 2090/0813 Accessories designed for easy sterilising, i.e. re-usable
• CPC Class Codes: A61B 90/70 Cleaning devices specially adapted for surgical instruments

Abstract

A surgical instrument includes an outer housing shell defining a cavity. The outer housing shell defines an upper outer housing half and a lower outer housing half. The upper outer housing half defines a longitudinal axis. An instrument module is selectively insertable into the cavity of the outer housing shell. The instrument module includes an inner housing shell, at least one motor disposed within the inner housing shell, a control board being in electrical communication with the at least one motor, and an energy source being in electrical communication with the at least one motor and the control board. The instrument module is inserted into the cavity of the outer housing shell in such a manner that the operative axis of the at least one motor is substantially parallel to the longitudinal axis of the upper outer housing half.

Claims

1. A method of assembling a surgical instrument, the method comprising:

inserting a proximal end of an instrument module into a proximal portion of an outer housing shell wherein the instrumental module includes at least one of a motor, a control board, or an energy source disposed therein; and

approximating the proximal portion of the outer housing shell and a distal portion of the outer housing shell thereby engaging a mating surface of the proximal portion of the outer housing shell with a corresponding mating surface of the distal portion of the outer housing shell to enclose the instrument module in a cavity cooperatively defined by the proximal and distal portions of the outer housing shell.

2. The method according to claim 1, wherein inserting the proximal end of the instrument module into the proximal portion of the outer housing shell includes moving the proximal end of the instrument module through an opening defined by a distally-oriented face of the proximal portion of the outer housing shell.

3. The method according to claim 2, further comprising moving the distal end of the instrument module through an opening defined by a proximally-oriented face of the distal portion of the outer housing shell.

4. The method according to claim 1, further comprising:

decoupling the mating surfaces of the proximal and distal portions of the outer housing shell; and

removing the instrument module from the cavity of the outer housing shell.

5. The method according to claim 4, further comprising inserting the instrument module into the cavity of the outer housing shell subsequent to providing the outer housing shell having at least a sterilized outer surface such that the outer surface of the outer housing shell is sterile following insertion of the instrument module into the outer housing shell.

6. The method according to claim 1, further comprising forming a fluid-tight seal between the outer housing shell and a drive shaft of the instrument module.

7. A surgical instrument, comprising:

an outer housing shell including;

a proximal portion having a face, the face of the proximal portion defining an opening therein and including a mating surface; and

a distal portion having a face, the face of the distal portion defining an opening therein and including a mating surface configured to mate with the mating surface of the proximal portion;

an instrument module configured for receipt in a cavity cooperatively defined by the proximal and distal portions of the outer housing shell, and through at least one of the opening of the proximal portion of the outer housing shell or the opening of the distal portion of the outer housing shell wherein the instrument module includes at least one of a motor, a control board, or an energy source disposed therein.

8. The surgical instrument according to claim 7, wherein the instrument module includes:

a proximal end configured for receipt within the proximal portion of the outer housing shell; and

a distal end configured for receipt within the distal portion of the outer housing shell.

9. The surgical instrument according to claim 7, wherein the distal portion of the outer housing shell includes an upper portion and a lower portion extending substantially perpendicularly from the upper portion.

10. The surgical instrument according to claim 7, wherein the outer housing shell has a first configuration, in which the instrument module is selectively insertable therein, and a second configuration, in which the mating surfaces of the proximal and distal portions of the outer housing shell are engaged to one another.

11. The surgical instrument according to claim 10, wherein in the first configuration, the face of the proximal portion of the outer housing shell is oriented distally, and the face of the distal portion of the outer housing shell is oriented proximally.

12. The surgical instrument according to claim 7, wherein the instrument module further includes a drive shaft disposed within the distal end of the instrument module.

13. The surgical instrument according to claim 12, wherein the outer housing shell includes a seal supported in the distal portion of the outer housing shell, the seal forming a fluid-tight seal between the outer housing shell and the drive shaft.

14. The surgical instrument according to claim 7, wherein each of the proximal and distal portions of the outer housing shell includes an outer surface and an inner surface, wherein at least the outer surface of each of the proximal and distal portions of the outer housing shell is sterile.

15. A method of assembling a surgical instrument, the method comprising:

providing an outer housing shell including;

a proximal portion having a face, the face of the proximal portion defining an opening therein and including a mating surface; and

a distal portion having a face, the face of the distal portion defining an opening therein and including a mating surface configured to mate with the mating surface of the proximal portion;

providing an instrument module having a proximal end, a distal end, and at least one of a motor, a control board, or an energy source disposed therein;

inserting the proximal end of the instrument module into the proximal portion of the outer housing shell; and

approximating the proximal portion of the outer housing shell and the distal portion of the outer housing shell thereby engaging the mating surface of the proximal portion of the outer housing shell with the mating surface of the distal portion of the outer housing shell to enclose the instrument module in a cavity cooperatively defined by the proximal and distal portions of the outer housing shell.

16. The method according to claim 15, wherein inserting the proximal end of the instrument module into the proximal portion of the outer housing shell includes moving the proximal end of the instrument module through the opening defined by the face of the proximal portion of the outer housing shell.

17. The method according to claim 16, further comprising moving the distal end of the instrument module through the opening defined by the face of the distal portion of the outer housing shell.

18. The method according to claim 15, further comprising:

decoupling the mating surfaces of the proximal and distal portions of the outer housing shell; and

removing the instrument module from the cavity of the outer housing shell.

19. The method according to claim 18, further comprising inserting the instrument module into the cavity of the outer housing shell subsequent to providing the outer housing shell having at least a sterilized outer surface such that the outer surface of the outer housing shell is sterile following insertion of the instrument module into the outer housing shell.

20. The method according to claim 15, further comprising forming a fluid-tight seal between the outer housing shell and a drive shaft of the instrument module.