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

• US 9,872,673 B2
• Filed: 01/07/2016
• Issued: 01/23/2018
• 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): PATTON, AMANDA K
• Application Number:
  US14/990,164
• Publication Number:
  US 20160113635A1
• Time in Patent Office: 747 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 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/28 Surgical forceps for holding suture needles or materials A61B17/0483; for removing or smashing calculi A61B17/221; surgical scissors A61B17/3201 ; obstetrical forceps A61B17/44; for inserting intraocular lenses A61F2/1662; hand-held gripping tools in general B25B7/00 ]
• CPC Class Codes: A61B 18/04 by heating by applying electromagnetic radiation A61B18/18; hyperthermia using electric or magnetic fields, radiation or ultrasound A61N
• CPC Class Codes: A61B 18/14 Probes or electrodes therefor
• 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 2017/00115 with audible or visual output with imaging means A61B90/37, A61B34/20
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00464 for use with different instruments with hole for different instruments A61B2017/22072
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/00907 for light
• CPC Class Codes: A61B 2017/00955 thermoplastic
• CPC Class Codes: A61B 2090/0813 Accessories designed for easy sterilising, i.e. re-usable
• CPC Class Codes: A61B 46/10 specially adapted for instruments, e.g. microscopes
• CPC Class Codes: H05K 999/99 dummy group

Abstract

A surgical instrument includes an outer housing shell defining a cavity, the outer housing shell defining an upper outer housing half and a lower outer housing half, wherein the upper outer housing half defines a longitudinal axis and an instrument module 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:

providing an outer housing shell that defines a cavity, the outer housing shell including an upper outer housing and a lower outer housing extending from the upper outer housing, the outer housing shell having a face that defines an opening that is in communication with the cavity;

providing an instrument module including an inner housing shell that defines a cavity therein, the inner housing shell having an upper inner housing and a lower inner housing extending from the upper inner housing; and

inserting the instrument module into the cavity of the outer housing shell through the opening of the outer housing shell, thereby positioning the upper inner housing of the inner housing shell in the upper outer housing of the outer housing shell and the lower inner housing of the inner housing shell in the lower outer housing of the outer housing shell.

2. The method according to claim 1, wherein the instrument module passes through the upper outer housing and the lower outer housing when the instrument module is inserted into the cavity of the outer housing shell.

3. The method according to claim 1, wherein the instrument module is inserted into the cavity of the outer housing shell in such a manner that the operative axis of a motor of the instrument module is substantially parallel to a longitudinal axis defined by the upper outer housing.

4. The method according to claim 1, further comprising rotating an instrument shell cover relative to the lower outer housing after the instrument module is inserted into the cavity of the outer housing shell.

5. The method according to claim 1, further comprising passing a drive shaft of the instrument module through an opening formed in a distal surface of the outer housing shell.

6. The method according to claim 5, further comprising forming a fluid-tight seal between the outer housing shell, the inner housing shell, and the drive shaft.

7. The method according to claim 1, further comprising engaging an instrument shell cover with the face of the outer housing shell thereby covering the cavity and enclosing the inner housing shell of the instrument module within the cavity.

8. The method according to claim 1, further comprising sterilizing an outer surface of the outer housing shell.

9. A surgical instrument, comprising:

an outer housing shell defining a cavity therein, the outer housing shell including;

an upper outer housing; and

a lower outer housing extending from the upper outer housing, the outer housing shell having a face defining an opening that is in communication with the cavity; and

an instrument module including an inner housing shell that defines a cavity therein, the inner housing shell having an upper inner housing and a lower inner housing extending from the upper inner housing, wherein the instrument module is configured to be selectively received within the cavity of the outer housing shell through the opening of the outer housing shell such that the upper inner housing of the inner housing shell is positioned in the upper outer housing of the outer housing shell and the lower inner housing of the inner housing shell is positioned in the lower outer housing of the outer housing shell.

10. The surgical instrument according to claim 9, wherein the face of the outer housing shell is formed at a proximal end of the upper outer housing and a proximal end of the lower outer housing, the opening of the outer housing shell collectively defined by the upper outer housing and the lower outer housing.

11. The surgical instrument according to claim 9, wherein the instrument module includes a motor disposed in the cavity of the inner housing shell, the motor defining an operative axis that is substantially parallel to a longitudinal axis defined by the upper outer housing.

12. The surgical instrument according to claim 9, further comprising an instrument shell cover rotatably coupled to the lower outer housing and configured to selectively enclose the inner housing shell of the instrument module within the cavity of the outer housing shell.

13. The surgical instrument according to claim 9, wherein the instrument module further includes a drive shaft disposed in the cavity of the inner housing shell and configured to extend through an opening formed in a distal surface of the outer housing shell.

14. The surgical instrument according to claim 9, wherein the outer housing shell includes a seal supported in a distal portion thereof.

15. The surgical instrument according to claim 9, wherein the instrument module includes a circuit board disposed within the cavity of the inner housing shell.

16. A surgical instrument, comprising:

an outer housing shell defining a cavity therein, the outer housing shell including;

an upper outer housing; and

a lower outer housing extending from the upper outer housing, the outer housing shell having a face defining an opening that is in communication with the cavity; and

an instrument module including;

an inner housing shell having an upper inner housing and a lower inner housing extending from the upper inner housing; and

at least one of a motor disposed in the inner housing shell or a drive shaft disposed in the inner housing shell, wherein the instrument module is configured to be selectively received within the cavity of the outer housing shell through the opening of the outer housing shell such that the upper inner housing of the inner housing shell is positioned in the upper outer housing of the outer housing shell and the lower inner housing of the inner housing shell is positioned in the lower outer housing of the outer housing shell.

17. The surgical instrument according to claim 16, wherein the motor is disposed within the upper inner housing of the inner shell housing.

18. The surgical instrument according to claim 16, wherein the drive shaft is disposed within the upper inner housing of the inner shell housing.

19. The surgical instrument according to claim 16, wherein the motor defines an operative axis that is substantially parallel to a longitudinal axis defined by the upper outer housing.

20. The surgical instrument according to claim 16, wherein the drive shaft is configured to extend through an opening formed in a distal surface of the outer housing shell.