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

• US 9,987,029 B2
• Filed: 02/28/2017
• Issued: 06/05/2018
• 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
• Application Number:
  US15/445,500
• Publication Number:
  US 20170164966A1
• Time in Patent Office: 462 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 surgical instrument, comprising:

an outer housing shell defining a cavity and including;

an upper outer housing portion defining a longitudinal axis; and

a lower outer housing portion extending from the upper outer housing portion; and

an instrument module selectively insertable into the cavity of the outer housing shell and including;

an inner housing shell defining a cavity therein; and

a drive shaft disposed within the cavity of the inner housing shell and defining an operative axis of rotation, wherein the instrument module is inserted into the cavity of the outer housing shell in such a manner that the operative axis of the drive shaft is substantially parallel to the longitudinal axis of the upper outer housing portion.

2. The surgical instrument according to claim 1, wherein the outer housing shell includes an instrument shell cover pivotably connected to one of the upper or lower outer housing portions, the instrument shell cover being configured to pivot between:

a first position, in which the instrument shell cover engages both the upper and lower outer housing portions to cover the cavity of the outer housing shell; and

a second position, in which the instrument module is insertable into the cavity of the outer housing shell.

3. The surgical instrument according to claim 1, further comprising an instrument shell cover removably coupled to the upper and lower outer housing portions.

4. The surgical instrument according to claim 1, wherein the instrument module further includes:

a motor disposed within the cavity of the inner housing shell and operatively coupled to the drive shaft;

a control board disposed within the cavity of the inner housing shell and being in electrical communication with the motor; and

an energy source disposed within the cavity of the inner housing shell and being in electrical communication with the motor and the control board.

5. The surgical instrument according to claim 1, wherein the outer housing shell is at least partially translucent.

6. The surgical instrument according to claim 1, wherein the outer housing shell is at least partially transparent.

7. The surgical instrument according to claim 1, wherein the upper outer housing portion includes at least one viewing window.

8. The surgical instrument according to claim 7, wherein the instrument module further includes a display screen coupled to the inner housing shell and having at least one of numerical indicators or color indicators.

9. The surgical instrument according to claim 1, wherein the outer housing shell defines at least one opening formed in a distal surface thereof, the at least one opening being configured to receive the drive shaft upon the instrument module being fully disposed in the outer housing shell.

10. The surgical instrument according to claim 9, wherein a seal is supported in the at least one opening of the outer housing shell, the seal forming a fluid-tight seal between the outer housing shell and the drive shaft.

11. The surgical instrument according to claim 1, wherein the outer housing shell has a proximally-oriented face that defines an opening formed in a proximal end of the upper outer housing portion and a proximal end of the lower outer housing portion.

12. A method of assembling a surgical instrument, comprising:

providing an outer housing shell defining a cavity and including;

an upper outer housing portion defining a longitudinal axis; and

a lower outer housing portion extending from the upper outer housing portion;

providing an instrument module including;

an inner housing shell defining a cavity therein; and

a drive shaft disposed within the cavity of the inner housing shell and defining an operative axis of rotation; and

inserting the instrument module into the cavity of the outer housing shell while the operative axis defined by the drive shaft of the instrument module is substantially parallel to the longitudinal axis of the upper outer housing portion.

13. The method according to claim 12, wherein inserting the instrument module into the cavity of the outer housing shell includes passing the instrument module through the upper outer housing portion and the lower outer housing portion.

14. The method according to claim 12, further comprising rotating an instrument shell cover relative to the lower outer housing portion after the instrument module is inserted into the cavity of the outer housing shell.

15. The method according to claim 12, further comprising passing the drive shaft of the instrument module through an opening formed in a distal surface of the outer housing shell.

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

17. The method according to claim 12, further comprising engaging an instrument shell cover with a proximally-oriented face of the outer housing shell thereby covering the cavity of the outer housing shell and enclosing the instrument module within the cavity of the outer housing shell.

18. The method according to claim 12, further comprising sterilizing an outer surface of the outer housing shell.