Surgical instruments and switch assemblies thereof

• US 9,991,069 B2
• Filed: 07/24/2015
• Issued: 06/05/2018
• Est. Priority Date: 10/22/2014
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Nicholas, David, Pribanic, Russell
• Primary Examiner(s): Weeks, Gloria R
• Assistant Examiner(s): Weller, William A
• Application Number:
  US14/808,314
• Publication Number:
  US 20160118201A1
• Time in Patent Office: 1,047 Days
• Field of Search: 2271751-1801, 200 4317, 200 4318, 606 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 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• 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 2017/00371 Multiple actuation, e.g. pushing of two buttons, or two working tips becoming operational
• CPC Class Codes: A61B 2017/00389 Button or wheel for performing multiple functions, e.g. rotation of shaft and end effector
• CPC Class Codes: A61B 2017/00393 with means for switching between functions
• 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: H01H 13/14 Operating parts, e.g. push-button
• CPC Class Codes: H01H 2300/014 Application surgical instrument
• CPC Class Codes: H01H 9/26 for interlocking two or more switches H01H13/568 takes precedence; by a detachable member H01H9/28 ; for electromagnetic relays H01H50/323

Abstract

A switch assembly includes a switch housing, a first switch subassembly, and a second switch subassembly. The first switch subassembly includes a shaft and a toggle button. The shaft is disposed within the switch housing and has a proximal end portion and a distal end portion. The shaft is pivotable relative to the switch housing about at least one pivot axis to actuate at least one function of a surgical instrument. The proximal end portion of the shaft includes a magnet. The toggle button is non-rotatably connected to the distal end portion of the shaft. The second switch subassembly includes a safety bar and a post. The safety bar is axially movable within the switch housing. The post extends through the safety bar such that movement of the safety bar along a longitudinal axis thereof moves the post between a firing position and a non-firing position.

Claims

1. A switch assembly for actuating functions of a hand-held surgical instrument, comprising:

a switch housing defining a channel therethrough, the switch housing defining a first longitudinal axis;

a first switch subassembly including;

a shaft disposed within the channel of the switch housing and having a proximal end portion and a distal end portion, the proximal end portion of the shaft including a magnet, the shaft being pivotable relative to the switch housing about a first pivot axis to actuate a first function of a surgical instrument and a second pivot axis to actuate a second function of the surgical instrument; and

a toggle button non-rotatably connected to the distal end portion of the shaft; and

a second switch subassembly including;

a safety bar extending through the switch housing, transverse to the first longitudinal axis, and being axially movable therein, the safety bar defining a second longitudinal axis and having a first end and a second end; and

a post extending through the safety bar, transversely thereto, such that movement of the safety bar along the second longitudinal axis moves the post between a firing position and a non-firing position.

2. The switch assembly according to claim 1, wherein the first switch subassembly further includes:

an outer member disposed within the channel of the switch housing, the outer member being prevented from moving distally relative to the switch housing; and

an inner member non-rotatably disposed within the outer member, the shaft of the first switch subassembly extending through the outer and inner members, the outer and inner members defining a cavity therein having a substantially spherical configuration, wherein the proximal end portion of the shaft has a spherical portion disposed in the spherical cavity.

3. The switch assembly according to claim 2, wherein the first switch subassembly further includes:

a first keyed member rotatably connected to the spherical portion of the shaft; and

a second keyed member rotatably connected to the spherical portion of the shaft such that the keyed members resist rotation of the shaft about a third longitudinal axis defined by the shaft.

4. The switch assembly according to claim 2, wherein the first switch subassembly further includes:

a pivoting member having a cone-shaped proximal end in abutment with a concave face of the outer member; and

a biasing member disposed between the cone-shaped proximal end of the pivoting member and the toggle button to center the toggle button within the channel.

5. The switch assembly according to claim 1, wherein a proximal end of the post of the second switch subassembly includes a magnet configured to communicate with a hall effect sensor of a surgical instrument.

6. The switch assembly according to claim 1, further comprising a third switch subassembly including an annular switch rotatably disposed within the switch housing to actuate at least one function of a surgical instrument.

7. A handle assembly of a hand-held surgical instrument, comprising:

a handle housing;

a plurality of motors disposed within the handle housing;

a plurality of hall effect sensors disposed within the handle housing and in communication with the plurality of motors to actuate at least one of the plurality of motors; and

a switch assembly supported on the handle housing and including;

a switch housing defining a channel therethrough, the switch housing defining a first longitudinal axis;

a first switch subassembly including;

a shaft disposed within the channel of the switch housing and having a proximal end portion and a distal end portion, the proximal end portion including a magnet disposed adjacent a first hall effect sensor of the plurality of hall effect sensors, the shaft being pivotable relative to the switch housing about a first pivot axis to signal the first hall effect sensor to actuate a first function of a surgical instrument and a second pivot axis to signal a second hall effect sensor of the plurality of hall effect sensors to actuate a second function of the surgical instrument; and

a toggle button non-rotatably connected to the distal end portion of the shaft; and

a second switch subassembly including;

a safety bar extending through the switch housing, transverse to the first longitudinal axis, and being axially movable therein, the safety bar defining a second longitudinal axis and having a first end and a second end; and

a post extending through the safety bar, transversely thereto, the post having a proximal end including a magnet in communication with the second hall effect sensor such that movement of the safety bar along the second longitudinal axis moves the post between a firing position, in which a first motor of the plurality of motors is actuatable by the first switch subassembly, and a non-firing position, in which the first motor of the plurality of motors is prevented from actuation by the first switch subassembly.

8. The handle assembly according to claim 7, wherein the first switch subassembly of the switch assembly further includes:

an outer member disposed within the channel of the switch housing, the outer member being prevented from moving distally relative to the switch housing; and

an inner member non-rotatably disposed within the outer member, the shaft of the first switch subassembly extending through the outer and inner members, the outer and inner members defining a cavity therein having a substantially spherical configuration, wherein the proximal end portion of the shaft has a spherical portion disposed in the spherical cavity.

9. The handle assembly according to claim 8, wherein the first switch subassembly of the switch assembly further includes:

a first keyed member rotatably connected to the spherical portion of the shaft; and

a second keyed member rotatably connected to the spherical portion of the shaft such that the keyed members resist rotation of the shaft about a third longitudinal axis defined by the shaft.

10. The handle assembly according to claim 8, wherein the first switch subassembly of the switch assembly further includes:

a pivoting member having a cone-shaped proximal end in abutment with a concave face of the outer member; and

a biasing member disposed between the cone-shaped proximal end of the pivoting member and the toggle button to center the toggle button within the channel.

11. The handle assembly according to claim 8, wherein the switch assembly further includes a third switch subassembly including an annular switch rotatably disposed within the switch housing, the annular switch having a magnet in communication with a third hall effect sensor of the plurality of hall effect sensors to actuate a second motor of the plurality of motors.

12. The handle assembly according to claim 8, further comprising a printed circuit board disposed within the handle housing and having the plurality of hall effect sensors arranged therealong.

13. The handle assembly according to claim 12, further comprising a battery coupled to the printed circuit board and electrically coupled to the plurality of motors.

14. The handle assembly according to claim 12, further comprising a battery removably received within the handle housing and electrically coupled to the plurality of motors.

15. The handle assembly according to claim 12, further comprising an electrical cord electrically coupled to the plurality of motors.

16. The handle assembly according to claim 7, wherein the handle housing includes:

a distal half-section having the switch assembly secured thereto; and

a proximal half-section pivotably connected to the distal half section, wherein the proximal half-section has at least a portion of the plurality of motors disposed therein.

17. A hand-held surgical instrument, comprising:

a handle assembly including;

a handle housing;

a plurality of motors disposed within the handle housing;

a plurality of hall effect sensors disposed within the handle housing and in communication with the plurality of motors to actuate at least one of the plurality of motors; and

a switch assembly supported on the handle housing and including;

a switch housing defining a channel therethrough, the switch housing defining a first longitudinal axis;

a first switch subassembly including;

a shaft disposed within the channel of the switch housing and having a proximal end portion and a distal end portion, the proximal end portion including a magnet disposed adjacent a first hall effect sensor of the plurality of hall effect sensors, the shaft being pivotable relative to the switch housing about a first pivot axis to signal the first hall effect sensor and a second pivot axis to signal a second hall effect sensor of the plurality of hall effect sensors to move an end effector; and

a toggle button non-rotatably connected to the distal end portion of the shaft; and

a second switch subassembly including;

a safety bar extending through the switch housing, transverse to the first longitudinal axis, and being axially movable therein, the safety bar defining a second longitudinal axis and having a first end and a second end; and

a post extending through the safety bar, transversely thereto, the post having a proximal end including a magnet in communication with the second hall effect sensor such that movement of the safety bar along the second longitudinal axis moves the post between a firing position, in which a first motor of the plurality of motors is actuatable by the first switch subassembly, and a non-firing position, in which the first motor is prevented from being actuated by the first switch subassembly; and

an adapter assembly including;

a proximal end having a plurality of rotatable shafts configured to be coupled to and driven by respective motors of the plurality of motors of the handle assembly; and

a distal end configured to be operatively coupled to the end effector.

18. The surgical instrument according to claim 17, wherein the first switch subassembly of the switch assembly further includes:

an outer member disposed within the channel of the switch housing, the outer member being prevented from moving distally relative to the switch housing; and

an inner member non-rotatably disposed within the outer member, the shaft of the first switch subassembly extending through the outer and inner members, the outer and inner members defining a cavity therein having a substantially spherical configuration, wherein the proximal end portion of the second switch subassembly has a spherical portion disposed in the spherical cavity.

19. The surgical instrument according to claim 18, wherein the first switch subassembly of the switch assembly further includes:

a first keyed member rotatably connected to the spherical portion of the shaft; and

a second keyed member rotatably connected to the spherical portion of the shaft such that the keyed members resist rotation of the shaft about a third longitudinal axis defined by the shaft.

20. The surgical instrument according to claim 18, wherein the first switch subassembly of the switch assembly further includes:

a pivoting member having a cone-shaped proximal end in abutment with a concave face of the outer member; and

a biasing member disposed between the cone-shaped proximal end of the pivoting member and the toggle button to center the toggle button within the channel.

21. The surgical instrument according to claim 17, wherein the switch assembly further includes a third switch subassembly including an annular switch rotatably disposed within the switch housing, the annular switch having a magnet in communication with a third hall effect sensor of the plurality of hall effect sensors to actuate a second motor of the plurality of motors.

22. The surgical instrument according to claim 17, further comprising a printed circuit board disposed within the handle housing and having the plurality of hall effect sensors arranged therealong.

23. A switch assembly for actuating functions of a hand-held surgical instrument, comprising:

a switch housing defining a channel therethrough, the switch housing defining a first longitudinal axis;

a first switch subassembly including;

a shaft disposed within the channel of the switch housing and having a proximal end portion and a distal end portion, the shaft being pivotable relative to the switch housing about at least one pivot axis to actuate at least one function of a surgical instrument, the proximal end portion of the shaft including a magnet;

a toggle button non-rotatably connected to the distal end portion of the shaft;

an outer member disposed within the channel of the switch housing, the outer member being prevented from moving distally relative to the switch housing; and

an inner member non-rotatably disposed within the outer member, the shaft of the first switch subassembly extending through the outer and inner members, the outer and inner members defining a cavity therein having a substantially spherical configuration, wherein the proximal end portion of the shaft has a spherical portion disposed in the spherical cavity; and

a second switch subassembly including;

a safety bar extending through the switch housing, transverse to the first longitudinal axis, and being axially movable therein, the safety bar defining a second longitudinal axis and having a first end and a second end; and

a post extending through the safety bar, transversely thereto, such that movement of the safety bar along the second longitudinal axis moves the post between a firing position and a non-firing position.