End-effector force measurement using digital drive circuits

Abstract

The surgical device includes a handle assembly having a controller and an adapter assembly, the adapter assembly including a tubular housing having a proximal end portion configured to be coupled to the handle assembly, and a distal end portion. The adapter assembly also includes a load sensing assembly arranged with the tubular housing. The load sensing assembly is configured to measure a load applied to the tubular housing and includes: a sensor body having a recess defined therein; a load sensor circuit disposed in the recess and coupled to the sensor body; and a signal processing circuit disposed within the recess and electrically coupled to the load sensor circuit. The load sensing assembly also includes a cover disposed above the recess and enclosing the load sensor circuit and the signal processing circuit therein, the cover being coupled to the sensor body to form a first airtight seal therebetween. The surgical device also includes a surgical end effector configured to be coupled to the distal end portion of the adapter assembly.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62 / 801,979, filed on February 6, 2019, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The present disclosure relates to surgical devices. More particularly, the present disclosure relates to a handheld electromechanical surgical system for performing surgical procedures having reusable components with load sensing devices. Background Art

[0004] One type of surgical device is a circular clamping, cutting and stapling device. Such devices can be used in surgical procedures to reattach a previously transected rectal portion or similar procedures. Conventional circular clamping, cutting and stapling devices include a pistol or linear grip-type structure having an elongated shaft extending therefrom and a staple cartridge supported on the distal end of the elongated shaft. In this case, the doctor can insert the loading unit portion of the circular stapling device into the patient's rectum and manipulate the device upward toward the transected rectal portion along the patient's colon tract. The loading unit includes a cartridge assembly with a plurality of staples. Along the proximal portion of the transected colon, the anvil assembly can be tucked in therein. Alternatively, if necessary, the anvil portion can be inserted into the colon through an incision adjacent to the transected colon. The anvil and cartridge assembly approach each other, and the staples are ejected from the cartridge assembly toward the anvil assembly to form staples in the tissue to achieve end-to-end anastomosis, and the annular knife is activated to core a portion of the clamped tissue portion. After an end-to-end anastomosis has been achieved, the circular stapling device is removed from the surgical site.

[0005] Many surgical device manufacturers have also developed proprietary powered drive systems for operating and / or manipulating end effectors.The powered drive system may include a reusable powered handle assembly and a disposable end effector removably connected to the powered handle assembly.

[0006] Many existing end effectors for use with existing powered surgical devices and / or handle assemblies are driven by a linear drive force. For example, end effectors used to perform internal gastrointestinal anastomosis procedures, end-to-end anastomosis procedures, and transverse anastomosis procedures are actuated by a linear drive force. As such, these end effectors are incompatible with surgical devices and / or handle assemblies that use rotational motion.

[0007] In order to make a linearly driven end effector compatible with a powered surgical device that uses rotary motion to deliver power, an adapter is required to interconnect the linearly driven end effector with the powered rotary driven surgical device. These adapters can also be reused and therefore need to be able to withstand multiple sterilization cycles.

[0008] As these adapters become more complex and include various electronic components, there is a need for the electronic components disposed within the adapter to be able to withstand multiple autoclave cycles. Summary of the invention

[0009] Powered surgical devices may include various sensors for providing feedback during their operation. However, one limitation of electronic devices and sensors used in the sterile environment of an operating room is that they need to be designed to withstand multiple cleaning and autoclave cycles. In order to collect information about the mechanical forces applied by the powered surgical device, a load sensing device such as a load cell is disposed on one or more mechanical components of the powered surgical device and / or an adapter coupled thereto.

[0010] The load sensing device is also coupled to a signal processing and conditioning circuit that is packaged separately from the load sensing device. In particular, components of the signal processing circuit are typically arranged on a printed circuit board ("PCB") that houses other electronic and electrical components associated with the powered surgical device. The remote placement of these circuit components away from the load sensing device is due to their size and shape, which prevents the PCB from being in close proximity to the load sensing device. Therefore, these circuits are connected to the load sensing device via a wired connection that includes longer leads (e.g., more than 10 cm of flexible printed circuit traces) for transmitting analog signals from the load sensing device to the signal processing circuit. Longer wired connections result in signal loss and also increase the chance of failure due to exposure to disinfection and sterilization cycles. The harsh environment caused by the disinfection solution and the residual moisture from the autoclave process can damage the components and coatings in the flexible circuits, resulting in signal attenuation. In addition, in surgical devices that use saline flushing, the saline further damages the mechanical integrity of these circuits, resulting in signal attenuation.

[0011] In addition, the spacing between the load sensing device and the signal processing circuit also affects the fidelity of the analog sensing signal sent from the load sensing device. Analog voltage signals are low voltage signals and are therefore more susceptible to interference with the load measured by the load sensing device due to moisture ingress in the PCB, solder connections and / or traces, small contamination including solder flux and autoclave mineral deposits, and radio frequency interference caused by long conductor travel distances. Remote placement of the signal processing circuit also results in lower bit resolution. In addition, due to inconsistencies in the sensor body that houses the load sensing device (e.g., during the manufacture and assembly of the sensor), conventional signal processing circuits used with the load sensing device do not have the ability to compensate for zero balance fluctuations in the load sensing device. As used herein, the term "zero balance" refers to a baseline signal from a load sensing device corresponding to a condition in which the load sensing device is unloaded.

[0012] The present disclosure provides a combined load sensing assembly having one or more load sensing devices and a signal processing circuit disposed within the airtight housing of the sensor. This eliminates the problem of transmitting analog load sensing signals along long leads and protects the load sensing device and the signal processing circuit from exposure to the elements including sterilization cycles (e.g., autoclaving). In addition, the signal processing circuit is programmable to optimize the sensor signal by adjusting the gain and offset values ​​of the sensor signal.

[0013] Conventional load sensing devices utilizing strain gauge technology typically suffer from a lack of adjustability or adjustability of the load sensing device. In particular, variations in the load sensing device, tolerances in the sensor body, placement of the load sensing device, and other factors result in zero balance variations, which results in a variable zero balance value throughout the load sensing device. Unfortunately, in conventional load sensing devices, the zero balance cannot be adjusted for each individual load sensing device. The present disclosure provides a signal processing circuit that can be programmed to adjust the zero balance after manufacturing and / or assembling the load sensor.

[0014] According to one embodiment of the present disclosure, a surgical device is disclosed. The surgical device includes a handle assembly having a controller and an adapter assembly, the adapter assembly including a tubular housing having a proximal end portion configured to be coupled to the handle assembly, and a distal end portion. The adapter assembly also includes a load sensing assembly arranged together with the tubular housing. The load sensing assembly is configured to measure a load applied to the tubular housing, and includes: a sensor body having a recess defined therein; a load sensor circuit disposed in the recess and coupled to the sensor body; and a signal processing circuit disposed in the recess and electrically coupled to the load sensor circuit. The load sensing assembly also includes a cover, which is disposed above the recess and encloses the load sensor circuit and the signal processing circuit therein, the cover being coupled to the sensor body to form a first airtight seal therebetween. The surgical device also includes a surgical end effector, which is configured to be coupled to the distal end portion of the adapter assembly.

[0015] According to an aspect of the above embodiment, the handle assembly includes an electrical socket configured to be coupled to the electrical connector, and the controller is coupled to the electrical socket.

[0016] According to another embodiment of the present disclosure, an adapter assembly is disclosed. The adapter assembly includes a tubular housing having a proximal end portion and a distal end portion and a load sensing assembly arranged together with the tubular housing. The load sensing assembly is configured to measure a load applied to the tubular housing and includes: a sensor body having a recess defined therein; a load sensor circuit disposed in the recess and coupled to the sensor body; and a signal processing circuit disposed in the recess and electrically coupled to the load sensor circuit. The load sensing assembly also includes a cover disposed above the recess and enclosing the load sensor circuit and the signal processing circuit therein, the cover being coupled to the sensor body to form a first airtight seal therebetween.

[0017] According to one aspect of any of the above embodiments, the adapter assembly further includes an actuation assembly having a trocar member.The sensor body includes a lumen defined therethrough, and the trocar assembly is movable through the lumen.

[0018] According to another aspect of any of the above embodiments, the adapter assembly further includes at least one conductive lead coupled to a plurality of pins of the load sensing assembly; and an electrical connector disposed at the proximal end portion and connected to the at least one conductive lead.

[0019] According to another embodiment of the present invention, a load sensing assembly is disclosed. The load sensing assembly includes: a sensor body having a recess defined therein; a load sensor circuit disposed in the recess and coupled to the sensor body; and a signal processing circuit disposed within the recess and electrically coupled to the load sensor circuit. The load sensing assembly also includes a cover disposed over the recess and enclosing the load sensor circuit and the signal processing circuit therein, the cover being coupled to the sensor body to form a first airtight seal therebetween.

[0020] According to one aspect of the above embodiment, the sensor body may further include a slot defined therein, the slot being connected to the recess. The load sensing assembly may further include a header including a plurality of pins coupled to the load sensor circuit and the signal processing circuit, wherein the header is coupled to the sensor body to form a second airtight seal therebetween.

[0021] According to another aspect of the above embodiment, the load sensing assembly includes a plurality of load sensing devices.

[0022] According to another aspect of the above embodiment, the signal processing circuit may include a flexible circuit board and may be covered by a dielectric wrap. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Embodiments of the present disclosure are described herein with reference to the accompanying drawings, in which:

[0024] Figure 1 is a perspective view of a handheld surgical device, an adapter assembly, an end effector with a reload, and an anvil assembly according to an embodiment of the present disclosure;

[0025] Figure 2 The present invention is a diagram showing an embodiment of the present invention. Figure 1 A perspective view of the connection between the adapter assembly and the handle assembly;

[0026] Figure 3 is a perspective view of internal components of a handle assembly according to an embodiment of the present disclosure;

[0027] Figure 4 According to an embodiment of the present disclosure, there is no reloading member. Figure 1 A perspective view of an adapter assembly;

[0028] Figure 5 According to the embodiment of the present disclosure Figure 1 a side cross-sectional view of a reload;

[0029] Fig. 6A is a perspective view of a distal end portion of an adapter assembly according to an embodiment of the present disclosure;

[0030] Figure 6B is a cross-sectional view of a distal end portion of an adapter assembly according to an embodiment of the present disclosure;

[0031] Figure 7 According to the embodiment of the present disclosure Figure 1 A perspective view of an electrical assembly of an adapter assembly;

[0032] Figure 8 According to the embodiment of the present disclosure Figure 7 a perspective view of a distal portion of an electrical assembly;

[0033] Fig. 9 According to the embodiment of the present disclosure Figure 7 a perspective top view of a load sensing assembly of an electrical assembly;

[0034] Fig.10 yes Fig. 9 A bottom perspective view of a load sensing assembly;

[0035] Fig.11 yes Fig. 9 a cross-sectional side view of a load sensing assembly;

[0036] Fig.12 There is no cover Figure 8 A perspective top view of a load sensing assembly;

[0037] Fig.13 yes Figure 8 A perspective top view of a load sensing assembly without the load sensor circuit and the signal processing circuit;

[0038] Fig.14 According to the embodiment of the present disclosure Fig. 9 a perspective top view of a cover of a load sensing assembly;

[0039] Fig.15 yes Fig.14 A bottom perspective view of the lid;

[0040] Fig.16 is a top view schematic diagram of a load sensor circuit and a signal processing circuit according to an embodiment of the present disclosure;

[0041] Fig.17 According to the embodiment of the present disclosure Fig. 9 A cross-sectional view of a pin connector of a load sensing assembly; and

[0042] Fig.18 According to the embodiment of the present disclosure Fig.16 Electrical schematic of the signal processing circuit. DETAILED DESCRIPTION

[0043] Embodiments of the present disclosure are now described in detail with reference to the drawings, wherein in each of several views, the same reference numerals designate the same or corresponding elements. As used herein, the term "clinician" refers to a doctor, a nurse or any other medical staff and may include an auxiliary staff. Throughout this specification, the term "proximal" will refer to the part or components of the device closer to the clinician, and the term "distal" will refer to the part or components of the device further away from the clinician. In addition, in the accompanying drawings and in the following description, for the convenience of description, simply use terms such as the front, rear, upper, lower, top, bottom and similar directional terms and are not intended to limit the present disclosure. In the following description, well-known functions or structures are not described in detail to avoid obscuring the present disclosure with unnecessary details.

[0044] The present disclosure relates to powered surgical devices having electronic sensors for monitoring mechanical strain and force applied to components of the powered surgical devices. More specifically, the present disclosure relates to load measurement sensors that include a load sensing device and analog and digital circuits that are hermetically sealed such that the load sensor is configured to withstand harsh environments. In the event that an electrical connection of the powered surgical device is damaged during use, the measurement signal output by the sensor of the present disclosure remains unchanged. In addition, the sensor is programmable to allow adjustment of gain and offset values ​​in order to optimize the measurement signal.

[0045] refer to Figure 1 , powered surgical device 10 includes a handle assembly 20 configured for selective connection with an adapter assembly 30, which in turn is configured for selective connection with an end effector such as a ring reload 40. Although generally referred to as a powered surgical device, it is contemplated that surgical device 10 may be manually actuated and may include a variety of configurations.

[0046] The handle assembly 20 includes a handle housing 22 having a lower housing portion 24, an intermediate housing portion 26 extending from and / or supported on a portion of the lower housing portion 24, and an upper housing portion 28 extending from and / or supported on a portion of the intermediate housing portion 26. Figure 2 As shown, a distal portion of the upper housing portion 28 defines a nose or connecting portion 28 a that is configured to receive a proximal end portion 30 b of the adapter assembly 30 .

[0047] See also Figure 3, the handle assembly 20 includes one or more motors 36 connected to a battery 37. The handle assembly 20 also includes a main controller 38 for operating the motors 36 and other electronic components of the handle assembly 20, the adapter assembly 30, and the reload 40. The motors 36 are connected to corresponding drive shafts 39 ( Figure 2 ), the corresponding drive shaft is configured to engage the socket 33 on the proximal end portion 30b so that the rotation of the drive shaft 39 is exerted on the socket 33. Actuation assembly 52 ( Figure 6B ) is connected to the corresponding socket 33. The actuation assembly 52 is configured to convert the rotational motion of the socket 33 into linear motion and actuate the reload 40 ( Figure 1 ).

[0048] refer to Figure 4 , the adapter assembly 30 includes a tubular housing 30a extending between a proximal end portion 30b configured for operably connecting to the connecting portion 28a of the handle assembly 20 and an opposite distal end portion 30c configured for operably connecting to the reload 40. In this way, the adapter assembly 30 is configured to convert the rotational motion provided by the handle assembly 20 into an axial translation, which can be used to advance / retract the trocar member 50 slidably disposed within the distal end portion 30c of the adapter assembly 30 to activate the nail ( Figure 5 ).

[0049] refer to Figure 2 , the connection portion 28a includes an electrical socket 29 having a plurality of electrical contacts 31 that are in electrical communication with electronic components (e.g., a main controller 38) and electrical components (e.g., a battery 37) of the handle assembly 20. The adapter assembly 30 includes a corresponding electrical connector 32 configured to engage the electrical socket 29. The electrical connector 32 also includes a plurality of electrical contacts 34 that engage and are electrically connected to their corresponding electrical contacts 31.

[0050] See also Figure 4 , the trocar member 50 is slidably disposed within the tubular housing 30a of the adapter assembly 30 and extends through the distal end portion 30c thereof. In this manner, the trocar member 50 is configured for axial translation, which in turn causes the anvil assembly 58 ( Figure 1 ) to activate a nail (not shown) disposed therein. The trocar member 50 includes a proximal end that is coupled to the tubular housing 30a of the adapter assembly 30. The distal end portion of the trocar member 50 is configured to selectively engage the anvil assembly 58 ( Figure 4In this manner, when anvil assembly 58 is connected to trocar member 50, axial translation of trocar member 50 in a first direction causes opening of anvil assembly 58 relative to reload 40, and axial translation of trocar member 50 in a second, opposite direction causes closing of anvil assembly 58 relative to reload 40, as will be described in detail below.

[0051] like Figure 1 and 5 As shown, the reload 40 is configured to be operably connected to the adapter assembly 30 and is configured to start and form an annular array of surgical staples and cut off a tissue ring. The reload 40 includes a housing 42 having a proximal end portion 42a and a distal end portion 42b and a staple cartridge 44 fixedly fastened to the distal end portion 42b of the housing 42. The proximal end portion 42a of the housing 42 is configured to be selectively connected to the distal end portion 30c of the adapter assembly 30 and includes a device for ensuring that the reload 40 is radially aligned or aligned relative to the adapter assembly 30.

[0052] See also Figure 5 , the housing 42 of the reload 40 includes an outer cylindrical portion 42c and an inner cylindrical portion 42d. The outer cylindrical portion 42c and the inner cylindrical portion 42d of the reload 40 are coaxial and define a groove 46. The groove 46 of the reload 40 includes a plurality of longitudinally extending ridges or splines 48 protruding from an inner surface thereof, which is configured to be radially aligned with the anvil assembly 58 relative to the reload 40 during the stapling procedure.

[0053] 6-8 , the adapter assembly 30 includes an electrical assembly 60 disposed within the adapter assembly and configured for electrical connection with and between the handle assembly 20 and the reload 40. The electrical assembly 60 provides communication (e.g., identification data, life cycle data, system data, load sensing signals) with the main controller 38 of the handle assembly 20 through the electrical receptacle 29.

[0054] The electrical assembly 60 includes the electrical connector 32, a proximal harness assembly 62 having a ribbon cable, a distal harness assembly 64 having a ribbon cable, a load sensing assembly 66, and a distal electrical connector 67. The electrical assembly 60 also includes the distal electrical connector 67, which is configured to selectively mechanically and electrically connect to a chip assembly (not shown) of the reload 40.

[0055] The electrical connector 32 of the electrical assembly 60 is supported within the proximal end portion 30b of the adapter assembly 30. The electrical connector 32 includes electrical contacts 34 that enable electrical connection to the handle assembly 20. The proximal wiring harness assembly 62 is electrically connected to the electrical connector 32 disposed on the printed circuit board 35.

[0056] The load sensing assembly 66 is electrically connected to the electrical connector 32 via the proximal and distal wiring harness assemblies 62, 64. The load sensing assembly is also electrically connected to the distal wiring harness assembly 64 via a sensor flex cable. Fig. 6A and 6B As shown, the actuation assembly 52 coupled to the trocar member 50 extends through the load sensing assembly 66. The load sensing assembly 66 provides a measurement of the strain applied to the adapter assembly 30 during movement of the trocar member 50 when coupled to the anvil assembly 58 during clamping, stapling, cutting, and other mechanical actuations.

[0057] For a detailed description of an exemplary powered surgical stapler including an adapter assembly and a reloader, reference is made to co-owned U.S. patent application publication No. 2016 / 0310134, entitled “Handheld Electromechanical Surgical System,” filed on April 12, 2016 by Contini et al., which is incorporated by reference above.

[0058] refer to Figure 9-13 , the load sensing assembly 66 includes a sensor body 68 having a platform 70 and a tubular portion 72 extending from the platform 70. The sensor body 68 also defines an inner cavity 73 passing through the platform 70, thereby dividing the platform 70 into a first portion 74 and a second portion 76. The inner cavity 73 allows the actuation assembly 52 to pass therethrough. The sensor body 68 can be formed of any suitable material, such as stainless steel, which allows the sensor body 68 to elastically deform when stressed. In an embodiment, the sensor body 68 can be made of stainless steel, such as 17-4 stainless steel heat treated to H-900 standard.

[0059] The platform 70 also includes a top surface 78 and a bottom surface 80 ( Fig.10 ) and a first slot 82 defined within the first portion 74 of the platform 70 and a second slot 84 defined through the second portion 76 of the platform 70. The slots 82 and 84 work in conjunction with the design of the sensor body 68 to provide uniform bending when loaded. The uniform loading and resulting strain output results in a load sensor circuit 86 ( Fig.11 and 12 ) to provide a linear strain output at the first portion 74 of the platform 70, which is measured by a load sensor circuit 86, which is fixed to the first portion 74 and covered by a cover 88, as shown in FIG. Fig.11 shown.

[0060] refer to Fig. 6A and6B , load sensing assembly 66 is disposed between support block 54 and connector sleeve 56. In particular, tubular portion 72 of sensor body 68 rests on support block 54, and top surface 78 of platform 70 abuts the proximal end of connector sleeve 56. During operation of surgical device 10 (i.e., clamping, stapling, and cutting), sensor body 68 elastically deforms (similar to a support beam) in proportion to the forces applied to support block 54 and connector sleeve 56. In particular, the deflection of sensor body 68 imparts an elastic force to load sensor circuit 86 ( Fig.11 and Fig.12 ) applies force, which deforms, resulting in an increase in its resistance, which is reflected in its measurement signal. Changes in the baseline of the measurement signal indicate the forces applied to the support block 54 and the connector sleeve 56, which generally describe the forces encountered during clamping, stapling and cutting.

[0061] refer to Fig.11 , 12 16, the load sensor circuit 86 is coupled to a signal processing circuit 90, which includes a flexible circuit board 92 having a contact portion 94 and a signal processing circuit portion 96. The contact portion 94 is interconnected with the signal processing circuit portion 96 via a flexible ribbon 98 and includes a plurality of first straight-through contacts 100. The signal processing circuit 90 includes analog and digital circuit components (e.g., a controller 130) that are configured to perform signal processing on the signal from the load sensor circuit 86 and output the measurement signal to the handle assembly 20.

[0062] Flexible circuit board 92 may be any suitable dielectric multilayer flexible material, such as those available from DuPont of Wilmington, Delaware. In an embodiment, the flexible circuit board 92 may include an additional dielectric layer that stiffens the flexible circuit board 92 so that the solder connections of components positioned along the flexible circuit board 92 are not subject to undesired movement due to thermal expansion and / or mechanical movement of the load sensing assembly 66. In an embodiment, the flexible circuit board 92 may be manufactured in a flat state ( Fig.16 ) and welded to the sensor body 68 ( Fig.11 In another embodiment, a fixture with or without heat may be used to pre-bend the flexible circuit board 92 to form Fig.11 The desired shape shown in .

[0063] The contact portion 94 is configured to be coupled to the load sensor circuit 86, which includes one or more load sensing devices 102 interconnected by a plurality of traces or other conductors. In an embodiment, the load sensing device 102 may be a strain gauge, a pressure sensor (e.g., a pressure sensing membrane), or any other suitable transducer device configured to measure mechanical force and / or strain and output an electrical signal in response thereto. The signal output is achieved when the load sensing circuit 86 is coupled to the sensor body 68 so that the load sensing device 102 is located in various regions of the linear strain output when the load sensing assembly 66 is elastically deformed.

[0064] The load sensor circuit 86 can be a single circuit board, such as a flexible circuit board, with the load sensing device 102 disposed thereon and electrically interconnected via internal traces. The load sensing device 102 is also electrically coupled to the plurality of second through-contacts 101 via traces. In an embodiment, the load sensing device 102 can be attached to the first portion 74 of the platform 70 separately rather than through the load sensor circuit 86 and then wired together to provide electrical coupling.

[0065] Multiple load sensing devices 102 may be arranged on the load sensor circuit 86 in various configurations to implement temperature compensation or other resistor networks, such as a Wheatstone bridge, where two load sensing devices 102 are arranged to move in response to tension of the load sensing assembly 66 and two load sensing devices 102 are arranged to move in response to compression of the load sensing assembly 66. Fig.16 As shown, the configuration of four load sensing devices 102 can provide maximum signal output and temperature compensation and is referred to as a full bridge circuit.

[0066] refer to Fig.13 , the first portion 74 also includes a cavity 104 having a measurement surface 106 for connecting the load sensor circuit 86 and the contact portion 94 of the signal processing circuit 90. In an embodiment, the load sensor circuit 86 can be coupled to the measurement surface 106 so that the signal processing circuit 90 outputs a measurement signal in response to the sensor body 68. The cavity 104 also includes a slot 108 having a plurality of pins 110 therethrough.

[0067] like Fig.11 As shown, the slot 108 passes through the cavity 104 to the bottom surface 80. The pin 110 is connected to the bottom surface 80 through a plurality of second through-contacts 101 ( Fig.16) is electrically connected to the signal processing circuit 90. In particular, when the load sensor circuit 86 is coupled to the recess 104, the second through-contact 101 is inserted above the pin 110. Thereafter, the first through-contact 100 of the contact portion 94 is also inserted onto the pin 110. The first and second through-contacts 100 and 101 are aligned so that after the pin 110 is soldered thereto, the signal processing circuit 90 and the load sensor circuit 86 are electrically coupled to the pin 110 and to each other. In an embodiment, there may be four pins 110, two of which act as communication lines, and the remaining two pins 110 provide power for energizing the load sensor circuit 86 and the signal processing circuit 90. After soldering, the flexible circuit board 92 may be arranged to be assembled within the cover 88.

[0068] In an embodiment, the flexible circuit board 92 may be Fig.11 and 12 In other embodiments, a support structure 112 can be disposed within the recess 104. The support structure 112 includes one or more surfaces 114 to which the flexible circuit board 92 is attached. The support structure 112 can have any suitable shape so that the flexible circuit board 92 conforms to the shape of the support structure 112. The flexible circuit board 92 can be fixed to the support structure 112 in any suitable manner, for example, adhesive, fasteners, etc.

[0069] In other embodiments, a wrap 116 may be provided over the flexible circuit board 92 to insulate the electronic components of the signal processing circuit portion 96 and prevent short circuits if the flexible circuit board 92 contacts the inner surface of the cover 88. The wrap 116 may be a polyimide tape or an ionomer resin tape, such as those available from DuPont of Wilmington, Delaware. and Shrink wrap, polyisoprene films, low durometer potting compounds, parylene coatings, and other dielectric materials and applications suitable for insulating electronic circuits.

[0070] refer to Figure 10-13 , the pin 110 is fixed in the header 118, and the header 118 hermetically seals the cavity 104 at the bottom surface 80. Fig.17 As shown, each pin 110 is encapsulated in a glass sleeve 120, which is then embedded in a peripheral housing 122. Once the head 118 is bonded to the slot 108 at the bottom surface 80 of the platform, this configuration seals the interior of the cover 88 and the cavity 104 from the exterior. The head 118 may be bonded (e.g., welded) to the bottom surface 80.

[0071] A hermetic seal can be formed by passing the pins 110 through their respective glass sleeves 120, after which the pins 110 and their glass sleeves 120 are inserted into corresponding holes of the peripheral housing 122 of the head 118. The entire assembly of the pins 110, glass sleeves 120, and peripheral housing 122 is heated. Upon heating, the holes of the peripheral housing 122, which can be formed of any suitable metal (e.g., stainless steel), expand, and the glass sleeves 120 fill the void. The pins 110 formed of metal expand minimally, and upon cooling, the glass sleeves 120 provide a compression seal around their respective pins 110 and holes of the peripheral housing 122. Figure 8 As shown, the pins 110 are coupled to the flex cable 65 , which in turn is coupled to the distal harness assembly 64 .

[0072] refer to Fig.13 , the recess 104 also includes a step 124 along the entire periphery of the recess 104. The size and shape of the step 124 corresponds to the flange 126 of the cover 88, as shown in FIG. Fig.14 and 15 As shown, to allow a hermetic seal to be formed. In addition, the flange 126 is configured to fit within the step 124 and be coplanar with the step 124. This allows the flange 126 to be located on a flat surface portion of the step 124.

[0073] The cover 88 can be formed of a similar material as the sensor body 68. The cover 88 can be secured to the sensor body 68 in any suitable manner to ensure that the signal processing circuit 90 is hermetically sealed within the cover 88. In an embodiment, the cover 88 and the sensor body 68 can be formed of a metal such as stainless steel, and the cover 88 can be welded (e.g., by a laser) to the platform 70 around their respective perimeters. The cover 88 can be manufactured using a deep drawing process, which provides economical manufacturing. In an embodiment, the sensor body 68 and the cover 88 can be manufactured using any suitable means such as machining, metal injection molding, 3-D printing, etc.

[0074] refer to Fig.16 and 18 , the signal processing circuit 90 includes a controller 130 having a storage device 132, which may be an electrically erasable programmable read-only memory ("EEPROM") or any other suitable non-volatile storage device. The controller 130 may be any suitable microcontroller or any other processor, such as the ARM microcontroller available from Cambridge, England. Microcontroller. The controller 130 may include an analog-to-digital converter, a digital-to-analog converter, a timer, a clock, a watchdog timer, and other functional components that enable the controller 130 to process analog measurement signals from the load sensing device 102. In particular, the controller 130 is configured to amplify the signal of the load sensing device 102 from the load sensor circuit 86, filter the analog signal, and convert the analog signal to a digital signal. The controller 130 is also configured to transmit the digital signal to the main controller 38 of the handle assembly 20, which controls the operation of the surgical device 10 based on the digital signal indicating the sensed mechanical load.

[0075] The controller 130 is programmable to allow the gain and offset parameters for processing analog signals to be adjusted. In particular, the controller 130 stores the zero balance value and the corresponding gain and offset parameters in the storage device 132. After the load sensing assembly 66 is assembled, the load sensor circuit 86 is calibrated. In an embodiment, the load sensor circuit 86 can be periodically recalibrated to ensure accurate measurement. The calibration can be performed under zero balance, that is, when the load sensor circuit 86 is unloaded. If the load sensor circuit 86 is outputting any signal even in an unloaded state, or conversely, in response to a loaded state, not enough signal is output, the controller 130 is programmed to compensate for this difference. This is achieved by adjusting the gain and offset parameters of the controller 130, which allows the controller 130 to adjust the analog signal to correspond to the zero balance state. The controller 130 can be programmed by the main controller 38, which is connected to the controller 130 by pins 110 as described above.

[0076] It should be understood that various modifications may be made to the embodiments of the adapter assembly currently disclosed. Therefore, the above description should not be interpreted as limiting, but merely as an illustration of an embodiment. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure.

Claims

1. A load sensing assembly comprising: a sensor body including a recess and a slot defined therein, with the slot connected to the recess; a load sensor circuit disposed within the recess and coupled to the sensor body; a signal processing circuit disposed within the recess and electrically coupled to the load sensor circuit; a cover disposed over the pocket and enclosing the load sensor circuit and the signal processing circuit therein, the cover being coupled to the sensor body to form a first hermetic seal therebetween; and a header including at least one pin coupled to the load sensor circuit and the signal processing circuit, wherein the header is coupled to the sensor body to form a second hermetic seal therebetween, wherein The recess comprises a step along the entire periphery of the recess, and the size and shape of the step corresponds to the flange of the cover to allow the first airtight seal to be formed, and The sensor body has a platform including a first slot defined in a first portion of the platform and a second slot defined through a second portion of the platform to provide uniform bending when loaded.

2. The load sensing assembly of claim 1, wherein the load sensing assembly comprises at least one load sensing device.

3. The load sensing assembly of claim 1, wherein the signal processing circuit comprises a flexible circuit board.

4. The load sensing assembly of claim 3, wherein the signal processing circuit is covered by a dielectric wrap.

5. An adapter assembly, comprising: a tubular housing having a proximal end portion and a distal end portion; as well as a load sensing assembly disposed on the tubular housing, the load sensing assembly being configured to measure a load applied to the tubular housing, the load sensing assembly comprising: a sensor body including a recess and a slot defined therein, with the slot connected to the recess; a load sensor circuit disposed within the recess and coupled to the sensor body; a signal processing circuit disposed within the recess and electrically coupled to the load sensor circuit; a cover disposed over the pocket and enclosing the load sensor circuit and the signal processing circuit therein, the cover being coupled to the sensor body to form a first hermetic seal therebetween; and a header including at least one pin coupled to the load sensor circuit and the signal processing circuit, wherein the header is coupled to the sensor body to form a second hermetic seal therebetween, wherein The recess comprises a step along the entire periphery of the recess, and the size and shape of the step corresponds to the flange of the cover to allow the first airtight seal to be formed, and The sensor body has a platform including a first slot defined in a first portion of the platform and a second slot defined through a second portion of the platform to provide uniform bending when loaded.

6. An adapter assembly according to claim 5, wherein the load sensing assembly includes at least one load sensing device.

7. The adapter assembly of claim 5, wherein the signal processing circuit comprises a flexible circuit board.

8. The adapter assembly according to claim 5, further comprising: An actuation assembly includes a trocar component.

9. The adapter assembly of claim 8, wherein the sensor body includes a lumen defined therethrough and the actuation assembly is movable through the lumen.

10. The adapter assembly of claim 5, further comprising: at least one conductive lead coupled to the at least one pin; and An electrical connector is disposed at the proximal end portion and is coupled to the at least one conductive lead.

11. A surgical device comprising: a handle assembly including a controller; An adapter assembly comprising: a tubular housing having a proximal end portion and a distal end portion configured to be coupled to the handle assembly; and a load sensing assembly disposed on the tubular housing, the load sensing assembly being configured to measure a load applied to the tubular housing, the load sensing assembly comprising: a sensor body including a recess and a slot defined therein, with the slot connected to the recess; a load sensor circuit disposed within the recess and coupled to the sensor body; a signal processing circuit disposed within the recess and electrically coupled to the load sensor circuit; a cover disposed over the pocket and enclosing the load sensor circuit and the signal processing circuit therein, the cover being coupled to the sensor body to form a first hermetic seal therebetween; and a header including at least one pin coupled to the load sensor circuit and the signal processing circuit, wherein the header is coupled to the sensor body to form a second hermetic seal therebetween; and a surgical end effector configured to be coupled to the distal end portion of the adapter assembly, wherein The recess comprises a step along the entire periphery of the recess, and the size and shape of the step corresponds to the flange of the cover to allow the first airtight seal to be formed, and The sensor body has a platform including a first slot defined in a first portion of the platform and a second slot defined through a second portion of the platform to provide uniform bending when loaded.

12. The surgical device of claim 11, wherein the load sensing assembly comprises at least one load sensing device.

13. The surgical device of claim 11, wherein the signal processing circuit comprises a flexible circuit board.

14. The surgical device of claim 11, wherein the adapter assembly further comprises an actuation assembly including a trocar member, and wherein the sensor body includes a lumen defined therethrough and the actuation assembly is movable through the lumen.

15. The surgical device of claim 11, wherein the adapter assembly further comprises: at least one conductive lead coupled to the at least one pin; and An electrical connector is disposed at the proximal end portion and is coupled to the at least one conductive lead. 16 . The surgical device of claim 15 , wherein the handle assembly includes an electrical receptacle configured to couple to the electrical connector, and the controller is coupled to the electrical receptacle.

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