Hand-held surgical instrument

Abstract

A handheld surgical instrument includes a handle housing, a shaft portion extending distally from the handle housing, and an articulating shaft. The articulating shaft can be configured to move axially within the shaft portion to articulate an end effector via manual activation or motor activation.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims the benefit of and priority to U.S. Provisional Application No. 62 / 948,870, filed December 17, 2019, the entire contents of which are incorporated herein by reference. TECHNICAL FIELD

[0003] The present disclosure relates to a surgical instrument. More particularly, the present disclosure relates to a hand-held electromechanical surgical instrument that articulates, rotates, and actuates a variety of other functions of a surgical attachment, such as an end effector configured to staple tissue. BACKGROUND

[0004] Electromechanical surgical instruments include a reusable handle assembly and a disposable loading unit and / or a single use loading unit, such as a surgical end effector. The end effector is selectively connected to the handle assembly prior to use and then disconnected from the handle assembly after use so that it can be disposed of or, in some cases, sterilized for reuse. Some surgical instruments can be capable of articulating the end effector during a surgical procedure to adjust the angle of orientation of the end effector. Within the handle assembly are one or more drive mechanisms for effecting articulation of the end effector and / or operational functions of the end effector. SUMMARY

[0005] In one aspect of the disclosure, a hand-held surgical instrument is provided and includes a handle housing, a shaft portion extending distally relative to the handle housing, a first motor disposed within the handle housing, a ball screw operably coupled to the first motor, a ball nut supported in a non-rotating manner in the shaft portion and operably coupled to the ball screw, and a firing shaft. The firing shaft has a proximal portion attached to the ball nut and a distal portion configured to fire a staple from an end effector. The ball nut is configured to translate the firing shaft along a longitudinal axis defined by the shaft portion in response to rotation of the ball screw.

[0006] In aspects, the hand-held surgical instrument can further include a battery configured to power the first motor. In aspects, the battery can be configured to power all of the motors, LEDs, and various other electronics.

[0007] In certain aspects, the handle housing can have a sleeve portion and a handle portion extending perpendicularly from the sleeve portion. The battery can be supported in the handle portion. In aspects, the battery can be supported in the sleeve portion.

[0008] In other aspects, the handle portion can include an upper segment fixed to the sleeve portion and a lower segment pivotably coupled to the upper segment, the battery disposed in the lower segment.

[0009] In other aspects, the handle portion can define a plane that extends parallel to a longitudinal axis of the shaft portion. The lower section can be configured to pivot relative to the upper section about a pivot axis that is parallel to the plane.

[0010] In aspects, the handheld surgical instrument can further include a printed circuit board supported in the upper section and configured to be in electrical communication with the battery and the first motor. In aspects, the printed circuit board can be in electrical communication with the motion control circuit.

[0011] In certain aspects, the handheld surgical instrument can further include a finger switch pivotably coupled to the upper section. The finger switch can have an upper button and a lower button that are each in communication with the printed circuit board for activating the battery. In aspects, the finger switch can activate the battery and control the first motor.

[0012] In other aspects, the handheld surgical instrument can further include a knob housing coupled to the handle housing, an articulation bar, and a first articulation shaft. The shaft portion can extend distally from the knob housing. The articulation bar can be rotatably coupled to the knob housing. The first articulation shaft can be operably coupled to the articulation bar such that rotation of the articulation bar translates the first articulation shaft to articulate the end effector.

[0013] In other aspects, the handheld surgical instrument can further include a cam plate coupling the articulation bar with a proximal end portion of the first articulation shaft. The cam plate can be configured to urge the first articulation shaft in one of a proximal or distal direction upon rotation of the cam plate.

[0014] In aspects, the handheld surgical instrument can further include an articulation lock assembly including a first ratchet gear operably coupled to the cam plate and a pawl engaged with the first ratchet gear. The pawl can be configured to limit rotation of the cam plate.

[0015] In certain aspects, the first ratchet gear can be non-rotatably coupled to the articulation bar and fixed to the cam plate such that rotation of the articulation bar rotates the cam plate.

[0016] In other aspects, the cam plate can have a pin extending through an elongated slot defined in the first ratchet gear. The first ratchet gear can be configured to rotate the cam plate after a delay.

[0017] In other aspects, the articulation lock assembly can include a second ratchet gear disposed between the first ratchet gear and the cam plate. The pawl can be engaged with the first and second ratchet gears.

[0018] In aspects, the first ratchet gear can have a plurality of teeth each defining a sloped surface and the second ratchet gear can have a plurality of teeth each defining a linear surface.

[0019] In certain aspects, adjacent teeth of the plurality of teeth of the first ratchet gear can define a triangular space therebetween, and adjacent teeth of the plurality of teeth of the second ratchet gear can define a rectangular space therebetween.

[0020] In other aspects, the second ratchet gear can be fixed to the cam plate such that the cam plate and the second ratchet gear rotate simultaneously with one another.

[0021] In other aspects, the cam plate can define a first helical slot, and the proximal portion of the first articulation shaft can have a protrusion received in the first helical slot.

[0022] In aspects, the handheld surgical instrument can further include a second articulation shaft having a protrusion extending from a proximal portion thereof. The protrusion of the second articulation shaft can be received in a second helical slot defined in the cam plate. The first and second articulation shafts can be configured to translate in opposite directions in response to rotation of the cam plate.

[0023] According to another aspect of the disclosure, a handheld surgical instrument is provided that includes a handle housing, a knob housing coupled to the handle housing, a shaft portion extending distally from the knob housing, an articulation bar rotatably coupled to the knob housing, a first articulation shaft, a cam plate, and an articulation lock assembly. The first articulation shaft is operably coupled to the articulation bar such that rotation of the articulation bar translates the first articulation shaft to articulate an end effector. The cam plate couples the articulation bar with a proximal portion of the first articulation shaft. The cam plate is configured to urge the first articulation shaft in one of a proximal or distal direction. The articulation lock assembly includes a first ratchet gear operably coupled to the cam plate, and a pawl engaged with the first ratchet gear. The pawl can be configured to limit rotation of the cam plate.

[0024] In certain aspects, the cam plate can have a pin extending through an elongated slot defined in the first ratchet gear. The first ratchet gear can be configured to rotate the cam plate after a delay.

[0025] In other aspects, the articulation lock assembly can include a second ratchet gear disposed between the first ratchet gear and the cam plate. The pawl can be engaged with the first and second ratchet gears.

[0026] In other aspects, the first ratchet gear can have a plurality of teeth each defining a sloped surface, and the second ratchet gear can have a plurality of teeth each defining a linear surface.

[0027] In aspects, adjacent teeth of the plurality of teeth of the first ratchet gear can define a triangular space therebetween, and adjacent teeth of the plurality of teeth of the second ratchet gear can define a rectangular space therebetween.

[0028] In certain aspects, the second ratchet gear can be fixed to the cam plate such that the cam plate and the second ratchet gear rotate simultaneously with one another.

[0029] In other aspects, the cam plate can define a first helical slot, and the proximal end portion of the first articulation shaft can have a protrusion received in the first helical slot.

[0030] In other aspects, the handheld surgical instrument can include a second articulation shaft having a protrusion extending from a proximal end portion thereof. The protrusion of the second articulation shaft can be received in a second helical slot defined in the cam plate. The first and second articulation shafts can be configured to translate in opposite directions in response to rotation of the cam plate.

[0031] According to yet another aspect of the disclosure, a shaft assembly for use with a handle assembly of a handheld surgical instrument is provided. The shaft assembly includes a knob housing, a shaft portion extending distally from the knob housing, an end effector coupled to a distal end portion of the shaft portion, an articulation bar rotatably coupled to the knob housing, a first articulation shaft, and a cam plate. The first articulation shaft is operably coupled to the articulation bar such that rotation of the articulation bar translates the first articulation shaft to articulate the end effector. The cam plate couples the articulation bar with a proximal end portion of the first articulation shaft. The cam plate is configured to urge the first articulation shaft in one of a proximal or distal direction in response to rotation of the cam plate.

[0032] In aspects, the shaft assembly can further include an articulation lock assembly including a first ratchet gear operably coupled to the cam plate and a pawl engaged with the first ratchet gear. The pawl can be configured to limit rotation of the cam plate.

[0033] In certain aspects, the first ratchet gear can be non-rotatably coupled to the articulation bar and fixed to the cam plate such that rotation of the articulation bar rotates the cam plate.

[0034] In other aspects, the cam plate can have a pin extending through an elongated slot defined in the first ratchet gear. The first ratchet gear can be configured to rotate the cam plate after a delay.

[0035] In other aspects, the articulation lock assembly can include a second ratchet gear disposed between the first ratchet gear and the cam plate. The pawl can be engaged with the first and second ratchet gears.

[0036] In aspects, the first ratchet gear can have a plurality of teeth each defining a sloped surface, and the second ratchet gear can have a plurality of teeth each defining a linear surface.

[0037] In certain aspects, adjacent teeth of the plurality of teeth of the first ratchet gear can define a triangular space therebetween, and adjacent teeth of the plurality of teeth of the second ratchet gear can define a rectangular space therebetween.

[0038] In other aspects, the second ratchet gear can be fixed to the cam plate such that the cam plate and the second ratchet gear rotate simultaneously with each other.

[0039] According to yet another aspect of the disclosure, a handheld surgical instrument is provided that includes a handle housing, a shaft portion extending distally relative to the handle housing, a first articulation shaft supported in the shaft portion, a sleeve cam, and an articulation motor. The first articulation shaft has a distal portion configured to operably engage an end effector. The sleeve cam is coupled to a proximal portion of the first articulation shaft. The articulation motor can be operably coupled to the sleeve cam and configured to rotate the sleeve cam. Rotation of the sleeve cam translates the first articulation shaft.

[0040] In aspects, the handheld surgical instrument can further include a knob housing coupled to the handle housing. The knob housing can have a shaft portion extending distally therefrom. Manual rotation of the knob housing can rotate the shaft portion and an attached end effector.

[0041] In certain aspects, the sleeve cam can have an inner annular surface defining a helical cam slot. The proximal portion of the first articulation shaft can have a protrusion received in the helical cam slot.

[0042] In other aspects, the handheld surgical instrument can further include a gear ring non-rotatably coupled to the sleeve cam. The articulation motor can have a motor gear operably coupled to the gear ring such that rotation of the motor gear causes rotation of the sleeve cam.

[0043] As used herein, the terms "parallel" and "perpendicular" are to be understood to encompass relative configurations that are substantially parallel and substantially perpendicular to within about + or - 10 degrees of true parallel and true perpendicular. BRIEF DESCRIPTION OF DRAWINGS

[0044] Embodiments of the disclosure are described herein with reference to the accompanying drawings, of which:

[0045] Figure 1 is a perspective view of a handheld electromechanical surgical instrument according to embodiments of the disclosure, the handheld electromechanical surgical instrument including a handle assembly, a shaft portion coupled to the handle assembly, and a surgical end effector coupled to the shaft portion;

[0046] Figure 2 is Figure 1 is an enlarged side view of the surgical instrument with half of the handle housing removed;

[0047] Figure 3 is a rear perspective view of the handle portion of the surgical instrument shown in an open state to remove the battery;

[0048] Figure 4 is a cross-sectional view taken along Figure 3 4-4 ofFigure 3 side cross-sectional view of the handle portion of

[0049] Figure 5 is a longitudinal cross-sectional view taken along Figure 1 5-5 of the drive motor and ball screw assembly for operating the suturing function of the end effector of

[0050] Figure 6 is a perspective view of the ball nut of the ball screw assembly of Figure 5

[0051] Figure 7 is a side perspective view of the shaft assembly of the surgical instrument of Figure 1

[0052] Figure 8 is a perspective view of components of the articulation assembly of the shaft assembly of Figure 7

[0053] Figure 9 is a magnified perspective view of the detail area indicated by Figure 8 Figure 8 the first and second articulation shafts of the articulation assembly of

[0054] Figure 10 is a perspective view of the cam mechanism of the articulation assembly of Figure 8

[0055] Figure 11 is a perspective view of the articulation lock assembly of the shaft assembly of Figure 7

[0056] Figure 12 is a top view of the articulation lock assembly of Figure 11

[0057] Figure 13 is a side view showing another embodiment of a hand-held electromechanical surgical instrument including a handle assembly, a shaft portion coupled to the handle assembly, and a surgical end effector coupled to the shaft portion; and

[0058] Figure 14 is a perspective view of components of the articulation assembly of the surgical instrument of Figure 13 DETAILED DESCRIPTION

[0059] ​​​​​​​​Embodiments of the surgical instrument presently disclosed are described in detail with reference to the drawings, wherein like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term "distal" refers to the portion of the surgical instrument or components thereof that is further from the user, while the term "proximal" refers to the portion of the surgical instrument or components thereof that is closer to the user.

[0060] Reference Figure 1 and Figure 2 A surgical instrument according to embodiments of the present disclosure is generally designated 10 and is in the form of an electrically powered hand-held electromechanical surgical instrument configured to selectively couple a plurality of different surgical end effectors (e.g., surgical end effector 20) thereto. The end effector 20 is configured to be actuated and manipulated by the electrically powered hand-held electromechanical surgical instrument 10.

[0061] The hand-held electromechanical surgical instrument 10 includes a handle assembly 12 and a shaft portion 14 extending distally from the handle assembly 12. The shaft portion 14 is configured to be selectively connected with a surgical attachment (e.g., end effector 20). The handle assembly 12 has a firing switch 16 configured to actuate various functions of the end effector 20. In addition, the handle assembly 12 has a safety switch 18 for preventing accidental actuation of the firing switch 16. A knob housing 22 is rotationally coupled to the handle assembly 12 and is configured to be manually rotated about a longitudinal axis "X" defined by the shaft portion 14 to rotate the end effector 20. An articulation bar 24 is rotationally coupled to the knob housing 22 and is configured to articulate the end effector 20 (e.g., to move the end effector 200 along a horizontal plane between a position coaxial with the shaft portion 14 and a plurality of positions misaligned with the shaft portion 14. The angular orientation of the longitudinal axis of the articulation bar relative to the longitudinal axis "X" corresponds to the angular orientation of the longitudinal axis of the end effector 20 relative to the longitudinal axis "X". Thus, the end effector 20 can be articulated in the same direction and over the same angular range as the articulation bar 24.

[0062] Reference Figures 2 to 4The handle assembly 12 includes a handle housing 26 that is comprised of a sleeve portion 28 that is substantially aligned with the longitudinal axis "X" and a handle portion 30 that extends perpendicularly downward from the sleeve portion 28. The handle portion 30 includes an upper section 32 that is fixed to and extends downward from the sleeve portion 28 and a lower section 34 that is pivotably coupled to the upper section 32. The handle assembly 12 includes a printed circuit board 36 that is supported in the upper section 32 and a battery 38 that is disposed in the lower section 34. The printed circuit board 36 is configured to be in electrical communication with the battery 38 and a drive motor 40. The motor 40 can be wirelessly connected, connected via wires, or otherwise electrically connected to the printed circuit board 36 and the battery 38. The firing switch 16 can be a finger switch that is pivotably coupled to the upper section 32 and has upper and lower buttons 16a, 16b, respectively, in communication with the printed circuit board 36 for activating the battery 38 to ultimately actuate the opening / closing and staple firing functions of the end effector 20.

[0063] As shown in Figure 3 and Figure 4 , the upper section 32 of the handle portion 30 has a flange 42, e.g., tab, extending downward therefrom and the lower section 34 defines a cutout 44 that is configured to receive the flange 42. An inner surface of the flange 42 has a deflectable locking hook 46 at its distal end and the lower section 34 includes a release button 48 having a tab 50 that extends into the cutout 44. The tab 50 of the release button 48 defines a notch 52 that is configured to selectively receive and lock the locking hook 46 of the upper section 32. In certain aspects, the upper and lower sections 32, 34 are detachably couplable to one another via any suitable fastening connection, e.g., a bayonet type connection. The upper and lower sections 32, 34 are pivotably coupled to one another about a hinge 54, e.g., pivot pin. The handle portion 30 defines a plane that extends parallel to the central longitudinal axis "X" of the shaft portion 14 such that the lower section 34 is pivotable relative to the upper section 32 about a pivot axis "Y" that is parallel to the plane Figure 2 .

[0064] With reference to Figure 5 and Figure 6 , the surgical instrument 10 further includes a ball screw assembly 56 that is operably coupled to the motor 40 to effect the end effector 20 Figure 1) opening / closing and suturing functions. The ball screw assembly 56 includes a ball nut 58, a ball screw 60, and a firing shaft 62. The ball screw 60 is drivingly coupled to the motor 40 such that actuation of the motor 40 causes rotation of the ball screw 60. The ball nut 58 is non-rotatably supported in the shaft portion 14 and is operably coupled to the ball screw 60. Specifically, the ball nut 58 can have first and second planar lateral sides 58a, 58b that inhibit rotation of the ball nut 58 relative to the shaft portion 14, and the ball nut 58 has an inner surface that defines threads 64 that accommodate bearings (not shown). The bearings are located between the threads 64 of the ball nut 58 and a threaded outer surface of the ball screw 60.

[0065] The firing shaft 62 defines a conduit 66 through a proximal end portion 62a thereof. The ball screw 60 extends through the conduit 66 and the proximal end portion 62a is fixed to the ball nut 58. In this manner, as the ball nut 58 moves axially within the shaft portion 14 and relative to the ball screw 60, the firing shaft 62 moves with the ball nut 58. The firing shaft 62 has a distal end portion 62b that is configured to be operably coupled to an axial drive member (not shown) of the end effector 20. The ball nut 58 has a cap or cover 68 for accommodating ball bearings therein.

[0066] Figures 7 to 10 A shaft assembly 70 of the surgical instrument 10 is shown. The shaft assembly 70 includes the knob housing 22, the shaft portion 14, and the end effector 20. The knob housing 22 supports an articulation assembly 72 that is configured to effect articulation of the end effector 20 relative to the shaft portion 14. An articulation lever 24 of the articulation assembly 72 is accessible from an exterior of the knob housing 22 and is configured to be manually rotated.

[0067] The articulation assembly 72 generally includes first and second articulation shafts 74, 76 and a cam plate 82. The first and second articulation shafts 74, 76 are axially movable within the shaft portion 14 and each has a proximal end portion 74a, 76a that is operably coupled to the articulation lever 22 and a distal end portion (not explicitly shown) that is operably coupled to opposite sides of the end effector 20. Accordingly, rotation of the articulation lever 22 causes the first and second articulation shafts 74, 76 to translate in opposite directions to articulate the end effector 20. The proximal end portions 74a, 76a of each of the articulation shafts 74, 76 have respective protrusions 78, 80. The cam plate 82 defines first and second helical slots 82a, 82b for receiving the respective protrusions 78, 80. The helical cam slots 82a, 82b are oriented such that rotation of the cam plate 82 causes the first and second articulation shafts 74, 76 to move axially in opposite directions. A helical coil 84 can be attached to a proximal end portion of the shaft portion 14 for guiding thereabout from the motor 40 Figure 5) extending cable (not shown). The helical coil 84 rotates with rotation of the shaft portion 14 and prevents cable binding and eliminates the need for an electrical slip ring.

[0068] Figure 11 and Figure 12 A hinge locking assembly 88 is shown for selectively locking the hinge rod 22 in a rotated position to prevent backdriving of the hinge rod 22. The hinge locking assembly 88 generally includes a ratchet assembly 90 operably coupled the cam plate 82 and the hinge rod 22, and a pawl 92 engaged with the ratchet assembly 90 and configured to limit rotation of the cam plate 82. The pawl 92 has a proximal portion 92a slidably supported on the helical coil 84 and a free distal portion 92b having an elongated distal tip 94. The pawl 92 is slidable along a longitudinal axis defined by the pawl 92. A pawl spring 96 is provided to resiliently bias the distal tip 94 of the pawl 92 in a distal direction. In aspects, the pawl 92 can be elastic or rigid. Figure 10 ) to resiliently bias the distal tip 94 of the pawl 92 in a distal direction. In aspects, the pawl 92 can be elastic or rigid.

[0069] The ratchet assembly 90 includes a first ratchet gear 98 and a second ratchet gear 100. The first ratchet gear 98 has a plate 102 and a stem 104 extending from the plate 102. The stem 104 is received in a correspondingly shaped aperture (not explicitly shown) defined in the hinge rod 22 to non-rotatably couple the first ratchet gear 98 to the hinge rod 22. The plate 102 of the first ratchet gear 98 has a plurality of teeth 106 arranged about an outer periphery of the first ratchet gear 98. Each of the teeth 106 defines a sloped surface 108 such that adjacent teeth 106 define a triangular space 110 therebetween that is configured to selectively receive the free distal tip 94 of the pawl 92.

[0070] The plate 102 of the first ratchet gear 98 is coupled to the cam plate 82 such that rotation of the hinge rod 22 imparts rotation of the cam plate 82. For example, the cam plate 82 has a pair of pins 112, 114 that extend through respective elongated slots 116, 118 defined in the first ratchet gear 98. The elongated slots 116, 118 define a length that is approximately 1.5 times a diameter of the pins 112, 114 of the cam plate 82. In this manner, rotation of the first ratchet gear 98 in response to rotation of the hinge rod 22 causes rotation of the cam plate 82 after a delay.

[0071] A second ratchet gear 100 is disposed between the plate 102 of the first ratchet gear 98 and the cam plate 82. The second ratchet gear 100 is fixed to the cam plate 82 (e.g., via pins 112, 114) such that the cam plate 82 and the second ratchet gear 100 rotate simultaneously with one another. The second ratchet gear 100 has a plurality of teeth 120 disposed about its outer periphery. The teeth 120 of the second ratchet gear 100 each define a linear surface 122 such that adjacent teeth 120 of the second ratchet gear 100 define a rectangular space 124 therebetween that is configured to selectively receive the distal tip 94 of the pawl 92. The distal tip 94 of the pawl 92 can be configured to wedge into the space 124 to resist rotation of the second ratchet gear 100 relative to the pawl 92.

[0072] The first and second ratchet gears 98, 100 are angularly oriented relative to one another such that the triangular spaces 110 of the first ratchet gear 98 overlap the respective rectangular spaces 124 of the second ratchet gear 100. In aspects, the spaces 110 of the first ratchet gear 98 can take the same shape as the spaces 124 of the second ratchet gear 100, and / or the spaces 110, 124 can take any suitable shape, such as an arcuate shape.

[0073] In operation, to articulate the end effector 20, the articulation lever 22 can be manually rotated in a direction intended for articulation of the end effector 20. Rotation of the articulation lever 22 imparts rotation of the first ratchet gear 98, whereby one of the angled surfaces 108 of the teeth 106 of the first ratchet gear 98 proximally protrudes the free distal tip 94 of the pawl 92 and disengages the space 110 between the teeth 106 of the first ratchet gear 98 and the space 124 between the teeth 120 of the second ratchet gear 100. The teeth 106 of the first ratchet gear 98 rotate into overlapping alignment with the space 124 defined between adjacent teeth 120 of the second ratchet gear 100, whereby the first ratchet gear 98 engages the pins 112, 114 of the cam plate 82 to drive rotation of the cam plate 82. As described, rotation of the cam plate 82 translates the first and second articulation shafts 74, 76 in opposite directions. Opposed translation of the first and second articulation shafts 74, 76 drives articulation of the end effector 20.

[0074] Since the second ratchet gear 100 is fixed to the cam plate 82, the second ratchet gear 100 rotates with the cam plate 82 to maintain the alignment of the teeth 106 of the first ratchet gear 98 with the corresponding spaces 124 of the second ratchet gear 100. In this manner, while the articulated rod 22 is being rotated, the distal tip 94 of the pawl 92 remains in the proximal position and disengaged from the spaces 110, 124 of the ratchet gears 98, 100. However, upon the removal of the application of the rotational force to the articulated rod 22, the resilient bias of the pawl 92 (due to the pawl spring 96) will project the first ratchet gear 98 to reposition the teeth 106 of the first ratchet gear 98 into alignment with the teeth 120 of the second ratchet gear 100. This is due to the selected distance of the free rotation of the first ratchet gear 98 relative to the second ratchet gear 100. Despite any counter driving force being exerted on the second ratchet gear 100 via the cam plate 82, the rotation of the second ratchet gear 100 is prevented due to the engagement of the distal tip 94 of the pawl 92 in the spaces 124 of the second ratchet gear 100. More specifically, the adjacent teeth 120 of the second ratchet gear 100 trap the distal tip 94 of the pawl 92 therebetween, thereby preventing the rotation of the second ratchet gear 100 and in turn the rotation of the cam plate 82.

[0075] Figure 13 and Figure 14 Another embodiment of a handheld surgical instrument 210 similar to the surgical instrument 10 described above is shown. The surgical instrument 210 differs in that it has a motorized articulation mechanism 220 rather than being manually actuated. Due to the similarities between the two surgical instruments, only those elements of the surgical instrument 210 that are deemed necessary to elucidate the differences from the surgical instrument 10 will be described in detail.

[0076] The surgical instrument 210 generally includes a handle housing 212, a knob housing 222 coupled to the handle housing 212, a shaft portion 214 extending distally from the knob housing 222, and an end effector, such as the end effector 20, operably coupled to a distal end portion of the shaft portion 214. An articulation switch 216 is pivotably coupled to the handle housing 212 to actuate articulation of the end effector 20. The knob housing 222 is manually rotatable to thereby rotate the shaft portion 214 and the attached end effector 20 about a longitudinal axis defined by the shaft portion 214. The shaft portion 214 has a first articulation shaft 274 and a second articulation shaft (not explicitly shown) supported therein, respectively.

[0077] The articulation mechanism 220 is at least partially received in the knob housing 222 and includes a sleeve cam 224, a sleeve cam gear 226, and an articulation motor 228. The sleeve cam 224 is comprised of first and second semicircular half sections 224a, 224b that collectively form a tubular sleeve cam 224. The sleeve cam 224 is received in and secured to the sleeve cam gear 226. In certain aspects, the sleeve cam 224 can be integrally formed with the sleeve cam gear 226. Each of the first and second semicircular half sections 224a, 224b of the sleeve cam 224 defines an opposing helical cam slot 230 in an inner annular surface 232 thereof. The helical cam slots 230 receive respective protrusions extending from proximal portions of the first and second articulation shafts 274. Accordingly, rotation of the sleeve cam 224 causes the first and second articulation shafts 274 to translate axially in opposite directions.

[0078] The sleeve cam gear 226 has a tubular body 226a and a ring gear 226b secured about the tubular body 226a. The articulation motor 228 has a drive shaft 236 and a drive gear 238 non-rotatably coupled to the drive shaft 236. The drive gear 238 of the articulation motor 228 is operably coupled to the ring gear 226b to rotate the sleeve cam 224 to translate the first and second articulation shafts 274.

[0079] In operation, the articulation switch 217 can be actuated to activate the articulation motor 228 to rotate the drive gear 238. Rotation of the drive gear 238 drives the sleeve cam 224 to rotate via the ring gear 226b. Because the protrusions or pins of the articulation shafts 274 are received in the opposing helical cam slots 230 of the sleeve cam 224, rotation of the sleeve cam 224 drives the first and second articulation shafts 274 to translate axially in opposite directions to articulate the end effector 20 relative to the shaft portion 214.

[0080] It is contemplated that any of the components described herein can be made of a metal, a plastic, a resin, or a composite material, among others, in view of strength, durability, wear resistance, weight, corrosion resistance, ease of manufacturability, cost of manufacture, and the like.

[0081] It should be understood that various modifications can be made to the presently disclosed surgical instruments including switch assemblies. Therefore, the above description should not be construed as limiting, but merely as exemplification of the embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the disclosure.

Claims

1. A handheld surgical instrument comprising: a handle housing; a shaft portion extending distally relative to the handle housing; a first motor disposed within the handle housing; a ball screw operably coupled to the first motor; a ball nut non-rotatably supported in the shaft portion and operably coupled to the ball screw; a firing shaft having a proximal end portion attached to the ball nut and a distal end portion configured to fire a staple from an end effector, wherein the ball nut is configured to translate the firing shaft along a longitudinal axis defined by the shaft portion in response to rotation of the ball screw; a knob housing coupled to the handle housing, the shaft portion extending distally from the knob housing; an articulation bar rotatably coupled to the knob housing; a first articulation shaft operably coupled to the articulation bar such that rotation of the articulation bar translates the first articulation shaft to articulate an end effector; a cam plate coupling the articulation bar with a proximal end portion of the first articulation shaft, wherein the cam plate is configured to urge the first articulation shaft in one of a proximal or distal direction upon rotation of the cam plate, wherein the cam plate includes a pair of pins extending therefrom, wherein the pair of pins of the cam plate are located on opposite sides of the longitudinal axis defined by the shaft portion; and an articulation lock assembly including: a first ratchet gear operably coupled to the cam plate, the first ratchet gear defining a pair of elongated slots formed therein, wherein each pin of the pair of pins of the cam plate extends through a respective slot of the pair of elongated slots defined in the first ratchet gear; and a pawl engaged with the first ratchet gear and configured to limit the rotation of the cam plate, the first ratchet gear non-rotatably coupled to the articulation bar and to the cam plate such that rotation of the articulation bar rotates the cam plate, wherein the first ratchet gear is configured to rotate the cam plate after a delay.

2. The handheld surgical instrument of claim 1, further comprising a battery configured to power the first motor.

3. The handheld surgical instrument of claim 2, wherein the handle housing has a sleeve portion and a handle portion extending perpendicularly from the sleeve portion, the battery supported in the handle portion.

4. The handheld surgical instrument of claim 3, wherein the handle portion includes: an upper segment fixed to the sleeve portion; and a lower segment pivotably coupled to the upper segment, the battery disposed in the lower segment.

5. The handheld surgical instrument of claim 4, wherein the handle portion defines a plane extending parallel to the longitudinal axis of the shaft portion, the lower segment configured to pivot relative to the upper segment about a pivot axis parallel to the plane.

6. The handheld surgical instrument of claim 4, further comprising a printed circuit board supported in the upper segment and configured to be in electrical communication with the battery and the first motor.

7. The handheld surgical instrument of claim 6, further comprising a finger switch pivotably coupled to the upper section and having an upper button and a lower button, the upper and lower buttons each in communication with the printed circuit board to activate the battery.

8. The handheld surgical instrument of claim 1, wherein the articulation lock assembly includes a second ratchet gear disposed between the first ratchet gear and the cam plate, the pawl being engaged with the first and second ratchet gears.

9. The handheld surgical instrument of claim 8, wherein the first ratchet gear has a plurality of teeth, each tooth defining a sloped surface, and the second ratchet gear has a plurality of teeth, each tooth defining a linear surface.

10. The handheld surgical instrument of claim 9, wherein adjacent teeth of the plurality of teeth of the first ratchet gear define a triangular space therebetween, and adjacent teeth of the plurality of teeth of the second ratchet gear define a rectangular space therebetween.

11. The handheld surgical instrument of claim 8, wherein the second ratchet gear is fixed to the cam plate such that the cam plate and the second ratchet gear rotate simultaneously with one another.

12. The handheld surgical instrument of claim 1, wherein the cam plate defines a first helical slot, and the proximal portion of the first articulation shaft has a protrusion received in the first helical slot.

13. The handheld surgical instrument of claim 12, further comprising a second articulation shaft having a protrusion extending from a proximal portion thereof, the protrusion of the second articulation shaft being received in a second helical slot defined in the cam plate, the first and second articulation shafts being configured to translate in opposite directions in response to rotation of the cam plate.

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