Surgical instrument comprising a sensor assembly

Abstract

An adapter assembly includes a knob housing, an outer tube, an end effector, an articulating link, and a sensor assembly. The end effector is movable from a first position in which the end effector is aligned with a longitudinal axis defined by the outer tube to a second position in which the end effector is disposed at an angle relative to the longitudinal axis. Longitudinal translation of the articulating link relative to the outer tube moves the end effector from its first position to its second position. The sensor assembly includes a first portion disposed in mechanical cooperation with the articulating link and a second portion at least partially disposed within the outer tube. The sensor assembly is configured to determine an actual amount of articulation of the end effector based on a distance that the articulating link is longitudinally translated relative to the outer tube.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit and priority of U.S. Provisional Patent Application No. 62 / 954,134, filed on December 27, 2019, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to surgical instruments for use with endoscopes, and more specifically, to surgical instruments comprising a connector assembly to which a surgical loading unit is articulated. Background Technology

[0004] Various types of surgical instruments for treating tissues via endoscopy are known in the art and are commonly used, for example, to close tissues or organs during transection, resection, and anastomosis, to occlude organs in thoracic and abdominal surgeries, and to fuse or seal tissues in electrosurgery.

[0005] An example of such surgical instruments is a surgical suture instrument. Typically, a surgical suture instrument includes: an end effector having an anvil assembly and a cartridge assembly for supporting an array of surgical staples; a proximity mechanism for approaching the cartridge assembly and the anvil assembly; a rotational assembly for rotating the cartridge assembly and the anvil assembly about an axis; and a firing mechanism for ejecting the surgical staples from the cartridge assembly.

[0006] During laparoscopic or endoscopic surgery, access to the surgical site is achieved through a small incision or by inserting a narrow cannula through a small incision in the patient. Because the area available for access to the surgical site is limited, many endoscopic instruments include mechanisms for hinged end-effectors relative to the instrument body to improve access to the tissue to be treated. Some instruments include a motor or drive element for hinged end-effectors and also include a rotating assembly for rotating the end-effector.

[0007] It would be advantageous to provide an improved surgical instrument or adapter assembly that can detect and / or correct any unwanted local articulations in the end effector. Summary of the Invention

[0008] This disclosure relates to a connector assembly configured to mechanically engage a surgical instrument. The connector assembly includes a knob housing, an outer tube, an end effector, a hinge link, and a sensor assembly. The outer tube extends distally from the knob housing and defines a longitudinal axis. The end effector extends distally from the outer tube and is movable from a first position aligned with the longitudinal axis to a second position at an angle relative to the longitudinal axis. The hinge link extends through at least a portion of the outer tube and is configured to mechanically engage with the end effector. Longitudinal translation of the hinge link relative to the outer tube moves the end effector from its first position to its second position. The sensor assembly includes a first portion configured to mechanically engage with the hinge link and a second portion at least partially disposed within the outer tube. The sensor assembly is configured to determine the actual amount of hinge engagement of the end effector based on the distance of longitudinal movement of the hinge link relative to the outer tube.

[0009] In the disclosed embodiments, the sensor assembly is configured to communicate with software that compares the actual hinge amount of the end effector with the desired hinge amount of the end effector. The software is disclosed to be located on a printed circuit board, at least partially within the knob housing.

[0010] It is also disclosed that one of the first or second parts of the sensor assembly is a magnet, and the other of the first or second parts of the sensor assembly is a magnetoresistive sensor.

[0011] It is also disclosed that one of the first or second parts of the sensor assembly is a leaf spring, and the other of the first or second parts of the sensor assembly is a thin-pot resistive sensor.

[0012] Additionally, a connector assembly is disclosed that includes a second sensor assembly at least partially disposed within the knob housing. The second sensor assembly is configured to detect manual rotation of the knob housing relative to the outer tube. In an embodiment, the second sensor assembly includes at least one sensor and at least one magnet, and the at least one sensor of the second sensor assembly includes at least two Hall effect sensors. It is also disclosed that the at least one magnet of the second sensor assembly includes a refrigerator-type magnet. In another embodiment, software is disposed on a printed circuit board at least partially disposed within the knob housing, and at least two Hall effect sensors are disposed on the printed circuit board.

[0013] This disclosure also relates to a surgical instrument comprising a handle assembly and a connector assembly. The handle assembly includes a first drive member. The connector assembly is configured to selectively engage the handle assembly and includes a knob housing, an outer tube, an end effector, a hinge link, a ring gear, and a sensor assembly. The outer tube extends distally from the knob housing and defines a longitudinal axis. The end effector extends distally from the outer tube and is movable from a first position aligned with the longitudinal axis to a second position where the end effector is angled relative to the longitudinal axis. The hinge link extends through at least a portion of the outer tube and is configured to mechanically engage with the end effector. Longitudinal translation of the hinge link relative to the outer tube moves the end effector from its first position to its second position. The ring gear is at least partially disposed within the knob housing and mechanically engages with the first drive member when the connector assembly engages with the handle assembly. Rotation of the first drive member causes the ring gear to rotate about the longitudinal axis, which causes longitudinal translation of the hinge link. The sensor assembly includes a first portion configured to mechanically engage with a hinged link and a second portion at least partially disposed within an outer tube. The sensor assembly is configured to determine the actual amount of articulation of the end effector based on the distance the hinged link has moved longitudinally relative to the outer tube.

[0014] In the disclosed embodiments, manual rotation of the knob housing causes the end effector to hinge undesirably. In the disclosed embodiments, a sensor assembly is configured to communicate with software that compares the actual hinge amount of the end effector with the desired hinge amount. It is further disclosed that the software is configured to instruct a first drive member of a surgical instrument to move a hinge link such that the actual hinge of the end effector equals the desired hinge of the end effector.

[0015] The surgical instrument also discloses a second sensor assembly, which is at least partially disposed within a knob housing. The second sensor assembly is configured to detect manual rotation of the knob housing relative to an outer tube. In an embodiment, the second sensor assembly includes at least one sensor and at least one magnet. It is also disclosed that at least one sensor of the second sensor assembly comprises at least two Hall effect sensors, and at least one magnet of the second sensor assembly comprises a refrigerator-type magnet (e.g., a magnet with suitably alternating north / south magnetic poles).

[0016] In the disclosed embodiments, one of the first or second portions of the sensor assembly is a magnet, and the other of the first or second portions of the sensor assembly is a magnetoresistive sensor.

[0017] In another embodiment, one of the first or second portions of the sensor assembly is a leaf spring, and the other of the first or second portions of the sensor assembly is a thin-can resistive sensor. Attached Figure Description

[0018] This document discloses, with reference to the accompanying drawings, an embodiment of a surgical instrument comprising the currently disclosed adapter assembly, wherein:

[0019] Figure 1A It is a perspective view of a surgical instrument including a connector assembly and a surgical loading unit, wherein the staple cartridge body of the surgical loading unit is shown being removed from the base of the surgical loading unit;

[0020] Figure 1B yes Figure 1A A perspective view of surgical instruments, in which the staple cartridge body of the surgical loading unit is shown mounted in a frame;

[0021] Figure 2 yes Figure 1A A perspective view of the internal components of the connector assembly;

[0022] Figure 3 Is Figure 2 The image shows a perspective view of the internal components of the connector assembly, with parts removed.

[0023] Figure 4 yes Figure 2 A rear perspective view of the cam housing and ring gear, the internal components of the connector assembly;

[0024] Figure 5 It is shown in the form of hidden lines. Figure 4 A side perspective view of the cam housing and the ring gear;

[0025] Figure 6 yes Figure 4 A side cross-sectional view of the cam housing and the ring gear;

[0026] Figure 7 yes Figure 1A A side cross-sectional view of the proximal segment of the connector assembly;

[0027] Figure 8 yes Figure 7 A side perspective view of a pair of first and second extension axes of the connector assembly;

[0028] Figure 9 This is a top cross-sectional view of the distal section of the connector assembly and surgical loading unit in Figure 1.

[0029] Figure 10 yes Figure 9 Enlarged top-view cross-sectional view of the connector assembly and surgical loading unit;

[0030] Figure 11 yes Figure 9A top cross-sectional view of the distal section of the connector assembly and the surgical loading unit, wherein the surgical loading unit is illustrated in a hinged position relative to the connector assembly.

[0031] Figure 12 yes Figure 1A A side cross-sectional view of the connector assembly;

[0032] Figure 13 yes Figure 12 A side cross-sectional view of the proximal segment of the connector assembly;

[0033] Figure 14 yes Figure 12 Side view of the I-beam assembly of the connector assembly;

[0034] Figure 15 yes Figure 14 A frontal cross-sectional view of the surgical loading unit and the I-beam assembly;

[0035] Figure 16A This is a side cross-sectional view of the surgical loading unit in its open configuration, illustrating the I-beam assembly in its retracted position;

[0036] Figure 16B This is a side cross-sectional view of a surgical loading unit in a closed configuration, illustrating the I-beam assembly in the forward position;

[0037] Figure 17 yes Figure 1A A rear perspective view of the adapter assembly, in which the housing is shown with hidden lines;

[0038] Figure 18 yes Figure 17 Rear perspective view of the internal components of the connector assembly;

[0039] Figure 19 This is a perspective view of a connector assembly according to another embodiment of the present disclosure;

[0040] Figure 20 yes Figure 19 A perspective view of the adapter component with parts of it omitted;

[0041] Figure 21 yes Figure 20 A magnified view of the detailed area;

[0042] Figure 22 It is along Figure 20 The side view of the proximal section of the connector assembly, taken by section line 22-22 in the figure;

[0043] Figure 23 yes Figures 19 to 22A perspective view of the internal components within the proximal segment of the connector assembly;

[0044] Figure 24 yes Figures 19 to 23 A perspective view of the sensor assembly of the adapter assembly;

[0045] Figure 25 yes Figure 24 A perspective view of a portion of the sensor assembly;

[0046] Figure 26 It is along Figure 24 A cross-sectional view of the sensor assembly and adapter assembly along lines 24-24 in the diagram;

[0047] Figure 27 Is with Figure 20 A perspective view of another embodiment of a sensor assembly used in conjunction with a connector assembly; and

[0048] Figure 28 yes Figure 27 A perspective view of the sensor components. Detailed Implementation

[0049] Those skilled in the art will understand that the adapter assembly and surgical loading unit specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments. It is conceivable that elements and features shown or described in connection with one exemplary embodiment may be combined with elements and features of another exemplary embodiment without departing from the scope of this disclosure. Furthermore, those skilled in the art will understand additional features and advantages of this disclosure based on the described embodiments. Therefore, this disclosure is not limited to what has been specifically shown and described, except as indicated by the appended claims.

[0050] As used herein, the term "distal" refers to the portion of a surgical instrument furthest from the clinician, while the term "proximal" refers to the portion of a surgical instrument closest to the clinician. Additionally, as used herein, the term "clinician" refers to a medical professional, including doctors, nurses, and support staff.

[0051] This disclosure relates to a surgical instrument comprising: a connector assembly configured to be actuated by a handheld actuator or a surgical robot system; and a surgical loading unit coupled to the connector assembly. The connector assembly includes a hinge mechanism that drives the surgical loading unit to hinge relative to the connector assembly. The hinge mechanism includes a cam housing defining a pair of cam slots, each of the pair of cam slots receiving a corresponding pin of a pair of elongated shafts. When the cam housing rotates, the cam slots drive opposing longitudinal movements of the pair of elongated shafts, thereby hinged the surgical loading unit. Additional advantages of the surgical instrument and its components of this disclosure are described below.

[0052] Figure 1A and Figure 1B A surgical instrument 10 is shown, comprising a handle assembly 12, a connector assembly 20 configured to couple to the handle assembly 12, and a surgical loading unit 30 pivotally coupled to the connector assembly 20. While the depicted surgical instrument 10 can be configured to fire suture staples, it is contemplated that the surgical instrument 10 can be adapted to fire any other suitable fasteners, such as clamps and two-piece fasteners. Furthermore, although the figures depict a linear surgical suture instrument 10, it is contemplated that certain components described herein can be adapted for use in other types of endoscopic surgical instruments, including nonlinear surgical suture loading units, endoscopic forceps, grippers, dissecters, other types of surgical suture instruments, powered vascular sealing and / or cutting devices, etc.

[0053] Typically, the adapter assembly 20 of the surgical instrument 10 includes a housing 21 and an outer tube 24 extending distally from the housing 21. The housing 21 includes a knob housing 22 and a coupling mechanism 25 extending proximally from the knob housing 22 and configured to be operatively coupled to a handle assembly 12 or a surgical robotic system (not shown) responsible for actuating the surgical instrument 10. The outer tube 24 has a proximal end portion fixed within the distal end portion of the knob housing 22. In other embodiments, the outer tube 24 may be rotatable relative to and within the knob housing 22. A surgical loading unit 30 is adapted to be attached to the distal end portion of the outer tube 24 of the adapter assembly 20 and may be configured for single use or for use more than once.

[0054] The surgical loading unit 30 includes a collar 32 pivotally coupled to the distal end portion of the outer tube 24 and an end effector 34 supported on the collar 32. The end effector 34 includes an anvil 36 non-rotatably coupled to the collar 32 and a staple cartridge assembly 37 disposed opposite the anvil 36. The staple cartridge assembly 37 has a base 38 pivotally coupled to the collar 32 and a staple cartridge body 40 configured for removably receiving in a channel 42 of the base 38.

[0055] For a detailed description of the handle assembly 12, reference can be made to U.S. Patent Application Publication No. 2015 / 0157320, filed November 21, 2014, and U.S. Patent Application Publication No. 2016 / 0310134, filed April 12, 2016, the entire contents of each of which are incorporated herein by reference.

[0056] refer to Figure 2 and Figure 3 The hinge mechanism of the adapter assembly 20 will now be described. The adapter assembly 20 includes a hinged input shaft 50, a firing input shaft 52, and a rotary input shaft 54, each input shaft being rotatably supported on the housing 21. Figure 1A In the coupling mechanism 25, the articulated input shaft 50 has a proximal end portion 50a, which is configured to be drivably coupled to a corresponding drive member 13a of the handle assembly 12 to achieve rotation of the articulated input shaft 50. The articulated input shaft 50 has a distal end portion 50b, which has a gear 56 (e.g., a spur gear) fixed near the distal end portion.

[0057] The adapter assembly 20 includes a ring gear 58 operably coupled to the articulated input shaft 50 and non-rotatably coupled to the cam housing 60. The ring gear 58 has an inner surface defining gear teeth 62 that engage with the gear teeth of a first gear 64a of a spur gear set 64. The spur gear set 64 has a second gear 64b fixed to and disposed adjacent to the first gear 64a, and having a diameter larger than that of the first gear 64a. The second gear 64b of the spur gear set 64 engages with a gear 56 non-rotatably fixed about the distal end portion 50b of the articulated input shaft 50. Thus, rotation of the articulated input shaft 50 rotates the first gear 64a and the second gear 64b of the spur gear set 64, which in turn drives the ring gear 58 to rotate.

[0058] refer to Figures 2 to 7The cam housing 60 of the adapter assembly 20 is rotatably supported within the knob housing 22. The cam housing 60 includes an annular plate or disk 66 and a tubular shaft 68 extending distally from the annular plate 66. The annular plate 66 can be disposed within and fixed to an annular gear 58, such that the cam housing 60 rotates with rotation of the annular gear 58. The tubular shaft 68 of the cam housing 60 defines a longitudinally extending channel 70 passing through it. The channel 70 is sized to receive various components of the hinge mechanism and firing mechanism of the adapter assembly 20, thereby allowing for a more compact design of the adapter assembly 20.

[0059] refer to Figures 4 to 7 The tubular shaft 68 of the cam housing 60 defines a proximal cam groove 72a communicating with the channel 70, and a distal cam groove 72b located distal to the proximal cam groove 72a and communicating with the channel 70. The proximal cam groove 72a and the distal cam groove 72b are longitudinally spaced from each other and surround a central longitudinal axis “X” defined by the channel 70 through the tubular shaft 68 of the cam housing 60. Figure 7 The cam grooves 72a and 72b each have opposite helical structures. For example, the proximal cam groove 72a may have a left-handed helical structure, while the distal cam groove 72b may have a right-handed helical structure, the importance of which is described in detail below. The cam grooves 72a and 72b are arranged at a specific interval, such that the set rotation of the tubular shaft 68 forms a defined hinge of the three-bar linkage.

[0060] refer to Figures 7 to 11 The adapter assembly 20 further includes a pair of first axially movable extension shafts 74 and second axially movable extension shafts 76, and a pair of first hinge links 86 and second hinge links 88. The first extension shafts 74 and second extension shafts 76 are located on opposite sides of the central longitudinal axis “X” of the cam housing 60. Each of the first extension shafts 74 and second extension shafts 76 has a proximal end portion 74a, 76a disposed within the knob housing 22 and a distal end portion 74b, 76b disposed within the outer tube 24.

[0061] The proximal end portion 74a of the first elongation shaft 74 has a radially outwardly extending protrusion or pin 82 received in the proximal cam groove 72a. The proximal end portion 76a of the second elongation shaft 76 has a radially outwardly extending protrusion or pin 84 received in the distal cam groove 72b. Since the proximal cam groove 72a and the distal cam groove 72b of the cam housing 60 have opposite helical configurations (e.g., right-hand thread and left-hand thread), the rotation of the cam housing 60 drives the first elongation shaft 74 and the second elongation shaft 76 in opposite longitudinal directions.

[0062] The first articulated link 86 of the surgical instrument 10 has a proximal end portion 86a pivotally coupled to the distal end portion 74b of the first extension shaft 74, and the second articulated link 88 has a proximal end portion 88a pivotally coupled to the distal end portion 76b of the second extension shaft 76. The first link 86 and the second link 88 each have distal end portions 86b, 88b pivotally coupled to opposite sides of the collar 32 of the surgical loading unit 30. Thus, the opposing longitudinal movements of the first extension shaft 74 and the second extension shaft 76 caused by the rotation of the cam housing 60 push and pull the corresponding first link 86 and second link 88 to articulate the surgical loading unit 30 relative to the connector assembly 20.

[0063] For details, please refer to the following: Figure 10 and Figure 11 The first hinge link 86 includes an inwardly facing surface 90, and the second hinge link 88 includes an inwardly facing surface 92, the inwardly facing surface of the second hinge link facing the inwardly facing surface 90 of the first link 86. The inwardly facing surface 90 of the first link 86 has a concave intermediate portion 90c disposed between a convex proximal end portion 90a and a convex distal end portion 90b of the inwardly facing surface 90. Similarly, the inwardly facing surface 92 of the second link 88 has a concave intermediate portion 92c disposed between a convex proximal end portion 92a and a convex distal end portion 92b of the inwardly facing surface 92. The inward-facing surfaces 90, 92 of the first link 86 and the second link 88 are configured to guide and support the blow-out plates 102a, 102b of the connector assembly 20 and the blade shaft 104 of the I-beam assembly 100 during the articulation of the surgical loading unit 30.

[0064] Specifically, the concave intermediate portion 90c of the inward-facing surface 90 of the first link 86 is sized such that, along the surgical loading unit 100... Figure 11 The first arc-extinguishing plate 102a of the I-beam assembly 30 is received during the hinged process, indicated by arrow "A" in the first direction, while the concave intermediate portion 92c of the inward-facing surface 92 of the second link 88 is sized to: [the text abruptly ends here, likely due to an incomplete sentence or missing information.] Figure 11 The second arc-extinguishing plate 102b of the I-beam assembly 30 is received during the hinged process in the second direction indicated by the arrow "B".

[0065] The convex distal end portions 90b and 92b of the inward-facing surfaces 90 and 92 of the first link 86 and the second link 88 also support the arc-extinguishing plates 102a and 102b and the blade shaft 104 of the I-beam assembly 100 during the hinge of the surgical loading unit 30. In this way, the inward-facing surfaces 90 and 92 of the corresponding first link 86 and the second link 88 accommodate the deflection of the blade shaft 104 and the arc-extinguishing plates 102a and 102b when the surgical loading unit 30 is hinged, to resist wear and tear on the blade shaft 104 and the arc-extinguishing plates 102a and 102b. For example, as optimally as in Figure 11 As shown, the hinge of the surgical loading unit 30 along the first direction causes the blade shaft 104 and the arc-extinguishing plates 102a, 102b to bend, thereby guiding and supporting the outer arc-extinguishing plate (e.g., the first arc-extinguishing plate 102a) through the concave intermediate portion 90c of the inward-facing surface 90 of the first link 86, and guiding and supporting the inner arc-extinguishing plate (e.g., the second arc-extinguishing plate 102b) through the convex distal end portion 92b of the inward-facing surface 92 of the second link 88. It is understood that during the hinge of the surgical loading unit 30 along the second direction, the first link 86 and the second link 88 work together in a similar manner to accommodate the deflection of the arc-extinguishing plates 102a, 102b and the blade shaft 104.

[0066] In operation, to articulate the surgical loading unit 30, the articulated input shaft 50 is rotated via actuation of the handle assembly 12. The articulated input shaft 50 transmits rotational motion from the gear 56 fixed near the articulated input shaft to the ring gear 58 via a spur gear set 64. Since the cam housing 60 is fixed to the ring gear 58, the cam housing 60 rotates together with the ring gear 58 about the central longitudinal axis “X”. As the cam housing 60 rotates, the proximal cam groove 72a of the cam housing 60 drives the pin 82 of the first extension shaft 74 along the… Figure 7 The arrow "C" in the diagram indicates the distal direction leading to the proximal cam groove 72, and the distal cam groove 72b of the cam housing 60 drives the pin 84 of the second extension shaft 76 along the path. Figure 7 The arrow "D" in the diagram indicates the proximal direction through the distal cam groove 72b.

[0067] Since the first hinge link 86 acts as a pivotable coupler between the first extension shaft 74 of the connector assembly 20 and the first side of the surgical loading unit 30, and the second link 88 acts as a pivotable coupler between the second extension shaft 76 of the connector assembly 20 and the second side of the surgical loading unit 30, the distal movement of the first extension shaft 74 and the proximal movement of the second extension shaft 76 are along the […]. Figure 11 Arrow "A" indicates the first direction driving the hinge of the surgical loading unit 30. Similarly, the proximal movement of the first extension axis 74 and the distal movement of the second extension axis 76 are along the direction indicated by the... Figure 11 The arrow "B" indicates the second direction driving the hinge of the surgical loading unit 30.

[0068] refer to Figure 12 Referring now to Figure 16, the firing mechanism and clamping mechanism of the adapter assembly 20 will be described. The firing input shaft 52 of the adapter assembly 20 is centrally located between the hinged input shaft 50 and the rotary input shaft 54, and is configured to perform clamping and suturing functions of the surgical loading unit 30. The firing input shaft 52 has a proximal end portion 52a configured to be drivably coupled to the drive member 13b of the handle assembly 12 to drive rotation of the firing input shaft 52. It is contemplated that the firing input shaft 52 can be configured as a drive screw having a threaded outer surface 106.

[0069] The adapter assembly 20 also includes the I-beam assembly 100 described above, which has a nut 108, a firing rod or firing tube 110, and a cutter shaft 104. The nut 108 of the I-beam assembly 100 is disposed within the tubular shaft 68 of the cam housing 60 and keyed to the inner tube 112, thereby preventing rotation of the nut 108 within the inner tube 112 during rotation of the firing input shaft 52. The nut 108, disposed within the cam housing 60 of the hinge mechanism, gives the adapter assembly 20 a compact design.

[0070] The firing rod 110 of the I-beam assembly 100 has a proximal end portion 110a fixed to a nut 108 and a distal end portion 110b fixed to a proximal end portion 104a of the cutter shaft 104 of the I-beam assembly 100. In an embodiment, the nut 108 may be directly attached to the proximal end portion 104a of the cutter shaft 104, rather than coupled via the firing rod 110. Since the cutter shaft 104 of the I-beam assembly 100 is fixed to the nut 108, the axial movement of the nut 108 through the outer tube 24 in response to the rotation of the firing input shaft 52 drives the axial movement of the cutter shaft 104.

[0071] refer to Figure 15 , Figure 16A and Figure 16B The blade shaft 104 of the I-beam assembly includes a plurality of stacked, elongated, rectangular blades 114. The plurality of blades 114 have an upper portion 114a extending through a longitudinally extending slot 116 defined in the anvil 36 and a lower portion 114b extending through a longitudinally extending slot 118 defined in the base 38 of the staple cartridge assembly 37. (As in...) Figure 15 As shown, the upper part 114a of the blade 114 overlaps with the anvil 36, and the lower part 114b of the blade 114 overlaps with the base 38. It can be expected that this overlapping arrangement prevents the blade shaft 104 from bending during firing.

[0072] The blade shaft 104 of the I-beam assembly 100 has a distal end portion 104b disposed within the surgical loading unit 30. The distal end portion 104b of the blade shaft 104 is configured to pivot the staple cartridge assembly 37 toward the anvil 36 during distal advance of the blade shaft 104. The distal end portion 104b of the blade shaft 104 has: an upper leg 120 disposed within a channel 121 defined by the anvil 36; a lower leg 122 disposed outside the base 38 of the staple cartridge assembly 37; and a sharp, distally oriented surface 124 extending between the upper and lower legs 120, 122. The distally oriented surface 124 is configured to sever tissue during distal advance of the end effector 34.

[0073] In operation, to fire and hold the surgical loading unit 30, the firing input shaft 52 is rotated by actuation of the handle assembly 12 of the coupling mechanism 25 attached to the adapter assembly 20. The firing input shaft 52 drives the nut 108 relative to the firing input shaft 52 along a path... Figure 13 The arrow "C" indicates the distal translation. Assuming the I-beam assembly 100, including nut 108, firing lever 110, and cutter shaft 104, is a single unit, the firing lever 110 and cutter shaft 104 advance distally together with nut 108. The distal end portion 104b of the cutter shaft 104 of the I-beam assembly 100 advances distally through anvil 36 and base 38, causing base 38 to pivot toward anvil 36. As the distal end portion 104b of the cutter shaft 104 advances distally through anvil 36 and base 38, the sharp, distally oriented surface 124 of the cutter shaft 104 severs any tissue disposed between the anvil and base.

[0074] refer to Figure 17 and Figure 18 The rotation mechanism of the adapter assembly 20 will now be described. The rotary input shaft 54 ​​of the adapter assembly 20 has a proximal end portion 54a configured to be droopily coupled to a drive member 13c of the handle assembly 12 to drive rotation of the rotary input shaft 54. The rotary input shaft 54 ​​has a gear 126 fixed around its distal end portion 54b. The gear 126 of the rotary input shaft 54 ​​is operatively coupled to the teeth 128 of a rotating ring gear 130 via a freewheeling gear 132. In an embodiment, the gear 126 of the rotary input shaft 54 ​​may directly engage with the rotating ring gear 130.

[0075] The rotating ring gear 130 has a pair of protrusions 134a, 134b extending radially outward from opposite radial positions of the rotating ring gear 130. The protrusions 134a, 134b of the rotating ring gear 130 interlock with corresponding recesses (not explicitly shown) defined in the inner surface of the knob housing 22, such that the knob housing 22, together with the rotating ring gear 130, is rotatable relative to the coupling mechanism 25. In embodiments, the rotating ring gear 130 may have any suitable features for securing the rotating ring gear 130 to the knob housing 22, such as, for example, threaded engagement, friction engagement, lock and key engagement, latch, button, bayonet connection, welding, gluing, and / or other structures.

[0076] In operation, to rotate the surgical loading unit 30, the rotary input shaft 54 ​​is rotated via the actuation of the handle assembly 12 of the coupling mechanism 25 attached to the connector assembly 20. The rotational motion of the rotary input shaft 54 ​​is transmitted to the rotary ring gear 130 via the idler gear 132. Since the protrusions 134a and 134b of the rotary ring gear 130 lock the knob housing 22 to the rotary ring gear, the rotation of the rotary ring gear 130 causes the knob housing 22 to rotate relative to the coupling mechanism 25 and about the input shafts 50, 52, and 54. The outer tube 24 of the connector assembly 20 is secured to the knob housing 22 and thus rotates with the knob housing 22, which in turn causes the surgical loading unit 30 to rotate about the longitudinal axis of the connector assembly 20.

[0077] Turn now Figures 19 to 28 Another embodiment of the adapter assembly is shown, which is generally indicated by reference numeral 200. Adapter assembly 200 has several parts that are the same as or similar to those discussed above with respect to adapter assembly 20. Therefore, many features of adapter assembly 200 will not be discussed in further detail. Additionally, the same reference numerals can be used to refer to features common to both adapter assembly 20 and adapter assembly 200.

[0078] The adapter assembly 200 includes structures that help limit, prevent, or correct accidental hinge of the end effector 34. For example, the hinge angle of the end effector 34 can also be changed during manual rotation of the knob housing 22a to rotate the end effector 34 and the outer tube 24 about a central longitudinal axis "X". Figure 19 As shown, when the cam housing 60 is held in its rotatable position (e.g., due to the engagement between the articulated input shaft 50 and the associated drive member 13a of the handle assembly 12), this unexpected change in the hinge angle of the end effector 34 may occur during manual rotation of the knob housing 22a in the general direction of arrow "M" (see...). Figure 1A , Figure 1B and Figure 22The knob housing 22a is non-rotatably connected to the distal sleeve 22b, which is non-rotatably connected to the ring gear 58. In this way, manual rotation of the knob housing 22a causes rotation of the distal sleeve 22b, which in turn causes rotation of the ring gear 58.

[0079] Now for reference Figure 23 The sensor assembly 210 can be used to determine whether the hinge movement is accidental, for example, during manual rotation of the knob housing 22a. Figure 19 and Figure 20 Here, sensor assembly 210 includes sensor 212 (e.g., Hall effect sensor) and magnet 214 (e.g., refrigerator-type magnet or magnet with suitably alternating north / south magnetic poles). Sensor 212 is orthogonally mounted on printed circuit board 222 within adapter assembly 200. Magnet 214 is mounted to ring gear 58 at a location detectable by sensor 212 and surrounds ring gear 58 circumferentially. Figure 23 As shown. Sensor 212 relays information related to the rotation of the ring gear 58 to a controller or software 220 on the printed circuit board 222 to indicate manual rotation of the knob housing 22 and thus accidental hinge of the end effector 34.

[0080] To facilitate limiting, preventing, or correcting unintended articulation of the end effector 34, as described below, the adapter assembly 200 includes software 220 and at least one sensor assembly. Typically, the sensor assembly detects unintended movement of the first articulated link 86 and / or the second articulated link 88, communicates with the software 220, and the software 220 sends signals to the drive member 13a (or a different motor) to make necessary adjustments, thereby returning the first articulated link 86 and / or the second articulated link 88 (and the accompanying sensor assembly or a portion thereof) to the desired position (see [link to relevant documentation]). Figure 21 ).

[0081] Software 220 may be contained on or within a printed circuit board 222 located on or within a portion of the surgical instrument 10, and may be connected to the sensor assembly and / or drive component 13a via electrical connections such as pins, straps, or wires. Figure 1B It can communicate, or it can communicate wirelessly. For example, Figure 22 and Figure 23 A printed circuit board 222 within the adapter assembly 200 is shown. Alternatively, the software 220 may be located at a remote location and communicate wirelessly with the sensor assembly and / or drive component 13a.

[0082] Various types of sensor assemblies can be used in conjunction with the adapter assembly 200 to detect movement of the first hinge link 86 and / or the second hinge link 88. For example, the adapter assembly 200 may include a giant magnetoresistive (GMR) sensor, a planar resistance sensor, a potentiometer sensor, an optical sensor, a sonar sensor, an inductive sensor, and / or other suitable sensors.

[0083] For details, please refer to the following: Figure 20 and Figures 24 to 26 The adapter assembly 200 is shown as comprising a sensor assembly 240 of a first type, which includes a magnetic or GMR sensor 242 and a corresponding magnet 244. The GMR sensor 242 (e.g., model AAK001-14E manufactured by NVECorporation) is at least partially disposed within the inner tube 212 of the adapter assembly 200. The magnet 244 is configured to engage with a first hinge link 86. The GMR sensor 242 is connected via an electric band 246 (… Figure 22 The electrical connection is made to software 220 (e.g., on a printed circuit board 222 or in a controller). Since the first hinge link 86 and the second hinge link 88 move together (in opposite directions), it is effective to include a magnet 244 that engages with a single hinge link. This disclosure also includes embodiments in which the GMR sensor 242 is configured to engage with the first hinge link 86 and the magnet is at least partially disposed within the inner tube 212 of the adapter assembly 200.

[0084] In use, GMR sensor 242 senses the position of magnet 244 (and therefore the first articulated link 86) relative to GMR sensor 242. As discussed above, the relative position (or displacement) of magnet 244 and the first articulated link 86 corresponds to the articulation amount of end effector 34. This position information is relayed to software 220. Software 220 contains data regarding the desired articulation amount of end effector 34 and the associated desired position of the first articulated link 86 / magnet 244. The desired articulation amount of end effector 34 can be determined by analyzing the amount of rotation of articulated input shaft 50.

[0085] Next, the software 220 compares the actual measured position of the magnet 244 with the desired position of the magnet 244, and sends a signal to the drive member 13a to move the first hinge link 86 a sufficient distance proximally or distally, thereby achieving the desired position of the first hinge link 86 and thus the desired amount of articulation of the end effector 34. Additionally, the software 220 can control the drive member 13a constantly or servo-wise to ensure that undesirable articulation of the end effector 34 is limited.

[0086] Now for reference Figure 27 and Figure 28The diagram illustrates a connector assembly 200 comprising a second type of sensor assembly 250, which includes a thin-can resistive sensor 252 and a corresponding biasing element (e.g., a leaf spring 260). The sensor assembly 250 is used to determine the longitudinal position of a first hinge link 86 relative to the inner tube 212 of the connector assembly 200. The sensor 252 is at least partially disposed within the inner tube 212 of the connector assembly 200, and the leaf spring 260 is configured to engage with the first hinge link 86 such that the leaf spring 260 contacts and is configured to slidably engage with the sensor 252. The sensor 252 communicates wirelessly, for example, with software 220 (e.g., in a printed circuit board 222 or a controller). Since the first hinge link 86 and the second hinge link 88 move together (in opposite directions), including a leaf spring 260 engaged with a single hinge link is effective. This disclosure also includes embodiments in which the sensor 252 is configured to engage with the first hinge link 86 and the leaf spring 260 is at least partially disposed within the inner tube 212 of the connector assembly 200.

[0087] In use, sensor 252 senses the position of leaf spring 260 (and therefore the first articulated link 86) relative to sensor 252. As discussed above, the relative position (or displacement) of leaf spring 260 and the first articulated link 86 directly corresponds to the articulation amount of end effector 34. This position information is relayed to software 220. Software 220 contains data regarding the desired articulation amount of end effector 34 and the associated desired position of the first articulated link 86 / leaf spring 260. The desired articulation amount of end effector 34 can be determined or calculated by analyzing the amount of rotation of articulated input shaft 50 and / or the amount of linear displacement of the first articulated link 86 and / or the second articulated link 88.

[0088] Next, the software 220 compares the actual measured position of the leaf spring 260 with the desired position of the leaf spring 260, and sends a signal to the drive member 13a to move the first hinge link 86 a sufficient distance proximally or distally, thereby achieving the desired position of the first hinge link 86 and thus the desired amount of articulation of the end effector 34. Additionally, the software 220 can control the drive member 13a constantly or servo-wise to ensure that undesirable articulation of the end effector 34 is limited.

[0089] It is also conceivable that the drive member 13a contains an encoder that can be monitored during use. Here, if the drive member 13a is mechanically reversed during the rotation of the knob 22, the drive member 13a can automatically correct its position, thereby limiting the amount of undesirable articulation of the end effector 34.

[0090] Those skilled in the art will understand that the adapter components and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments. It is contemplated that elements and features shown or described in connection with one exemplary embodiment may be combined with elements and features of another exemplary embodiment without departing from the scope of this disclosure. Furthermore, those skilled in the art will understand additional features and advantages of this disclosure based on the foregoing embodiments. Therefore, this disclosure is not limited to what has been specifically shown and described, except as indicated by the appended claims.

Claims

1. A connector assembly configured to mechanically engage a surgical instrument, the connector assembly comprising: Knob housing; An outer tube extends distally from the knob housing and defines a longitudinal axis; An end effector extending distally from the outer tube, the end effector being movable from a first position where the end effector is aligned with the longitudinal axis to a second position where the end effector is set at an angle relative to the longitudinal axis; A hinged link that extends through at least a portion of the outer tube and is configured to mechanically engage with the end effector; A ring gear, at least partially disposed within the knob housing, wherein rotation of the ring gear about the longitudinal axis causes longitudinal translation of the articulated link relative to the outer tube, thereby moving the end effector from its first position to its second position; and A sensor assembly comprising a first portion configured to mechanically engage with the articulated link and a second portion at least partially disposed within the outer tube, the sensor assembly being configured to determine the actual amount of articulation of the end effector based on the distance of longitudinal movement of the articulated link relative to the outer tube.

2. The adapter assembly of claim 1, wherein the sensor assembly is configured to communicate with software, and wherein the software compares the actual hinge amount of the end effector with the desired hinge amount of the end effector.

3. The adapter assembly of claim 2, wherein the software is disposed on a printed circuit board at least partially disposed within the knob housing.

4. The adapter assembly of claim 1, wherein one of the first or second portion of the sensor assembly is a magnet, and the other of the first or second portion of the sensor assembly is a magnetoresistive sensor.

5. The connector assembly of claim 1, wherein one of the first or second portion of the sensor assembly is a leaf spring, and wherein the other of the first or second portion of the sensor assembly is a thin-can resistive sensor.

6. The adapter assembly of claim 2 further includes a second sensor assembly, the second sensor assembly being at least partially disposed within the knob housing, the second sensor assembly being configured to detect manual rotation of the knob housing relative to the outer tube.

7. The adapter assembly of claim 6, wherein the second sensor assembly comprises at least one sensor and at least one magnet.

8. The adapter assembly of claim 7, wherein the at least one sensor of the second sensor assembly comprises at least two Hall effect sensors.

9. The adapter assembly of claim 8, wherein the at least one magnet of the second sensor assembly comprises a refrigerator-type magnet.

10. The adapter assembly of claim 9, wherein the software is disposed on a printed circuit board at least partially disposed within the knob housing, and wherein the at least two Hall effect sensors are disposed on the printed circuit board.

11. A surgical instrument comprising: A handle assembly, which includes a first drive component; as well as A connector assembly configured to selectively engage the handle assembly, the connector assembly comprising: Knob housing; An outer tube extends distally from the knob housing and defines a longitudinal axis; An end effector extending distally from the outer tube, the end effector being movable from a first position where the end effector is aligned with the longitudinal axis to a second position where the end effector is set at an angle relative to the longitudinal axis; A hinged link extending through at least a portion of the outer tube and configured to mechanically engage with the end effector, wherein longitudinal translation of the hinged link relative to the outer tube moves the end effector from its first position to its second position. A ring gear, at least partially disposed within the knob housing, and mechanically engaged with the first drive member when the adapter assembly engages with the handle assembly, wherein rotation of the first drive member causes the ring gear to rotate about the longitudinal axis, which causes the articulated link to translate longitudinally. as well as A sensor assembly comprising a first portion configured to mechanically engage with the articulated link and a second portion at least partially disposed within the outer tube, the sensor assembly being configured to determine the actual amount of articulation of the end effector based on the distance of longitudinal movement of the articulated link relative to the outer tube.

12. The surgical instrument of claim 11, wherein manual rotation of the knob housing relative to the outer tube causes the end effector to be undesirably hinged.

13. The surgical instrument of claim 12, wherein the sensor assembly is configured to communicate with software, and wherein the software compares the actual articulation of the end effector with the desired articulation of the end effector.

14. The surgical instrument of claim 13, wherein the software is configured to instruct the first drive member of the surgical instrument to move the articulated link such that the actual articulation of the end effector is equal to the desired articulation of the end effector.

15. The surgical instrument of claim 12, further comprising a second sensor assembly, the second sensor assembly being at least partially disposed within the knob housing, the second sensor assembly being configured to detect manual rotation of the knob housing relative to the outer tube.

16. The surgical instrument of claim 15, wherein the second sensor assembly comprises at least one sensor and at least one magnet.

17. The surgical instrument of claim 16, wherein the at least one sensor of the second sensor assembly comprises at least two Hall effect sensors.

18. The surgical instrument of claim 17, wherein the at least one magnet of the second sensor assembly comprises a refrigerator-type magnet.

19. The surgical instrument of claim 11, wherein one of the first portion or the second portion of the sensor assembly is a magnet, and wherein the other of the first portion or the second portion of the sensor assembly is a magneto-resistive sensor.

20. The surgical instrument of claim 11, wherein one of the first portion or the second portion of the sensor assembly is a leaf spring, and wherein the other of the first portion or the second portion of the sensor assembly is a thin can resistive sensor.

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