Handheld surgical instrument

Abstract

A surgical instrument module for powering a plurality of discrete surgical end effectors includes: a motor, a planetary gearbox, a high torque / low speed output operably coupled to the motor, and a high speed / low torque output operably coupled to the motor. The high torque / low speed is configured to be operably coupled to a driven member of a first type of surgical end effector, and the high speed / low torque output is configured to drive the operation of a second type of surgical end effector.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit and priority of U.S. Provisional Patent Application Serial No. 63 / 064,977, filed on August 13, 2020, the entire content of which is hereby incorporated by reference.

[0003] This application is a partial continuation application claiming the benefit and priority of U.S. Patent Application Serial No. 17 / 089,870, filed on November 5, 2020, which is a partial continuation application claiming the benefit and priority of U.S. Patent Application Serial No. 16 / 532,534, filed on August 6, 2019, which claims the benefit and priority of U.S. Provisional Patent Application No. 62 / 734,290, filed on September 21, 2018, the entire disclosure of which is hereby incorporated by reference into this application.

[0004] U.S. Patent Application Serial No. 17 / 089,870 also claims the benefit and priority of U.S. Provisional Patent Application Serial No. 63 / 087,501, filed on October 5, 2020, the entire content of which is hereby incorporated by reference.

[0005] This application is a partial continuation application claiming the benefit and priority of U.S. Patent Application Serial No. 17 / 089,827, filed on November 5, 2020, which claims the benefit and priority of U.S. Provisional Patent Application Serial No. 63 / 084,656, filed on September 29, 2020, the entire content of which is hereby incorporated by reference.

[0006] This application is a partial continuation application claiming the benefit and priority of U.S. Patent Application Serial No. 17 / 089,813, filed on November 5, 2020, which claims the benefit and priority of U.S. Provisional Patent Application Serial No. 62 / 944,548, filed on December 6, 2019, the content of which is hereby incorporated by reference.

[0007] This application is a partial continuation application claiming the benefit and priority of U.S. Patent Application Serial No. 17 / 089,789, filed on November 5, 2020, which claims the benefit and priority of U.S. Provisional Patent Application Serial No. 62 / 944,400, filed on December 6, 2019, the entire content of which is hereby incorporated by reference. Background Art

[0008] Multiple handle assembly manufacturers have developed product lines with exclusive drive systems for operating and / or manipulating electromechanical surgical instruments. In many cases, electromechanical surgical instruments include a reusable handle assembly, a disposable loading unit, and / or a single-use loading unit, such as a surgical end effector, which is selectively attached to the handle assembly prior to use and then disconnected from the handle assembly after use for disposal or in some cases sterilization for reuse. Summary of the Invention

[0009] In one aspect of the present disclosure, a powered surgical instrument module is provided for a surgical end effector. The surgical instrument module includes: a motor having a rotatable motor shaft defining a longitudinal axis; a main sun gear fixed to the motor shaft and configured to rotate with the motor shaft; first, second, third, and fourth planetary gear assemblies; a drive shaft; a high torque output; and a high speed output. The first planetary gear assembly is operably coupled to the main sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to rotation of the main sun gear. The second planetary gear assembly is operably coupled to the first planetary gear assembly such that the second planetary gear assembly rotates in response to rotation of the first planetary gear assembly. The drive shaft is non-rotatably coupled to the second planetary gear assembly such that the drive shaft rotates with the second planetary gear assembly. The third planetary gear assembly is operably coupled to the second planetary gear assembly such that the third planetary gear assembly rotates in response to rotation of the second planetary gear assembly. The fourth planetary gear assembly is operably coupled to the third planetary gear assembly such that the fourth planetary gear assembly rotates in response to rotation of the third planetary gear assembly. The high torque output is configured to be operably coupled to a driven member of a first surgical end effector. A high torque output gear is non-rotatably coupled to the fourth planetary gear assembly such that the high torque output rotates with the fourth planetary gear assembly. The high speed output is configured to be operably coupled to a driven member of a second surgical end effector. The high speed output is non-rotatably coupled to the drive shaft such that the high speed output rotates with the drive shaft.

[0010] In various aspects, the high speed output may be concentrically disposed within the high torque output.

[0011] In various aspects, the high speed and high torque outputs may be configured to rotate simultaneously in response to motor activation.

[0012] In various aspects, the high torque output may include a pinion gear and the high speed output may include a socket.

[0013] In various aspects, the drive shaft may longitudinally extend through the third and fourth planetary gear assemblies.

[0014] In various aspects, the drive shaft may have a proximal end portion fixed to the second planetary gear assembly and a distal end portion disposed within the high torque output and rotatable relative to the high torque output.

[0015] In various aspects, the high torque output may define a cavity therein, and the high speed output may be received within the cavity.

[0016] In various aspects, the high speed output may be configured to move longitudinally relative to and along the drive shaft.

[0017] In various aspects, the surgical instrument module may further include a biasing member captured between the inner surfaces of the high speed output and the high torque output. The biasing member may be configured to bias the high speed output distally.

[0018] In various aspects, the surgical instrument module may further include an elongated annular gear meshingly engaged with each of the planetary gear assemblies.

[0019] In various aspects, each of the planetary gear assemblies may be disposed within the elongated annular gear.

[0020] In various aspects, the elongated annular gear may be rotatably fixed relative to the motor.

[0021] In various aspects, the first planetary gear assembly may include a first planet carrier, a plurality of planet gears rotatably coupled to the first planet carrier and operatively engaged with the main sun gear, and a first sun gear rotatably fixed to the first planet carrier.

[0022] In various aspects, the second planetary gear assembly may include a second planet carrier, a plurality of planet gears rotatably coupled to the second planet carrier and operatively engaged with the first sun gear, and a second sun gear rotatably fixed to the second planet carrier.

[0023] In various aspects, the drive shaft may have a proximal end portion disposed within the second sun gear and rotatably fixed to the second sun gear.

[0024] In various aspects, the third planetary gear assembly may include a third planet carrier, a plurality of planet gears rotatably coupled to the third planet carrier and operatively engaged with the second sun gear, and a third sun gear rotatably fixed to the third planet carrier.

[0025] In various aspects, the fourth planetary gear assembly may include a fourth planet carrier non-rotatably fixed to the high torque output, and a plurality of planet gears rotatably coupled to the fourth planet carrier and operatively engaged with the third sun gear.

[0026] In various aspects, the surgical instrument module may further include an elongated annular gear meshingly engaged with the plurality of planet gears of each of the planetary gear assemblies.

[0027] In various aspects, the surgical instrument module may further include an outer housing that houses an elongate annular gear. The elongate annular gear may be non-rotatable relative to the outer housing.

[0028] In various aspects, the surgical instrument module may further include: a battery, housed in the outer housing and configured to power a motor; and a printed circuit board, which is housed in the outer housing and in communication with the battery and the motor.

[0029] According to another aspect of the present disclosure, there is provided a surgical instrument module for powering a plurality of discrete surgical end effectors. The surgical instrument module includes: a motor having a rotatable motor shaft that defines a longitudinal axis; a main sun gear fixed to the motor shaft and configured to rotate with the motor shaft; a first planetary gear assembly operatively coupled to the main sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to rotation of the main sun gear; a second planetary gear assembly operatively coupled to the first planetary gear assembly such that the second planetary gear assembly rotates in response to rotation of the first planetary gear assembly; a drive shaft having a proximal end portion non-rotatably coupled to the second planetary gear assembly; a high torque output; and a high speed output. The drive shaft is configured to rotate with the second planetary gear assembly. A high torque output gear is operatively coupled to the motor and configured to be operatively coupled to a driven member of a first type of surgical end effector. The high speed output is configured to drive the operation of a second type of surgical end effector. The high speed output is non-rotatably coupled to a distal end portion of the drive shaft such that the high speed output rotates with the drive shaft.

[0030] In various aspects, the distal end portion of the drive shaft may be disposed within the high torque output and may be rotatable relative to the high torque output.

[0031] In various aspects, the surgical instrument module may further include third and fourth planetary gear assemblies. The third planetary gear assembly may be operatively coupled to the second planetary gear assembly such that the third planetary gear assembly rotates in response to rotation of the second planetary gear assembly. The fourth planetary gear assembly may be operatively coupled to the third planetary gear assembly such that the fourth planetary gear assembly rotates in response to rotation of the third planetary gear assembly. The high torque output gear may be non-rotatably coupled to the fourth planetary gear assembly such that the high torque output rotates with the fourth planetary gear assembly.

[0032] In various aspects, the drive shaft may longitudinally extend through the third and fourth planetary gear assemblies.

[0033] In various aspects, the drive shaft may be rotatable relative to each of the third and fourth planetary gear assemblies.

[0034] According to another aspect of the present disclosure, a handle assembly for a handheld surgical instrument is provided. The handle assembly includes: a handle housing that defines a cavity therein; and an instrument module configured to be removably received within the cavity of the handle housing. The instrument module includes: an outer housing; a motor having a rotatable motor shaft that defines a longitudinal axis; a battery received within the outer housing and configured to power the motor; a printed circuit board received within the outer housing and in communication with the battery and the motor; a main sun gear fixed to the motor shaft and configured to rotate with the motor shaft; first and second planetary gear assemblies; a drive shaft configured to rotate with the second planetary gear assembly for high torque output, which is operably coupled to the motor; and a high speed output. The first planetary gear assembly is operably coupled to the main sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to rotation of the main sun gear. The second planetary gear assembly is operably coupled to the first planetary gear assembly such that the second planetary gear assembly rotates in response to rotation of the first planetary gear assembly. The drive shaft has a proximal end portion non-rotatably coupled to the second planetary gear assembly. The high speed output is non-rotatably coupled to a distal end portion of the drive shaft such that the high speed output rotates with the drive shaft.

[0035] In various aspects, the handle assembly may further include an elongated annular gear that meshingly engages each of the planetary gear assemblies.

[0036] In various aspects, each of the planetary gear assemblies may be disposed within the elongated annular gear.

[0037] In various aspects, the elongated annular gear may be rotatably fixed relative to the outer housing.

[0038] In various aspects, the handle assembly may further include third and fourth planetary gear assemblies. The third planetary gear assembly may be operably coupled to the second planetary gear assembly such that the third planetary gear assembly rotates in response to rotation of the second planetary gear assembly. The fourth planetary gear assembly may be operably coupled to the third planetary gear assembly such that the fourth planetary gear assembly rotates in response to rotation of the third planetary gear assembly. A high torque output gear may be non-rotatably coupled to the fourth planetary gear assembly such that the high torque output rotates with the fourth planetary gear assembly.

[0039] In various aspects, the drive shaft may longitudinally extend through the third and fourth planetary gear assemblies.

[0040] In various aspects, the drive shaft may be rotatable relative to each of the third and fourth planetary gear assemblies.

[0041] As used herein, the terms parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular within up to about + or - 10 degrees of true parallel and true perpendicular. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:

[0043] Figure 1 A side view of a handheld electromechanical surgical instrument including a handle assembly is shown, wherein the surgical instrument module is separated, the shaft portion is coupled to the handle assembly, and the surgical end effector is coupled to the shaft portion;

[0044] Figure 2 is a partial perspective view of the handle housing of the handle assembly showing Figure 1 ;

[0045] Figure 3A A perspective view of the surgical instrument module including a power assembly and an outer housing is shown, wherein the parts are separated; Figure 2 ;

[0046] Figure 3B A front elevation view of the assembly of the power assembly of the instrument module showing Figure 3A ;

[0047] Figure 4 A side view of the internal components of the handle assembly is shown, wherein half of the handle housing is removed;

[0048] Figure 5 A perspective view of the motor, the slender annular gear, and the output of the instrument module showing Figure 3A ;

[0049] Figure 6 A perspective view of a plurality of planetary gear assemblies of the instrument module showing Figure 3A ; wherein the slender annular gear is shown in dashed lines;

[0050] Figure 7 A perspective view of the components shown in Figure 5 ; wherein the parts are separated;

[0051] Figure 8 A cross-sectional view taken along line 8-8 in Figure 5 ;

[0052] Figure 9 A cross-sectional view taken along line 9-9 in Figure 8 ; and

[0053] Figure 10 Illustrates four discrete surgical instruments that can all be operated with the Figures 3A - 3B instrument module. DETAILED DESCRIPTION

[0054] Embodiments of a surgical instrument including its handle assembly disclosed herein are described in detail with reference to the accompanying drawings, in which like reference numerals represent the same or corresponding elements in each of the several views. As used herein, the term "distal" refers to the portion of the surgical instrument or its components that is farther from the user, while the term "proximal" refers to the portion of the surgical instrument or its components that is closer to the user.

[0055] As will be described in detail below, a surgical instrument module is provided that is configured to be received within the handle assemblies of a variety of discrete, hand-held surgical instruments. The instrument module may be reusable and is configured to operate the various functions of a variety of different types of surgical end effectors, such as linear staplers, circular staplers, hernia staplers, and small-diameter vascular staplers. The surgical instrument module has two outputs, each of which is operatively coupled to the same motor of the surgical instrument module. The high-speed / low-torque output may be concentrically disposed within the high-torque / low-speed output. The outputs are rotated simultaneously by the motor, but the speeds and torques of rotation are different from each other. Depending on the surgical instrument within which the instrument module is received and operatively engaged therewith, the high-speed / low-torque output or the high-torque / low-speed output of the instrument module selectively engages the corresponding drive components (such as linkages, screws, racks, gears, etc.) of the selected surgical instrument. Thus, although each of the surgical instruments has discrete power and speed requirements, the same instrument module can be used for a variety of surgical instruments. Other features and benefits of the disclosed surgical instrument are described in further detail below.

[0056] Reference Figure 1 and 2 , a surgical instrument according to an embodiment of the present disclosure is generally designated 10 and is in the form of a powered, hand-held, electromechanical linear stapler that is configured to selectively couple a surgical end effector 20 thereto. The end effector 20 is configured to be actuated and manipulated by the linear stapler 10. The hand-held, electromechanical surgical instrument 10 includes a handle assembly 100, a knob housing 102 coupled to the handle assembly 100, and a shaft portion 104 that extends distally from the knob housing 102 and is configured to selectively connect to a surgical attachment (such as the end effector 20).

[0057] The handle assembly 100 includes a disposable and sterile handle housing 110 having: a body, such as a barrel portion 118; a handle portion 108 that extends vertically downward from the barrel portion 118 or extends laterally and proximally from the barrel portion 118; and a hinged door 120 that is pivotally coupled to the handle portion 108. The door 120 selectively opens and closes to permit insertion or removal of a non-sterile or sterile surgical instrument module 122. The handle portion 108 and the door 120 each have an inner perimeter that, when the door 120 is closed, jointly define a sterile barrier for the surgical instrument module 122. In various aspects, the proximal end portion or any suitable location of the barrel portion 118 may have a transparent window (not shown) to permit viewing of a display (such as an LCD, not shown).

[0058] The handle assembly 100 has a firing switch 106 that is configured and adapted to actuate various functions of the end effector 20. The firing switch 106 may be configured as a toggle lever pivotally coupled to the handle portion 108 of the handle housing 110. Activation of the firing switch 106 starts the motor 112 ( Figure 3A and 3B ) depending on whether the top button or the bottom button of the firing switch 106 is actuated, to advance or retract a firing linkage (not explicitly shown) of the surgical instrument 10. The firing linkage is coupled to a drive assembly (not explicitly shown) of the end effector 20 (which includes a knife linkage and an actuation slider) such that advancement of the firing linkage advances the drive assembly of the end effector 20, which closes the jaw members 26, 28 of the end effector 20 and fires the end effector 20 when the safety switch 116 is in an actuated state.

[0059] The handle assembly 100 has a hinge switch 114 that extends laterally through the handle portion 108 and projects outwardly from the left and right sides of the handle portion 108. The hinge switch 114 is configured to actuate articulation of the end effector 20 (such as moving the end effector 20 along a horizontal plane between a position coaxial with the shaft portion 104 and a plurality of positions misaligned with the shaft portion 104). A knob housing 102 is rotatably coupled to the handle housing 110 and has a shaft portion 104 non-rotatably coupled thereto. Thus, manual rotation of the knob housing 102 causes corresponding rotation of the end effector 20 (such as the end effector 20 rotating about a central longitudinal axis "X" defined by the shaft portion 104).

[0060] Reference Figure 1 、 3A, 3B, and 4, the surgical instrument module 122 of the handle assembly 100 includes a sterile outer housing 128 and a reusable power assembly 130 configured to be removably received within the outer housing 128. The outer housing 128 has a lid 132 received in the open bottom end of the outer housing 128, and a spring-loaded tab 134 to facilitate removal of the lid 132.

[0061] The power assembly 130 of the instrument module 122 includes a motor 112, such as an electrically driven motor, which is electrically connected or wirelessly connected to a printed circuit board 136 and a battery 138. In various aspects, the battery 138 may include a boost circuit and may be rechargeable (e.g., wirelessly). The battery 138 has a card-edge connector 140 configured to removably receive a card-edge head 142 of the handle assembly 100 to permit communication from the firing switch 106, safety switch 116, articulation switch 114, and articulation encoder to the battery 138. The printed circuit board 136 may include a USB charging connector 144 to permit the battery 138 to be recharged with a USB charger or wirelessly (e.g., via induction). In various aspects, the printed circuit board 136 may have a motor controller or processor.

[0062] The instrument module 122 further includes: a gearbox 146, such as a planetary gearbox, operably coupled to the drive motor 112; and first and second outputs 148, 150 ( Figure 5 ), which are drivingly coupled to the gearbox 146 and configured to rotate about a longitudinal axis defined by the gearbox 146. The gearbox 146 is configured to convert the power from the motor 112 into rotation of the first output 148 at high torque and low speed, and rotation of the second output 150 at high speed and low torque. Rotation of the outputs 148, 150 by the motor 112 acts on drive shafts and / or gear components of the handle assembly 100 to perform various operations of the end effector 20. By way of example, the motor 112 is configured to move the jaw members 26, 28 of the end effector 20 relative to each other to fire staples from the end effector 20.

[0063] For a more detailed description of the various components responsible for converting the rotation of the outputs 148, 150 into movement of the components of the end effector 20, reference may be made to U.S. Provisional Application No. 62 / 944,400, filed December 6, 2019, the entire contents of which are incorporated herein by reference.

[0064] Reference Figures 5 - 9 , additional details of the various components of the instrument module 122 will now be described. The motor 112 has a rotatable motor shaft 152 ( Figure 7), the main sun gear 154 is non-rotatably fixed to the motor shaft 152 such that the main sun gear 154 rotates with the motor shaft 152 about the longitudinal axis defined by the motor shaft 152. The gearbox 146 includes a plurality of planetary gear assemblies 156, 158, 160, 162 and an elongated annular gear 164 disposed about the plurality of planetary gear assemblies 156, 158, 160, 162 and operatively coupled to the plurality of planetary gear assemblies 156, 158, 160, 162.

[0065] The first planetary gear assembly 156 is operatively coupled to the main sun gear 154 such that the first planetary gear assembly 156 rotates about the longitudinal axis of the motor shaft 152 in response to rotation of the main sun gear 154. The first planetary gear assembly 156 increases the torque output of the motor 112 while reducing the output rotational speed. The first planetary gear assembly 156 includes a first planet carrier 168, a first sun gear 166, and a plurality of planetary gears 156a, 156b, 156c. The first planet carrier 168 has a plurality (e.g., three) of pins 156d, 156e, 156f fixed thereto and extending proximally from its proximal side. The first sun gear 166 is rotatably fixed to the distal side of the first planet carrier 168 and is centered with respect to the longitudinal axis of the motor shaft 152. The planetary gears 156a, 156b, 156c are rotatably coupled to the respective pins 156d, 156e, 156f of the first planet carrier 168. The planetary gears 156a, 156b, 156c engage the main sun gear 154 for rotation in response to rotation of the main sun gear 154. As will be described, the elongated annular gear 164 is rotatably fixed relative to the outer housing 128 ( Figure 3A ) such that the first planetary gear assembly 156 rotates as a unit about the longitudinal axis of the motor shaft 152 in response to rotation of the main sun gear 154.

[0066] The second planetary gear assembly 158 includes a second planet carrier 170, a second sun gear 172, and a plurality of planetary gears 158a, 158b, 158c. The second planetary gear assembly 158 has an increased torque output and a decreased rotational speed output relative to the first planetary gear assembly 156. The second planet carrier 170 has a plurality (e.g., three) of pins 158d, 158e, 158f fixed thereto and extending proximally from its proximal side. The second sun gear 172 is rotatably fixed to the distal side of the second planet carrier 170 and is centered on the longitudinal axis of the motor shaft 152. The planetary gears 158a, 158b, 158c of the second planetary gear assembly 158 are rotatably coupled to respective pins 158d, 158e, 158f of the second planet carrier 170. The planetary gears 158a, 158b, 158c engage the first sun gear 166 of the first planetary gear assembly 156 and the fixed elongated ring gear 164 such that the second planetary gear assembly 158 rotates in response to rotation of the first planetary gear assembly 156.

[0067] The third planetary gear assembly 160 includes a third planet carrier 174, a third sun gear 176, and a plurality of planetary gears 160a, 160b, 160c. The third planetary gear assembly 160 has an increased torque output and a decreased rotational speed output relative to the second planetary gear assembly 158. The third planet carrier 174 has a plurality (e.g., three) of pins 160d, 160e, 160f fixed thereto and extending proximally from its proximal side. The third sun gear 176 is rotatably fixed to the distal side of the third planet carrier 174 and is centered on the longitudinal axis of the motor shaft 152. The planetary gears 160a, 160b, 160c of the third planetary gear assembly 160 are rotatably coupled to respective pins 160d, 160e, 160f of the third planet carrier 174. The planetary gears 160a, 160b, 160c of the third planetary gear assembly 160 engage the second sun gear 172 of the second planetary gear assembly 158 and the elongated ring gear 164 such that the third planetary gear assembly 160 rotates as a unit in response to rotation of the second planetary gear assembly 158.

[0068] The fourth planetary gear assembly 162 includes a fourth planet carrier 178 and a plurality of planetary gears 162a, 162b, 162c. The fourth planetary gear assembly 162 has an increased torque output and a decreased rotational speed output relative to the third planetary gear assembly 160. The fourth planet carrier 178 is connected to, integrally formed with, or otherwise non-rotatably coupled to the proximal end of the first output 148 and has a plurality (e.g., three) of pins 162d, 162e, 162f fixed thereto and extending proximally from its proximal side. The planetary gears 162a, 162b, 162c of the fourth planetary gear assembly 162 are rotatably coupled to respective pins 162d, 162e, 162f of the fourth planet carrier 178. The planetary gears 162a, 162b, 162c of the fourth planetary gear assembly 162 meshingly engage the third sun gear 176 and the elongate ring gear 164 of the third planetary gear assembly 160 such that the fourth planetary gear assembly 162 and the first output 148 rotate together in response to rotation of the third planetary gear assembly 160. It is contemplated that the gearbox 146 may include more or fewer than four planetary gear assemblies and / or other types of gears.

[0069] Continuing reference Figures 5 - 9 , the first output 148 is configured to produce a relatively high torque (e.g., about 625 oz-in) and a relatively low speed (e.g., 24 rpm) and includes a cylindrical body 148a received in the distal end portion of the elongate ring gear 164, and a gear 148b, such as a pinion gear, formed with the distal end portion of the cylindrical body 148a. The pinion gear 148b of the first output 148 is configured to be selectively operatively coupled to a first type of surgical end effector of the linear stapler 10 (e.g., surgical end effector 20( Figure 1 and 10 )) or a driven member (not explicitly shown) of the surgical end effector 300( Figure 10 ) of the circular stapler 310( Figure 10 ). It is contemplated that the handle assemblies 100, 302 or other components of the surgical instruments 10, 310 have corresponding driven components (e.g., gears, racks, etc.) that are configured to selectively engage the pinion gear 148b when the surgical instrument module 122 is received in the respective handle assemblies 100, 302.

[0070] The surgical instrument module 122 also includes a drive shaft 180 having a proximal end portion 180a that is non-rotatably coupled to the second planetary gear assembly 158, such that the drive shaft 180 is configured to rotate with the second planetary gear assembly 158. Specifically, the proximal end portion 180a of the drive shaft 180 is received in the second sun gear 172 of the second planetary gear assembly 158 and is rotatably fixed to the second sun gear 172. The drive shaft 180 has a distal end portion 180b that extends longitudinally through the third and fourth planetary gear assemblies 160, 162 and is freely rotatable therein. The distal end portion 180b of the drive shaft 180 may have a non-circular cross-sectional shape, such as a trilobate shape.

[0071] The second output 150 is attached to the distal end portion 180b of the drive shaft 180 and is configured to rotate with the drive shaft 180 around the longitudinal axis of the drive shaft 180. The second output 150 is configured to generate a relatively low torque (e.g., 25 oz-in) and a relatively high speed (e.g., 600 rpm), and includes a socket 151 that is configured to be operably coupled to a corresponding driven element (not explicitly shown) of a surgical end effector of a different type than the first output 148. For example, the second output 150 of the surgical instrument module 122 can be configured to implement the surgical end effector 400 ( Figure 10 ) or small diameter vascular stapler 500 ( Figure 10 ) of the surgical end effector 510 ( Figure 10 It is contemplated that the handle assembly or other component of the surgical instrument 410, 510 has a corresponding driven component (e.g., a connecting rod) that is configured to selectively engage the socket 151 when the surgical instrument module 122 is received in the corresponding handle housing.

[0072] The second output 150 is disposed concentrically within the first output 148 and is configured to rotate simultaneously with the first output 148 in response to activation of the same motor (i.e., motor 112). However, as described above, the first and second outputs 148, 150 rotate at different speeds and with different torques from each other. The second output 150 is received in an elongated cavity 182 defined by the cylindrical body 148a of the first output 148. A biasing member 184 is disposed within the cavity 182 and captured between the second output 150 and the interior surface of the cylindrical body 148a of the first output 148. The biasing member 184 is configured to bias the second output 150 distally to a position in which the second output 150 is concentric within the first output 148. The biasing member 184 ensures that even if the socket 151 of the second output 150 is not radially aligned with the driven element of the end effector assembly, the socket 151 will engage the driven element when the second output 150 rotates the socket 151 into radial alignment with the driven element.

[0073] Continue to refer Figures 5 - 9 The elongated ring gear 164 of the gearbox 146 encloses each of the planetary gear assemblies 156, 158, 160, 162 and is located relative to the outer housing 128 ( Figure 3A ) and the motor 112 are rotatably fixed. The elongated ring gear 164 has an annular interior surface defining a plurality of longitudinally extending teeth 186 that meshingly engage with the planetary gears of each of the planetary gear assemblies 156, 158, 160, 162. A first bushing 188 may be provided to capture the first output 148 in the elongated ring gear 164, and a second bushing 190 may be provided to capture the second output 150 in the first output 148.

[0074] In operation, a surgical instrument suitable for the operation to be performed is selected. For example, a linear stapler 10 ( Figure 10 The linear stapler 10 is typically used to staple tissue types that are more suitable for receiving staples deployed at high torque and low speed. The surgical instrument module 122 is inserted into the handle housing 110 of the linear stapler 10, whereby the pinion 148b of the first output 148 is operably engaged with a driven element, such as a rack 161 ( Figure 4 ) or a corresponding pinion of the handle assembly 100 of the linear stapler 10. In various aspects, a sterile funnel-shaped insertion guide may be implemented to assist in transferring the surgical instrument module 122 into the handle housing 110. When the insertion guide is removed, the handle housing 110 remains sterile through this sterile transfer procedure.

[0075] With the instrument module 122 positioned within the handle housing 110, the door 120 is closed, thereby sealing the instrument module 122 within the sterile handle portion 108. Additionally, the card edge header 142 of the printed circuit board 126 of the handle assembly 100 is connected to the card edge connector 140 of the instrument module 130.

[0076] In order to operate the surgical end effector 20 of the linear stapler 10, the firing switch 106 ( Figure 1 ), whereby the battery 138 of the instrument module 122 provides power to the motor 112, which in turn drives the first, second, third and fourth planetary gear assemblies 156, 158, 160, 162 to rotate. The planetary gear assemblies 156, 158, 160, 162 continuously increase the torque output through the pinion 148b of the first output 148 and reduce the speed compared to the torque and speed originating from the motor 112. The high torque and low speed output through the first output 148 cause the nail to be advanced from the end effector 20 into the tissue with high force and at low speed.

[0077] If a different surgical procedure is to be performed, for example, a herniorrhaphy procedure, the herniorrhaphy gun 410 (Figure 10 ) Instead of the linear stapler 10. To properly treat tissue, the hernia stapler 410 requires less torque than the linear stapler 10, but a higher actuation speed. The instrument module 122 is inserted into the handle portion 412 of the hernia stapler 410, whereby the socket 151 of the second output 150 engages a driven element (such as a linkage) of the hernia stapler 410.

[0078] To operate the surgical end effector 400 of the hernia stapler 410, the firing switch 414 of the hernia stapler 410 can be toggled, whereby the battery 138 of the instrument module 122 powers the motor 112, which in turn drives the first and second planetary gear assemblies 156, 158 to rotate. Since the drive shaft 180 is fixed to the second sun gear 172 of the second planetary gear assembly 158, the drive shaft 180 rotates with the rotation of the second planetary gear assembly 158. The second output 150, which is non-rotatably attached to the distal end portion 180b of the drive shaft 180, rotates with the drive shaft 180 to effect the functions of the hernia stapler 410, such as deploying surgical staples into tissue at low torque and high speed.

[0079] It is contemplated that each of the first and second drive outputs 148, 150 can be simultaneously coupled to two different driven elements of a particular surgical instrument to perform discrete functions of the surgical instrument.

[0080] Any of the components described herein can be made of metal, plastic, resin, composite materials, etc. considering strength, durability, wear resistance, weight, corrosion resistance, ease of manufacturability, cost of manufacture, etc. Any of the gears disclosed herein can be configured as any suitable gear, such as bevel gears, spur gears, helical gears, worm gears, etc.

[0081] It should be understood that various modifications can be made to the embodiments of the surgical instruments and surgical instrument modules disclosed herein. Accordingly, the foregoing description should not be construed as limiting, but merely as illustrative of embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure.

Claims

1. A surgical instrument module for powering a surgical end effector, the surgical instrument module comprising: A motor having a rotatable motor shaft defining a longitudinal axis; A main sun gear fixed to the motor shaft and configured to rotate with the motor shaft; A first planetary gear assembly operatively coupled to the main sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to rotation of the main sun gear, the first planetary gear assembly including: A first planet carrier; A plurality of planetary gears rotatably coupled to the first planet carrier and operatively engaged with the main sun gear; and A first sun gear rotatably fixed to the first planet carrier; A second planetary gear assembly operatively coupled to the first planetary gear assembly such that the second planetary gear assembly rotates in response to the rotation of the first planetary gear assembly, the second planetary gear assembly including: A second planet carrier; A plurality of planetary gears rotatably coupled to the second planet carrier and operatively engaged with the first sun gear; and A second sun gear rotatably fixed to the second planet carrier; A drive shaft non-rotatably coupled to the second planetary gear assembly such that the drive shaft rotates with the second planetary gear assembly, and the drive shaft has a proximal end portion disposed within and rotatably fixed to the second sun gear; A third planetary gear assembly operatively coupled to the second planetary gear assembly such that the third planetary gear assembly rotates in response to the rotation of the second planetary gear assembly, the third planetary gear assembly including: A third planet carrier; A plurality of planetary gears rotatably coupled to the third planet carrier and operatively engaged with the second sun gear; and A third sun gear rotatably fixed to the third planet carrier; A fourth planetary gear assembly operatively coupled to the third planetary gear assembly such that the fourth planetary gear assembly rotates in response to the rotation of the third planetary gear assembly, the fourth planetary gear assembly including: A fourth planet carrier; and A plurality of planetary gears rotatably coupled to the fourth planet carrier and operatively engaged with the third sun gear; An elongated ring gear meshingly engaged with the plurality of planetary gears of each of the planetary gear assemblies; An outer housing that houses the elongated ring gear, the elongated ring gear being non-rotatable relative to the outer housing; A high torque output configured to be operatively coupled to a driven member of a first surgical end effector, the fourth planet carrier of the fourth planetary gear assembly being non-rotatably coupled to the proximal end of the high torque output such that the high torque output rotates with the fourth planetary gear assembly; and A high speed output configured to be operatively coupled to a driven member of a second surgical end effector, the high speed output being non-rotatably coupled to the drive shaft such that the high speed output rotates with the drive shaft.

2. The surgical instrument module according to claim 1, wherein the high-speed output is concentrically disposed within the high-torque output.

3. The surgical instrument module according to claim 2, wherein the high-speed output and the high-torque output are configured to rotate simultaneously in response to activation of the motor.

4. The surgical instrument module according to claim 1, wherein the high-torque output includes a pinion gear and the high-speed output includes a socket.

5. The surgical instrument module according to claim 1, wherein the drive shaft longitudinally extends through the third planetary gear assembly and the fourth planetary gear assembly.

6. The surgical instrument module according to claim 5, wherein the drive shaft has a proximal end portion fixed to the second planetary gear assembly and a distal end portion disposed within the high-torque output and rotatable relative to the high-torque output.

7. The surgical instrument module according to claim 1, wherein the high-torque output defines a cavity therein and the high-speed output is received within the cavity.

8. The surgical instrument module according to claim 7, wherein the high-speed output is configured to move longitudinally relative to and along the drive shaft.

9. The surgical instrument module according to claim 8, further comprising a biasing member captured between inner surfaces of the high-speed output and the high-torque output, wherein the biasing member is configured to bias the high-speed output distally.

10. The surgical instrument module according to claim 1, wherein each of the planetary gear assemblies is disposed within the elongated annular gear.

11. The surgical instrument module according to claim 1, wherein the elongated annular gear is rotationally fixed relative to the motor.

12. The surgical instrument module according to claim 1, further comprising: a battery received within the outer housing and configured to power the motor; and a printed circuit board received within the outer housing and in communication with the battery and the motor.

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