Handheld electromechanical surgical instrument

Abstract

A handle assembly (12) of a handheld surgical instrument (10) includes a handle housing (26), an electric motor (36), and a dual-thread lead screw (46) operably coupled to the electric motor (36) and configured to move proximally and / or distally in response to actuation of the electric motor (36). A first pitch of the lead screw (46) is adapted to effect closure of jaw members (20a, 20b) of an end effector (20), and a second pitch of the lead screw (46) is adapted to effect a stapling function of the end effector (20).

Description

Technical Field

[0001] The present disclosure relates to surgical instruments. More particularly, the present disclosure relates to handheld electromechanical surgical instruments that articulate, rotate, and actuate various other functions of a surgical attachment, such as a surgical loading unit. Background Art

[0002] Electromechanical surgical instruments include a reusable handle assembly and a disposable and / or single-use loading unit, such as a surgical end effector. The end effector is selectively connected to the handle assembly before use and then disconnected from the handle assembly after use for disposal or, in some cases, sterilization or reconditioning for reuse. Some handle assemblies may include one or more drive mechanisms for carrying out the operating functions of the end effector. Summary of the Invention

[0003] In one aspect of the present disclosure, a handle assembly for a handheld surgical instrument is provided, comprising a handle housing, a motor disposed within the handle housing, and a lead screw operably coupled to the motor. The lead screw is configured to be translated by the motor to operate an end effector function and includes a proximal thread and a distal thread. The proximal thread has a first pitch, and the distal thread has a second pitch different from the first pitch of the proximal thread.

[0004] In various aspects, the first pitch of the proximal threads can be greater than the second pitch of the distal threads.

[0005] In some aspects, the distal threads can correspond to the clamping of the end effector and the proximal threads can correspond to the suturing function of the end effector.

[0006] In another aspect, the handle assembly may further include a gear assembly operably coupling the motor and the lead screw.

[0007] In a further aspect, the gear assembly can include a first collar disposed about the lead screw and threadably coupled to the lead screw such that rotation of the first collar translates the lead screw.

[0008] In various aspects, the first collar can have at least one pin received in the proximal or distal threads of the lead screw.

[0009] In some aspects, the gear assembly can include a second collar coupled to the motor.The second collar can have a bevel gear meshingly engaged with the bevel gear of the first collar.

[0010] In other aspects, the motor can have a drive shaft extending therefrom.The second collar can be non-rotatably coupled to the drive shaft such that the second collar rotates with the drive shaft in response to actuation of the motor.

[0011] In further aspects, the bevel gears of the second collar can be angled relative to the bevel gears of the first collar.

[0012] In another aspect, the handle housing can include an upper housing portion and a lower housing portion extending downwardly and proximally from the upper housing portion.The upper housing portion can define a longitudinal axis parallel to the lead screw.

[0013] In various aspects, the lower housing portion can define a longitudinal axis disposed at an angle of less than 90 degrees relative to a longitudinal axis of the upper housing portion.

[0014] In some aspects, the handle assembly can further include an outer tube disposed about the lead screw and pinned to the lead screw. The lead screw can be configured to rotate in response to manual rotation of the outer tube.

[0015] In a further aspect, the handle assembly may further include a cover covering the proximal end of the outer tube and detachably coupled to the handle housing. The cover may be configured to prevent the outer tube and thereby prevent the lead screw from rotating relative to the handle housing.

[0016] According to another aspect of the present disclosure, a handle assembly for a handheld surgical instrument is provided, comprising a handle housing, a motor supported by the handle housing, a lead screw operably coupled to the motor, a knob housing coupled to the handle housing, and a shaft portion. The lead screw is configured to move proximally and / or distally in response to actuation of the motor. The lead screw has dual threads configured to implement discrete functions of an end effector. The shaft portion has a proximal portion coupled to the knob housing and a distal portion configured to couple to the end effector.

[0017] In various aspects, the lead screw can include a proximal portion having a threaded outer surface, and a distal portion having a threaded outer surface. The threaded outer surface of the proximal portion can have a different pitch than the threaded outer surface of the distal portion of the lead screw.

[0018] In some aspects, the pitch of the threaded outer surface of the proximal portion of the lead screw can be greater than the pitch of the threaded outer surface of the distal portion of the lead screw.

[0019] In further aspects, the pitch of the threaded outer surface of the distal portion of the lead screw can correspond to the clamping of the end effector, and the pitch of the threaded outer surface of the proximal portion of the lead screw can correspond to the suturing function of the end effector.

[0020] In other aspects, the handle assembly may further include a gear assembly operably coupling the motor to the lead screw. The gear assembly may further include a first collar and a second collar. The first collar may be disposed about the lead screw and threadably coupled to the lead screw such that rotation of the first collar translates the lead screw. The second collar may be coupled to the motor and may have a bevel gear meshingly engaged with the bevel gear of the first collar.

[0021] In another aspect, the first collar can have at least one pin received in the double threads of the lead screw.

[0022] In various aspects, the motor can have a drive shaft extending therefrom.The second collar can be non-rotatably coupled to the drive shaft such that the second collar rotates with the drive shaft in response to actuation of the motor.

[0023] As used herein, the terms parallel and perpendicular should be understood to encompass relative configurations of substantially parallel and substantially perpendicular that vary from true parallel and true perpendicular by up to about + or - 10 degrees. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Embodiments of the present disclosure are described herein with reference to the accompanying drawings, in which:

[0025] Figure 1 is a side perspective view of a handheld electromechanical surgical instrument according to an embodiment of the present disclosure, the handheld electromechanical surgical instrument including a handle assembly, a shaft portion coupled to the handle assembly, and a surgical end effector coupled to the shaft portion;

[0026] Figure 2 for Figure 1 an enlarged side perspective view of a surgical instrument with handle housing halves removed to illustrate internal components of the handle assembly;

[0027] Figure 3 For illustration Figure 2 a top perspective view of a transmission assembly of a handle assembly including a motor, a lead screw, and a gear assembly;

[0028] Figure 4 To follow Figure 1 a cross-section taken along line 4-4 of FIG. 1 with parts removed to illustrate various components of the transmission mechanism;

[0029] Figure 5 To follow Figure 3 a cross section taken along line 5-5 in FIG, with parts removed to illustrate the lead screw and gear assembly of the transmission mechanism;

[0030] Figure 6 For illustration Figure 3 A side view of a lead screw of a transmission mechanism;

[0031] Figure 7 for Figure 5 , illustrating the lead screw being advanced relative to the gear assembly of the transmission mechanism; and

[0032] Figure 8 To pass through Figure 7 8-8 is a cross-sectional view taken from FIG. DETAILED DESCRIPTION

[0033] Embodiments of the disclosed surgical instrument are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term "distal" refers to the portion of the surgical instrument or its components farther from the user, while the term "proximal" refers to the portion of the surgical instrument or its components closer to the user.

[0034] refer to Figure 1 A surgical instrument according to an embodiment of the present disclosure is generally designated 10 and is in the form of a powered, electromechanical surgical instrument configured to selectively couple thereto a plurality of different surgical end effectors (e.g., surgical end effector 20). End effector 20 is configured to be actuated and manipulated by powered, electromechanical surgical instrument 10.

[0035] The handheld electromechanical surgical instrument 10 includes a handle assembly 12, a knob housing 22 rotatably coupled to the handle assembly 12, and a shaft portion 14 having a proximal portion 14a and a distal portion 14b coupled to the knob housing 22. The knob housing 22 is configured to be manually rotated about a longitudinal axis "X" defined by the shaft portion 14 to rotate an end effector 20 attached to its distal portion 14b. An articulation lever 24 is rotatably coupled to the knob housing 22 to actuate articulation of the end effector 20. The handle assembly 12 has a firing switch 16 configured to actuate the stapling and / or cutting functions of the end effector 20, and a clamp switch 18 for closing the jaw members 20a, 20b of the end effector 20. In various aspects, the same switch 16 or 18 can be used to operate the stapling function, the clamping function, and the cutting function of the end effector 20.

[0036] refer to Figure 1 and 2The handle assembly 12 includes a handle housing 26 having an upper housing portion or barrel portion 28 substantially aligned with a longitudinal axis "X" and a lower housing portion or handle portion 30 extending downwardly and proximally from the upper housing portion 28. The lower housing portion 30 defines a longitudinal axis "Y" disposed at an angle less than 90 degrees (e.g., from about 50 degrees to about 85 degrees) relative to the longitudinal axis "X." The handle assembly 12 includes a printed circuit board 32 extending through both the upper housing portion 28 and the lower housing portion 30, a battery 34 disposed in the upper housing portion 28, and a motor 36 (e.g., a DC motor) disposed in the lower housing portion 30. The printed circuit board 32 is configured to be in electrical communication (e.g., wirelessly or wired) with the battery 34 and the motor 36. The firing switch 16 and the clamping switch 18 are in communication with the printed circuit board 32 for activating the battery 34 to actuate the clamping function and staple firing and / or cutting function of the end effector 20 and / or tissue cutting.

[0037] The motor 36 is drivingly coupled to a gearbox 38 that transmits the force generated by the motor 36 into a mechanical output. The gearbox 38 has a drive shaft 40 coupled to and extending from the motor 36. The drive shaft 40 is operably coupled to the end effector 20 via a transmission assembly 42 such that rotation of the drive shaft 40 causes the jaw members 20a, 20b of the end effector 20 to close and ultimately fire staples from the end effector 20.

[0038] refer to Figures 3 to 6 , the transmission assembly 42 includes a gear assembly 44 and a lead screw 46. The gear assembly 44 includes a first collar 48 coupled to the lead screw 46 and a second collar 50 coupled to the drive shaft 40 of the gear box 38. The second collar 50 is fixed to the drive shaft 40 and is configured to rotate with the drive shaft 40 in response to actuation of the motor 36. Each of the first collar 48 and the second collar 50 has a respective bevel gear 52, 54 extending radially outward therefrom. The bevel gears 52, 54 of the first collar 48 and the second collar 50 are meshingly engaged with each other such that rotation of the second collar 50 causes rotation of the first collar 48. The bevel gears 52, 54 of the first collar 48 and the second collar 50 are angled relative to each other to allow the lower housing portion 30 ( Figure 2 ) is angled relative to the upper housing portion 28 (e.g., from about 50 degrees to about 85 degrees), which provides a more ergonomic feel for the clinician.

[0039] The first collar 48 is disposed about the lead screw 46 and is threadably coupled to the lead screw 46 such that rotation of the first collar 48 translates the lead screw 46. The first collar 48 has at least one pin 56 ( Figure 5 、 7and 8), the pin 56 being received therein and extending radially therethrough, and the at least one pin 56 being slidably received or disposed in the helical threads of the threaded outer surface of the lead screw 46. In various aspects, the first collar 48 can have a threaded inner annular surface threadably coupled to the threaded outer surface of the lead screw 46.

[0040] refer to Figure 3 and 4 , the handle assembly 12 includes a screw guide, such as an outer tube 70, disposed about the lead screw 46. The outer tube 70 defines a longitudinally extending channel 72 having the lead screw 46 slidably disposed therein. The lead screw 46 can be attached to the outer tube 70 via a pin 74 that allows the lead screw 46 to slide within the outer tube 70 while inhibiting rotation of the lead screw 46 within the outer tube 70. The outer tube 70 has a pair of arms 76a, 76b extending radially outward from a proximal end 78 thereof. The arms 76a, 76b are configured to be grasped by the hands of a clinician to manually rotate the outer tube 70, and thereby manually rotate the lead screw 46.

[0041] The handle assembly 12 may further include a cover 80 for covering and supporting the proximal end 78 of the outer tube 70 therein. The cover 80 may define recesses 84a, 84b therein for receiving the arms 76a, 76b of the outer tube 70 and for inhibiting rotation of the outer tube 70 relative to the cover 80. The cover 80 has a pair of flexible latch arms 82a, 82b extending distally therefrom that are configured to engage with the upper housing portion 28 ( Figure 2 )Removable snap-fit ​​connection.

[0042] The lead screw 46 is coaxial with the longitudinal axis "X" of the upper housing portion 28 and has a proximal portion 46a and a distal portion 46b. The distal portion 46b of the lead screw 46 has a rod 57 extending distally therefrom. The rod 57 is coupled to a firing shaft 58 via a universal coupler 60. The firing shaft 58 is configured to be coupled to a driven shaft (not shown) of the end effector 20 for performing the clamping and stapling functions of the end effector 20.

[0043] As in Figure 5 and 6As best shown in FIG. , lead screw 46 has dual threads 62, 64, each of which is configured to implement a respective function of end effector 20, such as a suturing function and a clamping function. Specifically, a proximal portion 46a of lead screw 46 has a threaded outer surface 62 having a first pitch, and a distal portion 46b of lead screw 46 has a threaded outer surface 64 having a second pitch that is different from the first pitch. The pitch of threaded outer surface 62 of proximal portion 46a of lead screw 46 is greater than the pitch of threaded outer surface 64 of distal portion 46b of lead screw 46. In various aspects, lead screw 46 may have a transitional thread between proximal portion 46a and distal portion 46b. In other aspects, the change in pitch between proximal portion 46a and distal portion 46b may be abrupt.

[0044] Because the pitch of the threaded outer surface 62 of the proximal portion 46a of the lead screw 46 is relatively large (e.g., approximately two times larger), the proximal portion 46a of the lead screw 46 is better suited for performing the suturing function of the end effector 20. For example, the larger pitch allows for greater axial translation of the lead screw 46 with each rotation thereof, thereby resulting in faster actuation of the suturing function of the end effector 20. Because the pitch of the threaded outer surface 64 of the distal portion 46b of the lead screw 46 is smaller, the distal portion 46b of the lead screw 46 is better suited for performing the clamping function of the end effector 20. For example, the smaller pitch allows for finer control over the opening and closing of the jaw members 20a, 20b of the end effector 20 due to the smaller distance the lead screw 46 translates with each rotation, and allows for a more controlled rate of compression of tissue disposed between the jaw members 20a, 20b.

[0045] In operation, with tissue received between the jaw members 20a, 20b of the end effector 20, the firing switch 16 can be actuated to transmit power from the battery 34 to the motor 36. The motor 36 rotates the drive shaft 40 of the gearbox 38, which drives the concomitant rotation of the second collar 50 and the first collar 48. Because the pin 56 of the first collar 48 is received in the threaded outer surface 64 of the distal portion 46b of the lead screw 46, the rotation of the first collar 48 drives the distal movement of the lead screw 46 to ultimately close the jaw members 20a, 20b of the end effector 20 around the tissue. Continued actuation of the motor 36 eventually advances the distal portion 46b of the lead screw 46 out of engagement with the first collar 48 and advances the proximal portion 46a of the lead screw 46 into the first collar 48.

[0046] refer to Figure 7 and 8In an embodiment, it is contemplated that the pin 56 includes a head portion 56a supported in the first collar 48 and a stem or body portion 56b extending into the helical groove of the lead screw 46. The body portion 56b of the pin 56 may have an elliptical transverse cross-sectional profile to contact and slide along the threads of the lead screw 46. Although the body portion 56b of the pin 56 is shown and described as having an elliptical transverse cross-sectional profile, it is contemplated that the body portion 56b may have a transverse cross-sectional profile of any shape capable of sliding along the threads of the lead screw 46, such as a circular, oval, triangular, crescent-shaped, etc. The elliptical transverse cross-sectional profile of the body portion 56b of the pin 56 facilitates the transition of the pin 56 between the different thread pitches of the proximal portion 46a and the distal portion 46b of the lead screw 46. Additionally, the elliptical transverse cross-sectional profile of the body portion 56b of the pin 56 increases the surface area of ​​contact between the pin 56 and the threads of the lead screw 46.

[0047] With the proximal end portion 46a of the lead screw 46 engaged with the first collar 48, rotation of the first collar 48 drives relatively rapid distal movement of the lead screw 46 due to the larger pitch of the proximal end portion 46a of the lead screw 46, as described above. The relatively rapid distal movement of the lead screw 46 quickly drives the staples from the end effector 20 into the tissue clamped between the jaw members 20a, 20b. Additionally, for end effectors 20 that include a translatable knife, it is contemplated that distal movement of the lead screw 46 may also result in distal translation of the knife (not shown) through the tissue, thereby cutting the tissue.

[0048] In the event that the battery 34 is low or dead, or actuation of the firing switch 16 otherwise fails to produce the desired output, the transmission mechanism 42 can be manually operated. Specifically, the cover 80 can be removed from the housing portion 26 to expose the outer tube 70 of the handle assembly 12. The clinician can grasp the arms 76a, 76b of the outer tube 70 and rotate the outer tube 70 about the longitudinal axis "X". Since the lead screw 46 is pinned to the outer tube 70, rotation of the outer tube 70 causes rotation of the lead screw 46 to manually open the end effector 20, close the end effector 20, fire staples from the end effector 20, or cut tissue.

[0049] Any of the components described herein may be made of metal, plastic, resin, composite, etc., taking into account strength, durability, wear resistance, weight, corrosion resistance, ease of manufacture, cost of manufacture, etc.

[0050] It should be understood that various modifications may be made to the embodiments of the surgical instrument disclosed herein. Therefore, the above 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. For example, any and all features of one described embodiment may be suitably incorporated into another embodiment.

Claims

1. A handle assembly for a handheld surgical instrument, comprising: handle housing; an electric motor disposed in the handle housing; and a lead screw operably coupled to the motor and configured to be translated by the motor to operate a function of an end effector, wherein the lead screw comprises: a proximal thread having a first pitch; and a distal thread having a second pitch different from the first pitch of the proximal thread; wherein the first pitch of the proximal thread is greater than the second pitch of the distal thread; and The distal thread corresponds to the clamping function of the end effector, and the proximal thread corresponds to the suturing function of the end effector. 2 . The handle assembly of claim 1 , further comprising a gear assembly operably coupling the motor and the lead screw.

3. The handle assembly of claim 2, wherein the gear assembly includes a first collar disposed about the lead screw and threadably coupled to the lead screw such that rotation of the first collar translates the lead screw. 4 . The handle assembly of claim 3 , wherein the first collar has at least one pin received in the proximal threads or the distal threads of the lead screw.

5. The handle assembly of claim 3, wherein the gear assembly includes a second collar coupled to the motor and having a bevel gear in meshing engagement with the bevel gear of the first collar.

6. The handle assembly of claim 5, wherein the motor has a drive shaft extending therefrom, the second collar being non-rotatably coupled to the drive shaft such that the second collar rotates with the drive shaft in response to actuation of the motor.

7. The handle assembly of claim 5, wherein the bevel gear of the second collar is angled relative to the bevel gear of the first collar.

8. The handle assembly of claim 7, wherein the handle housing comprises: an upper housing portion defining a longitudinal axis parallel to the lead screw; and A lower housing portion extends downwardly and proximally from the upper housing portion.

9. The handle assembly of claim 8, wherein the lower housing portion defines a longitudinal axis, the longitudinal axis of the lower housing portion being disposed at an angle of less than 90 degrees relative to the longitudinal axis of the upper housing portion.

10. The handle assembly of claim 1, further comprising an outer tube disposed about the lead screw and pinned to the lead screw, wherein the lead screw is configured to rotate in response to manual rotation of the outer tube.

11. The handle assembly of claim 10, further comprising a cover covering a proximal end of the outer tube and removably coupled to the handle housing, wherein the cover is configured to prevent rotation of the outer tube, and thereby the lead screw, relative to the handle housing.

12. A handle assembly for a handheld surgical instrument, comprising: handle housing; an electric motor supported by the handle housing; a lead screw operably coupled to the motor and configured to move at least one of proximally or distally in response to actuation of the motor, the lead screw having dual threads configured to implement discrete functions of an end effector; a knob housing coupled to the handle housing; and a shaft portion having a proximal end portion coupled to the knob housing and a distal end portion configured to be coupled to an end effector; wherein the lead screw comprises: a proximal portion having a threaded outer surface; and a distal portion having a threaded outer surface, the threaded outer surface of the proximal portion having a different pitch than the threaded outer surface of the distal portion of the lead screw; wherein the pitch of the threaded outer surface of the proximal portion of the lead screw is greater than the pitch of the threaded outer surface of the distal portion of the lead screw; and The pitch of the threaded outer surface of the distal portion of the lead screw corresponds to the clamping of an end effector, and the pitch of the threaded outer surface of the proximal portion of the lead screw corresponds to the suturing function of the end effector.

13. The handle assembly of claim 12, further comprising a gear assembly operably coupling the motor and the lead screw, the gear assembly comprising: a first collar disposed about the lead screw and threadably coupled to the lead screw such that rotation of the first collar translates the lead screw; and A second collar is coupled to the motor and has a bevel gear in meshing engagement with the bevel gear of the first collar.

14. The handle assembly of claim 13, wherein the first collar has at least one pin received in the double threads of the lead screw.

15. The handle assembly of claim 13, wherein the motor has a drive shaft extending therefrom, the second collar being non-rotatably coupled to the drive shaft such that the second collar rotates with the drive shaft in response to actuation of the motor.

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