Adapter for securing a loading unit to a handle assembly of a surgical stapling instrument

Abstract

The present disclosure relates to an adapter for securing a loading unit to a handle assembly of a surgical stapling instrument, and provides an adapter for releasably connecting a loading unit to a handle assembly, comprising a proximal drive shaft, a distal drive shaft, and a shear pin connecting the proximal drive shaft to the distal drive shaft. The proximal drive shaft comprises a proximal portion and a distal portion. The proximal portion of the proximal drive shaft is configured for releasable connection to the handle assembly. The distal drive shaft comprises a proximal portion and a distal portion. The distal portion of the distal drive shaft is configured for releasable connection to the loading unit. The shear pin is configured to rotationally fix the proximal drive shaft to the distal drive shaft, and is configured to break to allow rotation of the proximal drive shaft independent of rotation of the distal drive shaft upon a predetermined torque being applied to the distal drive shaft.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 084,750, filed on September 29, 2020, which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure relates to an electrically powered surgical stapler instrument having a rotary drive assembly. More specifically, this disclosure relates to an adapter for connecting a staple loading unit to an electrically powered handle assembly. Background Technology

[0004] Surgical staplers with electrically powered handles are known. Such devices typically include a replaceable loading unit that is releasably fastened to the electrically powered handle. An adapter assembly is used to connect the loading unit to the electrically powered handle. The adapter assembly can be released from the electrically powered handle, thus allowing for replacement, or it can be integrally formed with the electrically powered handle.

[0005] One or more drive assemblies extend from the electric handle and are operatively connected to the loading unit when it is fastened to the adapter assembly. In some engagement devices, the drive assembly rotates a drive screw in the loading unit, which advances a slider to cause closure of the jaw assembly of the loading unit and engagement of the tissue between the jaws of the jaw assembly. When the slider reaches the end of its stroke, or if the slider jams or otherwise locks with the jaw assembly without firing, the drive assembly is subjected to significant forces at the end of the engagement stroke, which may damage the adapter assembly and / or the handle assembly.

[0006] When the drive assembly is subjected to a large force, it would be beneficial to have a mechanism to prevent damage to the adapter assembly and / or handle assembly. Summary of the Invention

[0007] Therefore, an adapter for releasably connecting a loading unit to a handle assembly includes a proximal drive shaft, a distal drive shaft, and a shear pin connecting the proximal drive shaft to the distal drive shaft. The proximal drive shaft includes proximal and distal portions. The proximal portion of the proximal drive shaft is configured for releasable connection to the handle assembly. The distal drive shaft includes proximal and distal portions. The distal portion of the distal drive shaft is configured for releasable connection to the loading unit. The shear pin is configured to rotatably secure the proximal drive shaft to the distal drive shaft and to break when a predetermined torque is applied to the distal drive shaft to allow rotation of the proximal drive shaft independent of rotation of the distal drive shaft.

[0008] In certain aspects of the present disclosure, the proximal portion of the distal drive shaft includes an annular flange and the distal portion of the proximal drive shaft is received within the annular flange. The annular flange of the distal drive shaft and the distal portion of the proximal drive shaft can each define an opening. The shear pin can be configured for being received through the openings in the annular flange of the distal drive shaft and the distal portion of the proximal drive shaft.

[0009] In some aspects of the present disclosure, the adapter includes a locking plate that releasably secures the adapter to the handle assembly and the loading unit. The adapter can also include a button member secured to the locking plate. Movement of the button member can cause corresponding movement of the locking plate. The button member can be moved from a distal position in which the adapter is secured to the handle assembly and the loading unit to a proximal position in which the adapter is releasable from the handle assembly and the loading unit.

[0010] In other aspects of the present disclosure, the adapter includes first and second housing segments that rotatably support the proximal and distal drive shafts. The adapter can include a sleeve. The first and second housing segments can be received within the sleeve. The adapter can also include a spacer positioned between the proximal drive shaft and the distal drive shaft. BRIEF DESCRIPTION OF DRAWINGS

[0011] Aspects of the present disclosure are described herein with reference to the drawings, in which:

[0012] Figure 1 Perspective view of a surgical stapling instrument including a handle assembly and a loading unit connected to the handle assembly by an adapter in accordance with aspects of the present disclosure;

[0013] Figure 2 is Figure 1 Magnified view of the indicated detail area shown in

[0014] Figure 3 is Figure 1 Perspective side view of the adapter shown in

[0015] Figure 4 is Figure 1 Perspective view of the adapter shown in

[0016] Figure 5 is Figure 4 Magnified view of the indicated detail area shown in

[0017] Figure 6 is Figure 2 Side cross-sectional view of the adapter shown in Figure 3 Side cross-sectional view of the adapter shown in

[0018] Figure 7 FIG. 8 is a cross-sectional view of the adapter shown in FIG. 7, with the adapter’s lock plate and button member in an unlocked position; Figure 6 FIG. 9 is a cross-sectional view of the adapter shown in FIG. 8, with the adapter’s shear pin intact;

[0019] Figure 8 FIG. 10 is a cross-sectional view of the adapter shown in FIG. 9, after the shear pin has been sheared or broken; Figure 6 FIG. 11 is a cross-sectional view of the adapter shown in FIG. 10, after the adapter’s lock plate has been moved to a locked position; Figure 3 FIG. 12 is a cross-sectional view of the adapter shown in FIG. 11, after the adapter’s button member has been depressed;

[0020] Figure 9 FIG. 13 is a cross-sectional view of the adapter shown in FIG. 12, after the adapter’s button member has been released; Figure 1 FIG. 14 is a side cross-sectional view of the end effector of the loading unit of the surgical stapling instrument shown in FIG. 13, with the end effector’s cartridge assembly removed; and

[0021] Figure 10 FIG. 15 is a cross-sectional view of the adapter shown in FIG. 14, after the adapter’s lock plate has been moved to an unlocked position. Figure 8 FIG. 16 is a cross-sectional view of the adapter shown in FIG. 15, after the adapter’s button member has been depressed. DETAILED DESCRIPTION

[0022] The various aspects of the disclosed adapter for surgical instruments having at least one rotary drive assembly 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 adapter assembly or surgical device or component thereof that is further from the clinician, while the term “proximal” refers to the portion of the adapter assembly or surgical device or component thereof that is closer to the clinician. As used herein, the term “clinician” refers to the user, surgeon, assistant, or any other medical personnel involved in the procedure.

[0023] Figure 1 A surgical stapling instrument 5 incorporating an adapter in accordance with aspects of the present disclosure is shown, generally as adapter 100, which releasably connects a loading unit 50 with an adapter assembly 20 of a powered handle assembly 10.

[0024] The surgical stapling instrument 5 will be described only to the extent necessary to fully disclose aspects of the present disclosure. For a detailed description of the structure and function of an exemplary powered handle assembly, please refer to U.S. Patent Nos. 9,055,943 and 9,023,014. For a detailed description of the structure and function of an exemplary adapter assembly and loading unit, please refer to U.S. Patent No. 10,117,650.

[0025] The powered handle assembly 10 incorporates a handle 12 and an adapter assembly 20. The handle 12 is configured for operable engagement by a user and incorporates a battery (not shown) and a drive shaft 22 (not shown) extending through the adapter assembly 20 for driving a surgical instrument (not shown) in accordance with aspects of the present disclosure. Figure 6) rotating motor (not shown). While only a single drive shaft is shown and described, it is contemplated that the power handle assembly 10 can include multiple drive components. As described, the function of the drive shaft 22 includes effecting clamping and stapling of tissue. However, it is contemplated that rotation of the drive shaft 22 can effect alternative functions, such as articulation of the end effector 50.

[0026] The adapter assembly 20 can be integrally formed with the power handle assembly 10 or can be configured for releasable connection with the power handle assembly 10. While shown and described for use with the power handle assembly 10, it is contemplated that aspects of the adapter 100 can be modified for use with a manually actuated handle assembly (not shown).

[0027] As shown, the loading unit 50 includes a linear stapling end effector 52. In aspects of the disclosure, the loading unit 50 is a multiple use loading unit ("MULU") in that it is configured to releasably receive a staple cartridge assembly, such as the staple cartridge 64. While aspects of the adapter 100 are shown and described with reference to the loading unit 50, it is contemplated that the adapter 100 can be modified for use with any surgical instrument including a drive assembly having a rotating shaft.

[0028] Figure 2 The adapter 100 of the surgical stapling instrument 5 Figure 1 ) is shown securing the loading unit 50 to the adapter assembly 20 of the power handle assembly 10. As will be described in further detail below, when the adapter 100 is in the locked state, the button member 140 of the adapter 100 is in the distal or locked position.

[0029] Figure 3 and 4 The adapter 100 is shown separate from the loading unit 50 and the adapter assembly 20. The adapter 100 includes upper and lower housing segments 110, 120, a lock plate 130 slidably supported relative to the upper housing 110, a button member 140 attached to the lock plate 130, and a drive transmission assembly 150 supported within and extending through the upper and lower housing segments 110, 120. The upper and lower housing segments 110, 120 are secured together within the outer sleeve 102 and within the outer sleeve 102 by a rivet or pin 104. As will be described in further detail below, a spring 138 biases the lock plate 130 to the locked position Figure 5 ).

[0030] Each of the upper and lower housing sections 110, 120 defines longitudinal channels 111, 121, which, when housed within the outer sleeve 102, form a longitudinal channel 103 for housing the drive transmission assembly 150. The upper housing section 110 includes a first flange 112 and a second flange 114, and defines a cutout 113 between the first and second flanges 112, 114. The first and second flanges 112, 114 support a locking plate 130, a portion of which is slidably housed within the cutout 113. As shown, the upper and lower housing sections 110, 120 are fastened together and / or held longitudinally fixed to each other by tongues 116 and grooves 117 or by any other suitable means. It is contemplated that the upper and lower housing sections 110, 120 do not need to be fastened to each other and can instead be held relative to each other by being housed within the outer sleeve 102.

[0031] The locking plate 130 of the adapter 100 includes a planar body 132. The proximal portion 132a of the planar body 132 includes an adapter assembly 20 for engaging the electric handle assembly 10. Figure 1 ) 24 ( Figure 6 The latch 134. The distal portion 132b of the planar body 132 is configured to be housed in the slot 51 of the loading unit 50. Figure 5 Inside. Locking plate 130 releasably secures loading unit 50 to electric handle assembly 10.

[0032] The locking plate 130 of the adapter 100 defines a first elongated opening 133 in the proximal portion 132a of the planar body 132, a second elongated opening 135 in the distal portion 132b of the planar body 132, and a pair of openings 137 disposed between the first and second elongated openings 133, 135. The first and second elongated openings 133, 135 of the locking plate 130 receive corresponding first and second flanges 112, 114 of the upper housing section 110 of the adapter 100. The size of the first and second openings 133, 135 is set to allow longitudinal movement of the locking plate 130 relative to the upper housing section 110 when the first and second flanges 112, 114 are received within the corresponding first and second elongated openings 133, 135.

[0033] The locking plate 130 of the adapter 100 includes a pointed tip 136 extending into a first opening 133. The pointed tip 136 of the locking plate 130 supports a spring 138, which biases the locking plate 130 into its locked position. Figure 5 ).

[0034] The button member 140 of the adapter 100 is configured for operable engagement by a clinician. The button member 140 can include one or more indicia identifying the use of the button member 140. For example, and as shown, the button member 140 includes an unlock symbol 142 indicating to the clinician that movement of the button member 140 will unlock the adapter 100.

[0035] The button member 140 of the adapter 100 includes a pair of posts 144 that are received within a pair of openings 137 of the lock plate 130. The pair of posts 144 can be fastened to the lock plate 130 by a friction fit, welding, riveting, adhesive, screws, or other mechanical fasteners.

[0036] The drive transfer assembly 150 of the adapter 100 includes a proximal drive shaft 160 and a distal drive shaft 170 that is releasably fastened to the proximal drive shaft 160 by a shear pin 152. More specifically, the proximal drive shaft 160 of the drive transfer assembly 150 includes an insertion portion 162 and an annular flange 164 disposed proximal of the insertion portion 162. An opening 163 extends through the insertion portion 162. The distal drive shaft 170 of the drive transfer assembly 150 includes an annular sleeve 172 defining a recess 171 sized to receive the insertion portion 162 of the proximal drive shaft 160, and an opening 173 extending transversely through the annular sleeve 172 to receive the shear pin 152. The opening 173 in the distal drive shaft 170 is aligned with the opening 163 in the proximal drive shaft 160 to allow the shear pin 152 to be received within the openings 163, 173. A spacer 156 is disposed about the insertion portion 162 of the proximal drive shaft 160 and is received between the annular flange 164 of the proximal drive shaft 160 and the annular sleeve 172 of the distal drive shaft 170. Figure 6 ) of the annular sleeve 172 to receive the insertion portion 162 of the proximal drive shaft 160, and an opening 173 extending transversely through the annular sleeve 172 to receive the shear pin 152. The opening 173 in the distal drive shaft 170 is aligned with the opening 163 in the proximal drive shaft 160 to allow the shear pin 152 to be received within the openings 163, 173. A spacer 156 is disposed about the insertion portion 162 of the proximal drive shaft 160 and is received between the annular flange 164 of the proximal drive shaft 160 and the annular sleeve 172 of the distal drive shaft 170.

[0037] As shown, the proximal end of the proximal drive shaft 160 defines an opening 165 that receives an extension 22a of the drive shaft 22 that extends from the power handle assembly 10 of the surgical stapling instrument 5. Figure 6 ) of the annular sleeve 172 to receive the insertion portion 162 of the proximal drive shaft 160, and an opening 173 extending transversely through the annular sleeve 172 to receive the shear pin 152. The opening 173 in the distal drive shaft 170 is aligned with the opening 163 in the proximal drive shaft 160 to allow the shear pin 152 to be received within the openings 163, 173. A spacer 156 is disposed about the insertion portion 162 of the proximal drive shaft 160 and is received between the annular flange 164 of the proximal drive shaft 160 and the annular sleeve 172 of the distal drive shaft 170. Figure 6 Figure 1 Figure 6

[0038] Figure 5 ​​​A shear pin 152 driving the transmission assembly 150 is shown. The shear pin 152 includes a cylindrical body 152a having a central body portion 154a and first and second end portions 154b, 154c. As will be described in further detail below, the first and second end portions 154b, 154c of the shear pin 152 are configured to shear from the central body portion 154a of the shear pin 152 to prevent damage to the adapter assembly 20 Figure 4 ) and / or the power handle assembly 10 when a predetermined force is reached in the driving transmission assembly 150 Figure 1 ). More specifically, the first and second end portions 154b, 154c of the shear pin 152 are configured to shear from the central body portion 154a of the shear pin 152 when the distal drive shaft 160 is locked or otherwise prevented from moving. This can occur when the drive sled 70 of the end effector 60 is fully driven through the jaw assembly, or when the end effector 60 is not fired and the drive sled 70 is locked and no longer able to advance. In either case, continued rotation of the distal drive shaft 170 is prevented, which can cause significant damage to the adapter assembly 20 and / or the power handle assembly 10 without intervention.

[0039] In one aspect of the disclosure, the shear pin 152 defines annular grooves 155a, 155b between the respective first and second end portions 154b, 154c of the shear pin 152 and the central body portion 154a of the shear pin 152. The annular grooves 155a, 155b provide a weak point along the cylindrical body 152a of the shear pin 152 to facilitate shearing of the first and second end portions 154b, 154c from the body portion 154a. It is contemplated that the shear pin 152 can alternatively include a through hole (not shown), score, or otherwise be configured to facilitate shearing of the first and second end portions 154b, 154c from the body portion 154a. It is also contemplated that the shear pin 152 can include a single annular groove.

[0040] Figure 6 An adapter 100 securing a loading unit 50 of an adapter assembly 20 that is to be connected to a power handle assembly 10 Figure 1 ) is shown. The button member 140 is in a locked position such that the loading unit 50 cannot be separated from the adapter 100 and the adapter assembly 20 cannot be separated from the adapter 100. In the locked position, the button member 140 is in a distal-most position and is held in the locked position by the bias of the spring 138. In the locked position, the latches 134 on the proximal portion 132a of the locking plate 130 of the adapter 100 engage the tabs 24 of the adapter assembly 20 and the distal portion 132b of the locking plate 130 is received within the slot 51 of the loading unit 50 to prevent the adapter assembly 20 and the loading unit 50 from being separated from the adapter 100.

[0041] Figure 7 The adapter 100 is shown with the button member 140 in the unlocked position. In the unlocked position, the button member 140 is moved to the proximal-most or unlocked position against the bias of the spring 138. In the unlocked position, the latches 134 on the proximal portion 132a of the lock plate 130 of the adapter 100 are spaced apart from the tabs 24 of the adapter assembly 20, and the distal portion 132b of the lock plate 130 is withdrawn from the slot 51 in the loading unit 50. When the button member 140 is in the unlocked position, the loading unit 50 can be separated from the adapter 100, and the adapter 100 can be separated from the adapter assembly 20 and / or the power handle assembly 10.

[0042] Figure 8 A cross-sectional view of the drive transmission assembly 150 is shown taken through the shear pin 152 that connects the proximal and distal drive shafts 160, 170 together. During normal operation of the surgical stapling instrument 5 Figure 1 ), rotation of the proximal drive shaft 160 causes rotation of the distal drive shaft 170.

[0043] Figure 9 The end effector 60 of the loading unit 50 is shown. The end effector 60 includes an anvil assembly 62 and a cartridge assembly 64. A drive screw 66 extends through the cartridge assembly 64 Figure 1 ) and is rotationally supported thereby. The drive screw 66 is operably connected to the distal drive shaft 170 Figure 8 ) such that rotation of the distal drive shaft 170 causes rotation of the drive screw 66. A clamp member 68 is operably engaged with the drive screw 66 and is configured to move longitudinally along the drive screw 66 upon rotation of the drive screw 66. The end effector 60 further includes a sled 70 that is engaged by the clamp member 68 as the clamp member 68 advances through the cartridge assembly 64 to eject staples (not shown) from a cartridge 64a Figure 1 ) of the cartridge assembly 64.

[0044] Figure 10 A cross-sectional view of the drive transmission assembly 150 is shown taken through the shear pin 152 that connects the proximal and distal drive shafts 160, 170 to one another after the shear pin 152 has been sheared. As described above, when the sled 70 of the end effector 60 of the loading unit 50 is prevented from further advancing, for example, reaching the end of the drive stroke, or the sled binds with the cartridge assembly 64 Figure 1 ), the drive screw 66 is prevented from turning. Forcing the drive screw 66 to turn when it cannot further turn can damage the adapter assembly 20 Figure 1) and / or the powered handle assembly 10. To prevent damage to the adapter assembly 20 and / or the powered handle assembly 10, the first and second end portions 154b, 154c of the shear pin 152 are sheared or broken from the central body portion 154a of the shear pin 152 to allow the proximal drive shaft 160 to continue to rotate independent of the distal drive shaft 170.

[0045] After the shear pin 152 is sheared, the adapter 100 of the surgical stapling instrument 5 Figure 1 ) is no longer used to actuate the end effector 60 of the loading unit 50. Rather, shearing the shear pin 152 breaks the connection between the proximal and distal drive shafts 160, 170, which is not repairable without replacing the shear pin 152. Before the surgical stapling instrument 5 Figure 1 ) is reused, the adapter 100 is replaced with a new adapter 100. In this way, it is contemplated that a new adapter 100 can be used for each new firing of the surgical stapling instrument 5.

[0046] Any of the components described herein can be made of metal, plastic, resin, composite, etc. taking into account strength, durability, wear resistance, weight, corrosion resistance, ease of manufacturability, cost of manufacture, etc.

[0047] It should be understood that various modifications can be made to the aspects of the disclosed adapters. Therefore, the description above is not to be construed as limiting, but merely to be exemplary of the aspects of the present disclosure. Those skilled in the art will contemplate other modifications within the scope and spirit of the disclosure.

Claims

1. An adapter for releasably connecting a loading unit to a handle assembly, the adapter comprising: A proximal drive shaft having a proximal portion and a distal portion, the proximal portion of the proximal drive shaft being configured for releasable connection to the handle assembly; A distal drive shaft having a proximal portion and a distal portion, the distal portion of the distal drive shaft being configured for releasable connection to the loading unit; as well as A shear pin connects the proximal drive shaft to the distal drive shaft, wherein the shear pin is configured to rotatably secure the proximal drive shaft to the distal drive shaft and to break when a predetermined torque is applied to the distal drive shaft to allow rotation of the proximal drive shaft to be independent of rotation of the distal drive shaft.

2. The adapter of claim 1, wherein the proximal portion of the distal drive shaft includes an annular flange, and the distal portion of the proximal drive shaft is received within the annular flange.

3. The adapter of claim 2, wherein the annular flange of the distal drive shaft and the distal portion of the proximal drive shaft each define an opening.

4. The adapter of claim 3, wherein the shear pin is configured to be received through the opening in the annular flange of the distal drive shaft and the opening in the distal portion of the proximal drive shaft.

5. The adapter of claim 1, further comprising a locking plate that releasably secures the adapter to the handle assembly and the loading unit.

6. The adapter of claim 5, further comprising a button component fastened to the locking plate, wherein movement of the button component causes a corresponding movement of the locking plate.

7. The adapter of claim 6, wherein the button component is movable from a distal position where the adapter is secured to the handle assembly and the loading unit to a proximal position where the adapter is releasable from the handle assembly and the loading unit.

8. The adapter of claim 1, further comprising a first housing section and a second housing section that rotatably support the proximal drive shaft and the distal drive shaft.

9. The adapter of claim 8, further comprising a sleeve, wherein the first housing segment and the second housing segment are received within the sleeve.

10. The adapter of claim 1, further comprising a spacer positioned between the proximal drive shaft and the distal drive shaft.

11. A surgical stapler, comprising: Handle assembly; as well as An adapter releasably connected to the handle assembly, the adapter comprising, A proximal drive shaft having a proximal portion and a distal portion, the proximal portion of the proximal drive shaft being configured for releasable connection to the handle assembly; A distal drive shaft having a proximal portion and a distal portion, the distal portion of the distal drive shaft being configured for releasable connection to a loading unit; as well as A shear pin connects the proximal drive shaft to the distal drive shaft, wherein the shear pin is configured to rotatably secure the proximal drive shaft to the distal drive shaft and to break when a predetermined torque is applied to the distal drive shaft to allow rotation of the proximal drive shaft to be independent of rotation of the distal drive shaft.

12. The surgical stapler of claim 11, wherein the proximal portion of the distal drive shaft includes an annular flange, and the distal portion of the proximal drive shaft is received within the annular flange.

13. The surgical stapler of claim 12, wherein the annular flange of the distal drive shaft and the distal portion of the proximal drive shaft each define an opening.

14. The surgical stapler of claim 13, wherein the shear pin is configured to be received through the opening in the annular flange of the distal drive shaft and the opening in the distal portion of the proximal drive shaft.

15. The surgical stapler of claim 11, further comprising a locking plate that releasably secures the adapter to the handle assembly and the loading unit.

16. The surgical stapler of claim 15, further comprising a button component fastened to the locking plate, wherein movement of the button component causes a corresponding movement of the locking plate.

17. The surgical stapler of claim 16, wherein the button component is movable from a distal position where the adapter is secured to the handle assembly and the loading unit to a proximal position where the adapter is releasable from the handle assembly and the loading unit.

18. The surgical stapler of claim 11, further comprising a first housing section and a second housing section that rotatably support the proximal drive shaft and the distal drive shaft.

19. The surgical stapler of claim 18, further comprising a sleeve, wherein the first housing section and the second housing section are housed within the sleeve.

20. A surgical stapler, comprising: Handle assembly; Loading unit; as well as An adapter that releasably connects the loading unit to the handle assembly, the adapter comprising, A proximal drive shaft having a proximal portion and a distal portion, the proximal portion of the proximal drive shaft being configured for releasable connection to the handle assembly; A distal drive shaft having a proximal portion and a distal portion, the distal portion of the distal drive shaft being configured for releasable connection to the loading unit; as well as A shear pin connects the proximal drive shaft to the distal drive shaft, wherein the shear pin is configured to rotatably secure the proximal drive shaft to the distal drive shaft and to break when a predetermined torque is applied to the distal drive shaft to allow rotation of the proximal drive shaft to be independent of rotation of the distal drive shaft.

Images