Powered surgical staple applier

Abstract

An electric powered surgical staple applicator is configured to deploy surgical staples through tissue or a surgical mesh. The surgical staple applicator is articulatable to facilitate placement of the surgical staples to a desired surgical location. The electric powered surgical staple applicator includes a power module that includes a battery, an electric motor, and a gear box. The power module provides a high speed / low torque output and a low speed / high torque output.

Description

[0001] Cross-reference to related applications

[0002] This application is a continuation-in-part of U.S. Patent Application Serial No. 16 / 532,534, filed August 6, 2019, which claims the benefit and priority of U.S. Provisional Patent Application No. 62 / 734,290, filed September 21, 2018, the entire disclosure of which is incorporated herein by reference.

[0003] This application also claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 087,501, filed October 5, 2020, the entire disclosure of which is incorporated herein by reference. Technical Field

[0004] This disclosure relates to surgical instruments, and more specifically, to a surgical staple applicator for attaching a prosthesis to the appropriate position when repairing defects in tissues such as inguinal hernias. Background Technology

[0005] Various surgical procedures require instruments capable of applying fasteners to tissue to form tissue connections or securing objects to tissue. For example, during hernia repair, a mesh is typically fastened to the tissue. In some hernias, such as direct or indirect inguinal hernias, part of the intestine protrudes through a defect in the abdominal wall to form a hernial sac. The defect can be repaired using an open surgical procedure, in which a relatively large incision is made and the hernia is closed outside the abdominal wall by sutures. The mesh is attached to the opening in the abdominal wall with sutures to provide reinforcement. However, this can also be accomplished using minimally invasive surgical fasteners such as surgical staples.

[0006] Therefore, there is a need for a surgical staple applicator that includes a reusable power module that meets the performance requirements of various surgical instruments while suppressing premature staple ejection and timing issues when attempting to eject the staple. Summary of the Invention

[0007] This disclosure describes an apparatus for applying surgical staples, which demonstrates a practical method for meeting performance requirements and overcoming the usability challenges associated with applying surgical staples through surgical mesh into tissue.

[0008] According to this disclosure, a handle assembly for use with a surgical staple applicator includes an actuation assembly and a hinge rod assembly. The actuation assembly includes an electric motor, an actuating rod, and an actuation switch configured to actuate the electric motor. Specifically, the actuating rod has a first end operably coupled to the output shaft of the electric motor for simultaneous rotation therewith, and a second end operably coupled to a loading unit of the surgical staple applicator such that rotation of the actuating rod ejects a surgical staple from the loading unit. The hinge rod assembly is configured to hinge a hinged portion of the surgical staple applicator. The hinge rod assembly includes a hinge bar operably coupled to the hinged portion of the surgical staple applicator such that axial displacement of the hinge bar causes hinged engagement of the hinged portion; and a hinge rod operably coupled to the hinge bar.

[0009] In one aspect, the actuation assembly may further include a processor configured to control the electric motor.

[0010] On the other hand, the actuation assembly may further include an optical motor encoder configured to count rotations of the motor output shaft to ensure an appropriate number of rotations are performed to insert the surgical staple into the tissue. The optical motor encoder is operatively connected to the actuation rod and the processor.

[0011] On the other hand, the actuation assembly may further include an encoder wheel configured to ensure accurate timing of the distal end of the actuation rod relative to the loading unit.

[0012] In another aspect, the actuation assembly may further include a light-emitting diode coupled to the processor to indicate the state of the surgical staple being ejected from the loading unit.

[0013] On another front, the hinge rod may define a transverse aperture sized to accommodate a drive pin coupled to the hinge rod. The drive pin may define an aperture sized to accommodate an actuator rod passing through it.

[0014] In one aspect, the handle assembly may further include a battery pack electrically coupled to the motor and the processor.

[0015] In one aspect, the actuation assembly may further include a piezoelectric element configured to provide an audible sound that causes the surgical nail to be correctly ejected from the loading unit.

[0016] On the other hand, the handle assembly may further include a housing that pivotally supports the hinge rod.

[0017] On the other hand, the hinge rod may include a housing portion and an engagement portion slidably disposed on the engagement surface of the housing.

[0018] On the other hand, the mating surface may define an arcuate profile so that the mating portion can slide in an arc.

[0019] In another aspect, the hinge rod assembly may include a biasing member configured to bias the engagement portion of the hinge rod away from the housing of the handle assembly.

[0020] On the other hand, the housing may include a stop portion configured to secure the positioning of the hinge rod relative to the housing of the handle assembly.

[0021] In one aspect, the hinged rod assembly may further include a hinged pivot arm pivotally fastened to the housing of the handle assembly. The hinged pivot arm may be configured to receive the biasing member therebetween.

[0022] On the other hand, the hinged pivot arm can be housed in the housing portion of the hinge rod.

[0023] On another front, the hinge rod may define an inner cavity, the dimensions of which are configured to accommodate the actuating rod therein.

[0024] According to another aspect of this disclosure, a surgical staple applicator includes a handle assembly and an elongated member. The handle assembly includes an actuation assembly and a hinge rod assembly. The actuation assembly includes a motor, an actuating rod having a first end operably coupled to the output shaft of the motor for simultaneous rotation therewith, and an actuation switch configured to actuate the motor. The hinge rod assembly includes a hinge rod and a hinge arm operably coupled to the hinge rod. The elongated member extends distally from the handle assembly. The elongated member includes a loading unit having a plurality of surgical flathead staples and a hinged portion configured to pivot relative to a longitudinal axis defined by the elongated member. The hinge rod is operably coupled to the hinged portion of the elongated member such that axial displacement of the hinge rod causes the hinged portion to hinge. A second end of the actuating rod is operably coupled to the loading unit such that rotation of the actuating rod ejects the surgical flathead staples from the loading unit. The actuating rod extends through the hinge rod.

[0025] In one aspect, the actuation assembly may further include a processor configured to control the electric motor.

[0026] On the other hand, the actuation assembly may further include an optical motor encoder configured to count rotations of the motor output shaft to ensure an appropriate number of rotations are performed to insert the surgical staple into the tissue. The optical motor encoder is operatively connected to the actuation rod and the processor.

[0027] On the other hand, the actuation assembly may include an encoder wheel configured to ensure accurate timing of the distal end of the actuation rod relative to the loading unit.

[0028] According to another aspect of this disclosure, an electric surgical nail applicator includes a handle assembly, an elongated member, and a power module. The handle assembly includes an actuation assembly and a hinge rod assembly. The actuation assembly includes an actuating rod and an actuation switch. The hinge rod assembly includes a hinge rod and a hinge arm operatively coupled to the hinge rod. The elongated member extends distally from the handle assembly. The elongated member includes a loading unit and a hinged portion. The loading unit has a plurality of surgical nails. The loading unit is operatively coupled to the actuating rod of the actuation assembly such that rotation of the actuating rod unfolds a surgical nail from the loading unit. The hinged portion is pivotable relative to a longitudinal axis defined by the elongated member. The hinged portion is operatively coupled to the hinge rod of the handle assembly such that axial displacement of the hinge rod hinges the hinged portion. The power module is removably housed in the handle assembly. The power module includes a motor, a battery, and a gearbox. The electric motor is operatively coupled to the actuating rod of the actuation assembly to rotate the actuating rod. The battery is electrically coupled to the electric motor to supply power to it. The gearbox includes a main sun gear, a first planetary gear assembly, a second planetary gear assembly, a drive shaft, a third planetary gear assembly, a fourth planetary gear assembly, and a high-speed output. The main sun gear is fixed to the output shaft of the electric motor to rotate with the output shaft. The first planetary gear assembly is operatively coupled to the main sun gear such that the first planetary gear assembly rotates about a longitudinal axis defined by the output shaft in response to rotation of the main sun gear. The second planetary gear assembly is 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. The drive shaft is 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 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 is 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-speed output is coupled to the drive shaft to rotate with it. The high-speed output is operatively coupled to the actuator rod of the handle assembly.

[0029] In one aspect, the gearbox of the power module may further include a high torque output, which is non-rotatably coupled to the fourth planetary gear assembly, such that the high torque output rotates with the fourth planetary gear assembly.

[0030] On the other hand, the high-speed output can be co-located within the high-torque output.

[0031] On the other hand, the high-speed output and the high-torque output can be rotated simultaneously in response to the starting of the electric motor.

[0032] On the other hand, the drive shaft may extend longitudinally through the third planetary gear assembly and the fourth planetary gear assembly.

[0033] On the other hand, the drive shaft may have a proximal portion fixed to the second planetary gear assembly and a distal portion rotatable relative to the high torque output within the high torque output.

[0034] On one hand, the high torque output can define a cavity, the size of which is configured to accommodate the high-speed output.

[0035] On the other hand, the actuation assembly may further include a processor configured to control the electric motor.

[0036] In another aspect, the actuation assembly may further include an optical motor encoder configured to count the number of rotations of the output shaft of the motor to ensure the required number of rotations are performed to insert the surgical staple into the tissue. The optical motor encoder may be operatively connected to the actuation rod and the processor.

[0037] On another aspect, the actuation assembly may further include an encoder wheel configured to ensure accurate timing of the distal end of the actuation rod relative to the loading unit.

[0038] On another aspect, the gearbox of the power module may further include an elongated ring gear that engages with the first planetary gear assembly, the second planetary gear assembly, the third planetary gear assembly, and the fourth planetary gear assembly.

[0039] On the other hand, the first planetary gear assembly, the second planetary gear assembly, the third planetary gear assembly, and the fourth planetary gear assembly can be housed within the elongated gear ring.

[0040] On the other hand, the elongated gear ring can be rotated and fixed relative to the motor.

[0041] According to another aspect of this disclosure, an electric surgical staple applicator includes a handle assembly, an elongated member, and a power module. The handle assembly includes an actuation assembly and a hinge rod assembly. The actuation assembly includes an actuating rod. The hinge rod assembly includes a hinge rod and a hinge arm operatively coupled to the hinge rod. The elongated member extends distally from the handle assembly. The elongated member includes a loading unit and a hinged portion. The loading unit has a plurality of surgical staples. The loading unit is operatively coupled to the actuating rod of the actuation assembly such that rotation of the actuating rod unfolds a surgical staple from the loading unit. The hinged portion is pivotable relative to a longitudinal axis defined by the elongated member. The hinged portion is operatively coupled to the hinge rod of the handle assembly such that axial displacement of the hinge rod hinges the hinged portion. The power module is removably housed in the handle assembly. The power module includes a motor with an output shaft, a main sun gear, a first planetary gear assembly, a second planetary gear assembly, a drive shaft, a high-speed output, and a high-torque output. The main sun gear is fixed to the output shaft and configured to rotate with the output shaft. The first planetary gear assembly is operatively coupled to the main sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to the rotation of the main sun gear. The second planetary gear assembly is 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 drive shaft has a proximal portion coupled to the second planetary gear assembly to rotate with it. The high-speed output is configured to rotate the actuator rod. The high-speed output is coupled to the drive shaft to rotate with it. The high-torque output is operatively coupled to the driven member of a surgical end effector. The high-torque output is operatively coupled to the motor.

[0042] On one hand, the high-speed output can be co-located within the high-torque output.

[0043] On the other hand, the distal portion of the drive shaft may be housed within the high torque output and rotatable relative to the high torque output.

[0044] On the other hand, the high torque output can define a cavity therein, and the high speed output can be housed within the cavity.

[0045] On another front, the gearbox of the power module may further include a biasing member that is trapped between the inner surfaces of the high-speed output and the high-torque output.

[0046] On one hand, the biasing member can be configured to bias the high-speed output to the far side.

[0047] According to another aspect of this disclosure, a handle assembly for use with an electric surgical staple applicator includes an actuation assembly, a hinge rod assembly, and a power module. The actuation assembly includes an actuating rod and an actuation switch. The hinge rod assembly includes a hinge rod and a hinge arm operatively coupled to the hinge rod. The power module includes a motor having an output shaft, a battery supplying power to the motor, a printed circuit board communicating with the battery and the motor, and a gearbox. The gearbox includes a primary sun gear fixed to the output shaft, a first planetary gear assembly, a second planetary gear assembly, a drive shaft, a high-torque output, and a high-speed output. The first planetary gear assembly is operatively coupled to the primary sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to rotation of the primary sun gear. The second planetary gear assembly is 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. The drive shaft has a proximal portion and a distal portion non-rotatably coupled to the second planetary gear assembly. The drive shaft is configured to rotate with the second planetary gear assembly. The high-torque output is operatively coupled to the electric motor. The high-speed output is coupled to the distal portion of the drive shaft to rotate with it.

[0048] On one hand, the power module can be removably housed in the cavity of the handle assembly in a sealed manner. Attached Figure Description

[0049] The following description, with reference to the accompanying drawings which are incorporated in and form a part of this specification, illustrates various aspects of this disclosure, in which:

[0050] Figure 1 This is a perspective view of the handle assembly of the electric surgical nail applicator according to this disclosure;

[0051] Figure 2 This is a partial perspective view of the slender components of an electric surgical staple applicator;

[0052] Figure 3 for Figure 1 A partial perspective view of the loading unit of the surgical flathead screw applicator, illustrating the coil separated from the inner tube;

[0053] Figure 4 This is a longitudinal cross-sectional view of the distal end of a powered surgical flathead screw applicator, illustrating the surgical flathead screw being implanted into the underlying tissue through a surgical mesh;

[0054] Figure 5 For use with Figure 1A perspective view of a surgical mesh used with a powered surgical flathead screw applicator, illustrating the use of multiple surgical flathead screws to anchor the surgical mesh to the underlying tissue;

[0055] Figure 6 To remove half of the casing Figure 1 Side view of the handle assembly;

[0056] Figure 7 For the separation of its parts Figure 1 Exploded perspective view of the handle assembly;

[0057] Figure 8 for Figure 1 A partial side view of the handle assembly;

[0058] Figure 9 For removing a portion of the casing Figure 1 A partial side view of the handle assembly;

[0059] Figure 10 yes Figure 1 A partial perspective view of the handle assembly, which shows the actuation assembly;

[0060] Figure 11 This is a perspective view of a handle assembly for use with an electric surgical staple applicator, according to another aspect of this disclosure;

[0061] Figure 12 yes Figure 11 A perspective view of the handle assembly, with half of the housing removed;

[0062] Figure 13 yes Figure 11 Side view of the handle assembly;

[0063] Figure 14 This is a perspective view of an electric surgical staple applicator according to another aspect of this disclosure;

[0064] Figure 15 yes Figure 14 A partial perspective view of the handle assembly of an electric surgical staple applicator, in which a portion of the housing has been removed;

[0065] Figure 16 yes Figure 14 An exploded perspective view of the articulated assembly of an electric surgical staple applicator, with the parts separated.

[0066] Figure 17 yes Figure 14 A partial perspective view of the handle assembly;

[0067] Figure 18 yes Figure 14 Handle assembly along Figure 14A cross-sectional view taken by section line 18-18;

[0068] Figure 19 yes Figure 14 Handle assembly along Figure 14 The cross-sectional view taken by section line 19-19;

[0069] Figure 20 yes Figure 19 A cross-sectional view of the handle assembly, showing its use;

[0070] Figure 21 yes Figure 14 A perspective view of the handle assembly, wherein the power module is separate from the handle assembly;

[0071] Figure 22 yes Figure 14 A cross-sectional view of the handle assembly, with the power module removed from the handle assembly;

[0072] Figure 23 yes Figure 21 A perspective view of the power module;

[0073] Figure 24 yes Figure 23 A cross-sectional view of the power module; and

[0074] Figure 25 yes Figure 21 An exploded perspective view of the gearbox of the power module, with the various parts separated. Detailed Implementation

[0075] Embodiments of the disclosed surgical instruments are described in detail with reference to the accompanying drawings, in which similar reference numerals refer to the same or corresponding elements in each of the several views. As used herein, conventionally, the term "distal" will refer to the portion of the instrument, device, apparatus, or component thereof further away from the user, while the term "proximal" will refer to the portion of the instrument, device, apparatus, or component thereof closer to the user. In the following description, well-known functions or constructions are not described in detail to avoid obscuring this disclosure with unnecessary detail.

[0076] refer to Figures 1 to 4 A handle assembly for use with a surgical staple applicator for applying surgical staples 10 suitable for insertion through a surgical mesh "M" and tissue "T" is generally shown as a handle assembly 200. The surgical staple applicator generally comprises a handle assembly 200, an elongated member 50 having a hinged portion 60, and a loading unit 30 optionally connected to the distal end of the elongated member 50. The loading unit 30 is electromechanically coupled to the handle assembly 200 and supports a plurality of surgical staples 10.

[0077] The loading unit 30 includes an outer tube 32 defining an inner cavity (not shown), a helix or coil 36 fixedly disposed within the outer tube 32, and an inner tube 38 rotatably disposed within the coil 36. The inner tube 38 defines an inner cavity therethrough and includes a first portion 38a and a splined second portion 38b. The second portion 38b of the inner tube 38 is slotted, thereby defining a pair of teeth 38b1 and a pair of channels 38b2. The second portion 38b of the inner tube 38 is configured to support a plurality of surgical flathead screws 10 within the inner tube 38. Specifically, the surgical flathead screws 10 are loaded into the loading unit 30 such that a pair of opposing threaded sections 112a of the surgical flathead screw 10 extend through corresponding channels 38b2 of the second portion 38b of the inner tube 38 and are slidably disposed within grooves in the coil 36, and a pair of teeth 38b1 of the second portion 38b of the inner tube 38 are disposed within a pair of slotted sections 116a of the surgical flathead screw 10. In use, as the inner tube 38 rotates relative to the coil 36 about its longitudinal axis “XX”, a pair of teeth 38b1 of the inner tube 38 transmits the rotation to the surgical flathead 10 and pushes the surgical flathead 10 distally when the head thread 114a of the surgical flathead 10 engages with the coil 36.

[0078] Special Reference Figure 2 The surgical flathead screw applicator includes an operably hinged rod assembly 300 supported in a handle assembly 200. Figure 6 The hinge portion 60 is connected to the sliding tube. The hinge portion 60 may include a drive assembly (not shown) having a sliding tube and a hinge arm pivotally connected to the sliding tube. The hinge rod assembly 300 is connected to the sliding tube such that when the hinge rod assembly 300 is actuated, the sliding tube displaces through the elongated member 50. The longitudinal translation of the sliding tube moves the hinge arm so that the loading unit 30 can be hinged relative to the longitudinal axis "XX". Figure 3 Reference can be made to U.S. Patent Nos. 7,867,252 and 8,282,670, and U.S. Patent Application Publication No. 2016 / 0166255, the entire contents of each of which are incorporated herein by reference for a more detailed discussion of the structure and operation of a surgical flathead screw applicator comprising an articulated portion and a loading unit.

[0079] Now for reference Figure 6 The handle assembly 200 includes a housing 202 and a hinge portion 60 configured to hinge an elongated member 50. Figure 2The device includes a hinge rod assembly 300, an actuation assembly 400 configured to eject the surgical flathead screw 10 from the loading unit 30 of the elongated member 50, and a battery pack 440 removably attached to the housing 202. The housing 202 includes an ergonomic structure providing comfort, ease of use, and intuitiveness, such that when a clinician grips the housing 202, for example, the thumb can be positioned to slide the hinge rod assembly 300, and, for example, the index finger can be positioned to trigger the actuation switch 404 of the actuation assembly 400. Actuation of the actuation assembly 400 ejects the surgical flathead screw 10 ( Figure 4 The loading unit 30 pops out through the mesh "M" ( Figure 4 And it enters human tissue "T".

[0080] refer to Figure 6 and 7 The hinge rod assembly 300 includes a hinge rod 310 and a hinge rod 360 operably connected to the hinge rod 310. The hinge rod 310 is operably connected to the hinge portion 60 of the elongated member 50 of the surgical flathead screw applicator. Figure 2 The articulated rod 310 is connected via the defined channel 304. Figure 8 The mounting plate 312 is slidably supported on the housing 202 of the handle assembly 200, and the channel 304 is configured such that axial displacement of the hinge rod 310 passing through it can cause the hinge portion 60 ( Figure 2 The hinge rod 310 has a channel 317 of defined dimensions configured to receive the actuating rod 402 of the hinge assembly 400. Figure 8 The ring structure. The hinge rod 310 is further defined by a transverse hole 314 that accommodates the hinge drive pin 316 connected to the hinge rod 360.

[0081] Continue to refer to Figure 6 and 7 The hinge 360 ​​includes a housing portion 362 and an engagement portion 364 that slidably engages with an engagement surface 204 of the housing 202. The engagement surface 204 has an arcuate profile, allowing the engagement portion 364 to travel in, for example, an arcuate pattern. The housing portion 362 is housed within the housing 202 and is sized to accommodate hinged pivot arms 366a, 366b that fit together to accommodate a biasing member 368 therebetween. Each hinged pivot arm 366a, 366b defines a first bore 370a, 370b, a second bore 372a, 372b, and slots 374a, 374b. The first bores 370a, 370b are sized to accommodate a hinged pivot pin 378 that pivotally connects the hinged pivot arms 366a, 366b to the housing 202. Figure 8The second holes 372a and 372b are sized to receive a hinge drive pin 316 extending through a transverse hole 314 of the hinge rod 310. In this configuration, when the hinge pivot arms 366a and 366b pivot about the hinge pivot pin 378, the hinge drive pin 316 causes axial displacement of the hinge rod 310. The hinge drive pin 316 is sized to receive a transverse hole 380 through which the actuation rod 402 of the actuation assembly 400 passes. The slots 374a and 374b of the hinge pivot arms 366a and 366b are sized to cam-receive a cam pin 384 biased away from the hinge pivot pin 378 by a biasing member 368 sandwiched between the hinge pivot arms 366a and 366b.

[0082] Now for reference Figure 7 and 8 The housing portion 362 of the hinge rod 360 is sized to accommodate mating hinged pivot arms 366a, 366b. The housing portion 362 defines a slot 363 sized to cam-accommodate a cam pin 384, which is cam-slidable within slots 374a, 374b of the hinged pivot arms 366a, 366b. Furthermore, the housing portion 362 includes teeth 367 configured to engage a stop portion 208 of the housing 202 to prevent movement of the hinge rod 360 relative to the housing 202, thereby locking the axial position of the hinge rod 310, which in turn locks the hinge portion 60 of the surgical flathead screw applicator. Figure 2 The orientation of the hinge rod 360. In this configuration, the hinge rod 360 is biased away from the hinge pivot pin 378, such that the teeth 367 of the housing portion 362 engage the stop portion 208. When the engaging portion 364 of the hinge rod 360 is pressed toward the housing 202, the teeth 367 move away from the stop portion 208, allowing the clinician to engage the engagement surface 204 of the housing 202. Figure 6 The slidable engagement portion 364 of the surgical flathead screw applicator allows the hinge portion 60 of the surgical flathead screw applicator to be hinged to the desired orientation.

[0083] Now for reference Figure 9 The articulated rod assembly 300 further includes a cam wedge 350 having first, second, and third portions 350a, 350b, and 350c configured to engage a cam pin 384, which is cam-slidable in slots 374a and 374b of the articulated pivot arms 366a and 366b and in slot 363 of the articulated rod 360. The first, second, and third portions 350a, 350b, and 350c correspond to corresponding stop sections 208a, 208b, and 208c of the stop portion 208. In this way, the articulation clearance decreases as the cam pin 384 advances along the first, second, and third portions 350a, 350b, and 350c of the cam wedge 350.

[0084] Return to reference Figure 6 and 7 The actuation assembly 400 includes a loading unit 30 operably connected to the surgical flathead screw applicator. Figure 2 The actuator rod 402 and the motor 420 are connected and configured to actuate the motor 420 to eject the surgical flathead screw 10. Figure 4 The actuator 400 comprises an actuation switch 404, a printed circuit board 430 including a microprocessor (not shown) to control the actuation assembly 400, and a battery pack 440 removably attached to the housing 202 and electrically connected to the motor 420 and the printed circuit board 430. The proximal end of the actuator rod 402 is operably coupled to the output shaft of the motor 420 for simultaneous rotation therewith, such that when the clinician triggers the actuation switch 404, the motor 420 is actuated to apply axial rotation to the actuator rod 402. The distal end of the actuator rod 402 is operably coupled to the inner tube 38 of the loading unit 30. Figure 3 Connect to rotate simultaneously with it.

[0085] Now for reference Figure 10 The actuation assembly 400 may further include an encoder assembly 410 operatively connected to the processor of the actuation rod 402 and the printed circuit board 430. The encoder assembly 410 may include, for example, an optical motor encoder 405 configured to maintain an accurate count of rotations of the motor output shaft or the actuation rod 402 to ensure the appropriate number of rotations are performed to insert the surgical flathead screw 10 into, for example, a mesh “M” and into the tissue “T”. Figure 4 Furthermore, the encoder assembly 410 may further include, for example, a single notch encoder wheel 407, which is configured to ensure that the distal end of the actuator rod 402 is relative to the loading unit 30. Figure 2 The encoder assembly 410 may further include a light-emitting diode (“LED”) indicator 409 to indicate the ejection state of each surgical staple 10. For example, green light may indicate that the surgical staple 10 has been properly applied through the mesh “M” and into the tissue “T”, and red light may indicate improper application of the surgical staple 10, for example, due to an erroneous signal from the optical motor encoder 405 or a single notch encoder wheel 407. Alternatively, the encoder assembly 410 may further include a piezoelectric element 411 ( Figure 6 ), which is used to provide audible sound for the proper application of the surgical flathead screw 10.

[0086] Brief Reference Figure 6 The handle assembly 200 may further include a release lever 450 slidably attached to the housing 202. The release lever 450 is operatively coupled to the loading unit 30. Figure 2 The connection allows the loading unit 30 to disengage from the elongated member 50 of the surgical flathead screw applicator when the release lever 450 is pulled. Figure 2 ).

[0087] In use, the loading unit 30 is operably mounted to the distal end of the elongated member 50. The loading unit 30 is introduced into the target surgical site in a non-hinged state. The clinician can remotely hinge the loading unit 30 relative to the longitudinal axis "XX" to access the surgical site. Specifically, the clinician can slide the engagement portion 364 of the hinge rod 360 along the engagement surface 204 of the housing 202. As the hinge rod 310 is axially displaced, the loading unit 30 moves to the hinge orientation relative to the central longitudinal axis "XX". Furthermore, the clinician can position the surgical mesh "M" adjacent to the surgical site. Once the surgical mesh "M" is correctly positioned on the surgical site, the clinician can trigger the actuation switch 404 to eject the surgical staple 10 through the mesh "M" and into the tissue "T". Although the articulated rod 310 is configured for axial displacement, it is further considered that the articulated rod 1310 can be rotatably supported by the rotor 1370, such that the output of the articulated rod 1310 can be utilized by the loading unit 30 to achieve axial rotation of the articulation of the articulated rod, as referenced. Figure 11-13 Understandable. Further consideration is that the articulated assembly 400 may further include a transmission assembly for selectively imparting rotation of the output shaft of the motor 420 to the actuator rod 1310.

[0088] Figure 14-16 This demonstrates another aspect of the method for applying a "T" (T-shaped structure) suitable for penetrating tissue, according to this disclosure. Figure 4 ) and surgical mesh “M” ( Figure 5 ) Inserted surgical nails 10 ( Figure 3 The electric surgical staple applicator 3000 is described below. For the sake of brevity and to avoid obscuring this disclosure with unnecessary detail, structural and functional features of the electric surgical staple applicator 3000 that are substantially similar to those of the surgical staple applicator described above will not be described. The electric surgical staple applicator 3000 comprises a disposable part and a reusable part. The reusable part comprises a device with a motor 5420, as will be discussed below. Figure 23 ), Battery 5440 ( Figure 23 ) and power modules for electronic devices 5000 ( Figure 21In this configuration, the electric surgical staple applicator 3000 can aseptically house the power module 5000. For example, a non-sterile power module 5000 can be housed within a sealed compartment of the electric surgical staple applicator 3000, thus preventing any potential contamination. The reusable power module 5000 is compatible with a variety of surgical device applications. For example, other applications may include its use in linear tissue suture devices, circular suture devices, and small-diameter suture devices. Rechargeable batteries have a larger capacity than disposable alternatives, and reusable motors can offer higher quality and efficiency than a fully disposable design would be possible. Ergonomics and user controls can be customized for specific applications. Furthermore, the power module 5000 enables stable control of the end effector with minimal movement on the axis and tissue. However, it is also considered that a low-cost, disposable power module could be permanently integrated into the handle assembly for single-use devices.

[0089] Figure 14 An electric surgical staple applicator 3000 is shown, which includes a handle assembly 3200, an elongated member 3050 having a hinge portion 3060, and a loading unit 30 optionally connected to the distal end of the elongated member 3050. Figure 3 The loading unit 30 is electromechanically coupled to the handle assembly 3200 and supports a plurality of surgical nails 10. As the inner tube 38 of the loading unit 30 rotates about its longitudinal axis “XX” relative to the coil 36, a pair of teeth 38b1 of the inner tube 38 transmits the rotation to the surgical nails 10 and propels the surgical nails 10 distally when the head thread 114a of the surgical nails 10 engages with the coil 36.

[0090] Figure 14 A further illustration shows an electric surgical staple applicator 3000, which includes a hinge portion 3060 operatively coupled to a hinge rod assembly 3300 supported in a handle assembly 3200. As discussed above, the hinge portion 3060 may include a drive assembly having a slidable tube and a hinge arm pivotally coupled to the slidable tube. The hinge rod assembly 3300 is coupled to the slidable tube such that when the hinge rod assembly 3300 is actuated, the slidable tube displaces through an elongated member 3050. The longitudinal translation of the slidable tube moves the hinge arm so that the loading unit 30 can hinge within the plane defined by the elongated member 3050 and the loading unit 30.

[0091] Figure 15 A handle assembly 3200 is shown, the handle assembly including a housing 3202 and a hinge portion 3060 configured to allow an elongated member 3050 to... Figure 14The hinged hinge rod assembly 3300 is configured to allow the surgical nail 10 ( Figure 3 The device ejects the loading unit 30 from the actuation assembly 3400 and a power module 5000 removably fastened to the housing 3202. The housing 3202 incorporates ergonomic features such that when a clinician grasps the housing 3202, for example, the thumb can be positioned to slide the hinge assembly 3300, and for example, the index finger can be positioned to trigger the actuation switch 3404 of the actuation assembly 3400. Actuation of the actuation assembly 3400 ejects the surgical staple 10 from the loading unit 30 and into the body tissue "T" ( Figure 4 ) and through the mesh “M” ( Figure 5 ).

[0092] Figure 15 and 16 A hinge rod assembly 3300 is shown, comprising a hinge rod 3310 and a hinge arm 3360 operatively coupled to the hinge rod 3310. The hinge rod 3310 is operatively coupled to a hinge portion 3060 of an elongated member 3050 of an electric surgical staple applicator 3000. The hinge rod 3310 is slidable within an outer tube 3319 supported by a mounting plate 3312 within a housing 3202 of a handle assembly 3200. Axial displacement of the hinge rod 3310 causes the hinge portion 3060 to hinge based on the axial positioning of the hinge rod 3310. Specifically, the hinge rod 3310 has an annular structure with defined dimensions configured to receive a channel of the actuating rod 3402 of the hinge assembly 3400 therein. The hinge rod 3310 is further sized to accommodate a transverse hole 3314 for the hinge drive pin 3316 coupled to the hinge rod 3360.

[0093] Figure 16 The hinge rod 3360 is further shown, which includes a housing portion 3362 and an engagement surface 3204 that slidably engages with the housing 3202. Figure 15The engaging portion 3364. The engaging surface 3204 has an arcuate profile, allowing the engaging portion 3364 to travel in, for example, an arcuate pattern. The housing portion 3362 is disposed within the housing 3202 and is sized to accommodate hinged pivot arms 3366a, 3366b that fit together to accommodate therebetween the biasing member 368. Each hinged pivot arm 3366a, 3366b defines a first bore 3370a, 3370b, a second bore 3372a, 3372b, and slots 3374a, 3374b. The first bores 3370a, 3370b are sized to accommodate a hinged pivot pin 3378 that pivotally couples the hinged pivot arms 3366a, 3366b to the housing 3202. The second holes 3372a and 3372b are sized to accommodate a hinge drive pin 3316 extending through a transverse hole 3314 in the hinge rod 3310. In this configuration, when the hinge pivot arms 3366a and 3366b pivot about the hinge pivot pin 3378, the hinge drive pin 3316 causes axial displacement of the hinge rod 3310. The actuating rod 3402 of the actuation assembly 3400 extends between the hinge drive pins 3316. The slots 3374a and 3374b of the hinge pivot arms 3366a and 3366b are sized to cam-like accommodate a cam pin 3384 biased away from the hinge pivot pin 3378 by an offset member 3368 inserted between the hinge pivot arms 3366a and 3366b.

[0094] The housing portion 3362 of the hinge rod 3360 is sized to accommodate mating hinge pivot arms 3366a and 3366b. The housing portion 3362 is sized to accommodate a slot 3363 of a cam pin 3384 in a cam-like manner, the cam pin being slidable in a cam-like manner within the slots 3374a and 3374b of the hinge pivot arms 3366a and 3366b. Additionally, the housing portion 3362 includes teeth 3367 configured to engage a stop portion 3208 of the housing 3202. Figure 18 This prevents the hinge rod 3360 from moving relative to the housing 3202, thereby locking the axial positioning of the hinge rod 3310, which in turn locks the hinge portion 3060 of the electric surgical staple applicator 3000. Figure 14 The orientation of the screwdriver 3060 is such that, in this configuration, the hinge rod 3360 is offset away from the hinge pivot pin 3378, causing the teeth 3367 of the housing portion 3362 to engage the stop portion 3208. When the engaging portion 3364 of the hinge rod 3360 is pressed toward the housing 3202, the teeth 3367 move away from the stop portion 3208, allowing the clinician to slidably move the engaging portion 3364 on the engaging surface 3204 of the housing 3202, thereby enabling the hinge portion 3060 of the electric surgical screw applicator 3000 to be hinged to the desired orientation.

[0095] Figure 17 and 18 A hinge assembly 3300 is shown, which further includes a cam wedge 3350 having a first portion 3350a, a second portion 3350b, and a third portion 3350c configured to engage a cam pin 3384 in a cam-like manner. The cam pin is cam-like slidable in slots 3374a, 3374b of the hinge pivot arms 3366a, 3366b and in slot 3363 of the hinge rod 3360. The first portion 3350a, the second portion 3350b, and the third portion 3350c correspond to corresponding stop sections 3208a, 3208b, 3208c of the stop portion 3208. In this way, the hinge clearance decreases as the cam pin 3384 advances along the first portion 3350a, the second portion 3350b, and the third portion 3350c of the cam wedge 3350.

[0096] Figure 15 and 16 An actuation assembly 3400 is shown, the actuation assembly comprising a loading unit 30 ( Figure 14 The actuator rod 3402, power module 5000, and motor 5420 configured to actuate the power module 5000 are operatively coupled. Figure 23 The actuator switch 3404 that ejects the surgical nail 10 from the loading unit 30, the printed circuit board 3126 containing a microprocessor for controlling the actuation assembly 3400, and the battery 5440 of the power module 5000 are electrically connected to the motor 3420 and the printed circuit board 3126. Figure 23 The proximal end of the actuator rod 3402 is connected to the output shaft 5421 of the motor 5420. Figure 25 Operablely coupled such that when a clinician triggers actuation switch 3404, motor 5420 is actuated to impart axial rotation to actuation rod 5402, as will be discussed below. The distal end of actuation rod 3402 is connected to the inner tube 38 of loading unit 30. Figure 3 It is operatively coupled to accompany its rotation.

[0097] The actuation assembly 3400 includes an encoder assembly 3410 operatively connected to an actuator rod 3402 and a processor on a printed circuit board 3126. The encoder assembly 3410 may include, for example, an optical motor encoder 3405 configured to retain the rotation of the output shaft 5421 of the motor 5420. Figure 25 The precise counting of rotations of the actuator rod 3402 or the actuator rod 3402 is used to ensure that the appropriate number of rotations are made to insert the surgical staple 10 into, for example, tissue “T”. Figure 4 ) and mesh “M” ( Figure 5In addition, encoder assembly 3410 may further include, for example, encoder wheel 3407, which is configured to ensure that the distal end of actuator rod 3402 is relative to loading unit 30. Figure 14 The encoder wheel 3407 may contain a magnet, and the encoder assembly 3410 may contain a Hall effect sensor. The encoder wheel 3407 may be co-centeredly coupled to the actuator rod 3402 via a pin 3413 for accompanying rotation. The encoder wheel 3407 further includes a protrusion 3407a. Figure 17 The protrusion is configured to operatively engage the power module 5000, as will be discussed below. The encoder assembly 3410 may further include a light-emitting diode (“LED”) indicator 3409 to indicate the ejection status of each surgical staple 10. For example, green light may indicate that the surgical staple 10 has been correctly applied through the mesh “M” and into the tissue “T,” and red light may indicate incorrect application of the surgical staple 10, for example, due to an erroneous signal from the optical motor encoder 3405 or a single notch encoder wheel 3407. Alternatively, the encoder assembly 3410 may further include a piezoelectric element for providing an audible audible sound for the correct application of the surgical staple 10.

[0098] Figure 21 and 22 A handle assembly 3200 is shown, defining a chamber 3210 configured to removably house a power module 5000 therein. The chamber 3210 is provided with a seal to airtightly seal the chamber 3210. The power module 5000 can be reusable and configured to operate various functions of different types of surgical end effectors, such as an electric surgical stapler 3000, a linear suture device, a circular suture device, and a small-diameter vascular suture device. The power module 5000 has two outputs, each operatively coupled to the same motor of the power module. The outputs rotate simultaneously by the motor, but each at a different speed and torque than the other. The high-speed / low-torque output can be co-located within the high-torque / low-speed output. Depending on the surgical instrument in which the power module is housed and operatively engaged, the high-speed / low-torque output or the high-torque / low-speed output of the power module selectively engages the corresponding driven component (e.g., rod, screw, rack, gear, etc.) of the selected surgical instrument. Thus, although each surgical instrument has separate power and speed requirements, the same power module can be used across various surgical instruments.

[0099] The handle assembly 3200 includes a disposable and sterile housing 3202. A door 3216 is pivotally coupled to the housing 3202. The door 3216 is selectively opened and closed to allow placement or removal of a non-sterile or sterile power module 5000. Figure 23A power module 5000 is shown, comprising a sterile housing 5128 (shown in dashed lines) and a reusable power assembly 5130 for removable housing within the housing 5128. The housing 5128 has a cover 5132 housed in an open proximal end of the housing 5128 and a spring-loaded pull tab 5134 for facilitating removal of the cover 5132.

[0100] Figure 23 A power assembly 5130 is shown, which includes a motor 5420, such as an electric drive motor, electrically or wirelessly connected to a printed circuit board 5136 and a battery 5440. In various aspects, the battery 5440 may include a boost circuit and may be rechargeable (e.g., wirelessly). The battery 5440 has a card edge connector 5140 configured to detachably house the card edge head 3142 of the handle assembly 3200. Figure 20 This enables communication between the actuation switch 3404 and the battery 5440. The printed circuit board 5136 may include a USB charging connector to allow the battery 5440 to be charged using a USB charger or wirelessly (e.g., via induction). In various aspects, the printed circuit board 5136 may have a motor controller or processor. By providing a reusable power module 5000, the battery 5440 can be a rechargeable single-cell unit with a boost circuit to provide the necessary voltage. Rechargeable batteries have a larger capacity than disposable alternatives. Furthermore, the motor 5420 can have higher quality and efficiency than would be possible in a completely disposable design.

[0101] Figure 24 and 25 A power module 5000 is shown, which further includes a gearbox 6146, such as a planetary gearbox, operatively coupled to a motor 5420, and a first output 6148 and a second output 6150 configured to rotate about a longitudinal axis defined by the gearbox 6146. The gearbox 6146 is configured to transmit power from the motor 5420 to the first output 6148 at high torque and low speed, and to transmit power from the motor to the second output 6150 at high speed and low torque. The rotation of the first output 6148 and the second output 6150 can be used to perform operation of an end effector of a surgical instrument. Specifically, the high-speed / low-torque rotation of the second output 6150 is used to achieve rotation of an actuator 3402.

[0102] Figure 25An electric motor 5420 is shown, having an output shaft 5421 to which a primary sun gear 154 is fixed, causing the primary sun gear 6154 to rotate with the output shaft 5421. A gearbox 6146 includes a plurality of planetary gear assemblies 6156, 6158, 6160, 6162 and an elongated ring gear 6164 operably engaging the plurality of planetary gear assemblies 6156, 6158, 6160, 6162.

[0103] A first planetary gear assembly 6156 is operatively coupled to a main sun gear 6154 such that the first planetary gear assembly 6156 rotates about a longitudinal axis defined by the output shaft 5421 of the electric motor 5420 in response to rotation of the main sun gear 6154. The first planetary gear assembly 6156 increases the torque output of the electric motor 5420 while reducing the output rotational speed. The first planetary gear assembly 6156 includes a first carrier 6168, a first sun gear 6166, and a plurality of planetary gears 6156a, 6156b, 6156c. The first carrier 6168 has a plurality (e.g., three) of pins 6156d, 6156e, 6156f fixed to it and extending proximally therefrom. The first sun gear 6166 is rotatably fixed to the distal side of the first carrier 6168 and aligned with the center of the longitudinal axis of the output shaft 5421. Planetary gears 6156a, 6156b, and 6156c are rotatably coupled to corresponding pins 6156d, 6156e, and 6156f of the first carrier 6168. Planetary gears 6156a, 6156b, and 6156c mesh with the main sun gear 6154 and rotate in response to the rotation of the main sun gear 6154. As will be described, the elongated ring gear 6164 is positioned relative to the housing 5128 (…). Figure 20 The first planetary gear assembly 6156 is rotated as a whole around the longitudinal axis of the output shaft 5421 of the motor 5420 in response to the rotation of the main sun gear 6154.

[0104] The second planetary gear assembly 6158 includes a second carrier 6170, a second sun gear 6172, and a plurality of planetary gears 6158a, 6158b, and 6158c. The second planetary gear assembly 6158 has increased torque output and decreased rotational speed output relative to the first planetary gear assembly 6156. The second carrier 6170 has a plurality (e.g., three) of pins 6158d, 6158e, and 6158f fixed to it and extending proximally therefrom. The second sun gear 6172 is rotatably fixed to the distal side of the second carrier 6170 and aligned with the longitudinal axis center of the output shaft 5421 of the motor 5420. The planetary gears 6158a, 6158b, and 6158c of the second planetary gear assembly 6158 are rotatably coupled to the corresponding pins 6158d, 6158e, and 6158f of the second carrier 6170. Planetary gears 6158a, 6158b, and 6158c mesh with the first sun gear 6166 of the first planetary gear assembly 6156 and the fixed elongated gear ring 6164, causing the second planetary gear assembly 6158 to rotate in response to the rotation of the first planetary gear assembly 6156.

[0105] The third planetary gear assembly 6160 includes a third carrier 6174, a third sun gear 6176, and a plurality of planetary gears 6160a, 6160b, and 6160c. The third planetary gear assembly 6160 has increased torque output and decreased rotational speed output relative to the second planetary gear assembly 6158. The third carrier 6174 has a plurality (e.g., three) of pins 6160d, 6160e, and 6160f fixed to it and extending proximally therefrom. The third sun gear 6176 is rotatably fixed to the distal side of the third carrier 6174 and aligned with the longitudinal axis center of the output shaft 5421 of the motor 5420. The planetary gears 6160a, 6160b, and 6160c of the third planetary gear assembly 6160 are rotatably coupled to the corresponding pins 6160d, 6160e, and 6160f of the third carrier 6174. The planetary gears 6160a, 6160b, and 6160c of the third planetary gear assembly 6160 mesh with the second sun gear 6172 and the slender ring gear 6164 of the second planetary gear assembly 6158, such that the third planetary gear assembly 6160 rotates as a whole in response to the rotation of the second planetary gear assembly 6158.

[0106] The fourth planetary gear assembly 6162 includes a fourth carrier 6178 and a plurality of planetary gears 6162a, 6162b, 6162c. The fourth planetary gear assembly 6162 has increased torque output and decreased rotational speed output relative to the third planetary gear assembly 6160. The fourth carrier 6178 is connected to, integrally formed with, or otherwise non-rotatably coupled to the proximal end of the first output 6148 and has a plurality (e.g., three) of pins 6162d, 6162e, 6162f fixed to it and extending proximal to proximal. The planetary gears 6162a, 6162b, 6162c of the fourth planetary gear assembly 6162 are rotatably coupled to the corresponding pins 6162d, 6162e, 6162f of the fourth carrier 6178. The planetary gears 6162a, 6162b, and 6162c of the fourth planetary gear assembly 6162 mesh with the third sun gear 6176 and the elongated ring gear 6164 of the third planetary gear assembly 6160, such that the fourth planetary gear assembly 6162 and the first output 6148 rotate together in response to the rotation of the third planetary gear assembly 6160. It is contemplated that the gearbox 6146 may contain more or fewer than four planetary gear assemblies and / or other types of gears.

[0107] The first output 6148 is configured to produce relatively high torque (e.g., about 625 oz-in) and relatively low speed (e.g., 24 rpm) and includes a cylindrical body 6148a housed in the distal portion of an elongated gear ring 6164 and a gear 6148b, such as a pinion formed with the distal portion of the cylindrical body 6148a. The pinion 6148b of the first output 6148 is configured to be selectively operably coupled to a driven member of a surgical end effector of the first type, such as surgical end effector 20. It is contemplated that the handle assembly may have a corresponding driven component (e.g., gear, rack, etc.) configured to selectively engage the pinion 6148b after the power module 5000 is housed in the handle assembly 3200.

[0108] The power module 5000 further includes a drive shaft 6180 having a proximal portion 6180a non-rotatably coupled to a second planetary gear assembly 6158 such that the drive shaft 6180 is configured to rotate with the second planetary gear assembly 6158. Specifically, the proximal portion 6180a of the drive shaft 6180 is housed within and rotatably fixed to the second sun gear 6172 of the second planetary gear assembly 6158. The drive shaft 6180 has a distal portion 6180b extending longitudinally through the third planetary gear assembly 6160 and the fourth planetary gear assembly 6162, and is freely rotatable therein. The distal portion 6180b of the drive shaft 6180 may have a non-circular cross-sectional shape, such as a three-lobed shape.

[0109] The second output 6150 is attached to the distal portion 6180b of the drive shaft 6180 and configured to rotate with the drive shaft 6180 about its longitudinal axis. The second output 6150 is configured to produce relatively low torque (e.g., 25 oz-in) and relatively high speed (e.g., 600 rpm) and includes a socket 6151 configured to be operatively coupled to a corresponding driven element of a surgical end effector of a different type than the first output 6148. The electric surgical staple applicator 3000 requires less torque but higher actuation speed compared to other surgical instruments such as linear suture devices. When the power module 5000 is inserted into the chamber 3210 of the handle assembly 3200, the socket 6151 of the second output 6150 engages the driven element, namely, the protrusion 3407a of the encoder wheel 3407. Figure 16 ), to the actuator rod 3402 ( Figure 16 Rotation is provided. Consideration is given to surgical instrument handle assemblies or other components having a corresponding driven component (e.g., a rod) configured to selectively engage the socket 6151 after the power module 5000 is housed in the handle housing.

[0110] The second output 6150 is co-centered within the first output 6148 and configured to rotate simultaneously with the first output 6148 in response to the activation of the same electric motor, i.e., motor 5420. However, as noted above, the first output 6148 and the second output 6150 rotate at different speeds and with different torques. The second output 6150 is housed in an elongated cavity 6182 defined within the cylindrical body 6148a of the first output 6148. A biasing member 6184 is disposed within the cavity 6182 and is captured between the inner surfaces of the second output 6150 and the cylindrical body 6148a of the first output 6148. The biasing member 6184 is configured to bias the second output 6150 distally to a position co-centered within the first output 6148.

[0111] The elongated gear ring 6164 of gearbox 6146 encapsulates each of the planetary gear assemblies 6156, 6158, 6160, and 6162 and is located relative to the sterile housing 5128. Figure 23 The elongated gear ring 6164 is rotatably fixed to the motor 5420. The elongated gear ring 6164 has an annular inner surface defining a plurality of longitudinally extending teeth 6186 that mesh with the planetary gears of each of the planetary gear assemblies 6156, 6158, 6160, and 6162. A first bushing 6188 may be provided to capture a first output 6148 within the elongated gear ring 6164, and a second bushing 6190 may be provided to capture a second output 6150 within the first output 6148.

[0112] In use, the loading unit 30 is operatively mounted to the distal end of the elongated member 3050. The power module 5000 is inserted into the handle housing 3200, thereby enabling the encoder wheel 3407 to pass through the protrusion 3407a. Figure 16 Connect the second output 6050 to the socket 6151 ( Figure 25 With the power module 5000 housed within the handle housing 3200, the door 3216 is closed, thereby sealing the power module 5000 within the chamber 3210. Further, the clip edge head 3142 of the printed circuit board 3126 of the handle assembly 3200 (… Figure 16 The card edge connector 5140 connects to the power module 5000. Figure 24 The loading unit 30 is introduced into the target surgical site without being hinged. The clinician can remotely hinge the loading unit 30 to access the surgical site. Specifically, the clinician can slide the engagement portion 3364 of the hinge rod 3360 along the engagement surface 3204 of the housing 3202. Figure 16 As the articulated rod 3310 is axially displaced, the loading unit 30 moves relative to the central longitudinal axis "XX" toward the articulation. Furthermore, the clinician can position the surgical mesh "M" adjacent to the surgical site. Once the surgical mesh "M" is correctly positioned at the surgical site, the clinician can trigger the actuation switch 3404 to eject the surgical staple 10 through the mesh "M" and into the tissue "T". To deploy the surgical staple 10, the actuation switch 3404 can be switched, thereby powering the motor 5420 from the battery 5440 of the power module 5000, which in turn drives the rotation of the first planetary gear assembly 6156 and the second planetary gear assembly 6158. Since the drive shaft 6180 is fixed to the second sun gear 6172 of the second planetary gear assembly 6158, the drive shaft 6180 rotates with the rotation of the second planetary gear assembly 6158. The second output 6150, which is non-rotatably attached to the distal portion 6180b of the drive shaft 6180, rotates with the drive shaft 6180 to deploy the surgical staple 10 into the tissue with low torque and high speed.

[0113] While various configurations of this disclosure have been shown in the accompanying drawings, this disclosure is not intended to be limited thereto, as the scope of this disclosure is intended to be as broad as will be permitted in the art and the specification is intended to be read in the same manner. In various respects, the proximal portion of housing 3202 or any suitable location may have a transparent window to allow viewing of a display (e.g., LCD, not shown). Additionally, the first drive output 6148 and the second drive output 6150 may be simultaneously coupled to two different driven elements of a particular surgical instrument to perform discrete functions of the surgical instrument. Any of the gears disclosed herein can be configured as any suitable gear, such as a bevel gear, spur gear, helical gear, worm gear, etc. It is also contemplated that the first output 6148 may be used for high torque, low speed output requirements, for example, the hinge of the hinge portion 3060. Therefore, the above description should not be construed as limiting, but rather as exemplary only. Those skilled in the art will conjure other modifications within the scope and spirit of the appended claims.

Claims

1. An electric surgical staple applicator, comprising: Handle assembly, the handle assembly comprising: An actuation assembly, the actuation assembly comprising an actuation rod and an actuation switch; as well as A hinge rod assembly comprising a hinge rod and a hinge arm operatively coupled to the hinge rod; An elongated member extending distally from the handle assembly, the elongated member comprising: A loading unit having a plurality of surgical nails, the loading unit being operatively coupled to the actuation rod of the actuation assembly such that rotation of the actuation rod unfolds a surgical nail from the plurality of surgical nails from the loading unit; as well as A hinged portion, pivotable relative to a longitudinal axis defined by the elongated member, operatively coupled to the hinge bar of the handle assembly such that axial displacement of the hinge bar hinges the hinged portion; and A power module, removably housed in the handle assembly, the power module comprising: An electric motor, operatively coupled to the actuation rod of the actuation assembly to rotate the actuation rod; A battery, electrically coupled to the motor to supply power to the motor; as well as Gearbox, the gearbox comprising: A main sun gear, which is fixed to the output shaft of the motor to rotate with the output shaft; A first planetary gear assembly is operatively coupled to the main sun gear such that the first planetary gear assembly rotates about a longitudinal axis defined by the output shaft in response to rotation of the main sun gear. A second planetary gear assembly is 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 coupled to the second planetary gear assembly, such that the drive shaft rotates with the second planetary gear assembly; A third planetary gear assembly is 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. A fourth planetary gear assembly, which is 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; as well as A high-speed output is coupled to the drive shaft to rotate with it, and the high-speed output is operatively coupled to the actuator rod of the handle assembly.

2. The electric surgical staple applicator of claim 1, wherein the gearbox of the power module further includes a high torque output, the high torque output being non-rotatably coupled to the fourth planetary gear assembly such that the high torque output rotates with the fourth planetary gear assembly.

3. The electric surgical staple applicator according to claim 2, wherein the high-speed output is centrally located within the high-torque output.

4. The electric surgical staple applicator according to claim 2, wherein the high-speed output and the high-torque output are simultaneously rotatable in response to the start of the electric motor.

5. The electric surgical staple applicator of claim 1, wherein the drive shaft extends longitudinally through the third planetary gear assembly and the fourth planetary gear assembly.

6. The electric surgical staple applicator of claim 2, wherein the drive shaft has a proximal portion fixed to the second planetary gear assembly and a distal portion rotatable relative to the high torque output within the high torque output.

7. The electric surgical staple applicator of claim 2, wherein the high torque output defines a cavity, the cavity being sized to receive the high-speed output therein.

8. The electric surgical staple applicator of claim 1, wherein the actuation assembly further comprises a processor configured to control the electric motor.

9. The electric surgical staple applicator of claim 8, wherein the actuation assembly further comprises an optical motor encoder configured to count the number of rotations of the output shaft of the motor to ensure that the required number of rotations are performed to insert the surgical staple into the tissue, the optical motor encoder being operatively connected to the actuation rod and the processor.

10. The electric surgical staple applicator of claim 9, wherein the actuation assembly further comprises an encoder wheel configured to ensure correct timing of the distal end of the actuation rod relative to the loading unit.

11. The electric surgical staple applicator of claim 1, wherein the gearbox of the power module further comprises an elongated gear ring that engages with the first planetary gear assembly, the second planetary gear assembly, the third planetary gear assembly, and the fourth planetary gear assembly.

12. The electric surgical staple applicator of claim 11, wherein the first planetary gear assembly, the second planetary gear assembly, the third planetary gear assembly, and the fourth planetary gear assembly are disposed within the elongated gear ring.

13. The electric surgical staple applicator of claim 11, wherein the elongated toothed ring is rotatably fixed relative to the electric motor.

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