Adapter assembly with constant velocity joint

Abstract

A drive assembly for an adapter assembly of a surgical device includes an input shaft, an intermediate shaft, and an output shaft. The input shaft includes: a proximal portion configured to operably engage with a drive member of the handle assembly; and a distal portion including a first castellated portion. The intermediate shaft includes: a proximal portion having a first lobed portion operably engaged with the first castellated portion of the input shaft; and a distal portion having a second lobe-shaped portion. The output shaft includes a proximal portion having a second castellated portion operably engaged with the second lobed portion.

Description

Technical Field

[0001] The present disclosure relates to adapter assemblies for powered surgical devices and more particularly to adapter assemblies having a drive assembly with a lobe and castellated constant velocity (CV) joint to transmit rotational power through a curved portion of the adapter assembly. Background Art

[0002] Power surgical devices including an adapter assembly for connecting an end effector to a handle assembly are known. The adapter assembly of the power surgical device includes one or more drive members (e.g., screws, shafts, cables, belts) to transfer power from an actuation unit (e.g., a handle assembly) to the attached end effector. Typically, the actuation assembly is configured to supply rotational power to the adapter assembly, and the adapter assembly is configured to convert the rotational power into a thrust / pull force that is transmitted to the end effector. Alternatively, the adapter assembly can be configured to transmit the rotational power as a rotational force to the attached end effector.

[0003] Many adapter assemblies include a curved portion to assist in positioning an attached end effector within a patient. A drive assembly extending through the curved portion of the adapter assembly may include a flexible drive shaft to accommodate the curve. Alternatively, the drive assembly may use multiple rigid shafts connected to each other at a constant velocity (CV) joint. A conventional CV joint used in an adapter assembly of a powered surgical device includes a first shaft having a spherical member formed on a distal portion that is pinned within a slot that is defined in a U-shaped socket formed on a proximal portion of a second shaft. Conventional CV joints are complex and may be cost prohibitive.

[0004] It would therefore be advantageous to have a drive assembly for an adapter assembly that includes one or more improved CV joints. Summary of the invention

[0005] A drive assembly for an adapter assembly of a surgical device includes an input shaft, an intermediate shaft, and an output shaft. The input shaft has a proximal portion and a distal portion. The proximal portion of the input shaft is configured to operably engage with a drive member of a handle assembly, and the distal portion of the input shaft includes a first castellated portion. The intermediate shaft has a proximal portion and a distal portion. The proximal portion of the intermediate shaft includes a first lobe-shaped portion operably engaged with the first castellated portion of the input shaft, and the distal portion of the intermediate shaft includes a second lobe-shaped portion. The output shaft has a proximal portion and a distal portion. The proximal portion of the output shaft includes a second castellated portion operably engaged with the second lobe-shaped portion.

[0006] In various aspects of the present disclosure, the first lobe-shaped portion and the second lobe-shaped portion each include three lobe members. The first castellated portion and the second castellated portion may each include three flange members. The first castellated portion and the second castellated portion may define three cutouts. The cutouts of the first castellated portion correspond in number to the number of lobe members of the first lobe-shaped portion, and the cutouts of the second castellated portion correspond in number to the number of lobe members of the second lobe-shaped portion.

[0007] In certain aspects of the present disclosure, each of the three lobe members of the first lobe-shaped portion and the second lobe-shaped portion includes a semi-cylindrical portion and a waist portion. Each of the first lobe-shaped portion and the second lobe-shaped portion can define three recesses. The waist portion and the three recesses of the three lobe members of the first lobe-shaped portion can accommodate the pivoting of the intermediate shaft relative to the input shaft. The waist portion and the three recesses of the three lobe members of the second lobe-shaped portion can accommodate the pivoting of the output shaft relative to the intermediate shaft. The distal portion of the output shaft may include a drive screw.

[0008] An adapter assembly for connecting a handle assembly to an end effector includes a coupling assembly, a straight portion, a curved portion, and a drive assembly. The coupling assembly is configured to be operably connected to the handle assembly. The straight portion is fixed to the coupling assembly. The curved portion extends from the straight portion. The drive assembly extends from the handle assembly through the curved portion. The drive assembly includes an input shaft, an intermediate shaft, and an output shaft. The input shaft has a proximal portion and a distal portion. The proximal portion of the input shaft is configured to be operably engaged with a drive member of the handle assembly, and the distal portion of the input shaft includes a first castellated portion. The intermediate shaft has a proximal portion and a distal portion. The proximal portion of the intermediate shaft includes a first lobe-shaped portion operably engaged with the first castellated portion of the input shaft, and the distal portion of the intermediate shaft includes a second lobe-shaped portion. The output shaft has a proximal portion and a distal portion. The proximal portion of the output shaft includes a second castellated portion operably engaged with the second lobe-shaped portion.

[0009] In various aspects of the present disclosure, the first lobe-shaped portion and the second lobe-shaped portion of the intermediate shaft of the drive assembly each include three lobe members. The first castellated portion of the input shaft and the second castellated portion of the output shaft may each include three flange members. The first castellated portion and the second castellated portion may define three cutouts. The cutouts of the first castellated portion correspond in number to the number of lobe members of the first lobe-shaped portion, and the cutouts of the second castellated portion correspond in number to the number of lobe members of the second lobe-shaped portion.

[0010] In certain aspects of the present disclosure, each of the three lobe members of the first lobe-shaped portion and the second lobe-shaped portion includes a semi-cylindrical portion and a waist portion. Each of the first lobe-shaped portion and the second lobe-shaped portion can define three recesses. The waist portion and the three recesses of the three lobe members of the first lobe-shaped portion can accommodate the pivoting of the intermediate shaft relative to the input shaft. The waist portion and the three recesses of the three lobe members of the second lobe-shaped portion can accommodate the pivoting of the output shaft relative to the intermediate shaft. The distal portion of the output shaft may include a drive screw.

[0011] A surgical device includes a handle assembly, an adapter assembly, an end effector, and a drive assembly. The handle assembly includes a drive member. The adapter assembly is fixed to the handle assembly. The end effector is fixed to the adapter assembly. The drive assembly extends from the handle assembly and is positioned in the adapter assembly. The drive assembly includes an input shaft, an intermediate shaft, and an output shaft. The input shaft has a proximal portion and a distal portion. The proximal portion of the input shaft is configured to be operably engaged with the drive member of the handle assembly, and the distal portion of the input shaft includes a first castellated portion. The intermediate shaft has a proximal portion and a distal portion. The proximal portion of the intermediate shaft includes a first lobe-shaped portion operably engaged with the first castellated portion of the input shaft, and the distal portion of the intermediate shaft includes a second lobe-shaped portion. The output shaft has a proximal portion and a distal portion. The proximal portion of the output shaft includes a second castellated portion operably engaged with the second lobe-shaped portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various aspects of the present disclosure and, together with the general description of the present disclosure given above and the detailed description of the aspects given below, explain the principles of the present disclosure. In the drawings:

[0013] Figure 1 is a side perspective view of a surgical stapling device according to aspects of the present disclosure, the surgical stapling device including an adapter assembly having a drive assembly;

[0014] Figure 2 yes Figure 1 Magnified views of the indicated areas of detail are shown in;

[0015] Figure 3 yes Figure 1 A perspective view of a portion of a drive assembly shown in FIG.

[0016] Figure 4 It is along Figure 2 a cross-sectional side view taken along line 4-4 shown in FIG.

[0017] Figure 5 yes Figure 3 Magnified views of the indicated areas of detail are shown in;

[0018] Figure 6 yes Figure 3 a proximal end view of an intermediate shaft of the drive assembly shown in;

[0019] Figure 7 yes Figure 3 a distal end view of an input shaft of a drive assembly shown in;

[0020] Figure 8 yes Figure 3 Magnified views of the indicated areas of detail are shown in;

[0021] Fig. 9 yes Figure 2 Magnified views of the indicated areas of detail are shown in;

[0022] Fig.10 yes Figure 2 Magnified views of the indicated areas of detail are shown in;

[0023] Fig.11 yes Figure 3 A perspective view of a second joint of the drive assembly shown in , wherein the intermediate shaft is aligned with the output shaft; and

[0024] Fig.12 yes Figure 3 A perspective view of a second joint of a drive assembly shown in , wherein the intermediate shaft is angled relative to the output shaft. DETAILED DESCRIPTION

[0025] The disclosed powered surgical device and drive assembly will now be described in detail with reference to the accompanying drawings, wherein like reference numerals represent identical or corresponding elements in each of the several views. However, it should be understood that various aspects of the present disclosure are merely examples of the present disclosure and may be implemented in various forms. Well-known functions or configurations are not described in detail to avoid obscuring the present disclosure with unnecessary detail. Therefore, the specific structural and functional details disclosed herein should not be interpreted as limiting, but rather should be interpreted merely as the basis for the claims and as a representative basis for teaching those skilled in the art to employ the present disclosure in various ways in almost any structure that is appropriately detailed.

[0026] In this specification, the term "proximal" is generally used to refer to the portion of the device that is closer to the clinician during the use of the suturing device in its usual manner, and the term "distal" is generally used to refer to the portion of the device that is farther away from the clinician during the use of the suturing device in its usual manner. In addition, the term "clinician" is generally used to refer to medical personnel including doctors, nurses and support staff. In addition, directional terms such as front, back, upper, lower, top, bottom and similar terms are used to help understand the description and are not intended to limit the present disclosure.

[0027] The disclosed powered surgical device includes a drive assembly that transmits rotational power from a handle assembly of the powered surgical device to an end effector of the powered surgical device. The adapter assembly includes a curved portion to facilitate positioning the end effector within a patient. The drive assembly includes first and second constant velocity (CV) joints that accommodate the curvature of the adapter assembly. The CV joint includes: an intermediate shaft having a lobe-shaped proximal portion and a lobe-shaped distal portion; an input shaft having a castellated portion that engages the lobe-shaped proximal portion of the intermediate shaft; and an output shaft having a castellated portion that engages the lobe-shaped distal portion of the output shaft. As will become apparent from the description below, the disclosed CV joint is significantly stronger, less complex, and less expensive than conventional CV joints.

[0028] Figure 1 A powered surgical device in accordance with aspects of the present disclosure is shown generally as a suturing device 10. The suturing device 10 will be described only to the extent necessary to fully disclose the various aspects of the present disclosure. For a detailed description of an exemplary adapter assembly, see U.S. Pat. No. 10,226,254 ("the '254 patent").

[0029] The suturing device 10 includes a handle assembly 12, an adapter assembly 14, and an end effector 16. The handle assembly 12 includes a body 18 that defines a gripper 18a and includes a plurality of actuator buttons 20. The actuator buttons 20 control the operation of various functions of the suturing device 10, including clamping, burning, and cutting tissue. Although shown as including the handle assembly 12, it is contemplated that the adapter assembly 14 can be constructed as a component in a robotic system (not shown).

[0030] The adapter assembly 14 of the suturing device 10 includes a coupling assembly 22, a straight portion 24 extending from the coupling assembly 22, a curved portion 26 extending from the straight portion 24, and a connector assembly 28 fixed to the distal portion of the curved portion 26. The coupling assembly 22 includes a rotation knob 22a for rotating the end effector 16 around the longitudinal axis "X" of the straight portion 24. The connector portion 28 of the adapter assembly 14 is configured to releasably receive a circular stapler reloader or loading unit (not shown). The trocar assembly 30 is positioned within the connector assembly 28 and includes a trocar member 32 extending from the connector portion 28. The trocar member 32 of the trocar assembly 30 is configured to releasably receive an anvil assembly 40 and is selectively movable between an advanced position and a retracted position to position the anvil assembly 40 relative to a circular stapler reloader (not shown) fixed to the connector assembly 28 of the adapter assembly 14.

[0031] Although shown and described with reference to suturing device 10, aspects of the present disclosure may be modified for use with any surgical device (powered or manual) having a rotatable drive shaft. Aspects of the present disclosure may also be incorporated into a robotic system having a rotating drive shaft.

[0032] Figure 2 and Figure 3 A suturing device 10 ( Figure 1 ) of the adapter assembly 14. The drive assembly 100 is configured to operably connect the rotary drive member (not shown) of the handle assembly 12 with the trocar assembly 30 of the end effector 16. The drive assembly 100 includes an input shaft 102, an intermediate shaft or connector shaft 104, and an output shaft or drive screw 106. The input shaft 102 of the drive assembly 100 extends through the straight portion 24 of the adapter assembly 14 and includes a proximal portion (not shown) operably connected to the drive member (not shown) of the handle assembly 12, as is known in the art. The handle assembly 12 provides rotational power to the input shaft 102, as detailed in the '254 patent. The output shaft 106 can be a trocar assembly 30 ( Figure 1 ) or may otherwise be operably engaged with the trocar assembly 30. Rotation of the output shaft 106 in a first direction causes the trocar member 32 ( Figure 1 ) advances relative to the output shaft 106, and rotation of the output shaft 106 in a second direction causes the cannula needle assembly 32 to retract relative to the output shaft 106.

[0033] The input shaft 102, intermediate shaft 104, and output shaft 106 of the drive assembly 100 may be formed of stainless steel or other materials having a high yield strength (eg, PEEK). It is contemplated that the input shaft 102, intermediate shaft 104, and output shaft 106 may be formed of the same or different materials.

[0034] The distal portion 102b of the input shaft 102 of the drive assembly 100 includes a first castellated portion 110. The proximal portion 104a and the distal portion 104b of the intermediate shaft 104 include a first lobe-shaped portion 120 and a second lobe-shaped portion 130, respectively. The proximal portion 106a of the output shaft 106 includes a second castellated portion 140. The first castellated portion 110 of the input shaft 102 engages the first lobe-shaped portion 120 of the intermediate shaft 104 to form a first joint 108a. The second castellated connector 140 engages the second lobe-shaped connector 130 of the intermediate shaft 104 to form a second joint 108b.

[0035] Figure 4 The positions of the input shaft 102, the intermediate shaft 104, and the output shaft 106 relative to each other are shown. As shown, the longitudinal axis "x" of the input shaft 102 is at a first angle "α" relative to the longitudinal axis "y" of the intermediate shaft 104. The longitudinal axis "y" of the intermediate shaft 104 is at a second angle "β" relative to the longitudinal axis "z" of the output shaft 106. As described in further detail below, the configuration of the first joint 108a and the second joint 108b is such that the first angle "α" and the second angle "β" can be between 0° and 15°, and can be the same or different.

[0036] Although shown as extending through the rigid or semi-rigid curved portion 26 of the adapter assembly 14, and thus having fixed first angle "α" and second angle "β", it is contemplated that the drive assembly 100 may extend through a flexible portion (not shown) of the adapter 100. In this manner, the first angle "α" and second angle "β" are not fixed, and the intermediate shaft 104 may pivot in any direction away from the longitudinal axis "x" of the input shaft 102. Similarly, the output shaft 106 may pivot in any direction away from the longitudinal axis "y" of the intermediate shaft 104. It is further contemplated that the drive assembly 100 may be provided in any manner in the suturing device 10 ( Figure 1 ) to accommodate flexing of the adapter assembly 14 during operation.

[0037] Figure 5A first lobe-shaped portion 120 is shown on the proximal portion 104a of the intermediate shaft 104 of the drive assembly 100. In various aspects of the present disclosure, the first lobe-shaped portion 120 includes a first lobe member 122, a second lobe member 124, and a third lobe member 126. The first lobe member 122, the second lobe member 124, and the third lobe member 126 extend radially outward perpendicular to the longitudinal axis "y" of the intermediate shaft 104 and are equally spaced from each other. Thus, the angle between the first lobe member 122, the second lobe member 124, and the third lobe member 126 and the corresponding adjacent second lobe member 124, the third lobe member 126, and the first lobe member 122 is one hundred and twenty degrees (120°). The first lobe-shaped portion 120 defines a first recess 123 formed between the first lobe member 122 and the second lobe member 124 , a second recess 125 formed between the second lobe member 124 and the third lobe member 126 , and a third recess 127 formed between the third lobe member 126 and the first lobe member 122 .

[0038] Each of the first lobe member 122, the second lobe member 124 and the third lobe member 126 of the first lobe-shaped portion 120 includes a semi-cylindrical section 122a, 124a, 126a, respectively, and includes a waist section 122b, 124b, 126b, respectively. Each of the semi-cylindrical sections 122a, 124a, 126a of the respective first lobe member 122, the second lobe member 124 and the third lobe member 126 includes a diameter “d 1 ”.

[0039] Figure 6 An end view of intermediate shaft 104 of drive assembly 100 is shown with first lobe shaped portion 120 in the foreground and second lobe shaped portion 130 in the background. Second lobe shaped portion 130 is substantially similar to first lobe shaped portion 120 and includes first lobe member 132, second lobe member 134, and third lobe member 136 and defines a first recess 133 between first lobe member 132 and second lobe member 134, a second recess 135 between second lobe member 134 and third lobe member 136, and a third recess 137 between third lobe member 136 and first lobe member 132. First lobe member 132, second lobe member 134, and third lobe member 136 of second lobe shaped portion 130 are radially offset sixty degrees (60°) from first lobe member 122, second lobe member 124, and third lobe member 126 of first lobe shaped portion 120. In this manner, when the intermediate shaft 104 is rotated about its longitudinal axis “y” by the input shaft 102 of the drive assembly 100 , the rotational force passing through the intermediate shaft 104 is evenly distributed.

[0040] Each of the first lobe member 132, the second lobe member 134 and the third lobe member 136 of the second lobe-shaped portion 130 includes a semi-cylindrical section 132a, 134a, 136a, respectively, and includes a waist section 132b, ( Figure 6 Each of the semi-cylindrical sections 132a, 134a, 136a of the respective first lobe member 132, second lobe member 134 and third lobe member 136 comprises a diameter "d 2 As shown in the figure, the diameters “d 2 ” and the diameter “d 1 ” is the same. It can be imagined that the diameter “d 2 ” may be different from the diameter “d 1 ”.

[0041] Although shown as including three lobe members, it is contemplated that the first lobe-shaped portion 120 and the second lobe-shaped portion 130 may include more than three lobe members. It is also contemplated that the number of lobe members on the first lobe-shaped portion 120 and the second lobe-shaped portion 130 may be different.

[0042] Figure 7 A first castellated portion 110 is shown on the distal portion 102b of the input shaft 102 of the drive assembly 100. The first castellated portion 110 includes a first flange member 112, a second flange member 114, and a third flange member 116. The number of flange members corresponds to the number of lobe members of the first lobe-shaped portion 120. Each of the first, second, and third flange members 112, 114, 116 includes a first inner tapered surface 112a, 114a, 116a, respectively, a second inner tapered surface 112b, 114b, 116b, respectively, and a planar surface 112c, 114c, 116c extending between the respective first tapered surface 112a, 114a, 116a and the respective second tapered surface 112b, 114b, 116b, respectively. The planar surfaces 112 c , 114 c , 116 c of the respective first, second, and third flange members 112 , 114 , 116 define a longitudinal recess 111 configured to receive a first lobe-shaped portion 120 on the intermediate shaft 104 of the drive assembly 100 .

[0043] Each of the first inner tapered surfaces 112a, 114a, 116a of the respective first, second, and third flange members 112, 114, 116 forms an angle of one hundred twenty degrees (120°) relative to the respective second inner tapered surfaces 112b, 114b, 116b of the first, second, and third flange members 112, 114, 116. In this manner, the first inner tapered surface 112a of the first flange member 112 extends parallel to the second inner tapered surface 114b of the second flange member 114 and defines a first cutout 113, the first inner tapered surface 114a of the second flange member 114 extends parallel to the second inner tapered surface 116b of the third flange member 116 and defines a second cutout 115, and the first inner tapered surface 116a of the third flange member 116 extends parallel to the second inner tapered surface 112b of the first flange member 112 and defines a third cutout 117. Each pair of the first inner conical surface 112a of the first flange member 112 and the second inner conical surface 114b of the second flange member 114, the first inner conical surface 114a of the second flange member 114 and the second inner conical surface 116b of the third flange member 116, and the first inner conical surface 116a of the third flange member 116 and the second inner conical surface 112b of the first flange member 112 are separated by a distance “D1”. The distance “D1” is the same as the diameter “d1” of the semi-cylindrical sections 122a, 124a, 126a of the first lobe member 122, the second lobe member 124, and the third lobe member 126 of the first lobe-shaped portion 120 of the intermediate shaft 104 of the drive assembly 100. 1 " are the same respectively.

[0044] Figure 8 A drive assembly 100 ( Figure 2 ) of the output shaft 106. The second castellated portion 140 is substantially similar to the first castellated portion 110 ( Figure 7), the second castellated portion includes a first flange member 142, a second flange member 144, and a third flange member 146 corresponding in number to the number of the lobe members of the second lobe-shaped portion 130. Each of the first flange member 142, the second flange member 144, and the third flange member 146 includes a first inner tapered surface 142a, 144a, 146a, respectively, a second inner tapered surface 142b, 144b, 146b, respectively, and a planar surface 142c, 144c, 146c extending between the respective first inner tapered surface 142a, 144a, 146a and the respective second inner tapered surface 142b, 144b, 146b, respectively. The planar surfaces 142 c , 144 c , 146 c of the respective first, second, and third flange members 142 , 144 , 146 define a longitudinal recess 141 configured to receive the second lobe-shaped portion 130 on the intermediate shaft 104 of the drive assembly 100 .

[0045] Each of the first inner tapered surfaces 142a, 144a, 146a of the respective first, second, and third flange members 142, 144, 146 forms an angle of one hundred twenty degrees (120°) relative to the respective second inner tapered surfaces 142b, 144b, 146b of the first, second, and third flange members 142, 144, 146. In this manner, the first inner tapered surface 142a of the first flange member 142 extends parallel to the second tapered surface 144b of the second flange member 144 and defines a first cutout 143, the first inner tapered surface 144a of the second flange member 144 extends parallel to the second inner tapered surface 146b of the third flange member 146 and defines a second cutout 145, and the first inner tapered surface 146a of the third flange member 146 extends parallel to the second inner tapered surface 142b of the first flange member 142 and defines a third cutout 117.

[0046] Each pair of the first inner conical surface 142a of the first flange member 142 and the second inner conical surface 144b of the second flange member 144, the first inner conical surface 144a of the second flange member 144 and the second inner conical surface 146b of the third flange member 146, and the first inner conical surface 146a of the third flange member 146 and the second inner conical surface 142b of the first flange member 142 are separated by a distance "D2". The distance "D2" is the same as that of the drive assembly 100 ( Figure 3 ) of the semi-cylindrical sections 132a, 134a, 136a of the respective first lobe members 132, second lobe members 134 and third lobe members 136 of the second lobe-shaped portion 130 on the intermediate shaft 104 of 2 " are the same respectively.

[0047] Fig. 9 The first joint 108a of the drive assembly 100 is shown, which includes a first lobe-shaped portion 120 of the intermediate shaft 104 of the drive assembly 100, which engages with the first castellated portion 110 of the input shaft 102 of the drive assembly 100. More specifically, the first lobe-shaped portion 120 of the intermediate shaft 104 is received in the longitudinal recess 111 ( Figure 7 ), so that the first lobe member 122 of the first lobe-shaped portion 120 is positioned in the first cutout 113 of the first castellated portion 110, the second lobe member 124 is positioned in the second cutout 115 of the first castellated portion 110, and the third lobe member 126 ( Figure 6 ) is positioned at the third cutout 117 of the first castellated portion 110 ( Figure 7 ). The first recess 123 of the first lobe-shaped portion 120 accommodates the pivotal movement of the first flange member 112 of the first castellated portion 110 relative to the first lobe-shaped portion 120, and the second recess 125 ( Figure 5 ) accommodates the pivotal movement of the second flange member 114 of the first castellated portion 110 relative to the first lobe-shaped portion 120, and the third recess 127 ( Figure 6 ) adapted to the third flange member 116 of the first castellated portion 110 ( Figure 7 ) relative to pivotal movement of the first lobe-shaped portion 120.

[0048] Fig.10 The second joint 108b of the drive assembly 100 is shown, which includes the second lobe-shaped portion 130 of the intermediate shaft 104, which engages with the second castellated portion 140 of the output shaft 106. More specifically, the second lobe-shaped portion 130 of the intermediate shaft 104 is received in the longitudinal recess 141 ( Figure 8 ), so that the first lobe member 132 of the second lobe-shaped portion 130 is positioned in the first cutout 143 of the second castellated portion 140, and the second lobe member 134 ( Figure 6 ) is positioned at the second cutout 145 of the second castellated portion 140 ( Figure 8 ), and the third lobe member 136 ( Figure 6 ) is positioned at the third cutout 147 ( Figure 8 ). The first recess 133 of the second lobe-shaped portion 130 accommodates the pivotal movement of the second flange member 144 of the second castellated portion 140 relative to the second lobe-shaped portion 130, and the second recess 135 ( Figure 6 ) adapted to the third flange member 146 of the second castellated portion 140 ( Figure 8 ) relative to the pivotal movement of the second lobe-shaped portion 130, and the third recess 137 of the second lobe-shaped portion 130 accommodates the pivotal movement of the first flange member 146 of the second castellated portion 140 relative to the second lobe-shaped portion 130.

[0049] Fig.11 Engagement between the second lobe-shaped portion 130 of the intermediate shaft 104 of the drive assembly 100 and the second castellated portion 140 of the output shaft 106 of the drive assembly 100 is illustrated when the intermediate shaft 104 and the output shaft 106 are aligned. Although the interaction between the second lobe-shaped portion 130 and the second castellated portion 140 will be described in detail with respect to the first lobe member 132 and the first and third flange members 142, 146, it should be understood that the interaction between the second lobe member 134 and the third lobe member 136 of the second lobe-shaped portion 130 of the intermediate shaft 104 and the second and third flange members 144, 146, respectively, and between the second and first flange members 144, 142, and between the first lobe member 122, the second lobe member 124, the third lobe member 126 of the first lobe-shaped portion 120 and the corresponding first, second, and third flange members 112, 114, 116 of the first castellated portion 110 of the input shaft 102 are the same.

[0050] When the second lobe-shaped portion 130 on the intermediate shaft 104 of the drive assembly 100 is received in the longitudinal recess 141 of the second castellated portion 140 of the output shaft 106, the first lobe member 132 is received in the third cutout 147 defined between the first flange member 142 and the third flange member 146. As described above, the semi-cylindrical section 132a of the first lobe member 132 of the second lobe-shaped portion 130 includes a diameter "d2". The diameter "d2" is the same as the distance "D2" between the second tapered surface 142b of the first flange member 142 and the first tapered surface 146a of the third flange member 146. In this way, the semi-cylindrical section 132a of the first lobe member 132 engages the second tapered surface 142b of the first flange member 142 and the first tapered surface 144a of the third flange member 144, thereby locking the intermediate shaft 104 relative to the output shaft 106 in a rotational sense.

[0051] When the intermediate shaft 104 of the drive assembly 100 rotates in a first direction about its longitudinal axis “y” (as indicated by arrow “A”), engagement between the semi-cylindrical section 132a of the first lobe member 132 of the second lobe-shaped portion 130 of the intermediate shaft 104 and the second tapered surface 142b of the first flange member 142 and the first tapered surface 146a of the third flange member 146 of the output shaft 106 causes the output shaft 106 to rotate in the same first direction about its longitudinal axis “z”. Conversely, when the intermediate shaft of the drive assembly 100 rotates in a second direction about its longitudinal axis “y” (as indicated by arrow “B”), engagement between the semi-cylindrical section 132a of the first lobe member 132 of the second lobe-shaped portion 130 of the intermediate shaft 104 and the second tapered surface 142b of the first flange member 142 and the first tapered surface 146a of the third flange member 146 causes the output shaft 106 to rotate in the same second direction about its longitudinal axis “z”.

[0052] Fig.12 Engagement between the second lobe-shaped portion 130 of the intermediate shaft 104 and the second castellated portion 140 of the output shaft 106 is illustrated when the output shaft 106 is angled relative to the intermediate shaft 104. The semi-cylindrical section 132a of the first lobe member 132 of the first lobe-shaped portion 120 of the intermediate shaft 104 remains engaged with the second tapered surface 142b of the first flange member 142 and the first tapered surface 146a of the third flange member 146 of the output shaft 106 when the output shaft 106 is angled relative to the intermediate shaft 104. The waist section 132b of the first lobe member 132 of the second lobe-shaped portion 130 of the intermediate shaft 104 and the first recess 133 and the third recess 137 in the second lobe-shaped portion 130 receive the respective first and third flange members 142, 146 of the second castellated portion 140 of the output shaft 106 when the intermediate shaft 104 and the output shaft 106 are angled relative to each other.

[0053] When the output shaft 106 of the drive assembly is angled relative to the intermediate shaft 104 of the drive assembly 100, the output shaft 106 rotates in the same first direction about its longitudinal axis "z" as the intermediate shaft 104 rotates about its longitudinal axis "y" (as indicated by arrow "A"). When the intermediate shaft 104 and the output shaft 106 rotate in the first direction about their longitudinal axes "y" and "z", respectively, the semi-cylindrical section 132a of the first lobe member 132 of the second lobe member 130 remains engaged with the first flange member 142 and the third flange member 146 of the second castellated portion 140 as the second lobe-shaped portion 130 of the intermediate shaft 104 pivots relative to the second castellated portion 140. When the intermediate shaft 104 and the output shaft 106 rotate in a first direction about their respective longitudinal axes "y" and "z", the second lobe-shaped portion 130 of the intermediate shaft 104 pivots relative to the second castellated portion 140 of the output shaft 106, the waist section 132b of the first lobe component 132 of the second lobe-shaped portion 130 of the intermediate shaft 104 and the first recess 133 and the third recess 137 in the second lobe-shaped portion 130 accommodate the corresponding first flange component 142 and the third flange component 146 of the second castellated portion 140 of the output shaft 106.

[0054] Conversely, when the intermediate shaft of the drive assembly 100 rotates in the second direction about its longitudinal axis “y” (as indicated by arrow “B”), engagement between the semi-cylindrical section 132a of the first lobe member 132 of the second lobe-shaped portion 130 of the intermediate shaft 104 and the second tapered surface 142b of the first flange member 142 and the first tapered surface 146a of the third flange member 146 of the output shaft 106 causes the output shaft 106 to rotate in the same second direction about its longitudinal axis “z”. When the intermediate shaft 104 and the output shaft 106 rotate in the second direction about their longitudinal axes “y” and “z”, respectively, the semi-cylindrical section 132a of the first lobe member 132 of the second lobe-shaped portion 130 remains engaged with the first flange member 142 and the third flange member 146 of the second castellated portion 140 while the second lobe-shaped portion 130 of the intermediate shaft 104 pivots relative to the second castellated portion 140. When the intermediate shaft 104 and the output shaft 106 rotate in the second direction around their respective longitudinal axes "y" and "z", the second lobe-shaped portion 130 of the intermediate shaft 104 pivots relative to the second castellated portion 140 of the output shaft 106, the waist section 132b of the first lobe component 132 of the second lobe-shaped portion 130 of the intermediate shaft 104 and the first recess 133 and the third recess 137 in the second lobe-shaped portion 130 accommodate the corresponding first flange component 142 and the third flange component 146 of the second castellated portion 140 of the output shaft 106.

[0055] As described above, the distal end of the output shaft 106 may include a screw member 106b ( Figure 2 ) or may be otherwise connected to the trocar assembly 30 ( Figure 2 ). Rotation of the output shaft 106 in a first direction about its longitudinal axis "z" causes the trocar member 32 ( Figure 2 ) relative to the adapter assembly 14 ( Figure 1 Conversely, rotation of the output shaft 106 about its longitudinal axis “z” in a first direction causes the trocar member 32 of the trocar assembly 30 to retract relative to the adapter assembly 14.

[0056] Those skilled in the art will appreciate that the devices and methods specifically described herein and shown in the accompanying drawings are non-limiting exemplary aspects of the present disclosure. It is contemplated that the elements and features illustrated or described in conjunction with one exemplary aspect may be combined with the elements and features of another exemplary aspect without departing from the scope of the present disclosure. Similarly, those skilled in the art will appreciate further features and advantages of the present disclosure based on the various aspects of the present disclosure described above. Therefore, the present disclosure is not limited to what has been specifically shown and described, except as indicated in the appended claims.

Claims

1. A drive assembly for an adapter assembly of a surgical device, the drive assembly comprising: an input shaft having a distal portion including a first castellated portion; an intermediate shaft having a proximal portion and a distal portion, the proximal portion of the intermediate shaft including a first lobe-shaped portion operably engaged with the first castellated portion of the input shaft, the distal portion of the intermediate shaft including a second lobe-shaped portion; as well as An output shaft has a proximal portion and a distal portion, the proximal portion of the output shaft including a second castellated portion operably engaged with the second lobe-shaped portion.

2. The drive assembly according to claim 1, wherein: The first lobe-shaped portion and the second lobe-shaped portion each include three lobe members.

3. The drive assembly of claim 2, wherein: The first castellated portion and the second castellated portion each include three flange members.

4. The drive assembly of claim 3, wherein: The first castellated portion and the second castellated portion define three cutouts.

5. The drive assembly of claim 4, wherein: The cutouts of the first castellated portion correspond in number to the number of three lobe members of the first lobe-shaped portion, and the cutouts of the second castellated portion correspond in number to the number of lobe members of the second lobe-shaped portion.

6. The drive assembly of claim 5, wherein: Each of the three lobe members of the first lobe-shaped portion and the second lobe-shaped portion includes a semi-cylindrical portion and a waist portion.

7. The drive assembly of claim 6, wherein: Each of the first lobe-shaped portion and the second lobe-shaped portion defines three recesses.

8. The drive assembly of claim 7, wherein: The waist portions and three recesses of the three lobe members of the first lobe-shaped portion accommodate pivoting of the intermediate shaft relative to the input shaft.

9. The drive assembly of claim 7, wherein: The waist portions and three recesses of the three lobe members of the second lobe-shaped portion accommodate pivoting of the output shaft relative to the intermediate shaft.

10. The drive assembly of claim 1, wherein: The distal portion of the output shaft includes a drive screw.

11. An adapter assembly for connecting a handle assembly to an end effector, the adapter assembly comprising: a coupling assembly configured to be operably coupled to the handle assembly; a straight portion, the straight portion being fixed to the coupling assembly; a curved portion extending from the straight portion; as well as a drive assembly extending from the handle assembly through the curved portion, the drive assembly comprising an input shaft having a distal portion including a first castellated portion; an intermediate shaft having a proximal portion and a distal portion, the proximal portion of the intermediate shaft including a first lobe-shaped portion operably engaged with the first castellated portion of the input shaft, the distal portion of the intermediate shaft including a second lobe-shaped portion; as well as An output shaft has a proximal portion and a distal portion, the proximal portion of the output shaft including a second castellated portion operably engaged with the second lobe-shaped portion.

12. The adapter assembly of claim 11, wherein: The first lobe-shaped portion and the second lobe-shaped portion of the drive assembly each include three lobe members.

13. The adapter assembly of claim 12, wherein: The first castellated portion and the second castellated portion each include three flange members.

14. The adapter assembly of claim 13, wherein: The first castellated portion and the second castellated portion include three cutouts.

15. The adapter assembly of claim 14, wherein: The cutouts of the first castellated portion correspond in number to the number of lobe members of the first lobe-shaped portion, and the cutouts of the second castellated portion correspond in number to the number of lobe members of the second lobe-shaped portion.

16. The adapter assembly of claim 15, wherein: Each of the three lobe members of the first lobe-shaped portion and the second lobe-shaped portion includes a semi-cylindrical portion and a waist portion.

17. The drive assembly of claim 16, wherein: Each of the first lobe-shaped portion and the second lobe-shaped portion defines three recesses.

18. The adapter assembly of claim 17, wherein: The waist portions of the three lobe members of the first lobe-shaped portion and the three recesses of the first lobe-shaped portion accommodate pivoting of the intermediate shaft relative to the input shaft.

19. The adapter assembly of claim 17, wherein: The waist portions of the three lobe members of the second lobe-shaped portion and the three recesses of the second lobe-shaped portion accommodate pivoting of the output shaft relative to the intermediate shaft.

20. A surgical device comprising: Handle assembly; an adapter assembly, the adapter assembly being secured to the handle assembly; an end effector secured to the adapter assembly; as well as a drive assembly extending from the handle assembly and positioned within the adapter assembly, the drive assembly comprising: an input shaft having a distal portion including a first castellated portion; an intermediate shaft having a proximal portion and a distal portion, the proximal portion of the intermediate shaft including a first lobe-shaped portion operably engaged with the first castellated portion of the input shaft, the distal portion of the intermediate shaft including a second lobe-shaped portion; An output shaft has a proximal portion and a distal portion, the proximal portion of the output shaft including a second castellated portion operably engaged with the second lobe-shaped portion.

Images