Powered surgical device with switch controlling automatic retraction

Abstract

A powered surgical device includes a handle assembly (12, 312, 512) having: a rack (56, 356, 556); a first switch (62) for activating clamping and firing of the surgical device; and a second switch (68, 368, 568) for initiating automatic retraction of the rack (56, 356, 556). The second switch (68, 368, 568) is controlled by a switch control mechanism (80, 380, 580) that engages a rack (56, 356, 556) in the handle assembly (12, 312, 512) to initiate automatic retraction of the rack (56, 356, 556) upon completion of firing.

Description

Technical Field

[0001] The present disclosure relates to powered surgical devices, and more particularly to powered surgical stapling devices that automatically retract after firing. Background Art

[0002] Various types of surgical devices for endoscopically treating tissue are known in the art and are commonly used to close tissue or organs, for example, in transection, resection, anastomosis procedures, for occluding organs in thoracic and abdominal surgery, and for electrosurgical fusing or sealing of tissue.

[0003] An example of such a surgical device is a surgical stapling device. Typically, the surgical stapling device includes a tool assembly having an anvil assembly and a cartridge assembly, and a drive assembly. The drive assembly includes a flexible drive beam and a clamping member supported on the distal end of the drive beam. The drive assembly is movable to advance the clamping member through the tool assembly, thereby moving the tool assembly from an open position to a clamped position, and to advance the actuating slide and the blade through the cartridge assembly, thereby ejecting the staples from the cartridge assembly and cutting the tissue clamped between the anvil assembly and the cartridge assembly.

[0004] The surgical suturing device can be a manually actuated device or a powered suturing device. The powered suturing device includes one or more actuation buttons to enable the motor to start advancing the drive assembly and moving the tool assembly from an open position to a clamped position, and then advancing the actuation slide and the blade through the tool assembly to fire the suturing device (i.e., ejecting the staples from the cartridge assembly and cutting the tissue clamped between the cartridge assembly and the anvil assembly). Such a device includes a first switch and a second switch, the first switch being manually actuated to advance the drive assembly to move the tool assembly to a clamped position and fire the suturing device, the second switch being manually actuated to unclamp the tool assembly and retract the drive assembly after firing. Some suturing devices include a third switch and a fourth switch, the third switch stopping the drive assembly from advancing after clamping is completed, and the fourth switch stopping the drive assembly from retracting when the drive assembly is fully retracted after firing is completed.

[0005] There is a continuing need in the art for a powered stapling device that will automatically retract the drive assembly after the stapling device has been fired. Summary of the invention

[0006] The present application relates to a powered surgical device, which includes a handle assembly having a first switch for activating clamping and firing of the surgical device and a second switch for activating automatic retraction. The second switch is controlled by a switch control mechanism, which engages with a rack in the handle assembly to activate automatic retraction when firing is completed.

[0007] Aspects of the present disclosure relate to a powered handle assembly, the powered handle assembly comprising: an outer housing defining a cavity; an inner housing secured within the cavity; a rack; a drive assembly; a first switch; an automatic retract switch; and an automatic retract switch control mechanism. The inner housing defines a longitudinally extending path through the inner housing. The rack is positioned along the longitudinally extending path of the inner housing and includes a first engagement surface. The rack is movable between a retracted position and an advanced position. The drive assembly is supported by the inner housing and engages with the rack to move the rack between the retracted position and the advanced position. The first switch is supported within the cavity and coupled to the drive assembly. The first switch is manually movable from an open position to a closed position. The automatic retract switch is supported within the cavity and coupled to the drive assembly. The automatic retract switch is movable between an open position and a closed position. The automatic retract switch control mechanism includes an actuator supported on the inner housing adjacent to the automatic retract switch. The actuator is movable from a first position to a second position in response to the rack moving from the retracted position to the advanced position to move the automatic retract switch from the open position to the closed position. When the first switch is in the closed position and the automatic retract switch is in the open position, the drive assembly moves the rack toward the advanced position, and when the first switch is in the closed position and the automatic retract switch is in the closed position, the drive assembly moves the rack toward the retracted position.

[0008] In various aspects of the present disclosure, an automatically retracting switch control mechanism includes a cap member supported on the actuator and engaging the inner housing to resist movement of the actuator.

[0009] In some aspects of the present disclosure, the cap member includes a non-slip surface that engages the inner housing.

[0010] In certain aspects of the present disclosure, the non-slip surface of the cap member includes protrusions.

[0011] In various aspects of the present disclosure, the automatic retraction control mechanism includes a biasing member positioned to urge the cap member toward the inner housing.

[0012] In some aspects of the present disclosure, the actuator defines a bore, and the biasing member is received in the bore to urge the cap member into the outer surface of the inner housing.

[0013] In certain aspects of the present disclosure, the rack defines an elongated slot, and the actuator includes a finger received within the elongated slot.

[0014] In aspects of the present disclosure, the rack includes a first engagement surface positioned at a proximal end of the elongated slot, and the rack engages a finger of the actuator when in the advanced position to move the actuator from the first position to the second position.

[0015] In some aspects of the disclosure, the rack includes a second engagement surface positioned at a distal end of the elongated slot, and the rack engages a finger of the actuator when in the retracted position to move the actuator from the second position to the first position.

[0016] In certain aspects of the present disclosure, an actuator of the automatically retracting switch control mechanism is rotatably supported on the inner housing.

[0017] In various aspects of the present disclosure, the handle assembly includes a retraction button supported on the housing, the retraction button engaged with the actuator and movable to move the actuator from a first position to a second position.

[0018] Other aspects of the present disclosure relate to a surgical device, a tool assembly, an elongated body, and a powered handle assembly. The elongated body has a proximal portion and a distal portion. The tool assembly is supported on the distal portion of the elongated body and includes a first jaw and a second jaw that are movable between an unclamped position and a clamped position. The powered handle assembly is secured to the proximal portion of the elongated body and includes: an outer housing that defines a cavity; an inner housing that is secured within the cavity; a rack; a drive assembly; a first switch; an automatic retraction switch; and an automatic retraction switch control mechanism. The inner housing defines a longitudinally extending path through the inner housing. The rack is positioned along the longitudinally extending path of the inner housing and includes a first engagement surface. The rack is movable between a retracted position and an advanced position. The drive assembly is supported by the inner housing and engages with the rack to move the rack between the retracted position and the advanced position. The first switch is supported within the cavity and coupled to the drive assembly. The first switch is manually movable from an open position to a closed position. The automatic retract switch is supported in the cavity and coupled to the drive assembly. The automatic retract switch is movable between an open position and a closed position. The automatic retract switch control mechanism includes an actuator supported on the inner housing adjacent to the automatic retract switch. The actuator is movable from a first position to a second position in response to the rack moving from the retracted position to the advanced position to move the automatic retract switch from the open position to the closed position. When the first switch is in the closed position and the automatic retract switch is in the open position, the drive assembly moves the rack toward the advanced position, and when the first switch is in the closed position and the automatic retract switch is in the closed position, the drive assembly moves the rack toward the retracted position.

[0019] Other features of the present disclosure will be understood from the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Various aspects of the disclosed surgical device will be described below with reference to the accompanying drawings, in which:

[0021] Figure 1is a side perspective view of a surgical device according to aspects of the present disclosure in an unclamped, pre-fired position;

[0022] Figure 2 yes Figure 1 an enlarged view of the indicated detail area shown in , wherein the outer housing of the handle assembly of the surgical device is shown in phantom and the articulation knob and shaft of the adapter assembly of the suturing device are removed;

[0023] Figure 2A yes Figure 1 Schematic diagram of switches and controls of the surgical device shown in;

[0024] Figure 3 yes Figure 2 An exploded side perspective view of the components of the handle assembly shown in , which includes an inner housing, a rack, an automatic retraction switch, and a switch control mechanism;

[0025] Figure 4 yes Figure 3 A side perspective view of an actuator of a switch control mechanism shown in ;

[0026] Figure 5 yes Figure 2 A side perspective view of a cap of a switch control mechanism shown in ;

[0027] Figure 6 yes Figure 3 A side perspective view of a rack of the handle assembly shown in ;

[0028] Figure 7 When the actuator is keyed to the first half of the inner housing of the handle assembly, Figure 3 A side perspective view of a first side view of the internal components of the handle assembly shown in;

[0029] Figure 8 When the actuator is keyed to the first half of the inner housing of the handle assembly, Figure 3 A side perspective view of the interior components of the handle assembly shown in FIG.

[0030] Fig. 9 When the actuator of the switch control mechanism is rotated into position on the first half of the inner housing of the handle assembly, Figure 3 A side perspective view of the interior components of the handle assembly shown viewed from a first side;

[0031] Fig.10 When the actuator of the switch control mechanism is rotated into position on the first half of the inner housing of the handle assembly, Figure 3 a side perspective view of the interior components of the handle assembly as viewed from a second side;

[0032] Fig.11 yes Figure 2 A side perspective view of the internal components of the handle assembly shown in , wherein the suturing device is in a fully retracted position;

[0033] Fig.12 is along Fig.11 A cross-sectional view taken along section line 12-12;

[0034] Fig.13 is along Fig.11 A cross-sectional view taken along section line 13-13;

[0035] Fig.14 is along Fig.11 A cross-sectional view taken along section line 14-14;

[0036] Fig.15 yes Fig.11 a side cross-sectional view of the internal components of the handle assembly shown in FIG. 1 as the rack moves from a retracted position to an advanced position, wherein the actuator is shown in phantom;

[0037] Fig.16 yes Fig.11 a side cross-sectional view of the internal components of the handle assembly shown in , with the actuator shown in phantom and the rack in an advanced position;

[0038] Fig.17 yes Fig.11 a side cross-sectional view of the internal components of the handle assembly shown in FIG. 1 as the rack moves back from the advanced position to the retracted position, wherein the actuator is shown in phantom;

[0039] Fig.18 yes Figure 1 A side perspective view of an alternative version of a handle assembly of a suturing device shown in with the outer housing section removed and including a retraction button assembly;

[0040] Fig.19 yes Fig.18 A side perspective view of an outer housing section of a handle assembly and a retract button assembly shown in FIG.

[0041] Fig. 20 yes Fig.18 A side perspective view of an actuator of a switch control mechanism of a handle assembly shown in FIG.

[0042] Fig.21 yes Figure 1 A side perspective view of another alternative version of a handle assembly for a suturing device shown in , wherein the outer housing of the handle assembly is removed;

[0043] Fig. 22 yes Fig.21 A side perspective view of a rack of the handle assembly shown in ;

[0044] Fig.23 is from Fig.21 A perspective view of an actuator of a switch control mechanism of a handle assembly as shown in FIG.

[0045] Fig.24 is from Fig.23 A perspective view of the actuator as viewed from another side;

[0046] Fig.25 is along Fig.21 A cross-sectional view taken along section line 25-25;

[0047] Fig.26 is along Fig.25 A cross-sectional view taken along section line 26-26 of FIG. 1 , wherein the handle assembly is provided in a fired position; and

[0048] Fig. 27 is along Fig.25 A cross-sectional view taken along section line 26-26 of the embodiment of the present invention is shown with the handle assembly in a retracted position. DETAILED DESCRIPTION

[0049] The disclosed surgical device will now be described in detail with reference to the accompanying drawings, wherein in each of the several views, the same reference numerals represent the same or corresponding elements. However, it should be understood that the various aspects of the present disclosure are merely examples of the present disclosure and can be implemented in various forms. Well-known functions or configurations are not described in detail to avoid unnecessary details that obscure the present disclosure. Therefore, the specific structural and functional details disclosed herein should not be interpreted as restrictive, but should only be interpreted as the basis of the claims and as a representative basis for teaching those skilled in the art to adopt the present disclosure in various ways in almost any structure that is appropriately described in detail. In addition, the use of directional terms such as front, back, upper, lower, top, bottom and similar terms is to help understand the description and is not intended to limit the present disclosure.

[0050] In this specification, the term "proximal" is generally used to refer to the portion of the device that is closer to the clinician, while the term "distal" is generally used to refer to the portion of the device that is farther from the clinician. In addition, the term "endoscopic" is generally used to refer to endoscopy, laparoscopy, arthroscopy, and / or any other procedure performed through a small diameter incision or cannula. Further, the term "clinician" is generally used to refer to medical staff, including doctors, nurses, surgeons, and support staff.

[0051] The present disclosure relates to a powered surgical device including a handle assembly having a first switch for initiating clamping and firing of the surgical device and a second switch for initiating automatic retraction. The second switch is controlled by a switch control mechanism that engages a rack in the handle assembly to initiate automatic retraction when firing is completed.

[0052] Figure 1 and Figure 2 A surgical device, generally shown as a suturing device 10, is shown, which includes a powered handle assembly 12, an elongated body or adapter assembly 14, and a tool assembly 16. The handle assembly 12 includes an outer housing 18 that forms a fixed handle portion 18a. The fixed handle portion 18 supports one or more actuation buttons (e.g., a rocker 20) that can be actuated to control the operation of various functions of the suturing device 10, such as clamping and firing of the suturing device 10. In various aspects of the present disclosure, the outer housing 18 of the handle assembly 12 is formed by half sections 22 and 24 that are secured together to define a cavity 26 ( Figure 2 In various aspects of the present disclosure, the fixed handle portion 18a of the outer housing 18 supports the battery 28 and the drive assembly (eg, the motor / gear assembly 30).

[0053] The elongated body 14 of the suturing device 10 has a proximal portion 14a and a distal portion 14b and defines a longitudinal axis "X". The proximal portion 14a of the elongated body 14 supports a rotation knob 36 and an articulated lever 42, which is supported on the rotation knob 36. The rotation knob 36 is coupled to the handle assembly 12 and supports the elongated body 14 to facilitate rotation of the elongated body 14 and the tool assembly 16 relative to the handle assembly 12 about the longitudinal axis "X".

[0054] The tool assembly 16 is secured to the distal portion 14b of the elongated body 14 by a pivot member 44 that defines an axis “Y” that is transverse to the longitudinal axis “X”. An articulation lever 42 is operatively coupled to the tool assembly 16 via an articulation link (not shown) such that manipulation of the articulation lever 42 causes articulation of the tool assembly 16 about the axis “Y” between a non-articulated position in which the tool assembly 16 is aligned with the longitudinal axis “Y” and an articulated position in which the longitudinal axis of the tool assembly 16 defines an acute angle with the longitudinal axis “X” of the elongated body 14.

[0055] The tool assembly 16 includes a first jaw and a second jaw. In various aspects of the present disclosure, the first jaw supports the cartridge assembly 48, and the second jaw supports the anvil assembly 50. The cartridge assembly 48 includes a channel 52 that supports a staple cartridge 54. In various aspects of the present disclosure, the staple cartridge 54 is removably received in the channel 52 and can be replaced after each firing of the stapling device 10 to facilitate the reuse of the stapling device 10. The channel 52 is pivotally coupled to the anvil assembly 50 and can be moved between an unclamped position and a clamped position relative to the anvil assembly 50. Alternatively, the anvil assembly 50 can be pivotally coupled to the cartridge assembly 48 and can be moved between an unclamped position and a clamped position relative to the cartridge assembly 48.

[0056] Figure 2 and Figure 3 The internal components of the handle assembly 12 are shown, including the rack 56, the control rod 58, the inner housing 60 ( Figure 2 ), a first switch 62, a second switch 64, a third switch 66, a fourth switch 68, a fifth switch 70, and a switch control mechanism 72. The inner housing 60 is formed by sections 72 and 74, and is fastened within the outer housing 18 of the handle assembly 12 by screws or the like (not shown) to secure the handle assembly 12 ( Figure 1 )'s internal components are supported and aligned within the outer shell 18.

[0057] The inner housing 60 defines a longitudinally extending path or passage 78 ( Figure 3 ), the path or channel extends from the proximal end of the inner housing 60 to the distal end of the inner housing 60 and receives and supports the rack 56 for linear movement between the rack retracted position and the advanced position. The control rod 58 has a proximal end that is coupled to the distal portion of the rack 56 and is movable between the rod retracted position and the advanced position in response to the movement of the rack 56 between the rack advanced position and the retracted position. The control rod 58 is coupled to a drive assembly (not shown) that is movable in response to the movement of the rack 56 between the rack retracted position and the rack advanced position within the tool assembly 16 to actuate the tool assembly 12 (i.e., to move the tool assembly 12 between the unclamped position and the clamped position) and to fire the stapling device. The rack 56 includes teeth 56a that engage with the motor / gear assembly 30 so that activation of the motor / gear assembly 30 causes the rack 56 to move between the rack retracted position and the rack advanced position within the channel 72 of the inner housing 60. The inner housing 60 supports the motor / gear assembly 30 and the rack 56 to maintain proper alignment between the components.

[0058] The switches 62 to 70 of the handle assembly 12 are connected to logic gate circuits to input signals into the motor driver to control the forward and reverse movement of the motor of the motor / gear assembly 30. In various aspects of the present disclosure, the motor of the motor / gear assembly 30 includes a DC brushed motor, but other types of motors are also contemplated. The switches 62 to 70 are movable between an open position and a closed position to provide a control 71 ( Figure 2A ) to control the movement and direction of movement of the motor / gear assembly 30. These signals provide the controller with status information about the position of the rack 56 of the suturing device 10 and other mechanical components of the suturing device. In some aspects of the present disclosure, the switches can be coupled to the controller via logic gates. In various aspects of the present disclosure, the first switch 62 and the second switch 64 are embedded in a printed circuit board assembly (PCBA) (not shown) and are normally open. The first switch 62 can be activated via the rocker 20 ( Figure 1 ) is manually actuated to the closed position to advance the rack 56 and move the tool assembly to the clamped position, and to advance the rack 56 and fire the stapling device 10 ( Figure 1 ). The second switch 64 can be manually actuated via the rocker 20 to retract the rack 56 and move the tool assembly 16 from the clamped position to the unclamped position, and to retract the rack 56 and move the tool assembly 16 from the fired position to the unclamped position.

[0059] The third switch 66 is normally in the open position and automatically moves to the closed position when the tool assembly 16 moves from the unclamped position to the clamped position so as to stop the rack 56 from advancing after clamping is completed. A fourth switch 68 is provided for stopping the rack 56 from advancing when firing is completed and for stopping the rack 56 from retracting when the rack 56 reaches the rack retracted position. The fourth switch can also trigger the automatic retraction of the rack 56 when the first switch 62 is released and the second switch 64 is in the open position. The switch 58 is provided for when the second switch 64 is released via the rocker 20 ( Figure 1 ) is maintained in the closed position and the rack 56 stops retracting when it reaches the rack retracted position.

[0060] Figure 3 A switch control mechanism 80 is shown for controlling the operation of the fourth switch 68. The switch control mechanism 80 includes an actuator 82, a biasing member 84, and a cap member 86. Figure 4 The actuator 82 also shown in FIG. 8 includes a body 88 and a post 90 extending transversely from the body 88. The body 88 has an inner surface 92 and defines a transverse hole 94 that opens into the inner surface 92 of the body 88 of the actuator 82. In various aspects of the present disclosure, the body 88 of the actuator includes a bottom surface that defines an abutment member 96. The post 90 extends inwardly from the inner surface 92 of the actuator 82 and includes two downwardly extending fingers 98a and 98b.

[0061] Figure 5 The cap member 86 of the switch control mechanism 80 is shown, and the cap member includes a stepped body 100, which defines an inwardly extending annular extension 102 and a cap portion 104. The cap portion 104 has an inwardly facing non-slip surface 106. In various aspects of the present disclosure, the non-slip surface 106 includes a plurality of protrusions 108. The annular extension 102 is received in the transverse hole 94 of the actuator 82 so that the cap member 86 can move laterally relative to the body 88 of the actuator 82.

[0062] The biasing member 84 of the switch control mechanism 80 is received in the transverse hole 94 of the actuator 82 and is positioned to push the cap member 86 inwardly toward the section 74 of the inner housing 60 of the handle assembly 12, as described in further detail below. In various aspects of the present disclosure, the outer end of the transverse hole 94 of the actuator 82 is closed by the cover 110, and the biasing member 84 includes a coil spring compressed between the cover 110 and the cap member 86.

[0063] Figure 6 The rack 56 is shown, which includes teeth 56a and defines an elongated slot 112. The elongated slot 112 has a proximal end defined by a first engagement surface 114 and a distal end defined by a second engagement surface 116. When the switch control mechanism 80 is coupled to the inner housing 60 ( Figure 2 ), the elongated slot 112 receives the downwardly extending finger 98b of the actuator 82 of the switch control mechanism, as described in further detail below.

[0064] The actuator 82 is rotatably supported on the section 74 of the inner housing 60 about an axis defined by a post 90 which is transverse to the longitudinal axis "X" ( Figure 1 ). Half-segment 90 defines a circular opening 120 having a notch 122 that receives fingers 98a and 98b of post 90 when the post is inserted through opening 120. Half-segment 90 also has a flat outer surface 124 ( Figure 3 ), the flat outer surface engages the inner surface 92 of the actuator 82 when the actuator 82 is mounted on the segment 74.

[0065] The fourth switch 68 is mounted to the planar outer surface of the section 74 of the inner housing 60 at a location below the planar outer surface 124 of the section 74 of the inner housing 60. In aspects of the present disclosure, the section 74 of the inner housing 60 includes posts 126 that are received within holes 128 defined in the fourth switch 68 to mount the fourth switch 68 to the inner housing 60. Alternatively, other mounting techniques or components may be used to mount the fourth switch 68 to the inner housing 60.

[0066] Figures 8 to 13 The switch control mechanism 80 is shown mounted to the handle assembly 12 ( Figure 1 ) on the inner housing 60. When the switch control mechanism 80 is mounted on the section 74 of the inner housing 60, the post 90 of the actuator 82 is inserted through the opening 120. In order to fully insert the post 90 through the opening 120, the fingers 98a, 98b of the post 90 of the actuator 82 must be aligned with the notches 122 ( Figure 3 ) When the post 90 is fully inserted into the opening 120 , the end of the post 90 spaced apart from the body 88 of the actuator 82 is received in the opening 130 ( Fig.12 ) to rotatably support the actuator 82 on the inner housing 60, and the fingers 98a, 98b are positioned in the cavity 134 ( Fig.12 It should be noted that when the column 90 is inserted into the opening 120 of the inner housing 60 ( Figure 7 ), the biasing member 84 and the cap member 86 of the switch control mechanism 80 are received in the transverse hole 94 of the actuator 82 so that the anti-slip surface 106 of the actuator 82 faces inwardly toward the flat outer surface 124 of the inner housing 60.

[0067] Once the post 90 is fully inserted into the opening 120 in the inner housing 60, the actuator 82 can be moved along the Figures 8 to 10 The actuator 82 is rotated in the direction of arrow "A" in order to position the non-slip surface 106 of the actuator 82 to engage with the flat outer surface 124 of the inner housing 60. When the actuator 82 is rotated in the direction of arrow "A", the proximal end of the body 88 is received in the channel 140 ( Fig.10 ). The passage 140 is defined in part by an overhang 142 that prevents the actuator 82 from moving outwardly relative to the inner housing 60 when the proximal end of the body 88 is received in the passage 140. When the actuator 82 is rotated into the passage 140, the finger 98a of the actuator 82 moves to a position between the rack 56 and the inner housing 60, and the finger 98b moves into the slot 112 of the rack 56 ( Fig.12 ). In this position, the overhanging member 142 ( Fig.10 ) prevents the post 90 of the actuator 82 of the switch control mechanism 80 from being removed from the opening 120 of the inner housing 60. In addition, the biasing member 84 of the switch control mechanism 80 pushes the cap member 86 from the transverse hole 94 defined in the actuator 82 into the flat outer surface 124 of the inner housing 60 ( Fig.13), to hinder the rotation of the actuator 82 in the direction opposite to the arrow "A". More specifically, the protrusion 108 of the cap member 86 is biased to engage with the flat outer surface 124 of the inner housing 60 to generate friction between the switch control mechanism 80 and the inner housing 60, thereby maintaining the position of the actuator 82 relative to the inner housing 60 during the movement of the rack 56 ( Fig.13 ). It should be noted that the switch control mechanism 80 will operate without the cap member 86. More specifically, the cap member 86 can be removed so that the biasing member 84 of the switch control mechanism 80 is in direct contact with the inner housing 60 to maintain the position of the actuator 82 relative to the inner housing 60 during the movement of the rack 56. In various aspects of the present disclosure, the biasing member 84 can be in the form of a coil spring that includes a flat surface 84a ( Figure 3 ). In the assembled state, the abutment member 96 of the actuator 82 is positioned above the switch button 146 so that the fourth switch 68 is in the on position.

[0068] Fig.14 The switch control mechanism 80 and the rack 56 are shown, wherein the rack 56 is in a retracted position. This is when the suturing device 10 ( Figure 1 )like Figure 1 8 and rack 56 in the unclamped position. When rack 56 is in the retracted position, finger 98b extending from post 90 is positioned in the proximal end of elongated slot 112 of rack 56, adjacent first engagement surface 114 of rack 56.

[0069] Figures 15 to 17 The rack 56 is shown as it passes through the handle assembly 12 ( Figure 1 ) when the inner housing 60 moves to the forward position. As briefly described above, the rocker 20 ( Figure 1 ) to close the first switch 62 ( Figure 2 ) to advance the rack to clamp and fire the suturing device 10. The rocker 20 must be held in position to allow for the clamping and subsequent firing of the suturing device 10 ( Figure 1 ) closes the first switch 62 in two separate actions during the firing of the rack 56. After clamping is complete and the rocker 20 is pressed a second time and held by the clinician to close the first switch 62 and advance the rack 56 to the advanced position, the finger 98b will travel through the elongated slot 112 of the rack 56 until the finger 98b is engaged by the second engagement surface 116 of the rack 56. When this occurs, continued movement of the rack 56 will cause the switch control mechanism 80 to move along the Fig.16The switch 80 is rotated in the direction of arrow "C" so that the abutment member 96 of the actuator 82 of the switch control mechanism 80 engages the switch button 146 to move the fourth switch to the closed position. When this happens, the first switch 62 ( Figure 2 ) is held in the closed position, the motor gear assembly 30 ( Figure 2 ) will reverse its direction of rotation, causing the rack 56 to rotate in Fig.17 It should be noted that when the rack 56 is fully retracted and the first engagement surface 114 of the rack 56 engages the finger 98b of the actuator 82, the actuator 82 will rotate back to Fig.14 The position shown causes the fourth switch 68 to return to the open position to stop the rack 56 from retracting.

[0070] Figures 18 to 20 The handle assembly 12 ( Figure 1 ), which is generally shown as a handle assembly 312. The handle assembly 312 is the same as the handle assembly 12, except that the handle assembly 312 also includes a retract button assembly 320. The retract button assembly 320 is accessible through an opening 322 in the housing 318 of the handle assembly 312, and includes a retract button 320a, a biasing portion 324, and an engagement portion 326. The biasing portion 324 is secured to the retract button 320a and the housing 318, and is configured to move the retract button 320 upward within the opening 322 of the housing 318. In various aspects of the present disclosure, the biasing portion 324 includes resilient arms that are received within slots 330 of the housing 318 and are in tension to push the retract button 320a upward through the opening 322 of the housing 318. The engagement portion 326 of the retract button assembly 320 is secured to the retract button 320a and supported on the upper surface of the actuator 382 of the switch control mechanism 380. The actuator 382 is the same as the actuator 380 described above, except that the actuator 382 includes a platform 390 that supports the engagement portion 326 of the retract button assembly 320.

[0071] The function of the handle assembly 312 is the same as that of the handle assembly 12, except that when the first switch 62 ( Figure 2 ) is in the closed position, the clinician can initiate automatic retraction at any position of the rack 356 between the retracted position and the advanced position. More specifically, before the rack moves to the fully advanced position, wherein the first switch 62 is moved by the rocker 20 ( Figure 1) is held in the closed position, the clinician can press the retract button 320a to move the engagement portion 326 downward into the platform 390 of the actuator 382 to close the fourth switch 68. More specifically, when the clinician presses the retract button 320a, the engagement portion 326 of the actuator 382 moves downward against the push of the biasing portion 324 to press against the platform 390 of the actuator 382. When this happens, the actuator 382 pivots downward to engage with the switch button 394 of the fourth switch 368 to close the fourth switch 68.

[0072] In various aspects of the present disclosure, the retract button assembly 320 can be integrally formed. For example, the biasing portion 324 can be overmolded onto the button 320a and the engagement portion 326 to form an integral assembly 320. Other one-piece and multi-piece configurations are contemplated.

[0073] Figure 21 to Figure 27 Another alternative to handle assemblies 12 and 312 is shown, generally shown as handle assembly 512. Handle assembly 512 is similar to handle assemblies 12 and 312, and includes: a rack 556; an inner housing 560; a switch including a fourth switch 568; and a switch control mechanism 580 ( Fig.25 Inner housing 560 is formed from segments 572 and 574 that define a longitudinal path or passage 578 ( Fig.21 ), the longitudinal path or channel extends through the inner housing 560 and receives the rack 556. The rack 556 is movable within the channel 578 between a retracted position and an advanced position. Figure 3 ) as described above, the rack 556 is connected to the control rod 558 ( Fig. 27 ), the control rod is connected to a drive assembly (not shown) that is movable to actuate tool assembly 16 ( Figure 1 ).

[0074] Fig. 22 The rack 556 is shown, which includes teeth 556a and defines an elongated slot 612. The elongated slot 612 has a proximal end defined by a first engagement surface 614 and a distal end defined by a second engagement surface 616. When the switch control mechanism 580 is coupled to the inner housing 560 ( Figure 2 ), the elongated slot 612 receives the downwardly extending finger 598 of the actuator 582 of the switch control mechanism 580, as described in further detail below.

[0075] Fig.23 and Fig.24The actuator 582 of the switch control mechanism 580 is shown, and includes: a body 592 having a downwardly extending leg 594; a biasing member engagement surface 596; and a downwardly extending finger 598. The body 592 is supported on the top of the rack 556 so that the finger 598 is received in the elongated slot 612 of the rack 556. The downwardly extending leg 594 is positioned outward from the finger 598 and extends along the proximal side of the fourth switch 568 ( Fig.21 The downwardly extending leg 594 of the actuator 582 has an abutment member 599 ( Fig.24 ), the abutment member is positioned adjacent to the switch button 646 of the fourth switch 568. The abutment member 599 is movable relative to the fourth switch 569, as described in further detail below, to move the switch button 646 from the open position to the closed position.

[0076] The actuator 582 is supported on the housing 560 to move between the retracted position and the advanced position in response to the movement of the rack 556 between the rack retracted position and the rack advanced position. In various aspects of the present disclosure, the section 574 of the inner housing 560 defines a cavity 660 ( Fig.21 ), which receives a portion of the body 592 of the actuator 582. When the rack 556 moves from the rack retracted position to the rack advanced position, the first engagement surface 614 of the rack 556 engages the finger 598 of the actuator 582 of the switch control mechanism 580 to move the actuator 582 from the retracted position to the advanced position. When the actuator 582 is in the advanced position, the abutment member 599 on the downwardly extending leg 594 of the actuator 582 engages the switch button 646 of the fourth switch 568 to move the switch 568 from the open position to the closed position. Similarly, when the rack 556 moves from the rack advanced position to the rack retracted position, the second engagement surface 616 engages the finger 598 to move the actuator 582 from the advanced position to the retracted position, thereby allowing the switch 568 to return to the open position.

[0077] Fig.25 A switch control mechanism 580 is shown, which includes an actuator 582 and a biasing member 584. In various aspects of the present disclosure, the biasing member 584 of the switch control mechanism 580 is received in a blind hole 662 ( Fig.25 ). The biasing member 584 is in a compressed state and presses against the biasing member engagement surface 596 of the actuator 582 to press the actuator 582 against the inner surface of the inner housing 560. The biasing member 584 is in a compressed state and presses against the biasing member engagement surface 596 of the actuator 582 to press the actuator 582 against the inner surface of the inner housing 560. Figure 3) More specifically, the biasing member 584 pushes the actuator 582 against the inner surface of the inner housing 560 to resist movement of the actuator 582 between the retracted position and the advanced position.

[0078] Fig.26 The rack 556 is shown as it moves from the retracted position to the advanced position in the direction of arrow "E" to fire the stapling device 10 ( Figure 1 ) when the handle assembly 512 is in the closed position. When the rack 556 moves from the rack retracted position to the rack advanced position, the first engagement surface 614 of the rack 556 engages the finger 598 of the actuator 582 of the switch control mechanism 580 to move the actuator 582 from the retracted position to the advanced position in the direction of arrow "F" and to move the fourth switch 568 from the open position to the closed position. When this occurs, the rack 556 will automatically retract, as described above with respect to the handle assembly 12. It should be noted that the actuator 582 only needs to move a short distance from its retracted position to its advanced position to move the switch button 646 of the switch 568 from the open position to the closed position.

[0079] Fig. 27 shows that when the rack 556 is in the suturing device 10 ( Figure 1 ) is shown in the figure below. The handle assembly 512 is shown when the rack 556 is moved from the rack advanced position back to the rack retracted position in the direction of arrow "G" after being fired. When the rack 556 moves from the advanced position back to the retracted position, the second engagement surface 616 of the rack 556 engages the finger 598 of the actuator 582 of the switch control mechanism 580 to move the actuator 582 from its advanced position to its retracted position in the direction of arrow "H". When the actuator 582 moves from the advanced position back to the retracted position, the abutment member 599 on the downwardly extending leg 594 of the actuator 582 moves away from the off button 646 to allow the fourth switch 568 to move from the closed position to the open position. When this occurs, the motor / gear assembly 30 is deactivated and the rack 556 stops retracting.

[0080] The operation of the fourth switch 568 as described above causes the suturing device 10 to operate as described above with respect to the handle assembly 12 ( Figure 2 ) The switch control mechanism 580 allows the rack 556 to be in the suture device 10 ( Figure 1 ) automatically retracts after firing is completed.

[0081] 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 of the present disclosure 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 powered handle assembly, comprising: an outer shell defining a cavity; an inner housing secured within the cavity, the inner housing defining a longitudinally extending path therethrough; a rack positioned along a longitudinally extending path of the inner housing, the rack including a first engagement surface and movable between a retracted position and an advanced position; a drive assembly supported by the inner housing, the drive assembly engaged with the rack and operable to move the rack between the retracted position and the advanced position; a first switch supported within the cavity and coupled to the drive assembly, the first switch being manually movable from an open position to a closed position; an automatic retraction switch supported within the cavity, the automatic retraction switch coupled to the drive assembly and movable between an open position and a closed position; as well as an automatic retract switch control mechanism including an actuator supported on the inner housing adjacent the automatic retract switch, the actuator being movable from a first position to a second position in response to movement of the rack from the retracted position to the advanced position to cause the automatic retract switch to move from the open position to the closed position; wherein the first switch and the automatic retraction switch are configured such that when the first switch is in the closed position and the automatic retraction switch is in the open position, the drive assembly is actuated to move the rack toward the advanced position, and when the first switch is in the closed position and the automatic retraction switch is in the closed position, the drive assembly is actuated to move the rack toward the retracted position.

2. The powered handle assembly of claim 1, wherein: The automatic retracting switch control mechanism includes a cap member supported on the actuator, the cap member engaging the inner housing to resist movement of the actuator between the first position and the second position.

3. The powered handle assembly of claim 2, wherein: The cap member includes a non-slip surface that engages the inner housing.

4. The powered handle assembly of claim 1, wherein: The actuator is longitudinally movable between a retracted position and an advanced position to move the automatic retraction switch between the open position and the closed position.

5. The powered handle assembly of claim 2, wherein: The automatic retraction control mechanism includes a biasing member positioned to urge the cap member into engagement with the inner housing.

6. The powered handle assembly of claim 1, wherein: The automatic retraction control mechanism includes a biasing member, and the actuator includes a surface that engages the biasing member, the biasing member urging the actuator into engagement with the inner housing.

7. The powered handle assembly of claim 1, wherein: The rack defines an elongated slot, and the actuator includes a finger received within the elongated slot.

8. The powered handle assembly of claim 7, wherein: The rack includes a first engagement surface positioned at a proximal end of the elongated slot, the first engagement surface engaging a finger of the actuator when the rack is in the advanced position to move the actuator from the first position to the second position.

9. The powered handle assembly of claim 8, wherein: The rack includes a second engagement surface positioned at a distal end of the elongated slot, the second engagement surface engaging a finger of the actuator when the rack is in the retracted position to move the actuator from the second position to the first position.

10. The powered handle assembly of claim 1, further comprising a retract button supported on the housing, the retract button engaged with the actuator and movable to move the actuator from the first position to the second position.

11. A surgical device comprising: an elongated body having a proximal portion and a distal portion; a tool assembly supported on a distal portion of the elongated body, the tool assembly comprising a first jaw and a second jaw movable between an unclamped position and a clamped position; as well as a powered handle assembly secured to the proximal portion of the elongated body, the powered handle assembly comprising: an outer shell defining a cavity; an inner housing secured within the cavity, the inner housing defining a longitudinally extending path therethrough; a rack positioned along a longitudinally extending path of the inner housing, the rack including a first engagement surface and movable between a retracted position and an advanced position; a drive assembly supported by the inner housing, the motor gear / assembly engaging the rack and operable to move the rack between the retracted position and the advanced position; a first switch supported within the cavity and coupled to the drive assembly, the first switch being manually movable from an open position to a closed position; an automatic retraction switch supported within the cavity, the automatic retraction switch coupled to the drive assembly and movable between an open position and a closed position; and an automatic retract switch control mechanism including an actuator supported on the inner housing adjacent the automatic retract switch, the actuator being movable from a first position to a second position in response to movement of the rack from the retracted position to the advanced position to cause the automatic retract switch to move from the open position to the closed position; wherein the first switch and the automatic retraction switch are configured such that when the first switch is in the closed position and the automatic retraction switch is in the open position, the drive assembly is actuated to move the rack toward the advanced position, and when the first switch is in the closed position and the automatic retraction switch is in the closed position, the drive assembly is actuated to move the rack toward the retracted position.

12. The surgical device of claim 11, wherein: The automatic retracting switch control mechanism includes a cap member supported on the actuator, the cap member engaging the inner housing to resist movement of the actuator.

13. The surgical device of claim 12, wherein: The cap member includes a non-slip surface that engages the inner housing.

14. The surgical device of claim 13, wherein: The actuator is longitudinally movable between a retracted position and an advanced position to move the automatic retraction switch between the open position and the closed position.

15. The surgical device of claim 14, wherein: The automatically retracting switch control mechanism includes a biasing member positioned to urge the cap member toward the inner housing.

16. The surgical device of claim 15, wherein: The actuator defines a bore, and the biasing member is received in the bore to urge the cap member into the outer surface of the inner housing.

17. The surgical device of claim 11, wherein: The rack defines an elongated slot, and the actuator includes a finger received within the elongated slot.

18. The surgical device of claim 17, wherein: The rack includes a first engagement surface positioned at a proximal end of the elongated slot, the first engagement surface engaging a finger of the actuator when the rack is in the advanced position to move the actuator from the first position to the second position.

19. The surgical device of claim 18, wherein: The rack includes a second engagement surface positioned at a distal end of the elongated slot, the second engagement surface engaging a finger of the actuator when the rack is in the retracted position to move the actuator from the second position to the first position.

20. A powered handle assembly comprising: an outer shell defining a cavity; an inner housing secured within the cavity, the inner housing defining a longitudinally extending path therethrough; a rack positioned along a longitudinally extending path of the inner housing, the rack including a first engagement surface and movable between a retracted position and an advanced position; a drive assembly supported by the inner housing, the drive assembly engaged with the rack and operable to move the rack between the retracted position and the advanced position; a first switch supported within the cavity and coupled to the drive assembly, the first switch being manually movable from an open position to a closed position; an automatic retraction switch supported within the cavity, the automatic retraction switch coupled to the drive assembly and movable between an open position and a closed position; an automatic retract switch control mechanism including an actuator supported on the inner housing adjacent the automatic retract switch, the actuator being movable from a first position to a second position in response to movement of the rack from the retracted position to the advanced position to cause the automatic retract switch to move from the open position to the closed position; as well as a retraction button supported on the housing, the retraction button engaged with the actuator and movable to move the actuator from the first position to the second position to retract the rack before the rack moves to the advanced position; wherein the first switch and the automatic retraction switch are configured such that when the first switch is in the closed position and the automatic retraction switch is in the open position, the drive assembly is actuated to move the rack toward the advanced position, and when the first switch is in the closed position and the automatic retraction switch is in the closed position, the drive assembly is actuated to move the rack toward the retracted position.

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