Surgical stapler having actuation mechanism with rotatable shaft

Abstract

To provide a surgical stapler for reliable stapling of clamped tissue without complex mechanisms.SOLUTION: A handle assembly 40 for a surgical stapler 10 comprises a rotatable actuation shaft. The actuation shaft can have a first rotational orientation state, in which the actuation shaft can actuate a jaw assembly 30 in repeatable open and close modes, a second rotational orientation state, in which the actuation shaft can actuate the jaw assembly in a staple firing mode, and a third rotational orientation state, in which the actuation shaft can actuate the jaw assembly in a reversing mode. The handle assembly includes a rotational mechanism arranged to discretely position the rotatable actuation shaft in one of the rotational orientation states. The rotational mechanism is arranged to allow single handed operation, e.g., by including a slidable switch or selector to rotate the actuation shaft.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE This application relates generally to surgical closure instruments, and more particularly to surgical staplers.

[0002] Description of Related Applications This application claims the benefit of currently pending U.S. Provisional Patent Application No. 61 / 794,700, entitled "SURGICAL STAPLER HAVING ACTUATION MECHANISM WITH ROTATABLE SHAFT," filed March 15, 2013. The prior application is hereby incorporated by reference in its entirety. [Background technology]

[0003] Surgical staplers are used to approximate or clamp tissue and staple the clamped tissue together. Surgical staplers therefore have mechanisms for properly positioning and capturing tissue and for driving staples into the tissue. This has resulted in, for example, the provision of numerous triggers and handles in conjunction with complex mechanisms that allow for proper stapling of the clamped tissue. Summary of the Invention [Problem to be solved by the invention]

[0004] These complex mechanisms can make surgical staplers burdensome to manufacture and can be a potential source of instrument failure and confusion for the user. Thus, it would be desirable to reliably staple clamped tissue without the use of complex mechanisms. [Means for solving the problem]

[0005] In certain embodiments, a surgical stapler is provided herein. The surgical stapler includes an elongated shaft, a jaw assembly, and a handle assembly. The elongated shaft has a proximal end and a distal end. The elongated shaft defines a longitudinal axis between the proximal end and the distal end. The jaw assembly is disposed at the distal end of the elongated shaft. The jaw assembly includes a first jaw, a second jaw, and a plurality of staples. The jaw assembly is selectively positionable in one of a closed configuration, an open configuration, and a firing configuration. The handle assembly is disposed at the proximal end of the elongated shaft. The handle assembly includes a stationary handle, a movable trigger pivotally coupled to the stationary handle, and an actuation shaft. The actuation shaft is longitudinally slidable within the handle assembly relative to a longitudinal axis of the actuation shaft and rotatable within the handle assembly relative to the longitudinal axis. An actuation shaft is operably coupled to the jaw assembly such that the actuation shaft is slidable longitudinally in a first direction from a first position corresponding to an open configuration of the jaw assembly to a second position corresponding to a closed configuration of the jaw assembly and is slidable longitudinally in the first direction from the second position to a third position corresponding to a fired configuration. The actuation shaft is operably coupled to a movable trigger such that the actuation shaft is rotatable between a first orientation in which movement of the trigger moves the actuation shaft between the second and third positions and a second orientation in which movement of the trigger moves the actuation shaft from the third position to the first position.

[0006] In certain embodiments, a handle assembly for a surgical stapler is provided. The surgical stapler has an elongated shaft having proximal and distal ends and defining a longitudinal axis between the proximal and distal ends, and a jaw assembly disposed at the distal end of the elongated shaft. The handle assembly includes a housing, an actuation mechanism positioned within the housing, and a coupler. The actuation mechanism includes an advance drive, a retract drive, and an actuation shaft. The actuation shaft extends along a longitudinal axis. The actuation shaft is rotatably coupled to the housing relative to the longitudinal axis. The actuation shaft has an advance surface and a retract surface. The advance surface extends longitudinally along the actuation shaft. The retract surface extends longitudinally along the actuation shaft. The retract surface is angularly offset from the advance surface. The actuation shaft is rotatable between a first orientation in which the advance drive engages the advance surface and a second orientation in which the retract drive engages the retract surface. The coupler is adapted to engage an elongated shaft of a surgical stapler. In some embodiments of the handle assembly, the handle assembly further includes a stationary handle disposed on the housing and a movable handle pivotally coupled to the housing and pivotable between an open position spaced apart from the stationary handle and a closed position adjacent the stationary handle. The movable handle is pivotally coupled to the housing and pivotable between an open position spaced apart from the stationary handle and a closed position adjacent the stationary handle. An advancement drive is operably coupled to the movable handle, the advancement drive being translatable distally relative to the longitudinal axis in response to movement of the movable handle from the open position to the closed position. An advancement drive is operably coupled to the movable handle, the advancement drive being translatable proximally relative to the longitudinal axis in response to movement of the movable handle from the open position to the closed position.

[0007] In certain embodiments, a handle assembly for a surgical stapler is provided. The handle assembly includes a housing, an actuator coupled to the housing, and an actuation mechanism. The actuation mechanism includes a forward drive, a reverse drive, an actuation shaft, and a selector. The forward drive is operably coupled to the trigger. The reverse drive is operably coupled to the trigger. The actuation shaft has a longitudinal axis. The actuation shaft is rotatably coupled to the housing relative to the longitudinal axis. The actuation shaft has a forward interface surface and a reverse interface surface angularly offset from the forward interface surface. The actuation shaft is rotatable between a first orientation in which the forward interface surface engages the forward drive to move the drive shaft in a first direction in response to the actuator, and a second orientation in which the reverse interface surface engages the reverse drive to move the actuation shaft in a second direction opposite the first direction in response to the actuator. The selector is operably coupled to the actuation shaft to selectively rotate the actuation shaft between the first orientation and the second orientation. In some embodiments, the actuator includes a trigger pivotally coupled to the housing, and movement of the actuation shaft in the first and second directions is responsive to pivotal movement of the trigger. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view of an embodiment of a surgical stapling instrument showing the jaws in an open configuration; [Diagram 2] FIG. 2 is a perspective view of an embodiment of a cartridge for the surgical stapling instrument of FIG. 1 shown with the jaws in a closed configuration; [Diagram 3] FIG. 1 is a perspective view of an embodiment of a handle assembly for a surgical stapling instrument. [Figure 4] FIG. 4 is a perspective view of the handle assembly of FIG. 3, showing the movable handle in a closed configuration. [Diagram 5]FIG. 4 is a plan view of the handle assembly of FIG. 3, showing the selector in a first configuration; [Figure 6] FIG. 4 is a top plan view of the handle assembly of FIG. 3, showing the selector in a second configuration; [Figure 7] FIG. 4 is a side view of the handle assembly of FIG. 3. [Figure 8A] FIG. 4 is a cross-sectional side view of the handle assembly of FIG. 3 in an initial configuration. [Figure 8B] FIG. 8B is a cross-sectional perspective view of the handle assembly of FIG. 8A. [Figure 9A] FIG. 4 is a cross-sectional side view of the handle assembly of FIG. 3 actuated into a closed configuration. [Figure 9B] FIG. 9B is a cross-sectional perspective view of the handle assembly of FIG. 9A. [Figure 10A] FIG. 4 is a cross-sectional side view of the handle assembly of FIG. 3 in a forward drive configuration. [Figure 10B] FIG. 10B is a cross-sectional perspective view of the handle assembly of FIG. 10A. [Figure 11A] FIG. 4 is a cross-sectional side view of the handle assembly of FIG. 3 in a forward drive configuration. [Figure 11B] FIG. 11B is a cross-sectional perspective view of the handle assembly of FIG. [Figure 12A] FIG. 4 is a cross-sectional side view of the handle assembly of FIG. 3 in a fully driven forward configuration. [Figure 12B] FIG. 12B is a cross-sectional perspective view of the handle assembly of FIG. 12A. [Figure 13A] FIG. 4 is a cross-sectional side view of the handle assembly of FIG. 3 in a reverse drive configuration. [Figure 13B] FIG. 13B is a cross-sectional perspective view of the handle assembly of FIG. 13A. [Figure 14A] FIG. 4 is a cross-sectional side view of the handle assembly of FIG. 3 in a fully actuated reverse configuration. [Figure 14B] FIG. 14B is a cross-sectional perspective view of the handle assembly of FIG. 14A. [Figure 15] FIG. 13 is a side view of another embodiment of a surgical stapling instrument handle assembly. [Figure 16] FIG. 16 is a perspective view of the handle assembly of FIG. [Figure 17] FIG. 16 is a cutaway side view of the handle assembly of FIG. [Figure 18] FIG. 16 is a plan view of a rotation mechanism for the actuation mechanism of the handle assembly of FIG. [Figure 19] FIG. 20 is a plan view of the hub collar and actuation shaft of the rotation mechanism of FIG. 18, showing the hub collar in a first position. [Figure 20] FIG. 20 is a plan view of the hub collar and actuation shaft of the rotation mechanism of FIG. 18, showing the hub collar in a second position. [Figure 21] FIG. 20 is a plan view of the hub collar and actuation shaft of the rotation mechanism of FIG. 18, showing the hub collar in a third position. [Figure 22] FIG. 20 is a plan view of the hub collar and actuation shaft of the rotation mechanism of FIG. 18, showing the hub collar in a fourth position. [Diagram 23] FIG. 20 is a plan view of the hub collar and actuation shaft of the rotation mechanism of FIG. 18, showing the hub collar in a fifth position. [Figure 24] FIG. 20 is a plan view of the hub collar and actuation shaft of the rotation mechanism of FIG. 18, showing the hub collar in a sixth position. [Diagram 25] FIG. 20 is a plan view of the hub collar and actuation shaft of the rotation mechanism of FIG. 18, showing the hub collar in a seventh position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] With reference to Figures 1 and 2, an embodiment of a surgical stapling instrument is shown. The illustrated embodiment of a surgical stapler 10 has an elongated shaft 20, a jaw assembly 30, and a handle assembly 40. Figure 1 shows the surgical stapler 10 with the jaw assembly 30 in an open configuration. Figure 2 shows a removable cartridge having the elongated shaft 20 and jaw assembly 30 of the surgical stapler 10 with the jaw assembly 30 in a closed configuration.

[0010] 1 and 2, the illustrated embodiment of the surgical stapler 10 may be sized and shaped for use in laparoscopic surgical procedures. For example, the elongate shaft 20 and jaw assembly 30 may be sized and shaped for introduction into a surgical field through an access port or trocar cannula. In some embodiments, the elongate shaft 20 and jaw assembly 30 may be sized and shaped for insertion into a trocar cannula having a relatively small working channel diameter, for example, a diameter of less than 8 mm. In other embodiments, the elongate shaft 20 and jaw assembly 30 may be sized and shaped for insertion into a trocar cannula having a large working channel diameter, for example, a diameter of 10 mm, 11 mm, 12 mm, or 15 mm. In other embodiments, it is contemplated that certain aspects of the floor stapler described herein may be incorporated into a surgical stapling instrument used in an open surgical procedure.

[0011] 1 and 2, as shown, the elongated shaft 20 comprises a generally tubular member. The elongated shaft 20 extends from a proximal end 22 to a distal end 24. The elongated shaft 20 defines a central longitudinal axis L of the surgical stapler 10 that extends between the proximal end 22 and the distal end 24.

[0012] 1 and 2, in the illustrated embodiment, the jaw assembly 30 is coupled to the elongate shaft 20 at the distal end 24 of the elongate shaft 20. The jaw assembly 30 includes a first jaw 32 and a second jaw 34 pivotally coupled to the first jaw 32. In the illustrated embodiment, the first jaw 32 is fixed to the distal end 24 of the elongate shaft 20 such that the first jaw extends distally along a central longitudinal axis L and remains stationary relative to the elongate shaft 20. In other embodiments, it is contemplated that both the first jaw 32 and the second jaw 34 are pivotable relative to the elongate shaft. In certain other embodiments, it is contemplated that the jaw assembly 30 is articulatable relative to the elongate shaft 20. In an initial configuration, the first jaw 32 has a plurality of staples 36 disposed therein. In some embodiments, the staples may be initially disposed in the second jaw 34.

[0013] With continued reference to Figures 1 and 2, in the illustrated embodiment, the jaw assembly 30 can be actuated from an open configuration (Figure 1) to a closed configuration (Figure 2) to a stapling configuration by an actuation member or beam that is longitudinally slidable within the elongate shaft. In an initial position, the beam can be positioned at the distal end 24 of the elongate shaft 20. With the beam in the initial position, the second jaw 34 is pivoted away from the first jaw 32 such that the jaw assembly 30 is in the open configuration. The actuation beam engages the second jaw 34 upon translation of the actuation member or beam distally along the longitudinal axis L. The jaw assembly can be actuated from the open configuration to the closed configuration by translating the actuation beam distally a first distance from the initial position. With the jaw assembly 30 in the closed configuration, the actuation beam can be moved proximally back a first distance to return the jaw assembly 30 to the open configuration. The distal end of the actuation beam can advance a staple slider configured to deploy staples from the first jaw 32 such that further translation of the actuation beam distally beyond the first distance causes a plurality of staples 36 to be deployed from the first jaw 32.

[0014] 1 and 2, in the illustrated embodiment, the handle assembly is coupled to the elongate shaft 20 at the proximal end 22 of the elongate shaft 20. As illustrated, the handle assembly 40 has a pistol-grip configuration with a housing that defines a stationary handle 42 and an actuator, such as a movable handle 44 or trigger, pivotally coupled to the stationary handle 42. In other embodiments, it is contemplated that a surgical stapler instrument incorporating aspects described herein may have a handle assembly with other configurations, such as a scissor-grip configuration or an in-line configuration. As described in further detail below, the handle assembly 40 contains an actuation assembly configured to selectively advance an actuation shaft in response to movement of the movable handle 44. In some embodiments, the actuation mechanism may comprise an electrically actuated actuation mechanism, such as an electric motor, that can be actuated to selectively advance the actuation shaft. Actuation of the electric motor can be initiated by movement of the movable handle 44 or by actuation of a trigger, button, switch, or another actuator electrically operably coupled to the electric motor of the electrically actuated actuation mechanism.

[0015] In some embodiments, the surgical stapler 10 can have a plurality of staples 36 disposed within a disposable cartridge, while the handle assembly 40 is configured to be reused with multiple staple cartridges. In the illustrated embodiment, the elongated shaft 20 and the jaw assembly 30 comprise a disposable cartridge that is removably connectable to the handle assembly 40. Thus, in the illustrated embodiment, the handle assembly 40 includes a coupler 46 at its distal end. The coupler 46 is adapted to engage the elongated shaft 20 of the surgical stapler 10. The coupler 46 can be a bayonet type coupling having an outer connector that is removably connectable to the handle assembly 40 or the elongated shaft 20 and an inner connector that can removably connect the movable shaft of the handle assembly 40 to an actuating member of the elongated shaft 20. Thus, the surgical stapler 10 can be configured to allow the handle assembly 40 to be reused with multiple disposable cartridges during a surgical procedure. It is envisioned that in other embodiments, the handle assembly and a portion of the elongate shaft can be reusable, with the remainder of the elongate shaft within the jaw assembly making up a disposable cartridge. In certain other embodiments, the handle assembly and the elongate shaft can be reusable, while the jaw assembly makes up a disposable cartridge. In yet other embodiments, a jaw insert that houses a plurality of staples can make up a disposable cartridge, while the remainder of the surgical stapler is reusable.

[0016] 3-7, various views of an embodiment of a handle assembly 40 for a surgical stapler 10 are shown. In FIG. 3, a perspective view of the handle assembly 40 is shown with the movable handle 44 in an open position spaced apart from the stationary handle 42. The illustrated handle assembly 40 further includes a selector 72 operably coupled to an actuation mechanism housed within the handle assembly 40 as described further herein. As shown in FIG. 3, the selector 72 is in a first position.

[0017] Referring to Figure 4, another perspective view of the handle assembly 40 of Figure 3 is shown. As shown, the movable handle 44 is in a closed position adjacent to the stationary handle 42 and the selector 72 is in a second position. Figures 5 and 6 are top views of the handle assembly of Figure 3 with the selector 72, e.g., slider 74, in a first position (Figure 5) and in a second position (Figure 6). Figure 7 is a side view of the handle assembly 40 of Figure 3.

[0018] 8A and 8B are cross-sectional views of the handle assembly 40 in an initial configuration illustrating the principle of operation of the actuation assembly 50. In the illustrated embodiment, the actuation mechanism 50 is configured to selectively translate the actuation shaft 60 from a first position corresponding to the jaw assembly 30 in an open configuration to a second position corresponding to the jaw assembly 30 in a closed configuration and from the second position to a third position that positions the jaw assembly 30 in a stapling configuration to deploy a plurality of staples 36. In the initial configuration shown in FIGS. 8A and 8B, the actuation shaft 60 can be repeatedly translated between the first and second positions in response to movement of the movable handle 44 or trigger without deploying staples to provide an opening / closing function. This opening / closing function allows a user to position and clamp tissue and then reposition the stapler 10 to find a desired staple placement location prior to deploying the staples.

[0019] 8-14, in the illustrated embodiment, the actuation mechanism includes an advance or forward drive 52, a retract or reverse drive 54, an open drive 58, an advance face 62, a retract face 64, and an open face 66. The forward drive 52 may be operably coupled to the movable handle 44 such that movement of the movable handle 44 from the open position to the closed position causes the forward drive 52 to advance in a first direction, such as a distal direction within the handle assembly 40. The forward drive 52 may comprise a pawl or tooth configured to fit into a recess or slot.

[0020] The reverse drive 54 may be operably coupled to the movable handle 44 such that movement of the movable handle 44 from the open position to the closed position causes the reverse drive 54 to advance in a second direction opposite the first direction, e.g., proximally within the handle assembly 40. In some embodiments, the movable handle 44 may be operably coupled to the reverse drive 54 by a geared connection that includes an idler gear 56. The reverse drive 54 may comprise a pawl or tooth configured to fit into a recess or slot.

[0021] The opening driver 58 may be operably coupled to the movable handle 44 such that movement of the movable handle 44 from the open position to the closed position causes the opening driver 58 to advance in a first direction, such as distally within the handle assembly 40. In the illustrated embodiment, the opening driver 58 is coupled to the idler 56 by a pin and slot coupling to operably couple the opening driver 58 to the movable handle 44. The opening driver 58 may comprise a pawl or tooth configured to fit into a recess or slot.

[0022] Formed on the actuation shaft 60 are an advancing surface 62, a retreating surface 64, and an opening surface 66. In the illustrated embodiment, the advancing surface 62 comprises a rack or a plurality of spaced apart recesses or teeth formed longitudinally along the actuation shaft 60. As illustrated, the retreating surface 64 comprises a rack or a plurality of spaced apart recesses or teeth formed longitudinally along the actuation shaft 60 and angularly offset from the advancing surface 62. In the illustrated embodiment, the opening surface 66 comprises a recess formed in the actuation shaft 60.

[0023] In certain embodiments, the actuation shaft 60 is rotatable within the handle assembly 40 about the longitudinal axis of the stapler 10. The actuation shaft 60 can have a proximal portion 65 and a distal portion 61 that are rotatable independently of one another. For example, the proximal portion 65 can be coupled to the distal portion 61 at a rotatable coupling that longitudinally translates and couples the proximal portion to the distal portion while allowing free rotation of the proximal and distal portions. The handle assembly 40 can include a rotation mechanism 70 that provides selective rotation of the proximal portion 65 of the actuation shaft 60 within the handle assembly 40. The actuation shaft 60 can be rotatable between a first orientation in which the forward drive 52 is engageable with the advancing surface 62 and a second orientation in which the reverse drive 54 is engageable with the retracting surface 64. With the forward moving surface 52 angularly offset from the reverse moving surface 54 relative to the actuation shaft 60 and the actuation shaft in a first orientation, the reverse drive 54 is disengaged from the reverse moving surface 64, and with the actuation shaft in a second orientation, the forward moving surface 52 is disengaged from the forward moving surface 62.

[0024] 8-14, in certain embodiments, the rotation mechanism 70 includes a selector 72, e.g., a slider. The slider can extend laterally through the handle assembly 40. The slider can be operably coupled to the actuation shaft 60 such that positioning the slider in a first position extending from one side of the handle assembly 40 positions the actuation shaft 60 in a first orientation and positioning the slider in a second position extending from the opposite side of the handle assembly 40 rotates the actuation shaft 60 to the second orientation. In the illustrated embodiment, the slider is coupled to a rack 76 in mesh with a gear 78, which is rotatably fixed to the actuation shaft 60 and longitudinally slidable along the actuation shaft 60 (e.g., by a keyed connection). Desirably, the illustrated rotation mechanism 70, which includes a slider, positions the actuation shaft 60 discontinuously in a desired orientation to reduce the occurrence of mis-meshing of gearing within the actuation mechanism 50. In some embodiments, the slider can include a visual indicator, such as an arrow, that indicates to the user the orientation of the actuation shaft 60 and thus the operating mode of the stapler.

[0025] In the illustrated embodiment, the advancing and retracting surfaces 62, 64 are angularly offset about the actuation shaft by approximately 90°. Thus, the rotation mechanism 70 is configured to rotate the actuation shaft approximately 90° between the first and second orientations. In other embodiments, the advancing and retracting surfaces 62, 64 can have a different angular offset from one another, such as 120° or 70°, and the rotation mechanism 70 can be configured to rotate the actuation shaft 60 accordingly. Additionally, as described in more detail herein with respect to the opening / closing modes of the handle assembly 40, in the illustrated embodiment, the opening driver 58 engages the actuation shaft in the second orientation, and in other embodiments, the actuation shaft can be rotated to a third orientation in which the opening driver 58 engages the actuation shaft.

[0026] 8-14, a representative actuation sequence of the actuation mechanism 50 of the handle assembly 40 is shown. FIGS. 8A-8B and 9A-9B show actuation states of the handle assembly 40 in an initial configuration that provides opening / closing functionality to the jaw assembly 30. In FIG. 8A, the movable trigger 44 is in an open position and the actuation shaft 60 is in a first position corresponding to a first position of the actuation beam at the distal end of the elongated shaft 20. In the initial position, the actuation shaft 60 is positioned in a second orientation such that the reverse drive 54 is angularly aligned with the retraction surface 64. When the actuation shaft 60 is in the second orientation, the opening / closing drive 58 is positioned within the opening surface 66 or recess. As the movable handle 44 is moved from the open position ( FIGS. 8A and 8B ) to the closed position ( FIGS. 9A and 9B ), the forward driver 52 advances distally along the actuation shaft 60 and engages an advancement recess 63 formed in the actuation shaft 60 to drive the drive shaft 60 distally to a second position within the handle assembly 40. The second position of the actuation shaft 60 within the handle assembly 40 corresponds to a second position of the actuation beam that positions the jaw assembly 30 in a closed configuration.

[0027] The movable handle 44 may be biased to the open position by a biasing member, such as a coil spring 68 (FIG. 11A). Thus, when the movable handle 44 is released from the closed position shown in FIGS. 9A and 9B, the movable handle returns to the open position of FIGS. 8A and 8B. Similarly, by operably coupling the movable handle 44 to the opening driver 58, the opening driver 58 translates proximally within the handle assembly 40 as the movable handle 44 returns to the open position. In the second orientation of the actuation shaft 60, the opening driver 58 engages the opening surface 66 such that proximal movement of the opening driver 58 returns the actuation shaft 60 from the second position to the first position, thereby returning the jaw assembly 30 to the open configuration.

[0028] A user can seek out a desired stapling location within a surgical field by repeatedly opening and closing the jaws to clamp tissue in different locations. Once a desired stapling location is selected, the actuation mechanism 50 can be configured into a stapling or firing mode by rotating the actuation shaft 60 to a first orientation. With the jaw assembly in a closed configuration at a desired stapling location (shown in FIGS. 9A and 9B), the user can reposition the selector 72 by sliding the slider to a first position corresponding to the first orientation of the actuation shaft 60 (shown in FIGS. 10A and 10B). In the first orientation of the actuation shaft 60, the forward driver 52 is engageable with the advancing surface 62, the reverse driver 54 is in angular misalignment with the retracting surface 64, and the open driver 58 is in angular misalignment with the open surface 66. When actuation shaft 60 is in a first orientation, movable handle 44 can be released to the open position (FIGS. 11A and 11B), thereby engaging forward driver 52 with forward advancement surface 62.

[0029] 11A and 11B and 12A and 12B, with the actuation shaft 60 in a first orientation and the forward driver 52 engaged with the advancement surface 62, the actuation mechanism 50 is in a staple application or firing mode. Several cycles of movement of the movable handle 44 from the open position to the closed position and back to the open position advance the actuation shaft 66 from the second position (FIGS. 11A and 11B) to a third position (FIGS. 12A and 12B) where the actuation shaft 60 is moved to its most distal extent relative to the handle assembly 40. In some embodiments, the actuation mechanism can have a stop that blocks distal movement of the actuation shaft 60 at the third position. The second position of the actuation shaft corresponds to a second position of the actuation beam in the jaw assembly 30. The third position of the actuation shaft corresponds to a third position of the actuation beam in the jaw assembly 30 where a plurality of staples are deployed from the first jaw. When movement of the movable handle 44 or trigger is in a firing mode to advance the actuation shaft from the second position to the third position, the forward drive 52 advances sequentially over adjacent teeth or grooves of the actuation surface 62 in a ratcheted advancement manner.

[0030] 13A and 13B, once the actuation shaft 60 has been advanced to a third position to fire staples from the jaw assembly, the actuation mechanism 50 can be configured in a reverse mode. Thus, the rotation mechanism 70 can rotate the actuation shaft 60 to a second orientation to position the retraction surface 64 in angular alignment with the reverse driver 54. The slider can be slid to the second position to rotate the actuation shaft from the first orientation (FIGS. 12A and 12B) to the second orientation (FIGS. 13A and 13B). When the actuation shaft 60 is in the second orientation, repeated cycling of the movable handle 44 from the open position to the closed position and back to the open position causes the reverse driver 54 to engage the retraction surface 64 in a ratcheted forward position while the actuation shaft 60 is retracted proximally within the handle assembly 40. Once the reverse driver 54 drives the actuation shaft 60 proximally to the second position (shown in FIGS. 14A and 14B), the release driver 58 engages the release surface 66. The release driver 58 releases the movable handle 44 to the open position and returns the actuation shaft 60 to the first position (returning the handle assembly to the configuration shown in FIGS. 8A and 8B). With the actuation shaft 60 in the first position, the depleted cartridge without staples can be uncoupled from the handle assembly 40 and a new cartridge can be coupled to the handle assembly so that a new stapling session can begin.

[0031] 15-25, another embodiment of a handle assembly 40' for use with a surgical stapler 10' is shown. FIG. 15 is a side view of the handle assembly 40', and FIG. 16 is a perspective view of the handle assembly 40'. In the handle assembly 40', actuation of the rotation mechanism 70' is accomplished with a slidable switch 80 that is longitudinally slidable relative to a housing of the handle assembly 40'. Advantageously, such a slidable switch configuration allows a user to easily rotate the actuation shaft 60 with one hand.

[0032] 17, a cross-sectional view of the handle assembly 40' is shown, illustrating the actuation mechanism 50' and the rotation mechanism 70'. The actuation mechanism functions substantially as described above with reference to the embodiment of FIGS. 8A-8B and 14A-14B to advance the actuation shaft 60' from a first position to a second position in an open / close mode, from the second position to a third position in a staple mode, and from the third position to the first position in a reverse mode. The actuation mechanism 50' includes the movable handle 44, substantially as described above with reference to the embodiment of FIGS. 8A-8B and 14A-14B, and corresponding forward, reverse, and open drivers 52, 54, 58 operably coupled to the advancement surface 62, the retraction surface, and the opening surface of the actuation shaft 60'. However, in the embodiment shown in Figures 15-25, the actuation shaft 60' is discontinuously rotatable by a rotation mechanism 70' between a first orientation state corresponding to an open / close mode of the handle assembly in which the open drive 58 engages the open surface 66, a second orientation state corresponding to a stapling position in which the forward drive 52 engages the advancing surface 62, and a third orientation state corresponding to a reverse position in which the reverse drive 54 engages the retracting surface.

[0033] 17 and 18, certain aspects of the rotation mechanism 70' are shown. The rotation mechanism 70' includes a slidable switch 80 that is longitudinally slidable relative to the housing of the handle assembly 40', a hub collar 82 that is longitudinally slidable by the switch 80, and a biasing member or spring 98. In the illustrated embodiment, the slidable switch 80 is coupled to the hub collar 82 by a thin beam, such as a shim member. The hub collar 82 is rotationally fixed and longitudinally slidable relative to the housing of the handle assembly 40'. In some embodiments, the hub collar 82 can have first and second wings that can slide within corresponding first and second slots in the housing of the handle assembly, thereby allowing relative longitudinal movement and limiting relative rotational movement therebetween.

[0034] The hub collar 82 may be a generally tubular member disposed about the actuation shaft 60'. The hub collar 82 may extend between a first edge 84 having a plurality of ramps 86 formed therein and a second edge 88 having a plurality of recesses 90 formed therein. In the illustrated embodiment, the hub collar 82 has three ramps 86 formed on the first edge 84, each ramp being spaced approximately 120° from an adjacent ramp 86. As illustrated, the hub collar 82 has three recesses 90 formed on the second edge 88, each recess being spaced approximately 120° from an adjacent recess 86. In other embodiments, the number and relative spacing of the ramps 86 and recesses 90 may vary, provided that the actuation shaft 50 can be rotated between orientations different than that of the illustrated embodiment.

[0035] In some embodiments, the rotation mechanism 70' may include a spring 98 that biases the slidable switch 80 and hub collar 82 to a proximal position relative to the housing of the handle assembly 40'.

[0036] 17 and 18, the actuation shaft 60' can have a first plurality of protrusions 92 extending radially outwardly from the actuation shaft adjacent the first edge 84 of the hub collar 82. In the illustrated embodiment, the actuation shaft has three protrusions 92, each spaced approximately 120° from an adjacent protrusion. The actuation shaft 60' can also have a second plurality of protrusions 94 extending radially outwardly from the actuation shaft 60' adjacent the second edge 88 of the hub collar 82. In the illustrated embodiment, the actuation shaft 60' has three protrusions 94, each spaced approximately 120° from an adjacent protrusion. In other embodiments, the number and spacing of the protrusions 92, 94 can be varied to achieve rotational mechanisms with different rotational characteristics. In some embodiments, the protrusions 92, 94 may be formed on the actuation shaft 60', while in other embodiments the protrusions 92, 94 may be formed separately on a sleeve, for example, that is attached to the actuation shaft 60' or has a keyed engagement with the actuation shaft 60' or is otherwise rotationally fixed to the actuation shaft 60'.

[0037] 19-25, an actuation sequence of the rotation mechanism 70' for rotating the actuation shaft 60' from a first orientation to a second orientation is shown. FIG. 19 is a schematic diagram of the hub collar 82 and actuation shaft 50' in a first orientation. In the first orientation, a first protrusion 94a of the second plurality of protrusions 94 is located within a first recess 90a of the plurality of recesses 90, and a first protrusion 92a of the first plurality of protrusions is located adjacent to a first ramp 86a of the plurality of ramps 86.

[0038] 19-22, there is shown an actuation sequence of the rotation mechanism 70' as the slidable switch 80 is advanced distally. As the slidable switch 80 is advanced distally relative to the handle assembly housing, the hub collar 82 translates distally, causing the first plurality of protrusions 92 to slideably engage the plurality of ramps 86 of the hub collar 82 (shown in FIG. 20). Further distal advancement of the slidable switch 80 and hub collar 82 relative to the handle assembly housing advances the first plurality of protrusions 92 over and along the plurality of ramps 86 (shown in FIGS. 21 and 22). The angular profile of the ramps 86 acts as a camming surface, and movement of the first plurality of protrusions 92 along the plurality of ramps 86 rotates the actuation shaft 60'. Once the slidable switch reaches the distal-most end of its travel, the spring 98 biases the hub collar 82 and the slidable switch 80 proximally relative to the housing of the handle assembly 40. As the hub collar 82 returns to the proximal position, the second plurality of projections 94 engages the plurality of recesses 90 (shown in FIGS. 23-25). As shown in FIG. 25, following an actuation cycle of the slidable switch 80, the fourth projection 94a of the second plurality of projections 94 is positioned within the second recess 90b of the plurality of recesses, such that the actuation shaft 60′ is positioned in a second orientation that is rotated 120° from the first orientation. A next actuation cycle of the slidable switch 80 rotates the actuation shaft in discrete 120° increments.

[0039] In other embodiments, the rotation mechanism can include a handle directly coupled to the actuation shaft. For example, the proximal end of the actuation shaft can be coupled to a handle 70'' (FIG. 1) that extends proximally from the housing. Rotation of the handle relative to the longitudinal axis rotates the actuation shaft to configure the handle assembly in one of an open / closed mode, a forward mode, or a reverse mode.

[0040] Although the present application discloses certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends to other variations and / or uses of the invention beyond the specifically disclosed embodiments, as well as obvious modifications and equivalents thereof. Moreover, various features of the present invention can be utilized alone or in combination with other features of the invention other than those features of the invention expressly described above. Thus, the scope of the invention disclosed herein should not be limited by the specific disclosed embodiments described above, but should be determined only by a fair reading of the following claims.

Claims

1. 1. A surgical stapler comprising: an elongate shaft having a proximal end and a distal end and defining a longitudinal axis between said proximal and distal ends; a jaw assembly disposed at the distal end of the elongate shaft, the jaw assembly comprising: The first Joe, The second Joe, a plurality of staples; the jaw assembly is selectively positionable in one of a closed configuration, an open configuration, and a firing configuration; a handle assembly disposed at the proximal end of the elongated shaft, the handle assembly comprising: A stationary handle; A movable trigger; an actuation shaft, the actuation shaft being slidable longitudinally within the handle assembly relative to the longitudinal axis of the actuation shaft and rotatable within the handle assembly relative to the longitudinal axis of the actuation shaft; the actuation shaft is operably coupled to the jaw assembly, the actuation shaft being slidable longitudinally in a first direction from a first position corresponding to the open configuration of the jaw assembly to a second position corresponding to the closed configuration of the jaw assembly and slidable longitudinally in a first direction from the second position to a third position corresponding to the firing configuration; the actuation shaft is operably coupled to the movable trigger, the actuation shaft being rotatable between a first orientation in which movement of the trigger moves the actuation shaft between the second position and the third position, and a second orientation in which movement of the trigger moves the actuation shaft from the third position to the first position.

2. The surgical stapler of claim 1 , wherein the movable trigger is pivotally coupled to the stationary handle.

3. The handle assembly includes: a forward drive operably coupled to the movable trigger; a retraction drive operably coupled to the movable trigger; an advancement surface extending along the actuation shaft; a retreating surface extending along the actuation shaft at a location angularly offset from the advancement surface; 3. The surgical stapler of claim 1, wherein when the actuation shaft is in the first orientation, the forward drive engages the forward surface, and when in the second orientation, the retraction drive engages the retraction surface.

4. The surgical stapler of claim 3 , wherein the advancement driver comprises a pawl and the advancement surface comprises a first rack formed along the actuation shaft.

5. 5. The surgical stapler of claim 3 or 4, wherein the retraction driver comprises a pawl and the retraction surface comprises a second rack formed along the actuation shaft.

6. 6. The surgical stapler of claim 3, wherein the handle assembly further includes an idler operably coupled to the movable trigger, the forward drive, and the retraction drive, and wherein movement of the trigger causes the forward drive to move in a first direction and the retraction drive to move in a second direction opposite to the first direction.

7. 7. The surgical stapler of claim 1, wherein the handle assembly further includes an opening drive operably coupled to the actuation shaft, the opening drive biasing the actuation shaft from the second position to the first position, the opening drive selectively releasable from the actuation shaft.

8. 1. A handle assembly for a surgical stapler having an elongate shaft having proximal and distal ends and defining a longitudinal axis between said proximal and distal ends, and a jaw assembly disposed at the distal end of said elongate shaft, said handle assembly comprising: Housing and an actuation mechanism disposed within the housing, the actuation mechanism comprising: A forward drive; A reverse drive; an actuation shaft extending along the longitudinal direction, the actuation shaft rotatably coupled to the housing relative to the longitudinal axis, the actuation shaft comprising: an advancement surface extending longitudinally along the actuation shaft; a retreating surface extending longitudinally along the actuation shaft, the retreating surface being angularly offset from the forward facing surface; the actuation shaft is rotatable between a first orientation in which the forward drive engages the forward surface and a second orientation in which the retraction drive engages the retraction surface; A handle assembly including a coupler adapted to engage the elongated shaft of the surgical stapler.

9. a stationary handle provided on the housing; a movable handle pivotally coupled to the housing and pivotable between an open position spaced from the stationary handle and a closed position adjacent to the stationary handle; the forward drive is operably coupled to the movable handle, the forward drive being translatable distally relative to the longitudinal axis in response to movement of the movable handle from the open position to the closed position; 9. The handle assembly of claim 8, wherein the retraction drive is operably coupled to the movable handle, the retraction drive being translatable proximally relative to the longitudinal axis in response to movement of the movable handle from the open position to the closed position.

10. The handle assembly of claim 9 , wherein the actuation mechanism further comprises an idler operably coupled to the movable handle, the forward drive, and the reverse drive.

11. The handle assembly of any one of claims 8 to 10, further comprising a rotation mechanism for selectively rotating the actuation shaft between the first orientation and the second orientation.

12. A handle assembly according to any one of claims 8 to 11, wherein the coupler comprises a plug-in connector.

13. A handle assembly as claimed in any one of claims 8 to 12, wherein the forward drive comprises a pawl and the forward surface comprises a first rack formed on the actuation shaft.

14. A handle assembly according to any one of claims 8 to 13, wherein the retraction drive comprises a pawl and the retraction surface comprises a second rack formed on the actuation shaft.

15. 1. A handle assembly for a surgical stapler, comprising: Housing and an actuator coupled to the housing; and an actuation mechanism, the actuation mechanism comprising: a forward drive operably coupled to the actuator; a reverse drive operably coupled to the actuator; an actuation shaft having a longitudinal axis, the actuation shaft rotatably coupled to the housing relative to the longitudinal axis, the actuation shaft having a forward interface surface and a reverse interface surface angularly offset from the forward interface surface, the actuation shaft rotatable between a first orientation in which the forward interface surface engages the forward drive to move the drive shaft in a first direction in response to the actuator, and a second orientation in which the reverse interface surface engages the reverse drive to move the actuation shaft in a second direction opposite the first direction in response to the actuator; A handle assembly including a selector operably coupled to the actuation shaft for selectively rotating the actuation shaft between the first orientation and the second orientation.

16. 16. The handle assembly of claim 15, wherein the actuator includes a trigger pivotally coupled to the housing, and movement of the actuation shaft in the first and second directions is responsive to pivotal movement of the trigger.

17. 17. A handle assembly according to claim 15 or 16, wherein the selector has a slider extending transversely through the housing relative to the longitudinal axis of the actuation shaft, the slider being slidable between a first position in which the actuation shaft is in the first orientation and a second position in which the actuation shaft is in the second orientation.

18. The selector: a rack movable by said slider; 18. The handle assembly of claim 17, further comprising a gear engaging said rack and rotationally coupled to said actuation shaft.

19. The selector: a switch selectively slidable longitudinally relative to the longitudinal axis of the actuation shaft; a hub collar operably coupled to the switch and rotationally fixed to the housing and positioned about the actuation shaft, the hub collar having a first edge and a second edge, the hub collar comprising: a plurality of ramps formed on the first edge; a plurality of recesses formed in the second edge portion; a first plurality of projections extending radially outward from the actuation shaft adjacent the first edge of the hub collar; a second plurality of projections extending radially outwardly from the actuation shaft adjacent the second edge of the hub collar; 17. The handle assembly of claim 15 or 16, wherein the first plurality of protrusions and the second plurality of protrusions are positioned such that when the switch is slid in a first direction, each of the first plurality of protrusions engages with a corresponding one of the ramps and the actuating shaft rotates relative to the housing, and when the switch is returned in a second direction opposite to the first direction, each of the second plurality of protrusions fits into a corresponding recess.

20. The handle assembly of claim 18, wherein the switch is biased in the second direction.

21. 17. A handle assembly according to claim 15 or 16, wherein the selector comprises a handle rotationally fixed to the actuation shaft.

22. 22. The handle assembly of claim 21, wherein the actuation shaft has a proximal end and a distal end, and the handle extends from the proximal end of the actuation shaft.

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