Handheld Surgical Instruments

Abstract

To provide hand-held surgical instruments.SOLUTION: A surgical instrument module for powering a plurality of discrete surgical end effectors includes a motor, a planetary gear box, a high-torque / low-speed output operably coupled to the motor, and a high-speed / low-torque output operably coupled to the motor. The high-torque / low-speed output is configured to be operably coupled to a driven member of a first type of surgical end effector, and the high-speed / low-torque output is configured to drive an operation of a second type of surgical end effector.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 064,977, filed August 13, 2020, the entire disclosure of which is incorporated herein by reference.

[0002] This application is a continuation-in-part of U.S. Patent Application No. 17 / 089,870, filed November 5, 2020, which claims the benefit of and priority to U.S. Provisional Patent Application No. 62 / 734,290, filed September 21, 2018, which claims the benefit of and priority to U.S. Provisional Patent Application No. 16 / 532,534, filed August 6, 2019, the entire disclosure of which is incorporated herein by reference.

[0003] U.S. Patent Application No. 17 / 089,870 also claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 087,501, filed October 5, 2020, the entire disclosure of which is incorporated herein by reference.

[0004] This application is a continuation-in-part application which claims the benefit of and priority to U.S. Patent Application No. 17 / 089,827, filed November 5, 2020, and claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 084,656, filed September 29, 2020, the entire disclosure of which is incorporated herein by reference.

[0005] This application is a continuation-in-part application which claims the benefit of and priority to U.S. Patent Application No. 17 / 089,813, filed November 5, 2020, and claims the benefit of and priority to U.S. Provisional Patent Application No. 62 / 944,548, filed December 6, 2019, the entire disclosure of which is incorporated herein by reference.

[0006] This application is a continuation-in-part application which claims the benefit of and priority to U.S. Patent Application No. 17 / 089,789, filed November 5, 2020, and claims the benefit of and priority to U.S. Provisional Patent Application No. 62 / 944,400, filed December 6, 2019, the entire disclosure of which is incorporated herein by reference. [Background technology]

[0007] Numerous handle assembly manufacturers have developed product lines having proprietary drive systems for operating and / or manipulating electromechanical surgical instruments. Often, the electromechanical surgical instruments include a reusable handle assembly and a disposable loading unit and / or a single-use loading unit, such as, for example, a surgical end effector that is selectively connected to the handle assembly prior to use and then disconnected from the handle assembly after use for disposal and / or sterilization for reuse. Summary of the Invention [Means for solving the problem]

[0008] In one aspect of the present disclosure, a surgical tool module for powering a surgical end effector is provided. The surgical tool module includes a rotatable motor shaft defining a longitudinal axis, a main sun gear fixed to the motor shaft and configured to rotate therewith, first, second, third, and fourth planetary gear assemblies, a drive shaft, a high torque output, and a high speed output. The first planetary gear assembly is operably coupled to the main sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to rotation of the main sun gear. The second planetary gear assembly is operably coupled to the first planetary gear assembly such that the second planetary gear assembly rotates in response to rotation of the first planetary gear assembly. The drive shaft is non-rotatably coupled to the second planetary gear assembly such that the drive shaft rotates with the second planetary gear assembly. The third planetary gear assembly is operably coupled to the second planetary gear assembly such that the third planetary gear assembly rotates in response to rotation of the second planetary gear assembly. The fourth planetary gear assembly is operably coupled to the third planetary gear assembly such that the fourth planetary gear assembly rotates in response to rotation of the third planetary gear assembly. The high torque output is configured to be operably coupled to a driven member of the first surgical end effector. The high torque output gear is non-rotatably coupled to the fourth planetary gear assembly such that the high torque output rotates with the fourth planetary gear assembly. The high speed output is configured to be operably coupled to a driven member of the second surgical end effector. The high speed output is non-rotatably coupled to the drive shaft such that the high speed output rotates with the drive shaft.

[0009] In one aspect, the high speed output may be concentrically disposed within the high torque output.

[0010] In one aspect, the high speed and high torque outputs can be configured to rotate simultaneously in response to activation of the motor.

[0011] In one aspect, the high torque output may include a pinion gear and the high speed output may include a socket.

[0012] In one aspect, the drive shaft can extend longitudinally through the third and fourth planetary gear assemblies.

[0013] In one aspect, the drive shaft can have a proximal end portion fixed to the second planetary gear assembly and a distal end portion disposed within and rotatable relative to the high torque output.

[0014] In one aspect, the high torque output can define a cavity therein and the high speed output can be received within the cavity.

[0015] In one aspect, the high speed output can be configured to move longitudinally relative to and along the drive shaft.

[0016] In one aspect, the surgical tool module can further include a biasing member captured between the high speed output and an inner surface of the high torque output. The biasing member can be configured to bias the high speed output distally.

[0017] In one aspect, the surgical tool module can further include an elongated ring gear in meshing engagement with each of the planetary gear assemblies.

[0018] In one aspect, each of the planetary gear assemblies may be disposed within an elongated ring gear.

[0019] In one aspect, the elongated ring gear may be rotationally fixed relative to the motor.

[0020] In one aspect, the first planetary gear assembly can include a first carrier, a plurality of planetary gears rotatably coupled to the first carrier and in operative engagement with the main sun gear, and a first sun gear rotationally fixed to the first carrier.

[0021] In one aspect, the second planetary gear assembly can include a second carrier, a plurality of planetary gears rotatably coupled to the second carrier and in operative engagement with the first sun gear, and a second sun gear rotationally fixed to the second carrier.

[0022] In one aspect, the drive shaft can have a proximal end portion that is disposed within and rotationally fixed to the second sun gear.

[0023] In one aspect, the third planetary gear assembly can include a third carrier, a plurality of planetary gears rotatably coupled to the third carrier and in operative engagement with the second sun gear, and a third sun gear rotationally fixed to the third carrier.

[0024] In one aspect, the fourth planetary gear assembly can include a fourth carrier non-rotatably fixed to the high torque output and a plurality of planetary gears rotatably coupled to the fourth carrier and operably engaged with the third sun gear.

[0025] In one aspect, the surgical tool module can further include an elongated ring gear in meshing engagement with each of the plurality of planet gears of each planetary gear assembly.

[0026] In one aspect, the surgical tool module can further include an outer shell in which the elongated ring gear is received. The elongated ring gear can be non-rotatable relative to the outer shell.

[0027] In one aspect, the surgical tool module can further include a battery received within the outer shell and configured to power the motor, and a printed circuit board received within the outer shell and in communication with the battery and the motor.

[0028] According to another aspect of the present disclosure, a surgical tool module for powering a plurality of individual surgical end effectors is provided. The surgical tool module includes a motor having a rotatable motor shaft defining a longitudinal axis, a main sun gear fixed to the motor shaft and configured to rotate therewith, a first planetary gear assembly operably coupled to the main sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to rotation of the main sun gear, a second planetary gear assembly operably coupled to the first planetary gear assembly such that the second planetary gear assembly rotates in response to rotation of the first planetary gear assembly, a drive shaft having a proximal end portion non-rotatably coupled to the second planetary gear assembly, a high torque output section, and a high speed output section. The drive shaft is configured to rotate with the second planetary gear assembly. The high torque output gear is operably coupled to the motor and is configured to be operably coupled to a driven member of a first type of surgical end effector. The high speed output is configured to drive movement of a second type of surgical end effector. The high speed output is non-rotatably coupled to a distal end portion of the drive shaft such that the high speed output rotates with the drive shaft.

[0029] In one aspect, a distal end portion of the drive shaft may be disposed within and rotatable relative to the high torque output.

[0030] In one aspect, the surgical instrument module can further include a third and a fourth planetary gear assembly. The third planetary gear assembly can be operably coupled to the second planetary gear assembly such that the third planetary gear assembly rotates in response to rotation of the second planetary gear assembly. The fourth planetary gear assembly can be operably coupled to the third planetary gear assembly such that the fourth planetary gear assembly rotates in response to rotation of the third planetary gear assembly. The high torque output gear can be non-rotatably coupled to the fourth planetary gear assembly such that the high torque output rotates with the fourth planetary gear assembly.

[0031] In one aspect, the drive shaft can extend longitudinally through the third and fourth planetary gear assemblies.

[0032] In one embodiment, the drive shaft may be rotatable relative to each of the third and fourth planetary gear assemblies.

[0033] According to another aspect of the present disclosure, a handle assembly for a handheld surgical instrument is provided. The handle assembly includes a handle housing defining a cavity therein and an instrument module configured for removable reception within the cavity of the handle housing. The instrument module includes an outer shell, a motor having a rotatable motor shaft defining a longitudinal axis, a battery received within the outer shell and configured to power the motor, a printed circuit board received within the outer shell and in communication with the battery and the motor, a main sun gear secured to the motor shaft and configured to rotate therewith, first and second planetary gear assemblies, a drive shaft configured to rotate with the second planetary gear assembly, a high torque output operably coupled to the motor, and a high speed output. The first planetary gear assembly is operably coupled to the main sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to rotation of the main sun gear. The second planetary gear assembly is operatively coupled to the first planetary gear assembly such that the second planetary gear assembly rotates in response to rotation of the first planetary gear assembly. The drive shaft has a proximal end portion non-rotatably coupled to the second planetary gear assembly. The high speed output is non-rotatably coupled to a distal end portion of the drive shaft such that the high speed output rotates with the drive shaft.

[0034] In one aspect, the handle assembly may further include an elongated ring gear in meshing engagement with each of the planetary gear assemblies.

[0035] In one aspect, each of the planetary gear assemblies may be disposed within an elongated ring gear.

[0036] In one aspect, the elongated ring gear may be rotationally fixed relative to the outer shell.

[0037] In one aspect, the handle assembly may further include a third and a fourth planetary gear assembly. The third planetary gear assembly may be operably coupled to the second planetary gear assembly such that the third planetary gear assembly rotates in response to rotation of the second planetary gear assembly. The fourth planetary gear assembly may be operably coupled to the third planetary gear assembly such that the fourth planetary gear assembly rotates in response to rotation of the third planetary gear assembly. The high torque output gear may be non-rotatably coupled to the fourth planetary gear assembly such that the high torque output rotates with the fourth planetary gear assembly.

[0038] In one aspect, the drive shaft can extend longitudinally through the third and fourth planetary gear assemblies.

[0039] In one embodiment, the drive shaft may be rotatable relative to each of the third and fourth planetary gear assemblies.

[0040] As used herein, the terms parallel and perpendicular are understood to include relative configurations that are approximately parallel and approximately perpendicular, up to about + or -10 degrees from true parallel and true perpendicular. For example, the present application provides the following: (Item 1) 1. A surgical tool module for powering a surgical end effector, said surgical tool module comprising: a motor having a rotatable motor shaft defining a longitudinal axis; a main sun gear fixed to the motor shaft and configured to rotate with the motor shaft; a first planetary gear assembly operatively connected to the main sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to rotation of the main sun gear; and a second planetary gear assembly operatively connected to the first planetary gear assembly for rotation in response to rotation of an articulation knob of the first planetary gear assembly; a drive shaft non-rotatably coupled to the second planetary gear assembly such that the drive shaft rotates with the second planetary gear assembly; and a third planetary gear assembly operatively connected to the second planetary gear assembly such that the third planetary gear assembly rotates in response to the rotation of the second planetary gear assembly; and a fourth planetary gear assembly operatively connected to the third planetary gear assembly such that the fourth planetary gear assembly rotates in response to the rotation of the third planetary gear assembly; and a high torque output configured to be operatively coupled to a driven member of a first surgical end effector, the high torque output gear non-rotatably coupled to a fourth planetary gear assembly such that the high torque output rotates with the fourth planetary gear assembly; a high speed output section configured to be operatively coupled to a driven member of a second surgical end effector, the high speed output section non-rotatably coupled to the drive shaft such that the high speed output section rotates with the drive shaft. (Item 2) The surgical tool module of the preceding item, wherein the high speed output section is concentrically disposed within the high torque output section. (Item 3) 2. The surgical tool module of claim 1, wherein the high speed output section and the high torque output section are configured to rotate simultaneously in response to activation of the motor. (Item 4) The surgical tool module of any one of the preceding claims, wherein the high torque output section includes a pinion gear and the high speed output section includes a socket. (Item 5) The surgical instrument module of any preceding claim, wherein the drive shaft extends longitudinally through the third and fourth planetary gear assemblies. (Item 6) The surgical instrument module of any one of the preceding items, wherein the drive shaft has a proximal end portion fixed to the second planetary gear assembly and a distal end portion disposed within and rotatable relative to the high torque output portion. (Item 7) 2. The surgical tool module of claim 1, wherein the high torque output section defines a cavity therein and the high speed output section is received within the cavity. (Item 8) 2. The surgical tool module of claim 1, wherein the high speed output is configured to move longitudinally relative to and along the drive shaft. (Item 9) 2. The surgical instrument module of claim 1, further comprising a biasing member captured between the high speed output section and an inner surface of the high torque output section, the biasing member configured to bias the high speed output section distally. (Item 10) The surgical tool module of any preceding claim, further comprising an elongated ring gear in meshing engagement with each of the planetary gear assemblies. (Item 11) The surgical tool module of any preceding claim, wherein each of the planetary gear assemblies is disposed within the elongated ring gear. (Item 12) The surgical tool module of any preceding claim, wherein the elongated ring gear is rotationally fixed relative to the motor. (Item 13) The first planetary gear assembly, The first career, a plurality of planetary gears rotatably coupled to the first carrier and in operative engagement with the main sun gear; A surgical tool module according to any one of the preceding items, comprising: a first sun gear rotationally fixed to the first carrier. (Item 14) the second planetary gear assembly comprising: A second career and a plurality of planetary gears rotatably coupled to the second carrier and in operative engagement with the first sun gear; A surgical tool module according to any one of the preceding items, comprising: a second sun gear rotationally fixed to the second carrier. (Item 15) The surgical instrument module of any one of the preceding claims, wherein the drive shaft is disposed within the second sun gear and has a proximal end portion rotationally fixed to the second sun gear. (Item 16) said third planetary gear assembly comprising: The third career, a plurality of planetary gears rotatably coupled to the third carrier and in operative engagement with the second sun gear; and a third sun gear rotationally fixed to the third carrier. (Item 17) The fourth planetary gear assembly, a fourth carrier fixed non-rotatably to the high torque output portion; The surgical tool module of any one of the preceding items, further comprising: a plurality of planetary gears rotatably coupled to the fourth carrier and operably engaged with the third sun gear. (Item 18) The surgical tool module of any preceding claim, further comprising an elongated ring gear in meshing engagement with the plurality of planet gears of each of the planetary gear assemblies. (Item 19) The surgical tool module of any preceding claim, further comprising an outer shell in which the elongated ring gear is received, the elongated ring gear being non-rotatable relative to the outer shell. (Item 20) a battery received within the outer shell and configured to power the motor; The surgical tool module of any one of the preceding claims, further comprising a printed circuit board received within the outer shell and in communication with the battery and the motor. (Summary) A surgical instrument module for powering a plurality of individual surgical end effectors includes a motor, a planetary gearbox, a high torque / low speed output operably coupled to the motor, and a high speed / low torque output operably coupled to the motor, the high torque / low speed section configured to be operably coupled to a drive member of a first type of surgical end effector, and the high speed / low speed output configured to drive movement of a second type of surgical end effector. [Brief description of the drawings]

[0041] Embodiments of the present disclosure are described herein with reference to the accompanying drawings.

[0042] [Figure 1] FIG. 1 is a side view showing a handheld electro-mechanical surgical instrument including a handle assembly, a surgical instrument module shown separated, a shaft portion coupled to the handle assembly, and a surgical end effector coupled to the shaft portion. [Diagram 2] FIG. 2 is a partial perspective view of a handle housing of the handle assembly of FIG. 1. [Figure 3A] FIG. 3 is a perspective view, with parts separated, showing the surgical tool module of FIG. 2 including a power assembly and an outer shell. [Figure 3B] FIG. 3B is an assembled front view showing the power assembly of the tool module of FIG. 3A. [Figure 4] FIG. 13 is a side view of the handle housing with half the housing removed showing the internal components of the handle assembly. [Diagram 5] FIG. 3B is a perspective view showing the motor, elongated ring gear, and output of the tool module of FIG. 3A. [Figure 6] FIG. 3B is a perspective view, in phantom, of an elongated ring gear showing a multiple planetary gear assembly of the tool module of FIG. 3A; [Figure 7] FIG. 6 is a perspective view with parts separated of the components shown in FIG. [Figure 8] FIG. 8 is a cross-sectional view taken along line 8-8 in FIG. 5. [Figure 9] FIG. 9 is a cross-sectional view taken along line 9-9 in FIG. 8. [Figure 10] Shown are four separate surgical instruments that are all operable with the instrument module of FIGS. 3A-3B. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043] An embodiment of the presently disclosed surgical instrument including its handle assembly is described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term "distal" refers to that portion of or component of the surgical instrument that is further from the user, while the term "proximal" refers to that portion of or component of the surgical instrument that is closer to the user.

[0044] As described in detail below, a surgical tool module is provided that is configured to be received in the handle assembly of a plurality of individual handheld surgical tools. The tool module may be reusable and is configured to operate various functions of a plurality of different types of surgical end effectors, such as, for example, a linear stapler, a circular stapler, a hernia tacker, and a small diameter vessel stapler. The surgical tool module has two outputs, each operably coupled to the same motor of the surgical tool module. The high-speed / low-torque output may be concentrically disposed within the high-torque / low-speed output. The outputs are rotated simultaneously by the motor, but each rotates at a different speed and torque from the other. Depending on the surgical tool with which the tool module is received and operably engaged, either the high-speed / low-torque output or the high-torque / low-speed output of the tool module engages a corresponding driven component (e.g., rod, screw, rack, gear, etc.) of the selected surgical tool. In this manner, the same tool module can be used with a variety of surgical tools, albeit each surgical tool having individual power and speed requirements. Other features and advantages of the disclosed surgical instrument are detailed further below.

[0045] 1 and 2, a surgical instrument according to an embodiment of the present disclosure is generally designated as 10 and is in the form of a powered handheld electromechanical linear stapler configured for selective coupling thereto of a surgical end effector 20. The end effector 20 is configured for actuation and manipulation by the linear stapler 10. The handheld electromechanical surgical instrument 10 includes a handle assembly 100, a knob housing 102 coupled to the handle assembly 100, and a shaft portion 104 extending distally from the knob housing 102 and configured for selective connection with a surgical attachment, such as, for example, the end effector 20.

[0046] The handle assembly 100 includes a disposable, sterile handle housing 110 having a body, e.g., a barrel portion 118, a handle portion 108 extending vertically downward from the barrel portion 118 or laterally and proximally from the barrel portion 118, and a hinged door 120 pivotally connected to the handle portion 108. The door 120 is selectively opened and closed to allow for the insertion or removal of a non-sterile or sterile surgical instrument module 122. The handle portion 108 and the door 120 each have an inner periphery that collectively define a sterile barrier for the surgical instrument module 122 when the door 120 is closed. In one aspect, the proximal end portion or the barrel portion 118 may have a transparent window (not shown) at any suitable location to allow for the viewing of a display (e.g., liquid crystal, not shown).

[0047] The handle assembly 100 has a firing switch 106 configured and adapted to actuate various functions of the end effector 20. The firing switch 106 may be configured as a toggle bar pivotally coupled to a handle portion 108 of a handle housing 110. Activation of the firing switch 106 activates a motor 112 (FIGS. 3A and 3B) which advances or retracts a firing rod (not explicitly shown) of the surgical instrument 10 depending on whether an upper or lower button of the firing switch 106 is activated. The firing rod is coupled to a drive assembly (not explicitly shown) of the end effector 20 (including a knife rod and an actuation sled), and advancement of the firing rod advances the drive assembly of the end effector 20. This closes the jaw members 26, 28 of the end effector 20 when the safety switch 116 is in an activated state, firing the end effector 20.

[0048] The handle assembly 100 has an articulation switch 114 extending laterally through the handle portion 108 and projecting outwardly from the left and right sides of the handle portion 108. The articulation switch 114 is configured to actuate an articulation of the end effector 20 (e.g., move the end effector 20 along a horizontal plane between a position coaxial with the shaft portion 104 and a plurality of positions not aligned with the shaft portion 104). The knob housing 102 is rotatably coupled to the handle housing 110, and the shaft portion 104 is non-rotatably coupled thereto. Thus, manual rotation of the knob housing 102 results in a corresponding rotation of the end effector 20 (e.g., the end effector 20 rotates about a central longitudinal axis "X" defined by the shaft portion 104).

[0049] 1, 3A, 3B, and 4, surgical tool module 122 of handle assembly 100 includes a sterile outer shell 128 and a reusable power assembly 130 configured for removably receipt in outer shell 128. Outer shell 128 has a cover 132 received in an open lower end thereof and a spring-loaded pull tab 134 for facilitating removal of cover 132.

[0050] The power assembly 130 of the tool module 122 includes a motor 112, such as an electric drive motor, electrically or wirelessly connected to a printed circuit board 136 and a battery 138. In one aspect, the battery 138 may include a boost circuit and may be rechargeable (e.g., wirelessly). The battery 138 has a card edge connector 140 configured for removable reception of a card edge header 142 of the handle assembly 100, thereby allowing communication to the battery 138 from the firing switch 106, the safety switch 116, the articulation switch 114, and the articulation encoder. The printed circuit board 136 may include a USB charging connector 144 to allow the battery 138 to be recharged with a USB charger or wirelessly (e.g., via induction). In one aspect, the printed circuit board 136 may include a motor controller or processor.

[0051] The instrument module 122 further includes a gearbox 146, such as, for example, a planetary gearbox, operably coupled to the drive motor 112, and first and second outputs 148, 150 ( FIG. 5 ) drivingly coupled to the gearbox 146 and configured to rotate about a longitudinal axis defined by the gearbox 146. The gearbox 146 is configured to transfer power from the motor 112 to rotation of the first output 148 at high torque and low speeds, and rotation of the second output 150 at high and low speeds. Rotation of the outputs 148, 150 by the motor 112 serves to drive shafts and / or gear components of the handle assembly 100 to perform various operations of the end effector 20. For example, the motor 112 is configured to move the jaw members 26, 28 of the end effector 20 relative to one another and fire staples from the end effector 20.

[0052] For a more detailed description of the various components involved in transmitting rotation of the output portions 148, 150 to movement of the components of the end effector 20, reference may be made to U.S. Provisional Application No. 62 / 944,400, filed December 6, 2019, the entire contents of which are incorporated herein by reference.

[0053] With reference to Figures 5-9, further details of the various components of the instrument module 122 will now be described. The motor 112 has a rotatable motor shaft 152 (Figure 7) to which a primary sun gear 154 is non-rotatably fixed such that the primary sun gear 154 rotates therewith about a longitudinal axis defined by the motor shaft 152. The gear box 146 includes a plurality of planetary gear assemblies 156, 158, 160, 162 and an elongated ring gear 164 disposed about and operatively coupled to the plurality of planetary gear assemblies 156, 158, 160, 162.

[0054] The first planetary gear assembly 156 is operatively coupled to the main sun gear 154 such that the first planetary gear assembly 156 rotates about the longitudinal axis of the motor shaft 152 in response to rotation of the main sun gear 154. The first planetary gear assembly 156 increases the torque output of the motor 112 while decreasing the output rotational speed. The first planetary gear assembly 156 includes a first carrier 168, a first sun gear 166, and a plurality of planetary gears 156a, 156b, 156c. The first carrier 168 has a plurality (e.g., three) pins 156d, 156e, 156f secured thereto and extending proximally from a proximal side thereof. The first sun gear 166 is rotationally fixed to a distal side of the first carrier 168 and is centrally aligned with the longitudinal axis of the motor shaft 152. The planetary gears 156a, 156b, 156c are rotatably coupled to respective pins 156d, 156e, 156f of the first carrier 168. The planetary gears 156a, 156b, 156c are in meshing engagement with the main sun gear 154 for rotation in response to rotation of the main sun gear 154. As will be explained, the elongated ring gear 164 is rotationally fixed relative to the outer shell 128 (FIG. 3A) such that the first planetary gear assembly 156 rotates as a unit about the longitudinal axis of the motor shaft 152 in response to rotation of the main sun gear 154.

[0055] The second planetary gear assembly 158 includes a second carrier 170, a second sun gear 172, and a plurality of planetary gears 158a, 158b, 158c. The second planetary gear assembly 158 has an increased torque output and a decreased rotational speed output compared to the first planetary gear assembly 156. The second carrier 170 has a plurality (e.g., three) pins 158d, 158e, 158f secured thereto and extending proximally from a proximal side thereof. The second sun gear 172 is rotationally fixed to a distal side of the second carrier 170 and is centrally aligned with the longitudinal axis of the motor shaft 152. The planetary gears 158a, 158b, 158c of the second planetary gear assembly 158 are rotatably coupled to respective pins 158d, 158e, 158f of the second carrier 170. The planetary gears 158a, 158b, 158c mesh with and engage a first sun gear 166 and a fixed elongated ring gear 164 of the first planetary gear assembly 156 such that the second planetary gear assembly 158 rotates in response to rotation of the first planetary gear assembly 156.

[0056] The third planetary gear assembly 160 includes a third carrier 174, a third sun gear 176, and a plurality of planetary gears 160a, 160b, 160c. The third planetary gear assembly 160 has an increased torque output and a decreased rotational speed output compared to the second planetary gear assembly 158. The third carrier 174 has a plurality (e.g., three) pins 160d, 160e, 160f fixed thereto and extending proximally from a proximal side thereof. The third sun gear 176 is rotationally fixed to a distal side of the third carrier 174 and is centrally aligned with the longitudinal axis of the motor shaft 152. The planetary gears 160a, 160b, 160c of the third planetary gear assembly 160 are rotatably coupled to respective pins 160d, 160e, 160f of the third carrier 174. The planet gears 160a, 160b, 160c of the third planetary gear assembly 160 mesh with and engage the second sun gear 172 and the elongated ring gear 164 of the second planetary gear assembly 158 such that the third planetary gear assembly 160 rotates as a unit in response to rotation of the second planetary gear assembly 158.

[0057] The fourth planetary gear assembly 162 includes a fourth carrier 178 and a plurality of planetary gears 162a, 162b, 162c. The fourth planetary gear assembly 162 has an increased torque output and a decreased rotational speed output as compared to the third planetary gear assembly 160. The fourth carrier 178 is connected to, integrally formed with, or otherwise non-rotatably coupled to a proximal end of the first output section 148, and the fourth carrier 178 has a plurality (e.g., three) pins 162d, 162e, 162f secured thereto and extending proximally from a proximal side thereof. The planetary gears 162a, 162b, 162c of the fourth planetary gear assembly 162 are rotatably coupled to respective pins 162d, 162e, 162f of the fourth carrier 178. Planet gears 162a, 162b, 162c of fourth planetary gear assembly 162 mesh with third sun gear 176 and elongated ring gear 164 of third planetary gear assembly 160 such that fourth planetary gear assembly 162 and first output 148 rotate together in response to rotation of third planetary gear assembly 160. It is contemplated that gear box 146 may include more or less than four planetary gear assemblies and / or other types of gears.

[0058] 5-9, first output portion 148 is configured to generate a relatively high torque (e.g., about 625 oz-in) and a relatively low speed (e.g., 24 rpm) and includes a cylindrical body 148a received in a distal end portion of elongated ring gear 164 and a gear 148b, such as, for example, a pinion gear, formed with the distal end portion of cylindrical body 148a. Pinion gear 148b of first output portion 148 is configured to be selectively operably coupled to a driven member (not explicitly shown) of a first type of surgical end effector, such as, for example, surgical end effector 20 of linear stapler 10 (FIGS. 1 and 10) or surgical end effector 300 (FIG. 10) of circular stapler 310 (FIG. 10). It is contemplated that the handle assembly 100, 302 or other components of the surgical instrument 10, 310 will have a corresponding driven component (e.g., a gear, rack, etc.) configured to selectively engage with the pinion gear 148b upon reception of the surgical instrument module 122 within the respective handle assembly 100, 302.

[0059] The surgical instrument module 122 further includes a drive shaft 180 having a proximal end portion 180a non-rotatably coupled to the second planetary gear assembly 158 such that the drive shaft 180 is configured to rotate therewith. In particular, the proximal end portion 180a of the drive shaft 180 is received within and rotationally fixed to the second sun gear 172 of the second planetary gear assembly 158. The drive shaft 180 has a distal end portion 180b that extends longitudinally through the third and fourth planetary gear assemblies 160, 162 while being freely rotatable therein. The distal end portion 180b of the drive shaft 180 may have a non-circular cross-sectional shape, such as, for example, a tri-lobe shape.

[0060] The second output 150 is attached to a distal end portion 180b of the drive shaft 180 and configured to rotate with the drive shaft 180 about the longitudinal axis of the drive shaft 180. The second output 150 is configured to generate a relatively low torque (e.g., 25 oz-in) and a relatively high speed (e.g., 600 rpm) and includes a socket 151 configured to operably couple to a corresponding driven element (not explicitly shown) of a different type of surgical end effector than the first output 148. For example, the second output 150 of the surgical instrument module 122 can be configured to perform the functions of a surgical end effector 400 ( FIG. 10 ) of a hernia tacker 410 or a surgical end effector 510 ( FIG. 10 ) of a small diameter vessel stapler 500 ( FIG. 10 ). It is contemplated that the handle assemblies or other components of the surgical instruments 410, 510 will have corresponding drive components (e.g., rods) configured to selectively engage with the sockets 151 upon reception of the surgical instrument modules 122 within the respective handle housings.

[0061] The second output section 150 is concentrically disposed within the first output section 148 and is configured to rotate simultaneously with the first output section 148 in response to activation of the same motor, i.e., motor 112. However, as noted above, the first and second output sections 148, 150 rotate at different speeds and with different torques from one another. The second output section 150 is received in an elongated cavity 182 defined in the cylindrical body 148a of the first output section 148. A biasing member 184 is disposed within the cavity 182 and captured between the second output section 150 and an inner surface of the cylindrical body 148a of the first output section 148. The biasing member 184 is configured to bias the second output section 150 distally to a position that is concentric within the first output section 148. The biasing member 184 ensures that even if the socket 151 of the second output 150 is not radially aligned with the driven element of the end effector assembly, when the second output 150 is rotated to bring the socket 151 into radial alignment with the driven element, the socket 151 will engage with the driven element.

[0062] 5-9, the elongated ring gear 164 of the gear box 146 encloses each of the planetary gear assemblies 156, 158, 160, 162 and is rotationally fixed relative to the outer shell 128 (FIG. 3A) and the motor 112. The elongated ring gear 164 has an annular inner surface defining a plurality of longitudinally extending teeth 186 in meshing engagement with the planet gears of each of the planetary gear assemblies 156, 158, 160, 162. A first bushing 188 may be provided to capture the first output portion 148 of the elongated ring gear 164 and a second bushing 190 may be provided to capture the second output portion 150 of the first output portion 148.

[0063] In operation, a surgical instrument appropriate for the operation to be performed is selected. For example, a linear stapler 10 (FIG. 10) may be selected. The linear stapler 10 is typically used to staple a type of tissue that is more suited to receiving staples deployed at high torque and low speed. The surgical instrument module 122 is inserted into the handle housing 110 of the linear stapler 10, whereby the pinion gear 148b of the first output 148 operably engages a driven element, such as a rack 161 (FIG. 4) or a corresponding pinion gear of the handle assembly 100 of the linear stapler 10. In one aspect, a sterile funnel-shaped insertion guide may be implemented to aid in threading the surgical instrument module 122 through the handle housing 110. Once the insertion guide is removed, the handle housing 110 remains sterile throughout this sterile transfer procedure.

[0064] With the instrument module 122 positioned within the handle housing 110, the door 120 is closed, thereby sealing the instrument module 122 to the sterile handle portion 108. Additionally, the card edge header 142 of the printed circuit board 126 of the handle assembly 100 is connected to the card edge connector 140 of the instrument module 130.

[0065] To operate the surgical end effector 20 of the linear stapler 10, a firing switch 106 (FIG. 1) can be toggled such that the battery 138 of the instrument module 122 powers the motor 112, which in turn drives the rotation of the first, second, third, and fourth planetary gear assemblies 156, 158, 160, 162. The planetary gear assemblies 156, 158, 160, 162 successively increase the torque and reduce the speed output by the pinion gear 148b of the first output 148 as compared to the torque and speed generated by the motor 112. The high torque, low speed output by the first output 148 results in high force and low speed advancement of staples from the end effector 20 into tissue.

[0066] When performing another surgical procedure, such as a hernia repair procedure, one may choose to use hernia tacker 410 (FIG. 10) rather than linear stapler 10. To properly treat tissue, hernia tacker 410 requires less torque but a higher actuation speed than linear stapler 10. The instrument module 122 is inserted into the handle portion 412 of hernia tacker 410 such that socket 151 of second output section 150 engages a driven element (e.g., a rod) of hernia tacker 410.

[0067] To operate the surgical end effector 400 of the hernia tacker 410, a fire switch 414 of the hernia tacker 410 can be toggled, causing the battery 138 of the instrument module 122 to power the motor 112, which in turn drives the rotation of the first and second planetary gear assemblies 156, 158. The drive shaft 180 is fixed to the second sun gear 172 of the second planetary gear assembly 158 such that the drive shaft 180 rotates with the rotation of the second planetary gear assembly 158. The second output 150, non-rotatably attached to a distal end portion 180b of the drive shaft 180, rotates with the drive shaft 180 to perform functions of the hernia tacker 410, such as deploying surgical tacks into tissue at low torque and high speed.

[0068] It is contemplated that each of the first and second drive outputs 148, 150 may be simultaneously coupled to two separate drive elements of a particular surgical instrument to perform separate functions of the surgical instrument.

[0069] Any of the components described herein may be manufactured from any of metals, plastics, resins, composite materials, etc., taking into consideration strength, durability, wear resistance, weight, corrosion resistance, ease of manufacture, manufacturing costs, etc. Any of the gears disclosed herein may be configured as any suitable gear, such as bevel gears, spur gears, spiral gears, worm gears, etc.

[0070] It will be understood that various modifications may be made to the embodiments of the presently disclosed surgical instruments and surgical instrument modules. Thus, the above description should not be construed as limiting, but merely as exemplifications of embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure.

Claims

1. 1. A surgical tool module for powering a surgical end effector, said surgical tool module comprising: a motor having a rotatable motor shaft defining a longitudinal axis; a main sun gear fixed to the motor shaft and configured to rotate with the motor shaft; a first planetary gear assembly rotatably coupled to the main sun gear such that the first planetary gear assembly rotates about the longitudinal axis in response to rotation of the main sun gear, the first planetary gear assembly comprising a first carrier, a first sun gear, and a first plurality of planetary gears in meshing engagement with the main sun gear, the first plurality of planetary gears rotatably coupled to the first carrier, and the first sun gear is rotationally fixed to the first carrier; a second planetary gear assembly rotatably coupled to the first planetary gear assembly such that the second planetary gear assembly rotates in response to the rotation of the first planetary gear assembly, the second planetary gear assembly comprising a second carrier, a second sun gear, and a second plurality of planetary gears in meshing engagement with the first sun gear, the second plurality of planetary gears being rotatably coupled to the second carrier, and the second sun gear being rotationally fixed to the second carrier; a drive shaft non-rotatably coupled to the second planetary gear assembly such that the drive shaft rotates with the second planetary gear assembly; and a third planetary gear assembly rotatably coupled to the second planetary gear assembly such that the third planetary gear assembly rotates in response to the rotation of the second planetary gear assembly, the third planetary gear assembly comprising a third carrier, a third sun gear, and a third plurality of planetary gears in meshing engagement with the second sun gear, the third plurality of planetary gears being rotatably coupled to the third carrier, and the third sun gear being rotationally fixed to the third carrier; a fourth planetary gear assembly rotatably coupled to the third planetary gear assembly such that the fourth planetary gear assembly rotates in response to the rotation of the third planetary gear assembly, the fourth planetary gear assembly comprising a fourth carrier and a fourth plurality of planetary gears in meshing engagement with the third sun gear, the fourth plurality of planetary gears being rotatably coupled to the fourth carrier; a rotational torque output configured to be operatively coupled to a driven member of a first surgical end effector, said rotational torque output non-rotatably coupled to the fourth carrier such that said rotational torque output rotates with the fourth planetary gear assembly; a rotational speed output configured to be operatively coupled to a driven member of a second surgical end effector, said rotational speed output non-rotatably coupled to said drive shaft such that said rotational speed output rotates with said drive shaft; A surgical tool module comprising:

2. The surgical tool module of claim 1 , wherein the rotational speed output is concentrically disposed within the rotational torque output.

3. The surgical tool module of claim 2 , wherein the rotational speed output and rotational torque output are configured to rotate simultaneously in response to activation of the motor.

4. The surgical tool module of claim 1 , wherein the rotational torque output includes a pinion gear and the rotational speed output includes a socket.

5. The surgical instrument module of claim 1 , wherein the drive shaft extends longitudinally through the third and fourth planetary gear assemblies.

6. The surgical tool module of claim 5 , wherein the drive shaft has a proximal end portion fixed to the second planetary gear assembly and a distal end portion disposed within and rotatable relative to the rotational torque output.

7. The surgical tool module of claim 1 , wherein the rotational torque output defines a cavity therein and the rotational speed output is received within the cavity.

8. The surgical tool module of claim 7 , wherein the rotational speed output is configured for longitudinal movement relative to and along the drive shaft.

9. The surgical tool module of claim 8, further comprising a biasing member captured between the rotational speed output and an inner surface of the rotational torque output, the biasing member configured to bias the rotational speed output distally.

10. The surgical tool module of claim 1 , further comprising an elongated ring gear in meshing engagement with each of the planetary gear assemblies.

11. The surgical tool module of claim 10 , wherein each of the planetary gear assemblies is disposed within the elongated ring gear.

12. The surgical tool module of claim 10 , wherein the elongated ring gear is rotationally fixed relative to the motor.

13. The surgical instrument module of claim 1 , wherein the drive shaft is disposed within the second sun gear and has a proximal end portion rotationally fixed to the second sun gear.

14. The surgical tool module of claim 1 , further comprising an elongated ring gear in meshing engagement with the plurality of planet gears of each of the planetary gear assemblies.

15. The surgical tool module of claim 14, further comprising an outer shell in which the elongated ring gear is received, the elongated ring gear being non-rotatable relative to the outer shell.

16. a battery received within the outer shell and configured to power the motor; a printed circuit board received within the outer shell and in communication with the battery and the motor; The surgical tool module of claim 15 further comprising:

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