Surgical instrument and articulation mechanism

Abstract

A surgical instrument that includes a shaft assembly and an articulation mechanism with an articulation link configured to couple to a tool assembly. The articulation mechanism includes a cam disk with at least two slots, and a drive plate with at least two cam members receivable in the corresponding at least two slots providing for articulation of the tool assembly.

Description

A0012963W001SURGICAL INSTRUMENT AND ARTICULATION MECHANISMCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to U.S. Provisional Patent application No. 63 / 735,640, filed December 18, 2024, which is incorporated herein by reference in its entirety.BACKGROUND

[0002] Surgical devices for treating tissue can be utilized in a variety of treatment procedures, including for closure of tissue or organs (e.g., transection, resection, or anastomoses procedures), for occlusion of organs (e.g., thoracic or abdominal procedures), or for electrosurgically fusing or sealing of tissue (e.g., vessel sealing procedures).

[0003] In certain procedures, such as laparoscopic or endoscopic surgical procedures, access to a surgical site is achieved through a small incision or a narrow cannula inserted through a small entrance wound in a patient. In such a case, surgical instruments can include an elongated shaft coupled to an end effector or tool assembly suitable for use in tissue treatment within a limited space. Such surgical instruments can also include one or more articulation mechanisms providing for motion of a tool assembly relative to a longitudinal axis of the surgical device, such as side-to- side pivoting motion in one example.BRIEF SUMMARY

[0004] In one aspect, the disclosure relates to a surgical instrument. The surgical instrument includes a shaft assembly defining a longitudinal axis and comprising an elongated body extending along the longitudinal axis, and an articulation mechanism. The articulation mechanism includes an articulation lever, an articulation link extending through the elongated body and having a proximal link end and a distal link end, with the distal link end configured to couple to a tool assembly, a rotatable cam disk operably coupled to the articulation lever and comprising at least two cam slots, and a drive plate coupled to the proximal link end and longitudinally movable therewith, the drive plate having at least two cam members receivable within the corresponding at least two cam slots, wherein bidirectional rotation of the cam disk drives corresponding bidirectional longitudinal motion of the drive plate, wherein the bidirectional longitudinal motionA0012963W001 of the drive plate causes corresponding bidirectional articulation of the tool assembly by way of the articulation link.

[0005] In another aspect, the disclosure relates to a surgical instrument. The surgical instrument includes a handle assembly, a shaft assembly extending from the handle assembly and defining a longitudinal axis, the shaft assembly comprising an elongated body extending along the longitudinal axis, and an articulation mechanism. The articulation mechanism includes an articulation link extending through the elongated body and having a proximal link end and a distal link end, with the distal link end configured to couple to a tool assembly, a cam disk comprising a first cam slot spaced from a second cam slot, and an articulation drive member coupled to the proximal link end and having a first cam member receivable within the first cam slot, and having a second cam member receivable within the second cam slot, wherein motion of the first cam member along the first cam slot drives the articulation link to articulate the tool assembly to define a first angle with respect to the longitudinal axis, wherein motion of the second cam member along the second cam slot drives the articulation link to articulate the tool assembly to define a second angle with respect to the longitudinal axis, wherein the first angle and the second angle are adjacent angles with the longitudinal axis as a common arm.

[0006] In another aspect, the disclosure relates to an articulation mechanism for a surgical instrument configured to receive a tool assembly. The articulation mechanism includes an articulation link extending between a proximal link end and a distal link end, with the distal link end configured to couple to the tool assembly, a drive plate coupled to the articulation link and having at least two cam members, and a cam disk rotatable about a central axis. The cam disk includes a first surface having a first toothed edge, and a second surface opposite the first surface and confronting the drive plate, with at least two cam slots disposed in the second surface, and with the at least two cam members received in the corresponding at least two cam slots, wherein bidirectional rotation of the cam disk drives corresponding bidirectional longitudinal motion of the drive plate, wherein the bidirectional longitudinal motion of the drive plate is configured to generate corresponding bidirectional articulation of the tool assembly.BRIEF DESCRIPTION OF THE DRAWINGSA0012963W001

[0007] Various aspects of the disclosure are described herein with reference to the drawings, in which:

[0008] FIG. 1 is a perspective view of an exemplary surgical instrument in accordance with various aspects described herein.

[0009] FIG. 2 is a top view of the surgical instrument of FIG. 1 with a tool assembly illustrated in a first articulated position.

[0010] FIG. 3 is a top view of the surgical instrument of FIG. 2 with the tool assembly illustrated in a second articulated position.

[0011] FIG. 4 is a partially exploded view of the surgical instrument of FIG. 1 illustrating a handle assembly and an articulation mechanism with a cam disk in accordance with various aspects described herein.

[0012] FIG. 5 is a bottom perspective view of the cam disk of FIG. 4 illustrating first and second cam slots in accordance with various aspects described herein.

[0013] FIG. 6 is a top perspective view of the cam disk of FIG. 4 illustrating a toothed edge, a locking tab, and a mounting tab in accordance with various aspects described herein.

[0014] FIG. 7 is a cross-sectional view of the cam disk of FIG. 6 along line A- A.

[0015] FIG. 8 is a side view of the cam disk of FIG. 4.

[0016] FIG. 9 is a perspective view of a drive plate in the articulation mechanism of FIG. 4.

[0017] FIG. 10 is a schematic top sectional view of the handle assembly of FIG. 4 illustrating the cam disk in a first position.

[0018] FIG. 11 is a schematic top sectional view of the handle assembly of FIG. 4, similar to FIG. 10, and illustrating the cam disk in a second position.

[0019] FIG. 12 is a schematic top sectional view of the handle assembly of FIG. 4, similar to FIG. 10, and illustrating the cam disk in a third position.

[0020] FIG. 13 is a perspective view of the handle assembly of FIG. 4 illustrating a locking pawl and release member in accordance with various aspects described herein.

[0021] FIG. 14 is a sectional view of the handle assembly of FIG. 4 illustrating the locking pawl engaged with the cam disk.

[0022] FIG. 15 is a perspective view of a portion of the handle assembly of FIG. 4, and illustrating the locking tab of the cam disk of FIG. 6 with the drive plate of FIG. 9 in a first position.A0012963W001

[0023] FIG. 16 is a perspective view of the portion of the handle assembly of FIG. 15 illustrating the locking tab of the cam disk of FIG. 6 with the drive plate of FIG. 9 in a second position.DETAILED DESCRIPTION

[0024] Surgical devices may often include articulation mechanisms providing for lateral, pivoting, or other non-longitudinal motion of tool assemblies. Some solutions include the use of gear assemblies, which can add complexity for assembly. Other existing solutions include cam members wherein separate cam tracks are provided for each desired articulation direction. Such separated cam designs can add weight to the surgical instrument in addition to reserving additional space within the instrument housing.

[0025] Aspects of the technology of this disclosure provide for a surgical instrument and articulation mechanism with a singular, compact cam disk having multiple cam slots providing bidirectional articulation in a small form factor. The technology is thus able to save weight, as well as space, within the surgical instrument. Aspects of the technology also provide for a dual locking mechanism for the cam plate, preventing attempted articulation if (1) a tool assembly (e.g., a surgical reload) is not attached, or (2) if back-drive forces are present on the drive assembly, where the tool assembly is likely to be in active use and articulation motion is not desired.

[0026] Referring now to FIG. 1, an example surgical instrument 10 (also referred to herein as “instrument 10”) is shown in accordance with various aspects described herein. In the illustrated example, the surgical instrument 10 is in the form of a handheld surgical stapling device configured to perform tissue closure procedures, such as anastomoses or transection procedures in some examples. It will be understood that aspects of the disclosure are not so limited and can have general applicability in other surgical instruments, including electrosurgical instruments, ultrasonic surgical instruments, robotic surgical instruments, or network-controllable surgical instruments, in some examples.

[0027] In the example depicted, the surgical instrument 10 includes a handle assembly 20, a shaft assembly 30 extending from the handle assembly 20, and a tool assembly 40 coupled to the shaft assembly 30 as shown. The handle assembly 20 includes a handle portion 22 and a barrel portion 24. The handle portion 22 is illustrated with an activation switch or button 25 for operatingA0012963W001 the tool assembly 40. It is contemplated that the handle portion 22 may also include a movable handle, trigger, or the like.

[0028] The shaft assembly 30 includes an elongated body 32 extending from a proximal end 34 to a distal end 36, and defines a longitudinal axis 15 as shown. The proximal end 34 of the elongated body 32 may be coupled to the barrel portion 24. The tool assembly 40 is then coupled to the distal end 36 of the elongated body 32. In the non-limiting example shown, the tool assembly 40 includes jaw members 42 carrying a staple cartridge assembly for closing of tissue disposed between the jaw members 42. In some implementations, the tool assembly 40 is configured as a single-use or disposable loading unit (DLU). In such a case, the tool assembly 40 is releasably secured to the shaft assembly 30 for disposal upon completion of a surgical procedure. Additionally, or alternatively, the tool assembly 40 may include one or more electrodes for providing electrosurgical energy, one or more cutting elements for tissue dissection, or the like.

[0029] The example surgical instrument 10 includes a drive assembly 50 for driving operation of the tool assembly 40. The drive assembly 50 includes a control rod 51 extending through the shaft assembly 30 as shown. The drive assembly 50 may additionally include one or more driving elements 54 operably coupled to the control rod 51. One such driving element 54 is schematically illustrated in the handle assembly 20. The one or more driving elements 54 may be located at any suitable position, including the shaft assembly 30. The one or more driving elements 54 may also include any suitable manual or electronic switches, linkages, or the like, such as a manual handle and trigger assembly, an electronic actuator, a motor, or a gear system, in non-limiting examples. Regardless of the particular form, the one or more driving elements 54 are operably coupled to the control rod 51 providing for at least longitudinal driving motion of the control rod 51.

[0030] The surgical instrument 10 is configured for longitudinal, rotational, and / or articulating motion of the tool assembly 40. In particular, an articulation mechanism 60 is provided for pivoting or articulating motion of the tool assembly 40 with respect to the longitudinal axis 15. In the example depicted, the articulation mechanism 60 includes an articulation lever 62 (also referred to herein as “lever 62”) mounted on a top surface of the barrel portion 24. In some implementations, the lever 62 can be mounted on a side surface of the barrel portion 24.

[0031] FIGS. 2-3 illustrate non-limiting examples of articulating motion for the tool assembly 40 during operation of the instrument 10. In the example of FIG. 2, the lever 62 is shown in a firstA0012963W001 positional. The jaw members 42 define a tool axis 43 and are articulated to define a first angle P with respect to the longitudinal axis 15. In the example of FIG. 3, the lever 62 is shown in a second position B and the jaw members 42 are articulated such that the tool axis 43 defines a second angle Q with the longitudinal axis 15. The first angle P and the second angle Q can be adjacent angles, with the longitudinal axis 15 forming a common arm for the first angle P and the second angle Q. In some examples, the first angle P can be the same as the second angle Q, providing for a symmetric articulation range with respect to the longitudinal axis 15.

[0032] More specifically, the tool assembly 40 may include a mounting portion 44 coupled to the shaft assembly 30 and defining a pivot 46 with the jaw members 42. In such a case, the pivot 46 at least partially defines the first angle P and the second angle Q. In another example, the shaft assembly 30 includes a movable distal portion defining the pivot 46, and the tool assembly 40 is articulated by way of the shaft assembly 30. In addition, the mounting portion 44 and the jaw members 42 are shown with similar lengths such that the pivot 46 is in a central region of the tool assembly 40, though this need not be the case. In some implementations, the pivot 46 is located adjacent to the distal end 36 of the elongated body 32.

[0033] Turning to FIG. 4, a partially exploded view illustrates portions of the handle assembly 20 and the shaft assembly 30 in further detail. In the example depicted, the barrel portion 24 includes an upper housing 24A and a lower housing 24B as shown. A tool release switch 28 is provided for detachment of the tool assembly 40 (FIG. 3) from the shaft assembly 30. In the nonlimiting example shown, the tool release switch 28 is provided with the lower housing 24B.

[0034] A sensor tube 26 is disposed in the handle assembly 20 and configured to sense or detect a presence of the tool assembly 40 coupled to the shaft assembly 30. More specifically, the sensor tube 26 may include an aperture that receives the control rod 51, wherein the sensor tube 26 can be moved longitudinally upon coupling the tool assembly 40. It is contemplated that the sensor tube 26 can detect the presence of the tool assembly 40 by way of a spring-biased mechanism that is moved proximally upon coupling the tool assembly 40.

[0035] The articulation mechanism 60 may further include an articulation link 63 and a drive plate 64. The articulation link 63 extends from a proximal link end 63A to a distal link end 63B as shown. The drive plate 64 is coupled to the articulation link 63 and movable along the longitudinal axis 15. The drive plate 64 may also overlie the sensor tube 26 as shown.A0012963W001

[0036] A cam disk 100 is provided in the articulation mechanism 60. The cam disk 100 may be operably coupled to the lever 62 and rotatable about a central axis 105. The cam disk 100 includes a first surface 111 and a second surface 112 as shown. When assembled, the cam disk 100 is arranged with the first surface 111 oriented toward the upper housing 24A and the second surface 112 oriented toward the lower housing 24B. In the examples depicted, the second surface 112 also confronts the drive plate 64 for engagement as shown. During operation, rotation of the lever 62 causes rotation of the cam disk 100, which engages the drive plate 64 to move longitudinally. Such longitudinal motion of the drive plate 64 leads to corresponding motion of the articulation link 63, which actuates the pivot 46 (FIGS. 2-3) for articulating the tool assembly 40.

[0037] The cam disk 100 may also be selectively locked or unlocked for rotation. More specifically, a locking pawl 90, a release member 94, and a bias member 95 may be provided for selective engagement or locking of the cam disk 100. The first surface 111 of the cam disk 100 can confront the release member 94 as shown. The release member 94 may be coupled to the lever 62 and co-rotate with the lever 62 about the central axis 105, as shown in further detail in FIG. 13.

[0038] FIGS. 5-6 illustrate the cam disk 100 in further detail. In FIG. 5, the second surface 112 is shown with a central aperture 106 extending through the cam disk 100. The central aperture 106 may include a counterbore portion 107 as shown. In some examples, the central aperture 106 includes a protuberance, or is flush, co-planar, tangent, or the like with respect to the second surface 112.

[0039] The second surface 112 also includes one or more cam slots for receiving a cam member. In the illustrated example, a first cam slot 121 and a second cam slot 122 are disposed in the second surface 112. The first cam slot 121 can extend from a first opening 123A on an outer edge 101 of the cam disk 100 to a first stop 126 A located inward of the outer edge 101 as shown. The second cam slot 122 may extend from a second opening 123B on the outer edge 101 of the cam disk 100 to a second stop 126B located inward of the outer edge 101 as shown. The first cam slot 121 and the second cam slot 122 may also have an arcuate geometric profile. In the non-limiting example shown, the first cam slot 121 defines a circular arc with a constant radius of curvature Rl. The second cam slot 122 defines a spiral curve with a decreasing radius of curvature, shown as a second radius of curvature R2 at the first opening 123 A, and a third radius of curvature R3 at the first stop 126 A, where the third radius of curvature R3 is less than the second radius of curvature R2. AnyA0012963W001 number or arrangement of slots may be utilized, and such slots can have any suitable geometric profile.

[0040] The cam disk 100 may also include a locking tab 125 projecting from the second surface 112. The locking tab 125 may be configured for locking engagement with components of the instrument 10, such as the sensor tube 26 (shown in further detail in FIG. 15). While the locking tab 125 is illustrated at an outer edge of the cam disk 100, the locking tab 125 may be located at any suitable position. In some implementations, multiple locking tabs 125 may be provided.

[0041] In FIG. 6, the first surface 111 is shown with the central aperture 106 having an optional protuberance 108. In the example depicted, the first surface 111 includes a first toothed edge 131 as shown. The first toothed edge 131 is shown extending partially around a perimeter of the first surface 111 (e.g., less than 70% of the perimeter). In some examples, the first toothed edge 131 may extend fully around the first surface 111.

[0042] In addition, the first toothed edge 131 may define a first geometric profile 13 IP, such as square, rounded, pointed, curved, beveled, radiused, or the like, or combinations thereof. As shown, the first geometric profile 13 IP includes squared outer edges interspersed between rounded connecting portions. The first toothed edge 131 can also be stepped from an outer edge of the cam disk 100 to define a stepped surface 113 as shown. In some implementations, the first toothed edge 131 can at least partially define an outer edge 101 of the cam disk 100 without being stepped inward.

[0043] In the example depicted, the cam disk 100 further includes one or more mounting tabs for securing the cam disk 100 within the instrument 10. As shown, a first mounting tab 151 and a second mounting tab 152 are provided and project from the first surface 111. In some implementations, a single mounting tab may be provided. The first mounting tab 151 and the second mounting tab 152 may have an arcuate geometric profile, such as a profile that substantially matches to profile of the outer perimeter of the cam disk 100. The first mounting tab 151 and the second mounting tab may also be arranged to oppose one another about the central aperture 106 (e.g., be on opposite sides of the central aperture 106). Any suitable number of mounting tabs, or geometric profiles thereof, can be utilized. In addition, in the illustrated example the locking tab 125 is radially aligned with the first and second mounting tabs 151, 152. Such an arrangement mayA0012963W001 provide additional strength for the cam disk 100 under applied longitudinal forces or stresses during operation.

[0044] FIG. 7 illustrates a cross-sectional view of the cam disk 100 along line 7-7 of FIG. 6. As shown, the first surface 111 defines a first surface width 141 and the second surface 112 defines a second surface width 142. The second surface width 142 can be larger than the first surface width 141, corresponding to the first toothed edge 131 being stepped inward. Additionally, the first surface width 141 and the second surface width 142 represent one selected dimension of the respective first surface 111 and the second surface 112, which may or may not extend through the central aperture 106.

[0045] The cam disk 100 may be a unitary, monolithic disk having at least the first mounting tab 151, the second mounting tab 152, the first cam slot 121, the second cam slot 122, and the locking tab 125. In addition, either or both of the first cam slot 121 or the second cam slot 122 may underlie at least a portion of the stepped surface 113. The second cam slot 122 is shown with a recessed surface 124 spaced from the stepped surface 113. In this manner, the second cam slot may have a slot depth that does not extend fully through a thickness of the cam disk 100.

[0046] FIG. 8 illustrates additional details of the cam disk 100 via a side view of the cam disk 100. In FIG. 8, a side view of the cam disk 100 illustrates the second opening 123B of the second cam slot 122 extending to the outer edge 101, below the stepped surface 113. The first cam slot 121 and the second cam slot 122 can also widen at their respective first and second openings 123 A, 123B as shown.

[0047] FIG. 9 illustrates additional details of the drive plate 64. In FIG. 9, the drive plate 64 is shown having a first cam member 71 and a second cam member 72. The first and second cam members 71, 72 are shown as cam pins in the illustrated example, and can also include spheres, wedges, rollers, or the like in some implementations. The cam members 71, 72 protrude outwardly (e.g., upward) from a flat surface of the drive plate 64 in the example depicted. The drive plate 64 can additionally include an arm portion 65 for coupling to or engaging the articulation link 63 (FIG. 4). The arm portion 65 extends at an angle from the flat plate of the drive plate 64. For instance, the arm portion 65 may extend downward at an angle between 70-110 degrees from a plane formed by the flat plate of the drive plate 64.A0012963W001

[0048] With general reference to FIGS. 10-12, a bottom sectional view of the instrument 10 is shown with the cam disk 100 rotated into three different positions by the lever 62 (FIG. 4). In FIG. 10, the cam disk 100 is in a first position 201 wherein the first cam member 71 is spaced from the cam disk 100, and the second cam member 72 is disposed within the second cam slot 122 at the second stop 126B. In this position, the second cam member 72 limits further counterclockwise rotation of the cam disk 100, thereby defining a maximum distal position 211 of the drive plate 64. Put another way, the first position 201 of the cam disk 100 represents an articulation stop or extent of motion for the tool assembly 40 (FIG. 3) in a first direction.

[0049] In FIG. 11, the cam disk 100 is shown in a second position 202, for instance after clockwise rotation from the first position 201. In the second position 202, the first cam member 71 is at the first opening 123A of the first cam slot 121. The second cam member 72 is within the second cam slot 122 and spaced from the second stop 126B. The drive plate 64 is in a second position 212, spaced from the maximum distal position 211, due to the second cam member 72 sliding away from the second stop 126B through the second cam slot 122.

[0050] In FIG. 12, the cam disk 100 is shown in a third position 203, for instance after additional clockwise rotation from the second position 202. In the third position 203, the first cam member 71 is disposed within the first cam slot 121 at the first stop 126A, and the second cam member 72 is spaced from the cam disk 100. In this position, the first cam member 71 limits further clockwise rotation of the cam disk 100, thereby defining a maximum proximal position 213 of the drive plate 64. Put another way, the third position 203 of the cam disk 100 represents another articulation stop or extent of motion for the tool assembly 40 (FIG. 3) in a second direction.

[0051] In this manner, bidirectional rotation of the cam disk 100 (e.g., by way of the lever 62) drives corresponding bidirectional longitudinal motion of the drive plate 64. Such motion of the drive plate 64 drives corresponding bidirectional articulation of the tool assembly 40 by way of the articulation link 63. Thus, articulation of the tool assembly 40 is achieved by rotation of the cam disk 100.

[0052] Referring now to FIG. 13, additional details of the locking pawl 90 and the release member 94 are shown with the articulation mechanism 60. In the example depicted, the locking pawl 90 confronts the first toothed edge 131 of the cam disk 100. The bias member 95 biases the locking pawl 90 toward engagement with the first toothed edge 131.A0012963W001

[0053] The release member 94 can be coupled to the lever 62 for substantial co-rotation. In the non-limiting example shown, the release member 94 includes a shaft portion 94A and a disk portion 94B. The shaft portion 94 A can be coupled to the lever 62, and the disk portion 94B can confront the cam disk 100 (e.g., for engagement with the cam disk 100). The disk portion 94B also includes a second toothed edge 96 overlying the first toothed edge 131.

[0054] FIG. 14 illustrates a sectional view of portions of the handle assembly 20. More specifically, a sectional view of the release member 94 is shown with the disk portion 94B assembled with the cam disk 100, and with the locking pawl 90 biased into engagement with the first toothed edge 131. As shown, the locking pawl 90 secures the cam disk 100 and prevents rotation, and corresponding articulation of the tool assembly 40, when the lever 62 is not being actively rotated. For instance, the tool assembly 40 resists articulation from other forces, such as pushing forces directly on the tool assembly 40 during surgery.

[0055] The release member 94 may include a first mounting recess 91 and a second mounting recess 92 that receive the respective first mounting tab 151 and second mounting tab 152 of the cam disk 100. In this manner, the release member 94 can be coupled to the cam disk 100 for substantial co-rotation.

[0056] To allow for release of the pawl 90, the release member 94 is configured to partially slip with respect to the cam disk 100. More specifically, each of the first mounting recess 91 and the second mounting recess 92 define a recess length 98 as shown. Each of the first mounting tab 151 and the second mounting tab 152 define a tab length 155. The recess length 98 is longer than the tab length 155 to define a slip distance or lost motion distance for the release member. Put another way, the release member 94 can be freely rotated by the lever 62 through the slip distance prior to engaging the cam disk 100, and then drive rotation of the cam disk 100 with additional movement beyond the slip distance.

[0057] The first and second toothed edges 131, 96 have substantially aligned teeth when the locking pawl 90 is engaged. As the lever 62 (FIG. 13) is rotated, the release member 94 initially rotates through the slip distance while the cam disk 100 remains secured by the locking pawl 90. Upon rotating through the slip distance, the second toothed edge 96 is anti-aligned with the first toothed edge 131 (e.g., the teeth of the second tooth edge 96 are positioned between the teeth of the first toothed edge 131). For instance, the tab length 155 and the recess length 98 can be selectedA0012963W001 such that after the release member 94 rotates through the slip distance, teeth on the second toothed edge 96 are rotated to a position between adjacent teeth on the first toothed edge 131. For instance, the slip distance may be equal to half of the pitch of the teeth of the first toothed edge 131. In this manner, the second toothed edge 96 can actuate the pawl 90 against the biasing member 95, thereby disengaging the pawl 90 from the first toothed edge 131 and allowing the cam disk 100 to rotate. For example, a tooth of the second toothed edge 96 contacts the pawl 90, which causes the pawl 90 to move proximally and disengage from the teeth of the first toothed edge 131. In the example depicted, this occurs due to the slanted surfaces (e.g., triangular) of the pawl 90 and the teeth of the second toothed edge 96.

[0058] The teeth of the second toothed edge 96 can additionally define a second geometric profile 96P that may differ from the first geometric profile 13 IP. As shown, the second geometric profile 96P includes triangular or ramped profiles. When overlying the first toothed edge 131, the stacked combination of the first and second geometric profiles 13 IP, 96P may provide for smooth actuation of the pawl 90 during rotation.

[0059] Referring now to FIGS. 15 and 16, additional details are shown regarding aspects of the cam disk 100, the drive plate 64, and the sensor tube 26. In the illustrated example, a sectional view of the drive plate 64 is shown assembled with the sensor tube 26 in the lower housing 24B. A sectional view of the cam disk 100 illustrates only the locking tab 125 for visual clarity. It should be understood that the locking tab 125 extends downwardly from the second surface 112 of the cam disk 100 (e.g., FIG. 8).

[0060] The sensor tube 26 may include a cutout 27, such as a surface catch, that is sized to receive the locking tab 125 and prevent rotation of the cam disk 100. More specifically, the cutout 27 and the locking tab 125 are arranged to prevent rotation when no tool assembly is coupled to the shaft assembly 30 (FIG. 4). Upon coupling a tool assembly 40 to the shaft assembly 30, such coupling exerts a proximally directed force on the control rod 51 (FIG. 4). Accordingly, the sensor tube 26 is translated through a longitudinal distance 66 as shown in FIG. 16. With the tool assembly 40 coupled, and the sensor tube 26 shifted proximally through the longitudinal distance 66, the cutout 27 is shifted proximally away from the locking tab 125. In this manner, the cam disk 100 can be secured against rotation when a tool assembly is not attached, and the cam disk 100 can be released for rotation by way of the lever 62 (FIG. 14) upon coupling the tool assembly.A0012963W001

[0061] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the stapling apparatus need not apply staples, but rather may apply two part fasteners as is known in the art. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended thereto.

[0062] Those skilled in the art will recognize that the methods and systems of the present disclosure may be implemented in many manners and as such are not to be limited by the foregoing aspects and examples. In other words, functional elements being performed by a single or multiple components, in various combinations of hardware and software or firmware, and individual functions, can be distributed among software applications at either the client or server level or both. In this regard, any number of the features of the different aspects described herein may be combined into single or multiple aspects, and alternate aspects having fewer than or more than all of the features herein described are possible.

[0063] Functionality may also be, in whole or in part, distributed among multiple components, in manners now known or to become known. Thus, a myriad of software / hardware / firmware combinations are possible in achieving the functions, features, interfaces and preferences described herein. Moreover, the scope of the present disclosure covers conventionally known manners for carrying out the described features and functions and interfaces, and those variations and modifications that may be made to the hardware or software firmware components described herein as would be understood by those skilled in the art now and hereafter.

[0064] Although the disclosure provides specific examples, various modifications and changes can be made without departing from the scope of the disclosure as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present disclosure. Any benefits, advantages, or solutions to problems that are described herein with regard to a specific example are not intended to be construed as a critical, required, or essential feature or element of any or all the claims.

[0065] Further aspects of the disclosure are provided by the following:

[0066] A surgical instrument, comprising: a shaft assembly defining a longitudinal axis and comprising an elongated body extending along the longitudinal axis; and an articulationA0012963W001 mechanism, comprising: an articulation lever; an articulation link extending through the elongated body and having a proximal link end and a distal link end, with the distal link end configured to couple to a tool assembly; a rotatable cam disk operably coupled to the articulation lever and comprising at least two cam slots; and a drive plate coupled to the proximal link end and longitudinally movable therewith, the drive plate having at least two cam members receivable within the corresponding at least two cam slots; wherein bidirectional rotation of the cam disk drives corresponding bidirectional longitudinal motion of the drive plate; wherein the bidirectional longitudinal motion of the drive plate causes corresponding bidirectional articulation of the tool assembly by way of the articulation link.

[0067] The surgical instrument as described herein, further comprising a handle assembly carrying at least the cam disk and the drive plate.

[0068] The surgical instrument as described herein, further comprising a sensor tube configured to move through a longitudinal distance upon coupling the tool assembly to the shaft assembly.

[0069] The surgical instrument as described herein, wherein the cam disk comprises a projecting tab in locking engagement with the sensor tube, wherein the projecting tab disengages from the sensor tube when the sensor tube moves through the longitudinal distance upon coupling the tool assembly.

[0070] The surgical instrument as described herein, wherein the cam disk further comprises: a first surface having a first toothed edge; and a second surface opposite the first surface and confronting the drive plate, with the at least two cam slots disposed in the second surface.

[0071] The surgical instrument as described herein, wherein the first surface defines a first surface width, and the second surface defines a second surface width larger than the first surface width such that the first toothed edge is stepped from an outer edge of the cam disk.

[0072] The surgical instrument as described herein, wherein the cam disk further comprises a projecting tab extending from the second surface and configured for locking engagement with a sensor tube disposed in the handle assembly.

[0073] The surgical instrument as described herein, further comprising: a locking pawl confronting the first toothed edge of the cam disk; a bias member biasing the locking pawl toward engagement with the first toothed edge; and a release member coupled to the articulation lever andA0012963W001 co-rotatable therewith, the release member confronting the cam disk and having a second toothed edge overlying the first toothed edge.

[0074] The surgical instrument as described herein, wherein the cam disk further comprises a mounting tab projecting from the first surface, and the release member comprises a mounting recess configured to receive the mounting tab.

[0075] The surgical instrument as described herein, wherein the mounting tab defines a tab length and the mounting recess defines a recess length, with a difference between the recess length and the tab length defining a slip distance through which the release member is rotatable relative to the cam disk.

[0076] The surgical instrument as described herein, wherein rotation of the release member through the slip distance moves the second toothed edge to disengage the locking pawl from the first toothed edge.

[0077] The surgical instrument as described herein, wherein the release member is co-rotatable with the cam disk upon further rotation beyond the slip distance.

[0078] A surgical instrument, comprising: a handle assembly; a shaft assembly extending from the handle assembly and defining a longitudinal axis, the shaft assembly comprising an elongated body extending along the longitudinal axis; and an articulation mechanism, comprising: an articulation link extending through the elongated body and having a proximal link end and a distal link end, with the distal link end configured to couple to a tool assembly; a cam disk comprising a first cam slot spaced from a second cam slot; and an articulation drive member coupled to the proximal link end and having a first cam member receivable within the first cam slot, and having a second cam member receivable within the second cam slot; wherein motion of the first cam member along the first cam slot drives the articulation link to articulate the tool assembly to define a first angle with respect to the longitudinal axis; wherein motion of the second cam member along the second cam slot drives the articulation link to articulate the tool assembly to define a second angle with respect to the longitudinal axis; wherein the first angle and the second angle are adjacent angles with the longitudinal axis as a common arm.

[0079] The surgical instrument as described herein, wherein the cam disk is rotatable, and the articulation drive member comprises a longitudinally movable drive plate having the first camA0012963W001 member and the second cam member, wherein rotation of the cam disk causes corresponding longitudinal motion of the drive plate.

[0080] The surgical instrument as described herein, wherein the cam disk further comprises: a first surface having a first toothed edge; and a second surface opposite the first surface and confronting the articulation drive member, with the first cam slot and the second cam slot disposed in the second surface.

[0081] An articulation mechanism for a surgical instrument configured to receive a tool assembly, the articulation mechanism comprising: an articulation link extending between a proximal link end and a distal link end, with the distal link end configured to couple to the tool assembly; a drive plate coupled to the articulation link and having at least two cam members; and a cam disk rotatable about a central axis and comprising: a first surface having a first toothed edge; and a second surface opposite the first surface and confronting the drive plate, with at least two cam slots disposed in the second surface, and with the at least two cam members received in the corresponding at least two cam slots; wherein bidirectional rotation of the cam disk drives corresponding bidirectional longitudinal motion of the drive plate; wherein the bidirectional longitudinal motion of the drive plate is configured to generate corresponding bidirectional articulation of the tool assembly.

[0082] The articulation mechanism as described herein, wherein the cam disk further comprises a projecting tab extending from the second surface and configured for locking engagement with a sensor tube of the surgical instrument, wherein the projecting tab is configured to disengage from the sensor tube upon coupling the tool assembly to the surgical instrument.

[0083] The articulation mechanism as described herein, further comprising: a locking pawl confronting the first toothed edge of the cam disk; a bias member biasing the locking pawl toward engagement with the first toothed edge; and a release member confronting the cam disk and having a second toothed edge overlying the first toothed edge.

[0084] The articulation mechanism as described herein, wherein the cam disk further comprises a mounting tab projecting from the first surface, and the release member comprises a mounting recess configured to receive the mounting tab.

[0085] The articulation mechanism as described herein, wherein the mounting tab defines a tab length and the mounting recess defines a recess length, with a difference between the recess lengthA0012963W001 and the tab length defining a slip distance through which the release member is rotatable relative to the cam disk; wherein rotation of the release member through the slip distance moves the second toothed edge to disengage the locking pawl from the first toothed edge.

[0086] As used herein, the terms “a” or “an,” as used herein, are defined as one or more than one. Also, the use of introductory phrases such as “at least one” and “one or more” in the claims should not be construed to imply that the introduction of another claim element by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim element to containing only one such element, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an.” The same holds true for the use of definite articles. In addition, “a set” of elements as used herein can refer to any number of elements, including only one element.

[0087] Further, as used herein, the phrase “at least one of element A, element B, or element C” is intended to convey any of: element A, element B, element C, elements A and B, elements A and C, elements B and C, and elements A, B, and C. In addition, one having skill in the art will understand the degree to which terms such as “about” or “substantially” convey in light of the measurements techniques utilized herein. To the extent such terms may not be clearly defined or understood by one having skill in the art, the term “about” shall mean plus or minus ten percent.

[0088] Unless stated otherwise, terms such as "first" and "second" are used to arbitrarily distinguish between the components such terms describe, and are not intended to indicate relative, temporal, or other prioritization of such components.

[0089] All directional references as may be used herein, e.g., proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, etc., are only used for identification purposes to aid the reader's understanding of the present disclosure and do not create limitations, particularly as to the position, orientation, or use of the disclosure. Connection references as may be used herein (e.g., attached, coupled, connected, or joined) are to be construed broadly and can include intermediate members between a collection of elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected or in fixed relation to one another. Additionally, the drawings of the present disclosure are for purposes of illustration only, and the dimensions, positions, order, or relative sizes of components reflected in the drawings can vary.A0012963W001

[0090] The following examples are illustrative of the techniques described herein.

[0091] Example 1. A surgical instrument, comprising: a shaft assembly defining a longitudinal axis and comprising an elongated body extending along the longitudinal axis; and an articulation mechanism, comprising: an articulation lever; an articulation link extending through the elongated body and having a proximal link end and a distal link end, with the distal link end configured to couple to a tool assembly; a rotatable cam disk operably coupled to the articulation lever and comprising at least two cam slots; and a drive plate coupled to the proximal link end and longitudinally movable therewith, the drive plate having at least two cam members receivable within the corresponding at least two cam slots; wherein bidirectional rotation of the cam disk drives corresponding bidirectional longitudinal motion of the drive plate; wherein the bidirectional longitudinal motion of the drive plate causes corresponding bidirectional articulation of the tool assembly by way of the articulation link.

[0092] Example 2. The surgical instrument of example 1 , further comprising a handle assembly carrying at least the cam disk and the drive plate.

[0093] Example 3. The surgical instrument of example 2, further comprising a sensor tube configured to move through a longitudinal distance upon coupling the tool assembly to the shaft assembly.

[0094] Example 4. The surgical instrument of example 3, wherein the cam disk comprises a projecting tab in locking engagement with the sensor tube, wherein the projecting tab disengages from the sensor tube when the sensor tube moves through the longitudinal distance upon coupling the tool assembly.

[0095] Example 5. The surgical instrument of example 1, wherein the cam disk further comprises: a first surface having a first toothed edge; and a second surface opposite the first surface and confronting the drive plate, with the at least two cam slots disposed in the second surface.

[0096] Example 6. The surgical instrument of example 5, wherein the first surface defines a first surface width, and the second surface defines a second surface width larger than the first surface width such that the first toothed edge is stepped from an outer edge of the cam disk.

[0097] Example 7. The surgical instrument of example 5, wherein the cam disk further comprises a projecting tab extending from the second surface and configured for locking engagement with a sensor tube disposed in the handle assembly.A0012963W001

[0098] Example 8. The surgical instrument of example 5, further comprising: a locking pawl confronting the first toothed edge of the cam disk; a bias member biasing the locking pawl toward engagement with the first toothed edge; and a release member coupled to the articulation lever and co-rotatable therewith, the release member confronting the cam disk and having a second toothed edge overlying the first toothed edge.

[0099] Example 9. The surgical instrument of example 8, wherein the cam disk further comprises a mounting tab projecting from the first surface, and the release member comprises a mounting recess configured to receive the mounting tab.

[0100] Example 10. The surgical instrument of example 9, wherein the mounting tab defines a tab length and the mounting recess defines a recess length, with a difference between the recess length and the tab length defining a slip distance through which the release member is rotatable relative to the cam disk.

[0101] Example 11. The surgical instrument of example 10, wherein rotation of the release member through the slip distance moves the second toothed edge to disengage the locking pawl from the first toothed edge.

[0102] Example 12. The surgical instrument of example 11, wherein the release member is co- rotatable with the cam disk upon further rotation beyond the slip distance.

[0103] Example 13. A surgical instrument, comprising: a handle assembly; a shaft assembly extending from the handle assembly and defining a longitudinal axis, the shaft assembly comprising an elongated body extending along the longitudinal axis; and an articulation mechanism, comprising: an articulation link extending through the elongated body and having a proximal link end and a distal link end, with the distal link end configured to couple to a tool assembly; a cam disk comprising a first cam slot spaced from a second cam slot; and an articulation drive member coupled to the proximal link end and having a first cam member receivable within the first cam slot, and having a second cam member receivable within the second cam slot; wherein motion of the first cam member along the first cam slot drives the articulation link to articulate the tool assembly to define a first angle with respect to the longitudinal axis; wherein motion of the second cam member along the second cam slot drives the articulation link to articulate the tool assembly to define a second angle with respect to the longitudinal axis; wherein the first angle and the second angle are adjacent angles with the longitudinal axis as a common arm.A0012963W001

[0104] Example 14. The surgical instrument of example 13, wherein the cam disk is rotatable, and the articulation drive member comprises a longitudinally movable drive plate having the first cam member and the second cam member, wherein rotation of the cam disk causes corresponding longitudinal motion of the drive plate.

[0105] Example 15. The surgical instrument of example 13, wherein the cam disk further comprises: a first surface having a first toothed edge; and a second surface opposite the first surface and confronting the articulation drive member, with the first cam slot and the second cam slot disposed in the second surface.

[0106] Example 16. An articulation mechanism for a surgical instrument configured to receive a tool assembly, the articulation mechanism comprising: an articulation link extending between a proximal link end and a distal link end, with the distal link end configured to couple to the tool assembly; a drive plate coupled to the articulation link and having at least two cam members; and a cam disk rotatable about a central axis and comprising: a first surface having a first toothed edge; and a second surface opposite the first surface and confronting the drive plate, with at least two cam slots disposed in the second surface, and with the at least two cam members received in the corresponding at least two cam slots; wherein bidirectional rotation of the cam disk drives corresponding bidirectional longitudinal motion of the drive plate; wherein the bidirectional longitudinal motion of the drive plate is configured to generate corresponding bidirectional articulation of the tool assembly.

[0107] Example 17. The articulation mechanism of example 16, wherein the cam disk further comprises a projecting tab extending from the second surface and configured for locking engagement with a sensor tube of the surgical instrument, wherein the projecting tab is configured to disengage from the sensor tube upon coupling the tool assembly to the surgical instrument.

[0108] Examplel8. The articulation mechanism of example 17, further comprising: a locking pawl confronting the first toothed edge of the cam disk; a bias member biasing the locking pawl toward engagement with the first toothed edge; and a release member confronting the cam disk and having a second toothed edge overlying the first toothed edge.

[0109] Example 19. The articulation mechanism of example 18, wherein the cam disk further comprises a mounting tab projecting from the first surface, and the release member comprises a mounting recess configured to receive the mounting tab.A0012963W001

[0110] Example 20. The articulation mechanism of example 19, wherein the mounting tab defines a tab length and the mounting recess defines a recess length, with a difference between the recess length and the tab length defining a slip distance through which the release member is rotatable relative to the cam disk; wherein rotation of the release member through the slip distance moves the second toothed edge to disengage the locking pawl from the first toothed edge.

Claims

A0012963W001WHAT IS CLAIMED IS:

1. A surgical instrument (10), comprising: a shaft assembly (30) defining a longitudinal axis and comprising an elongated body (32) extending along the longitudinal axis; and an articulation mechanism (60), comprising: an articulation lever (62); an articulation link (63) extending through the elongated body and having a proximal link end and a distal link end, with the distal link end configured to couple to a tool assembly (40); a rotatable cam disk (100) operably coupled to the articulation lever and comprising at least two cam slots; and a drive plate (64) coupled to the proximal link end and longitudinally movable therewith, the drive plate (64) having at least two cam members (71, 72) receivable within the corresponding at least two cam slots; wherein bidirectional rotation of the cam disk (100) drives corresponding bidirectional longitudinal motion of the drive plate (64); wherein the bidirectional longitudinal motion of the drive plate (64) causes corresponding bidirectional articulation of the tool assembly (40) by way of the articulation link (63).

2. The surgical instrument of claim 1, further comprising a handle assembly carrying at least the cam disk and the drive plate.

3. The surgical instrument of claim 2, further comprising a sensor tube configured to move through a longitudinal distance upon coupling the tool assembly to the shaft assembly.

4. The surgical instrument of claim 3, wherein the cam disk comprises a projecting tab in locking engagement with the sensor tube, wherein the projecting tab disengages from the sensor tube when the sensor tube moves through the longitudinal distance upon coupling the tool assembly.

5. The surgical instrument of claim 1, wherein the cam disk further comprises:A0012963W001 a first surface having a first toothed edge; and a second surface opposite the first surface and confronting the drive plate, with the at least two cam slots disposed in the second surface.

6. The surgical instrument of claim 5, wherein the first surface defines a first surface width, and the second surface defines a second surface width larger than the first surface width such that the first toothed edge is stepped from an outer edge of the cam disk.

7. The surgical instrument of claim 5, wherein the cam disk further comprises a projecting tab extending from the second surface and configured for locking engagement with a sensor tube disposed in the handle assembly.

8. The surgical instrument of claim 5, further comprising: a locking pawl confronting the first toothed edge of the cam disk; a bias member biasing the locking pawl toward engagement with the first toothed edge; and a release member coupled to the articulation lever and co-rotatable therewith, the release member confronting the cam disk and having a second toothed edge overlying the first toothed edge.

9. The surgical instrument of claim 8, wherein the cam disk further comprises a mounting tab projecting from the first surface, and the release member comprises a mounting recess configured to receive the mounting tab.

10. The surgical instrument of claim 9, wherein the mounting tab defines a tab length and the mounting recess defines a recess length, with a difference between the recess length and the tab length defining a slip distance through which the release member is rotatable relative to the cam disk.

11. The surgical instrument of claim 10, wherein rotation of the release member through the slip distance moves the second toothed edge to disengage the locking pawl from the first toothed edge.A0012963W00112. The surgical instrument of claim 11, wherein the release member is co-rotatable with the cam disk upon further rotation beyond the slip distance.

13. A surgical instrument (10), comprising: a handle assembly (20); a shaft assembly (30) extending from the handle assembly (20) and defining a longitudinal axis, the shaft assembly (30) comprising an elongated body extending along the longitudinal axis; and an articulation mechanism (60), comprising: an articulation link (63) extending through the elongated body and having a proximal link end and a distal link end, with the distal link end configured to couple to a tool assembly (40); a cam disk (100) comprising a first cam slot spaced from a second cam slot; and an articulation drive member (64) coupled to the proximal link end and having a first cam member (71) receivable within the first cam slot, and having a second cam member (72) receivable within the second cam slot; wherein motion of the first cam member (71) along the first cam slot drives the articulation link (63) to articulate the tool assembly (40) to define a first angle with respect to the longitudinal axis; wherein motion of the second cam member (72) along the second cam slot drives the articulation link (63) to articulate the tool assembly (40) to define a second angle with respect to the longitudinal axis; wherein the first angle and the second angle are adjacent angles with the longitudinal axis as a common arm.

14. The surgical instrument of claim 13, wherein the cam disk is rotatable, and the articulation drive member comprises a longitudinally movable drive plate having the first cam member and the second cam member, wherein rotation of the cam disk causes corresponding longitudinal motion of the drive plate.A0012963W00115. The surgical instrument of claim 13, wherein the cam disk further comprises: a first surface having a first toothed edge; and a second surface opposite the first surface and confronting the articulation drive member, with the first cam slot and the second cam slot disposed in the second surface.

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