ADAPTER ASSEMBLIES FOR INTERCONNECTING SURGICAL LOADING UNITS AND HANDLE ASSEMBLIES

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62/066,983 filed Oct. 22, 2014, the entire disclosure of which is incorporated by reference herein.

[0002] 1. Technical Field

[0003] The present disclosure relates to adapter assemblies for use with an electromechanical surgical system and their methods of use. More specifically, the present disclosure relates to hand-held, electromechanical surgical instruments capable of detecting a presence of a loading unit and/or identifying one or more parameters of a loading unit attached to an adapter assembly.

[0004] 2. Background of Related Art

[0005] Linear clamping, cutting, and stapling surgical devices may be employed in surgical procedures to resect tissue. Conventional linear clamping, cutting, and stapling devices include a handle assembly, an elongated shaft and a distally located surgical loading unit. The loading unit includes a pair of gripping members, which clamp about tissue to be stapled. One of the gripping members includes a staple cartridge receiving region and a mechanism for driving the staples up through tissue and against an anvil portion on the other gripping member.

[0006] In many instances, the handle assembly is reusable and the loading unit is disposable. The disposable loading unit may be selectively coupled to the handle assembly via an adapter assembly prior to use and then disconnected from the adapter assembly and therefore decoupled from the reusable handle assembly following use in order to be disposed of or in some instances sterilized for re-use.

[0007] A need exists for various types of adapter assemblies that communicate relevant information to a handle assembly of a surgical instrument upon a proper engagement of a loading unit with the handle assembly.

[0008] The present disclosure relates to adapter assemblies for use between handle assemblies and loading units. The present disclosure also relates to switch assemblies of an adapter assembly that effectively communicate information about a loading unit to a handle assembly, which is coupled to the adapter assembly, upon engagement of the loading unit with the handle assembly.

[0009] In an aspect of the present disclosure, an adapter assembly is provided. The adapter assembly includes a housing, an elongated body, a switch assembly and a switch actuator. The housing is configured to be coupled to a handle assembly. The elongated body defines a longitudinal axis along a length thereof and extends distally from the housing. The elongated body is configured to be coupled to a surgical loading unit. The switch assembly is disposed within the housing and configured to communicate that the surgical loading unit is coupled to the elongated body. The switch assembly includes a substrate, a switch, and at least one wire. The substrate has a top surface and a bottom surface. The switch is mounted on the top surface of the substrate. The wire is coupled to the substrate. The switch actuator is movably disposed within the housing and configured to actuate the switch upon engagement of the surgical loading unit with the elongated body.

[0010] In embodiments, the substrate may include a step disposed at an end thereof. The step may have a first planar surface that extends perpendicularly from the top surface of the substrate and a second planar surface extending perpendicularly from the first planar surface and being parallel with the top and bottom surfaces of the substrate. The wire may be coupled to the first planar surface and may extend along the longitudinal axis of the elongated body. The wire may include a first portion coupled to the second planar surface extending perpendicularly therefrom and a second portion extending perpendicularly from the first portion and along the longitudinal axis of the elongated body.

[0011] In embodiments, the wire may be coupled to the bottom surface of the substrate and may extend along the longitudinal axis of the elongated body.

[0012] In embodiments, the switch assembly may further include a shim disposed within the housing and may define a channel along at least a portion of a length thereof. The substrate may be disposed on the shim. The shim may further define an opening through a thickness thereof. The substrate may include an annular notch defined in an end thereof and a portion of the wire may be disposed within the annular notch.

[0013] In embodiments, the switch actuator may include a resilient member in communication with the switch. The adapter assembly may further include a release button in communication with the resilient member. The release button may move between a first position, in which the resilient member engages the switch, and a second position, in which the resilient member disengages the switch.

[0014] In another aspect of the present disclosure, a surgical instrument is provided. The surgical instrument includes a handle assembly, a surgical loading unit, and an adapter assembly. The surgical loading unit has a proximal end and a distal end including an end effector. The adapter assembly has a housing configured to be coupled to the handle assembly and an elongated body extending distally from the housing and configured to be coupled to the proximal end of the surgical loading unit. The adapter assembly includes a switch assembly disposed therein and configured to communicate that the loading unit is coupled to the elongated body. The switch assembly includes a substrate, a switch, and at least one wire. The substrate has a top surface and a bottom surface. The switch is mounted on the top surface of the substrate. The wire is coupled to the substrate. The switch actuator is movably disposed within the housing and configured to actuate the switch upon engagement of the surgical loading unit with the elongated body.

[0015] In embodiments, the substrate may include a plurality of layers. The plurality of layers may include a plurality of dielectric layers and at least one conductive layer disposed over at least one of the top surface, the bottom surface, or in between the plurality of dielectric layers. The substrate may include a plurality of vias interconnecting the switch and the at least one conductive layer.

[0016] In embodiments, the plurality of layers may define a first portion and a second portion. The first portion of the plurality of layers may include at least one dimension that is different than a corresponding dimension of the second portion of the plurality of layers to define a step. The step may include a first planar surface that extends perpendicularly from the first portion and a second planar surface extending perpendicularly from the first portion along the second portion.

[0017] In embodiments, the conductive layer may be disposed between the first portion and the second portion and may include at least one contact disposed on at least one of the first planar surface or the second planar surface of the step. The wire may be coupled to the contact. The contact may be coupled to the first planar surface such that the wire extends along the longitudinal axis of the elongated body. The contact may be coupled to the second planar surface. A first portion of the wire may extend perpendicularly from the second planar surface and a second portion of the wire may extend perpendicularly from the first portion of the wire and along the longitudinal axis of the elongated body.

[0031] Embodiments of the presently disclosed surgical instruments, surgical loading units, and adapter assemblies for electromechanical surgical devices and/or handle assemblies are 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 the surgical instrument, adapter assembly, handle assembly, loading unit, or components thereof, farther from the user, while the term “proximal” refers to that portion of the surgical instrument, adapter assembly, handle assembly, loading unit, or components thereof, closer to the user. As used herein, the term “toggle” is defined as a transition between a first condition, in which a switch is engaged, and a second condition, in which the switch is disengaged.

[0032] With reference to FIGS. 1A-1C, a surgical instrument, in accordance with an embodiment of the present disclosure, is generally designated as 10, and is in the form of a powered, hand-held, electromechanical surgical instrument 10. Surgical instrument 10 includes a handle assembly 100 configured for selective attachment thereto with any one of a number of adapter assemblies, such as, for example, adapter assembly 200, and, in turn, each unique adapter assembly 200 is configured for selective connection with any number of surgical loading units, such as, for example, loading unit 300. Loading unit 300 and adapter assembly 200 are configured for actuation and manipulation by handle assembly 100.

[0033] Reference may be made to International Publication No. WO 2009/039506 and U.S. Patent Application Publication No. 2011/0121049, the entire contents of both of which are incorporated herein by reference, for a detailed description of the construction and operation of an exemplary electromechanical, hand-held, powered surgical instrument.

[0034] Handle assembly 100 includes one or more controllers (not shown), a power source (not shown), a processor 104, and a drive mechanism having one or more motors 106, gear selector boxes (not shown), gearing mechanisms (not shown), and the like. Processor 104 is configured to control motors 106 and to detect a presence of a loading unit, for example, loading unit 300, and/or determine one or more parameters of loading unit 300, as described herein. Handle assembly 100 further includes a control assembly 108. Control assembly 108 may include one or more finger-actuated control buttons, rocker devices, joystick or other directional controls, whose input is transferred to the drive mechanism to actuate adapter assembly 200 and loading unit 300.

[0035] In particular, with reference to FIG. 1C, the drive mechanism is configured to drive shafts and/or gear components in order to selectively move an end effector 304 of loading unit 300 to rotate end effector 304 about a longitudinal axis “X” relative to handle assembly 100, to move an anvil assembly 306 relative to a cartridge assembly 308 of end effector 304, and/or to fire a stapling and cutting cartridge within cartridge assembly 308 of end effector 304.

[0036] With continued reference to FIG. 1A, handle assembly 100 defines a nose or connecting portion 110 configured to accept a corresponding drive coupling assembly 210 (FIG. 1B) of adapter assembly 200. Connecting portion 110 of handle assembly 100 has a cylindrical recess (not shown) that receives drive coupling assembly 210 of adapter assembly 200 when adapter assembly 200 is mated to handle assembly 100. Connecting portion 110 houses one or more rotatable drive connectors (not shown) that interface with corresponding rotatable connector sleeves (not shown) of adapter assembly 200.

[0037] When adapter assembly 200 is mated to handle assembly 100, each of the rotatable drive connectors of handle assembly 100 couples with a corresponding rotatable connector sleeve of adapter assembly 200. In this regard, the interface between the plurality of drive connectors of handle assembly 100 and the plurality of corresponding connector sleeves of the adapter assembly are keyed such that rotation of each of the drive connectors causes rotation of the corresponding connector sleeves of adapter assembly 200.

[0038] The mating of the drive connectors of handle assembly 100 with the connector sleeves of adapter assembly 200 allows rotational forces to be independently transmitted via each of the three respective connector interfaces. The drive connectors of handle assembly 100 are configured to be independently rotated by the drive mechanism.

[0039] Since each of the drive connectors of handle assembly 100 has a keyed and/or substantially non-rotatable interface with the respective connector sleeves of adapter assembly 200, when adapter assembly 200 is coupled to handle assembly 100, rotational force(s) are selectively transferred from drive mechanism of handle assembly 100 to adapter assembly 200.

[0040] With continued reference to FIGS. 1A-1C, the selective rotation of drive connector(s) of handle assembly 100 allows surgical instrument 10 to selectively actuate different functions of end effector 304. Selective and independent rotation of first drive connector of handle assembly 100 corresponds to the selective and independent opening and closing of end effector 304, and driving of a stapling/cutting component of end effector 304. Also, the selective and independent rotation of second drive connector of handle assembly 100 corresponds to the selective and independent articulation of end effector 304 about an articulation axis that is transverse to longitudinal axis “X.” In particular, end effector 304 defines a second or respective longitudinal axis and is movable from a first position in which the second or respective longitudinal axis is substantially aligned with longitudinal axis “X” to at least a second position in which the second longitudinal axis is disposed at a non-zero angle with respect to longitudinal axis “X.” Additionally, the selective and independent rotation of the third drive connector of handle assembly 100 corresponds to the selective and independent rotation of loading unit 300 about longitudinal axis “X” relative to handle assembly 100 of surgical instrument 10.

[0041] With continued reference to FIGS. 1A and 1B, adapter assembly 200 includes a housing, such as, for example, a knob housing 202 and an elongated body 204 extending from a distal end of knob housing 202. Elongated body 204 is dimensioned for endoscopic insertion. For example, elongated body 204 is passable through a typical trocar port, cannula or the like. Knob housing 202 is dimensioned to not enter the trocar port, cannula of the like. Elongated body 204 of adapter assembly 200 has a proximal portion 206a coupled to knob housing 202 and a distal portion 206b configured to be coupled to loading unit 300. Knob housing 202 is configured and dimensioned to house the components of adapter assembly 200 and to be coupled to handle assembly 100. Knob housing 202 includes a release button 203 in communication with a switch assembly 220 (see FIG. 3) of adapter assembly 200, as described in greater detail below.

[0042] With reference to FIGS. 2-4, knob housing 202 of adapter assembly 200 further includes a switch assembly 220 and a switch actuator, such as, for example, a leaf spring or resilient member 230 configured to actuate a switch 222 of switch assembly 220 in response to a coupling of loading unit 300 to distal portion 206b of elongated body 204. Switch assembly 220 includes switch 222, a substrate 250, and a pair of wires “W” (FIG. 4), connecting the switch 222 to processor 104. Switch assembly 220 is disposed within an inner housing 214, which is disposed within a distal end of knob housing 202. Switch 222 is mounted on substrate 230 and includes a button 224 and a platform 226. Button 224 is movable (e.g., resiliently depressible) relative to platform 226 in response to a downwardly oriented force being imparted thereon.

[0043] With specific reference to FIG. 3, resilient member 230 is movably disposed within inner housing 214. Resilient member 230 overlies or overlaps switch 222 and is configured to actuate switch 222 upon engagement of surgical loading unit 300 with distal end 206b of elongated body 204.

[0044] With specific reference to FIG. 4, substrate 250 mechanically supports switch 222 thereon and electrically connects switch 222 to processor 104 of handle assembly 100 via electrical wires “W,” such that upon toggling of switch 222, switch 222 communicates to handle assembly 100 that loading unit 300 is lockingly engaged to distal portion 206b of elongated body 204 or that loading unit 300 is disengaged from distal portion 206b of elongated body 204. In embodiments, switch 222 may communicate with processor 104 using wireless communication, including various radio frequency protocols such as near field communication, radio frequency identification “RFID,” BLUETOOTH®, (owned by Bluetooth SIG, Inc.), etc.

[0045] Substrate 250 may be in the form of a printed circuit board or an MMA board. Substrate 250 has a top surface 252a and a bottom surface 252b. Top surface 252a includes a pair of spaced apart electrical contacts 254. Wires “W” are coupled to respective electrical contacts 254 (e.g., via soldering). Wires “W” may be bent at any suitable angle, e.g., approximately at 90 degrees, to provide for connection between the wires “W” and contacts 254 and to define a first portion 256a and a second portion 256b of wires “W.” First portion 256a of wire “W” is coupled to respective electrical contacts 254 and extends perpendicularly upward relative to top surface 252a of substrate 250. Second portion 256b of wire “W” extends perpendicularly from first portion 256a, such that second portion 256b of each electrical wire “W” is substantially parallel with respect to longitudinal axis “X.”

[0046] With reference to FIG. 1C, as mentioned above, surgical instrument 10 includes loading unit 300. Loading unit 300 has a proximal portion 302a configured for engagement with distal end 206b of elongated body 204 of adapter assembly 200 and a distal portion 302b. Distal portion 302b of loading unit 300 has an end effector 304 extending therefrom. End effector 304 is pivotally attached to distal portion 302b. End effector 304 includes an anvil assembly 306 and a cartridge assembly 308. Cartridge assembly 308 is pivotable in relation to anvil assembly 306 and is movable between an open or unclamped position and a closed or clamped position for insertion through a cannula of a trocar.

[0047] Reference may be made to U.S. Pat. No. 7,819,896, entitled “TOOL ASSEMBLY FOR A SURGICAL STAPLING DEVICE”, the entire content of which is incorporated herein by reference, for a detailed discussion of the construction and operation of a suitable end effector.

[0048] In operation, when proximal portion 302a of loading unit 300 is coupled to distal portion 206b of elongated body 204, release button 203 is moved in a distal direction, indicated by arrow “A” in FIG. 1B, from a second position or proximal position, in which switch 222 is disengaged, to a first position or distal position. As release button 203 moves from the proximal position to the distal position, release button 203 deflects resilient member 230 downwardly into engagement with switch 222 to toggle switch 222. When switch 222 is toggled, switch 222 communicates to handle assembly 100 that loading unit 300 is lockingly engaged to adapter assembly 200 and/or communicates to handle assembly 100 parameters pertaining to loading unit 300. The parameter may include a serial number of a loading unit, a type of a loading unit, a size of a loading unit, a staple size, information identifying whether the loading unit has been fired, a length of a loading unit, and/or a maximum number of uses of a loading unit.

[0049] To selectively release loading unit 300 from adapter assembly 200, release button 203 is moved or translated in a proximal direction, indicated by arrow “B” in FIG. 1B. As release button 203 moves from the distal position to the proximal position, release button 203 disengages resilient member 230 such that the resilient bias of resilient member 230 deflects resilient member 230 upwardly and out of engagement with switch 222. Upon resilient member 230 disengaging switch 222, switch 222 communicates to handle assembly 100 that loading unit 300 is no longer lockingly engaged with adapter assembly 200 and not ready for operation.

[0050] While an electrical interface between loading unit 300, adapter assembly 200, and/or handle assembly 100 is shown and described, it is contemplated that any other form or communication is within the scope of the present disclosure, for transmitting any or all of the operating parameters and/or the life-cycle information from loading unit 300 to handle assembly 100.

[0051] With reference to FIG. 5, another embodiment of a switch assembly 320, which is substantially similar to switch assembly 220 discussed above, is provided. Contrasting with switch assembly 220, switch assembly 320 has a pair of wires “W” extending from a bottom surface 352b thereof. In particular, switch assembly 320 includes a switch 322, a substrate 350, and wires “W.” Substrate 350 mechanically supports switch 322 thereon and electrically connects switch 322 with processor 104 of handle assembly 100 via electrical wires “W.” Substrate 350 may be in the form of a printed circuit board or an MMA board. Substrate 350 has a top surface 352a and bottom surface 352b. Bottom surface 352b includes a pair of spaced apart electrical contacts 354. Wires “W” are coupled to respective electrical contacts 354 (e.g., via soldering). Accordingly, wires “W” extend from bottom surface 354 of substrate 350 and are substantially parallel to longitudinal axis “X” of elongated body 204.

[0052] With reference to FIG. 6, another embodiment of a switch assembly 420, which is substantially similar to switch assembly 220 discussed above, is provided. Switch assembly 420 also includes a switch 422, a substrate 450, and a pair of wires “W.” Substrate 450 mechanically supports switch 422 thereon and electrically connects switch 422 with processor 104 of handle assembly 100 via electrical wires “W.” Substrate 450 includes a top surface 452a and a bottom surface 452b and defines a thickness “t” of substrate 450 therebetween. Top and bottom surfaces 452a, 452b may be fabricated from a non-conductive material.

[0053] Substrate 450 includes a plurality of layers, such as, for example, a plurality of dielectric layers 456 disposed between top and bottom surfaces 452a, 452b and a conductive layer 458 disposed between dielectric layers 456. In some embodiments, one or more conductive layers may be disposed between dielectric layers or disposed on top surface 452a and/or bottom surface 452b of substrate 450. A plurality of vias 460 interconnect switch 422 and conductive layer 458. Layers 456, 458 define a first portion or top portion 462a of substrate 450 and a second portion or bottom portion 462b of substrate 450. Conductive layer 458 is disposed between top and bottom portions 462a, 462b.

[0054] First portion 462a of substrate 450 includes a dimension, such as, for example, a first length, that is different (e.g., less) than a corresponding dimension, such as, for example, a second length, of second portion 462b to define a step or cutout portion 464 disposed at an end of substrate 450. Step 464 has a first surface 466a having a planar configuration and a second surface 466b having a planar configuration. First surface 466a extends perpendicularly downward from top surface 452a of substrate 450 and defines a height, which may be about half of the thickness “t” of substrate 450. Second surface 466b extends perpendicularly from first surface 466a such that second surface 466b is substantially parallel with and disposed between top and bottom surfaces 452a, 452b of substrate 450. First surface 466a has a pair of spaced apart electrical contacts 454 attached thereto. Wires “W” are coupled to respective electrical contacts 454 (e.g., via soldering). Accordingly, wires “W” extend perpendicularly from first surface 466a of step 464 in line with longitudinal axis “X” of elongated body 204.

[0055] With reference to FIG. 7, another embodiment of a switch assembly 520, which is substantially similar to switch assembly 420 discussed above, is provided. Contrasting with switch assembly 420, switch assembly 520 has a pair of bent wires “W” that extend perpendicularly upwardly from a second surface 566b of a step 564, as described herein. In particular, switch assembly 520 includes a switch 522, a substrate 550, and wires “W.” Substrate 550 mechanically supports switch 522 thereon and electrically connects switch 522 with processor 104 of handle assembly 100 via electrical wires “W.” Substrate 550 includes a top surface 552a and a bottom surface 552b and defines a thickness “t” of substrate 550 therebetween. Top and bottom surfaces 552a, 552b may be fabricated from a non-conductive material.

[0056] Substrate 550 includes a plurality of layers, such as, for example, a plurality of dielectric layers 556 disposed between top and bottom surfaces 552a, 552b and a conductive layer 558 disposed between dielectric layers 556. In some embodiments, one or more conductive layers may be disposed between dielectric layers or disposed on top surface 552a and/or bottom surface 552b of substrate 550. A plurality of vias 560 interconnect switch 522 and conductive layer 558. Layers 556, 558 define a first portion or top portion 562a of substrate 550 and a second portion or bottom portion 562b of substrate 550. Conductive layer 558 is disposed between top and bottom portions 562a, 562b of substrate 550.

[0057] First portion 562a of substrate 550 includes a dimension, such as, for example, a first length, that is different (e.g., less) than a corresponding dimension, such as, for example, a second length, of second portion 562b to define a step or cutout portion 564 disposed at an end of substrate 550. Step 564 has a first surface 566a having a planar configuration and a second surface 566b having a planar configuration. First surface 566a extends perpendicularly downward from top surface 552a of substrate 550 and defines a height, which may be about two-thirds of the thickness “t” of substrate 550. Second surface 566b extends perpendicularly from first surface 566a such that second surface 566b is substantially parallel with and disposed between top and bottom surfaces 552a, 552b of substrate 550. Second surface 566b has a pair of spaced apart electrical contacts 554 attached thereto.

[0058] Wires “W” are coupled to respective electrical contacts 554 (e.g., via soldering).

[0059] Wires “W” may be bent at any suitable angle, e.g., approximately at 90 degrees, to provide for connection between the wires “W” and contacts 554 and to define a first portion 570a and a second portion 570b of wires “W.” First portion 570a of wires “W” extends perpendicularly upward from second surface 566b. Second portion 570b of wires “W” extends perpendicularly from first portion 570a of wires “W.” Accordingly, second portion 570b of each wire “W” is substantially parallel with longitudinal axis “X.”

[0060] With reference to FIGS. 8-10, another embodiment of an adapter assembly 600, which is similar to adapter assembly 200 discussed above, is provided. Adapter assembly 600 includes a switch assembly 620 and a switch actuator, such as, for example, a resilient member 630. Switch assembly 620 is disposed within an inner housing 614 of adapter assembly 600, which is disposed within knob housing 202 (see FIG. 1B). Resilient member 630 is configured to actuate a switch 622 of switch assembly 620 in response to a coupling of loading unit 300 (see FIG. 1C) to distal portion 206b of elongated body 204 (see FIG. 1B).

[0061] Switch assembly 620 includes switch 622, a substrate 650, a pair of electrical wires “W,” and a shim 680. Substrate 650 mechanically supports switch 622 thereon and electrically connects switch 622 with processor 104 (see FIG. 1A) of handle assembly 100 via electrical wires “W.” Substrate 650 may be in the form of a printed circuit board or an MMA board.

[0062] With reference to FIG. 9, substrate 650 has a top surface 652a and a bottom surface 652b and defines a thickness “t” of substrate 650 therebetween. Bottom surface 652b includes a pair of spaced apart electrical contacts 654 (see FIG. 8). Wires “W” are coupled to respective electrical contacts 654 (e.g., via soldering). Substrate 650 has a first end 666a and a second end 666b and defines a length of substrate 650 therebetween. Second end 666b includes an annular notch 668 defined therein configured for disposal of a bent portion 670 (see FIG. 8) of electrical wires “W,” as described in greater detail below.

[0063] With specific reference to FIG. 10, shim 680 is disposed within inner housing 614 and supports substrate 650 thereon. Shim 680 has a rectangular configuration. In embodiments, shim 680 may be variously configured, such as, for example, oval, square, triangular, arcuate, polygonal, uniform, non-uniform, and/or tapered. Shim 680 includes a first end 682a and a second end 682b and defines a length “L” of shim 680 therebetween. Shim 680 includes a top surface 684a and a bottom surface 684b and defines a thickness “t” of shim 680 therebetween. Shim 680 defines a channel 688 along a portion of its length “L.” Shim 680 further defines an opening or hole 690 that extends through the thickness “t” of shim 680 and is adjacent first end 682a of shim 680. Opening 690 is configured to provide access to bottom surface 652b of substrate 650 with a soldering tool to solder wires “W” to electrical contacts 654.

[0064] In assembly, with reference to FIG. 8, shim 680 is positioned within inner housing 614. Wires “W” are bent to form a first portion 692a and a second portion 692b. First portion 692a of wires “W” is disposed within channel 688 of shim 680 and in alignment with opening 690 of shim 680 such that second portion 692b is in line with longitudinal axis “X” of elongated body 204. Substrate 650 is positioned on top surface 684a of shim 680 such that bent portion 670 of each wire “W” is disposed within notch 668 defined in substrate 650. In this way, wires “W” are directed away from metal surfaces (e.g., resilient member 630) to prevent shorting.

[0065] It will be understood that various modifications may be made to the embodiments of the presently disclosed adapter assemblies. Therefore, 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.