Power module for use with a surgical instrument

[0001] The present disclosure relates to surgical instruments. In various forms, the present disclosure relates to a power module for use with powered surgical cutting and fastening instruments.

[0021] Certain exemplary embodiments will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the devices and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the various embodiments of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention.

[0022] Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment”, or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment”, or “in an embodiment”, or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features structures, or characteristics of one or more other embodiments without limitation. Such modifications and variations are intended to be included within the scope of the present invention.

[0023] The terms “proximal” and “distal” are used herein with reference to a clinician manipulating the handle portion of the surgical instrument. The term “proximal” referring to the portion closest to the clinician and the term “distal” referring to the portion located away from the clinician. It will be further appreciated that, for convenience and clarity, spatial terms such as “vertical”, “horizontal”, “up”, and “down” may be used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute.

[0024] Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the person of ordinary skill in the art will readily appreciate that the various methods and devices disclosed herein can be used in numerous surgical procedures and applications including, for example, in connection with open surgical procedures. As the present Detailed Description proceeds, those of ordinary skill in the art will further appreciate that the various instruments disclosed herein can be inserted into a body in any way, such as through a natural orifice, through an incision or puncture hole formed in tissue, etc. The working portions or end effector portions of the instruments can be inserted directly into a patient's body or can be inserted through an access device that has a working channel through which the end effector and elongated shaft of a surgical instrument can be advanced.

[0025] Referring to FIG. 1, one form of a power module 10 is illustrated. The power module 10 can be used to power a surgical instrument such as, for example, surgical instrument 200 (See FIG. 11) and can be integral with the surgical instrument 200. Alternatively, the power module 10 can be removably coupled to the surgical instrument 200. As illustrated in FIGS. 2-4, the power module 10 may include a housing 12, a motor assembly 13, a first motion conversion assembly 16, a second motion conversion assembly 18, and a transmission assembly 20. In at least one form, the motor assembly 13 may include a motor 14 which can be affixed to the housing 12 and can be activated to generate rotational motions which can be selectively transmitted by the transmission assembly 20 to the first motion conversion assembly 16 or the second motion conversion assembly 18.

[0026] Referring primarily to FIG. 2, the first motion conversion assembly 16 may include a first rotary drive 22 in operable engagement with a first axial drive 24. The first rotary drive 22 can be rotatably seated in the housing 12 and can be mechanically constrained from translating in any direction. In addition, the second motion conversion assembly 18 may include a second rotary drive 26 in operable engagement with a second axial drive 28. The second rotary drive 26 can also be rotatably seated in the housing 12 and can be mechanically constrained from translating in any direction by the housing 12, for example.

[0027] Further to the above, referring primarily to FIG. 3, the second rotary drive 26 can be rotatable about a longitudinal axis L-L defined by the motor 14. As illustrated in FIG. 3, the longitudinal axis L-L may extend longitudinally through the motor 14 which can be concentrically arranged with the second rotary drive 26. The second rotary drive 22 may comprise the shape of a hollow cylinder wherein the motor 14 can be positioned at least partially within the second rotary drive 22. In certain forms, the motor 14 may be a DC brushed driving motor having a maximum rotation of, approximately, 25,000 RPM, for example. In other arrangements, the motor may include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor.

[0028] Further to the above, referring again to FIG. 3, the first rotary drive 22 and the second rotary drive 26 can be concentrically arranged and can be rotatable about the axis L-L. In certain circumstances, the first rotary drive 22 and the second rotary drive 26 may comprise the shape of a hollow cylinder wherein the motor 14 can be positioned, at least partially, within the second rotary drive 26 which, in turn, can be positioned, at least partially, within the first rotary drive 22. The concentric arrangement of the motor 14, the first rotary drive 22 and the second rotary drive 26 within the housing 12 may reduce the size of the power module 10.

[0029] Referring primarily to FIG. 3, the first rotary drive 22 can be threadedly engaged with the first axial drive 24 and the second rotary drive 26 can be threadedly engaged with the second axial drive 28. For example, the first rotary drive 22 may include an outer wall 30 and an inner wall 32 which may include an inner thread 34, as illustrated in FIG. 3. In addition, the first axial drive 24 may include a first rack 36 which may be operably engaged with the inner thread 34 of the first rotary drive 22 such that rotation of the first rotary drive 22, for example in a clockwise direction, about the longitudinal axis L-L may cause the first axial drive 24 to be axially translated relative to the housing 12 in a distal direction, for example, and rotation of the first rotary drive 22, in a counterclockwise direction, about the longitudinal axis L-L may cause the first axial drive 24 to be axially translated relative to the housing 12 in a proximal direction, for example.

[0030] Further to the above, the second rotary drive 26 may include an inner wall 38 and an outer wall 40 which may include an outer thread 42, as illustrated in FIG. 2. In addition, the second axial drive 28 may include a second rack 44 which may be operably engaged with the outer thread 42 of the second rotary drive 26 such that rotation of the second rotary drive 26, for example in a clockwise direction, about the longitudinal axis L-L may cause the second axial drive 28 to be axially moved relative to the housing 12 in a distal direction, for example, and rotation of the second rotary drive 26, for example in a counterclockwise direction, about the longitudinal axis L-L may cause the second axial drive 28 to be axially moved relative to the housing 12 in a proximal direction, for example.

[0031] As described above, the motor 14, the first rotary drive 22 and the second rotary drive 26 can be concentrically arranged within the housing 12, in part, to reduce the size of the power module 10. To accommodate the motor 14, as illustrated in FIG. 5A, the inner wall 38 of second rotary drive 26 may possess a diameter D2 that is greater than a diameter D1 of the outer wall 15 of the motor 14. Similarly, to accommodate the second rotary drive 26, the inner wall 32 of the first rotary drive 22 may possess a diameter D4 greater than a diameter D3 of the outer wall 40 of the second rotary drive 26, as illustrated in FIG. 5B.

[0032] Referring to FIG. 2, the housing 12 may comprise a first chamber 12A which may include a first inner wall 46 and a second chamber 12B which may include a second inner wall 48. The first inner wall 46 and the second inner wall 48 may each comprise a cylindrical or at least substantially cylindrical shape, as illustrated in FIG. 2. In addition, the first inner wall 46 may comprise an inner diameter D6 (See FIG. 5B) extending from one side of the first inner wall 46 to an opposite side of the first inner wall 46 and crossing the longitudinal axis LL, and the second inner wall 48 may comprise an inner diameter D7 (See FIG. 5A) extending from one side of the second inner wall 48 to an opposite side of the second inner wall 48 and crossing the longitudinal axis LL.

[0033] Referring again to FIG. 2, the first rotary drive 22 can be housed in the first chamber 12A of the housing 12 and can be rotatably supported therein. To accommodate the first rotary drive 22, as illustrated in FIG. 5B, the inner diameter D6 of the first inner wall 46 may be sufficiently greater than an outer diameter D5 of the first rotary drive 22 to provide sufficient clearance for the rotation of the first rotary drive 22 within the first chamber 12A of the housing 12. For example, the diameter D6 can be 1-3 mm greater than the diameter D5. In certain examples, the first inner wall 46 of the chamber 12A and/or the outer wall 30 of the first rotary drive 22 may be in contact with each other and may be each coated with a friction reducing material such as, for example, Polytetrafluoroethylene (PTFE) or other friction reducing materials. In certain examples, the first rotary drive 22 may be rotatably supported within the chamber 12A by conventional bearing arrangement(s). Other means for reducing friction between the inner wall 46 of the first chamber 12A and the outer wall 30 of the first rotary drive 22 are contemplated by the present disclosure. Furthermore, as illustrated in FIG. 2, the first chamber 12A may include a proximal wall 50 and a distal wall 52 to mechanically constrain the first rotary drive 22 from translating in any direction. As illustrated in FIG. 2, the proximal wall 50 and the distal wall 52 can be separated by a distance L1 which can be slightly greater than a length L2 of the first rotary drive 22 to allow sufficient clearance for the first rotary drive 22 to be rotatably supported within the chamber 12A. In addition, the inner surfaces of the walls 50 and 52 can be coated with a friction reducing material such as, for example, Polytetrafluoroethylene (PTFE) or other suitable materials to reduce friction between these surfaces and the first rotary drive 22.

[0034] Referring primarily to FIGS. 2-3, the second rotary drive 26 can be housed or at least partially housed in the second chamber 12B and can be rotatably supported within the second chamber 12B. The motor 14 can be seated or at least partially seated within the second rotary drive 26, as illustrated in FIG. 2, and the second rotary drive 26 can be rotatably supported around the motor 14. As described above, the diameter D2 of the inner wall 38 of second rotary drive 26 may be greater than the diameter D1 of the outer wall 15 of the motor 14. In certain examples, the diameter D2 may be sufficiently greater than the diameter D1 to provide sufficient clearance for the rotation of the second rotary drive 26 relative to the motor 14. For example, the diameter D2 can be 1-3 mm greater than the diameter D1. In certain examples, the outer wall 15 of the motor 14 and the inner wall 38 of the second rotary drive 26 may be in contact with each other and may each be coated with a friction reducing material such as, for example, Polytetrafluoroethylene (PTFE) which may reduce friction between the outer wall 15 of the motor 14 and the inner wall 38 of the second rotary drive 26 when the second rotary drive 26 is rotated relative to the motor 14. In certain examples, the second rotary drive 26 may rotatably supported relative to the motor 14 by conventional bearing arrangement(s). Other means for reducing friction between the inner wall 38 of the second rotary drive 26 and the outer wall 15 of the motor 14 are contemplated by the present disclosure.

[0035] In certain circumstances, as illustrated in FIG. 2, at least a proximal portion of the motor assembly 13 and/or a proximal portion of the second rotary drive 26 may extend into and can be accommodated within the first rotary drive 22. Furthermore, the first axial drive 24 and/or the second axial drive 28 can extend, or at least partially extend, between the first rotary drive 22 and the second rotary drive 26, as illustrated in FIG. 2, which may reduce the size of the power module 10. In addition, the first axial drive 24 and/or the second axial drive 28 can be movably supported through the housing 12. In certain circumstances, the first axial drive 24 may include two lateral flanges 54 which may extend longitudinally along a length of the first axial drive 24 and may be movably supported within two opposing recesses 56 extending longitudinally through opposing walls of the second chamber 12B. Similarly, the second axial drive 28 may include two lateral flanges 58 which may extend longitudinally along a length of the second axial drive 28 and may be movably supported within two opposing recesses 60 extending longitudinally through opposing walls of the second chambers 12B.

[0036] As described above, the first axial drive 24 can be threadedly engaged with the first rotary drive 22 such that the first axial drive 24 may be extended or retracted in response to the rotational motions of the first rotary drive 22. The pitch, angle, and/or, number of starts of the thread 36 of the first rotary drive 22 may be selected to control the direction, speed, magnitude, and/or duration of the translation of the first axial drive 24. Similarly, the second axial drive 28 can be threadedly engaged with the second rotary drive 26 such that the second axial drive 28 may be extended or retracted in response to the rotational motions of the second rotary drive 26. The pitch, angle, and/or, number of starts of the thread 42 of the second rotary drive 26 may be selected to control the direction, speed, magnitude, and/or duration of the translation of the second axial drive 28.

[0037] Referring primarily to FIG. 4, the motor assembly 13 may transmit the rotational motions generated by the motor 14 to the transmission assembly 20. For example, the motor assembly 13 may include a motor coupling 62 which can be coupled to a motor output shaft 64. In addition, the motor coupling 62 can be operably coupled to a transmission shaft 66 which may be configured to transmit the rotational motions generated by the motor 14 to the transmission assembly 20. For example, as illustrated in FIG. 4, the motor coupling 62 may include a hollow proximal portion which may include a proximal annular wall 68 disposed around the longitudinal axis LL. A plurality of axially extending splines 70 can be spaced around the annular wall 68 and may protrude inwardly toward the longitudinal axis LL. In addition, a distal portion 72 of the transmission shaft 66 may also include a plurality of axially extending splines 74 spaced around an outer wall of the distal portion 72 of the transmission shaft 66. The splines 74 may protrude outwardly from the outer wall of the distal portion 72 and away from the longitudinal axis LL. In certain examples, the motor 14 can be operably disconnected from the transmission assembly 20 by retracting the transmission shaft 66 thereby disengaging the splines 74 from matting engagement with the splines 70 of the motor coupling 62. Such arrangement can be advantageous in allowing manual manipulation of the power module 10, for example, if the motor 10 seizes during operation.

[0038] In use, the distal portion 72 of the transmission shaft 66 can be received within the hollow proximal portion 68 of the motor coupling 62 to bring the splines 72 into mating engagement with the splines 74 such that the rotational motions generated by the motor 14 may be transmitted through the motor coupling 62 to the transmission shaft 66 when the splines 72 and 74 are in mating engagement. The reader will appreciate that the motor output shaft 64 can be adapted to work as a transmission shaft thereby nullifying the need for a motor coupling.

[0039] Referring to FIGS. 3 and 4, the transmission assembly 20 may include a transmission member 76 configured to receive the rotational motions generated by the motor 14 from the transmission shaft 66 and to selectively transmit such rotational motions to the first rotary drive 22 or the second rotary drive 26. The transmission member 76 may be selectively movable along the longitudinal axis LL to a first position, a neutral position, and/or a second position, for example. In the first position, as illustrated in FIG. 5, the transmission member 76 may be operably engaged with the first rotary drive 22 such that the rotational motions generated by the motor 14 may cause the first rotary drive 22 to rotate thereby causing the first axial drive 24 to translate in a proximal direction or a distal direction depending on the direction of rotation of the motor 14. In the second position, as illustrated in FIG. 9, the transmission member 76 may be operably engaged with the second rotary drive 26 such that the rotational motions generated by the motor 14 may cause the second rotary drive 26 to rotate thereby causing the second axial drive 28 to translate in a proximal direction or a distal direction depending on the direction of rotation of the motor 14. Furthermore, in the neutral position, as illustrated in FIG. 8, the transmission member 76 may not be operably engaged with either the first rotary drive 22 or the second rotary drive 26. The neutral position could be located along the longitudinal axis LL between the first position and the second position such that the transmission member 76 can be slidably moved distally from the first position to the neutral position and from the neutral position to the second position, for example. The transmission member 76 can also be slidably moved proximally from the second position to the neutral position and from the neutral position to the first position, for example. Operably disconnecting the motor 14 from the first rotary drive 22 and the second rotary drive 26 by placing the transmission member 76 in the neutral position may provide an advantage of permitting manual manipulation of the power module 10. For example, if the motor 14 seizes during operation, an operator may move the transmission member 76 to the neutral position and manually move the first rotary drive 22 and/or the second rotary drive 26 to a default position.

[0040] Referring to FIGS. 3 and 4, the transmission member 76 may comprise a gear assembly 78 at a distal portion thereof, for example. The gear assembly 78 may include a distal facing gear portion 80 and a proximal facing gear portion 82. In addition, the first rotary drive 22 may include an annular wall 84 at a proximal portion thereof, as illustrated in FIG. 3, for example. The annular wall 84 may be disposed around the longitudinal axis LL and may include a gear portion 86 protruding distally therefrom. The gear portion 86 may be configured to mesh with the proximal facing gear portion 82 when the transmission member 76 is in the first position, as illustrated in FIG. 5. Furthermore, the second rotary drive 26 may include an annular wall 88 at a proximal portion thereof, as illustrated in FIG. 4, for example. The annular wall 88 may be disposed around the longitudinal axis LL and may include a gear portion 90 protruding proximally therefrom, as illustrated in FIG. 4. The gear portion 90 may be configured to mesh with the distal facing gear portion 80 of the when the transmission member 76 is in the second position, as illustrated in FIG. 9.

[0041] As described above, the transmission member 76 can be selectively axially movable among the first position, the neutral position, and the second position. To maintain operable engagement with the transmission shaft 66 in these positions, the transmission member 76 may comprise a hollow inner wall 92 (See FIG. 3) which can be substantially cylindrical in shape and can be configured to slidably receive the transmission shaft 66 which can be keyed to allow rotary coupling with the transmission member 76 such that rotational forces may be coupled from the shaft 66 to the transmission member 76. This arrangement permits the transmission member 76 to slide axially between the first, neutral and second positions while remaining in operable engagement with the transmission shaft 66.

[0042] Referring to FIGS. 3-5, the transmission member 76 can be operably engaged with an actuator 96 via a connector 98 such that the actuator 96 may be actuated to selectively translate the transmission member 76 among the first, the neutral, and the second positions. In certain circumstances, the actuator 96 may comprise a rotatable nut 97 which can be in threaded engagement with a proximal portion of the connector 98, as illustrated in FIG. 3. Furthermore, the connector 98 may be operably coupled with the transmission member 76 in such a manner that allows the transmission member 76 to be freely rotated relative to the connector 98 while permitting the connector 98 to transmit axial motions to the transmission member 76 to move the transmission member 76 axially among the first, neutral, and second positions. For example, the connector 98 may include a hollow distal portion 100 which may comprise an annular wall 102 extending around the longitudinal axis LL and comprising an annular recess 104, as illustrated in FIG. 5. In addition, the transmission member 76 may include an annular flange 106 protruding from a proximal portion thereof away from the longitudinal axis LL and extending around the longitudinal axis LL, as illustrated in FIG. 3. The recess 104 may be configured to receive the annular flange 106 therein, as illustrated in FIG. 5. The annular flange 106 may be freely rotated relative to the recess 104 thereby allowing the transmission member 76 to be freely rotated relative to the connector 98. However, the annular flange 106 may be constrained from axial motion relative to the recess 104 which may permit the connector 98 to transmit axial motions to the transmission member 76.

[0043] Further to the above, as illustrated in FIGS. 7 and 8, the actuator 96 may be rotated in a first direction, for example in a clockwise direction, to cause the connector 98, which is in threaded engagement with the actuator 96, to be translated in the distal direction, for example, which may cause the transmission member 76 to be translated distally from the first position, as illustrated in FIG. 5, to the neutral, position, as illustrated in FIG. 8. In result, the proximal facing gear portion 80 of the gear assembly 78 may be translated distally from the first position into the neutral position and out of meshing engagement with the gear portion 86 of the first rotary drive 22, as illustrated in FIG. 8. In addition, referring to FIGS. 8 and 9, the actuator 96 may be further rotated in the first direction to cause the connector 98 to be translated further in the distal direction. Such additional movement of the connector 98 may result in additional distal movement of the transmission member 76 from the neutral position, as illustrated in FIG. 8, to the second position, as illustrated in FIG. 9. Such movement of the transmission member 76 may cause the distal facing gear portion 80 to move into meshing engagement with the gear portion 90 of the second rotary drive 26.

[0044] To return the transmission member 76 from the second position to the neutral position, the actuator 96 can be rotated in a second direction opposite the first direction, for example in a counterclockwise direction, which may cause the connector 98 to be translated in the proximal direction thereby moving the transmission member 76 proximally to the neutral position and out of meshing engagement with the gear portion 90 of the second rotary drive 26. In addition, to return the transmission member 76 to the first position, the actuator 96 can be further rotated second direction which may cause the connector 98 to be translated further proximally thereby moving the transmission member 76 further proximally to the second position and into meshing engagement with the gear portion 86 of the first rotary drive 22.

[0045] Referring to FIGS. 5-7, as described above in greater detail, the first rotary drive 22 can be housed in the chamber 12A of the housing 12. In certain circumstances, to minimize friction between the first rotary drive 22 and the chamber 12A when the first rotary drive 22 is rotated in response to rotational motions generated by the motor 14, the proximal wall 50 and the distal wall 52 of the chamber 12A, which mechanically constrain the first rotary drive 22 from axial translation, may be sufficiently spaced apart to provide clearance for the rotation the first rotary drive 22. For example, as illustrated in FIG. 5, a clearance distance C is shown between the distal wall 52 and the first rotary drive 22. Accordingly, in such circumstances, the first rotary drive 22 can be slightly axially translated between the proximal wall 50 and the distal 52 within the permitted clearance distance C. However, the clearance distance C may not be so great as to permit the gear portion 86 of the first rotary drive 22 to be unintentionally displaceable out of meshing engagement with the transmission member 76 during operation.

[0046] Further to the above, a biasing member 103 such as, for example, a coil spring may be positioned between the housing 12 and the connector 98, as illustrated in FIG. 5. The biasing member 103 may exert a biasing force against the connector 98 in a proximal direction which may be transmitted to the transmission member 76 and, in turn, to the first rotary drive 22 when engaged with the transmission member 76 in the first position. The biasing force of the biasing member 103 may ensure that the gear portion 86 of the first rotary drive 22 and the transmission member 76 remain meshing engagement during operation while the transmission member 76 is in the first position. In such circumstances, the actuator 98 must overcome the biasing force exerted by the biasing member 103 against the connector 98 in order to successfully translate the connector 98 and, in turn, the transmission 76 distally, for example, to the neutral position which may cause the biasing member to be compressed, as illustrated in FIG. 8.

[0047] As illustrated in FIG. 5, in at least one form, the motor 14 can be affixed to the housing 12. For example, as illustrated in FIG. 5, a distal portion 107 of the motor 14 may be fixedly coupled to a distal portion 108 of the chamber 12B, for example, via screws or other suitable mechanical fasteners 110. Other means for fixing the motor 14 to the housing 12 are contemplated by the present disclosure. In addition, the second rotary drive 26 may be rotatably coupled to the distal portion 108 of the chamber 12B which mechanically constrain the second rotary drive 26 from axial movement. For example, a distal flange 112 may extend around and protrude from a distal portion of the second rotary drive 26, as illustrated in FIG. 5. The distal flange 112 can be rotatably supported and mechanically constrained from axial movement within the distal portion 108 of the chamber 12B.

[0048] Referring now to FIG. 11, an exemplary surgical instrument 200, which can be used with the power module 10, is illustrated. In at least one form, the surgical instrument 200 may include a handle 203, a shaft 204, and an end effector 202 which can be rotated relative to the shaft 204 about the longitudinal axis LL. The end effector 202 is configured to act as an endocutter for clamping, severing and stapling tissue. However, it will be appreciated that various alternative embodiments may include end effectors that are configured to act as other surgical devices including, for example, graspers, cutters, staplers, clip appliers, access devices, drug/gene therapy delivery devices, ultrasound, RF, and/or laser energy devices, etc. See, for example, U.S. Pat. No. 8,322,455, entitled “MANUALLY DRIVEN SURGICAL CUTTING AND FASTENING INSTRUMENT”, the entire disclosure of which is hereby incorporated by reference herein.

[0049] Further to the above, still referring to FIG. 11, the handle 203 of the instrument 200 may include a trigger 214 to actuate the end effector 202. It will be appreciated that instruments having end effectors directed to different surgical tasks may have different numbers or types of triggers or other suitable controls for operating an end effector. The end effector 202 is connected to the handle 203 by shaft 204. It should be appreciated that spatial terms such as vertical, horizontal, right, left etc., are given herein with reference to the figures assuming that the longitudinal axis of the surgical instrument 200 is co-axial to the central axis of the shaft 204, with the trigger 214 extending downwardly at an acute angle from the bottom of the handle 203. In actual practice, however, the surgical instrument 200 may be oriented at various angles and as such these spatial terms are used relative to the surgical instrument 200 itself. Further, proximal is used to denote a perspective of a clinician who is behind the handle 203 who places the end effector 202 distal, or away from him or herself.

[0050] Referring to FIGS. 11, the end effector 202 of the surgical instrument 200 is depicted in a closed configuration, with a staple cartridge 250 positioned within an elongate channel 252. On a lower surface of an anvil 256, a plurality of staple forming pockets may be arrayed to correspond to a plurality of staple cavities 254 including upwardly facing apertures in an upper surface of the staple cartridge 250. A knife bar 258 (See FIG. 12) can be advanced through the cartridge 250 to cut tissue captured between the anvil 256 and the staple cartridge 250. The staple cartridge 250 can include a molded cartridge body 260 that can hold a plurality of staples (not shown) which may rest upon staple drivers (not shown) within the staple cavities 254. A wedge sled (not shown) can be driven distally by I-beam 262, sliding upon a cartridge tray (not shown) that holds together the various components of the replaceable staple cartridge 250. The wedge sled can upwardly cam the staple drivers to force out the staples into deforming contact with the anvil 256 while the knife 258 severs clamped tissue. See, for example, U.S. patent application Ser. No. 13/803,130, entitled “DRIVE TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS”, filed Mar. 14, 2013, now U.S. Pat. No. 9,351,727, the entire disclosure of which is hereby incorporated by reference herein.

[0051] Referring to FIGS. 11 and 12, the elongate channel 252 can be coupled to the handle 203 by means of a spine assembly 206 that may include a proximal spine section 218 and a distal spine section 216 which can be rotatably supported relative to the proximal spine section 218. The elongate channel 252 may be coupled to the distal spine section 218 and may include anvil cam slots that may pivotally receive a corresponding anvil pivot on the anvil 256. In addition, a closure sleeve 208 may be received over the spine assembly 206 and may include a distally presented tab 210 that engages an anvil closure tab on the anvil 256 to thereby effect opening and closing of the anvil 256 by axially moving the sleeve 208 along the longitudinal axis LL and relative to the spine assembly 206. Furthermore, the sleeve 208 can be rotatably coupled to the distal spine section 218 such that the rotation of the sleeve 208 may effect a rotation of the distal spine section 218 and, in turn, the end effector 202 relative to the proximal spine section 218.

[0052] Further to the above, the sleeve 208 may include an annular flange 220 extending around the longitudinal axis LL and protruding from a proximal portion of the sleeve 208, as illustrated in FIG. 12. Furthermore, the flange 220 may be rotatably supported in a slot 222 in a carriage member 224 within the handle 203 such that the sleeve 208 may be freely rotated relative to the carriage member 224 and such that the sleeve 208 may be advanced distally and retracted proximally along the longitudinal axis LL by advancing and retracting the carriage member 224. In addition, the carriage member 224 may be coupled to the first axial drive 26, as illustrated in FIG. 13. Accordingly, rotation of the first rotary drive 22 in a first direction, for example a clockwise direction, may cause the first axial drive 24 to translate distally, as described in greater detail above, which may cause the carriage member 224 and, in turn, the sleeve member 208 to translate distally. In result, the tab 210 of the sleeve 208 may engage the closure tab on the anvil 256 and apply a camming force to the anvil 256 thereby transitioning the end effector 202 from an open configuration to the closed configuration. In certain circumstances, a biasing member (not shown) can be used to maintain the anvil 256 in the open configuration. In such circumstances, the camming force applied by the tab 210 to the anvil 256 as the sleeve 208 is advanced distally must overcome the biasing force of the biasing member to bring the end effector 202 to the closed configuration. Also in such circumstances, the retraction of the sleeve 208 proximally by rotating the first rotary drive 22 in a second direction opposite the first direction may release the anvil 256 thereby allowing the biasing member to move the anvil 256 to the open configuration. The reader will appreciate that other arrangements can be utilized to motivate the anvil 256 to move between the closed configuration and the open configuration in response to the axial motions of the first axial drive 24.

[0053] As described above in greater detail, the second axial drive 28 can be advanced distally and retracted proximally along the longitudinal axis LL in response to rotational motions generated by the motor 14. Referring to FIGS. 13 and 14, the I-beam 262 can be operably coupled to the second axial drive 28 such that the I-beam 262 can be advanced distally to deploy the staples from the staple cartridge 250 and/or cut tissue captured between the anvil 256 and the staple cartridge 250 when the second axial drive 28 is advanced distally and can be retracted proximally when the second axial drive 28 is retracted proximally.

[0054] Referring again to FIG. 13, the second axial drive 28 can be coupled to a firing drive 226 which can be slidably disposed within the proximal spline section 218. In addition, the I-beam 262 can be disposed at a distal portion of a firing bar 230 which can be operably coupled to the firing drive 226 via a connector member 228, wherein the firing bar 230 may be slidably disposed within the distal spline section 216. Furthermore, the firing drive 226 may comprise a tapered distal portion 227 which can be received within a hollow proximal portion of the connector member 228. For example, the tapered distal portion 227 can be designed for snapping engagement with the hollow proximal portion of the connector 227 such that the connector member 228 can be rotated about the longitudinal axis LL relative to the firing drive 226. Furthermore, the connector member 228 may include a slit 231 at a distal portion thereof which may be configured to frictionally receive an upstanding tab 229 disposed at a proximal portion of the firing bar 230. This exemplary arrangement permits axial motions to be transmitted from the second axial drive 28 to the I-beam 262. For example, the second axial drive 28 can be extended distally along the longitudinal axis LL by rotating the second rotary drive 26 in a first direction, for example in a clockwise direction. In turn, the firing drive 226, the connector member 228, and the firing bar 230 may be advanced distally, in response to the advancement of the second axial drive 28, which may cause the I-beam 262 to deploy the staples from the staple cartridge 250 and/or cut tissue captured between the anvil 256 and the staple cartridge 250, for example. In addition, the second axial drive 28 can be retracted proximally along the longitudinal axis LL by rotating the second rotary drive 26 in a second direction opposite the first direction, for example in a counterclockwise direction. In turn, the firing drive 226, the connector member 228, and the firing bar 230 may be retracted proximally, in response to the retraction of the second axial drive 28, which may cause the I-beam 262 to be retracted to a default position.

[0055] Referring primarily to FIG. 13, the power module 10 may be integral with the handle 203 of the surgical instrument 200. For example, as illustrated in FIG. 13, the power module 10 can be disposed in a body portion 207 of the handle 203 along the longitudinal axis LL. In certain examples, as illustrated in FIG. 13, the actuator 96 may be operably coupled to a rotatable knob 234 which can be rotated by an operator to rotate the actuator 96 and, in turn, move the transmission member 76 among the first position, the neutral position, and the second position, as described above. Furthermore, a battery 236 (or “power source” or “power pack”), such as a Li ion battery, for example, may be provided in a pistol grip portion 238 of the handle 203 adjacent to the motor 14 wherein the battery can supply electric power to the motor 14 via a control circuit 240 (See FIG. 14). According to various embodiments, a number of battery cells connected in series may be used as the power source to power the motor 14. In addition, the power source may be replaceable and/or rechargeable. In still other embodiments, the power source may comprise a source of alternate current available in the surgical suite.

[0056] Referring to FIG. 14, the control circuit 240 may comprise a microcontroller 242 which may generally comprise a memory 244 and a microprocessor 246 (“processor”). The processor 246 may be operably coupled to a motor driver 248 which can be configured to control the position, direction of rotation, and velocity of the motor 14. In addition, the control circuit 240 may be operably coupled to a variety of sensors which may, for example, detect the position of the first rotary drive 22, the first axial drive 24, the second rotary drive 26, the second axial drive 28, the I-beam 262, the sleeve 208, the transmission member 76 and/or the anvil 256. The detected position(s) can be communicated to the processor 246. See, for example, U.S. patent application Ser. No. 13/803,130, entitled “DRIVE TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS”, filed Mar. 14, 2013, now U.S. Pat. No. 9,351,727, the entire disclosure of which is hereby incorporated by reference herein.

[0057] In certain circumstances, the microcontroller 242 may be an LM 4F230H5QR, available from Texas Instruments, for example. In one embodiment, the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Core comprising on-chip memory 7006 of 256 KB single-cycle flash memory, or other non-volatile memory, up to 40 MHz, a prefetch buffer to improve performance above 40 MHz, a 32 KB single-cycle serial random access memory (SRAM), internal read-only memory (ROM) loaded with StellarisWare software, 2 KB electrically erasable programmable read-only memory (EEPROM), two pulse width modulation (PWM) modules, with a total of 16 advanced PWM outputs for motion and energy applications, two quadrature encoder inputs (QEI) analog, two 12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels, among other features that are readily available for the product datasheet. Other microcontrollers may be readily substituted for use in the control circuit 240. Accordingly, the present disclosure should not be limited in this context.

[0058] In certain circumstances, the driver 248 may be a A3941 available from Allegro Microsystems, Inc. The A3941 driver 248 can be a full-bridge controller for use with external N-channel power metal oxide semiconductor field effect transistors (MOSFETs) specifically designed for inductive loads, such as brush DC motors. The driver 248 comprises a unique charge pump regulator that provides full (>10 V) gate drive for battery voltages down to 7 V and allows the A3941 to operate with a reduced gate drive, down to 5.5 V. A bootstrap capacitor may be employed to provide the above-battery supply voltage required for N-channel MOSFETs. An internal charge pump for the high-side drive may allow DC (100% duty cycle) operation. The full bridge can be driven in fast or slow decay modes using diode or synchronous rectification. In the slow decay mode, current recirculation can be through the high-side or the lowside FETs. The power FETs are protected from shoot-through by resistor adjustable dead time. Integrated diagnostics provide indication of undervoltage, overtemperature, and power bridge faults, and can be configured to protect the power MOSFETs under most short circuit conditions. Other motor drivers may be readily substituted for use in the motor control circuit 240. Accordingly, the present disclosure should not be limited in this context.

[0059] In certain circumstances, a voltage polarity provided by the battery 236 can operate the electric motor 14 in a clockwise direction wherein the voltage polarity applied to the electric motor 14 by the battery 236 can be reversed in order to operate the electric motor 14 in a counter-clockwise direction. The direction of rotation of the motor 14 may determine the direction of axial motion of the first axial drive 24 when the transmission member 76 is engaged with the first rotary drive 22 and may determine the direction of axial motion of the second axial drive 28 when the transmission member 76 is engaged with the second rotary drive 24.

[0060] Referring to FIGS. 13 and 14, the trigger 214 can be movable between an unactuated position and an actuated position. In addition, the trigger 214 can be operably coupled to a switch 270 which can be electrically coupled to the microcontroller 242 via an electric circuit 272, as illustrated in FIG. 14. The switch 270 can be moved to open or close the circuit 272 when the trigger 214 is moved between the actuated and unactuated positions. For example, the switch 270 can be mechanically coupled to the trigger 214 such that the switch 270 closes the circuit 272 when the trigger 214 is in the actuated position and opens the circuit 272 when the trigger 214 is in the unactuated position. In any event, the closing or opening of the circuit 272 may signal the microcontroller 242 to activate the motor 14 to close or open the end effector 202, as described above.

[0061] In certain circumstances, the trigger 214 may be biased in the unactuated position by a biasing member (not shown). In use, an operator of the surgical instrument 200 may rotate the knob 234 to move the transmission member 76 from the neutral position to the first position into coupling engagement with the first rotary drive 22. The operator may then actuate the trigger 214 to cause the microcontroller 242, for example by moving the switch 270 to close the circuit 272, to activate the motor 14 to close the end effector 202. Upon releasing the trigger 214, the biasing force of the biasing member may return the trigger 214 to the unactuated position thereby moving the switch 270 to open the circuit 272. A second actuation of the trigger 214 by the operator may cause the microcontroller 242 to activate the motor 14 to rotate in a second direction opposite the first direction, for example a counterclockwise direction, to open the end effector 202.

[0062] As with the other forms described herein, the surgical instrument 200 can also include sensors configured to detect the position of the first axial drive 24, direction in which the first axial drive 24 is being moved, the position of the second axial drive 28, and/or the direction in which the second axial drive 28 is being moved. In addition, the surgical instrument 200 can also include sensors configured to detect the position of the transmission member 76. All such information can be communicated to the processor 246 and may be stored in the memory 244.

[0063] Further to the above, an operator may repeat the opening and closing of the end effector 202, as described above, until desired tissue is captured between the anvil 256 and the cartridge 250. The operator may then rotate the knob 234 to move the transmission member 76 into the second position and into coupling engagement with the second rotary drive 26. Upon actuating the trigger 214, the processor 246 may check the memory 244 for the positions of the first axial drive 24, second axial drive 28, and the transmission member 76 to conclude that the end effector is closed and that the transmission member 76 is in the second position. As such, the microcontroller 242 may activate the motor 14 to rotate in a first direction, for example a clockwise direction, to advance the I-beam 262 to fasten and cut the captured tissue, as described above. Upon a second actuation of the trigger 214, the microcontroller 242 may activate the motor 14 to rotate in a second direction opposite the first direction, for example a counterclockwise direction, to retract the I-beam 262 to a default position. To free the fastened tissue, the operator may actuate the trigger 214 to open the end effector 202. Upon receiving the signal from the circuit 272, as described above, the microcontroller 242 may check the memory 244 for the positions of the first axial drive 24, the second axial drive 28, and the transmission member 76. In response, the microcontroller 242 may activate the motor 14 to open the end effector 202, as described above.

[0064] Referring now to FIGS. 15 and 16, a handle 203′ is shown. The handle 203′ is similar to the handle 203 in many respects and is configured for use with a surgical instrument such as, for example, the surgical instrument 200 in a similar manner to the handle 203. In addition, the handle 203′ includes a power module 10′ which is similar in many respects to the power module 10. The power 10′, however, is removably couplable to the handle 203′. As such, the power module 10′ can be used with multiple surgical instruments. For example, upon completion of a surgical procedure, the operator may detach the power module 10′ from the handle 203′ of the surgical instrument 200 which can be disposed of appropriately. The power module 10′ can then be resterilized, for example, and used with a new surgical instrument 200 by inserting the power module 10′ into the handle 203′ of the new surgical instrument 200.

[0065] As illustrated in FIG. 15, the power module 10′ can be separably coupled to the handle 203′. For example, the first axial drive 22 can be separably coupled to the firing drive 226 and the second axial drive 28 can be separably coupled to the carriage member 224. For example, as illustrated in FIG. 16, dovetail joints 274 and 276 may separably couple the first axial drive 22 to a proximal portion of the carriage member 224 and the second axial drive 28 to a proximal portion of the firing drive 226, respectively. Furthermore, the actuator 96 can be designed for snapping engagement with the knob 234. In addition, the motor 14 of the power module 10′ and the driver 248 may be separably couplable to each other via appropriate electrical contacts that provide an electrical path therebetween. Furthermore, the handle 203′ may be configured to include a detachable outer shell which can be removed to give way for inserting and detaching a power module such as, for example, the power module 10′ into operably engagement with the handle 203′.

[0066] In certain examples, a power module for use with a surgical instrument includes an end effector, the power module comprising a first motion conversion assembly which comprises a first rotary drive and a first axial drive operably coupled to the first rotary drive. The power module further comprises a second motion conversion assembly comprising a second rotary drive and a second axial drive operably coupled to the second rotary drive. The power module further comprises a motor configured to generate at least one rotational motion to actuate the end effector and a transmission assembly configured to selectively engage the motor with the first rotary drive and the second rotary drive, wherein the motor is concentrically arranged with the first rotary drive and the second rotary drive.

[0067] In certain examples, a power module for use with a surgical instrument includes an end effector, the power module comprising a first motion conversion assembly which comprises a first rotary drive and a first axial drive operably coupled to the first rotary drive. The power module further comprises a second motion conversion assembly comprising a second rotary drive and a second axial drive operably coupled to the second rotary drive. The power module further comprises a motor configured to generate at least one rotational motion to actuate the end effector, the motor defining an actuation axis and a transmission assembly configured to selectively operably couple the motor to the first rotary drive and the second rotary drive, wherein the first rotary drive is rotatable about the actuation axis in response to the at least one rotational motion when the motor is operably coupled to the first rotary drive, and wherein the second rotary drive is rotatable about the actuation axis in response to the at least one rotational motion when the motor is operably coupled to the second rotary drive.

[0068] In certain examples, a surgical instrument comprises a shaft, a housing extending proximally from the shaft, an end effector extending distally from the shaft, and a power module at least partially positioned within the housing. The power module comprises a first rotary drive, a second rotary drive, a motor configured to generate at least one rotational motion, the motor defining an actuation axis, and a transmission assembly configured to selectively operably couple the motor to the first rotary drive and the second rotary drive, wherein the first rotary drive is rotatable about the actuation axis in response to the at least one rotational motion when the motor is operably coupled to the first rotary drive, wherein the second rotary drive is rotatable about the actuation axis in response to the at least one rotational motion when the motor is operably coupled to the second rotary drive, and wherein the motor extends along the actuation axis.

[0069] The reader will appreciate that the compact nature of the power modules described herein such as, for example, the power module 10 may be advantageous for use in a surgical setting. These power modules can be a source for a plurality of reciprocating axial motions which may serve a variety of functions in a surgical instrument such as, for example, the surgical instrument 200. In addition, the power modules described herein such as, for example, the power module 10′ may possess the additional advantage of being available for use with multiple surgical instruments. The ability to retrieve, resterilize, and reuse the power module 10′ can provide an advantageous cost saving.

[0070] Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

[0071] While this invention has been described as having exemplary designs, the present invention may be further modified within the spirit and scope of the disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.