Coupling member configured for use with surgical devices

[0001] Technical Field

[0002] The present disclosure relates to a coupling member for coupling an actuating device to a removable tool assembly. More specifically, the present disclosure relates to a coupling member including a locking assembly for securing a surgical actuating device to a disposable loading unit or reload of a surgical apparatus.

[0003] Description of Related Art

[0004] Surgical apparatus including a surgical actuating device and a disposable single use or multiple use loading unit or reload are known. Typically, during a surgical procedure, a reload, which may be in the form of a stapler, clip applier or the like, is connected to a surgical actuating device to perform a surgical procedure. After the surgical procedure is completed, the spent reload may be replaced with a fresh reload to facilitate performance of another surgical procedure.

[0005] During surgical procedures, it is imperative that the reload be securely fastened to the surgical actuating device in a manner to prevent separation of the reload from the surgical actuating device during actuation of the reload. It is also important that the reload be capable of attachment to and detachment from the surgical actuating device quickly.

[0006] As can be appreciated, an electromechanical surgical device including a tool assembly that is easy to install and configured to lock when the electromechanical surgical device is fired may prove useful in the surgical arena.

[0007] Embodiments of the present disclosure are described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. As used herein, the term “distal” refers to the portion that is being described which is further from a user, while the term “proximal” refers to the portion that is being described which is closer to a user.

[0008] An aspect of the present disclosure provides a surgical apparatus. The surgical actuating device including a shaft having a distal end supporting a first coupling member. The first coupling member including one or more pairs of aperture. A reload includes a tool assembly. The reload includes a second coupling member including a locking assembly. The second coupling member including a pair of spring pins that are positioned to be received within the at least one pair of apertures. The spring pins being movable from an inward position to a radial outward position. The locking assembly including a lock plate that is moveable from a first position located between the spring pins to prevent movement of the spring pins from the radial outward position to the inward position to a second position spaced from the spring pins. In the radial outward position, the spring pins are received within the apertures of the first coupling member to secure the reload to the surgical actuating member and wherein when the lock plate is in the first position, the reload cannot be separated from the surgical actuating device. The surgical actuating device may be electromechanically actuated.

[0009] The second coupling member may include an axle for supporting one or more springs and the pair of spring pins. The spring(s) may be positioned between the pair of spring pins and configured to bias the pair of spring pins to the radial outward position. Each of the spring pins of the second coupling member may include a tapered outer peripheral edge. Contact between the tapered outer edges of the spring pins and an outer edge of the first coupling member cams the spring pins inwardly against the bias of the spring(s).

[0010] The lock plate may include one or more hinges that pivotably couple the lock plate to an internal surface of the tool assembly of the reload. The lock plate may include a clevis at a top portion thereof. The clevis may be configured to connect to a proximal end of a plunger of the locking assembly. The plunger may support a spring for biasing the lock plate into engagement with the pair of spring pins when a knife of a cartridge of the tool assembly is fired.

[0011] The first coupling member may include two or more pairs of apertures. Each of the pairs of apertures may be configured to engage the pair of spring pins. The two pairs of apertures may be oriented orthogonally in relation to one another.

[0022] Detailed embodiments of the present disclosure are disclosed herein; however, the disclosed embodiments are merely examples of the disclosure, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure.

[0023] Referring initially to FIG. 1, a reload 10 in accordance with the present disclosure is shown. Reload 10 may be configured to be coupled to a variety of different surgical actuating devices, shown schematically as 11 in FIG. 1, including manually operated actuation devices, robotically controlled actuation devices, electromechanical actuation devices, motorized actuation devices, etc. The reload 10 supports an end effector or tool assembly 14 which can be in the form of a stapler, clip applier, grasper or the like.

[0024] The surgical actuating device 11 includes a shaft assembly 12 which includes a distal end supporting a first coupling member 36 configured to releasably support the reload 10. In one embodiment, the tool assembly 14 is in the form of a stapler and includes a first jaw member 19 supporting an anvil 21 and a second jaw member 23 supporting a cartridge 25. In any of the embodiments disclosed herein, the cartridge 25 may be removably couplable to the second jaw member 23.

[0025] Referring to FIGS. 1-5, the first coupling member 36 is supported at the distal end 15 of the shaft assembly 12 and is configured to be removably coupled to a second coupling member 51 (FIG. 5) of the of the reload 10 to releasably couple the reload 10 to the surgical actuating device 11. The first coupling member 36 includes a collar 40 which includes two pairs of spaced apart apertures 42a, 42b that are oriented orthogonally with respect to one another. The apertures 42a, 42b are arranged to allow a user to couple the reload 10 to the shaft assembly 12 in at least two different positions relative to the distal end 15 of the shaft assembly 12. In embodiments, the apertures 42a, 42b may be tapered, beveled for reasons to be discussed in further detail below.

[0026] As noted above, the reload 10 may be configured for use with various surgical instruments. For example, in an embodiment, the reload may be configured for use with a surgical instrument that utilizes electromechanical linear driven actuation. In this particular embodiment, a pair of output drives 44a, 44b may be provided within the coupling member 36 and may be oriented 90 degrees from one another to engage the reload 10 when the reload 10 is coupled to the coupling member 36. The output drives 44a, 44b may be spaced 90 degrees from one another to give a clinician the flexibility to position the rotatably secure the reload 10 to the shaft assembly 12 by rotating the reload 10 in either a clockwise or counter clockwise direction in relation to the shaft assembly 12 as will be discussed in further detail below. In any of the embodiments disclosed herein, the apertures 42a and 42b can be spaced a different angular distance from one another, and the output drives arranged accordingly, so as to provide the surgeon with different orientation of the tool assembly with respect to the shaft of the instrument.

[0027] Referring to FIGS. 4-5, the reload 10 includes a second coupling member 51. Coupling member 51 includes a pair of spring pins 52a, 52b which are configured to be received within a respective one of the pairs of apertures 42a or 42b defined in the first coupling member 36 for removably coupling the reload 10 to the distal end 15 of the shaft assembly 12. Each of the spring pins 52a, 52b can have a tapered outer peripheral edge 54a, 54b and an annular flange 56a, 56b. The pair of spring pins 52a, 52b is positioned on an axle 58. A biasing member, e.g., a spring 60, is positioned about each axle 58 and includes a first end which abuts a respective annular flange 56a, 56b and a second end which abuts a clevis 64 (FIG. 7) to bias the pair of spring pins 52a, 52b radially outwardly for reception within apertures 42a, 42b of first coupling member 36. The spring pins 52a, 52b are deflectable inwardly against the bias of the spring 60 when the proximal end of reload 10 is inserted into the first coupling member 36. More specifically, when the reload 10 is inserted into the first coupling member 36, the tapered edges 54a, 54b of pins 52a, 52b engage an outer wall of the first coupling member 36 and are cammed inwardly to allow passage of the second coupling member 51 into the first coupling member 36. Prior to positioning the second coupling member 51 within the first coupling member 36, the reload 10 may be rotated in relation to the shaft assembly 12 to align pins 52a, 52b with one of the pair of apertures 42a, 42b defined in the first coupling member 36 such that pins 52a, 52b are received within a respective pair of apertures 42a, 42b. As noted above, the apertures 42a, 42b may tapered, beveled or otherwise configured to guide the spring pins 52a, 52b into one of the corresponding pairs of apertures 42a, 42b on the first coupling member 36.

[0028] Referring to FIGS. 4-7, the second coupling member 51 also includes a lock assembly which includes a lock plate 48 and a plunger 50. The lock plate 48 includes a pair of left and right hinges 62a, 62b that are pivotably coupled to an internal surface 45 of the tool assembly 14 (as best seen in FIG. 6). Alternatively, a single hinge, living hinge or any structure capable of pivotally supporting the lock plate 48 adjacent the proximal end of the reload 10 may be provided to pivotally support the lock plate 10. In the illustrated embodiment, the lock plate 48 is pivotable about the hinges 62a, 62b from a first unlocked position (FIG. 7) to a second locked position (FIGS. 6 and 8). In the locked position, left and right sidewalls 47a, 47b of the lock plate 48 are positioned between the annular flanges 56a, 56b of spring pins 52a, 52b of the second coupling member 51. In this position, lock plate 48 prevents the spring pins 52a, 52b from moving radially inward and, thus, prevents pins 52a, 52b from exiting the apertures 42a, 42b to prevent separation of the reload 10 from the shaft assembly 12. In the unlocked position, the left and right sidewalls 47a, 47b of the lock plate 48 are not positioned between the annular flanges 56a, 56b of the spring pins 52a, 52b of the second coupling member 51. In this position, the spring pins 52a, 52b are capable of inward movement. A clevis 64 is provided at a top portion 49 of the lock plate 48 and is configured to connect to a proximal end 66 of the plunger 50 to the lock plate 48. The clevis 64 may be connected to the proximal end 66 of the plunger 50 via a pin, detent/indent configuration or other suitable connection method.

[0029] The plunger 50 includes an elongated body portion 68 that supports a flange 70 at a distal end thereof. The flange 70 is configured to contact a proximal end of a knife 72 (or clamping member) when the knife 72 is disposed in a proximal most position (see FIG. 7 for example). For a more detailed discussion of the knife 72 and other components of the reload (or loading unit), see U.S. Pat. No. 5,865,361 ('361 patent) which is incorporated herein by reference. A spring 74 is supported about the elongated body portion 68 of the plunger 50 between the flange 70 and an inner wall 70a (FIG. 8) of the reload housing 10a to urge the plunger 68 distally such that flange 70 abuts the knife 72. By biasing plunger 68 distally, lock plate 48 is urged towards the locked position (FIG. 8) between the spring pins 52a, 52b. When the knife 72 is in its proximal-most position, lock plate 48 is prevented from moving to the locked position. As such, when the knife 72 is in its proximal-most position, the reload 10 can be disengaged from the shaft assembly 12 of the surgical actuating device 11.

[0030] Referring to FIGS. 6-7, as noted above, the surgical actuating device can include an electromechanical linear driven actuation. To this end, the reload 10 can include an input drive 76 at a proximal end of the tool assembly 14 which is configured to selectively engage either one of the output drives 44a, 44b included at the distal end of shaft assembly 12 adjacent the first coupling member 36. In the illustrated embodiment, the input drive 76 includes a hexagonal fitting that is received within a hexagonal recess of the output drives 44a, 44b. The input drive 76 can be connected to either of the output drives 44a, 44b depending on the orientation of the reload 10 in relation to the shaft assembly 12.

[0031] For illustrative purposes, operation of the reload 10 is now described in association with an electromechanical, hand-held surgical stapling apparatus 100 (apparatus 100) shown in FIG. 9. It is noted that the coupling member 51 of reload 10 can be used to couple reload 10 to a variety of different surgical actuating devices 11 as discussed above.

[0032] Briefly, apparatus 100 includes a handle 118 that defines a nose or connecting portion 126 configured to releasably engage the proximal end 13 of the shaft assembly 12. Alternatively, the handle 118 and the shaft assembly 12 can be fixedly connected. A drive mechanism (not shown) is configured to drive the output drives 44a, 44b of shaft assembly 12 to actuate the tool assembly 14 to effect movement of anvil 19 and/or to fire the staples and sever tissue. This operation is described in detail in U.S. patent application Ser. Nos. 12/622,827, 13/769,419 which are incorporated herein by reference. In any of the embodiments disclosed herein, the shaft assembly can be removable and replaceable and can correspond to the particular reload being used (such as clip applier, electrosurgical, stapler configurations, etc.) or the shaft assembly can be permanently attached to the handle.

[0033] In use, the knife 72 of the cartridge 23 is initially positioned at a proximal end of the cartridge 23. The cartridge 23 can be installed onto a jaw member of the tool assembly 14 (FIG. 7) or, in the alternative, can be fixedly supported on the jaw member of the reload 10. In this position, the plunger 50 of the locking assembly 46 is biased proximally, which, in turn, maintains the lock plate 48 in the unlocked configuration, i.e., the lock plate 48 is positioned proximally of annular flanges 56a, 56b of the spring pins 52a, 52b such that inward movement of the spring pins 52a, 52b is permitted. In this configuration, a proximal end of the tool assembly 14 can be inserted into the first coupling member 36 so that the spring pins 52a, 52b of the second coupling member 51 are received within the pair of apertures 42a, 42b on the first coupling member 36. As can be appreciated, engagement of the tapered peripheral edges 54a, 54b of the spring pins 52a, 52b with the outer edge of the first coupling member 36 cams the spring pins 52a, 52b inwardly against the bias of the spring 60. This allows the first coupling member 36 to move into the second coupling member 51 to move the spring pins 52a, 52b of the second coupling member 51 into the apertures 42a, 42b of the first coupling member 36 to secure the reload 10 to the shaft assembly 12.

[0034] When the apparatus 100 is fired to staple tissue, the knife 72 moves out of engagement with the flange 70. When this occurs, the spring 74 urges the plunger 50 distally such that the lock plate 48 of the locking assembly 46 pivots about the hinges 62a, 62b and moves between the inside flange portions 56a, 56b of the spring pins 52a, 52b (FIGS. 6 and 8). In this configuration, the spring pins 52a, 52b are prevented from inward movement. Thus, spring pins 52a, 52b cannot be removed from apertures 42a, 42b and reload 10 cannot be disengaged from the shaft assembly 12.

[0035] Thereafter, the knife 72 may be returned to the proximal most position, which, in turn, moves the lock plate 48 proximally from between the spring pins 52a, 52b and out of the locked configuration. In this position, a user can remove the tool assembly 17 from the first coupling member. As noted above, the tapered peripheral edges 54a, 54b of the spring pins 52a, 52b facilitate biasing the spring pins 52a, 52b inwardly against the bias of the spring 60 as the spring pins 52a, 52b are moved into and out of engagement with the apertures 42a, 42b, which, in turn, allows the spring pins 52a, 52b to slide out of engagement with the apertures 42a, 42b with a simple axial motion.

[0036] The unique configuration of the locking assembly 46 and spring pins 52a, 52b overcome the aforementioned drawbacks, typically, associated with conventional staplers that are configured for use with removably couplable tool assemblies. That is, the tool assembly 14 is maintained in a locked configuration on at the distal end 15 of the shaft assembly 12 when the apparatus 100 is fired, and the tool assembly 14 can be installed to the first coupling member 36 with a simple straight push/pull motion.

[0037] From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications can also be made to the present disclosure without departing from the scope of the same. For example, one or more sensors 78 (FIG. 4) may be provided in and/or on the first coupling member 36 to detect when the tool assembly 14 is coupled to the first coupling member 36. In this embodiment, the sensor 78 may communicate with one or more components associated with any of the aforementioned surgical devices.

[0038] Moreover, the first coupling member 36 of the reload 10 may be modified to receive different linear drive mechanisms. For example, in an embodiment, the reload 19 may be configured to connect to a manually actuatable surgical stapling device that utilizes a drive beam configured to translate within a staple cartridge to fire a sled of the staple cartridge. In this embodiment, for example, the first coupling member 36 may include an aperture, slot or channel configured to receive the drive beam therethrough when the manually actuatable surgical stapling device is fired.

[0039] While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.