US 9,801,646 B2Grant

Adapter load button decoupled from loading unit sensor

Issue Date:2017-10-31

•17 Claims

•31 Drawing Sheets

Abstract

A surgical device is provided. The surgical device includes: a jaw assembly comprising a first jaw and a second jaw moveable relative to the first jaw and an elongated body removably coupled to a proximal end of the jaw assembly. The elongated body includes an actuation bar movable upon engagement of the jaw assembly with the elongated body to secure the jaw assembly thereto; a release button coupled to the actuation bar such that the release button is movable by the actuation bar upon engagement of the jaw assembly with the elongated body and the release button is configured to move the actuation bar to allow for removal of the jaw assembly from the elongated body; and a lockout button in mechanical cooperation with the release button, the lockout button configured to prevent actuation of the release button.

Metadata

Assignee

Covidien LP

Inventors

Earl M. Zergiebel
Russell Pribanic
David Chowaniec
Ryan V. Williams
Jonathan W. Sapienza

Application Information

Application Number:US 14/274,173

Filing Date:2014-05-09

Priority Date:2013-05-30

Art Unit:3766

Classifications

IPC:

A61B17/00A61B17/32A61B17/28A61B17/072A61B17/29A61B90/00

Field of Search:

A61B 17/320016A61B 17/07207A61B 17/28A61B 2017/0046A61B 2017/00398A61B 2017/00464A61B 2017/00473A61B 2017/00477A61B 2017/00734A61B 2017/2808A61B 2017/2946

Patent Drawings (31 sheets)

Description

Cross-Reference to Related Applications

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/828,726, filed May 30, 2013, the entire disclosure of which is incorporated by reference herein.

Background

[0002] 1. Technical Field

[0003] The present disclosure relates to surgical apparatuses, devices and/or systems for performing endoscopic surgical procedures and methods of use thereof. More specifically, the present disclosure relates to electromechanical, hand-held surgical apparatuses, devices and/or systems configured for use with removable disposable loading units and/or single use loading units for clamping, cutting and/or stapling tissue.

[0004] 2. Background of Related Art

[0005] A number of surgical device manufacturers have developed product lines with proprietary drive systems for operating and/or manipulating electromechanical surgical devices. In many instances the electromechanical surgical devices include a reusable handle assembly, and disposable or single use loading units. The loading units are selectively connected to the handle assembly prior to use and then disconnected from the handle assembly following use in order to be disposed of or in some instances sterilized for re-use.

[0006] Many of the existing end effectors for use with many of the existing surgical devices and/or handle assemblies are driven by a linear force. For examples, end effectors for performing endo-gastrointestinal anastomosis procedures, end-to-end anastomosis procedures and transverse anastomosis procedures, each typically require a linear driving force in order to be operated. As such, these end effectors are not compatible with surgical devices and/or handle assemblies that use a rotary motion to deliver power or the like.

[0007] In order to make the linear driven end effectors compatible with surgical devices and/or handle assemblies that use a rotary motion to deliver power, a need exists for adapters and/or adapter assemblies to interface between and interconnect the linear driven end effectors with the rotary driven surgical devices and/or handle assemblies that include locking and release mechanisms for coupling to the end effectors.

Summary

[0008] Further details and aspects of exemplary embodiments of the present invention are described in more detail below with reference to the appended Figures.

[0009] According to an embodiment of the present disclosure, a surgical device adapter for coupling an end effector to a handle assembly is disclosed. The surgical device adapter includes: a sensor link assembly engagable by the end effector upon coupling the end effector to the surgical device adapter; a load link movable by the end effector from a first position to a second position, wherein in the second position the load link locks the sensor link assembly and in the first position releases the sensor link assembly; and a sensor engagable by the sensor link assembly upon proximal movement thereof in response to release by the load link.

[0010] According to another aspect of the present disclosure, the load link is distally biased and is configured to prevent proximal movement of the sensor link assembly until the load link is distally biased and the end effector is coupled to the surgical device adapter.

[0011] According to another aspect of the present disclosure, the surgical device adapter further includes a lock spring actuatable by proximal movement of the load link, the lock spring configured to couple to a proximal portion of the sensor link assembly and prevent proximal movement thereof.

[0012] According to another aspect of the present disclosure, the sensor link assembly includes a proximal sensor link, a distal sensor link and a biasing member disposed therebetween.

[0013] According to another aspect of the present disclosure, the proximal sensor link includes a ring configured to interface with the lock spring.

[0014] According to another aspect of the present disclosure, the adapter includes a bayonet connection at a distal end thereof configured to couple to a pair of lugs of the end effector.

[0015] According to another aspect of the present disclosure, the end effector is configured to be inserted linearly into the bayonet connection.

[0016] According to another aspect of the present disclosure, load link is moved proximally to allow for rotation of lugs within the bayonet connection.

[0017] According to another aspect of the present disclosure, at least one lug of the pair of lugs engages the distal sensor link upon rotation of the end effector within the bayonet connection thereby compressing the biasing member.

[0018] According to another aspect of the present disclosure, the load link is moved distally to secure at least one lug of the pair of lugs within the bayonet connection.

[0019] According to another aspect of the present disclosure, distal movement of the load link releases the lock spring allowing the biasing member to move the proximal sensor link proximally to engage the sensor.

[0020] According to another embodiment of the present disclosure, a method an end effector to a surgical device adapter. The method includes the steps of: inserting an end effector including a pair of lugs disposed at a proximal end thereof into a distal end of the surgical device adapter; proximally moving a distally-biased load link within the surgical device adapter to secure a sensor link assembly; rotating the end effector within the adapter assembly, wherein at least one lug of the pair of lugs engages and secured at least a portion of the sensor link assembly; and distally moving the load link to secure the end effector within the surgical device adapter and to release the sensor link assembly allowing the sensor link assembly to move proximally to engage a sensor.

[0021] According to another aspect of the present disclosure, the sensor link assembly includes a distally-biased proximal sensor link, a distal sensor link, and a biasing member disposed therebetween.

[0022] According to another aspect of the present disclosure, moving the load link proximally secures the proximal sensor link.

[0023] According to another aspect of the present disclosure, rotating the end effector engages at least one lug of the pair of lugs engages the distal sensor link thereby compressing the biasing member.

[0024] According to another aspect of the present disclosure, moving the load link distally secures at least one lug of the pair of lugs to release the proximal sensor link allowing the biasing member to move the proximal sensor link proximally to engage the sensor.

[0025] According to another aspect of the present disclosure, the load link is coupled to the sensor link assembly via a biasing member at proximal ends thereof.

Brief Description of the Drawings

[0026] Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:

[0027] FIG. 1 is a perspective, disassembled view of an electromechanical surgical system including a surgical instrument, an adapter assembly, and an end effector, according to the present disclosure;

[0028] FIG. 2 is a perspective view of the surgical instrument of FIG. 1, according to the present disclosure;

[0029] FIG. 3 is perspective, exploded view of the surgical instrument of FIG. 1, according to the present disclosure;

[0030] FIG. 4 is a perspective view of a battery of the surgical instrument of FIG. 1, according to the present disclosure;

[0031] FIG. 5 is a top, partially-disassembled view of the surgical instrument of FIG. 1, according to the present disclosure;

[0032] FIG. 6 is a front, perspective view of the surgical instrument of FIG. 1 with the adapter assembly separated therefrom, according to the present disclosure;

[0033] FIG. 7 is a side, cross-sectional view of the surgical instrument of FIG. 1, as taken through 7-7 of FIG. 1, according to the present disclosure;

[0034] FIG. 8 is a top, cross-sectional view of the surgical instrument of FIG. 1, as taken through 8-8 of FIG. 1, according to the present disclosure;

[0035] FIG. 9 is a perspective, exploded view of a control assembly of the surgical instrument of FIG. 1, according to the present disclosure;

[0036] FIG. 10 is a perspective view of the adapter assembly of FIG. 1, according to the present disclosure;

[0037] FIG. 11 is a perspective, exploded view of the adapter assembly of FIG. 1, according to the present disclosure;

[0038] FIG. 12 is a perspective, exploded view of a coupling assembly of the adapter assembly of FIG. 1, according to the present disclosure;

[0039] FIG. 13 is a perspective, exploded view of a drive transmitting assembly of the adapter assembly of FIG. 1, according to the present disclosure;

[0040] FIG. 14 is a side, cross-sectional view of the adapter assembly of FIG. 1, according to the present disclosure;

[0041] FIG. 15 is a top, cross-sectional view of the adapter assembly of FIG. 1, according to the present disclosure;

[0042] FIG. 16 is an enlarged, side, cross-sectional view of a proximal area of detail of the adapter assembly of FIG. 1, according to the present disclosure;

[0043] FIG. 17 is an enlarged, top, cross-sectional view of the proximal area of detail of the adapter assembly of FIG. 1, according to the present disclosure;

[0044] FIG. 18 is an enlarged, side, cross-sectional view of a distal area of detail of the adapter assembly of FIG. 1, according to the present disclosure;

[0045] FIG. 19 is an enlarged, top, cross-sectional view of the distal area of detail of the adapter assembly of FIG. 1, according to the present disclosure;

[0046] FIG. 20 is an enlarged perspective view, with parts separated, of a coupling cuff of the adapter assembly illustrated in FIG. 13;

[0047] FIG. 21 is a perspective, exploded view of a end effector of FIG. 1, according to the present disclosure;

[0048] FIG. 22 is a perspective, partially-disassembled view of the adapter assembly of FIG. 1, according to the present disclosure;

[0049] FIG. 23 is a perspective view of a load link of the adapter assembly of FIG. 1, according to the present disclosure;

[0050] FIG. 24 is a perspective view of a proximal portion of the load link of FIG. 23, according to the present disclosure;

[0051] FIG. 25 is a perspective view of a proximal sensor link of the adapter assembly of FIG. 1, according to the present disclosure;

[0052] FIG. 26 is a perspective view of a proximal portion of the proximal sensor link of FIG. 25, according to the present disclosure;

[0053] FIG. 27 is a perspective view of a seal spacer of the adapter assembly of FIG. 1, according to the present disclosure;

[0054] FIG. 28 is a perspective view of a lock spring of the adapter assembly of FIG. 1, according to the present disclosure;

[0055] FIG. 29 is an enlarged, perspective, partially-disassembled view of a proximal portion of the adapter assembly of FIG. 1 in an unloaded configuration, according to the present disclosure;

[0056] FIG. 30 is a perspective view of a distal tip housing of the adapter assembly of FIG. 1, according to the present disclosure;

[0057] FIG. 31 is an enlarged, perspective, partially-disassembled view of a distal portion of the adapter assembly of FIG. 1 in the unloaded configuration, according to the present disclosure;

[0058] FIG. 32 an enlarged, side, partially-disassembled view of a distal portion of the adapter assembly of FIG. 1 in the unloaded configuration, according to the present disclosure;

[0059] FIG. 33 is an enlarged, perspective, partially-disassembled view of the distal portion of the adapter assembly of FIG. 1 with the end effector linearly inserted therein, according to the present disclosure;

[0060] FIG. 34 is an enlarged, perspective, partially-disassembled view of a proximal portion of the adapter assembly of FIG. 1 in an unloaded configuration, according to the present disclosure;

[0061] FIG. 35 is an enlarged, perspective, partially-disassembled view of the proximal portion of the adapter assembly of FIG. 1 with the end effector linearly inserted therein, according to the present disclosure;

[0062] FIG. 36 is an enlarged, perspective, partially-disassembled view of the distal portion of the adapter assembly of FIG. 1 with the end effector rotated therein, according to the present disclosure;

[0063] FIG. 37 is an enlarged, perspective, partially-disassembled view of the proximal portion of the adapter assembly of FIG. 1 with the end effector rotated therein, according to the present disclosure;

[0064] FIG. 38 is an enlarged, perspective, partially-disassembled view of the distal portion of the adapter assembly of FIG. 1 with the end effector in a locked configuration, according to the present disclosure;

[0065] FIG. 39 is an enlarged, perspective, partially-disassembled view of the proximal portion of the adapter assembly of FIG. 1 with the end effector in an unlocked configuration, according to the present disclosure;

[0066] FIG. 40 is a perspective view of a distal sensor link of the adapter assembly of FIG. 1, according to the present disclosure;

[0067] FIG. 41 is a perspective view of a distal sensor link of the adapter assembly of FIG. 1, according to another embodiment of the present disclosure;

[0068] FIG. 42 is a perspective view of a distal sensor link of the adapter assembly of FIG. 1, according to a further embodiment of the present disclosure;

[0069] FIG. 43 is an enlarged, perspective, partially-disassembled view of the proximal portion of an adapter assembly according to another embodiment of the present disclosure;

[0070] FIG. 44 is a perspective view of a button link of the adapter assembly of FIG. 43, according to the present disclosure;

[0071] FIG. 45 is a perspective view of a load link of the adapter assembly of FIG. 43, according to the present disclosure;

[0072] FIG. 46 is a perspective view of a proximal portion of the load link of FIG. 45, according to the present disclosure;

[0073] FIG. 47 is a front view of a ring of the adapter assembly of FIG. 43, according to another embodiment of the present disclosure;

[0074] FIG. 48 is a perspective view of a proximal sensor link of the adapter assembly of FIG. 43, according to the present disclosure;

[0075] FIG. 49 is a perspective view of a proximal portion of the proximal sensor link of FIG. 48, according to the present disclosure;

[0076] FIGS. 50-55 are an enlarged, perspective, partially-disassembled view of the proximal portion of an adapter assembly of FIG. 42 illustrating assembly thereof, according to the present disclosure;

[0077] FIGS. 56A-C are perspective, schematic views of a multi-part load link, according to the present disclosure;

[0078] FIG. 57 is a perspective, schematic view of a multi-part proximal sensor link, according to the present disclosure;

[0079] FIG. 58 is a perspective, schematic view of a multi-part load link, according to another embodiment of the present disclosure; and

[0080] FIG. 59 is a perspective, schematic view of a multi-part proximal sensor link, according to another embodiment of the present disclosure.

Detailed Description of Embodiments

[0081] Embodiments of the presently disclosed electromechanical surgical system, apparatus and/or device 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 electromechanical surgical system, apparatus and/or device, or component thereof, that are farther from the user, while the term “proximal” refers to that portion of the electromechanical surgical system, apparatus and/or device, or component thereof, that are closer to the user. The terms “left” and “right” refer to that portion of the electromechanical surgical system, apparatus and/or device, or component thereof, that are on the left and right sides, respectively, from the perspective of the user facing the distal end of the electromechanical surgical system, apparatus and/or device from the proximal end while the surgical system, apparatus and/or device is oriented in non-rotational configuration.

[0082] Referring initially to FIGS. 1-8, an electromechanical, hand-held, powered surgical system, in accordance with an embodiment of the present disclosure is shown and generally designated 10. Electromechanical surgical system 10 includes a surgical apparatus or device in the form of an electromechanical, hand-held, powered surgical instrument 100 that is configured for selective attachment thereto of a plurality of different end effectors 300, via an adapter assembly 200 (e.g., elongated body). The end effector 300 and the adapter assembly 200 are configured for actuation and manipulation by the electromechanical, hand-held, powered surgical instrument 100. In particular, the surgical instrument 100, the adapter assembly 200, and the end effector 300 are separable from each other such that the surgical instrument 100 is configured for selective connection with adapter assembly 200, and, in turn, adapter assembly 200 is configured for selective connection with any one of a plurality of different end effectors 300.

[0083] Reference may be made to U.S. Pat. No. 7,963,433, filed Sep. 22, 2008 and U.S. Patent Application Publication No. 2011/0121049, filed on Nov. 20, 2009, the entire contents of all of which are incorporated herein by reference, for a detailed description of the construction and operation of exemplary electromechanical, hand-held, powered surgical instrument 100.

[0084] As illustrated in FIGS. 1-3, surgical instrument 100 includes a handle housing 102 having a lower housing portion 104, an intermediate housing portion 106 extending from and/or supported on lower housing portion 104, and an upper housing portion 108 extending from and/or supported on intermediate housing portion 106. Intermediate housing portion 106 and upper housing portion 108 are separated into a distal half-section 110a that is integrally formed with and extending from the lower portion 104, and a proximal half-section 110b connectable to distal half-section 110a by a plurality of fasteners. When joined, distal and proximal half-sections 110a, 110b define a handle housing 102 having a cavity 102a therein in which a circuit board 150 and a drive mechanism 160 is situated.

[0085] With reference to FIGS. 2 and 3, distal and proximal half-sections 110a, 110b are divided along a vertical plane that traverses a longitudinal axis “X-X” of upper housing portion 108. Handle housing 102 includes a gasket 112 extending completely around a rim of distal half-section and/or proximal half-section 110a, 110b and being interposed between distal half-section 110a and proximal half-section 110b. Gasket 112 seals the perimeter of distal half-section 110a and proximal half-section 110b. Gasket 112 functions to establish an air-tight seal between distal half-section 110a and proximal half-section 110b such that circuit board 150 and drive mechanism 160 are protected from sterilization and/or cleaning procedures.

[0086] In this manner, the cavity 102a of handle housing 102 is sealed along the perimeter of distal half-section 110a and proximal half-section 110b yet is configured to enable easier, more efficient assembly of circuit board 150 and a drive mechanism 160 in handle housing 102.

[0087] Intermediate housing portion 106 of handle housing 102 provides a housing in which circuit board 150 is situated. Circuit board 150 is configured to control the various operations of surgical instrument 100, as will be set forth in additional detail below.

[0088] Lower housing portion 104 of surgical instrument 100 defines an aperture (not shown) formed in an upper surface thereof and which is located beneath or within intermediate housing portion 106. As shown in FIGS. 3 and 4, the aperture of lower housing portion 104 provides a passage through which wires 152 pass to electrically interconnect electrical components situated in lower housing portion 104, e.g., a battery 156 and a circuit board 154, with electrical components situated in intermediate housing portion 106 and/or upper housing portion 108, e.g., circuit board 150, drive mechanism 160, etc.

[0089] Handle housing 102 includes a gasket 107 disposed within the aperture of lower housing portion 104 (not shown) thereby plugging or sealing the aperture of lower housing portion 104 while allowing wires 152 to pass therethrough. Gasket 107 functions to establish an air-tight seal between lower housing portion 106 and intermediate housing portion 108 such that circuit board 150 and drive mechanism 160 are protected from sterilization and/or cleaning procedures.

[0090] With continued reference to FIGS. 3 and 4, lower housing portion 104 of handle housing 102 provides a housing in which the battery 156 is removably disposed therein. The battery 156 may be a rechargeable battery (e.g., lead-based, nickel-based, lithium-ion based, etc.). It is also envisioned that the battery 156 may be a single-use, non-rechargeable battery. Battery 156 is configured to supply power to any of the electrical components of surgical instrument 100. Lower housing portion 104 defines a cavity (not shown) into which battery 156 is inserted. Lower housing portion 104 includes a door 105 pivotally connected thereto for closing cavity of lower housing portion 104 and retaining battery 156 therein.

[0091] With continued reference to FIGS. 3 and 5, distal half-section 110a of upper housing portion 108 defines a nose or connecting portion 108a. A nose cone 114 is supported on nose portion 108a of upper housing portion 108 (FIG. 6). Nose cone 114 is fabricated from a transparent, light-transmissive material. An illumination member 116 is disposed within nose cone 114 such that illumination member 116 is visible therethrough. The nose cone 114 may be tinted, such that the illumination member 116 is visible when it is activated.

[0092] With reference to FIG. 5, the illumination member 116 may include a plurality of any suitable light emitting devices, such as light emitting diodes (LEDs), disposed on printed circuit board (LED PCB) 116a which is disposed in a vertical plane transverse to the longitudinal axis “X-X.” The illumination member 116 is configured to illuminate in multiple colors with a specific color pattern being associated with a unique discrete event. In embodiments, the LEDs may be single-color or multi-color LEDs.

[0093] Upper housing portion 108 of handle housing 102 provides a housing in which drive mechanism 160 is situated. As illustrated in FIG. 5, drive mechanism 160 is configured to drive shafts and/or gear components in order to perform the various operations of surgical instrument 100. In particular, drive mechanism 160 is configured to drive shafts and/or gear components in order to selectively move tool assembly 304 of end effector 300 relative to proximal body portion 302 of end effector 300, to rotate end effector 300 about the longitudinal axis “X-X” (FIG. 2) relative to handle housing 102, to move anvil assembly 306 relative to cartridge assembly 308 of end effector 300, and/or to fire a stapling and cutting cartridge within cartridge assembly 308 of end effector 300.

[0094] The drive mechanism 160 includes a selector gearbox assembly 162 that is located immediately proximal relative to adapter assembly 200. Proximal to the selector gearbox assembly 162 is a function selection module 163 having a first (e.g., selector) motor 164 that functions to selectively move gear elements within the selector gearbox assembly 162 into engagement with an input drive component 165 having a second (e.g., drive) motor 166.

[0095] As illustrated in FIGS. 1-4, distal half-section 110a of upper housing portion 108 defines a connecting portion 108a configured to accept a corresponding drive coupling assembly 210 of adapter assembly 200.

[0096] As illustrated in FIGS. 6-8, connecting portion 108a of surgical instrument 100 has a cylindrical recess 108b that receives a drive coupling assembly 210 of adapter assembly 200 when adapter assembly 200 is mated to surgical instrument 100. Connecting portion 108a houses three rotatable drive connectors 118, 120, 122.

[0097] With reference to FIG. 6, when adapter assembly 200 is mated to surgical instrument 100, each of rotatable drive connectors 118, 120, 122 of surgical instrument 100 couples with a corresponding rotatable connector sleeve 218, 220, 222 of adapter assembly 200. In this regard, the interface between corresponding first drive connector 118 and first connector sleeve 218, the interface between corresponding second drive connector 120 and second connector sleeve 220, and the interface between corresponding third drive connector 122 and third connector sleeve 222 are keyed such that rotation of each of drive connectors 118, 120, 122 of surgical instrument 100 causes a corresponding rotation of the corresponding connector sleeve 218, 220, 222 of adapter assembly 200.

[0098] The mating of drive connectors 118, 120, 122 of surgical instrument 100 with connector sleeves 218, 220, 222 of adapter assembly 200 allows rotational forces to be independently transmitted via each of the three respective connector interfaces. The drive connectors 118, 120, 122 of surgical instrument 100 are configured to be independently rotated by drive mechanism 160. In this regard, the function selection module 163 of drive mechanism 160 selects which drive connector or connectors 118, 120, 122 of surgical instrument 100 is to be driven by the input drive component 165 of drive mechanism 160.

[0099] Since each of drive connectors 118, 120, 122 of surgical instrument 100 has a keyed and/or substantially non-rotatable interface with respective connector sleeves 218, 220, 222 of adapter assembly 200, when adapter assembly 200 is coupled to surgical instrument 100, rotational force(s) are selectively transferred from drive mechanism 160 of surgical instrument 100 to adapter assembly 200.

[0100] The selective rotation of drive connector(s) 118, 120 and/or 122 of surgical instrument 100 allows surgical instrument 100 to selectively actuate different functions of end effector 300. As discussed in greater detail below, selective and independent rotation of first drive connector 118 of surgical instrument 100 corresponds to the selective and independent opening and closing of tool assembly 304 of end effector 300, and driving of a stapling/cutting component of tool assembly 304 of end effector 300. Also, the selective and independent rotation of second drive connector 120 of surgical instrument 100 corresponds to the selective and independent articulation of tool assembly 304 of end effector 300 about an articulation axis that is transverse to longitudinal axis “X-X” (FIG. 2). In particular, the end effector 300 defines a second longitudinal axis and is movable from a first position in which the second longitudinal axis is substantially aligned with the first longitudinal axis “X-X” to at least a second position in which the second longitudinal axis is disposed at a non-zero angle with respect to the first longitudinal axis “X-X.” Additionally, the selective and independent rotation of third drive connector 122 of surgical instrument 100 corresponds to the selective and independent rotation of end effector 300 about longitudinal axis “X-X” (FIG. 2) relative to handle housing 102 of surgical instrument 100.

[0101] As illustrated in FIGS. 1-3 and FIG. 9, handle housing 102 supports a control assembly 103 on a distal surface or side of intermediate housing portion 108. Control assembly 103, in cooperation with intermediate housing portion 108, supports a pair of finger-actuated control buttons 124, 126 and rocker devices 128, 130. In particular, control assembly 103 defines an upper aperture 124a for slidably receiving a first control button 124, and a lower aperture 126a for slidably receiving a second control button 126.

[0102] Each one of the control buttons 124, 126 and rocker devices 128, 130 includes a respective magnet (not shown) that is moved by the actuation of an operator. In addition, circuit board 150 includes, for each one of the control buttons 124, 126 and rocker devices 128, 130, respective Hall-effect switches 150a-150d (FIG. 7) that are actuated by the movement of the magnets in the control buttons 124, 126 and rocker devices 128, 130. In particular, located immediately proximal to the control button 124 is a first Hall-effect switch 150a (FIGS. 3 and 7) that is actuated upon the movement of a magnet within the control button 124 upon the operator actuating control button 124. The actuation of first Hall-effect switch 150a, corresponding to control button 124, causes circuit board 150 to provide appropriate signals to function selection module 163 and input drive component 165 of the drive mechanism 160 to close a tool assembly 304 of end effector 300 and/or to fire a stapling/cutting cartridge within tool assembly 304 of end effector 300.

[0103] Also, located immediately proximal to rocker device 128 is a second Hall-effect switch 150b (FIGS. 3 and 7) that is actuated upon the movement of a magnet (not shown) within rocker device 128 upon the operator actuating rocker device 128. The actuation of second Hall-effect switch 150b, corresponding to rocker device 128, causes circuit board 150 to provide appropriate signals to function selection module 163 and input drive component 165 of drive mechanism 160 to articulate tool assembly 304 relative to body portion 302 of end effector 300. Advantageously, movement of rocker device 128 in a first direction causes tool assembly 304 to articulate relative to body portion 302 in a first direction, while movement of rocker device 128 in an opposite, e.g., second, direction causes tool assembly 304 to articulate relative to body portion 302 in an opposite, e.g., second, direction.

[0104] Furthermore, located immediately proximal to control button 126 is a third Hall-effect switch 150c (FIGS. 3 and 7) that is actuated upon the movement of a magnet (not shown) within control button 126 upon the operator actuating control button 126. The actuation of third Hall-effect switch 150c, corresponding to control button 126, causes circuit board 150 to provide appropriate signals to function selection module 163 and input drive component 165 of drive mechanism 160 to open tool assembly 304 of end effector 300.

[0105] In addition, located immediately proximal to rocker device 130 is a fourth Hall-effect switch 150d (FIGS. 3 and 7) that is actuated upon the movement of a magnet (not shown) within rocker device 130 upon the operator actuating rocker device 130. The actuation of fourth Hall-effect switch 150d, corresponding to rocker device 130, causes circuit board 150 to provide appropriate signals to function selection module 163 and input drive component 165 of drive mechanism 160 to rotate end effector 300 relative to handle housing 102 surgical instrument 100. Specifically, movement of rocker device 130 in a first direction causes end effector 300 to rotate relative to handle housing 102 in a first direction, while movement of rocker device 130 in an opposite, e.g., second, direction causes end effector 300 to rotate relative to handle housing 102 in an opposite, e.g., second, direction.

[0106] As seen in FIGS. 1-3, surgical instrument 100 includes a fire button or safety switch 132 supported between intermediate housing portion 108 and upper housing portion, and situated above control assembly 103. In use, tool assembly 304 of end effector 300 is actuated between opened and closed conditions as needed and/or desired. In order to fire end effector 300, to expel fasteners therefrom when tool assembly 304 of end effector 300 is in a closed condition, safety switch 132 is depressed thereby instructing surgical instrument 100 that end effector 300 is ready to expel fasteners therefrom.

[0107] As illustrated in FIGS. 1 and 10-20, surgical instrument 100 is configured for selective connection with adapter assembly 200, and, in turn, adapter assembly 200 is configured for selective connection with end effector 300.

[0108] Adapter assembly 200 is configured to convert a rotation of either of drive connectors 120 and 122 of surgical instrument 100 into axial translation useful for operating a drive assembly 360 and an articulation link 366 of end effector 300, as illustrated in FIG. 29 and discussed in greater detail below.

[0109] Adapter assembly 200 includes a first drive transmitting assembly for interconnecting third rotatable drive connector 122 of surgical instrument 100 and a first axially translatable drive member of end effector 300, wherein the first drive transmitting assembly converts and transmits a rotation of third rotatable drive connector 122 of surgical instrument 100 to an axial translation of the first axially translatable drive assembly 360 of end effector 300 for firing.

[0110] Adapter assembly 200 includes a second drive transmitting assembly for interconnecting second rotatable drive connector 120 of surgical instrument 100 and a second axially translatable drive member of end effector 300, wherein the second drive transmitting assembly converts and transmits a rotation of second rotatable drive connector 120 of surgical instrument 100 to an axial translation of articulation link 366 of end effector 300 for articulation.

[0111] With reference to FIGS. 10 and 11, adapter assembly 200 includes a knob housing 202 and an outer tube 206 extending from a distal end of knob housing 202. Knob housing 202 and outer tube 206 are configured and dimensioned to house the components of adapter assembly 200. Outer tube 206 is dimensioned such that outer tube 206 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.

[0112] Knob housing 202 is configured and adapted to connect to connecting portion 108a of upper housing portion 108 of distal half-section 110a of surgical instrument 100. With reference to FIGS. 10-12, adapter assembly 200 includes a surgical device drive coupling assembly 210 at a proximal end thereof and to an end effector coupling assembly 230 at a distal end thereof. Drive coupling assembly 210 includes a distal drive coupling housing 210a and a proximal drive coupling housing 210b rotatably supported, at least partially, in knob housing 202. Drive coupling assembly 210 rotatably supports a first rotatable proximal drive shaft 212, a second rotatable proximal drive shaft 214, and a third rotatable proximal drive shaft 216 therein.

[0113] Proximal drive coupling housing 210b is configured to rotatably support first, second and third connector sleeves 218, 220 and 222, respectively. Each of connector sleeves 218, 220, 222 is configured to mate with respective first, second and third drive connectors 118, 120, 122 of surgical instrument 100, as described above. Each of connector sleeves 218, 220, 222 is further configured to mate with a proximal end of respective first, second and third proximal drive shafts 212, 214, 216.

[0114] Proximal drive coupling assembly 210 includes a first, a second and a third biasing member 224, 226 and 228 disposed distally of respective first, second and third connector sleeves 218, 220, 222. Each of biasing members 224, 226 and 228 is disposed about respective first, second and third rotatable proximal drive shaft 212, 214 and 216. Biasing members 224, 226 and 228 act on respective connector sleeves 218, 220 and 222 to help maintain connector sleeves 218, 220 and 222 engaged with the distal end of respective drive rotatable drive connectors 118, 120, 122 of surgical instrument 100 when adapter assembly 200 is connected to surgical instrument 100.

[0115] In particular, first, second and third biasing members 224, 226 and 228 bias respective connector sleeves 218, 220 and 222 in a proximal direction. In this manner, during assembly of adapter assembly 200 to surgical instrument 100, if first, second and or third connector sleeves 218, 220 and/or 222 is/are misaligned with the drive connectors 118, 120, 122 of surgical instrument 100, first, second and/or third biasing member(s) 224, 226 and/or 228 are compressed. Thus, when drive mechanism 160 of surgical instrument 100 is engaged, drive connectors 118, 120, 122 of surgical instrument 100 will rotate and first, second and/or third biasing member(s) 224, 226 and/or 228 will cause respective first, second and/or third connector sleeve(s) 218, 220 and/or 222 to slide back proximally, effectively coupling drive connectors 118, 120, 122 of surgical instrument 100 to first, second and/or third proximal drive shaft(s) 212, 214 and 216 of proximal drive coupling assembly 210.

[0116] Upon calibration of surgical instrument 100, each of drive connectors 118, 120, 122 of surgical instrument 100 is rotated and biasing of connector sleeve(s) 218, 220 and 222 properly seats connector sleeve(s) 218, 220 and 222 over the respective drive connectors 118, 120, 122 of surgical instrument 100 when the proper alignment is reached.

[0117] Adapter assembly 200 includes a first, a second and a third drive transmitting assembly 240, 250, 260, respectively, disposed within handle housing 202 and outer tube 206. Each drive transmitting assembly 240, 250, 260 is configured and adapted to transmit or convert a rotation of a first, second and third drive connector 118, 120, 122 of surgical instrument 100 into axial translation of drive tube 246 and drive bar 258 of adapter assembly 200, to effectuate closing, opening, articulating and firing of end effector 300; or a rotation of ring gear 266 of adapter assembly 200, to effectuate rotation of adapter assembly 200.

[0118] As shown in FIGS. 13-19, first drive transmitting assembly 240 includes a first distal drive shaft 242 rotatably supported within housing 202 and outer tube 206. A proximal end portion 242a of first distal drive shaft 242 is keyed to a spur gear 242c which is configured for connection to a spur gear 212a keyed to first rotatable proximal drive shaft 212, via a compound gear 243. First distal drive shaft 242 further includes a distal end portion 242b having a threaded outer profile or surface.

[0119] First drive transmitting assembly 240 further includes a drive coupling nut 244 rotatably coupled to threaded distal end portion 242b of first distal drive shaft 242, and which is slidably disposed within outer tube 206. Drive coupling nut 244 is keyed to an inner housing tube 206a of outer tube 206 so as to be prevented from rotation as first distal drive shaft 242 is rotated. In this manner, as first distal drive shaft 242 is rotated, drive coupling nut 244 is translated through and/or along inner housing tube 206a of outer tube 206.

[0120] First drive transmitting assembly 240 further includes a drive tube 246 surrounding first distal drive shaft 242 and having a proximal end portion connected to drive coupling nut 244 and a distal end portion extending beyond a distal end of first distal drive shaft 242. The distal end portion of drive tube 246 supports a connection member 247 (FIG. 13) configured and dimensioned for selective engagement with drive member 374 of drive assembly 360 of end effector 300.

[0121] In operation, as first rotatable proximal drive shaft 212 is rotated, due to a rotation of first connector sleeve 218, as a result of the rotation of the first respective drive connector 118 of surgical instrument 100, spur gear 212a of first rotatable proximal drive shaft 212 engages first gear 243a of compound gear 243 causing compound gear 243 to rotate. As compound gear 243 rotates, a second gear 243b of compound gear 243 is rotated and thus causes spur gear 242c that is keyed to first distal drive shaft 242, that is engaged therewith, to also rotate thereby causing first distal drive shaft 242 to rotate. As first distal drive shaft 242 is rotated, drive coupling nut 244 is caused to be translated axially along first distal drive shaft 242.

[0122] As drive coupling nut 244 is caused to be translated axially along first distal drive shaft 242, drive tube 246 is caused to be translated axially relative to inner housing tube 206a of outer tube 206. As drive tube 246 is translated axially, with connection member 247 connected thereto and connected to a drive member 374 of drive assembly 360 of end effector 300, drive tube 246 causes concomitant axial translation of drive member 374 of end effector 300 to effectuate a closure of tool assembly 304 and a firing of tool assembly 304 of end effector 300.

[0123] With reference to FIGS. 13-19, second drive transmitting assembly 250 of adapter assembly 200 includes second rotatable proximal drive shaft 214 rotatably supported within drive coupling assembly 210. Second rotatable proximal drive shaft 214 includes a non-circular or shaped proximal end portion 214a configured for connection with second connector 220 which is connected to respective second connector 120 of surgical instrument 100. Second rotatable proximal drive shaft 214 further includes a distal end portion 214b having a threaded outer profile or surface.

[0124] As illustrated in FIG. 20, second drive transmitting assembly 250 further includes a coupling cuff 254 rotatably and translatably supported within an annular race or recess formed in knob housing 202. Coupling cuff 254 defines a lumen 254a therethrough, and an annular race or recess formed in a surface of lumen 254a. Second drive transmitting assembly 250 further includes a coupling slider 256 extending across lumen 254a of coupling cuff 254 and slidably disposed within the race of coupling cuff 254. Coupling slider 256 is threadably connected to threaded distal end portion 214b of second rotatable proximal drive shaft 214. As so configured, coupling cuff 254 can rotate about second rotatable proximal drive shaft 214, thereby maintaining a radial position of second rotatable proximal drive shaft 214 relative to first rotatable proximal drive shaft 242.

[0125] Second rotatable proximal drive shaft 214 defines an axis of rotation, and coupling cuff 254 defines an axis of rotation that is spaced a radial distance from the axis of rotation of second rotatable proximal drive shaft 214. Coupling slider 256 defines an axis of rotation that is coincident with the axis of rotation of coupling cuff 254.

[0126] Second drive transmitting assembly 250 further includes a drive bar 258 translatably supported for axial translation through outer tube 206. Drive bar 258 includes a proximal end portion 258a coupled to coupling cuff 254, and a distal end portion 258b defining a coupling hook 258c configured and dimensioned for selective engagement with hooked proximal end 366a of articulation link 366 of end effector 300 (FIG. 29).

[0127] In operation, as illustrated in FIGS. 10-19, as drive shaft 214 is rotated due to a rotation of second connector sleeve 220, as a result of the rotation of the second drive connector 120 of surgical instrument 100, coupling slider 256 is caused to be translated axially along threaded distal portion 214b of second rotatable proximal drive shaft 214, which in turn causes coupling cuff 254 to be translated axially relative to knob housing 202. As coupling cuff 254 is translated axially, drive bar 258 is caused to be translated axially. Accordingly, as drive bar 258 is translated axially, with hook 258c thereof connected to hooked proximal end 366a of articulation link 366 of end effector 300 (FIG. 29), drive bar 258 causes concomitant axial translation of articulation link 366 of end effector 300 to effectuate an articulation of tool assembly 304.

[0128] As seen in FIGS. 10-19, adapter assembly 200 includes a third drive transmitting assembly 260 supported in knob housing 202. Third drive transmitting assembly 260 includes first and second rotation housing half-sections 262, 264 rotatably supported in knob housing 202, respectively, and an internal rotation ring gear 266 supported and interposed between first and second rotation housing half-sections 262, 264. Each of first and second rotation housing half-sections 262, 264 includes an arm 262a, 264b extending distally therefrom and which are parallel to one another and spaced a transverse distance from one another. Each arm 262a, 264a includes a boss 262b, 264b extending radially inward near a distal end thereof.

[0129] Third drive transmitting assembly 260 further includes a pair of rotation transmitting bars 268, 270, each, connected at a proximal end thereof to bosses 262b, 264b of arms 262a, 264a, and at a distal end thereof to a distal coupling assembly 230 supported at a distal end of outer tube 206.

[0130] Third drive transmitting assembly 260 includes a ring gear 266 defining an internal array of gear teeth 266a. Ring gear 266 includes a pair of diametrically opposed, radially extending protrusions 266b projecting form an outer edge thereof. Protrusions 266b are disposed within recesses 262c, 264c defined in an inner surface of first and second rotation housing half-sections 262, 264, such that rotation of ring gear 266 results in rotation of first and second rotation housing half-sections 262, 264.

[0131] Third drive transmitting assembly 260 further includes third rotatable proximal drive shaft 216 rotatably supported within housing 202 and outer tube 206. A proximal end portion of third rotatable proximal drive shaft 216 is keyed to third connector 222 of adapter assembly 200. Third rotatable proximal drive shaft 216 includes a spur gear 216a keyed to a distal end thereof. A gear set 274 inter-engages spur gear 216a of third rotatable proximal drive shaft 216 to gear teeth 266a of ring gear 266. Gear set 274 includes a first gear 274a engaged with spur gear 216a of third rotatable proximal drive shaft 216, and a second gear 274b engaged with gear teeth 266a of ring gear 266.

[0132] In operation, as illustrated in FIGS. 10-19, as third rotatable proximal drive shaft 216 is rotated, due to a rotation of third connector sleeve 222, as a result of the rotation of the third respective drive connector 122 of surgical instrument 100, spur gear 216a of third rotatable proximal drive shaft 216 engages first gear 272a of gear set 274 causing gear set 274 to rotate. As gear set 274 rotates, second gear 274b of gear set 274 is rotated and thus causes ring gear 266 to also rotate thereby causing first and second rotation housing half-sections 262, 264 to rotate. As first and second rotation housing half-sections 262, 264 are rotated, rotation transmitting bars 268, 270, and distal coupling assembly 230 connected thereto, are caused to be rotated about longitudinal axis “X-X” of adapter assembly 200 (FIG. 10). As distal coupling 230 is rotated, end effector 300, that is connected to distal coupling assembly 230, is also caused to be rotated about a longitudinal axis of adapter assembly 200.

[0133] Referring to FIG. 21, drive assembly 360 of end effector 300 includes a flexible drive shaft 364 having a distal end which is secured to a dynamic drive beam 365, and a proximal engagement section 368. Engagement section 368 includes a stepped portion defining a shoulder 370. A proximal end of engagement section 368 includes diametrically opposed inwardly extending fingers 372. Fingers 372 engage a hollow drive member 374 to fixedly secure drive member 374 to the proximal end of shaft 364. Drive member 374 defines a proximal porthole which receives a connection member of drive tube 246 (FIG. 1) of adapter 200 when end effector 300 is attached to distal coupling 230 of adapter 200.

[0134] When drive assembly 360 is advanced distally within tool assembly 304, an upper beam of drive beam 365 moves within a channel defined between anvil plate 312 and anvil cover 310 and a lower beam moves within a channel of the staple cartridge 305 and over the exterior surface of carrier 316 to close tool assembly 304 and fire staples therefrom.

[0135] Proximal body portion 302 of end effector 300 includes a sheath or outer tube 301 enclosing an upper housing portion 301a and a lower housing portion 301b. The housing portions 301a and 301b enclose an articulation link 366 having a hooked proximal end 366a which extends from a proximal end of end effector 300. Hooked proximal end 366a of articulation link 366 engages a coupling hook (not shown) of adapter 200 when end effector 300 is secured to distal housing 232 of adapter 200. When drive bar (not shown) of adapter 200 is advanced or retracted as described above, articulation link 366 of end effector 300 is advanced or retracted within end effector 300 to pivot tool assembly 304 in relation to a distal end of proximal body portion 302.

[0136] As illustrated in FIG. 21, cartridge assembly 308 of tool assembly 304 includes a staple cartridge 305 supportable in carrier 316. Staple cartridge 305 defines a central longitudinal slot 305a, and three linear rows of staple retention slots 305b positioned on each side of longitudinal slot 305a. Each of staple retention slots 305b receives a single staple 307 and a portion of a staple pusher 309. During operation of instrument 100, drive assembly 360 abuts an actuation sled 350 and pushes actuation sled 350 through cartridge 305. As the actuation sled moves through cartridge 305, cam wedges of the actuation sled 350 sequentially engage staple pushers 309 to move staple pushers 309 vertically within staple retention slots 305b and sequentially eject a single staple 307 therefrom for formation against anvil plate 312.

[0137] The end effector 300 may also include one or more mechanical lockout mechanisms, such as those described in commonly-owned U.S. Pat. Nos. 5,071,052, 5,397,046, 5,413,267, 5,415,335, 5,715,988, 5,718,359, 6,109,500, the entire contents of all of which are incorporated by reference herein.

[0138] With reference to FIGS. 22-39, adapter assembly 200 further includes a lock mechanism 400 for fixing the axial position and radial orientation of drive tube 246 (see FIG. 13) for the connection and disconnection of end effector 300 thereto. Lock mechanism 400 includes a release button 282 (see FIG. 13) slidably supported on knob housing 202. Release button 282 is connected to a load link 402 that extends longitudinally through outer tube 206. The lock mechanism 400 also includes a sensor link assembly 451 having a proximal sensor link 450 and a distal sensor link 480. Load link 402 and proximal sensor link 450 are interposed between outer tube 206 and inner housing tubes 206a, 206b and distal tip housing 460. Load link 402 and proximal sensor link 450 move in response to the insertion of end effector 300 and/or movement of lock release button 282. The tip housing 460 is configured and dimensioned for insertion of end effector 300 thereinto as described in further detail below.

[0139] The tip housing 460 includes a bayonet connection mount 461 for releasably connecting to the end effector 300. With reference to FIG. 21, the end effector 300 includes a pair of lugs 303a and 303b disposed at a proximal portion of the end effector 300. The lugs 303a and 303b are configured and dimensioned to be inserted into the bayonet connection mount 461 having a pair of corresponding bayonet channels.

[0140] With reference to FIGS. 22-24, load link 402 includes a distal portion 404 defining a cut-out 404a, and a finger 404b extending distally from distal portion 404. The finger 404b of load link 402 includes a distal surface 404c. The load link 402 further includes a proximal portion 406 having an opening 407 configured and dimensioned to engage a lock spring 440 as described in further detail below. The load link 402 further includes a button link 408 configured as a cantilevered tab. The button link 408 is configured and dimensioned to engage the button 282. In use, longitudinal movement (e.g., proximal) of the button 282 is imparted to the load link 402 via the button link 408 thereby allowing for disengagement of the end effector 300 from the adapter 200.

[0141] With reference to FIGS. 25 and 26, the proximal sensor link 450 includes a distal portion 454 defining a distal cut-out 454a, and a pair of tines 454b, 454c extending distally from distal portion 454. The proximal sensor link 450 further includes a proximal portion 456 having a proximal cut-out 456a and a ring 457 disposed at a proximal end of the proximal sensor link 450. The ring 457 defines an opening 457a and includes a rib 457b disposed on an outer surface thereof for engagement with the lock spring 440 as described in further detail below.

[0142] With reference to FIGS. 27 and 29, lock mechanism 400 also includes a seal spacer 430 for aligning the load link 402 and proximal sensor link 450 within the inner housing tubes 206a, 206b. The seal spacer 430 includes four separation walls 430a-430d, which are used to separate the load link 402, proximal sensor link 450, the driver bar 258, and rotation transmitting bars 268, 270 into four quadrants, allowing for longitudinal movement thereof. The walls 430a-430d also space apart the load link 402 and the sensor link assembly 451 from the inner housing tubes 206a, 206b.

[0143] In embodiments, the seal spacer 430 may be formed from any suitable material including, but not limited to, polymers, metals, and combinations thereof. The seal spacer 430 may be formed using any suitable manufacturing methods depending on the materials being used, including but not limited to, injection molding, casting, stamping, and combinations thereof.

[0144] The seal spacer 430 may be formed within the adapter assembly 200 by injecting a liquid composition that later solidifies and forms the seal spacer 430. In embodiments, liquid siloxane polymers, such as polydimethylsiloxane, may be used. In further embodiments, two-part epoxy compositions may also be injected. In additional embodiments, the seal spacer 430 may be formed as a skeletal structure that is then contacted with a composition that reacts with the structure to form a solid structure (e.g., filling the voids). In further embodiments, the seal spacer 430 may be a foam or a sponge that is compressed prior to insertion into the adapter assembly 200 and is then allowed to expand to its original shape to fill the space of the adapter assembly 200. Expansion of the sponge/foam may be facilitated by contacting via a catalyst.

[0145] As shown in FIG. 29 the proximal portion 406 of the load link 402 is disposed between the separation walls 430a, 430b and the proximal portion 456 of the sensor link 450 is disposed between the separation walls 430a, 430d. A ring 490 secures the proximal portions 406, 450 of the load link 402 and the sensor link 450, respectively, to the seal spacer 430 while allowing for longitudinal movement thereof. The seal spacer 430 also includes an opening 431 formed therein. In embodiments, the seal spacer 430 may include a plurality of openings 431 within each quadrant. The opening 431 is used to secure the lock spring 440 therein.

[0146] With reference to FIG. 28, the lock spring 440 includes a base 442 configured and dimensioned to be secured to the seal spacer 430 and a resilient arm 444 extending from the base 442. In particular, the base 442 includes a pair of tabs 442a and 442b configured and dimensioned to frictionally engage a pair of opposing tabs 431a, 431b defined within the opening 431 as shown in FIG. 26. The resilient arm 444 includes an angled tab 444a configured to engage the rib 457b of the ring 457 of sensor link 450 and secure the proximal sensor link 450 as described in further detail below.

[0147] FIG. 29 shows a proximal portion of the lock mechanism 400, which includes a sensor 487 (e.g., leaf spring sensor) disposed at the distal end of the coupling cuff 254 and in longitudinal travel path of the ring 457 of the proximal sensor link 450. The sensor 487 is toggled by the proximal sensor link 450 (e.g., the ring 457) as the end effector 300 is inserted into the adapter assembly 200 as described in further detail below.

[0148] With reference to FIGS. 22 and 30, the lock mechanism 400 includes a distal tip housing 460 having a first longitudinal depression 462 and a second longitudinal depression 464. The depressions 462, 464 are configured and dimensioned for longitudinal travel of the load link 402 and the proximal sensor link 450, respectively. The depression 462 also includes a channel or a groove 462a formed therein for accommodating a biasing member 470, which is also disposed within the cut-out 404a of the load link 402 as shown in FIGS. 22 and 29. The biasing member 470 pushes the load link 402 in the distal direction.

[0149] The second longitudinal depression 464 includes a first channel 464a and a second channel 464b disposed proximally of the first channel 464a. The first channel 464a is configured and dimensioned to accommodate a biasing member 472, which is also disposed within the first channel 464a thereby pushing the proximal sensor link 450 in the distal direction as shown in FIGS. 26, 30 and 31. The second channel 464b is configured and dimensioned to accommodate a biasing member 474, which is disposed between the tines 454b, 454c of proximal sensor link 450. The depression 464 also includes a slot 464c for a distal sensor link 480. In embodiments, the biasing members 470, 472, 474 may have a substantially similar spring rate. In further embodiments, the biasing members 470, 472, 474 may have any suitable spring rate for balancing the load link 402, and the proximal and distal sensor links 450 and 480, respectively.

[0150] With reference to FIGS. 31 and 33, the biasing member 474 is coupled to a distal sensor link 480, with the biasing member 474 decoupling the proximal sensor link 450 from the distal sensor link 480. The distal sensor link 480 includes a proximally-facing shaft 482 configured and dimensioned to engage a distal end of the biasing member 474. The distal sensor link 480 also includes a distal edge 484 defining a stop edge 484a for interfacing with a distal portion of the slot 464c of depression 464 and a linear surface 484b for interfacing with the lug 303b of the end effector 300.

[0151] With reference to FIGS. 29, 31, and 34, the lock mechanism 400 is illustrated in its “home” (e.g., unloaded) configuration in which the end effector 300 is not connected to the adapter assembly 200. In this configuration, the load link 402 including the finger 404b and the proximal sensor link 450 are biased (e.g., spring-loaded) distally via the biasing members 470, 472, respectively (FIG. 31). The biasing members 472 and 474 push apart the proximal and distal sensor links 450 and 480. Since the load link 402 is biased distally, the button link 408 and the ring 457 are also disposed distally, such that the button 282 and the sensor 287 are not actuated.

[0152] With reference to FIGS. 33 and 35, insertion of the end effector 300 into adapter assembly 200 is illustrated. The end effector 300 is initially inserted linearly. As the end effector 300 is inserted into the bayonet connection mount 461 of the tip housing 460, the lug 303a of end effector 300 engages the finger 404b of the load link 402 pushing it proximally. In response to proximal movement of the load link 402, the proximal portion 406 of the load link 402 engages the lock spring 440 flexing down the resilient arm 444. In response thereto, the lock spring 440 engages the rib 457b of the ring 457, via the tab 444a, and secures the proximal sensor link 450. The proximal sensor link 450 remains in place as the distal sensor link 480 is engaged by the lug 303b of end effector 300 upon rotation of the end effector 300 as described in further detail below.

[0153] The lug 303b also engaged the surface 484b thereby pushing the distal sensor link 480 in the proximal direction until the distal sensor link 480 is fully moved proximally. This compresses the biasing member 474 disposed between the proximal and distal sensor links 450, 480 more so than the biasing member 472. Since the proximal sensor link 450 is immobilized by the lock spring 440, the biasing member 474 is compressed solely by the proximal sensor link 450 and biases the proximal sensor link 450 in the distal direction. In particular, the biasing member 474 is compressed more than the biasing member 472, resulting net distal biasing of the proximal sensor link 450. In embodiments, the biasing member 474 is stronger (e.g., higher spring rate) than the biasing member 472 allowing compression of the biasing member 474 to also compress the biasing member 472. However, since the ring 457 is engaged by the lock spring 440, the proximal sensor link 450 does not move distally.

[0154] With reference to FIG. 36, after the end effector 300 is inserted linearly, the end effector 300 is rotated about its longitudinal axis to secure the end effector 300 to the adapter 200 within the bayonet connection mount 461. Rotation of the end effector 300 causes the lugs 303a, 303b to rotate within the bayonet connection mount 461, which in turn, engages the lug 303b with the distal sensor link 480. As the lug 303b is rotated, it maintains contact with the surface 484b of distal sensor link 480 thereby maintaining the distal sensor link 480 in the proximal position.

[0155] With reference to FIGS. 37 and 38, once the end effector 300 is fully rotated, the lugs 303a, 303b are rotated past the finger 404b of the load link 402 and distal sensor link 480, allowing the load link 402 to move distally thereby securing the end effector 300 within the adapter 200. As the load link 402 is moved distally, the proximal portion 406 thereof is moved off the lock spring 440 thereby disengaging the rib 457a of the ring 457. This also disengages the proximal sensor link 450, which is being pushed in the proximal direction by the biasing member 474 that was being compressed between the proximal and distal sensor links 450 and 480. In particular, the biasing member 474 is under more compression than the biasing member 472.

[0156] As shown in FIG. 38, as the distal sensor link 480 is maintained in the proximal position by the lug 303b of end effector 300. The proximal sensor link 450 is then moved proximally due to the equalization of the compression of the biasing members 472 and 474 as the ring 457 is released. The proximal sensor link 450, namely, the ring 457, comes in contact with and toggles the sensor 487. This signals the surgical instrument 100 that the end effector 300 has been inserted and secured.

[0157] With reference to FIG. 39, disconnection of the end effector 300 is described. Once the end effector 300 has been loaded, actuation of the button 282 moves the load link 402 in a proximal direction, which allows for rotation of the end effector 300 and its removal from the adapter 200. This moves the load link 402 in the proximal direction without signaling the surgical instrument 100 that the end effector 300 has been disengaged since the proximal sensor link 450 remains seated on the sensor 487. While the release button 282 (e.g., the load link 402) is continuously engaged in the proximal direction, the end effector 300 is rotated and then pulled out from the adapter assembly 200. Rotational movement of the end effector 300 moves the lug 303b of end effector 300 from the distal sensor link 480, allowing the distal sensor link 480 to move distally due to the biasing member 474. This in turn, allows the proximal sensor link 450 to also move in the distal direction and release the sensor 487, thereby toggling the sensor 487 to signal the surgical instrument 100 that the end effector 300 has been removed.

[0158] In embodiments, the load link 402 and the proximal sensor link 450 and other components of the lock mechanism 400 may be formed from any suitable material including, but not limited to, polymers, metals, and combinations thereof. The components may be formed using any suitable manufacturing methods depending on the materials being used, including but not limited to, injection molding, casting, stamping, and combinations thereof. The components may be formed as integral pieces or formed from two or more subcomponents (e.g., ring 457 being coupled to proximal sensor link 450) that are then assembled. The subcomponents may be coupled using any suitable techniques including, but not limited to, adhesives (e.g., epoxy), soldering, welding, friction fitting, snap fitting, and combinations thereof.

[0159] FIGS. 40-42 show various embodiments of distal sensor links 580, 680, 780, which are substantially similar to the distal sensor link 480 of FIG. 31 and only the differences between the distal sensor links 480, 580, 680, and 780 are described.

[0160] With reference to FIGS. 40 and 41 the distal sensor links 580 and 680 are formed from sheet metal or any other suitable malleable material. In embodiments, the distal sensor links 580 and 680 may be formed by stamping. The distal sensor link 780 may be formed by injection molding from polymers, metals, combinations thereof, and the like. Each of the distal sensor links 580, 680, 780 includes a proximally-facing shaft 582, 682, 782, respectively configured and dimensioned to engage a distal end of the biasing member 474. Each of the distal sensor links 580, 680, 780 also includes a distal edge 584, 684, 784 defining a stop edge 584a, 684a, 784a for interfacing with a distal portion of the slot 464c (FIG. 30) and a linear surface 584b, 684b, 784b for interfacing with the lug 303b of the end effector 300. Each of the distal sensor links 580 and 680 also includes an opening therein 581, 681, which acts as a stress-relief feature allowing for three-dimensional shaping of the distal sensor links 580 and 680 during stamping.

[0161] With reference to FIGS. 43-55, another embodiment of a lock mechanism 500 is shown. The lock mechanism 500 is substantially similar to the lock mechanism 400 of FIGS. 22-39 and only the differences therebetween are described.

[0162] Lock mechanism 500 includes a load link 502 that extends longitudinally through outer tube 206. The lock mechanism 500 also includes a sensor link assembly 551 having a proximal sensor link 550. The link assembly 551 includes any suitable distal sensor link 480.

[0163] With reference to FIGS. 43-46, load link 502 includes a distal portion 504, which is substantially similar to the distal portion 404 of the load link 402. The load link 502 further includes a proximal portion 506 having a pair of tines 509a, 509b defining an opening 507, which is configured and dimensioned to engage a button link 508. The button link 508 is configured and dimensioned to engage the button 282 and the lock spring 440 as described in further detail below.

[0164] The button link 508 includes a mounting portion 511 having a pair of guides 511a, 511b (e.g., folds) configured to frictionally engage the pair of tines 509a, 509b, respectively. The mounting portion 511 also includes a cutout 511c having a contact edge 511d for contacting the lock spring 440. A button shaft 513 extends from the mounting portion 511 and is configured to engage the button 282.

[0165] With reference to FIGS. 47-49, the proximal sensor link 550 includes a distal portion 554, which is substantially similar to the distal portion 454 of the load link 450. The proximal sensor link 550 further includes a proximal portion 556 having a pair of flexible tabs 556a, 556b configured to engage a ring 557.

[0166] The ring 557 defines an opening 557a and includes a depression 556c for accommodating the proximal portion 506 of the load link 502. The ring 557 also includes a nub 557b disposed on an outer surface of the depression 556c for engagement with the lock spring 440 as described in further detail below. The ring 557 includes a slot 557d for engaging the flexible tabs 556a, 556b of the proximal sensor link 550.

[0167] With reference to FIG. 43, the lock mechanism 500 also includes the seal spacer 430 for aligning the load link 502 and proximal sensor link 550 within the inner housing tubes 206a, 206b. FIGS. 50-55 show assembly of the lock mechanism 500. Initially, the seal spacer 430 is inserted between the load link 502 and proximal sensor link 550 as described above. Thereafter, the button link 508 is coupled to the proximal portion 502 of the load link 502 as shown in FIG. 51. The load link 502 is pulled proximally to aid in the assembly. With reference to FIG. 52, the load link 502 is pushed distally into its home position to disengage the lock spring 440. With reference to FIG. 53, the ring 557 is coupled to the proximal portion 556 of the proximal sensor link 550. The lock mechanism 500 is thereafter coupled to the proximal portion of the adapter assembly 200 including the sensor 287 as shown in FIG. 54. With reference to FIG. 55, an anchor 559 is coupled to the seal spacer 430 to secure the proximal portion 556 of the proximal sensor link 550 to the seal spacer 430 between the flexible tabs 556a, 556b.

[0168] FIGS. 56A-C show various embodiments of multi-part load links 602, 702, 802. The load links 602, 702, 802 are substantially similar to the load link 402 of FIGS. 23 and 24 and only the differences therebetween are described. With reference to FIG. 56A, the load link 602 includes a proximal portion 606 and a distal portion 604 that are interconnected via a locking tab assembly 610. The distal portion 604 includes an opening 609. The proximal portion 606 includes a resilient tab 607 having a protrusion 607a at a distal end thereof configured and dimensioned to fit within the opening 609. During assembly, the distal and proximal portions 604, 606 are pushed together, with the resilient tab 607 being deflected until the protrusion 607a is within the opening 609, at which point the resilient tab 607 maintains the protrusion 607a therein.

[0169] With reference to FIG. 56B, the load link 702 is substantially similar to the load link 602. The load link 702 includes a distal portion 704 having a longitudinal groove 705 and an opening 709. The load link 702 also includes a proximal portion 706 that includes a resilient tab 707 having a protrusion 707a at a distal end thereof configured and dimensioned to fit within the opening 709. The groove 705 is configured and dimensioned to guide the protrusion 707a to the opening 709.

[0170] With reference to FIG. 56C, the load link 802 includes a distal portion 804 having a pair of openings 809 and a proximal portion 806 having a pair of tabs 807. Each of the tabs 807 includes a post 807a configured and dimensioned to frictionally engage the openings 809, thus obviating the need for resilient tabs.

[0171] FIG. 57 shows a multi-part proximal sensor link 650. The proximal sensor link 650 is substantially similar to the proximal sensor link 450 of FIGS. 25 and 26 and only the differences therebetween are described. The proximal sensor link 650 includes a distal portion 654 having diametrically opposed inwardly extending fingers 672. The proximal sensor link 650 also includes a proximal portion 656 having opposed outwardly extending tabs 674. During assembly, the distal and proximal portions 654, 656 are pushed together with the fingers 672 engaging the tabs 674.

[0172] FIG. 58 shows another embodiment of a multi-part load link 902, which is substantially similar to the load link 402 of FIGS. 23 and 24 and only the differences therebetween are described. The load link 902 includes a proximal portion 906 and a distal portion 904 that are interconnected via a connector plate 910. Each of the distal portion 904 and the proximal portion 906 includes one or more openings 909. The connector plate 910 includes one or more posts 911 at proximal and distal ends thereof configured and dimensioned to frictionally fit within the openings 909. In embodiments, the posts 911 may be disposed on either the top and/or bottom surfaces of the connector plate 910. During assembly, the connector plate 910 is coupled to both the distal and proximal portions 904, 906 to secure the distal and proximal portions 904, 906.

[0173] FIG. 59 shows a multi-part proximal sensor link 750. The proximal sensor link 750 is substantially similar to the proximal sensor link 450 of FIGS. 25 and 26 and only the differences therebetween are described. The proximal sensor link 750 includes a distal portion 754 and a proximal portion 756, each of which includes outwardly extending tabs 774 and 776, respectively. The proximal sensor link 750 also includes a connector plate 780 having diametrically opposed inwardly extending fingers 772 at its proximal and distal ends. During assembly, the connector plate 780 is coupled to both the distal and proximal portions 754, 756 as the fingers 772 engage the tabs 774 and 776 to secure the distal and proximal portions 754, 756.

[0174] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the instrument 100 need not apply staples but rather may apply two part fasteners as is known in the art. Further, the length of the linear row of staples or fasteners may be modified to meet the requirements of a particular surgical procedure. Thus, the length of a single stroke of the actuation shaft and/or the length of the linear row of staples and/or fasteners within a disposable loading unit may be varied accordingly. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended thereto.

Claims

The invention claimed is:

1. A surgical device adapter for coupling an end effector to a handle assembly, the surgical device adapter comprising:

a sensor link assembly longitudinally movable and engagable by the end effector upon coupling the end effector to the surgical device adapter;

a load link movable by the end effector from a first longitudinal position to a second longitudinal position, wherein in the second longitudinal position the load link locks the sensor link assembly and in the first longitudinal position releases the sensor link assembly; and

a sensor engagable by the sensor link assembly upon proximal movement thereof in response to release by the load link.

2. The surgical device adapter according to claim 1, wherein the load link is distally biased and is configured to prevent proximal movement of the sensor link assembly until the load link is distally biased and the end effector is coupled to the surgical device adapter.

3. The surgical device adapter according to claim 2, further comprising a lock spring actuatable by proximal movement of the load link, the lock spring configured to couple to a proximal portion of the sensor link assembly and prevent proximal movement thereof.

4. The surgical device adapter according to claim 3, wherein the sensor link assembly comprises a proximal sensor link, a distal sensor link and a biasing member disposed therebetween.

5. The surgical device adapter according to claim 4, wherein the proximal sensor link comprises a ring configured to interface with the lock spring.

6. The surgical device adapter according to claim 4, wherein the surgical device adapter comprises a bayonet connection at a distal end thereof configured to couple to a pair of lugs of the end effector.

7. The surgical device adapter according to claim 6, wherein the end effector is configured to be inserted linearly into the bayonet connection.

8. The surgical device adapter according to claim 7, wherein the load link is moved proximally to allow for rotation of the pair of lugs within the bayonet connection.

9. The surgical device adapter according to claim 8, wherein at least one lug of the pair of lugs engages the distal sensor link upon rotation of the end effector within the bayonet connection thereby compressing the biasing member.

10. The surgical device adapter according to claim 9, wherein the load link is moved distally to secure at least one lug of the pair of lugs within the bayonet connection.

11. The surgical device adapter according to claim 10, wherein distal movement of the load link releases the lock spring allowing the biasing member to move the proximal sensor link proximally to engage the sensor.

12. A method for coupling an end effector to a surgical device adapter, comprising the steps of:

inserting an end effector comprising a pair of lugs disposed at a proximal end thereof into a distal end of the surgical device adapter;

proximally moving a distally-biased load link within the surgical device adapter to secure a sensor link assembly;

rotating the end effector within the adapter assembly, wherein at least one lug of the pair of lugs engages and secures at least a portion of the sensor link assembly; and

distally moving the distally-biased load link to secure the end effector within the surgical device adapter and to release the sensor link assembly allowing the sensor link assembly to move proximally to engage a sensor.

13. The method according to claim 12, wherein the sensor link assembly comprises a distally-biased proximal sensor link, a distal sensor link, and a biasing member disposed therebetween.

14. The method according to claim 13, wherein moving the distally-biased load link proximally secures the distally-biased proximal sensor link.

15. The method according to claim 14, wherein rotating the end effector engages at least one lug of the pair of lugs and engages the distal sensor link thereby compressing the biasing member.

16. The method according to claim 15, moving the distally-biased load link distally secures at least one lug of the pair of lugs to release the distally-biased proximal sensor link allowing the biasing member to move the distally-biased proximal sensor link proximally to engage the sensor.

17. The method according to claim 12, wherein the distally-biased load link is coupled to the sensor link assembly via a biasing member at proximal ends thereof.

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Abstract