Adapter assemblies for interconnecting electromechanical handle assemblies and surgical loading units

Patent metadata

Field	Value
Publication number	US-10835255-B2
Application number	US-201715421798-A
Country	US
Kind code	B2
Filing date	Feb 1, 2017
Priority date	Feb 10, 2016
Publication date	Nov 17, 2020
Grant date	Nov 17, 2020

Abstract

A surgical instrument includes a handle assembly and an adapter assembly. The handle assembly includes a handle housing and a processor disposed within the handle housing. The adapter assembly includes a knob housing, an elongate body, a plurality of electrical components, and a flex circuit. The knob housing is configured to be connected to the handle housing. The elongate body extends distally from the knob housing and has a distal end configured to be coupled to an end effector. The electrical components are disposed within the elongate body. The flex circuit has a proximal end configured to be electrically connected to the processor, and a distal end configured to be electrically connected to the electrical components.

First claim

The invention claimed is:

1. A surgical instrument, comprising:
a handle assembly including:
a handle housing; and
a processor disposed within the handle housing; and

an adapter assembly configured to convert a rotation of drive elements of the handle assembly into axial movement of driven members of the adapter assembly to actuate functions of an end effector of a surgical loading unit, the adapter assembly including:
a knob housing configured to be connected to the handle housing;
an elongate body extending distally from the knob housing and having a distal end configured to be coupled to the end effector;
a plurality of electrical components disposed within the elongate body; and
a flex circuit extending longitudinally through the knob housing and the elongate body and having a proximal end configured to be electrically connected to the processor, and a distal end configured to be electrically connected to the plurality of electrical components.

2. The surgical instrument according to claim 1 , wherein the flex circuit includes at least two surface layers stacked upon one another, a first surface layer of the at least two surface layers being configured to electrically couple the processor to two of the plurality of electrical components, and a second surface layer of the at least two surface layers being configured to electrically couple the processor to another of the plurality of electrical components.

3. The surgical instrument according to claim 1 , wherein the distal end of the flex circuit includes a switch configured to be activated by one type of end effector upon connection of the one type of end effector to the distal end of the elongate body, whereby a memory of the flex circuit transmits operating parameters of the adapter assembly to the processor.

4. The surgical instrument according to claim 1 , wherein one of the plurality of electrical components is a linear position sensor assembly that is disposed in the distal end of the elongate body, and wherein the distal end of the flex circuit is electrically and mechanically connected to the linear position sensor assembly.

5. The surgical instrument according to claim 4 , wherein the linear position sensor assembly includes plurality of sensors axially aligned with one another along a longitudinal axis of the linear position sensor assembly.

6. The surgical instrument according to claim 4 , wherein the linear position sensor assembly has five contacts electrically connected to the distal end of the flex circuit.

7. The surgical instrument according to claim 4 , wherein another of the plurality of electrical components is a pressure sensor, the distal end of the flex circuit being bifurcated forming a first distal end electrically and mechanically connected to the linear position sensor assembly and a memory, and a second distal end electrically and mechanically connected to the pressure sensor, the second distal end extending in a generally proximal direction and disposed proximally of the first distal end.

8. The surgical instrument according to claim 7 , wherein the pressure sensor is a strain gauge.

9. The surgical instrument according to claim 7 , wherein the pressure sensor has five contacts electrically connected to the second distal end of the flex circuit.

10. The surgical instrument according to claim 1 , wherein one of the plurality of electrical components is a memory having stored therein at least one operating parameter of the surgical instrument, the distal end of the flex circuit being electrically connected to the memory.

11. The surgical instrument according to claim 10 , wherein the at least one operating parameter is selected from the group consisting of a speed of operation of a motor of the handle assembly, an amount of power to be delivered by the motor of the handle assembly during operation thereof, a selection of which motors of the handle assembly are to be actuated, and a type of function of an end effector to be performed by the handle assembly.

12. The surgical instrument according to claim 10 , wherein the memory has an identification code stored therein corresponding to one type of end effector.

13. The surgical instrument according to claim 1 , wherein the memory is a 1-wire eeprom having two contacts electrically and mechanically connected to the distal end of the flex circuit.

14. A surgical instrument, comprising:
a handle assembly including:
a handle housing;
a motor disposed within the handle housing; and
a processor disposed within the handle housing;

an adapter assembly configured to convert a rotation of drive elements of the handle assembly into axial movement of driven members of the adapter assembly to actuate functions of an end effector of a surgical loading unit, the adapter assembly including:
a knob housing configured to be connected to the handle housing;
an elongate body extending distally from the knob housing and having a distal end;
a plurality of electrical components disposed within the elongate body; and
a flex circuit extending longitudinally through the knob housing and the elongate body and having a proximal end configured to be electrically connected to the processor, and a distal end configured to be electrically connected to the plurality of electrical components; and

the surgical loading unit having a proximal end configured to be operably coupled to the distal end of the elongate body of the adapter assembly and a distal end having the end effector.

15. The surgical instrument according to claim 14 , wherein the flex circuit includes at least two surface layers stacked upon one another, a first surface layer of the at least two surface layers being configured to electrically couple the processor to two of the plurality of electrical components, and a second surface layer of the at least two surface layers being configured to electrically couple the processor to another of the plurality of electrical components.

16. The surgical instrument according to claim 15 , wherein a first electrical component of the plurality of electrical components is a linear position sensor assembly that is disposed in the distal end of the elongate body, a distal end of the first surface layer of the at least two surface layers of the flex circuit being electrically and mechanically connected to the linear position sensor assembly.

17. The surgical instrument according to claim 16 , wherein a second electrical component of the plurality of electrical components is a pressure sensor, a distal end of the second surface layer of the at least two surface layers of the flex circuit being bifurcated from the first surface layer and having a distal end electrically and mechanically connected to the pressure sensor.

18. The surgical instrument according to claim 17 , wherein a third electrical component of the plurality of electrical components is a memory having stored therein at least one operating parameter of the surgical instrument, the distal end of the first surface layer of the at least two surface layers of the flex circuit being electrically connected to the memory.

19. The surgical instrument according to claim 18 , wherein the distal end of the flex circuit includes a switch configured to be activated by the surgical loading unit upon connection of the surgical loading unit to the adapter assembly such that upon connecting the surgical loading unit with the adapter assembly, the memory automatically transmits the at least one operating parameter to the processor via the flex circuit.

20. The surg

Assignees

• Covidien Lp

Inventors

• Collins Ethan
• Richard Paul
• Calderoni Anthony
• Hryb John

Classifications

• A61B17/115

  Staplers for performing anastomosis, e.g. in a single operation · CPC title

• A61B2090/0808

  for indicating correct assembly of components, e.g. of the surgical apparatus · CPC title

• A61B2017/00398

  using powered actuators, e.g. stepper motors, solenoids · CPC title

• A61B2017/00482

  with a code · CPC title

• A61B2017/00734

  battery operated · CPC title