Mechanical lockout for ultrasonic surgical instrument

Patent metadata

Field	Value
Publication number	US-10945755-B2
Application number	US-201815951773-A
Country	US
Kind code	B2
Filing date	Apr 12, 2018
Priority date	Apr 12, 2018
Publication date	Mar 16, 2021
Grant date	Mar 16, 2021

Abstract

An ultrasonic surgical instrument includes a first modular assembly including at least one operator input feature an ultrasonic transducer supported by the first modular assembly, and a second modular assembly configured to be removably coupled with the first modular assembly. The second modular assembly includes at least a portion of an end effector extending distally from a distal end portion of the second modular assembly. The instrument includes a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration. In the locked configuration, the first modular assembly and the second modular assembly are partially coupled together such that the operator is physically prevented from activating the instrument using the operator input feature. In the unlocked configuration, the first modular assembly and the second modular assembly are completely coupled together and the operator is able to activate the instrument using the operator input feature.

First claim

We claim:

1. An ultrasonic surgical instrument, comprising:
(a) a first modular assembly including at least one operator input feature;
(b) an ultrasonic transducer supported by the first modular assembly and operatively connected to the at least one operator input feature;
(c) a second modular assembly configured to be removably coupled with the first modular assembly, wherein the second modular assembly further includes at least a portion of an end effector extending distally from a distal end portion of the second modular assembly; and
(d) a mechanical lockout assembly configured to switch between at least an unlocked configuration and a locked configuration,
wherein in the locked configuration, the first modular assembly and the second modular assembly are partially coupled together such that the operator is physically prevented from activating the ultrasonic transducer using the at least one operator input feature, and
wherein in the unlocked configuration, the first modular assembly and the second modular assembly are completely coupled together and the operator is able to activate the ultrasonic transducer using the at least one operator input feature.

2. The ultrasonic surgical instrument of claim 1 , wherein the first modular assembly further includes a handle assembly, a proximal outer sheath, and an ultrasonic blade, wherein the second modular assembly further includes a clamp arm assembly and a distal outer sheath, wherein the mechanical lockout assembly further includes at least one lockout member having a body that includes a lockout feature, wherein the lockout feature includes at least one of a curve, a change in angle, a slot, or a proximal extrusion from the body, wherein in the locked configuration, the lockout feature prevents rotation of the clamp arm assembly relative to the ultrasonic blade, and wherein in the unlocked configuration, the proximal outer sheath is configured to couple with the distal outer sheath allowing closure of the clamp arm assembly relative to the ultrasonic blade.

3. The ultrasonic surgical instrument of claim 2 , wherein in the locked configuration, the lockout member prevents actuation of the clamp arm assembly due to an interference with both the clamp arm assembly and the distal outer sheath.

4. The ultrasonic surgical instrument of claim 2 , wherein the mechanical lockout assembly further includes a pin that pivotably couples the distal outer sheath with both the clamp arm assembly and the lockout member.

5. The ultrasonic surgical instrument of claim 2 , wherein the proximal outer sheath includes a projection that displaces the lockout member distally when coupling the proximal outer sheath with the distal outer sheath.

6. The ultrasonic surgical instrument of claim 1 , wherein the first modular assembly includes a handle assembly that includes a proximal outer sheath, and an ultrasonic blade, wherein the second modular assembly includes a clamp arm assembly and a distal outer sheath, wherein the mechanical lockout assembly further includes at least one projection operatively coupled with a clamp arm assembly, wherein in the locked configuration the projection is not received by a corresponding recess in the distal outer sheath, the locked configuration configured to prevent an operator from rotating the clamp arm assembly relative to the ultrasonic blade, and wherein in the unlocked configuration where the proximal outer sheath is coupled with the distal outer sheath, the projection is received by the corresponding recess in the distal outer sheath enabling the operator from rotating the clamp arm assembly relative to the ultrasonic blade.

7. The ultrasonic surgical instrument of claim 1 , wherein the first modular assembly further includes a handle assembly that includes the at least one operator input feature, wherein the at least one operator input feature includes at least one energy control button separated by a passageway from a switch, wherein the mechanical lockout assembly further includes a barrier that includes a body portion and at least one aperture that translates between the locked configuration and the unlocked configuration within the passageway, wherein in the locked configuration, the body portion is disposed within the passageway between the at least one energy control button and the switch preventing the switch from activating the instrument, and wherein in the unlocked configuration, the at least one aperture is disposed within the passageway between the at least one energy control button and the switch enabling the switch to activate the instrument.

8. The ultrasonic surgical instrument of claim 7 , wherein the barrier includes a flexible member that is operatively coupled with a shaft assembly of the second modular assembly, wherein the flexible element is pushed into the passageway such that in the locked configuration the flexible member extends between the at least one energy control button and the switch.

9. The ultrasonic surgical instrument of claim 7 , wherein in the unlocked configuration, at least one of the at least one energy control button or the switch extends at least partially through the at least one aperture of the barrier and makes direct physical contact with the other of the at least one energy control button or the switch through the at least one aperture.

10. The ultrasonic surgical instrument of claim 7 , wherein the second modular assembly further includes a shaft assembly, wherein the mechanical lockout assembly further includes an angled slide that is configured to be contacted by a projection of the shaft assembly, wherein the angled slide is configured to contact the barrier causing the mechanical lockout assembly to transition from the locked configuration to the unlocked configuration, and wherein in the locked configuration, the body portion of the barrier is disposed within the passageway between the at least one energy control button and the switch preventing the switch from activating the ultrasonic transducer.

11. The ultrasonic surgical instrument of claim 1 , wherein the first modular assembly includes the at least one operator input feature, wherein the at least one operator input feature includes at least one switch and a first portion of an energy control button, wherein the second modular assembly further includes a shaft assembly and a handle assembly that includes a second portion of the at least one energy control button, wherein in the locked configuration when the shaft assembly is partially coupled with the handle assembly, misalignment of the first and second portions of the at least one energy control button prevents the at least one switch from activating the ultrasonic transducer, and wherein in the unlocked configuration when the shaft assembly is completely coupled with the handle assembly, alignment of the first and second portions of the at least one energy control button enables the at least one switch to activate the ultrasonic transducer.

12. The ultrasonic surgical instrument of claim 1 , wherein the first modular assembly further includes a handle assembly that includes a trigger, wherein the second modular assembly further includes a shaft assembly, wherein the mechanical lockout assembly further includes a closure lever link operatively coupled with the trigger, wherein in the locked configuration when the shaft assembly is partially coupled with the handle assembly, the closure lever link is pulled over center in a first direction, preventing the closure lever link from being rotated closed which prevents the trigger from being actuated, and wherein in the unlocked configuration when the shaft assembly is completely coupled with the handle assembly, insertio

Assignees

• Ethicon Llc

Inventors

• Brady John E
• Cuti Alexander R
• Fiebig Kevin M
• Burkart Ellen
• Harris Demetrius N
• Kolpitcke Andrew
• Krumm Amy M
• Kuhn Matthew T
• Lesko Jason R
• Leuck Stephen M
• Lucas Guion Y
• Mclain Cameron D
• Meyers Andrew S
• Otrembiak Candice
• Waters Grace E

Classifications

• A61B2018/00994

  combining two or more different kinds of non-mechanical energy or combining one or more non-mechanical energies with ultrasound · CPC title

• A61B2017/320095

  with sealing or cauterizing means · CPC title

• A61B2018/0063

  Sealing · CPC title

• A61B2017/00424

  ergonomic, e.g. fitting in fist · CPC title

• A61B2017/00402

  Piezo electric actuators · CPC title