Patent Application
20230050248
The present disclosure relates to surgical instruments and, more particularly, to shaft-based surgical instruments for grasping, treating, and/or dividing tissue incorporating shaft retention features.
Some energy-based surgical instruments, such as energy-based surgical forceps, utilize mechanical clamping action and application of energy, e.g., radio frequency (RF) energy, ultrasonic energy, microwave energy, light energy, thermal energy, etc., to affect hemostasis by heating tissue to coagulate, cauterize, and/or seal tissue. Coagulation may be sufficient to achieve hemostasis on some tissue, e.g., non-vascular tissue, small blood vessels below about two millimeters in diameter, and tissues including small vessels. However, for other tissue, e.g., large blood vessels above about two millimeters in diameter and tissues including larger vessels, coagulation may be insufficient to achieve hemostasis; instead, these tissues may be required to be sealed, a process by which the collagen in the tissue is heated up, denatured, and reformed into a fused mass to permanently close the vessel(s). Once hemostasis is achieved, the treated tissue may be cut (mechanically, electrically, or electro-mechanically) to divide the tissue.
As used herein, the term “distal” refers to the portion that is being described which is further from an operator, e.g., a surgeon or a surgical robot, while the term “proximal” refers to the portion that is being described which is closer to the operator. Terms including “generally,” “about,” “substantially,” and the like, as utilized herein, are meant to encompass variations, e.g., manufacturing tolerances, material tolerances, use and environmental tolerances, measurement variations, and/or other variations, up to and including plus or minus 10 percent. Further, any or all of the aspects described herein, to the extent consistent, may be used in conjunction with any or all of the other aspects described herein.
Provided in accordance with aspects of the present disclosure is a surgical instrument including a housing, a shaft, an end effector assembly, and a bobbin. The housing defines a distal aperture and includes an internal partition proximally-spaced from the distal aperture to define an interior cavity therebetween. The internal partition defines a shaft aperture therethrough. The shaft includes a proximal end portion disposed within the housing having at least one protrusion. The shaft extends distally through the shaft aperture of the internal partition, the internal cavity, and the distal aperture of the housing to a distal end portion of the shaft that is distally-spaced from the housing. The end effector assembly is supported at the distal end portion of the shaft. The bobbin includes a body, a proximal rim, and a distal cylinder. The bobbin is disposed about the shaft such that the at least one protrusion is captured within a track defined within the distal cylinder. The bobbin is configured for positioning within the housing such that the body extends through the shaft aperture of the internal partition with the proximal rim disposed on a proximal side of the partition and the distal cylinder disposed within the interior cavity on a distal side of the partition, thereby rotatably supporting the proximal end portion of the shaft within the housing.
In an aspect of the present disclosure, the bobbin is formed as a single, monolithic piece of material. In such aspects, the distal cylinder of the bobbin may define at least one access opening therethrough to permit manipulation of the at least one protrusion of the shaft with the bobbin disposed about the at least one protrusion. In aspects, the at least one protrusion is at least one tab and the manipulation includes flaring the at least one tab radially outwardly from the shaft.
In another aspect of the present disclosure, the bobbin is formed from first and second pieces. The first piece may include the body, the proximal rim, and a portion of the distal cylinder, while the second piece includes a remaining portion of the distal cylinder. The second piece may be configured to engage the first piece to capture the at least one protrusion within the track.
In still another aspect of the present disclosure, the first and second pieces include semi-cylinders each defining approximately half of the distal cylinder.
In yet another aspect of the present disclosure, the first and second pieces are configured for snap-fit engagement with one another.
In still yet another aspect of the present disclosure, the first piece includes a proximal wall of the distal cylinder and the second piece includes the remainder of the distal cylinder. In such aspects, the proximal wall of the first piece may include a plurality of fingers extending therefrom configured for receipt within cut-outs defined within a distal wall of the second piece. Alternatively or additionally, a plurality of pins may be provided to rotationally lock the first and second pieces with one another.
In another aspect of the present disclosure, the surgical instrument further includes a drive assembly including a movable handle pivotably coupled to the housing and a drive sleeve extending through the shaft and operably coupled between the movable handle and the end effector assembly. Actuation of the movable handle translates the drive sleeve to thereby actuate the end effector assembly.
In another aspect of the present disclosure, the at least one protrusion includes at least one flared tab cut out from and configured to be flared radially outwardly from the shaft.
The above and other aspects and features of the present disclosure will become more apparent in view of the following detailed description when taken in conjunction with the accompanying drawings wherein like reference numerals identify similar or identical elements.
Referring generally to
Shaft 100 extends distally from housing 200 and supports end effector assembly 700 at a distal end portion 104 thereof. A bobbin 110 is disposed about a proximal end portion 102 of shaft 100 within housing 200. Bobbin 110 includes a body 112 and a rim 114 disposed at either end of body 112. Bobbin 110 is supported within housing 200, as detailed below, to thereby rotatably support proximal end portion 102 of shaft 100 within housing 200. One or more flared tabs 108 (in aspects, a plurality of flared tabs 108) are cut out from shaft 100 and flared outwardly therefrom. Tabs 108 are positioned distally of bobbin 110 and, due to the radially-outwardly flared configuration thereof, inhibit distal sliding of bobbin 110 along shaft 100 and over tabs 108. In aspects, two diametrically opposed tabs 108 are provided, although greater or fewer tabs 108 and/or other arrangements of tabs 108 are also contemplated. As an alternative to tabs 108, any other suitable protrusion(s) extending radially outwardly from shaft 100 are also contemplated, e.g., one or more bosses extending from shaft 100, a coupler engaged about shaft 100, a flange engaged about or formed with shaft 100, etc. Various different bobbin configurations, engagements thereof about proximal end portion 102 of shaft 100, and/or rotatable supporting thereof within housing 200 are described in detail below with reference to
Housing 200 of instrument 10 includes first and second housing parts 210, 220 secured to one another, e.g., via ultrasonic welding, to operably support and/or enclose various components of instrument 10 within housing 200. More specifically, housing parts 210, 220 may either or both define a distal aperture 244 through which shaft 100 extends distally from housing 200 and a partition 254, e.g., formed from one or more transverse internal walls, defining a shaft aperture 256 that is proximally-spaced from distal aperture 244 of housing 200 such that an internal cavity 258 is defined between distal aperture 244 at the distal end of housing 200 and partition 254. Bobbin 110 is support within housing 200 about partition 254, e.g., with body 112 extending through shaft aperture 256 and rims 114 disposed on either side of partition 254. Shaft 100 is positioned such that tabs 108 (or other suitable protrusion(s)) are disposed within internal cavity 258 between distal aperture 244 at the distal end of housing 200 and partition 254. In this manner, shaft 100 is rotational relative to housing 200 and is constrained but permitted some amount of longitudinal motion due to clearance within internal cavity 258 that allows shaft to move between a proximal position wherein tabs 108 abut the distal rim 114 of proximal collar 110 and a distal position wherein tabs 108 abut the distal internal surface of housing 200. This longitudinal motion, whereby movement of the shaft 100 and end effector assembly 700 relative to the housing 200 is permitted to a relatively small extent, facilitates actuation of end effector assembly 700 while inhibiting over-drive of the drive assembly 300.
Drive assembly 300 includes, among other components, a movable handle 310 that is operably coupled to a drive sleeve 360 within housing 200. Drive sleeve 360 extends from housing 200 through shaft 100 to operably couple with end effector assembly 700 such that pivoting of movable handle 310 relative to housing 200 between an un-actuated position, wherein movable handle 310 is farther spaced-apart from the fixed handle portion of housing 200, and an actuated position, wherein movable handle 310 is more closely approximated relative to the fixed handle portion of housing 200, pivots movable jaw member 720 of end effector assembly 700 relative to fixed jaw member 760 of end effector assembly 700 from a spaced-apart position to an approximated position. Movable handle 310 is further movable towards the fixed handle portion of housing 200 to an activated position to activate activation button 810 of activation assembly 800, although a separate hand switch disposed on housing 200 is also contemplated.
Rotation assembly 400 includes a rotation wheel 410 and a continuous rotation assembly 420. Rotation wheel 410 is engaged about proximal end portion 102 of shaft 100 within housing 200 and extends outwardly through windows defined within either side of housing 200 to enable manual manipulation of rotation wheel 410. More specifically, rotation wheel 410 is continuously rotatable in either direction to thereby rotate shaft 100, and end effector assembly 700 supported by shaft 100, relative to housing 200. Continuous rotation assembly 420 maintains electrical connection of jaw members 720, 760 of end effector assembly 700 with the lead wires from cable 900 and/or activation assembly 800 regardless of the rotational orientation of rotation wheel 410 and shaft 100 relative to housing 200.
Trigger assembly 500 includes a trigger 510 and a plurality of linking structures 520 that operably connect trigger 510 to knife assembly 600 such that actuation of trigger 510 relative to housing 200 from an un-actuated position to an actuated position advances knife assembly 600 to thereby translate knife 610 of knife assembly 600 between jaw members 720, 760 to cut tissue grasped therebetween.
End effector assembly 700 is supported at distal end portion 104 of shaft 100 and includes a movable jaw member 720 and fixed jaw member 760 each including an opposed electrically-conductive plate 750, 790. A pivot pin 106 (
One or both electrically-conductive plate 750, 790 may include a series of stop members 792 configured to maintain a gap between electrically-conductive plates 750, 790 and inhibit electrical shorting therebetween, e.g., by being formed from an insulative material or by being electrically-isolated from one or both of the electrically-conductive plates 750, 790. Electrically-conductive plates 750, 790 further cooperate to define a knife channel 798 extending longitudinally therethrough in the approximated position of jaw members 720, 760 to facilitate and guide reciprocation of knife 610 of knife assembly 600 (
Lead wires (not explicitly shown) are adapted to connect electrically-conductive plates 750, 790 to a source of electrosurgical energy, e.g., an electrosurgical generator (not shown), via cable 900 and continuous rotation assembly 420 of rotation assembly 400 such that, upon activation, electrically-conductive plates 750, 790 are energized to different potentials to enable the conduction of energy therebetween and through the grasped tissue to treat, e.g., seal, the grasped tissue.
Further aspects and features of instrument 10, and more detail regarding the above-noted aspects and features of instrument 10 can be found in U.S. patent application Ser. Nos. 17/122,062; 17/122,113; and Ser. No. 17/122,144, all filed on Dec. 15, 2020, the entire contents of each of which are hereby incorporated herein by reference.
Referring to
Bobbin 1110 is configured for positioning about shaft 100 with flared tabs 108 (or other suitable protrusion(s)) of shaft 100 disposed within distal cylinder 1116. Bobbin 1110, more specifically, is moved into this position prior to the outward flaring of tabs 108. With bobbin 1110 positioned in this manner, a suitable tool(s) (not shown) may be inserted through the one or more apertures 1126 and utilized to flare the one or more tabs 108 radially outwardly from shaft 100 into track 1124 of distal cylinder 1116 of bobbin 1110, thereby longitudinally retaining bobbin 1110 in position about shaft 100.
Bobbin 1110, engaged about shaft 100 as detailed above, is configured for positioning within housing 200 with body 1112 extending through shaft aperture 256, proximal rim 1114 disposed on a proximal side of partition 254 and distal cylinder 1116 disposed on a distal side of partition 254 within internal cavity 258 between distal aperture 244 at the distal end of housing 200 and partition 254. In this manner, proximal end portion 102 of shaft 100 is rotatably supported within housing 200 and longitudinally constrained thereby while still permitting some amount of longitudinal motion due to distal cylinder 1116 defining a length slightly less than a length of internal cavity 258 (that is, a distance between the distal end of housing 200 and partition 254).
With reference to
Bobbin 2110 includes a body 2112, a proximal rim 2114 disposed at a proximal end of body 2112, and a two-piece distal cylinder 2116 disposed at a distal end of body 2112. Body 2112, proximal rim 2114, and a first piece 2118 of two-piece distal cylinder 2116 may be formed as a single, monolithic piece of material. Second piece 2120 of distal cylinder 2116 is configured to engage first piece 2118 to form distal cylinder 2116. More specifically, first and second pieces 2118, 2120 may be substantially semi-cylindrical (wherein each defines half a cylinder plus or minus 10%) and configured such that, when engaged with one another, an internal annular track 2122 is defined therein. Other configurations are also contemplated, e.g., wherein one of the pieces 2118, 2120 defines a substantially greater portion of a cylinder than the other.
First and second pieces 2118, 2120 of distal cylinder 2116 may be engagable with one another via a male-female snap-fit connection 2124 wherein one or more male components 2126 is disposed on one or both of first or second pieces 2118, 2120 and one or more female components 2128 are defined on the other or both of first or second pieces 2118, 2120. One or more sets of complementary interfitting alignment structures 2130, 2132 may also be provided on or defined within first and second pieces 2118, 2120 to facilitate alignment thereof during engagement of first and second pieces 2118, 2120 with one another. In aspects, two sets of diametrically-opposed complementary interfitting alignment structures 2130, 2132 are provided.
Bobbin 2110 is configured for positioning about shaft 100 with flared tabs 108 (or other suitable protrusion(s)) of shaft 100 disposed within first piece 2118 of distal cylinder 2116 prior to engagement of second piece 2118b thereon. Bobbin 2110, more specifically, is moved into this position prior to the outward flaring of tabs 108. With bobbin 2110 positioned in this manner, a suitable tool (not shown) may be utilized to flare the one or more tabs 108 radially outwardly from shaft 100. Alternatively, tabs 108 may be flared prior to slidable positioning of bobbin 2110. Once bobbin 2110 is positioned as noted above, second piece 2120 of distal cylinder 2116 may be engaged with first piece 2118 to capture the one or more flared tabs 108 within track 2122 of distal cylinder 2116 of bobbin 2110, thereby rotationally retaining bobbin 2110 about shaft 100. Bobbin 2110 is retained within housing 200 similarly as detailed above with respect to bobbin 1110 (
Referring to
Bobbin 3110 includes a body 3112, a proximal rim 3114 disposed at a proximal end of body 3112, and a two-piece distal cylinder 3116 disposed at a distal end of body 3112. Body 3112, proximal rim 3114, and a first piece 3118 of two-piece distal cylinder 3116 may be formed as a single, monolithic piece of material. Second piece 3120 of distal cylinder 3116 is configured to engage first piece 3118 to form distal cylinder 3116.
First piece 3118 of two-piece distal cylinder 3116 defines the proximal ring wall 3122 of distal cylinder 3116 and includes a plurality of radially-arranged lock fingers 3130 extending distally from proximal ring wall 3122. Second piece 3120 of two-piece distal cylinder 3116 defines the distal ring wall 3124 of distal cylinder 3116 and casing 3126 of distal cylinder 3116 and includes a plurality of radially-arranged lock cut-outs 3132 defined within the distal ring wall 3124.
Bobbin 3110 is configured for positioning about shaft 100 with flared tabs 108 (or other suitable protrusion(s)) of shaft 100 disposed within lock fingers 3130 of first piece 3118 of distal cylinder 3116 prior to engagement of second piece 3120 thereon. Bobbin 3110 may be moved into this position prior to the outward flaring of tabs 108 or afterwards. With bobbin 3110 positioned in this manner, second piece 3120 of distal cylinder 3116 is slid proximally over shaft 100 until lock fingers 3130 of first piece 3118 are received through lock cut-outs 3132 of second piece 3120. Once this position is achieved, second piece 3120 is rotated relative to first piece 3118 such that lock fingers 3130 of first piece 3118 and lock cut-outs 3132 of second piece 3120 are at least partially misaligned, thereby locking first and second pieces 3118, 3120 in engagement with one another and capturing the one or more flared tabs 108 (
As an alternative to the above-detailed rotation-to-lock configuration, first and second pieces 3118, 3120 may also be configured to engage one another via snap-fitting of lock fingers 3130 within lock cut-outs 3132, friction fitting of lock fingers 3130 within lock cut-outs 3132, adhesion, and/or other suitable mechanical, chemical, or other securement technique. In other aspects, no lock feature is provided; rather, with lock fingers 3130 of first piece 3118 received within lock cut-outs 3132 of second piece 3120, thereby rotationally retaining first and second pieces 3118, 3120 relative to one another, the subsequent positioning of distal cylinder 3116 of bobbin 3110 within internal cavity 258 of housing 200 between distal aperture 244 at the distal end of housing 200 and partition 254 of housing 200 retains first and second pieces 3118, 3120 in sufficient approximation with one another due to the presence of partition 254 and the distal end of housing 200 on either side thereof (see
Bobbin 4110 includes a body 4112, a proximal rim 4114 disposed at a proximal end of body 4112, and a two-piece distal cylinder 4116 disposed at a distal end of body 4112 and including a first piece 4118 defining a proximal ring wall 4120 of distal cylinder 4116. A plurality of distally-facing recesses 4122 are defined within a distally-facing surface of proximal ring wall 4120. Second piece 4124 of two-piece distal cylinder 4116 defines a cylinder 4126 itself. Cylinder 4126 defines a lumen 4128 therethrough and includes a plurality of proximally-facing recesses 4130 defined within a proximal face thereof.
Bobbin 4110 is configured for positioning about shaft 100 with flared tabs 108 (or other suitable protrusion(s)) of shaft 100 disposed proximally adjacent proximal ring wall 4120 of first piece 4118 of distal cylinder 4116 prior to engagement of second piece 4124 therewith. Bobbin 4110 may be moved into this position prior to the outward flaring of tabs 108 or afterwards. With bobbin 4110 positioned in this manner, second piece 4124 of distal cylinder 4116 is slid proximally over shaft 100. A plurality of set pins 4132 are configured for receipt within recesses 4122 and 4130 such that, upon further proximal sliding of second piece 4124 of distal cylinder 4116 into approximation with first piece 4118, set pins 4132 rotationally retain first and second pieces 4118, 4124 relative to one another with tabs 108 captured within a track 4129 defined therein. The subsequent positioning of distal cylinder 4116 of bobbin 4110 within internal cavity 258 between distal aperture 244 at the distal end of housing 200 and partition 254 may retain first and second pieces 4118, 4124 in sufficient approximation with one another due to the presence of partition 254 and the distal end of housing 200 on either side thereof (see
While several configurations of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular configurations. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
