Adapter assemblies and surgical loading units

An adapter assembly includes an elongate body configured to receive a surgical loading unit and an elongate loading bar coupled to the elongate body and configured to selectively lock the surgical loading unit to the adapter assembly. The elongate loading bar has a distal end defining a slot therein configured for receipt of an articulation link of the surgical loading unit upon an improper insertion of the surgical loading unit into the adapter assembly. With the articulation captured in the slot, rotation of the surgical loading unit toward a fully assembled state with the adapter assembly is resisted.

FIELD

The present technology is generally related to adapter assemblies for use with an electromechanical surgical system and their methods of use. More specifically, the present technology relates to electromechanical surgical instruments configured to ensure the proper connection of a loading unit with an adapter assembly.

BACKGROUND

Linear clamping, cutting, and stapling surgical devices may be employed in surgical procedures to resect tissue. Conventional linear clamping, cutting, and stapling devices include a handle assembly, an adapter assembly extending from the handle assembly, and a surgical loading unit detachably coupled to the adapter assembly. The surgical loading unit includes a pair of opposing gripping jaw members, which clamp about the tissue. One or both of the jaw members, such as the anvil portion, moves or pivots relative to the overall structure. Actuation of the device may be controlled by a grip trigger maintained in the handle assembly or via a robotic assembly.

In addition to the jaw members, the surgical loading unit may also include a stapling mechanism. One of the jaw members of the surgical loading unit may include a staple cartridge receiving region and a mechanism for driving staples up through tissue clamped against the anvil portion, thereby sealing the tissue. The jaw members may be integrally formed with the adapter assembly or may be detachable such that various gripping and stapling elements may be interchangeable.

SUMMARY

The techniques of this disclosure generally relate to adapter assemblies for interconnecting handle assemblies and surgical loading units. The present disclosure also relates to mechanical features that ensure a proper assembly of the surgical loading unit with the adapter assembly.

According to an aspect of the present disclosure, a surgical instrument is provided and includes a surgical loading unit and an adapter assembly. The surgical loading unit has a proximal body portion, a pair of surface features extending outwardly from the proximal body portion, an articulation link slidably coupled to the proximal body portion, and a tool assembly coupled to a distal end portion of the proximal body portion. The articulation link has a distal end portion coupled to the tool assembly and configured to articulate the tool assembly relative to the proximal body portion. The adapter assembly includes an elongate body and an elongate loading bar coupled to the elongate body. The elongate body has a distal end portion configured to receive the proximal end portion of the proximal body portion of the surgical loading unit. The elongate loading bar is configured to move relative to the elongate body between a proximal position and a distal position and has a distal end defining a slot therein. The slot is configured for receipt of a proximal end portion of the articulation link of the surgical loading unit upon an improper insertion of the surgical loading unit into the adapter assembly, whereby the engagement of the proximal end portion of the articulation link with the slot of the elongate loading bar resists rotation of the surgical loading unit relative to the adapter assembly toward an assembled state.

In aspects, the distal end portion of the elongate body may have an inner surface defining an opening, a pair of diametrically opposed apertures, and a slot. The opening may be configured for receipt of the proximal end portion of the proximal body portion of the surgical loading unit. The pair of diametrically opposed apertures may be configured for receipt of the pair of surface features of the surgical loading unit. The slot may be configured for receipt of the articulation link of the surgical loading unit during a proper insertion of the surgical loading unit into the adapter assembly.

In aspects, the elongate loading bar may have a distal extension configured to selectively lock the surgical loading unit to the adapter assembly when the elongate loading bar is in the distal position.

In aspects, a first surface feature of the pair of surface features may be configured to engage the distal extension of the elongate loading bar to move the elongate loading bar towards the proximal position during a proper insertion of the surgical loading unit into the adapter assembly.

In aspects, the distal extension of the elongate loading bar may be configured for locking engagement with the first surface feature of the surgical loading unit upon the proper insertion and rotation of the surgical loading unit into the elongate body of the adapter assembly.

In aspects, the adapter assembly may further include an annular member rotatably disposed within the distal end portion of the elongate body. The annular member may include a first surface feature configured to interface with a second surface feature of the pair of surface features of the surgical loading unit, such that the annular member is rotatable by the surgical loading unit when the second surface feature of the surgical loading unit is engaged with the first surface feature of the annular member.

In aspects, the annular member may include a second surface feature engaged with the distal extension of the elongate loading bar when the elongate loading bar is in the distal position, such that the distal extension of the elongate loading bar resists rotation of the annular member when the elongate loading bar is in the distal position.

In accordance with another aspect, an adapter assembly is provided and includes an elongate body and an elongate loading bar coupled to the elongate body. The elongate body includes a distal end portion configured to receive a surgical loading unit. The elongate loading bar is configured to move relative to the elongate body between a proximal position, in which the surgical loading unit is removable from the elongate body, and a distal position, in which the elongate loading bar locks the surgical loading unit to the elongate body. The elongate loading bar has a distal end defining a slot therein configured for receipt of an articulation link of the surgical loading unit upon an improper insertion of the surgical loading unit into the adapter assembly, whereby the engagement of the articulation link with the slot of the elongate loading bar resists rotation of the surgical loading unit relative to the adapter assembly toward an assembled state.

In aspects, the distal end portion of the elongate body may have an inner surface defining an opening, a pair of apertures in communication with the opening, and a slot in communication with the opening. The opening may be configured for receipt of the surgical loading unit. The apertures may be configured for receipt of a pair of surface features of the surgical loading unit. The slot may be configured for receipt of the articulation link of the surgical loading unit during a proper insertion of the surgical loading unit into the adapter assembly.

In aspects, the slot of the elongate body may be disposed between the pair of apertures.

In aspects, the slot of the distal end of the elongate loading bar may have substantially the same width as the slot of the elongate body.

In aspects, the elongate loading bar may have a distal extension configured to selectively lock the surgical loading unit to the adapter assembly when the elongate loading bar is in the distal position.

In aspects, the adapter assembly may further include an annular member rotatably disposed within the distal end portion of the elongate body. The annular member may include a first surface feature defining a cavity configured to interface with a lug of the surgical loading unit, such that the annular member is rotatable by the surgical loading unit when the lug of the surgical loading unit is captured in the cavity of the annular member.

In aspects, the annular member may include a second surface feature engaged with the distal extension of the elongate loading bar when the elongate loading bar is in the distal position, such that the distal extension of the elongate loading bar resists rotation of the annular member when the elongate loading bar is in the distal position.

DETAILED DESCRIPTION

As used herein, the terms parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular up to about + or −10 degrees from true parallel and true perpendicular.

Aspects of the presently disclosed surgical instruments including handle assemblies, adapter assemblies, and surgical loading units thereof, 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 surgical instrument, adapter assembly, handle assembly, loading unit, or component thereof, farther from the user, while the term “proximal” refers to that portion of the surgical instrument, adapter assembly, handle assembly, loading unit or component thereof, closer to the user.

For more details of certain aspects of the adapter assembly disclosed herein, reference may be made to U.S. Pat. No. 10,426,466, the entire contents of which are incorporated by reference herein.

Presently, if a surgical loading unit is inserted incorrectly into an adapter assembly and rotated after the incorrect insertion, an annular member or rotating ring of the adapter assembly is caused to be rotated out of a normal position. After the surgical loading unit is removed, the rotating ring remains out of the normal position. As such, a subsequent attempt at inserting a surgical loading unit into the adapter assembly is prohibited due to the rotating ring being displaced from its normal operating position.

The present disclosure provides a surgical instrument that includes a surgical loading unit and an adapter assembly that interconnects the surgical loading unit with either a handle assembly or a robotic assembly. The adapter assembly includes a plurality of mechanical features that ensure that the surgical loading unit is connected to the adapter assembly in a proper orientation to prevent the improper displacement of the rotating ring.

With reference toFIG.1, a surgical instrument10, in accordance with an aspect of the present disclosure, is shown as a powered, hand-held, electromechanical surgical instrument. The surgical instrument10includes a handle assembly100configured for selective connection with any one of a number of adapter assemblies200, and, in turn, each unique adapter assembly200is configured for selective connection with any number of surgical loading units300. The surgical loading unit300and adapter assembly200are configured for actuation and manipulation by the handle assembly100or, in aspects, a robotic assembly (not shown).

With reference toFIGS.1and2, the surgical loading unit300of the surgical instrument10has a proximal body portion302and a tool assembly or end effector304coupled to a distal end portion302bof the proximal body portion302. The proximal body portion302has a proximal end portion302aconfigured for engagement with a distal end portion206bof an elongate body204of the adapter assembly200. The proximal body portion302has a pair of surface features, such as, for example, lugs303a,303bextending outwardly from opposite sides of the proximal end portion302aof the surgical loading unit300. The lugs303a,303bmay assume any suitable shape, such as a square or a cylinder. The end effector304is pivotally attached to the proximal body portion302and includes an anvil assembly306and a cartridge assembly308. The cartridge assembly308is pivotable in relation to the anvil assembly306and is movable between an open or unclamped position and a closed or clamped position for insertion through a cannula of a trocar. In aspects, the end effector304may be configured to perform alternate functions, such as, electrosurgical sealing.

The surgical loading unit300further includes an articulation link310extending through the proximal body portion302and centrally between the lugs303a,303b. The articulation link310has a proximal end portion310ahaving a flag312protruding proximally and radially outward from the proximal body portion302. The flag312of the articulation link310is configured to operably couple to an articulation drive member (not explicitly shown) of the adapter assembly200for driving a translation of the articulation link310. The articulation link310has a distal end portion310boperably coupled to the end effector304, such that the end effector304is configured to articulate relative to the proximal body portion302in response to a translation of the articulation link310. For example, the end effector304is movable from a first position in which the end effector304is aligned with a longitudinal axis of the proximal body portion302to at least a second position in which the end effector304is disposed at a non-zero angle with respect to the longitudinal axis of the proximal body portion302.

Reference may be made to U.S. Pat. No. 7,819,896, the entire contents of which are incorporated herein by reference, for a detailed discussion of the construction and operation of an exemplary end effector.

With further reference toFIG.1, the adapter assembly200includes a knob housing202and an elongate body204extending from a distal end of the knob housing202. The knob housing202and elongate body204are configured and dimensioned to house the components of the adapter assembly200. The elongate body204may be dimensioned for endoscopic insertion. In aspects, the elongate body204may be passable through a typical trocar port, cannula or the like. The knob housing202may be dimensioned to not enter the trocar port, cannula of the like. The elongate body204has a proximal end portion206aattached to the knob housing202, which is configured to be attached to the handle assembly100. The elongate body204also includes a distal end portion206bconfigured to be coupled to the proximal body portion302of the surgical loading unit300.

With reference toFIGS.1,3, and4, the elongate body204of the adapter assembly200further includes a distal cap or ring member208extending distally from the distal end portion206b. In aspects, the ring member208may be formed with the elongate body204and/or may be housed therein. The ring member208has an inner surface210that defines an opening or channel212configured for receipt of the proximal end portion302aof the proximal body portion302of the surgical loading unit300. The inner surface210of the ring member208further defines a pair of diametrically opposed apertures214a,214band a slot216each being circumferentially disposed about the ring member208. The slot216is disposed between the apertures214a,214band is spaced circumferentially from each of the apertures214a,214bby about 90 degrees. The apertures214a,214bare configured for receipt of the respective pair of lugs303a,303bof the surgical loading unit300and the slot216is configured for receipt of the proximal end portion310a(e.g., the flag312) of the articulation link310of the surgical loading unit300during a proper insertion of the surgical loading unit300into the adapter assembly200, as shown inFIG.4.

With reference toFIGS.5and7, the adapter assembly200further includes an elongate loading bar or locking link280disposed within the elongate body204of the adapter assembly200. The elongate loading bar280is slidingly disposed within the elongate body204and is resiliently biased toward a distal, locking position, as shown inFIG.5. The elongate loading bar280has a distal extension282configured for locking engagement with the lug303a(FIG.2) of the surgical loading unit300upon the proper insertion of the surgical loading unit300into elongate body204. The distal extension282has a distal end284having a distally-facing edge283defining a slot286therein. The slot286has a similar shape and size as the flag312of the surgical loading unit300to accommodate the flag312therein during an improper insertion of the surgical loading unit300into adapter assembly200(FIG.5). The slot286as illustrated has a rectangular shape, but other suitable shapes are contemplated, such as rounded, triangular, or the like.

With reference toFIGS.6and7, the adapter assembly200further includes an annular member260rotatably disposed within the elongate body204of the adapter assembly200. The annular member260functions to electromechanically communicate to a processor (not shown) of the handle assembly100that the surgical loading unit300is either properly or improperly connected to the adapter assembly200. In particular, upon rotating the annular member260relative to the elongate body204, about a longitudinal axis of the elongate body204, from a starting or first orientation to a second orientation, the annular member260transmits a signal to the processor of the handle assembly100indicating that the surgical loading unit300is secured to the adapter assembly200and is ready for use.

The annular member260defines a cylindrical passageway264therethrough configured for disposal of the proximal body portion302of the surgical loading unit300. The annular member260includes a surface feature, such as, for example, a pair of tabs276a,276bdefining a cavity278therebetween configured to interface with the lug303bof the surgical loading unit300, such that the annular member260is rotatable by and with the surgical loading unit300when the surgical loading unit300is properly inserted into the adapter assembly200.

The annular member260further includes an appendage or additional surface feature290protruding radially outward therefrom and disposed on an opposite side of the annular member260as the pair of tabs276a,276b. The appendage or tab290is positioned in abutting engagement with a lateral edge surface288of the distal extension282of the elongate loading bar280(FIG.7) when the elongate loading bar280is in the distal position. The elongate loading bar280prevents the annular member260, and in turn, the surgical loading unit300, from being rotated relative to the elongate body204due to the engagement of the appendage290of the annular member260with the elongate loading bar280. As such, only when the lug303aof the surgical loading unit300engages and proximally moves the elongate loading bar280out of engagement with the appendage290(during a proper insertion of the surgical loading unit300) will the annular member260be able to be rotated by the surgical loading unit300.

In operation, to properly assemble the surgical loading unit300with the adapter assembly200, the surgical loading unit300is rotationally oriented (about a longitudinal axis thereof) so that the pair of lugs303a,303bof the surgical loading unit300are aligned with the pair of apertures214a,214bof the ring member260and the flag312of the articulation link310of the surgical loading unit300is aligned with the slot216of the ring member208, as shown inFIG.4. With the surgical loading unit300properly oriented, the surgical loading unit300may be translated toward the adapter assembly200to pass the proximal body portion302of the surgical loading unit300into the elongate body204of the adapter assembly200and, in turn, into the annular member260. Upon fully inserting the surgical loading unit300into the adapter assembly200, the lug303bof the surgical loading unit300is received between the surface features276a,276bof the annular member260, the lug303aof the surgical loading unit300engages the elongate loading bar280to retract the elongate loading bar280towards its proximal position, and the flag312of the articulation link310couples to the articulation drive member (not shown) of the adapter assembly200.

After moving the elongate loading bar280to the proximal position by the lug303aof the surgical loading unit300, the distal extension282of the elongate loading bar280is no longer engaged with the appendage290of the annular member260, and therefore no longer preventing the annular member260from rotating out of the first orientation. With the surgical loading unit300in this initial insertion position within the adapter assembly200, the surgical loading unit300is not yet lockingly engaged with the adapter assembly200and the annular member260remains in the first orientation. To complete the mechanical coupling of the surgical loading unit300to the adapter assembly200, the surgical loading unit300is then rotated relative to the elongate body204. Since the lug303bof the surgical loading unit300is received in the cavity278defined between the surface features276a,276bof the annular member260, rotation of the surgical loading unit300drives a rotation of the annular member260from the first orientation to the second orientation. Rotation of the annular member260from the first orientation to the second orientation establishes an electrical connection between the annular member260and the processor of the handle assembly100, whereby the processor registers that the surgical loading unit300is lockingly engaged with the adapter assembly200and surgical instrument10is ready for operation.

For a more detailed description of the electrical connection between the annular member260and the processor, reference may be made to U.S. Pat. No. 10,314,579, the entire contents of which are incorporated by reference herein.

The rotation of the surgical loading unit300moves the lug303aof the surgical loading unit300into an inner groove (not explicitly shown) defined in the ring member208of the elongate body204and out of a longitudinal path of the elongate loading bar280. The resilient bias of the elongate loading bar280drives an axial translation thereof to dispose the elongate loading bar280in the distal or locking position. With the elongate loading bar280in the distal position, the lug303aof the surgical loading unit300is captured between the ring member208and the distal extension282, thereby preventing the surgical loading unit300from sliding or rotating out of the adapter assembly200. In this state, the surgical loading unit300is properly releasably, lockingly engaged to the adapter assembly200and ready for use.

In some instances, it is possible for a clinician to inadvertently improperly orient the surgical loading unit300(about a longitudinal axis thereof) relative to the adapter assembly200prior to inserting the surgical loading unit300into the adapter assembly200. For example, with reference toFIG.5, the surgical loading unit300may be improperly oriented 90 degrees counter-clockwise (about the longitudinal axis thereof) from the proper orientation. When the rotational orientation of the surgical loading unit300is improper, the surgical loading unit300may still be longitudinally inserted into the adapter assembly200. However, in this orientation, instead of the lug303aof the surgical loading unit300engaging the distal extension282of the elongate loading bar280, the flag312of the articulation link310is received in the slot286of the distal extension282. Accordingly, when the clinician attempts to complete the assembly of the surgical loading unit300with the adapter assembly200by exerting a rotational force on the surgical loading unit300, the engagement of the flag312of the articulation link310with the slot286of the elongate loading bar280, which is non-rotatable, advantageously prevents the surgical loading unit300from being rotated. Therefore, the clinician will be unable to operate the surgical instrument10and will be alerted to the fact that the surgical loading unit300is improperly oriented.

With reference toFIGS.6and7, the surgical loading unit300may be improperly oriented 90 degrees clockwise (about the longitudinal axis thereof) from the proper orientation. In this orientation, the flag312of the articulation link310is received in the cavity278defined by the pair of surface features276a,276bof the annular member260instead of the lug303bof the surgical loading unit300, as shown inFIG.6. In addition, neither lug303anor lug303bof the surgical loading unit300will engage the distal extension282of the elongate loading bar280, such that the distal extension282remains engaged with the appendage290of the annular member260. Accordingly, when the clinician attempts to complete the assembly of the surgical loading unit300with the adapter assembly200by exerting a rotational force on the surgical loading unit300, the engagement of the appendage290with the distal extension282advantageously prevents the annular member260, and in turn, the surgical loading unit300from being rotated. Therefore, the clinician will be unable to operate the surgical instrument10and will be alerted to the fact that the surgical loading unit300is improperly oriented.