Abstract:
An adapter assembly for operably connecting an end effector to an electromechanical surgical instrument includes a drive transfer assembly, a drive member, and a first pusher assembly. The drive transfer assembly includes first and second rotatable shafts. The drive member is operably connected to the first rotatable shaft for transferring rotational motion from the first rotatable shaft to effect a first function and the first pusher assembly is operably connected to the second rotatable shaft for converting rotational motion from the second rotatable shaft to longitudinal movement to effect a second function. The first pusher assembly includes a brake member for rotationally locking the drive member relative to the first pusher assembly.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 62/334,013, filed May 10, 2016, the entire disclosure of which is incorporated by reference herein. 
     
    
     BACKGROUND 
     Technical Field 
       [0002]    The present disclosure relates to adapter and extension assemblies for selectively connecting tool assemblies to actuation units of powered surgical devices. More specifically, the present disclosure relates to a brake member for preventing rotation of a drive assembly in the adapter assemblies. 
       Background of Related Art 
       [0003]    Powered devices for use in surgical procedures are known. To permit reuse of the handle assemblies of these powered surgical devices and so that the handle assembly may be used with a variety of end effectors, adapter assemblies and extension assemblies have been developed for selective attachment to the handle assemblies and to a variety of end effectors. Following use, the adapter and/or extension assemblies may be disposed of along with the end effector. In some instances, the adapter assemblies and extension assemblies may be sterilized for reuse. 
         [0004]    The adapter assemblies are configured to permit rotation of actuation units relative to the adapter assemblies. When the actuation units are rotated relative to the adapter assemblies, the free wheel or back drive of the motors in the actuation units require more torque than the free turning or advancing of the drive members within the adapter assemblies, resulting in movement of drive members within the adapter assemblies. Movement of the drive members within the adapter assemblies may effect of the calibration the drive members within the adapter assembly. 
         [0005]    To maintain calibration of the drive members within the adapter assemblies, it would be beneficial to provide a brake to prevent rotation of the drive member within the adapter assembly as the adapter assembly is rotated relative to the handle assembly. 
       SUMMARY 
       [0006]    An adapter assembly for operably connecting an end effector to an electrosurgical instrument is provided. The adapter assembly includes a drive transfer assembly, a drive member, and a first pusher assembly. The drive transfer assembly includes first and second rotatable shafts. The drive member is operably connected to the first rotatable shaft for transferring rotational motion from the first rotatable shaft to effect a first function and the first pusher assembly is operably connected to the second rotatable shaft for converting rotational motion from the second rotatable shaft to longitudinal movement to effect a second function. The first pusher assembly includes a brake member for rotationally locking the drive member relative to the first pusher assembly. 
         [0007]    In embodiments, the adapter assembly may further include a second pusher assembly and the drive transfer assembly may include a third rotatable shaft. The second pusher assembly may be operably connected to the third rotatable shaft for converting rotational motion from the third rotatable shaft to longitudinal movement to effect a third function. The adapter assembly may further include an extension assembly having a flexible band assembly operably connected to the first pusher assembly. The first pusher assembly may include a planetary gear assembly. The first pusher assembly may include a drive screw operably connected to the planetary gear assembly. The first pusher assembly includes a pusher member operably received about the first drive screw. Rotation of the drive screw may cause longitudinal movement of the pusher member. 
         [0008]    In embodiments, the brake member may be disposed within the pusher member. The brake member may include a collet having a plurality of leaves. The plurality of leaves may extend radially inward. The plurality of leaves extend proximally. The plurality of leaves of the collet may engage the drive member. The drive member may extend through the collet. The drive member may define a longitudinal axis and the collet may define a plane extending perpendicular to the longitudinal axis. 
         [0009]    Also provided is a surgical stapling device including an electromechanical surgical instrument, an end effector, and an adapter assembly for operably connecting the end effector to the electromechanical surgical instrument. The adapter assembly includes a drive member for transferring rotational motion from a first rotatable shaft to effect a first function, and a first pusher assembly for converting rotational motion from a second rotatable shaft to longitudinal movement to effect a second function. The first pusher assembly includes a brake member for rotationally locking the drive member relative to the first pusher assembly. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein: 
           [0011]      FIG. 1  is a perspective view of an adapter assembly, in accordance with an embodiment of the present disclosure, an exemplary extension assembly, an exemplary tool assembly, and an exemplary electromechanical surgical device; 
           [0012]      FIG. 2  is a perspective side view of a proximal end of the adapter assembly of  FIG. 1 ; 
           [0013]      FIG. 3  is a cross-sectional side view of the adapter assembly of  FIGS. 1 and 2 , taken along line  3 - 3  in  FIG. 9 ; 
           [0014]      FIG. 4  is a cross-sectional side view of the adapter assembly of  FIGS. 1 and 2 , taken along line  4 - 4  in  FIG. 3 ; 
           [0015]      FIG. 5  is a perspective end view of a distal portion of a pusher member and a brake member of a pusher assembly of the adapter assembly of  FIGS. 1-4 , with parts separated; 
           [0016]      FIG. 6  is perspective distal side view of the adapter assembly of  FIGS. 1-4 , with an outer sleeve and an upper half-section of a rotation handle of a rotation handle assembly of the adapter assembly removed; 
           [0017]      FIG. 7  is a cross-sectional perspective side view of a distal portion of the adapter assembly of  FIGS. 1-4 ; 
           [0018]      FIG. 8  is an enlarged, perspective view of a coupling assembly and a transfer assembly of the adapter assembly of  FIGS. 2-7 ; and 
           [0019]      FIG. 9  is a perspective end view of the adapter assembly of  FIGS. 1-4  with the outer sleeve and rotatable handle in a first orientation relative to the coupling assembly. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0020]    Embodiments of the presently disclosed adapter assemblies for surgical devices and/or actuation units 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 adapter assembly or surgical device, or component thereof, farther from the user, while the term “proximal” refers to that portion of the adapter assembly or surgical device, or component thereof, closer to the user. 
         [0021]    With reference to  FIG. 1 , an adapter assembly in accordance with an embodiment of the present disclosure, shown generally as the adapter assembly  100  configured for selective connection to a powered hand held electromechanical instrument shown, generally as actuation unit  10 , and for connection with an extension assembly  200 . As illustrated in  FIG. 1 , the actuation unit  10  is configured for releasable connection with the adapter assembly  100 , and, in turn, the adapter assembly  100  is configured for releasable connection with the extension assembly  200 . Alternatively, the adapter assembly  100  and the extension assembly  200  may be integrally formed. The extension assembly  200  is configured for selective connection with a tool assembly or end effector, e.g. tool assembly  30 , including, in the illustrative embodiment shown, a loading unit, e.g. loading unit  40 , and an anvil assembly, e.g., anvil assembly  50 , for applying a circular array of staples (not shown) to tissue (not shown). 
         [0022]    The actuation unit  10 , the adapter assembly  100 , the extension assembly  200  and the tool assembly  30  are collectively referred to as the surgical stapling device  1 . Although the embodiments of the present disclosure will be discussed as relates to a surgical stapling device, it is envisioned that the aspects of the present disclosure may be modified for various surgical devices. 
         [0023]    The actuation unit  10  and the extension assembly  200  will only be described in detail to the extent necessary to fully disclose the aspects of the present disclosure. For a detailed description of the structure and function of an exemplary actuation unit, please refer to commonly owned U.S. Pat. No. 9,055,943 (“the &#39;943 patent”), the content of which is incorporated by reference herein in its entirety. For a detailed description of the structure and function of an exemplary extension assembly, please refer to commonly owned U.S. patent application Ser. No. 14/875,766 (“the &#39;766 application”), filed Oct. 6, 2015, the content of which is incorporated by reference herein in its entirety. 
         [0024]    With additional reference to  FIGS. 2-4 , the adapter assembly  100  includes a proximal end portion  102  configured for operable connection to the actuation unit  10  ( FIG. 1 ) and a distal end portion  104  configured for operable connection to the extension assembly  200  ( FIG. 1 ). From the proximal end portion  102  to the distal end portion  104 , the adapter assembly  100  includes a drive coupling assembly  110 , a drive transfer assembly  130  operably connected to the drive coupling assembly  110 , a first pusher assembly  160  operably connected to the drive transfer assembly  130 , and a second pusher assembly  180  operably connected to the drive transfer assembly  130 . The first pusher assembly  160  and the second pusher assembly  180  are operably maintained within an outer sleeve  106 . As will be described in further detail below, a drive shaft  108  extends longitudinally through the adapter assembly  100  and is operably connected to the drive transfer assembly  130 . 
         [0025]    The drive coupling assembly  110  is configured to releasably secure the adapter assembly  100  to the actuation unit  10  ( FIG. 1 ). The drive coupling assembly  110  includes first, second, and third rotatable proximal drive shafts  116 ,  118 ,  120  and respective first, second, and third connector sleeves  122 ,  124 ,  126  rotatably supported within a connector housing  112 . Each of the first, second, and third connector sleeves  122 ,  124 ,  126  is configured to mate with respective first, second, and third drive connectors (not shown) of actuation unit  10  ( FIG. 1 ). 
         [0026]    The drive coupling assembly  110  also includes first, second and third biasing members  122   a ,  124   a  and  126   a  disposed distally of the respective first, second and third connector sleeves  122 ,  124 ,  126  to help maintain the connector sleeves  122 ,  124 , and  126 , respectively, engaged with the distal end of the respective drive rotatable drive connectors (not shown) of the actuation unit  10  when the adapter assembly  100  is connected to the actuation unit  10 . 
         [0027]    For a detailed description of an exemplary drive coupling assembly, please refer to the &#39;766 application, the contents of which were previously incorporated herein by reference. 
         [0028]    With continued reference to  FIGS. 3 and 4 , the drive transfer assembly  130  operably connects distal ends of first, second and third rotatable proximal drive shafts  116 ,  118  and  120  to drive shaft  108 , first pusher assembly  160 , and second pusher assembly  180 , respectively. The drive transfer assembly  130  includes a drive transfer housing  134  secured to the connector housing  112  of the drive coupling assembly  110 . The drive transfer housing  134  operates to rotatably support first and second rotatable distal drive shafts  136 ,  138  and a drive member  140  therein and rotatably support a rotation handle assembly  132  thereabout. The rotation handle assembly  132  is securely affixed to the outer sleeve  106  of the adapter assembly  100  and facilitates selective rotation of the outer sleeve  106 , and the attached extension assembly  200  ( FIG. 1 ) and tool assembly  30  ( FIG. 1 ). For a detailed description of an exemplary rotation handle assembly, please refer to commonly owned U.S. Pro. Pat. App. Ser. No. 62/333,976 filed May 10, 2016, the content of which is incorporated by reference herein in its entirety. 
         [0029]    The drive transfer assembly  130  also includes a drive connector  148  ( FIG. 3 ) operably connecting the first rotatable distal drive shaft  136  to the first pusher assembly  160  and a tubular connector  150  operably connecting the second rotatable distal drive shaft  138  to the second pusher assembly  180 . 
         [0030]    The first pusher assembly  160  includes proximal and distal housing sections  162 ,  164  ( FIG. 3 ), a planetary gear assembly  166  operably mounted within the proximal housing section  162 , a screw member  168  operably connected to the planetary gear assembly  166  and rotatably supported within the distal housing section  164 , and a pusher member  170  operably connecting screw member  168  and slidably disposed within distal housing section  164 . The first pusher assembly  160  will only be described to the extent necessary to disclose the aspects of the present disclosure. For a detailed description of the operation and function of an exemplary pusher assembly, including an exemplary planetary gear assembly, please refer to the &#39;766 application, the contents of which were previously incorporated herein in its entirety. 
         [0031]    The screw member  168  of the first pusher assembly  160  is rotatably supported within proximal housing portion  162  and operably engages the pusher member  170 . Operation of the planetary gear assembly  166  rotates the screw member  168 . As screw member  168  is rotated in a first direction, the pusher member  170  is moved in a proximal direction and when the screw member  168  is rotated in a second direction, the pusher member  170  is moved in a distal direction. The pusher member  170  operably engages the screw member  168  and includes a pair of tabs  178  for engaging connector extensions  240 ,  242  ( FIG. 4 ) of outer flexible band assembly  230  ( FIG. 4 ) of extension assembly  200  ( FIG. 1 ). 
         [0032]    The second pusher assembly  180  is substantially similar to first pusher assembly  160 , and includes proximal and distal housing sections  182 ,  184  ( FIG. 3 ), a planetary gear assembly  186  operably mounted within the proximal housing section  182 , a screw member  188  operably connected to the planetary gear assembly  186  and rotatably supported within the distal housing section  184 , and a pusher assembly  190  operably connected to the screw member  188  and slidably disposed within the distal housing section  184 . 
         [0033]    The screw member  188  is rotatably supported within the proximal housing portion  182  and operably engages the pusher assembly  190 . Operation of the planetary gear assembly  186  rotates the screw member  188 . As the screw member  188  is rotated in a first direction, the pusher assembly  190  is moved in a distal direction, and when the screw member  188  is rotated in a second direction, the pusher assembly  190  is moved in a proximal direction. 
         [0034]    The pusher member  190  includes a proximal portion  190   a  configured to operably engage the screw member  188 , and a distal portion or nut portion  190   b  for operably engaging the extension assembly  200 . More particularly, the proximal portion  190   b  of the pusher member  190  includes a pair of tabs  198  for engaging connector extensions  220 ,  222  ( FIG. 4 ) of inner flexible band assembly  210  ( FIG. 4 ) of extension assembly  200  ( FIG. 1 ). Although shown as separate components, it is envisioned that the proximal and distal portions  190   a ,  190   b  of the pusher member  190  may be integrally formed, e.g., monolithic. 
         [0035]    With additional reference now to  FIGS. 5 and 6 , the pusher member  190  of the second pusher assembly  180  further includes a brake member, e.g., collet or Belleville washer spring  191 . The collet  191  includes an outer ring  191   a  and a plurality of leaves  193  extending radially inwardly from the outer ring  191   a  and in a proximal direction (when mounted to the pusher member  190 ). Although shown including four (4) leaves  193 , it is envisioned that the collet  191  can include any number of leaves  193 . Each of the plurality of leaves  193  extend radially inward and proximally. The collet  191  is secured within the distal portion  190   b  of the pusher member  190  using welding, adhesive, or in any manner suitable for maintaining the collet  191  rotationally fixed relative to the pusher member  190 . 
         [0036]    Each of the leaves  193  of the collet  191  include free ends  193   a  configured to engage the drive shaft  108  when the pusher member  190  of the second pusher assembly  180  is moved in a proximal direction, as indicated by arrow “A” in  FIG. 7 . Engagement of the free ends  193   a  of the leaves  193  with the drive shaft  108  prevents the drive shaft  108  from rotating relative to the pusher member  190  during rotation of the actuation unit  10  relative to the adapter assembly  100 . In this manner, when the leaves  193  of the collet  191  engage the drive shaft  108 , the drive shaft  108  is rotationally fixed relative to the pusher member  190  such that the drive shaft  108  back drives the first drive connector (not shown) of the actuation unit  10  as the actuation unit  10  is rotated relative to the adapter assembly  100 . 
         [0037]    Conversely, the free ends  193   a  of the leaves  193  of the collet  191  disengage from the drive shaft  108  when the pusher assembly  190  is moved in a distal direction, as indicated by arrow “C” in  FIG. 7 , to unlock the drive shaft  108  and permit rotation of the drive shaft  108  relative to the pusher member  190 . It is envisioned that the drive shaft  108  may include flattened sides to facilitate engagement of the leaves  193  of the collet  191  with the drive shaft  108 . 
         [0038]    Although the brake member of the present disclosure is shown and described as being a component of the second pusher assembly  180  of the adapter assembly  100 , it is envisioned that the brake member may instead, or additionally, be incorporated into the first pusher assembly  160  of the adapter assembly  100 . 
         [0039]    As noted above, the extension assembly  200  operably connects the adapter assembly  100  with the tool assembly  30 . More particularly, the extension assembly  200  includes a trocar assembly  270  ( FIG. 1 ) operably connected to the drive shaft  108  for advancing and retracting, for example, the anvil assembly  50  ( FIG. 1 ) relative to the loading unit  40  ( FIG. 1 ), to clamp tissue (not shown). The inner flexible band assembly  210  ( FIG. 4 ) of the extension assembly  200  is operably connected to the pusher member  190  of the second pusher assembly  180  for advancing and retracting, for example, a staple pusher (not shown) of the loading unit  40 , to staple tissue (not shown), and the outer flexible band assembly  230  ( FIG. 4 ) is operably connected to the pusher member  170  of the first pusher assembly  160  for advancing and retracting, for example, a knife pusher (not shown) of the loading unit  40 , to cut tissue (not shown). For a detailed description of the function and operation of an exemplary extension assembly, please refer to the &#39;766 application. 
         [0040]    The operation of the adapter assembly  100 , and more particularly the brake member  191 , will now be described with reference to  FIGS. 7-9 . After the extension assembly  200  is secured to adapter assembly  100 , the adapter assembly  100  is secured to the actuation unit  10  ( FIG. 1 ), and the loading unit  40  ( FIG. 1 ) of tool assembly  30  ( FIG. 1 ) is secured to the extension assembly  200 , the adapter assembly  100  and the extension assembly  200  are used to position the loading unit  40  within the patient (not shown) in a traditional manner. Depending on the procedure being performed, the anvil assembly  50  ( FIG. 1 ) of the tool assembly  30  may be secured to the trocar assembly  270  of the extension assembly  200  prior to or subsequent the positioning of the loading unit  40  within the patient. 
         [0041]    During positioning and operation of the surgical stapling device  1  ( FIG. 1 ), it may be necessary to rotationally orient the actuation unit  10  relative to the adapter assembly  100  to, for example, accommodate the limitations in space in the operating room, and/or for ease of use by the clinician. In order to maintain calibration of the adapter assembly  100 , the extension assembly  200 , and/or the tool assembly  30  ( FIG. 1 ), the drive shaft  108  of the adapter assembly  100  is rotationally locked relative to the adapter assembly  100  as the actuation unit  10  ( FIG. 1 ) and the adapter assembly  100  are rotated relative to one another other such that the drive shaft  108  back drives the first drive connector (not shown) of the actuation unit  10 . 
         [0042]    With particular reference to  FIG. 7 , prior to rotating the actuation unit  10  relative to the adapter assembly  100 , the actuation unit  10  is activated to cause the pusher member  190  of the second pusher assembly  180  to move proximally, i.e., retract, as indicated by arrow “A”. More particularly, the third drive connector (not shown) of the actuation unit  10  rotates third proximal drive shaft  120  ( FIG. 4 ) of the coupling assembly  110  ( FIG. 4 ), which rotates the second distal drive shaft  138  ( FIG. 4 ) of the drive transfer assembly  130  ( FIG. 4 ), which rotates the tubular connector  150  ( FIG. 4 ) of the drive transfer assembly  130 , which drives the planetary gear system  186  of the second pusher assembly  180 , which causes rotation of the screw member  188 , and subsequent retraction of the pusher member  190  of the second pusher assembly  180 . 
         [0043]    With continued reference to  FIG. 7 , retraction of the pusher member  190  of the second pusher assembly  180  causes the free ends  193   a  of the leaves  193  of the collet  191  of the second pusher assembly  180  to engage the drive shaft  108  extending through the adapter assembly  100 . Engagement of the collect  191  with the drive shaft  108  rotationally locks or fixes the drive shaft  108  relative to the pusher member  190 , thereby rotationally fixing the drive shaft  108  within the outer sleeve  106  of the adapter assembly  100 . 
         [0044]    It is envisioned that the adapter assembly  100  may be provided to the clinician with the pusher member  190  of the second pusher assembly  180  in the proximal position, and thus, with the drive shaft  108  already rotationally fixed. 
         [0045]    Once the drive shaft  108  is rotationally fixed relative to the adapter assembly  100 , the actuation unit  10  ( FIG. 1 ), including the coupling assembly  110  of the adapter assembly  100 , and the rotation handle  132  ( FIG. 1 ) and outer sleeve  108  of the adapter assembly  100  may be rotated relative to one another while the calibration of the tool assembly  30  ( FIG. 1 ) is maintained. As actuation unit  10  is rotated relative to the adapter assembly  100 , the rotationally locked or fixed condition of the drive shaft  108  results in the first drive connector (not shown) of the actuation unit  10  back driving a motor (not shown) connected to the first drive connector (not shown). 
         [0046]    Following rotation of the actuation unit  10  ( FIG. 1 ) and the adapter assembly  100  relative to one another, the actuation unit  10  is activated to cause the pusher member  190  of the second pusher assembly  180  to move distally, e.g., advance, as indicated by arrow “C” in  FIG. 7 . Advancement of the pusher member  190  of the second pusher assembly  180  causes the leaves  193  of the collet  191  to disengage from the drive shaft  108 . Once the leaves  193  of the collet  191  are disengaged from the drive shaft  108 , the drive shaft  108  is free to rotate and the adapter assembly  100  operates in a traditional manner. 
         [0047]    For a detailed description of the operation of an exemplary adapter assembly, extension assembly, and tool assembly, please refer to the &#39;766 application 
         [0048]    Any of the components described herein may be fabricated from either metals, plastics, resins, composites or the like taking into consideration strength, durability, wearability, weight, resistance to corrosion, ease of manufacturing, cost of manufacturing, and the like. 
         [0049]    Persons skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments. It is envisioned that the elements and features illustrated or described in connection with one exemplary embodiment may be combined with the elements and features of another without departing from the scope of the present disclosure. As well, one skilled in the art will appreciate further features and advantages of the disclosure based on the above-described embodiments. Accordingly, the disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims.