Abstract:
An adapter assembly for connecting an end effector to a handle assembly includes first, second, and third drive assemblies configured for converting rotational motion from the handle assembly to linear motion for performing first, second, and third functions.

Description:
BACKGROUND 
       [0001]    1. Technical Field 
         [0002]    The present disclosure relates generally to powered surgical devices. More specifically, the present disclosure relates to adapter and extension assemblies for selectively connecting end effectors to actuation units of powered surgical devices. 
         [0003]    2. Background of Related Art 
         [0004]    Powered surgical devices for use in surgical procedures are known. To permit reuse of the handle assemblies of powered surgical devices and so that the handle assembly may be used with a variety of end effectors, adapter assemblies have been developed for selective attachment to the handle assemblies and to a variety of end effectors. Following use, the adapter may be disposed of along with the end effector. In some instances, the adapter assemblies may be sterilized for reuse. 
       SUMMARY 
       [0005]    An assembly for operably connecting an end effector to a handle assembly is provided. The adapter assembly includes a coupling assembly and first, second, and third drive assemblies. The first drive assembly extends from the coupling assembly, defines a first longitudinal axis, and includes a first drive screw. The second drive assembly extends from the coupling assembly and is received about the first drive assembly. The second drive assembly defines a second longitudinal axis and includes a second drive screw in direct engagement with the first drive screw. The third drive assembly extends from the coupling assembly and is received about the first and second drive assemblies. The third drive assembly defines a third longitudinal axis and includes a third drive screw in direct engagement with the second drive screw. 
         [0006]    In embodiments, the coupling assembly includes first, second, and third connector sleeves. The first connector sleeve may operably connect the first drive assembly to a first rotation transmitting member of a handle assembly, the second connector sleeve may operably connect the second drive assembly to a second rotation transmitting member of the handle assembly, and the third connector sleeve may operably connect the third drive assembly to a third rotation transmitting member of the handle assembly. 
         [0007]    Each of the first, second, and third drive assemblies may include a proximal drive shaft, a distal drive shaft, and a drive screw. The first drive assembly may include a first drive screw having a threaded portion and a trocar member operably received about the threaded portion. Rotation of the first drive screw may cause longitudinal movement of the trocar member. The first, second, and third longitudinal axes may be co-axial. 
         [0008]    The first drive assembly may further include a thrust plate. The first drive screw may engage the thrust plate during operation of the first drive assembly. Each of the first, second, and third drive assemblies may include a bearing assembly for rotatably supporting the respective first, second and third drive screws. 
         [0009]    The adapter assembly may further include a connection assembly configured for operable connection to a handle assembly. Each of the first, second, and third drive assemblies may include a housing plate for supporting the respective first, second, and third drive screws. The first, second, and third longitudinal axes may be offset from a longitudinal axis of a handle assembly. 
         [0010]    The adapter assembly may further include an outer sleeve. Each of the first, second, and third drive assemblies may extend through the outer sleeve. A distal end of the outer sleeve may be configured for operable connection to an end effector. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein: 
           [0012]      FIG. 1  is a perspective end view of an adapter assembly, in accordance with an embodiment of the present disclosure, secured to an exemplary handle assembly and with an exemplary tool assembly secured thereto; 
           [0013]      FIG. 2  is a perspective end view of the adapter assembly of  FIG. 1 ; 
           [0014]      FIG. 3  is a perspective side view of the adapter assembly of  FIG. 1  with a handle member and sleeve removed, and secured to the handle assembly of  FIG. 1  (shown in phantom); 
           [0015]      FIG. 4  is a cross-sectional side view taken along line  4 - 4  of  FIG. 3 ; 
           [0016]      FIG. 5  is an enlarged view of the indicated area of detail of  FIG. 4 ; 
           [0017]      FIG. 6  is a perspective end view of a coupling assembly and a drive mechanism of the adapter assembly of  FIG. 1 ; 
           [0018]      FIG. 7  is an enlarged perspective end view of the coupling assembly and the drive mechanism of  FIG. 6 ; 
           [0019]      FIG. 8  is another enlarged perspective end view of the coupling assembly and the drive mechanism of  FIG. 6 ; 
           [0020]      FIG. 9  is a perspective end view of a first drive assembly of the drive mechanism of  FIG. 6  supported within a base member of the adapter assembly (shown in phantom); 
           [0021]      FIG. 10  is an enlarged perspective end view of a proximal end of the first drive assembly shown in  FIG. 9 ; 
           [0022]      FIG. 11  is a perspective end view of a second drive assembly of the drive mechanism of  FIG. 6  supported within the base member of the adapter assembly (shown in phantom); 
           [0023]      FIG. 12  is a perspective end view of the second drive assembly shown in  FIG. 11 ; 
           [0024]      FIG. 13  is another perspective end view of the second drive assembly shown in  FIG. 11 ; 
           [0025]      FIG. 14  is a perspective end view of a third drive assembly of the drive mechanism of  FIG. 6  supported within the base member of the adapter assembly (shown in phantom); and 
           [0026]      FIG. 15  is a perspective end view of the third drive assembly shown in  FIG. 14 . 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0027]    Embodiments of the presently disclosed adapter assembly for surgical devices and/or handle assemblies 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. 
         [0028]    With reference to  FIG. 1 , an adapter assembly in accordance with an embodiment of the present disclosure, shown generally as adapter assembly  100 , is configured for selective connection to a powered hand-held electromechanical actuator shown, generally as handle assembly  20 . As illustrated in  FIG. 1 , the adapter assembly  100  is configured for selective connection with the handle assembly  20 . A tool assembly or end effector, e.g. tool assembly  30 , which may, in exemplary embodiments, include a loading unit  40  and an anvil assembly  50 , for applying a circular array of staples (not shown) to tissue (not shown) is configured for selective connection with the adapter assembly  100 . The handle assembly  20 , the adapter assembly  100 , and the tool assembly  30  form a surgical stapling device  10 . Although shown and described for use with a circular stapling loading unit, it is envisioned that the adapter assemblies of the present disclosure may be modified for use with stapling assembly having alternative configurations, and/or with non-stapling end effectors. 
         [0029]    For a detailed description of the structure and function of an exemplary handle assembly, please refer to commonly owned U.S. Pat. Appl. Publ. No. 2012/0253329 (“the &#39;329 application”), the content of which is incorporated by reference herein in its entirety. 
         [0030]    Referring initially to  FIGS. 1-3 , adapter assembly  100  includes a proximal portion  102  configured for operable connection to the handle assembly  20  ( FIG. 1 ) and operable engagement by a user, and a distal portion  104  configured for operable connection to, and placement of, the tool assembly  30  ( FIG. 1 ), including the loading unit  40  ( FIG. 1 ) and the anvil assembly  50  ( FIG. 1 ). More particularly, the proximal portion  102  of the adapter assembly  100  includes a base member  106 , and a handle member  108  rotatably secured to the base member  106 . The distal portion  104  includes a sleeve  109  fixedly secured to and extending from the handle member  108 . A central longitudinal axis “x” ( FIG. 4 ) of the adapter assembly  100  is offset a distance “d” ( FIG. 4 ) from a central longitudinal axis “y” ( FIG. 4 ) of the handle assembly  20  ( FIG. 1 ). In one embodiment, the offset distance “d” is approximately 0.25 inches, while in another embodiment, the offset distance “d” is approximately 0.075 inches. 
         [0031]    The adapter assembly  100  includes a coupling assembly  110  disposed within the base member  106  of the adapter assembly  100  for operatively connecting the drive shafts (not shown) of the handle assembly  20  with a drive mechanism  118  of the adapter assembly  100 . The coupling assembly  110  includes first, second, and third connector sleeves  112 ,  114 ,  116  rotatably supported within the base member  106  of the adapter assembly  100 . The first, second, and third connector sleeves  112 ,  114 ,  116  of the coupling assembly  110  operably connect respective, first, second, and third drive shafts (not shown) of the handle assembly  20  ( FIG. 1 ) with respective first, second, and third drive assemblies  120 ,  140 ,  160  of the drive mechanism  118  of the adapter assembly  100 . For a more detailed description of an exemplary coupling assembly, please refer to commonly owned U.S. Provisional Patent Application Ser. No. 62/066,518, filed Oct. 21, 2014, the content of which are incorporated herein by reference in its entirety. 
         [0032]    With reference now to  FIGS. 9 and 10 , the first drive assembly  120  of the drive mechanism  118  ( FIG. 6 ) of the adapter assembly  100  includes a first drive shaft  122  and a first distal drive shaft  124  rotatably supported within the base member  106 , and a first drive screw  126  rotatably supported between a first housing plate  128  ( FIG. 9 ; shown in phantom) and a thrust plate  130  ( FIG. 9 ; shown in phantom). A proximal end of the first drive shaft  122  is operably connected to the first connector sleeve  112  of the coupling assembly  110 . A distal end of the first drive shaft  122  includes a first drive gear  122   b  integrally formed therewith, or non-rotatably supported thereon. A proximal end of the first distal drive shaft  124  includes a second drive gear  124   a  integrally formed therewith, or non-rotatably supported thereon, operably connected with the first drive gear  122   b.  A distal end of the first distal drive shaft  124  is operably connected to the first drive screw  126 . Although shown as separate components, it is envisioned that the first distal drive shaft  124  and the first drive screw  126  may be monolithically formed. A proximal end of the first drive screw  126  includes a gear flange  126   a  integrally formed therewith, or non-rotatably supported thereon. A distal end of the first drive screw  126  includes a threaded portion  126   b.    
         [0033]    The gear flange  126   a  of the first drive screw  126  of the first drive assembly  120  is rotatably received between the first housing plate  128  ( FIG. 9 ; shown in phantom) and the thrust plate  130  ( FIG. 9 ; shown in phantom). A first bearing assembly  134  ( FIG. 5 ) facilitates rotation of the first drive screw  126  between the first housing plate  128  and the thrust plate  130 . Although not shown, the thrust plate  130  engages the handle member  108  of the adapter assembly  100  to distribute the load from the first drive assembly  120  to the handle member  108 . A central longitudinal axis of the first drive screw  126  extends along the central longitudinal axis “x” of the adapter assembly  100 . 
         [0034]    As shown in  FIG. 4 , a threaded proximal end  132   a  of a trocar member  132  of the first drive assembly  120  is operably received about the threaded portion  126   b  of the first drive screw  126 . Rotation of the first drive screw  126  about the longitudinal axis “x” effects longitudinal movement of the trocar member  132 . When the anvil assembly  50  ( FIG. 1 ) is secured to a distal end  132   b  of the trocar member  132 , rotation of the first drive screw  126  in a first direction causes approximation of the anvil assembly  50  relative to the loading unit  40  (FIG.  1 ). Conversely, rotation of the first drive screw  126  in a second direction causes the anvil assembly  50  to move away from the loading unit  40 . Alternatively, the first drive screw  126  operatively connects to a linearly or rotationally actuated assembly (not shown) of an end effector (not shown) for effecting performance of a first function, e.g., clamping tissue (not shown). In one embodiment, the thrust plate  130  may include a strain gauge for measuring the clamping forces during operation of the first drive assembly  120 . By changing the size of the first and second drive gears  122   b,    124   a  of the first drive assembly  120 , the rate at which the drive screw  126  rotates relative to the input from the handle assembly  20  may be varied. 
         [0035]    With reference now to  FIGS. 11-13 , the second drive assembly  140  of the drive mechanism  118  ( FIG. 6 ) of the adapter assembly  100  ( FIG. 1 ) includes a second drive shaft  142  and a compound gear shaft  144  rotatably supported within the base member  106 , and a second drive screw  146  rotatably supported between the gear flange  126   a  of the first drive screw  126  and a second housing plate  148 . As will be described in further detail below, when the second drive screw  146  of the second drive assembly  140  experiences a load in the proximal direction, engagement of the second drive screw  146  with the first drive screw  126  of the first drive assembly  120  distributes the load from the second drive assembly  140  to the first drive assembly  120 . This arrangement balances the load experienced in the first drive assembly  120 , i.e., in the distal direction, with the load experienced in the second drive assembly  140 , i.e., in the proximal direction, during operation of the adapter assembly  100 . 
         [0036]    A proximal end of the second drive shaft  142  of the second drive assembly  140  is operably connected to the second connector sleeve  114  of the coupling assembly  110 . A distal end of the second drive shaft  142  includes a first drive gear  142   b  integrally formed therewith, or non-rotatably supported thereon. A proximal end of the compound gear shaft  144  includes a second drive gear  144   a  integrally formed therewith, or non-rotatably supported thereon and a distal end of the compound gear shaft  144  includes a third drive gear  144   b.  The second drive gear  144   a  is operably connected with the first drive gear  142   b  and the third drive gear is operably connected to the second drive screw  146 . As shown, the second drive gear  144   a  includes a larger diameter than the third drive gear  144   b.  In this manner, the compound gear shaft  146  operates to reduce the output speed and increase the output torque delivered to the second drive screw  146  from the handle assembly  20 . In embodiments, the second compound gear shaft  146  replaces a planetary gear system (not shown), thereby saving space within the adapter assembly  100  and reducing the number of gears necessary for the operation of the adapter assembly  100 . 
         [0037]    A proximal end of the second drive screw  146  includes a gear flange  146   a  integrally formed therewith, or non-rotatably supported thereon, in operable engagement with the third drive gear  144   b  of the compound gear shaft  144 . A distal end of the second drive screw  146  includes a threaded portion  146   b.  The second drive screw  146  of the second drive assembly  140  is received about the threaded portion  126   b  of the first drive screw  126  of the first drive assembly  120  and accommodates receipt of the trocar member  132  of the first drive assembly  120  about the threaded portion  126   a  of the first drive screw  126 . 
         [0038]    The gear flange  146   a  of the second drive screw  146  of the second drive assembly  140  is rotatably received between the gear flange  126   a  of the first drive screw  126  and the second housing plate  148 . A second bearing assembly  154  facilitates rotation of the second drive screw  146  between the gear flange  126   a  of the first drive screw  126  and the second housing plate  148 . A central longitudinal axis of the second drive screw  146  extends along the central longitudinal axis “x” ( FIG. 4 ) of the adapter assembly  100 . 
         [0039]    The threaded portion  146   b  of the second drive screw  146  operably connects to a linearly or rotationally actuated assembly (not shown) of the loading unit  40  ( FIG. 1 ) of the tool assembly  30  ( FIG. 1 ), or other suitable end effector, for effecting performance of a second function, e.g., stapling tissue (not shown). 
         [0040]    With reference now to  FIGS. 15 and 16 , the third drive assembly  160  of the drive mechanism  118  of the adapter assembly  100  includes a third drive shaft  162  and a compound gear shaft  164  rotatably supported within the base member  106 , and a third drive screw  166  rotatably supported between the gear flange  146   a  of the second drive screw  146  and a third housing plate  168 . As will be described in further detail below, when the third drive screw  166  of the third drive assembly  160  experiences a load in the proximal direction, engagement of the third drive screw  166  of the third drive assembly  160  with the second drive screw  146  of the second drive assembly  140 , and engagement of the second drive screw  146  of the second drive assembly  140  with the first drive screw  126  of the first drive assembly  120 , distributes the loads from the second and third drive assemblies  140 ,  160  to the first drive assembly  120 . This arrangement balances the load experienced in the first drive assembly  120 , i.e., in the distal direction, with the loads experienced in the second and third drive assemblies  140 ,  160 , i.e., in the proximal direction, during operation of the adapter assembly  100 . 
         [0041]    A proximal end of the third drive shaft  162  of the third drive assembly  160  operably engages the third connector sleeve  116  of the coupling assembly  110 . A distal end of the third drive shaft  162  includes a first drive gear  162   b  integrally formed therewith, or non-rotatably supported thereon. A proximal end of the compound gear shaft  164  includes a second drive gear  164   a  integrally formed therewith, or non-rotatably supported thereon, and a distal end of the compound gear shaft  164  includes a third drive gear  164   b.  The second drive gear  164   a  is operably connected with the first drive gear  162   b  and the third drive gear is operably connected to the second drive screw  166 . As shown, the second drive gear  164   a  includes a larger diameter than the third drive gear  164   b.  In this manner, the compound gear shaft  164  operates to reduce the output speed and increase the output torque delivered to the third drive screw  166  from the handle assembly  20 . In embodiments, the third compound gear shaft  164  replaces a planetary gear system (not shown) used in previous embodiments, thereby saving space within the adapter assembly  100  and reducing the number of gears necessary for the operation of the adapter assembly  100 . 
         [0042]    A proximal end of the third drive screw  166  includes a gear flange  166   a  integrally formed therewith, or non-rotatably supported thereon, in operable engagement with the third drive gear  164   b  of the compound gear shaft  164 . A distal end of the third drive screw  166  includes a threaded portion  166   b.  The third drive screw  166  of the third drive assembly  160  is received about the second drive screw  146  of the second drive assembly  140  between the gear flange  146   a  of the second drive screw  146  and the threaded portion  146   b  of the second drive screw  146 . 
         [0043]    The gear flange  166   a  of the third drive screw  166  of the third drive assembly  160  is rotatably received between the gear flange  146   a  of the second drive screw  146  of the second drive assembly  140  and the third housing plate  168 . A third bearing assembly  174  facilitates rotation of the third drive screw  166  of the third drive assembly  160  between the second flange  146   a  of the second drive screw  146  of the second drive assembly  140  and the third housing plate  168 . A central longitudinal axis of the third drive screw  166  extends along the central longitudinal axis “x” of the adapter assembly  100 . Accordingly, each of the central longitudinal axes of the first, second, and third drive assemblies  120 ,  140 ,  160  of the drive mechanism  118  extend along the central longitudinal axis “x” ( FIG. 4 ) of the adapter assembly  100 , i.e., the first second, and third drive screws  126 ,  146 ,  166  of the respective first, second, and third drive assemblies  120 ,  140 ,  160  are coaxial. In this manner, an end effector attached to the distal portion  104  of the adapter assembly  100  may be rotated about the central longitudinal axis “x” to facilitate rotational positioning of the end effector. 
         [0044]    The threaded portion  166   b  of the third drive screw  166  of the third drive assembly  160  operably connects to a linearly or rotationally actuated assembly (not shown) of the loading unit  40  ( FIG. 1 ) of the tool assembly  30  ( FIG. 1 ), or other suitable end effector, for effecting performance of a third function, e.g., cutting tissue (not shown). 
         [0045]    The operation of adapter assembly  100  will now be described with reference to the figures. The adapter assembly  100  is secured to the handle assembly  20  ( FIG. 1 ) and loading unit  40  of the tool assembly  30  ( FIG. 1 ) is secured to the adapter assembly  100  in a traditional manner. Subsequent to placement of the anvil assembly  50  ( FIG. 1 ) of the tool assembly  30  ( FIG. 1 ) through tissue to be stapled (not shown) and/or the placement of the tissue to be stapled around the anvil assembly  50 , e.g., with a purse-string suture, the anvil assembly  50  is secured to the trocar member  132  of the adapter assembly  100 . 
         [0046]    The handle assembly  20  may then be actuated to cause individual or simultaneous rotation of any of the first, second, and third drive shafts (not shown) of the handle assembly  20  to effect actuation of the respective first, second, and third drive assemblies  120 ,  140 ,  160  of the drive mechanism  118  of the adapter assembly  100 . 
         [0047]    Referring briefly to  FIGS. 9 and 10 , during actuation of the handle assembly  20  ( FIG. 1 ) to actuate the first drive assembly  120 , rotation of the first drive shaft (not shown) of the handle assembly  20  rotates the first connector sleeve  112 , which rotates the first drive shaft  122 , which rotates the first distal drive shaft  124  to cause rotation of the first drive screw  126 . Rotation of the first drive screw  126  in the first direction causes longitudinal movement of the trocar member  132  in the proximal direction, i.e., retraction, and rotation of the first drive screw  126  in the second direction causes longitudinal movement of the trocar member  132  in the distal direction, i.e., advancement. 
         [0048]    As noted above, during actuation of the first drive assembly  120  of the drive mechanism  118 , the gear flange  126   a  of the first drive screw  126  engages the thrust plate  130 . The configuration of the adapter assembly  100  is such that the thrust plate  130  only experiences load during actuation of the first drive assembly  120 . In this manner, the adapter assembly  100  will have better resolution during operation than an adapter assembly (not shown) in which the thrust plate  130  experiences additional loads from the second and third drive assemblies  140 ,  160 . As noted above, the thrust plate  130  may include a strain gauge for measuring the clamping forces during operation of the first drive assembly  120 . 
         [0049]    Turning to  FIGS. 11-13 , during actuation of handle assembly  20  ( FIG. 1 ) to actuate the second drive assembly  140 , rotation of the second drive shaft (not shown) of handle assembly  20  rotates the second connector sleeve  114 , which rotates the second drive shaft  142 , which rotates the compound gear shaft  144  to cause rotation of the second drive screw  146 . Rotation of the second drive screw  146  in the first direction causes longitudinal movement of an attached first pusher member (not shown) in a distal direction, i.e., advancement, and rotation of the second drive screw  146  in the second direction causes longitudinal movement of the attached pusher member (not shown) in a proximal direction, i.e., retraction. As noted above, during actuation of the second drive assembly  140  of the drive mechanism  118 , the gear flange  146   a  of the second drive screw  146  engages the gear flange  126   a  of the first drive screw  126 . 
         [0050]    Turning to  FIGS. 14 and 15 , during actuation of handle assembly  20  ( FIG. 1 ) to actuate the third drive assembly  160 , rotation of the third drive shaft (not shown) of handle assembly  20  rotates the third connector sleeve  116 , which rotates the third drive shaft  162 , which rotates the compound gear shaft  164  to cause rotation of the third drive screw  166 . Rotation of the third drive screw  166  in the first direction causes longitudinal movement of an attached second pusher member (not shown) in a distal direction, i.e., advancement, and rotation of the third drive screw  166  in the second direction causes longitudinal movement of the attached pusher member (not shown) in a proximal direction, i.e., retraction. As noted above, during actuation of the third drive assembly  160  of the drive mechanism  118 , the gear flange  166   a  of the third drive screw  166  engages the gear flange  146   a  of the second drive screw  146  which engages the gear flange  126   a  of the first drive screw  126 . 
         [0051]    The axial load path of the adapter assembly  100  extends through the first, second, and third drive screws  126 ,  146 ,  166  of the respective first, second, and third drive assemblies  120 ,  140 ,  160 . In this manner, the sleeve  109  of the adapter assembly does not experience loads from the second and third drive assemblies  140 ,  160 . As noted above, the common central longitudinal axis of the first, second, and third drive assemblies  120 ,  140 ,  160  allows the sleeve  109  of the adapter assembly  100  to be rotated along the longitudinal axis “x” of the adapter assembly  100 . 
         [0052]    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. 
         [0053]    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.