Patent Description:
For example, <CIT> describes hand-held surgical instruments having features according to the preamble of claim <NUM>.

Certain optional features of the invention are defined in the dependent claims. The present invention provides a hand-held surgical instrument is provided and includes a handle assembly, a shaft portion having a proximal end portion and a distal end portion, a knob housing coupled between the proximal end portion of the shaft portion and the handle assembly, an articulation lever rotationally coupled to the knob housing, a cam plate non-rotationally coupled to the articulation lever and disposed within the knob housing, a slider supported in the knob housing and configured to translate within and relative to the knob housing between a proximal position and a distal position, and a surgical loading unit having a proximal body portion and an end effector pivotably coupled to the proximal body portion. The cam plate defines a notch therein and the slider has a tab configured for receipt in the notch of the cam plate when the slider is in the distal position to prevent rotation of the cam plate. The proximal body portion of the surgical loading unit is configured to detachably couple to the distal end portion of the shaft portion. The cam plate is configured to operably couple to the end effector such that the end effector articulates relative to the proximal body portion in response to a rotation of the cam plate. The surgical loading unit is configured to move the slider toward the proximal position upon assembling the surgical loading unit to the distal end portion of the shaft portion.

In embodiments, the hand-held surgical instrument may further include a flag and a sensor disposed adjacent the flag. The flag may be attached to the slider and configured to move with the slider between the proximal and distal positions. The sensor may be configured to sense whether the slider is in the proximal position or the distal position.

In these embodiments, the sensor may be a photointerrupter fixed within the handle assembly, and the flag may be configured to block a signal of the photointerrupter when the slider is in the proximal position.

In embodiments, the hand-held surgical instrument may further include a motor configured to actuate a function of the end effector. The sensor may be in communication with the motor and configured to prevent operation of the motor when the sensor senses that the slider is in the distal position and/or permit operation of the motor when the sensor senses that the slider is in the proximal position.

In embodiments, the slider may be an elongate body resiliently biased toward the distal position.

In embodiments, the hand-held surgical instrument may further include an articulation link extending through the shaft portion. The articulation link may include a proximal end portion having a cam pin, and a distal end portion configured to operably couple to the end effector. The cam plate may define a cam slot in which the cam pin is received. The articulation link may be configured to translate in response to a rotation of the cam plate to articulate the end effector relative to the proximal body portion.

In embodiments, the hand-held surgical instrument may further include a pawl received in the knob housing. The cam plate may have a plurality of teeth extending from an outer periphery of the cam plate. The pawl may be engaged to the plurality of teeth to maintain a radial orientation of the cam plate.

In embodiments, the shaft portion may be configured to rotate about a longitudinal axis defined by the shaft portion in response to a manual rotation of the knob housing.

In embodiments, the hand-held surgical instrument may further include a firing rod extending longitudinally through a longitudinal passageway defined through the slider. The firing rod may have a distal end portion configured to detachably couple to the surgical loading unit. The firing rod may be configured to translate through the shaft portion to actuate a function of the end effector.

Embodiments of the present invention are described herein with reference to the accompanying drawings, wherein:.

Embodiments of the hand-held surgical stapling instruments according to the present invention 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, or component thereof, farther from the user, while the term "proximal" refers to that portion of the surgical instrument, or component thereof, closer to the user.

As will be described in detail below, provided is a hand-held surgical instrument including a handle assembly, a shaft assembly coupled to the handle assembly, and a surgical loading unit detachably coupled to a distal end of the shaft assembly. The shaft assembly has a motor-driven firing rod configured to carry out a function of a surgical end effector of the surgical loading unit. The shaft assembly has a manual articulation lever operably coupled to the end effector for manually articulating the end effector between a non-articulation orientation and various articulated orientations. The shaft assembly includes a cam plate that is rotated by the articulation lever, and a slider block that translates proximally during loading of the surgical loading unit into the shaft assembly. The slider block interlocks with the cam plate when no surgical loading unit is assembled to the shaft assembly, whereby the slider block prevents manual rotation of the articulation lever. As such, articulation is not permitted unless a surgical loading unit is properly engaged to the shaft assembly. Other features and benefits of the disclosed surgical instruments are further detailed below.

With reference to <FIG>, a surgical instrument, in accordance with an embodiment of the present invention, is generally designated as <NUM>, and is in the form of a powered hand-held electromechanical surgical instrument configured for selective coupling thereto of a plurality of different surgical loading units, for example, the surgical loading unit <NUM> of <FIG>. As will be described in further detail below, the surgical loading unit <NUM> includes a proximal body portion <NUM> detachably coupled to a shaft assembly <NUM> of the surgical instrument <NUM>, and an end effector <NUM> pivotably coupled to the proximal body portion <NUM>. The end effector <NUM> is configured for actuation and manipulation by the powered hand-held electromechanical surgical instrument <NUM>.

The hand-held electromechanical surgical instrument <NUM> includes a handle assembly <NUM> and the shaft assembly <NUM>, which includes a knob housing <NUM> coupled to the handle assembly <NUM>, and a shaft portion <NUM> extending distally from the knob housing <NUM> and configured for selective connection with a surgical attachment, such as, for example, the surgical loading unit <NUM>. The handle assembly <NUM> includes a disposable and sterile handle housing <NUM> and an instrument module <NUM> (<FIG>) configured for removable receipt within handle housing <NUM>.

The handle housing <NUM> has a body, such as, for example, a barrel portion <NUM>, a handle portion <NUM> extending perpendicularly downward from the barrel portion <NUM> or transversely and proximally from the barrel portion <NUM>, and a hinged door <NUM> pivotably coupled to the handle portion <NUM>. The door <NUM> is selectively opened and closed to allow for the insertion or removal of the instrument module <NUM>. The handle portion <NUM> and the door <NUM> each have an inner periphery collectively defining a sterile barrier for the instrument module <NUM> upon closing the door <NUM>. In aspects, a proximal end portion or any suitable location of the barrel portion <NUM> may have a clear window (not shown) to allow for viewing of a display (e.g., an LCD, not shown).

The handle assembly <NUM> has a fire switch <NUM> configured and adapted to actuate the various functions of the end effector <NUM>. The fire switch <NUM> may be constructed as a toggle bar pivotably coupled to the handle portion <NUM> of the handle housing <NUM>. An activation of the fire switch <NUM> activates a motor <NUM> to advance or retract a firing rod <NUM> of the shaft assembly <NUM> depending on whether a top button 122a or a bottom button 122b of the fire switch <NUM> is actuated. The firing rod <NUM> has a distal end portion 124b configured to couple to a drive assembly <NUM> (<FIG>) of the surgical loading unit <NUM> (which includes a knife rod <NUM> and an actuation sled <NUM>), such that advancement of the firing rod <NUM> advances the drive assembly <NUM> of the surgical loading unit <NUM>, which closes the jaw members <NUM>, <NUM> of the end effector <NUM> and fires the end effector <NUM> when a safety switch <NUM> is in an actuated state.

With reference to <FIG>, the surgical instrument module <NUM> of the handle assembly <NUM> is configured for powering surgical instrument <NUM>. In other aspects, other means for powering surgical instrument <NUM> are contemplated, such as, for example, a battery-powered motor that is permanently fixed within handle housing <NUM>. The surgical instrument module <NUM> includes a sterile outer shell <NUM> and a reusable power assembly <NUM> configured for removably receipt in the outer shell <NUM>. The outer shell <NUM> has a cover <NUM> received in an open bottom end of the outer shell <NUM>, and a spring-loaded pull tab <NUM> to facilitate removal of the cover <NUM>.

The power assembly <NUM> of the instrument module <NUM> includes the motor <NUM>, such as, for example, an electrical drive motor, which is electrically connected or wirelessly connected to a printed circuit board <NUM> and a battery <NUM>. In aspects, the battery <NUM> may include a boost circuit and may be rechargeable (e.g., wirelessly). The battery <NUM> has a card edge connector <NUM> configured for detachable receipt of a card edge header <NUM> of the handle assembly <NUM> to allow for communication from the fire switch <NUM>, the safety switch <NUM>, and an articulation encoder to the battery <NUM>. The printed circuit board <NUM> may include a USB charging connector <NUM> to allow for the battery <NUM> to be recharged with a USB charger or wirelessly (e.g., via induction). In aspects, the printed circuit board <NUM> may have a motor controller or a processor.

The instrument module <NUM> further includes a gearbox <NUM>, such as, for example, a planetary gearbox, operably coupled to the drive motor <NUM>, and first and second outputs <NUM>, <NUM> (<FIG>) drivingly coupled to the gearbox <NUM> and configured to rotate about a longitudinal axis defined by the gearbox <NUM>. The gear box <NUM> is configured to transfer power from the motor <NUM> into a rotation of the first output <NUM> at a high-torque and low-speed, and a rotation of the second output <NUM> at a high-speed and low-torque. Rotation of the output <NUM> or output <NUM> by the motor <NUM> functions to drive shafts and/or gear components of the handle assembly <NUM> in order to perform an operation of a corresponding surgical loading unit, such as, for example, the surgical loading unit <NUM> (<FIG>). For example, the motor <NUM> is configured move the jaw members <NUM>, <NUM> of the end effector <NUM> relative to one another and to fire staples from the end effector <NUM>.

With reference to <FIG>, further details of the various components of the instrument module <NUM> will now be described. The motor <NUM> has a rotatable motor shaft <NUM> (<FIG>) to which a main sun gear <NUM> is non-rotatably fixed such that the main sun gear <NUM> rotates with the motor shaft <NUM> about a longitudinal axis defined by the motor shaft <NUM>. The gear box <NUM> includes a plurality of planetary gear assemblies <NUM>, <NUM>, <NUM>, <NUM> and an elongate ring gear <NUM> disposed about and operably coupled to the plurality of planetary gear assemblies <NUM>, <NUM>, <NUM>, <NUM>.

The first planetary gear assembly <NUM> is operably coupled to the main sun gear <NUM> such that the first planetary gear assembly <NUM> rotates about the longitudinal axis of the motor shaft <NUM> in response to a rotation of the main sun gear <NUM>. The first planetary gear assembly <NUM> increases the torque output of the motor <NUM> while reducing the output rotational speed. The first planetary gear assembly <NUM> includes a first carrier <NUM>, a first sun gear <NUM>, and a plurality of planetary gears 356a, 356b, 356c. The first carrier <NUM> has a plurality (e.g., three) of pins 356d, 356e, 356f fixed thereto and extending proximally from a proximal side thereof. The first sun gear <NUM> is rotationally fixed to a distal side of the first carrier <NUM> and centrally aligned with the longitudinal axis of the motor shaft <NUM>. The planetary gears 356a, 356b, 356c are rotatably coupled to the respective pins 356d, 356e, 356f of the first carrier <NUM>. The planetary gears 356a, 356b, 356c are in meshing engagement with the main sun gear <NUM> to rotate in response to a rotation of the main sun gear <NUM>. As will be described, the elongate ring gear <NUM> is rotationally fixed relative to the outer shell <NUM> (<FIG>) such that the first planetary gear assembly <NUM> rotates as a unit about the longitudinally axis of the motor shaft <NUM> in response to a rotation of the main sun gear <NUM>.

The second planetary gear assembly <NUM> includes a second carrier <NUM>, a second sun gear <NUM>, and a plurality of planetary gears 358a, 358b, 358c. The second planetary gear assembly <NUM> has an increased torque output and reduced rotational speed output relative to the first planetary gear assembly <NUM>. The second carrier <NUM> has a plurality (e.g., three) of pins 358d, 358e, 358f fixed thereto and extending proximally from a proximal side thereof. The second sun gear <NUM> is rotationally fixed to a distal side of the second carrier <NUM> and centrally aligned with the longitudinal axis of the motor shaft <NUM>. The planetary gears 358a, 358b, 358c of the second planetary gear assembly <NUM> are rotatably coupled to the respective pins 358d, 358e, 358f of the second carrier <NUM>. The planetary gears 358a, 358b, 358c are in meshing engagement with the first sun gear <NUM> of the first planetary gear assembly <NUM> and the fixed elongate ring gear <NUM> such that the second planetary gear assembly <NUM> rotates in response to a rotation of the first planetary gear assembly <NUM>.

The third planetary gear assembly <NUM> includes a third carrier <NUM>, a third sun gear <NUM>, and a plurality of planetary gears 360a, 360b, 360c. The third planetary gear assembly <NUM> has an increased torque output and reduced rotational speed output relative to the second planetary gear assembly <NUM>. The third carrier <NUM> has a plurality (e.g., three) of pins 360d, 360e, 360f fixed thereto and extending proximally from a proximal side thereof. The third sun gear <NUM> is rotationally fixed to a distal side of the third carrier <NUM> and centrally aligned with the longitudinal axis of the motor shaft <NUM>. The planetary gears 360a, 360b, 360c of the third planetary gear assembly <NUM> are rotatably coupled to the respective pins 360d, 360e, 360f of the third carrier <NUM>. The planetary gears 360a, 360b, 360c of the third planetary gear assembly <NUM> are in meshing engagement with the second sun gear <NUM> of the second planetary gear assembly <NUM> and the elongate ring gear <NUM> such that the third planetary gear assembly <NUM> rotates as a unit in response to a rotation of the second planetary gear assembly <NUM>.

The fourth planetary gear assembly <NUM> includes a fourth carrier <NUM> and a plurality of planetary gears 362a, 362b, 362c. The fourth planetary gear assembly <NUM> has an increased torque output and reduced rotational speed output relative to the third planetary gear assembly <NUM>. The fourth carrier <NUM> is connected to, monolithically formed with, or otherwise non-rotatably coupled to a proximal end of the first output <NUM> and has a plurality (e.g., three) of pins 362d, 362e, 362f fixed thereto and extending proximally from a proximal side thereof. The planetary gears 362a, 362b, 362c of the fourth planetary gear assembly <NUM> are rotatably coupled to the respective pins 362d, 362e, 362f of the fourth carrier <NUM>. The planetary gears 362a, 362b, 362c of the fourth planetary gear assembly <NUM> are in meshing engagement with the third sun gear <NUM> of the third planetary gear assembly <NUM> and the elongate ring gear <NUM> such that the fourth planetary gear assembly <NUM> and the first output <NUM> rotate together in response to a rotation of the third planetary gear assembly <NUM>. It is contemplated that the gear box <NUM> may include more or less than the four planetary gear assemblies and/or other types of gears.

With continued reference to <FIG>, the first output <NUM> is configured to generate a relatively high torque (e.g., about <NUM> oz-in or <NUM>) and a relatively low speed (e.g., <NUM> rpm) and includes a cylindrical body 348a received in a distal end portion of the elongate ring gear <NUM>, and a gear 348b, such as, for example, a pinion gear formed with a distal end portion of the cylindrical body 348a. The pinion gear 348b of the first output <NUM> is configured to be selectively operably coupled to a driven member <NUM> (<FIG>) of a first type of surgical end effector, such as, for example, surgical end effector <NUM> (<FIG>) of the linear stapler <NUM>.

The surgical instrument module <NUM> further includes a drive shaft <NUM> having a proximal end portion 380a non-rotatably coupled to the second planetary gear assembly <NUM> such that the drive shaft <NUM> is configured to rotate with the second planetary gear assembly <NUM>. In particular, the proximal end portion 380a of the drive shaft <NUM> is received within and rotationally fixed to the second sun gear <NUM> of the second planetary gear assembly <NUM>. The drive shaft <NUM> has a distal end portion 380b extending longitudinally through the third and fourth planetary gear assemblies <NUM>, <NUM> while being freely rotatable therein. The distal end portion 380b of the drive shaft <NUM> may have a non-circular cross-sectional shape, such as, for example, a tri-lobe shape.

The second output <NUM> is attached to the distal end portion 380b of the drive shaft <NUM> and is configured to rotate with the drive shaft <NUM> about a longitudinal axis of the drive shaft <NUM>. The second output <NUM> is configured to generate a relatively low torque (e.g., <NUM> oz-in or <NUM>) and a relatively high speed (e.g., <NUM> rpm) and includes a socket <NUM> that is configured to operably couple to a corresponding driven element (not explicitly shown) of a different type of surgical end effector than the first output <NUM>. For example, the second output <NUM> of the surgical instrument module <NUM> may be configured to carry out functions of a surgical end effector of a hernia tacker (not shown) or a surgical end effector of a small-diameter vascular stapler (not shown).

The second output <NUM> is concentrically disposed within the first output <NUM> and is configured to rotate simultaneously with the first output <NUM> in response to an activation of the same motor, namely the motor <NUM>. However, as noted above, the first and second outputs <NUM>, <NUM> rotate at different speeds and with different torques from one another. The second output <NUM> is received in an elongate cavity <NUM> defined in the cylindrical body 348a of the first output <NUM>. A biasing member <NUM> is disposed within the cavity <NUM> and captured between the second output <NUM> and an inner surface of the cylindrical body 348a of the first output <NUM>. The biasing member <NUM> is configured to distally-bias the second output <NUM> into a position in which the second output <NUM> is concentric within the first output <NUM>. The biasing member <NUM> ensures that even if the socket <NUM> of the second output <NUM> is out of radial alignment with the driven element of the end effector assembly that the socket <NUM> will engage the driven element as the second output <NUM> rotates the socket <NUM> into radial alignment with the driven element.

With continued reference to <FIG>, the elongate ring gear <NUM> of the gear box <NUM> encapsulates each of the planetary gear assemblies <NUM>, <NUM>, <NUM>, <NUM> and is rotationally fixed relative to the outer shell <NUM> (<FIG>) and the motor <NUM>. The elongate ring gear <NUM> has an annular inner surface defining a plurality of longitudinally-extending teeth <NUM> that are in meshing engagement with the planetary gears of each of the planetary gear assemblies <NUM>, <NUM>, <NUM>, <NUM>. A first bushing <NUM> may be provided to capture the first output <NUM> in the elongate ring gear <NUM> and a second bushing <NUM> may be provided to capture the second output <NUM> in the first output <NUM>.

With brief reference to <FIG>, the handle assembly <NUM> further includes a rack <NUM> located in the barrel portion <NUM> of the handle housing <NUM> and extends parallel with the barrel portion <NUM>. The rack <NUM> is axially supported in the handle housing <NUM> has a distal end portion axially fixed to a firing rod <NUM> (<FIG>) configured to operably couple to the drive assembly <NUM> (<FIG>) of the end effector <NUM>. The rack <NUM> is operably coupled to the output pinion gear <NUM> (<FIG>). In aspects, the rack <NUM> may be directly engaged to the output pinion gear <NUM>.

In operation, a surgical instrument is selected that is suitable for an operation to be performed. For example, the linear stapler <NUM> (<FIG>) may be selected. The linear stapler <NUM> is typically used for stapling a type of tissue that is more suitable to receiving staples that are deployed with a high torque and at a low speed. The surgical instrument module <NUM> is inserted into the handle housing <NUM> of the linear stapler <NUM>, whereby the pinion gear 348b of the first output <NUM> operably engages a driven element, such as rack <NUM> (<FIG>) or a corresponding pinion gear of the handle assembly <NUM> of the linear stapler <NUM>. In aspects, a preassembled, disposable, sterile, and/or funnel-shaped insertion guide may be implemented to assist in passing the surgical instrument module <NUM> into the handle housing <NUM>. When the insertion guide is removed, the handle housing <NUM> remains sterile through this aseptic transfer procedure. With the instrument module <NUM> disposed within the handle housing <NUM>, the door <NUM> is closed, thereby sealing the instrument module <NUM> in the sterile handle portion <NUM>. Further, the card edge header <NUM> of the printed circuit board <NUM> of the handle assembly <NUM> is connected to the card edge connector <NUM> of the instrument module <NUM>.

To operate a stapling function of the surgical end effector <NUM> of the linear stapler <NUM>, the fire switch <NUM> (<FIG>) may be toggled, whereby the battery <NUM> of the instrument module <NUM> provides power to the motor <NUM>, which drives a rotation, in turn, of the first, second, third, and fourth planetary gear assemblies <NUM>, <NUM>, <NUM>, <NUM>. The planetary gear assemblies <NUM>, <NUM>, <NUM>, <NUM> consecutively enhance the torque and reduce the speed output by the pinion gear 348b of the first output <NUM> compared to the torque and speed originating from the motor <NUM>. The high-torque, low-speed output by the first output <NUM> results translates the rack <NUM> (<FIG>) along the longitudinal axis of the barrel portion <NUM> of the handle housing <NUM>. Since the rack <NUM> is operably coupled to the drive assembly <NUM> of the surgical end effector <NUM> via the firing rod <NUM> (<FIG>), translation of the rack <NUM> results in one of an opening or closing of the jaw members <NUM>, <NUM> depending on the direction of translation of the rack <NUM>. To fire staples from the surgical end effector <NUM>, the safety switch <NUM> (<FIG>) is actuated, and then the bottom button 122b of the fire switch <NUM> is actuated, whereby the sled <NUM> (<FIG>) of the surgical end effector <NUM> translates through the cartridge assembly <NUM> to fire the staples into tissue with a high force and at a low speed.

If a different surgical procedure is to be performed, for example, a hernia repair procedure, a hernia tacker may be selected for use rather than the linear stapler <NUM> while still enabling utilization of the same surgical instrument module <NUM>. To properly treat tissue, a hernia tacker demands less torque but a higher actuation speed than the linear stapler <NUM>. The instrument module <NUM> is inserted into a handle portion of a hernia tacker, whereby the socket <NUM> of the second output <NUM> engages a driven element (e.g., a rod) of the hernia tacker. To operate the hernia tacker, an actuation of a switch or toggle activates the battery <NUM> of the instrument module <NUM>, thereby providing power to the motor <NUM>, which drives a rotation, in turn, of the first and second planetary gear assemblies <NUM>, <NUM>. Since the drive shaft <NUM> is fixed to the second sun gear <NUM> of the second planetary gear assembly <NUM>, the drive shaft <NUM> rotates with the rotation of the second planetary gear assembly <NUM>. The second output <NUM>, which is non-rotatably attached to the distal end portion 380b of the drive shaft <NUM>, rotates with the drive shaft <NUM> to effect a function of the hernia tacker, such as a deployment of a surgical tack into tissue at a low torque and a high speed.

It is contemplated that each of the first and second drive outputs <NUM>, <NUM> may be simultaneously coupled to two distinct driven elements of a particular surgical instrument to perform discrete functions of the surgical instrument.

With reference to <FIG> and <FIG>, the shaft assembly <NUM> of the surgical instrument <NUM> generally includes the knob housing <NUM>, the shaft portion <NUM>, which has a proximal end portion 106a received within and non-rotationally coupled to the knob housing <NUM>, and an articulation switch <NUM>, such as, for example, a manual articulation lever coupled to an upper housing half of the knob housing <NUM>. The knob housing <NUM> is supported between the barrel portion <NUM> and the proximal end portion 106a of shaft portion <NUM>. The knob housing <NUM> is rotatably coupled to the handle housing <NUM> such that a manual rotation of the knob housing <NUM> results in a corresponding rotation of the surgical loading unit <NUM> (e.g., the surgical loading unit <NUM> rotates about a central longitudinal axis "X" defined by the shaft portion <NUM>).

The articulation switch or lever <NUM> has a stem <NUM> protruding downwardly therefrom, which is received in a corresponding aperture <NUM> defined in the upper housing half of the knob housing <NUM>. The articulation lever <NUM> is configured to actuate an articulation of the end effector <NUM> (e.g., move the end effector <NUM> along a horizontal plane between a position coaxial with the shaft portion <NUM> and multiple positions out of parallel alignment with the shaft portion <NUM>), as will be described herein.

With reference to <FIG>, the shaft assembly <NUM> further includes a plurality of mechanical components responsible for converting the manual rotation of the articulation lever <NUM> into the articulation of the end effector <NUM> (<FIG>). In particular, the shaft assembly <NUM> includes a cam plate <NUM> coupled to the articulation lever <NUM> and an articulation link <NUM> coupled to the cam plate <NUM> and the surgical loading unit <NUM> when the surgical loading unit <NUM> is coupled to the shaft portion <NUM>. The cam plate <NUM> is received within the knob housing <NUM> and is non-rotationally coupled to the articulation lever <NUM>. For example, the stem <NUM> of the articulation lever <NUM> may be fixed to the cam plate <NUM> via fasteners such that rotation of the articulation lever <NUM> about a pivot axis "Y" (<FIG>) results in a rotation of the cam plate <NUM>.

The cam plate <NUM> has an annular outer periphery having a plurality of gear teeth or ridges <NUM>. A pawl <NUM> may be provided within the knob housing <NUM> and may be resiliently biased by a pawl spring <NUM> into engagement with the teeth <NUM> of the cam plate <NUM> to resist, without preventing, rotation of the cam plate <NUM>. In this way, an articulation orientation of the end effector <NUM>, as set by the radial orientation of the articulation lever <NUM> relative to the knob housing <NUM>, is maintained by the engagement of the pawl <NUM> with the teeth <NUM> of the cam plate <NUM>.

The articulation link <NUM> has a proximal end portion 136a received within the knob housing <NUM> and a distal end portion 136b extending through the shaft portion <NUM> for selective engagement with a hooked proximal end portion <NUM> (<FIG>) of an articulation shaft <NUM> of the surgical loading unit <NUM>. The proximal end portion 136a of the articulation link <NUM> may be an elongated plate disposed below the cam plate <NUM>, and the distal end portion 136b of the articulation link <NUM> may be a shaft or bar fixed to and extending distally from the elongated plate 136a. A cam pin <NUM> is fixed to the proximal end portion 136a of the articulation link <NUM> and protrudes upwardly therefrom and into an arcuate cam slot <NUM> defined in the cam plate <NUM>. The cam slot <NUM> is configured to drive a translation of the cam pin <NUM> as the cam plate <NUM> rotates in either of a clockwise or counter-clockwise direction. The distal end portion 136b of the articulation link <NUM> has a hooked distal end 136c configured to operably couple to the hooked proximal end <NUM> (<FIG>) of the articulation shaft <NUM> of the surgical loading unit <NUM> such that the translation of the articulation link <NUM> results in an articulation of the end effector <NUM> relative to the proximal body portion <NUM> of the surgical loading unit <NUM>.

With continued reference to <FIG>, the shaft assembly <NUM> further includes a plurality of operably connected mechanical and electrical components responsible for preventing an actuation of articulation lever <NUM> or an activation of the motor <NUM> unless the surgical loading unit <NUM> is properly assembled/loaded to the shaft assembly <NUM>. In particular, the shaft assembly <NUM> includes a slider <NUM>, such as, for example, an elongate body supported in the knob housing <NUM> and configured to translate within and relative to the knob housing <NUM> between a proximal position and a distal position. The slider <NUM> may be rectangular, tubular, cylindrical, block-shaped, or assume any other suitable shape. The slider <NUM> is keyed to an internal surface of the knob housing <NUM> to prevent relative rotation between the slider <NUM> and the knob housing <NUM>. The slider <NUM> defines a longitudinally-extending passageway <NUM> (<FIG>) through which the firing rod <NUM> extends.

The slider <NUM> has a tab <NUM>, such as, for example, a fin protruding upwardly from a proximal end portion 150a thereof. In aspects, the tab <NUM> may be any suitable surface feature, such as, for example, a ridge, a tooth, or the like. The tab <NUM> of the slider <NUM> is configured for removable receipt in a correspondingly-shaped notch <NUM> defined in the cam plate <NUM>. In aspects, the notch <NUM> may be elongated and extend radially inward from the outer periphery of the cam plate <NUM>. The notch <NUM> is configured to be parallel with the longitudinal axis "X" of the shaft portion <NUM> when the articulation lever <NUM> is parallel with the longitudinal axis "X" of the shaft portion <NUM> (e.g., when the articulation lever <NUM> is in a non-articulated orientation). A biasing member <NUM>, such as, for example, a coil spring, may be provided to bias the slider <NUM> in the distal position, in which the tab <NUM> is received in the notch <NUM> of the cam plate <NUM> to prevent rotation of the articulation lever <NUM>. In aspects, the cam plate <NUM> may have a tab whereas the slider <NUM> may have a corresponding notch.

With reference to <FIG>, <FIG>, <FIG>, and <FIG>, the shaft assembly <NUM> further includes a tubular shaft <NUM> and a coupling assembly <NUM> attached to a distal end portion 160b of the tubular shaft <NUM>. The tubular shaft <NUM> extends through the shaft portion <NUM> and is disposed about the firing rod <NUM>. The tubular shaft <NUM> has a proximal end portion 160a extending into the knob housing <NUM> and into abutment with a distal end portion 150b of the slider <NUM>. In aspects, the proximal end portion 160a of the tubular shaft <NUM> may be fixed to or otherwise coupled to the distal end portion 150b of the slider <NUM> so that proximal or distal translation of the tubular shaft <NUM> results in a corresponding translation of the slider <NUM>.

The coupling assembly <NUM>, as best shown in <FIG> and <FIG>, is fixed to the distal end portion 160b of the tubular shaft <NUM> and is disposed adjacent a distal end portion 106b of the shaft portion <NUM>. The coupling assembly <NUM> includes a proximal link <NUM> fixed to the tubular shaft <NUM> and a distal link <NUM> fixed to the proximal link <NUM>. The distal link <NUM> is configured to be engaged to the proximal body portion <NUM> (<FIG>) of the surgical loading unit <NUM> such that the tubular shaft <NUM> and the slider <NUM> translate proximally from the distal position to the proximal position upon receipt of the surgical loading unit <NUM> in the distal end portion 106b of the shaft portion <NUM>.

With reference to <FIG>, the shaft assembly <NUM> further includes a tubular member <NUM> fixed within the proximal end portion 150a of slider <NUM> and projecting proximally therefrom. The biasing member <NUM> may be received within the tubular member <NUM> to distally bias the slider <NUM>. The tubular member <NUM> has a flag <NUM> extending laterally outward therefrom and received within the handle housing <NUM>. The flag <NUM> is configured to move with the slider <NUM> as the slider <NUM> translates between the proximal and distal positions. In aspects, the flag <NUM> may be monolithically formed with or otherwise coupled directly to the slider <NUM>.

The handle assembly <NUM> further includes a sensor <NUM> fixed to the printed circuit board <NUM> and disposed adjacent the flag <NUM>. The sensor <NUM> may be in communication with the motor <NUM> (<FIG>), either directly or via a processor <NUM> (<FIG>), and configured to sense an axial position of the flag <NUM>. For example, the sensor <NUM> may be a photointerrupter fixed within the handle assembly <NUM>, and the flag <NUM> may be configured to block a signal of the photointerrupter <NUM> when the slider <NUM> is in the proximal position. In aspects, the sensor <NUM> may be any suitable type of position sensor, such as, for example, a hall effect sensor, an electro-optical sensor, photoelectric sensor, or the like.

The sensor <NUM> may be configured to prevent operation of the motor <NUM> when the sensor <NUM> senses that the slider <NUM> is in the distal position, which is indicative of an absence of a properly loaded surgical loading unit <NUM> to the shaft assembly <NUM> and/or permit operation of the motor <NUM> when the sensor <NUM> senses that the slider <NUM> is in the proximal position, which is indicative of a surgical loading unit <NUM> being properly loaded to the shaft assembly <NUM>. In aspects, the processor <NUM> may be programmed to inhibit power from being delivered to the motor <NUM> upon the sensor <NUM> sensing that the flag <NUM> is in the distal position or failing to sense that the flag <NUM> is in the proximal position. In aspects, the processor <NUM> may be programmed to permit power to be delivered to the motor <NUM> upon the sensor <NUM> sensing that the flag <NUM> is in the proximal position or failing to sense that the flag is in the distal position. In other aspects, the sensor <NUM> may be in communication with a display or speaker for providing a visual or audible indication that the surgical loading unit <NUM> is not properly inserted.

In aspects, the sensor <NUM> may be configured to enable the software control to know that a SULU is present. The flag <NUM> engages the photo interrupter or sensor <NUM>, acting as a switch and electrically notifying the device that a SULU is present. When all other safety conditions are met, such as the device is fully clamped, the green safety switch is enabled, allowing the green safety to change states if depressed. Once depressed, the LED indicator may transition from blinking to illuminating a solid green light. With the solid green indicator, fire mode is enabled and the surgical instrument <NUM> may be actuated when ready.

With reference to <FIG>, the surgical loading unit <NUM> includes the proximal body portion <NUM> and the end effector <NUM>. The proximal body portion <NUM> is releasably attached to the distal end portion 106b of the shaft portion <NUM>, and the end effector <NUM> is pivotally attached to a distal end of the proximal body portion <NUM> of the end effector <NUM>. The end effector <NUM> is configured to articulate relative to the proximal body portion <NUM> via a manual rotation of articulation lever <NUM>. The end effector <NUM> includes an anvil assembly <NUM> and a cartridge assembly <NUM>. The cartridge assembly <NUM> is pivotal in relation to the anvil assembly <NUM> and is movable between an open or unclamped position and a closed or clamped position for insertion through a cannula of a trocar.

To assemble the surgical loading unit <NUM> to the surgical instrument <NUM>, the proximal body portion <NUM> of the surgical loading unit <NUM> is axially inserted within the distal end portion 106b of the shaft portion <NUM> and rotated relative to the shaft portion <NUM> to lockingly engage a pair of bosses 224a, 224b (<FIG>) of the surgical loading unit <NUM> within a corresponding pair of recesses defined within shaft portion <NUM>. Upon axially inserting the surgical loading unit <NUM> into shaft portion <NUM>, proximal body portion <NUM> engages the coupling assembly <NUM> (<FIG> and <FIG>) to proximally translate the tubular shaft <NUM> and the attached slider <NUM> against the distally-oriented bias of the biasing member <NUM>. As the slider <NUM> is moved from the distal position to the proximal position, the tab <NUM> of the slider <NUM> is displaced out of the notch <NUM> in the cam plate <NUM> to allow for a manual rotation of the articulation lever <NUM>. Prior to loading the surgical loading unit <NUM>, the tab <NUM> of the slider <NUM> is received within the notch <NUM> of the cam plate <NUM> preventing an inadvertent rotation of the articulation lever <NUM>, which could damage components of the surgical instrument <NUM> and/or result in the improper loading of the surgical loading unit <NUM>.

With reference to <FIG>, <FIG>, and <FIG>, to articulate the end effector <NUM> relative to the proximal body portion <NUM>, a clinician may rotate the articulation lever <NUM>, which in turn rotates the cam plate <NUM> to drive one of a distal or proximal translation of the articulation link <NUM> due to cam slot <NUM> of the cam plate <NUM> acting on the cam pin <NUM> of the articulation link <NUM>. A translation of the articulation link causes a concomitant translation of the articulation shaft <NUM> of the surgical loading unit <NUM>, whereby the end effector <NUM> is caused to articulate relative to the proximal body portion <NUM> either toward the left or the right (from the perspective of the user).

With reference to <FIG>, in aspects, a plurality of surgical loading units may be provided with each having a different length (e.g., <NUM>, <NUM> and <NUM>). There are multiple methods for the power assembly to determine the firing length, thereby determining when to begin retraction. One method is to install a one-wire ID chip <NUM> on the proximal end of the proximal body portion <NUM> configured to mate with a corresponding electrical contact (not explicitly shown) disposed within the distal end portion 106b of shaft portion <NUM> for communicating information about the surgical loading unit <NUM> to the processor <NUM> (<FIG>) of the handle assembly <NUM>. The chip <NUM> may have a unique identifier that will provide the handle assembly <NUM> with electronic information as to the reload length and required number of firing turns which in turn can be programmed into the software.

Another method is to use an algorithm that monitors the amount of motor current used to detect when the I-beam <NUM> of the surgical loading unit <NUM> has advanced to the point of colliding with the end of the anvil <NUM> slot. This contact will form a current spike that can be measured in software indicating the end-stop has been reached. The algorithm can be finely tuned to minimize the amount of force and articulation hinge deflection required to make this detection.

Another method integrates a sensor (not explicitly shown) inside the handle assembly <NUM>. The sensor may, for example, measure motor torque and correlate the motor toque to the I-beam force or include a strain gauge to measure the module reaction torque. Both of these methods could effectively determine when the I-beam <NUM> end stop has been reached as a load spike will form when the I-beam <NUM> makes contact with the end of the anvil <NUM> slot.

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.

Claim 1:
A hand-held surgical instrument (<NUM>), comprising:
a handle assembly (<NUM>);
a shaft portion (<NUM>) having a proximal end portion (106a) and a distal end portion (106b);
a knob housing (<NUM>) coupled between the proximal end portion (106a) of the shaft portion (<NUM>) and the handle assembly (<NUM>);
an articulation lever (<NUM>) rotationally coupled to the knob housing (<NUM>);
a cam plate (<NUM>) non-rotationally coupled to the articulation lever (<NUM>) and disposed within the knob housing (<NUM>), the cam plate defining a notch (<NUM>) therein;
a slider (<NUM>) supported in the knob housing (<NUM>) and configured to translate within and relative to the knob housing between a proximal position and a distal position; and
a surgical loading unit (<NUM>) having a proximal body portion (<NUM>) configured to detachably couple to the distal end portion (106b) of the shaft portion (<NUM>), and an end effector (<NUM>) pivotably coupled to the proximal body portion,
characterised in that:
the slider (<NUM>) has a tab (<NUM>) configured for receipt in the notch (<NUM>) of the cam plate (<NUM>) when the slider is in the distal position to prevent rotation of the cam plate; and
the cam plate (<NUM>) is configured to operably couple to the end effector (<NUM>) such that the end effector articulates relative to the proximal body portion (<NUM>) in response to a rotation of the cam plate, wherein the surgical loading unit (<NUM>) is configured to move the slider (<NUM>) toward the proximal position upon assembling the surgical loading unit to the distal end portion (106b) of the shaft portion (<NUM>).