FIRING STROKE CONTROL MECHANISM FOR POWERED STAPLERFIELDThe disclosure is directed to surgical stapling devices and, more particularly, to powered surgical stapling devices.
BACKGROUNDSurgical stapling devices for simultaneously stapling and cutting tissue are well known in the art and include a handle assembly, an adapter assembly, and a tool assembly. The adapter assembly supports a drive assembly and includes a proximal portion that is coupled to the handle assembly and a distal portion that supports the tool assembly. The tool assembly includes an anvil assembly and a cartridge assembly that are coupled together to facilitate movement of the tool assembly between an open position and a clamped position. The cartridge assembly includes a staple cartridge that has a cartridge body that defines a knife slot and supports staples, pushers, and an actuation sled. The drive assembly is movable over an actuation stroke through the cartridge body to move the actuation sled into sequential engagement with the pushers to eject the staples from the cartridge body.
In some stapling devices, the tool assembly or a portion of the tool assembly including the staple cartridge, e.g., a reload, is releasably coupled to the stapling device and is replaceable to facilitate reuse of the handle assembly and adapter assembly during a surgical procedure. Typically, the reload is available with staple cartridges of different lengths, e.g., 30mm, 45mm, and 60mm, requiring the actuation stroke of the drive assembly to be set based upon the length of the staple cartridge coupled to the stapling device.
In powered stapling devices, the handle assembly includes a drive assembly or motor to control advancement of the drive assembly through the actuation stroke. If the drive assembly is not advanced to the appropriate actuation stroke length, the staples can be malformed, or the stapling device can be damaged.
A continuing need exists for a powered stapling device that includes a firing stroke control mechanism to control operation of the motor within the handle assembly to advance the drive assembly a stroke length suitable for the length of the staple cartridge coupled to the stapling device.
SUMMARYThis disclosure is directed to a powered surgical stapling device that includes a reload assembly that is releasably secured to an elongate body of the stapling device. The stapling device includes a reload length identification mechanism to identify the length of a staple cartridge mounted to the elongate body, and a firing stroke control mechanism to deactivate the drive assembly when a toothed rack advances through the appropriate actuation stroke.
Aspects of this disclosure are directed to a surgical stapling device that includes an elongate body, a reload assembly, a reload length identification mechanism, and a handle assembly. The elongate body has a proximal portion and a distal portion having a first coupling structure. The reload assembly includes a proximal body and a tool assembly. The proximal body has a distal portion supporting the tool assembly and a proximal portion that includes a second coupling structure. The second coupling structure is adapted to releasably couple to the first coupling structure to secure the reload assembly to the elongate body. The tool assembly includes a staple cartridge that has a first length or a second length that is greater than the first length. The reload length identification mechanism includes a first component that is supported on the distal portion of the elongate body and a second component that is supported on the proximal portion of the proximal body of the reload assembly. The reload length identification mechanism identifies the length of the staple cartridge. The handle assembly is secured to the proximal portion of the elongate body and includes a housing, a drive assembly, a toothed rack, and a stroke control mechanism. The toothed rack is engaged with the drive assembly and is movable through an actuation stroke in response to activation of the drive assembly. The stroke control mechanism includes a trigger plate and a sensor assembly. The trigger plate is engaged with the toothed rack and movable from a pre-fired position to at least two different positions in relation to the sensor assembly in response to movement of the toothed rack through the actuation stroke. The reload length identification mechanism communicates the length of the staple cartridge to the handle assembly, and the stroke control mechanism deactivates the drive assembly when the toothed rack has moved through the actuation stroke appropriate for the staple cartridge.
In aspects of the disclosure, the toothed rack defines a first channel having a first abutment surface and a second channel having a second abutment surface, and the trigger plate includes a first tab that is received within the first channel and a second tab that is received in the second channel. The first abutment surface is movable into engagement with the first tab of the trigger plate to move the trigger plate to a first position in relation to the sensor assembly to identify that the toothed rack has moved through the actuation stroke appropriate for the staple cartridge having the first length, and the second abutment surface is movable into engagement with the second tab to move the trigger plate to a second position in relation to the sensor assembly to identify that the toothed rack has moved through the actuation stroke appropriate for the staple cartridge having the second length.
In some aspects of the disclosure, the staple cartridge has the first length, the second length, or a third length, the toothed rack defines a third channel having a third abutment surface, and the trigger plate has a third tab that is received in the third channel. The third abutment surface is movable into engagement with the third tab of the trigger plate to move the trigger plate to a third position in relation to the sensor assembly to identify that the toothed rack has moved through the actuation stroke appropriate for the staple cartridge having the third length.
In certain aspects of the disclosure, the third length is greater than the second length.
In aspects of the disclosure, the trigger plate is rotatably supported within the housing of the handle assembly and includes a shaft portion, a first plate shield, and a second plate shield, and the first tab, the second tab, and the third tab are supported on the shaft portion.
In some aspects of the disclosure, the sensor assembly is fixedly supported within the housing and includes a first sensor that defines a first slot and includes a first sensing element and a second sensor that defines a second slot and includes a second sensing element.
In certain aspects of the disclosure, the first plate shield is received within the first slot to cover the first sensing element when the trigger plate is in the first position, and the second plate shield is received within the second slot to cover the second sensing element when the trigger plate is in the second position.
In aspects of the disclosure, when the trigger plate is in the third position, the first plate shield is positioned to uncover the first sensing element and the second plate shield is positioned to cover the second sensing element.
In some aspects of the disclosure, the handle assembly includes an inner support housing, and the trigger plate includes a projection that is urged into engagement with the inner support housing to releasably frictionally retain the trigger plate in its current position within the housing.
In certain aspects of the disclosure, the first and second sensors of the sensor assembly are electromagnetic wave sensors.
In aspects of the disclosure, the electromagnetic wave sensors are optical sensors.
In some aspects of the disclosure, the first component of the reload length identification mechanism includes a magnetic field sensor and the second component of the reload length identification mechanism includes one or more magnets.
In certain aspects of the disclosure, the magnetic field sensor includes a Hall effect sensor.
In aspects of the disclosure, the drive assembly includes a motor, and the handle assembly further includes a printed circuit board and a motor controller supported on the printed circuit board.
In some aspects of the disclosure, the sensor assembly and the reload length identification assembly communicate with the motor controller.
Other features of the disclosure will be appreciated from the following description.
BRIEF DESCRIPTION OF THE DRAWINGSVarious aspects of the disclosure are described herein below with reference to the drawings, wherein:
FIG. 1 is side perspective view of a stapling device according to aspects of the disclosure including a tool assembly in an open position;
FIG. 2 is a side view of a reload assembly of the stapling device shown in FIG. 1 including a tool assembly of a first length;
FIG. 2A is a side perspective view of a distal portion of an elongate body of the stapling device shown in FIG. 1 with a portion of the outer tube of the elongate body cutaway;
FIG. 3 is a side view of a reload assembly of the stapling device shown in FIG. 1 including a tool assembly of a second length;
FIG. 4 is a side view of a reload assembly of the stapling device shown in FIG. 1 including a tool assembly of a third length;
FIG. 5 is a side perspective view of a handle assembly of the stapling device shown in FIG. 1 with a housing of the handle assembly shown in phantom and components removed to show a rack, a trigger plate, and a sensor assembly of the handle assembly;
FIG. 6 is a plan view of the rack of the handle assembly shown in FIG. 5;
FIG. 7 is a side perspective view of a rack, a trigger plate, and a sensor assembly of the handle assembly shown in FIG. 5;
FIG. 8 is a perspective view from an inboard side of the trigger plate shown in FIG. 6;
FIG. 9 is a perspective view from an outboard side of the trigger plate shown in FIG. 6;
FIG. 10 is a side perspective view of the trigger plate shown in FIG. 6;
FIG. 11 is a perspective view from the distal end of the sensor assembly shown in FIG. 6;
FIG. 12 is a perspective, exploded view from the distal end of the sensor assembly shown in FIG. 11;
FIG. 13 is a cross-sectional view taken along section line 13-13 of FIG. 5;
FIG. 14 is a side view of the rack, the trigger plate, and sensor assembly shown in FIG. 6 with the rack in a retracted or unclamped position;
FIG. 15 is a plan view of the rack, the trigger plate, and sensor assembly shown in FIG. 6 with the rack in the unclamped position;
FIG. 16 is a cross-sectional view taken along section line 16-16 of FIG. 15;
FIG. 17 is a side perspective view from above of the rack, the trigger plate, and the sensor assembly in a first stop position;
FIG. 18 is a plan view of the rack, the trigger plate, and the sensor assembly in the first stop position;
FIG. 19 is a cross-sectional view taken along section line 19-19 of FIG. 18;
FIG. 20 is a side view of the trigger plate and the sensor assembly in the first stop position;
FIG. 21 is a side perspective view from above of the rack, the trigger plate, and the sensor assembly in a second stop position;
FIG. 22 is a plan view of the rack, the trigger plate, and the sensor assembly in the second stop position;
FIG. 23 a cross-sectional view taken along section line 23-23 of FIG. 22;
FIG. 24 is a side view of the trigger plate and the sensor assembly in the second stop position;
FIG. 25 is a side perspective view from above of the rack, the trigger plate, and the sensor assembly in a third stop position;
FIG. 26 is a plan view of the rack, the trigger plate, and the sensor assembly in the third stop position;
FIG. 27 a cross-sectional view taken along section line 27-27 of FIG. 26; and
FIG. 28 is a side view of the trigger plate and the sensor assembly in the third stop position.
DETAILED DESCRIPTIONThe disclosed surgical stapling device will now be described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. However, it is to be understood that aspects of the disclosure are merely exemplary of the disclosure and may be embodied in various forms. Well-known functions or constructions are not described in detail to avoid obscuring the disclosure in unnecessary detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the disclosure in virtually any appropriately detailed structure.
In this description, the term “proximal” is used generally to refer to that portion of the device that is closer to a clinician during use of the stapling device in its customary manner, while the term “distal” is used generally to refer to that portion of the device that is farther from the clinician during use of the stapling device in its customary manner. In addition, the term “clinician” is used generally to refer to medical personnel including doctors, nurses, and support personnel. Further, directional terms such as front, rear, upper, lower, top, bottom, and similar terms are used to assist in understanding the description and are not intended to limit the disclosure.
The disclosed surgical stapling device includes a powered handle assembly, an elongate body having a proximal portion connected to the handle assembly and a distal portion, and a reload assembly supported on the distal portion of the elongate body. The handle assembly includes a drive assembly and a rack that is longitudinally movable through an actuation stroke in response to activation of the drive assembly to advance a clamping assembly within a tool assembly of the reload assembly to actuate the tool assembly. The elongate body is adapted to be coupled to reload assemblies that have different length staple cartridges, e.g., 30mm, 45mm, 60mm. The stapling device includes a reload length identification mechanism to identify the length of the staple cartridge mounted to the elongate body, and a firing stroke control mechanism to deactivate the drive assembly when the toothed rack advances through the appropriate actuation stroke.
FIG. 1 illustrates a surgical stapling device according to aspects of the disclosure shown generally as stapling device 10. The stapling device 10 includes a handle assembly 12, an elongate body 14 that defines a longitudinal axis “X” , and a reload assembly 16. The handle assembly 12 includes a body 18 that defines a hand grip 18a, at least one actuator button 20, a rotation knob 22, an articulation lever 24, and a battery pack 25. The rotation knob 22 is rotatably supported on a distal portion of the body 18 of the handle assembly 12 and supports the elongate body 14 to facilitate rotation of the elongate body 14 and the reload assembly 16 in relation to the handle assembly 12 about the longitudinal axis “X” . The actuator button 20 controls operation of the various functions of the stapling device 10 including clamping, firing, and cutting of tissue. The articulation lever 24 is operable to pivot the tool assembly 16 about an articulation axis “Y” that is transverse to the longitudinal axis “X” of the elongate body 14. In aspects of the disclosure, the articulation lever 24 is supported on the rotation knob 22 and is rotatable about the longitudinal axis “X” with the rotation knob 24.
FIG. 2 illustrates the reload assembly 16 which includes a proximal body 26, a mounting member 27, and a tool assembly 28. The mounting member 27 is secured to the tool assembly 28 and coupled to the proximal body 26 by a pivot member 27a to facilitate pivotal movement of the tool assembly 28 in relation to the proximal body 26 about the articulation axis “Y”. The tool assembly 28 includes an anvil 30 and a cartridge assembly 32 that is coupled to the anvil 28 to facilitate movement of the tool assembly 28 between an open position and a clamped position. In aspects of the disclosure, the anvil 30 is fixedly coupled to the mounting member 27 and the cartridge assembly 32 is pivotably coupled to the mounting member 27 and movable in relation to the anvil 30 between the open position and the clamped position. It is envisioned that the cartridge assembly can be fixedly mounted to the mounting member 27 and the anvil 30 can be pivotably mounted in relation to the cartridge assembly 32. The cartridge assembly 32 includes a staple cartridge 32a with a first length “L1” , e.g., 60 mm.
The proximal body 26 of the reload assembly 16 includes a proximal portion and a distal portion. The distal portion of the proximal body 26 of the reload assembly 16 is pivotably coupled to the mounting member 27 by the pivot member 27a to pivotably couple the tool assembly 28 to the proximal body 26. The proximal portion of the proximal body 26 includes coupling structure 34 that is adapted to be releasably coupled to coupling structure 35 (FIG. 2A) included on a distal portion of the elongate body 14 (FIG. 1) to releasably couple the reload assembly 16 to the elongate body 14. In aspects of the disclosure, the coupling structures 34, 35 form a bayonet type coupling mechanism that allows the reload assembly 16 to be rotatably secured to the elongate body 14 of the stapling device 10. Alternately, other coupling configurations are envisioned.
In some aspects of the disclosure, the distal portion of the elongate body 14 and the proximal portion of the proximal body 26 of the reload assembly 16 include a reload length identification mechanism 33 (FIG. 1) that includes a first component supported on the proximal body 26 of the reload assembly 16 and a second component supported on the distal portion of the elongate body 14. The first component and the second component interact to generate a signal that is transmitted to the handle assembly 12 to set the actuation stroke length required to actuate the tool assembly 28 as described in further detail below. In aspects of the disclosure, the first component of the length identification mechanism 33 includes one or more magnets 36 supported on the proximal portion of the proximal body 26 of the reload assembly 16 and the second component of the length identification mechanism 33 includes a magnetic field sensor 38 (FIG. 2A) , e.g., Hall effect sensor, that is supported on the distal portion of the elongate body 14 of the stapling device 10. The magnetic field sensor 38 detects the presence of a magnetic field generated by the one or more magnets 36 of the reload assembly 16 to generate a voltage proportional to the strength of the magnetic field created by the magnets 36 which is transmitted to a processor or motor controller 45 (FIG. 5) in the handle assembly 12 to set the firing stroke length of the stapling device 10 appropriate for size of the tool assembly of the reload assembly 16 coupled to the elongate body 14, e.g., a reload assembly 28 having a staple cartridge 32a having the length “L1” . For a more detailed description of an exemplary reload assembly, see U.S. Patent No. 6,241,139 ( “the ’139 Patent” ) .
FIGS. 3 and 4 illustrate reload assemblies 16’ and 16” which are identical to the reload assembly 16 except for the length of the tool assembly 28’ and 28” and the position, number, and/or strength of the magnets 36’ and 36”. The reload assembly 16’ (FIG. 3) has proximal body 26’ and a tool assembly 28’ including a staple cartridge 32a’ having a length “L2” that is less than the length “L1” of the staple cartridge 32a of the tool assembly 16 (FIG. 2. The magnets 36’ are positioned or configured on the proximal body 26’ of the reload assembly 16’ to produce a magnetic field that differs from the magnetic field generated by the magnets 36 of the reload assembly 16 (FIG. 2) when the reload assembly 16’ is coupled to the distal portion of the elongate body 14 of the stapling device 10 (FIG. 1) . In aspects of the disclosure, the length “L2” of the staple cartridge 32a’ is less than the length “L1” of the staple cartridge 32, e.g., 45 mm. When the reload assembly 16’ is coupled to the elongate body 14, the length identification mechanism 33 communicates with the handle assembly 12 to set the firing stroke length to be appropriate for the reload assembly 28’ including the staple cartridge 32a’, e.g., 45mm.
The reload assembly 16” (FIG. 4) has proximal body 26” and a tool assembly 28” including a staple cartridge 32a” having a length “L3” that is less than the length “L2” of the staple cartridge 32a’ of the tool assembly 16’ (FIG. 2) . The magnets 36” are positioned or configured on the proximal body 26” of the reload assembly 16” to produce a magnetic field that differs from the magnetic fields generated by the magnets 36 and 36’ of the reload assemblies 16 and 16’ (FIGS. 2 and 3) when the reload assembly 16” is coupled to the distal portion of the elongate body 14 of the stapling device 10 (FIG. 1) . In aspects of the disclosure, the length “L3” of the staple cartridge 32a” is less than the length “L2” of the staple cartridge 32a’, e.g., 30 mm. When the reload assembly 16” is coupled to the elongate body 14, the length identification mechanism 33 communicates with the handle assembly 12 to set the firing stroke length to be appropriate for a reload assembly 28” having a staple cartridge 32a” having the length “L3” , e.g., 30mm.
FIG. 5 illustrates portions of the handle assembly 12 of the stapling device 10 including a drive assembly 39, a printed circuit board (hereinafter “PCB” ) 44, a drive assembly controller 45, a toothed rack 46, a trigger plate 48, and a sensor assembly 50. The drive assembly 39 is engaged with the toothed rack 46 and is operable to move the toothed rack 46 within the housing 18 of the handle assembly 12 between retracted and advanced positions through an actuation stroke. The trigger plate 48 and the sensor assembly 50 form a stroke control mechanism 51 that interacts with the toothed rack 46 and communicates with the drive assembly controller 45 to identify when the toothed rack 46 has moved the stroke length set by the reload length identification mechanism 33. The drive assembly controller 45 is supported on the PCB 44 and is electrically coupled to the sensor assembly 50 and the magnetic field sensor 38 on the elongate body 14. The signal generated by the magnetic field sensor 38 is transmitted to the drive assembly controller 45 to set the appropriate stroke length of the toothed rack 46 based upon the size or length of the tool assembly 28 supported on the elongate body 14. The sensor assembly 50 generates a signal that is delivered to the motor controller 45 regarding the travel distance of the toothed rack 46 to deactivate the drive assembly 39, e.g., motor 40, when the toothed rack has been advanced a distance that corresponds to the stroke length set by the reload length identification mechanism 33.
In aspects of the disclosure, the drive assembly 39 includes motor 40 having an output shaft 52 that is coupled to a gear assembly 42. In some aspects of the disclosure, the gear assembly 42 includes a first bevel gear 54, a second bevel gear 56, a gear shaft 58, and a spur gear 60. The first bevel gear 54 is coupled to the output shaft 52 of the motor 40 and is engaged with the second bevel gear 56 such that rotation of the first bevel gear 54 causes rotation of the second bevel gear 56. The second bevel gear 56 is secured to the gear shaft 58 to translate rotation of the second bevel gear 56 to rotation of the gear shaft 58, the spur gear 60 is fixedly supported on, and rotatable with, the gear shaft 58.
FIGS. 5 and 6 illustrate the toothed rack 46 of the handle assembly 12 which includes a distal portion 62, a lower surface 64, and an upper surface 66. The distal portion 62 of the toothed rack 46 is coupled to a control rod 68 (FIG. 5) of the stapling device 10 to translate longitudinal movement of the toothed rack 46 to the control rod 68. The control rod 68 includes a distal end 68a (FIG. 2A) that is configured to releasably couple to a clamp assembly (not shown) of the reload assembly 16 when the reload assembly 16 is coupled to the elongate body 14 of the stapling device 10 such that longitudinal movement of the control rod 68 causes longitudinal movement of the clamp assembly. In aspects of the disclosure, the distal portion 62 of the toothed rack 46 defines a recess 70 that receives an enlarged head 68a of the control rod 68 to allow the control rod 68 to rotate in relation to the toothed rack 46. In certain aspects of the disclosure, the clamp assembly (not shown) includes an I-beam that is movable through the tool assembly 28 to actuate the tool assembly 28. See, e.g., the ‘139 Patent.
The lower surface 46 of the toothed rack 46 includes longitudinally aligned teeth 72 that are engaged with teeth 60a of the spur gear 60. The teeth 60a of the toothed rack 46 translate rotation of the spur gear 60 to longitudinal movement of the toothed rack 46 and longitudinal movement of the control rod 68 to actuate the tool assembly 28 of the reload assembly 16. The toothed rack 46 is movable from a retracted position to an advanced position through a pre-selected firing stroke in response to activation of the motor 40 to actuate the tool assembly 28 of the reload assembly 16. The length of the firing stroke of the toothed rack 46 is set by the reload length identification mechanism 33.
The upper surface 66 of the toothed rack 46 defines a stepped channel 74 that has a distal portion 74a, a middle portion 74b, and a proximal portion 74c. In some aspects of the disclosure, the distal portion 74a of the stepped channel 74 is longitudinally aligned with the proximal portion 74c of the stepped channel 74, and the middle portion 74b of the stepped channel 74 is laterally offset from the distal and proximal portions 74a, 74c of the stepped channel 74. The distal portion 74a of the stepped channel 74 includes a distal abutment surface 76a and a proximal abutment surface 76b, the proximal portion of the stepped channel 74 includes a distal abutment surface 76c and a proximal abutment surface 76d, and the middle portion 74b of the stepped channel 74 includes a distal abutment surface 76e and a proximal abutment surface 76f. Although illustrated as being a single stepped channel 74, it is envisioned that the stepped channel 74 could be formed as three separate and distinct channels, i.e., a first channel, a second channel, and a third channel, that correspond to the distal portion 74a, the middle portion 74b, and the proximal portion 74c of the stepped channel 74.
FIGS. 8-10 illustrate the trigger plate 48 which is rotatably supported within the housing 18 of the handle assembly 12 and includes a shaft portion 80, a head portion 82 that is supported about one end of the shaft portion 80, a first plate shield 84 supported on the head portion 82, and a second plate shield 86 supported on the head portion 82. The first and second plate shields 84, 86, respectively, are laterally spaced from each other and have semi-annular configurations that have leading ends 84a, 86a, respectively, that are angularly offset from each other and trailing ends 84b, 86b that are angularly offset from each other. The head portion 82 defines an annular cavity 90 that is positioned about the shaft portion 80 and receives a biasing member 92, e.g., a coil spring. The biasing member 92 is positioned between an inner surface of the head portion 82 and an outer surface of an inner support housing 94 (FIG. 13) of the handle assembly 12 to urge the trigger plate 48 outwardly within the housing 18 of the handle assembly 12. The shaft portion 80 includes a first end portion 96a that is received within a first opening 98a defined in one side of the inner support housing 94 and a central portion 96b that is received within a second opening 98b formed in an opposite side of the inner support housing 94 to rotatably support the trigger plate 48 on the inner support housing 94 of the handle assembly 12.
The shaft portion 80 defines a shaft axis “Z” (FIG. 10) that is transverse to the longitudinal axis “X” defined by the elongate body 14 of the stapling device 10 and supports a first tab 100, a second tab 102, a third tab 104, and a projection 106. The projection 106 is positioned to engage an inner surface of the inner support housing 94 (FIG. 13) adjacent to the second opening 98b to limit outward movement of the trigger plate 48 by the biasing member 92 (FIG. 13) . Engagement between the projection 106 and the inner surface of the inner support housing 94 creates frictional resistance between the trigger plate 48 and the inner support housing 94 to releasably retain the trigger plate 48 in its current position within the housing 18 of the stapling device 10 (FIG. 1) . In some aspects of the disclosure, the first tab 100 and the third tab 104 are angularly spaced about the shaft portion 80 but aligned with each other along the shaft axis “Z” . The second tab 102 is laterally offset along the shaft axis “Z” and angularly spaced from the first and third tabs 100, 104. The first tab 100 is positioned to be received within the first portion 74a of the stepped channel 74, the second tab 102 is positioned to be received within the second portion 74b of the stepped channel 74, and the third tab 104 is positioned to be received within third portion 74c of the stepped channel 74 during operation of the stapling device 10 (FIG. 1) as described in further detail below.
FIGS. 11 and 12 illustrate the sensor assembly 50 of the handle assembly 12 (FIG. 5) which includes a sensor holder 110, a first sensor 112, and a second sensor 114. The sensor holder 110 is fixedly mounted within the housing 18 of the handle assembly 12 proximally of the head portion 82 of the trigger plate 48 and defines an inboard slot 116 and an outboard slot 118. In aspects of the disclosure, the sensor holder 110 includes a mounting plate 110a that can be secured to an outer surface of the inner support housing 94 (FIG. 13) . In some aspects of the disclosure, the mounting plate 110a of the sensor holder 110 includes a fitting 110b that is received within an opening (not shown) defined in the inner support block 94. The inboard slot 116 is longitudinally aligned with the first plate shield 84 of the trigger plate 48 and the outboard slot 118 is longitudinally aligned with the second plate shield 86 of the trigger plate 48 such that when the trigger plate 48 is rotated by the toothed rack 46, the first plate shield 84 moves into the inboard slot 116 and the second plate shield 86 moves into the outboard slot 118.
In aspects of the disclosure, the sensor holder 110 defines a first socket 120 that receives the first sensor 112 and a second socket 122 that receives the second sensor 114. Each of the sensors 112, 114 includes a body 112a, 114a that defines a slot 112b, 114b, respectively. The slot 112b of the first sensor 112 is aligned with the inboard slot 116 of the sensor holder 110 and the slot 114b of the second sensor 114 is aligned with the outboard slot 118 of the sensor holder 110. The first sensor 112 and the second sensor 114 include sensing elements 112c, 114c, respectively, that are positioned within the slots 112b, 114b of the first and second sensors 112, 114, respectively, and provide status information identifying the travel distance of the toothed rack 46 when the first and second shields 84 and 86 of the trigger plate 48 are received within the slots 112b, 114b of the first and second sensors 112, 114 to cover or uncover the sensing elements 112c, 114c as described in further detail below. In some aspects of the disclosure, the sensing elements 112c, 114c are electromagnetic wave sensors or optical sensors, e.g., such as infrared sensors, which include contacts 112d, 114d that are coupled to the PCB 44 by a suitable conductor (not shown) . It is envisioned that a variety of different sensor types could be suitable to perform the function of the first and second sensors 112, 114.
FIGS. 14-16 illustrate the toothed rack 46, the trigger plate 48, and the sensor assembly 50 of the handle assembly 12 when the tool assembly 28 of the stapling device 10 is in an unclamped position with the toothed rack 46 in the retracted position. In the retracted position of the toothed rack 46, trigger plate 48 is in a pre-fired position such that the plate shield 84 of the trigger plate 48 is spaced from, but aligned with, the slot 112b of the sensor 112 and the plate shield 86 is spaced from, but aligned with, the slot 114b of the sensor 114. The first tab 100 of the trigger plate 48 is received within the distal portion 74a of the stepped channel 74 adjacent to the distal abutment surface 76a of the distal portion 74a of the stepped channel 74.
When the actuator button 20 of the handle assembly 12 is pressed to activate the drive assembly 39 to advance the toothed rack 46 and move the tool assembly 28 from the unclamped position to the clamped position, the first tab 100 moves within the distal portion 74a of the stepped channel 74 while the trigger plate 48 including the plate shields 84 and 86 remains stationary. As described above, the biasing member 92 (FIG. 13) urges the trigger plate 48 outwardly to press the projection 106 against the inner support housing 94 of the handle assembly 12 to frictionally retain the trigger plate 48 in its current position within the housing 18 of the handle assembly 12. Although not shown, when the toothed rack 46 is advanced to move the tool assembly 28 of the reload assembly 16 to the clamped position, the first tab 100 of the trigger plate 48 remains spaced from the proximal abutment surface 76b of the distal portion 74a of the stepped channel 74.
FIGS. 17-19 illustrate the illustrate the toothed rack 46, the trigger plate 48, and the sensor assembly 50 of the handle assembly 12 when a reload assembly 16” having a tool assembly 28” with a staple cartridge 32a” having a length “L3” is attached to the elongate body 14 and the stapling device 10 is fired. As described above, when the reload assembly 16” is attached to the elongate body 14 of the stapling device 10, the length identification mechanism 33 (FIG. 1) transmits a signal to the handle assembly 12 to set the actuation stroke length to length “L3” , e.g., 30mm. When the stapling device 10 is activated to fire staples from a staple cartridge 32a” having a length “L3” , the toothed rack 46 is advanced by the motor 40 in the direction indicated by arrow “A” in FIGS. 17-19. When the toothed rack 46 is advanced a distance sufficient for the proximal abutment surface 76b of the distal portion 74a of the stepped channel 74 to engage the first tab 100 of the trigger plate 48, further advancement of the toothed rack 46 causes the trigger plate 48 to rotate in the direction of arrow “B” to move the leading end 84a of the first plate shield 84 into the slot 112b of the first sensor 112. When the leading end 84a of the first plate shield 84 is received within the slot 112b of the first sensor 112 and covers the sensing element 112c, the sensor assembly 50 transmits a signal to the motor controller 45 (FIG. 5) that the toothed rack 46 has been advanced a stroke distance “L3” appropriate for the reload assembly 28” . As described above, the leading end 84a of the first plate shield 84 is angularly offset from the leading end 86a of the second plate shield 86. When the leading end 84a of the first plate shield 84 covers the sensing element 112c, the leading end 86a of the second plate shield 86 is spaced from the slot 114b of the second sensor 114.
FIGS. 21-24 illustrate the illustrate the toothed rack 46, the trigger plate 48, and the sensor assembly 50 of the handle assembly 12 when a reload assembly 16’ having a tool assembly 28’ with a staple cartridge 32a’ having a length “L2” is attached to the elongate body 14 and the stapling device 10 is fired. As described above, when the reload assembly 16’ is attached to the elongate body 14 of the stapling device 10, the length identification mechanism 33 (FIG. 1) transmits a signal to the handle assembly 12 to set the actuation stroke length to length “L2” , e.g., 45mm. When the stapling device 10 is activated to fire staples from a staple cartridge 32a’ having a length “L2” , the toothed rack 46 is advanced by the motor 40 in the direction indicated by arrow “A” in FIGS. 21-23. When the toothed rack 46 is advanced a distance sufficient for the proximal abutment surface 76b of the distal portion 74a of the stepped channel 74 to engage the first tab 100 of the trigger plate 48, further advancement of the toothed rack 46 causes the trigger plate 48 to rotate in the direction of arrow “B” to move the leading end 84a of the first plate shield 84 into the slot 112b of the first sensor 112 to cover the sensing element 112c. As the trigger plate 48 rotates and the toothed rack 46 advances, the second tab 102 of the trigger plate 48 rotates into the middle portion 74b of the stepped channel 74 of the toothed rack 46 and the first tab 100 rotates out of the distal portion 74a of the stepped channel 74. When the toothed rack 46 is advanced to a position in which the proximal abutment surface 76f of the middle portion 74b of the stepped channel 74 engages the second tab 102 of the trigger plate 48, continued advancement of the toothed rack 46 further rotates the trigger plate 48 in the direction of arrow “B” to move the leading end 86a of the second plate shield 86 into the slot 114b of the second sensor 114 to cover the sensing element 114c of the second sensor 114. When the first plate shield 84 is received within the slot 112b of the first sensor 112 to cover the first sensing element 112c and the second plate shield 86 is received within the slot 114b of the second sensor 114 to cover the second sensing element 114c, the sensor assembly 50 transmits a signal to the motor controller 45 (FIG. 5) that the toothed rack 46 has been advanced a stroke distance “L2 and the motor 40 is deactivated to stop advancement of the toothed rack 46.
FIGS. 25-28 illustrate the toothed rack 46, the trigger plate 48, and the sensor assembly 50 of the handle assembly 12 when a reload assembly 16 having a tool assembly 28 with a staple cartridge 32a having a length “L1” is attached to the elongate body 14 and the stapling device 10 is fired. As described above, when the reload assembly 16 is attached to the elongate body 14 of the stapling device 10, the length identification mechanism 33 (FIG. 1) transmits a signal to the handle assembly 12 to set the actuation stroke length to length “L1” , e.g., 30mm. When the stapling device 10 is activated to fire staples from a staple cartridge 32a’ having a length “L1” , the toothed rack 46 is advanced by the motor 40 in the direction indicated by arrow “A” . When the toothed rack 46 is advanced a distance sufficient for the proximal abutment surface 76b of the distal portion 74a of the stepped channel 74 to engage the first tab 100 of the trigger plate 48, further advancement of the toothed rack 46 causes the trigger plate 48 to rotate in the direction of arrow “B” to move the leading end 84a of the first plate shield 84 into the slot 112b of the first sensor 112 to cover the sensing element 112c. As the trigger plate 48 rotates and the toothed rack 46 advances, the second tab 102 of the trigger plate 48 rotates into the middle portion 74b of the stepped channel 74 of the toothed rack 46 and the first tab 100 rotates out of the distal portion 74a of the stepped channel 74. When the toothed rack 46 is advanced to a position in which the proximal abutment surface 76f of the middle portion 74b of the stepped channel 74 engages the second tab 102 of the trigger plate 48, continued advancement of the toothed rack 46 further rotates the trigger plate 48 in the direction of arrow “B” to move the leading end 86a of the second plate shield 86 into the slot 114b of the second sensor 114 to cover the sensing element 114c. As the toothed rack 46 continues to advance, the second tab 102 of the trigger plate 48 rotates out of the middle portion 74b of the stepped channel 74 and the third tab 104 rotates into the proximal portion 74c of the stepped channel 74. When the proximal abutment surface 76d of the proximal portion 74c of the stepped channel 74 engages the third tab 104 of the trigger plate 48, the trigger plate 48 is rotated further in the direction of arrow “B” until the trailing end 84b of the first plate shield 84 passes by and uncovers the sensing element 112c of the sensor 112. As described above, the trailing end 84b of the first plate shield 84 is angularly offset from the trailing end 86b of the second plate shield 86 (FIG. 8) such that the sensing element 114c of the sensor 114 remains covered by the second plate shield 86 when the sensing element 112c of the sensor 112 is uncovered. When the sensing element 112c is uncovered and the sensing element 114c is covered, the sensor assembly 50 transmits a signal to the motor controller 45 (FIG. 5) that the toothed rack 46 has been advanced the stroke distance “L” appropriate for the reload assembly 28 and the motor 40 is deactivated to stop advancement of the toothed rack 46.
The combination of the length identification mechanism 33 included on the reload assembly 28, 28’, 28” and the elongate body 14 of the stapling device 10 and the stroke control mechanism 51 in the handle assembly 12 facilitates operation of the stapling device 10 with reload assemblies of different lengths. When the stapling device 10 is operated to retract the toothed rack 46, the distal abutment surface 76c of the proximal portion 74c of the stepped channel 74 engages the third tab 104 of the trigger plate 48, the distal abutment surface 76e of the middle portion of the stepped channel 74 engages the second tab 102 of the trigger plate 48, and the distal abutment surface 76a of the stepped channel 74 engages the first tab 100 of the trigger plate 48 to return the trigger plate 48 to the pre-fired position.
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 aspects of the disclosure. It is envisioned that the elements and features illustrated or described in connection with one exemplary aspects of the disclosure may be combined with the elements and features of other aspects of the disclosure without departing from the scope of the disclosure. One skilled in the art will appreciate further features and advantages of the disclosure based on the above-described aspects of the disclosure. Accordingly, the disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims.