Scribd Logo
Upload

Welcome to Scribd!

  • US10542978

    Uploaded by

    Vansala Ganesan
    7 views11 pages

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    7 views11 pages

    US10542978

    Uploaded by

    Vansala Ganesan

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 11
    2) United States Patent Chowaniec et al (34) METHOD OF INT SEALING A HANDI RNALLY POTTING OR pLD MEDICAL DEVICE, (75) Inventors: Matthew Chowanies, Middletown, CT (US); Ningrul Chen, Hamden, CT (US); Michael Zemlok, Prospect, CT (us) (73) Assignoe: Covidien LP, Mansfield, MA (US) (9). Notice: Subject to any dislaimer the term of this patent is extended or adjusted under 35 USC. 154) by 1213 days 21) Appl. Now 13/017,410 (22) Filed: May 27, 2011 6s) Prior Publication Data US 201210303002 Al Nov. 29, 2012 (1) Incr. AGLB 1700 (2006.01) (6ib 17072 (2006.01) (2) USL orc A6IB 17107207 (201301) (58) Field of Classification Search CPC sos AGIB 17/00017: AGIB 17/00115; AGLB. 17/00128; GIB 17/00398; AGB. 17/00734: A61B 17107207; AGILE. 17/2927; AGIP 205010813 usp 29/5271 527.4, 611, B41 Se application file for complete search history. cd 66) References USS. PATENT DOCUMENTS. AASS6I3 A 51979 Bran HOI 1196 US010542978B2 (10) Patent No.: (4s) Date of Patent: US 10,542,978 B2 Jan. 28, 2020 ATMO A * IDI9ES Arends Gosn 1923 31058 520.7 A+ 21904 Rydell ‘was S5S48a1 A | 911996 Paterson al @3onoe BL* $2002 Ane ae Faas BL* $2010 Roche oo.tis 232686) B2 62010. Brandsaier ea. 7si046 BE 103010 Le 7sasaoT BE 122010 Wan eta S378572 2" Tina et ist sasou6 Bo Chin ‘Reis ass 6.206, 2n040ns6sa8 AL Duet al 20080288678 AL Ductal aono00076 AL Zero tal dononriea29 Al* Gisjia ssa 21018370 AL 12011 Duet al FOREIGN PATENT DOCUMENTS en o1s706 AL 1011985 Gh HISIOS AU 'S/1968 (Cominved) (OTHER PUBLICATIONS Furopean Search Report for EP 121604400-2310 date of comple tion fs Aug. 23, 2012 (9 page) (Continved) Primary Bvaminer (74) Attornes, Agent, or Firm LLP Michael 1 D Abreu Carte, DeL.nea & Farrell on ABSTRACT The present disclosure provides @ powered surgical insta ‘ment incloding a housing defining an inner cavity therein; at Teast one internal component disposed within the housing ‘nd potting material injected into the inner cavity encapst- Jating at least a portion of the at least one inter compo- 5 Claims, 5 Drawing Sheets US 10,542,978 B2 Page 2 66) References Cited PORFIGN PATENT DOCUMENTS WO Wo set09s7 AL 41996 WO wo 2mn7o0ris0 A2 12007 (OTHER PUBLICATIONS EPO-TEK 3771 Techctl Data Shes, Jan. 31, 2007, pp. 1 ‘PS5038972, reve om the Internet: URL: hips apoek ‘com ses tases. 37h pa [treve on fan. 2002).* “graph ite fied epoxy”, “ESDEMI shilling of semiconductor devices td clctonis”* Extended European Search Report for app. No. 161897111 dated Feb. §, 2017, Anonymous “Resin dispensing Wikipedia”, Wikpetia, Nov. 6. 2010 (Nov. 6, 2010), pp 1-6, XPOSS330617, Wikipdiaveuieved fromthe Internet: URL ps: en.wikipedia.org winds pte Resin-dspensingoldid-395241833#Sealing of electronic pats Ircicved om Jan, 27, 2017] "Chapter 8.1 Scaling of electronic pus ‘Canadian Ofice Action dated Apr. 28,2018 isu in corresponding ‘Astaltn Appl, No. 2.776.740, * cited by examiner U.S. Patent Jan. 28,2020 Sheet 1 of § FIG. 1 U.S. Patent Jan. 28, 2020 Sheet 2 of 5 US 10,542,978 B2 U.S. Patent Jan. 28, 2020 Sheet 3 of 5 US 10,542,978 B2 FIG. 3 US 10,542,978 B2 Sheet 4 of 5 Jan. 28, 2020 U.S. Patent U.S. Patent Jan. 28, 2020 Sheet 5 of 5 US 10,542,978 B2 (aa $10 SEAL HOUSING | “a $20 INJECT POTTING MATERIAL INTO HOUSING | me $30 SOLIDIFY POTTING MATERIAL FIG. 5 US 10,542,978 B2 1 METHOD OF INTERNALLY POTTING OR SEALING A HANDHELD MEDICAL DEVICE BACKGROUND ‘Technical Pld The present disclosure relates to @ powered surgical instrument having housing enclosing a plurality of intemal ‘components, including a drive mechanism an a contol ‘ircuit. More particularly, he present disclosure relates to 3 surgical instrument including intemal components that are ‘encapsulated ina potting material within the housing. ackground of Related Art ‘Surgical devices whereia tissues first grasped or clamped between opposing jaw stricture and then joined by surgical fasteners are well known ia the at. In some instruments @ knife is provided to cut the tissue which has been joined by the fasteners. The fasteners are typically in the form of surgical staples but two part polymeric fasteners can also be 2 utilized. Instruments for this purpose may include two elongated embers which are respectively used to capture or clamp tissue. Typically, one of the members caries a staple ca teidge which houses plurality of staples arranged in atleast ‘wo Tateral rows while the other member has an anil that ‘defines surface for forming the staple Tegs as the staples are driven from the staple cartridge. Generally, the stapling ‘operation is effected hy cam bars that travel longitudinally through the staple cartridge, withthe cam bars acting upon staple pushers to sequentially eject the staples from the staple cartridge. A knife can travel between the staple rows to longitudinally eot andor open the taped tissue between the rows of staples. In endoscopic or laparoscopic procedures, surgery is performed through « small incision or through a narrow ‘cannola inserted throvgh small entrance wounds i the ski, In onder to address the specific needs of endoscopic andor Japaroscopie surgiesl procedures, endoscopic surgical star pling devices have been developed Current known devices can typically require. 10460 pounds of manual hand force to clamp tissue and deploy and orm surgical fasteners in tissue which, over repented use, ‘can cause a surgeon’s hand to become fatigued. Gas pow= ‘ered pacumatic staplers which implant surgical fasteners Jno tissue are known in the at, Certain ofthese instruments tullize a pressurized gas supply which connocts to a trigger mechanism. The tigger mechanism, when depressed, s ply releases pressurized gas to implant fastener into tissue ‘Motor-powered surgical staplers are also Known in the ar ‘These include powered surgical staples having motors ‘which activate staple firing mechanisms, However, these motor powered devices also inelude a variety of intemal ‘components (eg, eiteits) which requte additional protee= tion from moisture, chemical cleaners, vapors, gases, and biological contaminants. There i a continual need for new and improved powered surgical staplers which provide protection tothe internal components SUMMARY “The present disclosure provides a powered surgical insta ‘ment including a housing defining an inner cavity therein; st Jeast one intemal component disposed within the housing ‘and potting material injected into the inner cavity encaps- lating at least a portion of the atleast one internal compo= nent 0 o 2 ‘The present disclosure also provides @ method for man ‘eturing a powered surgical device. The method includes injecting a Tiguid potting material injected into @ housing defining an inner cavity therein, the housing including at least one internal component disposed within the housing and sotidifying the potting material. encapsulate at least a portion ofthe at least one infernal comportnt. The present disclosure further provides a powered surgi- cal instrument. The instrament includes a howsing defining an inner cavity therein, the housing including handle portion: a body portion extending distally from the handle Portion a tool assembly disposed at a distal end ofthe body portion: a contol circuit and a drive motor disposed withia the inner cavity, wherein the drive motor is mechanically coupled 10 the Tool assembly and the control circuit is configured to control the operation ofthe drive motor; and ‘8 potting material injected into the inner cavity encapstlat- ‘ng atleast a portion of atleast one ofthe contol ciruit and the drive motor, [BRIEF DESCRIPTION OF THE DRAWINGS Various. embodiments of the subject instrument are scribed hercin with reference to the drawings wherci: FIG. 1 is & perspective view of a powered surgical instrument aeconting tothe present disclosure FIG, 2 is a panial enlarged perspective view of the powered surgical instrament according to the embodiment fof the present disclosure of FIG. 1 according tothe present disclosure, FIG. 3 is a partial enlarged plan view of the powered surgical instrument according to the embodiment of the present disclosure of FIG. 1 according to the present dis closure: and FIG. 4 is a partial perspective sectional view of intemal ‘components of the powered surgical instrument of FIG, 1 according to the present disclose. FIG. § is a Mlowehart of an embodiment of a method of injecting potting material according to the present diselo- DETAILED DESCRIPTION Embodiments of the presently disclosed powered surgical instrument are now deseribed in deal with reference to the drawings, in which like reference numerals designate iden- tical or corresponding elements in each of the several views As used herein the tem “stl refers to that portion ofthe powered surgical instrument, or eomponent thereof, farther from the user while the term “proximal” refers to that portion of the powered surgical instrument or component {hereo, loser to the usr. ‘A powered surgical instrument ea surgical stapler, ia cordance with the present disclosure is refered to in the Tigures as reference numeral 10, Refering intially o FIG. 1, possered surgical instrament 100 includes a housing 110, an endoscopic portion 140 defining a first longitudinal axis ‘A-Acextending therethrough, and an arteulating too! assem bly (ex. end effector 160), defining a second longitudinal axis B-B extending therethrough. Endoscopic portion 140 extends distally from housing 110 and the end effector 160 js disposed adjacent a distal portion of endoseopie portion 140. In an embodiment, the components of the housing 110 fare sealed against infiration of particulate andor Avid contamination and help prevent damage ofthe components by sterilization processes, The instrament 100 also inclxdes a power source 300 US 10,542,978 B2 3 According to an embodiment of the present disclosure, ‘end efector 160 includes a first jaw member having one oF more surgical fsteners (ex, cartridge assembly 168) and a second opposing jaw member ineliding an anvil portion for ‘deploying and forming the surgical festeners (eg. an anvil assembly 162). In certsin embodiments, the staples are housed in cartridge assembly 166 to apply linear rows of staples to hody tissue either in simultancous or sequential ‘manner. Ether one or both ofthe anvil assembly 162 and the cartridge assembly 164 are movable in relation to one ‘another between an open positon, in which the anvil assem bly 162 is spaced from vartidge assembly 164, and ua approximated or clamped position, in. which the anvil assembly 162 is in juxtsposed alignment with canridge assembly 164, Tris further envisioned that end effector 160 is attached 10 ‘8 mounting portion 166, which is pivotably attached to 2 body portion 168. Body portion 168 may be integral with ‘enxdoscopie portion 140 of powered surgical instrument 100, for may be removably attached to the instrument 100 16 provide a replaceable, disposable loading unit (DLU) or ingle use loading unit (SULU) eg, loading unit 169). Ia certain embodiments, the reusable portion may be config lured for sterilization and re-use in subsequent stngical procedure. The loading unit 169 may be connectable to endoscopic Portion 140 through bayonet connection. Iti envisioned that dhe loading unit 169 has an areulston Tink connected to mounting portion 166 of the loading unit 169 and the ‘antculation link is connected ta Finkage rod so thatthe end effector 160 is articulated as the linkage rd is translated in the dista-proximal direction along fit longitudinal axis ASA. Other means of connccting end effector 160 to end scopic portion 140 to allow articulation may’ be wsed, sve! fe 8 Bexible the or a tube comprising a plurality of pivotable members. “The loading unit 169 may incorporate or be configured to incomporate various end effectors, such as vessel sealing devices, lincar stapling devices, circular stapling devices, ‘utters, graspers, ete, Such end effectors may’ be coupled 10 ‘enudoscopic portion 140 of powered surgical instrament 100, An intermediate flexible shaft may be included between handle portion 112 and loading unt, It is envisioned that the incoporation of a flexible shaft may facilitate access 10 ‘andioe within certain areas of the body. ‘With reference to FIGS. {and 2, an enlarged view of the housing 110s illustrated according to an embodiment ofthe present disclosure, In the illustrated embodiment, housing 110 includes « handle portion 112 having a main drive switch I14 disposed theteon. The switeh 114 may include first and second switches 114 and 1148 formed together as a toggle switch. The handle portion 112, which defines & handle sais 1-H, is configured o be grasped by fingers of @ tier. The handle portion 112 has an ergonomic shape pro- viding ample palm grip leverage which helps prevent the handle portion 112 from heing squcezed out ofthe user's hand during operation. Fach switch 114 and 114bis shown as being disposed at suitable location on handle portion 112 to facilitate its depression by a users finger o fingers. ‘Additionally, and with continued reference to FIGS. Land 2, switehes 14a, 1146 may be used for stating andor ‘stopping movement of # drive mechanism (eg, drive motor 200) (FIG. 4). The drive motor 200 is configured t0 actuate the end effector 160, including but not limited t, articuls tion, closing of the jaw members, ejection of fasteners citing, andthe like. in one embodiment. the switch Ida is ‘configured to aetvate the drive motor 200 in first direction 0 o 4 fo advance fring rod (not explicitly shown) in a distal direction thereby approximating the anvil and the eardge asseublies 162 and 164, Conversely, the switeh 1146 may be configured to retract the firing od to open the anvil and cartidge assemblies 162 and 164 by activating the drive ‘motor 200 in a reverse direction, The retraction mode initiates mechanical lock out, preventing futher progres- sion of stapling and cutting by the loading unit 169. The foggle has a fist position for activating switeh M14, @ sevond postion lor activating switch 114B, and a neutral position between the first and second positions, Further, the Switches 14a and 114 may have high tactile feedback requiring increased pressure for activation, Tn one embodiment, the switches 14a and 1146 are configured as multi-speed (eg, 1 or more), ineremental or Variable speed switches which control the speed ofthe drive ‘motor 200 an! the fring rod in a non-linear manner. For ample, switches Ida, 114b can be pressure-seasitive, This type of contol interface allows for gradual increase in the rate of speed ofthe drive components From a slower and ‘more precise mode to a faster operation. To prevent acc ental aetivation of retraction, the switch 4% may be ‘sconnected electronically util a fail safe switch Ide is pressed The switehes 14a and 114) are coupled to a noa-linear speed control circuit 400 which may inehude a noa-linear speed control circuit implemented as a voltage regulation circuit, a variable resistance circuit, or microelectronic pulse width modulation eireut. The switches Ia and 144 ‘may interface with the contol cieuit 400 by displacing oF actuating variable contro! devices, such as thoostatic ‘devices, multiple position switeh cient, Hinear andor olary variable displacement transducers, linear andlor rotary potentiometers optical encoders, ferromagnetic sensors, and Hall Effect sensors. Ths allows the switehes 14a and 114 tw operate the drive motor 200 in multiple speed modes, such fas gradually increasing the speed of the drive motor 200 cither inecomentally oF graduslly depending on the type of ‘the control circuit being used, based on the depression of the switches Hea and 1140, FIGS, 2-4 illustrate an articulation mechanism 170 including an ariculation howsing 172, a powered articul- tion switch 174, an articulation motor 132 and # manval aniculation knob 176. Translation of the powered articul- ‘ion switch 174 or pivoting of the manual articulation kaob 176 activates the aniculation motor 1¥2 which then actuates ‘an articulation gear 233 of the atculation mechanism 170 ‘as shown in FIG. 4, Actuation of articulation mechanism 170 teases the end effector 160 {0 move from its Hest position, ‘where longitudinal axis B-B is substantially aligned with longitudinal axis A-A, towands a position in whieh longitu- inal axis B-B is disposed stn angle to fongitudinal sxis \-A. The powered articulation switch 174 may also incor- porate similar non-linear spesd controls as the clamping srechanism, ‘Additionally, articulation hovsing 172 and powered aniculaion switch 174 are mounted to a rotating housing assembly 180, Rotation of a rotation knob 182 about first Tongitudinal axis A-A causes housing assembly 180 28 well ay articulation housing 172 and powered articulation switch 174 (0 rotate about first longitudinal axis AA, and thus rotating the end effector 160 about first longitudinal sxis A-A. Tho articulation mechanism 170 is electeo-mechani- cally coupled to one or more conductive rings that are disposed on a housing nose assembly 188 (FIG. 4). The ‘onctive rings may be saldered andor crimped onto the rose assembly 155 an are in electical contaet with the US 10,542,978 B2 5 power source 300 thereby providing electrical power to the ficlation mechanism 170, The nose assembly 188 may be modular and may be attached to the housing 110 during assembly to allow for easier soldering and/or erimping ofthe Fings. The articulation mechanism 170 may include one oF ‘more brush andlor spring oaded contacts in contact with the ‘conductive rings such that a8 the housing assembly 180 is rotated along with the articulation housing 172 the arcu Jation mechanism 170 is in continuous contact with the ‘conductive rings thereby receiving electrical power fom the power source 300, Further dels’ of anieulation housing 172, powered ‘anicultion switch 174, manual articulation knob 176 and, providing articulation to end effector 160 are described in ‘deta in commoaly-ovned US. patent application Se. No, 11/724,733 filed Mar. 15, 2007, the eontents of whieh are hereby incorporated by reference in their entirety. It is ‘eavisioned that any combinations of limit switches, prox- lmity sensors (ea, optical and/or ferromagnetic), linear Variable displacement transducers and shaft encoders which may be disposed within housing 110, may be wilized to ‘control andiar recont an articulation angle of end effector 160 and/or postion of the fring rod 220, ‘As showin in FIG. 4, the instrament 100 also ineludes the ‘contol circuit 400 electrically coupled to the motor 200 and, various sensors disposed inthe insteument 100. The sensors defect various operating parameters of the instrument 100 (ex, linear speed, rotation speed, aniculaion position, temperature, battery charge, and the like), which are then reported to the control circuit 400, The conto} circuit 400 may then respond accordingly to the measured opersting parameters to contol the setuation of the end effector 160 (ea adjust the sped of the motor 200, contro articulation angle, shut-off the power supply, report eeror conditions, ete) “As shown in FIGS, 3 and 4, the conteolczcuit 400 is also ‘coupled to one or more visual devices which may include ‘one oF more colored visible lights or light emitting diodes 401 CLED") to relay feedback to the user. The LEDs 401 ‘may disposed on top of the honsing 110 such thatthe LEDs 4401 are mised and protrde in relation tthe housing 110 providing for better visibility thereof as shown in FIG. 4 In ‘embodiments, the LEDs 401 may be disposed within the housing. 110 as shown ia FIG, 4. The LEDs 401 may be ‘setivaed in a various combinations to denote ‘The multiple Fights may be activated in a certain combi nation to lustatea specific operational mode tothe use. Ia ‘one embodiment, the LEDs 401 jnchude a phiality of multi-colored lights—a first light (ex. yellow), a second Tight (est, green) and a third light (ered), The hts are ‘operated in # particular combination associated with 3 Particular operational mode as liste in Table 1 below. Tails OF or Storeng Senne fection Rot Neti wa Taig OF” 0 o 6 TABLE L-sontinued suse Sue _ Open Mode Fie ige NA Totnancm 100 dete wd pene Second it OF fun ang spc or emang Thiig Na, Fine Lit On" Ane loatiog i 10 ode he et Stcod ight On eto 16 ly laps ad the Thiol Ligit Of inant 100 tm fe spe al tig ides, Fine Lie On Due high tating fres«pulse mode Secu ight Fishing in eect proving ra ted de Thin Ligh OF hich de compet Fitige NA. Resssen emom doested Sccondisk NA Thin OF Fine Lig On Tie sks adr Sing ot high Sccondisht On the waming sub overden Fiore NA Pansona symm enor ie tetas Sccond‘ight NA 1 ehoul be eae In another embodiment, the LEDs 401 may he mul colored LEDs which display a particular color associated ‘with the operational modes as discussed above with respoct to the fis, sooond and third lights in Table 1 ‘The housing 110 defines an inner eavity 402 in whieh the contol eireit 400 and the motor 200 as well as other ‘components of the instrament 100 are disposed, With re ference 10 FIG. 5, during step $20, a potting material 404 is injected into the cavity 402 s0 thatthe material flows into ‘nd through the cavity 402, thereby coating and encapst- lating the intemal components (eg, the contol circuit 400 and the motor 200) ofthe instrument 100. The material 404 ‘may be injected such thatthe cavity 402 s either partially or ‘wholly filled with the material 404, Encapsulation of the internal components eliminates voids within the inner cavity 4402, which may collect moisture and condensation. Further, the material 404 als seals the components, therchy provide ‘ng protection from moisture, chemical compounds (¢g. cleaners) vapors, g25S¢5, and biological contaminants. This ‘would also allow for sterilization of the instrument 100 providing for multiple uses, Prior to injecting the material 404 into de housing 110 uring slep S20, the housing 110 may be suitably sealed ‘during step $10 to withstand pressures ofthe sealing process as well 2s to hemmetcaly seal the housing 110 as described above. The material 404 may be any material that may be ‘any liquid or amorphous material that solidifies upon injee- ‘ion into the cavity 402, In embodiments, the material 404 may be any material or combination of materials (ex. epoxy) that may change its phase after injection into the ‘housing 110, such hat the material 404 is initially ina iguid phase and then transitions into solid phase to eneapsulste ‘he components, Once solidified during step $30, the mate- rial 404 may be relatively rigid to protect the components {rom shock, maintain compliance and to reduce stress under ‘temperature extrenes an! other environmental conditions ezsbodiments, the material 404 maybe aliquid sari that may be solidified by one of the following processes \hiel include, but are not imited to, room temperature vuleanization, a thermosetting polymer reaction (e, epoxy), curing (eg, anaerobic or ultfa-viole) and combi- nations thereof. The material 404 may be a polymer, which ‘may include, but not limited to, polyesters, silicones, rub- bers, epocies, nylons, polyphthalamide, lguid crystal poly- anes, and combinations thereo US 10,542,978 B2 7 The material 404 once solidified may have a hardness as smessured bya durometer fom about § Shore Aw abot 100 Shore A in embosinents from about 10 Shore to about 30 Shore: In embodiments, the material 404 may be compl ‘ant anor elastic. This prevent hgh physical stoss that thes ‘nsirament 100 is subjected o from being transfered to the internal components sno in embodiments where compo- nents or mlerils of the instrament 100 have diserepant thermal expansion properties. In addition, elasticity ofthe taleial 404 absorbs noise aad vibration yeneratd by the ‘ive moror 200 and oiber drive mechanisms, which ‘eahances the handling caractrisis of the instrument 100 “The material 404 may ince one or more thermally conductive andlor dickectie additives to draw themmal ‘energy from the components a Well st electrically isolate ‘lectonie and other sensitive components (e, deve mechanisms, batteries, et) In ation, material 44 thats themully conductive also reduces theaaal shock and tee perature extremes associated with strlization (eg suo- ‘having) processes The motel 404 may bave « them > ‘conductance from abou 0.024 watts per meters C. (Winn? C) and ahove, The material 404 may have an clactecal resistance fm about 3 millivolts per cer unr standard temperature and pressure (STP) (nVim) and above. The material 404 may have a coeficient of thermal expansion from about 1 pacts per millon” C. (ppm? C.) t about 30 ppm” C, in embodiments from about 5 ppm” Co about 20 ppav C. The material may have a surface energy fom abot 10 dynes por centimater (dynesem’) to abou 45

    You might also like