EP3845147A2

Surgical instrument comprising a sensing system

Abstract

A surgical instrument comprising a sensing system is disclosed.

EP3845147A2, drawing sheet 1
Sheet 1 of 31

Term

14.3 yearsto projected expiry

Projected expiry 29 December 2040, counted from filing; an application has no term until it is granted.

  1. Priority and filed
  2. Published
  3. Today
  4. Projected expiry

28 claims: 7 independent, 21 dependent

  1. 1
    A surgical instrument assembly, comprising:a shaft;and an end effector extending from said shaft, wherein said end effector comprises: a first jaw;a second jaw movable relative to the first jaw;an anvil;a staple cartridge channel;a staple cartridge positioned within said staple cartridge channel;and a plurality of pressure sensors positioned between said staple cartridge and said staple cartridge channel configured to detect clamping pressure within said end effector.
  2. 2
    The surgical instrument assembly of Claim 1, wherein said end effector comprises a first side and a second side defined by a firing stroke path, and wherein said plurality of pressure sensors are positioned on both said first side and said second side.
  3. 3
    The surgical instrument assembly of Claim 1, wherein said plurality of pressure sensors are distributed longitudinally along a firing stroke path.
  4. 4
    The surgical instrument assembly of Claim 1, further comprising a flex circuit coupled to said plurality of pressure sensors.
  5. 5
    A surgical instrument assembly, comprising:a shaft;a drive member movable within said shaft, wherein said drive member comprises a discontinuity portion;and a flex circuit positioned within shaft and coupled to a surgical control circuit, wherein said flex circuit comprises an integrated strain gauge mounted on said drive member within said discontinuity portion, wherein said surgical control circuit is configured to determine a load experienced by said drive member by way of said strain gauge.
  6. 6
    The surgical instrument assembly of Claim 5, wherein said discontinuity portion comprises a necked-down portion.
  7. 7
    The surgical instrument assembly of Claim 5, wherein said drive member comprises a channel spine comprising a channel positioned on a distal end of said drive member, wherein said channel is configured to receive a staple cartridge therein.
  8. 8
    The surgical instrument assembly of Claim 5, wherein said drive member comprises a first drive member, wherein said surgical instrument assembly further comprises a second drive member movable within said shaft, wherein said integrated strain gauge comprises a first integrated strain gauge, and wherein said flex circuit further comprises a second integrated strain gauge mounted on said second drive member.
  9. 9
    The surgical instrument assembly of Claim 5, wherein said flex circuit comprises a flexible portion and a non-flexible portion.
  10. 10
    The surgical instrument assembly of Claim 5, wherein said drive member further comprises a primary body portion, and wherein said discontinuity portion is configured to experience more strain than said primary body portion.
  11. 11
    A surgical instrument system, comprising:a batch of staple cartridges, wherein each staple cartridge of said batch of staple cartridges comprises a predetermined load profile range;a surgical instrument assembly, wherein a staple cartridge of said batch of staple cartridges is configured to be installed into said surgical instrument assembly;and a control circuit configured to: detect the predetermined load profile range of said installed staple cartridge;execute a motor control program to fire said installed staple cartridge with said surgical instrument assembly;monitor an actual load profile of said installed staple cartridge when said installed staple cartridge is fired;compare the predetermined load profile range and the actual load profile;output the result of the comparison of the predetermined load profile range and the actual load profile;and modify the motor control program such that each subsequent staple cartridge of said batch of staple cartridges installed into said surgical instrument assembly is fired within the predetermined load profile range.
  12. 12
    A surgical instrument assembly, comprising:a shaft;an end effector attached to said shaft;a sub-component system configured to experience strain within said surgical instrument assembly;and a woven conductive fabric attached to said sub-component system, wherein said woven conductive fabric comprises: a primary body portion;and a plurality of conductive fibers extending through said primary body portion;a control circuit configured to monitor the resistance of said woven conductive fabric and determine the load on said sub-component based on the resistance of said woven conductive fabric.
  13. 13
    The surgical instrument assembly of Claim 12, wherein said plurality of conductive fibers are woven.
  14. 14
    The surgical instrument assembly of Claim 12, wherein said plurality of conductive fibers are wired in parallel.
  15. 15
    The surgical instrument assembly of Claim 12, wherein said plurality of conducitve fibers are wired in series.
  16. 16
    The surgical instrument assembly of Claim 12, wherein said woven conductive fabric is attached to a grounded location within said shaft.
  17. 17
    The surgical instrument assembly of Claim 12, wherein said woven conductive fabric comprises a first woven conductive fabric, wherein said first woven conductive fabric is configured to measure load applied to said sub-component system in a first plane, wherein said surgical instrument assembly further comprises a second woven conductive fabric configured to measure load applied to said sub-component system in a second plane.
  18. 18
    The surgical instrument assembly of Claim 12, wherein the resistance of said woven conductive fabric is configured to correspond to displacement of said sub-component system.
  19. 19
    A surgical instrument assembly, comprising:a shaft;an end effector attached to said shaft;an actuation member movable within said shaft, wherein said actuation member comprises a partially opaque portion;and a sensing system configured to detect a load on said actuation member, wherein said sensing system comprises: a light source directed toward said partially opaque portion of said actuation member;and a sensor configured to detect resultant light diffraction caused by said partially opaque portion of said actuation member, wherein the resultant light diffraction comprises a range of diffraction patterns corresponding to the load on said actuation member.
  20. 20
    A surgical instrument assembly, comprising:a shaft comprising a first distal end;an articulation joint comprising a distal-most articulation link;an end effector attached to said shaft by way of said articulation joint, wherein said end effector is coupled to said distal-most articulation link;an articulation drive member configured to articulate said end effector about said articulation joint, wherein said articulation drive member is movable relative to said shaft, and wherein said articulation drive member comprises a second distal end;a Hall effect sensor attached to said second distal end of said articulation joint;a magnet attached to said distal-most articulation link, wherein said distal-most articulation link is actuatable to a fully-articulated position;and a surgical control circuit configured to: monitor the position of said magnet by way of said Hall effect sensor;and advance the articulation drive member to move said distal-most articulation link to said fully-articulated position based on the position of said magnet.
  21. 21
    A surgical instrument, comprising:a shaft comprising a frame, wherein said frame comprises a discontinuity portion;a drive member movable within said shaft;and a flex circuit positioned within shaft and coupled to a control circuit, wherein said flex circuit comprises an integrated strain gauge mounted on said frame within said discontinuity portion, wherein said control circuit is configured to determine a load experienced by said shaft by way of said strain gauge.
  22. 22
    The surgical instrument of Claim 21, wherein said discontinuity portion comprises a notch, wherein said notch comprises a depth, wherein said integrated strain gauge comprises a thickness, and wherein said thickness does not exceed said depth.
  23. 23
    The surgical instrument of Claim 21, wherein said flex circuit comprises a longitudinal portion and said integrated strain gauge comprises a tab extending laterally from said longitudinal portion.
  24. 24
    The surgical instrument of Claim 23, wherein said longitudinal portion is flexible and said tab is rigid.
  25. 25
    The surgical instrument of Claim 24, wherein said longitudinal portion is not mounted to said frame.
  26. 26
    The surgical instrument of Claim 24, wherein said tab is mounted to said frame by at least one adhesive.
  27. 27
    The surgical instrument of Claim 21, wherein said discontinuity comprises a necked-down portion comprising a smaller cross-section than a distal frame portion positioned distally with respect to the necked-down portion and a proximal frame portion positioned proximally with respect to the necked-down portion.
  28. 28
    The surgical instrument of Claim 21, wherein said discontinuity comprises a fin extending outwardly therefrom, and wherein said integrated strain gauge is mounted to said fin,
Independent claims28