EP4665248A2 - Chirurgisches system mit einer batterie und steuermodul - Google Patents

Chirurgisches system mit einer batterie und steuermodul

Info

Publication number
EP4665248A2
EP4665248A2 EP24710328.6A EP24710328A EP4665248A2 EP 4665248 A2 EP4665248 A2 EP 4665248A2 EP 24710328 A EP24710328 A EP 24710328A EP 4665248 A2 EP4665248 A2 EP 4665248A2
Authority
EP
European Patent Office
Prior art keywords
surgical tool
module
handpiece
powered surgical
housing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP24710328.6A
Other languages
English (en)
French (fr)
Inventor
Conor MAC AN TUILE
Thomas Stritch
Matteo NICOLASI
Daniela BURIN
Krishanu CHOUDHURY
Vineet Mittal
Dustin James PAYNE
Cian MARTIN
Arthur Carlos PALLAR DA SILVA
Amanda FERRANTE
Ellis ARCHULETA
Daniel Jay HUIZENGA
Kana MORIYAMA
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Stryker Corp
Original Assignee
Stryker Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Stryker Corp filed Critical Stryker Corp
Publication of EP4665248A2 publication Critical patent/EP4665248A2/de
Pending legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B17/16—Instruments for performing osteoclasis; Drills or chisels for bones; Trepans
    • A61B17/1613—Component parts
    • A61B17/1626—Control means; Display units
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B17/16—Instruments for performing osteoclasis; Drills or chisels for bones; Trepans
    • A61B17/1613—Component parts
    • A61B17/162—Chucks or tool parts which are to be held in a chuck
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B17/16—Instruments for performing osteoclasis; Drills or chisels for bones; Trepans
    • A61B17/1613—Component parts
    • A61B17/1628—Motors; Power supplies
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B17/14—Surgical saws
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B17/16—Instruments for performing osteoclasis; Drills or chisels for bones; Trepans
    • A61B17/1613—Component parts
    • A61B17/1622—Drill handpieces
    • A61B17/1624—Drive mechanisms therefor
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B2017/00017—Electrical control of surgical instruments
    • A61B2017/00022—Sensing or detecting at the treatment site
    • A61B2017/00039—Electric or electromagnetic phenomena other than conductivity, e.g. capacity, inductivity, Hall effect
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B2017/00367—Details of actuation of instruments, e.g. relations between pushing buttons, or the like, and activation of the tool, working tip, or the like
    • A61B2017/00398—Details of actuation of instruments, e.g. relations between pushing buttons, or the like, and activation of the tool, working tip, or the like using powered actuators, e.g. stepper motors, solenoids
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B2017/0046—Surgical instruments, devices or methods with a releasable handle; with handle and operating part separable
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B2017/00681—Aspects not otherwise provided for
    • A61B2017/00734—Aspects not otherwise provided for battery operated
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B90/00—Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups A61B1/00 - A61B50/00, e.g. for luxation treatment or for protecting wound edges
    • A61B90/08—Accessories or related features not otherwise provided for
    • A61B2090/0813—Accessories designed for easy sterilising, i.e. re-usable
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B90/00—Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups A61B1/00 - A61B50/00, e.g. for luxation treatment or for protecting wound edges
    • A61B90/90—Identification means for patients or instruments, e.g. tags

Definitions

  • Modular handheld powered surgical tools are ubiquitous in the modem surgical theatre.
  • Exemplary powered surgical tools include burs, drills, saws, and shavers.
  • Modular handheld powered surgical tools typically include a handpiece component including a motor that is sized sufficiently to meet the demands of the surgical procedure, for example, resecting cortical bone and other hardened anatomical structures.
  • Modular handheld powered surgical tools also typically include a device housing configured to couple with and power the motor of the handpiece component. As uses of modular handheld powered surgical tools continue to develop, it is important for modular handheld powered surgical tools to include device housings that are able to accommodate and identify a wide variety of devices.
  • a powered surgical tool comprising: a handpiece including a motor and a tool coupler, the handpiece defining at least one of a rail and a slot, and the handpiece further defining a receiver surface; and a battery and control module including: a device housing including the other of the rail and the slot, the rail and slot configured such that the rail is slidable within the slot to allow coupling between the handpiece and the battery and control module, the device housing further defining a void space; a rechargeable battery module disposed in the void space; a printed circuit board assembly including a controller configured to regulate power drawn from the rechargeable battery module based on user input, the printed circuit board assembly further comprising a motor sensor configured to output a motor sensor signal representative of a state of the motor; and at least three conductive terminals that extend through the device housing for establishing an electrical connection between the printed circuit board assembly and the handpiece.
  • a powered surgical tool comprising: a handpiece including a motor and a tool coupler, wherein the handpiece defines a cannulation; and a battery and control module including: a device housing defining a void space; a rechargeable battery module disposed in the void space; a printed circuit board assembly including a controller configured to regulate power drawn from the rechargeable battery module based on user input, the printed circuit board assembly further comprising a motor sensor configured to output a motor sensor signal representative of a state of the motor; and at least three conductive terminals that extends through the device housing for establishing an electrical connection between the printed circuit board assembly and the handpiece, wherein the battery and control module is free from cannulation.
  • a surgical handpiece for coupling to a battery and control module.
  • the surgical handpiece comprising: a housing; a tool coupler; an electric motor disposed within the housing; a rotor defining an axis, the rotor being coupled to the electric motor and the tool coupler; a rigid circuit board including a controller, the rigid circuit board being disposed within the housing and oriented perpendicular to the axis of the rotor; and a plurality of terminals extending through the housing and engaging the rigid circuit board.
  • surgical handpiece for coupling to a battery and control module.
  • the surgical handpiece comprising: a housing; a tool coupler; an electric motor disposed within the housing; a rotor defining an axis, the rotor being coupled to the electric motor and the tool coupler; a circuit board including a controller, the circuit board disposed within the housing, the circuit board including a rigid portion and a flexible portion, the rigid portion defining an axis that is oriented parallel to the axis of the rotor; and a plurality of terminals extending through the housing and engaging the flexible portion of the circuit board.
  • a powered surgical tool comprising: a handpiece including a motor; and a battery and control module including: a device housing having a recess for removably receiving the handpiece, the device housing defining a void space; a rechargeable battery module disposed in the void space; a first printed circuit board disposed in the void space and being rigid; a second printed circuit board disposed in the void space and being rigid, the second printed circuit board being coupled to the first printed circuit board, the second printed circuit board and the first printed circuit board being arranged in a stacked configuration, a plurality of motor control sensors connected to the second printed circuit board; and a controller configured to regulate power drawn from the rechargeable battery module based on user input, the controller being mounted to one of the first printed circuit board and the second printed circuit board.
  • a powered surgical tool comprising: a handpiece including a motor; and a battery and control module including: a device housing having a recess for removably receiving the handpiece, the device housing defining a void space; a rechargeable battery module disposed in the void space; a printed circuit board assembly disposed in the void space, the printed circuit board assembly including a rigid portion; a plurality of motor control sensors disposed on the rigid portion of the printed circuit board assembly; and a controller configured to regulate power drawn from the rechargeable battery module based on user input, the controller being mounted to the printed circuit board assembly.
  • a powered surgical tool is provided in a seventh aspect.
  • the powered surgical tool comprising: a handpiece including a motor, the motor including a plurality of magnets; and a control module including: a device housing for removably receiving the handpiece, the device housing defining a void space; a first terminal; a sensor configured to provide a sensor signal, the sensor being positioned to sense at least one of the plurality of magnets when the handpiece is received; and a controller configured to regulate power supplied to the first terminal based on the sensor signal.
  • a powered surgical tool having a pencil-grip configuration comprising: a plastic housing defining an integral mounting base, the integral mounting base defining a first and second aperture, a first pin and a second pin extending through the first and second apertures respectively, with the first pin defining a pivot axis and pivot surface, the first pin and the second pin defining a press-fit engagement with one another; and a lever pivotably coupled to the pivot surface of the first pin.
  • a powered surgical tool comprises: a housing defining a void; a circuit board disposed in the void of the housing for regulating operation of an electric motor; a rechargeable battery module disposed within the void; at least three motor pins spaced apart from one another to define an array of motor pins that extends through the housing and out of the void for establishing an electrical connection between the circuit board and the electric motor, wherein a hermetically-sealed housing-terminal interface is defined by the housing and the at least three motor pins; a routing feature disposed about the at least three motor pins, the routing feature defining a plurality of channels; and at least three wires, each of the three wires including a wire terminal connected to a first wire end of the at least three wires and the other end of the wire connected to the circuit board, each of wire terminals including a first end portion and a second end portion opposite the first end portion, the first end portion connected to one of the at least three wire
  • a powered surgical tool comprises: a handpiece including a motor; a module housing configured to couple with one of the handpiece and a charging module, wherein each of the handpiece and the charging module are configured to generate a magnetic field; and a printed circuit board assembly including a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging module based on the magnetic field sensed by the analog hall effect sensor.
  • a system for identifying a device coupled with a powered surgical tool comprises: a handpiece configured to generate a magnetic field; a charging module configured to generate a magnetic field; and a powered surgical tool comprising: a module housing configured to couple with one of the handpiece and the charging module; and a printed circuit board assembly including: a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging module based on the magnetic field sensed by the analog hall effect sensor.
  • a powered surgical tool comprises: a first handpiece including a motor; a second handpiece including a motor; a module housing configured to couple with one of the first handpiece and the second handpiece, wherein each of the handpiece and the charging module are configured to generate a magnetic field; and a printed circuit board assembly including: a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging module based on the magnetic field sensed by the analog hall effect sensor.
  • a system for identifying a device coupled with a powered surgical tool comprises: a handpiece configured to generate a magnetic field; a charging module coupled to a charging adapter, the charging adapter being configured to generate a magnetic field; and a powered surgical tool comprising: a module housing configured to couple with one of the handpiece and the charging module; and a printed circuit board assembly including: a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging adapter based on the magnetic field sensed by the analog hall effect sensor.
  • a surgical handpiece for coupling to a battery and control module.
  • the surgical handpiece comprises: a housing; an electric motor disposed within the housing and including a rotor including an output shaft defining a longitudinal axis, the output shaft being, at a first end, coupled to the electric motor and, at a second end, configured to be coupled to a surgical tool, wherein the output shaft defines a lumen centered upon the longitudinal axis of the output shaft; a cannula disposed partially within the lumen and extending from a first proximal end of the surgical handpiece to a second distal end of the surgical handpiece, the cannula defining a cannula flange; a sealing plug connected to the housing and configured to prevent a liquid from entering an interior of the surgical handpiece, wherein the cannula passes through the sealing plug; a seal disposed around an outside of the cannula; and a plurality of terminals extending through the sealing plug.
  • a powered surgical tool comprises: a surgical handpiece, including: a housing; an electric motor disposed within the housing and including a rotor including an output shaft defining a longitudinal axis, the output shaft being, at a first end, coupled to the electric motor and, at a second end, configured to be attached to a surgical tool, wherein the output shaft defines a lumen centered upon the longitudinal axis of the output shaft; a cannula disposed partially within the lumen and extending from a first proximal end of the surgical handpiece to a second distal end of the surgical handpiece, the cannula defining a cannula flange; a sealing plug connected to the housing, wherein the cannula passes through the sealing plug; a seal disposed around an outside of the cannula.
  • the powered surgical tool further comprises: a plurality of terminals extending through the sealing plug and a battery and control module including a module lumen configured to receive
  • a charging system for charging a rechargeable battery module of a powered surgical tool, the powered surgical tool including a module housing configured to receive a handpiece.
  • the charging system comprising: a charger comprising a recess; and an adapter comprising: a charger protrusion configured to be received by the recess, wherein the recess includes a surface facing a first direction; and a module protrusion configured to be received by the module housing to allow the charger to provide power to the rechargeable battery module via the adapter, wherein the module protrusion extends in a direction different than the first direction.
  • a charging system for charging a rechargeable battery module of a first powered surgical tool of a pencil grip type and a rechargeable battery module of a second powered surgical tool of a pistol grip type, wherein the first and second powered surgical tools each include a module housing configured to receive a handpiece is provided.
  • the charging system comprising: a charger including a recess; and an adapter including: a charger protrusion configured to be received by the recess; and a module protrusion configured to be received by: the module housing of the first powered surgical tool to allow the charger to provide power to the rechargeable battery module of the first powered surgical tool via the adapter; and the module housing of the second powered surgical tool to allow the charger to provide power to the rechargeable battery module of the second powered surgical tool via the adapter.
  • a charging system comprising: a charger including a recess; an adapter including: a charger protrusion configured to be received by the recess; a module protrusion; and a magnet disposed on the module protrusion, the magnet being configured to generate a magnetic field; a first powered surgical tool including: a first module housing configured to receive the module protrusion, the first module housing including a first end and a second end; a first hall sensor located a first distance from the first end of the module housing; and a first controller configured to transition from a sleep state to an active state based on the first hall sensor sensing a magnetic field, wherein the first controller is configured to communicate with the charger when the first controller is in the active state; and a second powered surgical tool including: a second module housing configured to receive the module protrusion, the second module housing including a first end and a second end; a second hall sensor located a second distance from the first end of the second module housing, the
  • a charging system comprising: a charger; a battery configured to receive power from the charger in response to contacting the charger; an adapter including: a charger protrusion configured to contact the charger; a module protrusion; and a magnet disposed on the module protrusion, the magnet being configured to generate a magnetic field; and a powered surgical tool including: a module housing configured to receive the module protrusion; a hall sensor; and a controller configured to transition from a sleep state to an active state based on the hall sensor sensing a magnetic field, wherein the controller is configured to communicate with the charger when the controller is in the active state.
  • a powered surgical tool in a twentieth aspect, includes a battery and control module.
  • the battery and control module includes a sealed housing assembly including a printed circuit board including at least one trigger sensor, a plurality of housings sealingly joined together and configured to encase the printed circuit board and the at least one trigger sensor therewithin, and at least one trigger lumen configured to receive a trigger, wherein the at least one trigger sensor is disposed proximate to the at least one trigger lumen.
  • the powered surgical tool further includes at least one trigger installed to the battery and control module within the at least one trigger lumen, the at least one trigger including a stem portion configured to be engaged with the at least one trigger lumen, wherein the stem portion includes at least one magnet configured to interact with the at least one trigger sensor.
  • a method of operating a powered surgical tool includes the step of providing a battery and control module including a sealed housing assembly, the housing assembly encapsulating a printed circuit board that includes at least one trigger sensor and at least one trigger lumen configured to receive a trigger.
  • the method further includes the step of installing at least one trigger into the trigger lumen, the trigger including a stem portion with at least one magnet configured to interact with the trigger sensor without compromising the seal of the sealed housing assembly.
  • a method of repairing a powered surgical tool includes the step of providing a battery and control module including a sealed housing assembly, the housing assembly encapsulating a printed circuit board that includes at least one trigger sensor, the battery and control module further including a trigger with a magnet.
  • the handpiece defines a cannula, and wherein the device housing is free from cannulation.
  • the surgical handpiece defines a longitudinal axis, and the surgical handpiece defines a cannula surrounding the longitudinal axis.
  • the rigid circuit board defines an aperture, the aperture surrounding the cannula. In some implementations, the aperture and the cannula are coaxial. In some implementations, the battery and control module include a safety vent. In some implementations, the battery and control module further comprises a plurality of support ribs and a board mount, the board mount including a plurality of wings for engaging the support ribs. In some implementations, the device housing defines a mounting post, and the third printed circuit board abuts the mounting post such that an axial position of the third printed circuit board is controlled within the battery and control module.
  • the battery and control module further comprises a board mount, the board mount includes one of a set of notches or a set of protrusions, and the device housing defines the other of the set of notches or the set of protrusions, wherein set of protrusions engages the set of notches to prevent the board mount from moving relative to the device housing in a plurality of degrees of freedom.
  • the battery and control module further comprises board mount, wherein the board mount includes one of a set of notches or a set of protrusions, and the device housing defines the other of the set of notches or the set of protrusions, wherein set of protrusions engages the set of notches to prevent the rigid portion of the printed circuit board assembly from moving relative to the device housing in two or more degrees of freedom.
  • the set of notches and/or set of protrusions are positioned in an arcuate arrangement relative to one another.
  • the board mount includes the set of protrusions, and each of the set of protrusions define a receptacle for securing one of the plurality of motor control sensors.
  • the board mount comprises a body portion and a flange, the flange defining a bore for insertion of a fastener, the flange extending perpendicularly from the body portion.
  • the battery and control module further comprises a plurality of spacers, the plurality of spacers disposed between the first printed circuit board and the second printed circuit board.
  • each of the plurality of spacers define a bore, wherein the battery and control module comprises a plurality of fasteners arranged to extend through the first printed circuit board, the bore of at least one of the plurality of spacers, and the second printed circuit board.
  • the board mount defines a plurality of mount bores, each of the plurality of mount bores include a threaded insert.
  • the battery and control module comprises a latch assembly including a locking member and a biasing member, the biasing member positioned to urge the locking member towards the receiver surface.
  • the motor is an electric motor.
  • the motor sensor is further defined as a hall-effect sensor.
  • the motor includes a plurality of magnets and wherein the device housing includes the set of notches, the notches defining a series of notch peaks and notch valleys, wherein an innermost surface of the notch peak is farther from magnets of the motor than an innermost surface of the notch valleys.
  • the sensor is further defined as a first set of sensors, the first set of sensors being aligned axially with at least a portion of one of the plurality of magnets when the handpiece is received in the control module.
  • the first set of sensors are digital hall effect sensors.
  • the powered surgical tool further comprises a second set of sensors, wherein the second set of sensors are analog hall effect sensors.
  • the controller is configured to energize the first terminal based the first set of sensors, and wherein the controller is configured to commutate the motor based on the second set of sensors.
  • each sensor is the first set of sensors is aligned with one another.
  • each sensor in the second set of sensors is aligned with one another.
  • the first set of sensors is axially offset from the second set of sensors.
  • the motor includes a motor rotor, a lamination stack surrounding the rotor of the motor, and a plurality of magnets surrounding the rotor, wherein a portion of the plurality of magnets extend axially beyond the lamination stack.
  • the controller is configured to transition between a sleep state and an active state, wherein the powered surgical tool is configured to cause the controller to transition from the sleep state to the active state based on the sensor signal.
  • the powered surgical tool further comprises a second terminal, the second terminal being energized while the controller is in the sleep state and the active state.
  • the controller is in the sleep state, the powered surgical tool has current draw less than 5 mA.
  • the battery and control module further comprises a third printed circuit board, the third printed circuit board connected to one of the first and the second printed circuit boards via a conductor, wherein the third printed circuit board comprises at least three conductive terminals that extends at least partially through the device housing for establishing an electrical connection between the third printed circuit board and the handpiece.
  • the handpiece includes a memory device electrically connected to at least one of the plurality of terminals.
  • the handpiece includes a memory device electrically connected to at least one of the at least three of conductive terminals.
  • the at least three conductive terminals are soldered to the third printed circuit board.
  • the conductor is further defined as a flexible circuit.
  • the first printed circuit board has greater surface area than the second circuit board. In some implementations, the first printed circuit board is farther from the motor than the second circuit board when the handpiece is coupled to the battery and control module. In some implementations, the first printed circuit board and the second printed circuit board are interconnected with a board header. In some implementations, the second printed circuit board includes two major sides, wherein the board mount contacts only one of the two major sides. In some implementations, the second printed circuit board includes at least four minor sides, wherein the board mount contacts two or fewer minor sides of the second printed circuit board. In some implementations, the second printed circuit board includes at least four minor sides, wherein the board mount contacts no minor sides of the second printed circuit board.
  • the third printed circuit board includes a light source
  • the device housing includes a light guide aligned with the light source.
  • the handpiece includes a memory device and a data terminal, the data terminal in electrical communication with the memory device, and wherein the data terminal is configured to connect with the second terminal of the control module when the handpiece is received in the recess.
  • a distal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module. In some implementations, a portion of a proximal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.
  • the plastic housing defines a first recess, the first recess adjacent the first aperture, with the first recess including a first flat surface, with the first pin including a head and a shaft extending from the head, with the head including a second flat surface, the first pin positioned within the first aperture such that the second flat surface of the head engages the first flat surface of the first recess.
  • the plastic housing defines a channel, wherein the lever is pivotable about the first pin between a first fully depressed position and a second non-depressed position, and wherein the lever is at least partially disposed within the channel in both the first fully depressed position and the second non-depressed position.
  • At least one motor pin of the at least three motor pins define a longitudinal axis and the circuit board defines a longitudinal axis, wherein the longitudinal axis of the at least one motor pin is parallel to the longitudinal axis of the circuit board.
  • at least three motor pins is further defined as at least six motor pins, and where the at least three wires is further defined as at least six wires.
  • the at least six motor pins are positioned equidistant from a center of the array.
  • the powered surgical tool further comprises: a handpiece including a motor; and wherein the plastic housing defines a recess for removably receiving the handpiece, the plastic housing defining a void space; a printed circuit board disposed in the void space; a rechargeable battery module disposed in the void space; the lever configured to receive an input from a user to cause power to be drawn from the rechargeable battery module and supplied to the motor, wherein the powered surgical tool has a pencil grip configuration; and wherein the plastic housing comprises a controller configured to regulate power drawn from the rechargeable battery module based on movement of the lever.
  • the powered surgical tool further comprises a handswitch sensor configured to output a handswitch sensor signal based on a position of the lever, wherein the controller is configured to receive the handswitch sensor signal and regulate power drawn from the rechargeable battery module based on the handswitch sensor signal.
  • the handswitch sensor is further defined as a first handswitch sensor and the handswitch sensor signal is further defined as a first handswitch sensor signal
  • the powered surgical tool further comprising a second handswitch sensor being configured to output a second handswitch sensor signal based on a position of the lever, wherein the controller is configured to receive the second handswitch sensor signal and regulate power drawn from the rechargeable battery module based on the first handswitch sensor signal and the second handswitch sensor signal.
  • the first handswitch sensor and the second handswitch sensor are each mounted to opposing surfaces of the printed circuit board, the controller being disposed on the printed circuit board.
  • the lever includes a run- safe switch slidably mounted to the lever, a magnet being mounted to the run- safe switch, a lever extension movably coupled to the lever, wherein the handswitch sensor is a
  • the powered surgical tool further including a torsion spring including a coil, a first leg, and a second leg, with the first leg and the second legs extending from opposite ends of the coil, with the coil surrounding the first pin.
  • a torsion spring including a coil, a first leg, and a second leg, with the first leg and the second legs extending from opposite ends of the coil, with the coil surrounding the first pin.
  • the routing feature defines a rim, the rim defining the plurality of channels, and the rim surrounding the at least three motor pins.
  • the first end portion of the wire terminal is disposed inside the rim and the second end portion of the wire terminal is disposed outside the rim.
  • the wire terminal defines a bend of at least 70 degrees, and wherein the first end portion of the wire terminal is separated from the second end portion of the wire terminal by the bend.
  • the plurality of channels includes a first channel and a second channel, wherein the first channel has a first depth and the second channel includes a second depth, the first depth being different from the second depth.
  • the first end portion of the at least one of the wire terminals defining a plurality of arms, the arms crimped to engage the first wire end.
  • the second end portion of the wire terminals defining a cylindrical void, the cylindrical void being disposed about the motor pins.
  • control module is further defined as a battery and control module, wherein the battery and control module further comprises a rechargeable battery module.
  • the powered surgical tool comprises a rechargeable battery module, wherein the digital hall effect sensor is configured to receive power from the rechargeable battery module in the sleep state, and wherein the analog hall effect sensor is configured to receive power from the rechargeable battery in the active state.
  • the analog hall effect sensor receives a greater amount of power from the rechargeable battery in the active state than the digital hall effect sensor in the sleep state.
  • the controller is configured to: communicate with the handpiece using a first communication protocol in response to determining that the module housing has been coupled with the handpiece; and communicate with the charging module using a second communication protocol in response to determining that the module housing has been coupled with the charging module.
  • the controller is configured to communicate using the first communication protocol by communicating at a first transmission speed, and wherein the controller is configured to communicate using the second communication protocol by communicating at a second transmission speed.
  • the controller is configured to communicate using the first communication protocol by communicating using full duplex transmission, and wherein the controller is configured to communicate using the second communication protocol by communicating using half duplex transmission.
  • the controller is configured to transmit a communication signal to the handpiece based on determining that the module housing has been coupled with the handpiece. In some implementations, the controller is configured to transmit a communication signal to the charging module based on determining that the module housing has been coupled with the charging module. In some implementations, the controller is configured to receive a communication signal from the programming fixture based on determining that the module housing has been coupled with the programming fixture.
  • the module housing is further configured to couple with a programming fixture, wherein the programming fixture is configured to generate a magnetic field, and wherein the controller is configured to determine whether the module housing has coupled with programming fixture based on the magnetic field sensed by the analog hall effect sensor.
  • the analog hall effect sensor is further defined as a first analog hall effect sensor, wherein the printed circuit board assembly further includes a second analog hall effect sensor, and a third analog hall effect sensor.
  • the handpiece further includes a motor including a first rotor magnet and a second rotor magnet each being configured to generate a magnetic field to cause rotation of the motor; the first analog hall effect sensor, the second analog hall effect sensor, and the third analog hall effect sensor are each configured to sense the magnetic fields generated by the first rotor magnet and the second rotor magnet; the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing the magnetic fields generated by the first rotor magnet and the second rotor magnet; and the controller is configured to determine that the module housing has coupled with the handpiece based on the first analog hall effect sensor, the second analog hall effect sensor, and the third analog hall effect sensor sensing the magnetic fields generated by the first rotor magnet and the second rotor magnet.
  • the system further comprises a programming fixture including a magnet configured to generate a first magnetic field
  • the charging module includes a magnet configured to generate a second magnetic field
  • the analog hall effect sensor is configured to sense a magnetic field by sensing a magnitude of the magnetic field
  • a position of the magnet of the programming fixture and a position of the magnet of the charging module are selected such that the magnitude of the first magnetic field sensed by the analog hall effect sensor is different than the magnitude of the second magnetic field sensed by the analog hall effect sensor.
  • the system further comprises a programming fixture including a magnet configured to generate a first magnetic field
  • the charging module includes a magnet configured to generate a second magnetic field
  • the analog hall effect sensor is configured to sense a magnetic field by sensing a polarity of the magnetic field
  • a polarity of the magnet of the programming fixture and a polarity of the magnet of the charging module are selected such that the polarity of the first magnetic field sensed by the analog hall effect sensor is different than the polarity of the second magnetic field sensed by the analog hall effect sensor.
  • the system further comprises a programming fixture including a magnet configured to generate a first magnetic field
  • the charging module includes a magnet configured to generate a second magnetic field
  • the analog hall effect sensor is configured to sense a magnetic field by sensing a polarity of the magnetic field
  • a polarity of the magnet of the programming fixture and a polarity of the magnet of the charging module are selected such that the polarity of the first magnetic field sensed by the analog hall effect sensor is different than the polarity of the second magnetic field sensed by the analog hall effect sensor.
  • the charger includes two recesses, and wherein the adapter includes two charger protrusions configured to engage the two recesses.
  • the adapter includes two module protrusions.
  • each recess includes a width; each of the module protrusions includes a width; and a sum of the widths of the module protrusions is less than the width of a recess.
  • the two charger protrusions of the adapter are disposed along a first direction, and wherein the two module protrusions are disposed along a second direction different than the first direction.
  • the module protrusion includes: a first latch configured to engage an interface of the module housing of the first powered surgical tool; and a second latch configured to engage an interface of the module housing of the second powered surgical tool.
  • the module protrusion includes a first portion shaped to be received by the module housing of the first powered surgical tool; and a second portion shaped to be received by the module housing of the second powered surgical tool.
  • the module housing of the first powered surgical tool includes a first radius; the module housing of the second powered surgical tool includes a second radius different than the first radius; the first portion of the module protrusion includes a cylindrical shape sized to be received by the module housing of the first powered surgical tool; and the second portion of the module protrusion includes a cylindrical shape sized to be received by the module housing of the second powered surgical tool.
  • the module protrusion includes: a first latch disposed on the first portion, the first latch being configured to engage an interface of the module housing of the first powered surgical tool; and a second latch disposed on the second portion, the second latch being configured to engage an interface of the module housing of the second powered surgical tool.
  • the first hall sensor is configured to sense the magnetic field generated by the magnet in response to the first module housing receiving the module protrusion.
  • the second hall sensor is configured to sense the magnetic field generated by the magnet in response to the second module housing receiving the module protrusion.
  • the controller is configured to communicate using a first communication protocol
  • the charger is configured to communicate using a second communication protocol
  • the adapter is configured to translate one of the first communication protocol and the second communication protocol into the other one of the second communication protocol and the first communication protocol such that the controller is configured to communicate with the charger via the adapter.
  • the charger includes a charger power terminal and a charger communication terminal
  • the charger protrusion includes an adapter communication contact configured to contact the charger communication terminal and an adapter power contact configured to contact the charger power terminal
  • the module protrusion includes a first adapter communication terminal and a second adapter communication terminal in communication with the adapter communication contact, and wherein the first and second adapter communication terminals are shorted to one another to such that the controller is configured to communicate with the charger via the adapter.
  • the controller is configured to communicate using the first communication protocol by communicating using full duplex transmission
  • the charger is configured to communicate using the second communication protocol by communicating using half duplex transmission
  • the adapter is configured to translate the second communication protocol into the first communication protocol by translating a half duplex transmission into a full duplex transmission.
  • the second distal end includes a tool coupler.
  • the lumen centered upon the longitudinal axis of the output shaft is a first lumen; wherein the seal includes a cylinder shape with a second lumen; and wherein the cannula is disposed within the second lumen.
  • the seal includes a first sealing surface upon an end surface of the cylinder shape, wherein the end surface abuts a mating surface upon the sealing plug.
  • the seal includes a second sealing surface including an annular ring-shaped surface upon an inner diameter of the seal, the annular ringshaped surface abutting an outer surface of the cannula.
  • the sealing plug comprises a polymer.
  • the housing includes an internal structure insert disposed within the housing and including an inner diameter at the first proximal end of the surgical handpiece; and wherein the sealing plug is press-fit within the inner diameter of the internal structure insert.
  • the surgical handpiece further comprises a socket stopper disposed around an outside of the internal structure insert and the sealing plug, wherein the socket stopper is configured to retain the sealing plug within the inner diameter of the internal structure insert.
  • the seal is disposed in contact with the cannula flange.
  • the battery and control module further includes a cannula access point configured to enable external access to the cannula within the first proximal end of the surgical handpiece.
  • the second distal end includes a tool coupler.
  • the seal includes a cylinder shape with a hollow center; and wherein the cannula is disposed within the hollow center of the seal.
  • the seal includes a first sealing surface upon an end surface of the cylinder shape abutting a mating surface upon the sealing plug; and wherein the seal includes a second sealing surface including an annular ring upon an inner diameter of the seal abutting an outer surface of the cannula.
  • the battery and control module defines a pistol grip.
  • the at least one trigger lumen includes a trigger vent cutout formed in a wall of the at least one trigger lumen, the trigger vent cutout is formed in a surface of the wall without compromising a seal of the sealed housing assembly, and the trigger vent cutout is configured to enable air to be released from behind the at least one trigger when the at least one trigger is depressed or installed.
  • the at least one trigger is retained in the at least one trigger lumen with a screw and a front plate, and the screw and the front plate enable the at least one trigger to be replaced without compromising a seal of the sealed housing assembly.
  • the sealed housing assembly includes two trigger lumens, and the powered surgical tool further includes two triggers.
  • the sealed housing assembly further includes a battery including at least one battery cell. In some implementations, the sealed housing assembly further includes a handpiece lumen configured to receive a handpiece including a modular motor configured to provide energy to a surgical end effector. In some implementations, the at least one trigger sensor is configured to detect the at least one magnet through one of the plurality of housings. In some implementations, the plurality of housings sealingly joined together are welded together with one of a vibration welding process or a laser-process.
  • FIG. 1 is a perspective view of a first implementation of the powered surgical tool shown with the battery and control module spaced from the surgical handpiece, according to the teachings of the present disclosure.
  • FIG. 2 is a perspective view of the control module of FIG. 1.
  • FIG. 3 is a side view of the control module of FIG. 2.
  • FIG. 4 is an exploded view of the control module of FIG. 2.
  • FIG. 5 is a perspective view of a printed circuit board assembly of FIG. 4.
  • FIG. 6 is a top view of the printed circuit board assembly of FIG. 5.
  • FIG. 7 is a front view of the printed circuit board assembly of FIG. 5.
  • FIG. 8 is an exploded view of the printed circuit board assembly of FIG. 5.
  • FIG. 9 depicts a rear perspective view of a front portion of the control module
  • FIG. 2 according to the teachings of the present disclosure.
  • FIG. 10 depicts a cross-sectional view of the control module of FIG. 3.
  • FIG. 11 depicts a perspective view of a printed circuit board and wiring assembly of the control module of FIG. 4.
  • FIG. 12 depicts a perspective view of the wiring assembly of FIG. 11.
  • FIG. 13 depicts a rear view of the wiring assembly of FIG. 12 without the wiring shown.
  • FIG. 14 depicts a perspective view of a second implementation of the powered surgical tool with a second handpiece coupled with the battery and control module.
  • FIG. 15 depicts a cross sectional view of battery and control module of FIG. 14.
  • FIG. 16 depicts a first perspective view of a printed circuit board assembly of the battery and control module of FIG. 14.
  • FIG. 17 depicts a second perspective view of a printed circuit board assembly of the battery and control module of FIG. 14.
  • FIG. 18 A depicts an exploded view of a first instance of the printed circuit board assembly of FIG. 16.
  • FIG. 18B depicts an exploded view of a second instance of the printed circuit board assembly of FIG. 16.
  • FIG. 19 depicts a rear perspective view of a portion of the printed circuit board assembly of FIG. 16 adjacent to a portion of the battery and control module of FIG 14.
  • FIG. 20 depicts the rear perspective view of the battery and control module of
  • FIG. 14 with the printed circuit board assembly of FIG. 16 removed.
  • FIG. 21 depicts a cross section view of a base portion of a first implementation of the powered surgical tool of FIG. 2, according to the teachings of the present disclosure.
  • FIG. 22 depicts a cross section view of battery and control module of FIG. 1.
  • FIG. 23 depicts a perspective view of a third implementation of the powered surgical tool with a third handpiece coupled with the battery and control module.
  • FIG. 24 depicts a rear perspective view of the third implementation of the powered surgical tool shown in FIG. 23.
  • FIG. 25 depicts a front perspective view of the third implementation of the powered surgical tool shown in FIG. 23 with the third handpiece removed.
  • FIG. 26 depicts a rear perspective view of third handpiece of FIG. 23.
  • FIG. 27 depicts a perspective view a portion of interior of the third handpiece of FIG. 26.
  • FIG. 28 depicts a perspective view of the exterior of the third handpiece of FIG.
  • FIG. 29 depicts a cross section view of the third handpiece of FIG. 26.
  • FIG. 30 depicts a cross-section of a fourth handpiece.
  • FIG. 31 depicts a perspective view of the fourth handpiece of FIG. 30.
  • FIG. 32 depicts a perspective view a portion of interior of a fifth handpiece.
  • FIG. 33 depicts a cross section view of the fifth handpiece of FIG. 32.
  • FIG. 34 is a perspective view of a first implementation of a pin of the battery and control module of FIG. 1.
  • FIG. 35 is a perspective view of a second implementation of a pin of the battery and control module of FIG. 1.
  • FIG. 36 is a perspective view of a charging module and a charging adapter, wherein the charging module is coupled with the battery and control module FIG. 1 and with the battery and control module of FIG. 14 via the charging adapter.
  • FIG. 37 is a perspective view of the charging module and charging adapter of
  • FIG. 36 wherein the charging adapter is not received by the charging module.
  • FIG. 38 is a perspective view of a module protrusion of the charging adapter of
  • FIG. 36 is a diagrammatic representation of FIG. 36.
  • FIG. 39 is an exploded view of the charging adapter of FIG. 36.
  • FIG. 40 is a bottom view of the charging adapter of FIG. 36.
  • FIG. 41 is a schematic view of the battery and control module FIG. 1, the battery and control module of FIG. 14, the charging adapter of FIG. 36, and the charging module of FIG.
  • FIG. 42 is a perspective view of a programming fixture.
  • FIG. 43 is a front view of the programming fixture of FIG. 42.
  • FIG. 44 is a schematic view of a system for identifying a device coupled with a powered surgical tool.
  • FIG. 45 is a state diagram illustrating an operation of the system for identifying a device coupled with a powered surgical tool shown in FIG. 1.
  • FIG. 46 is a graph illustrating sensed readings of analog hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIGS . 14 or 23 when the battery and control module is not coupled with a device.
  • FIG. 47 is a graph illustrating sensed readings of the analog hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIGS. 14 or 23 when the battery and control module is coupled with a handpiece.
  • FIG. 48 is a graph illustrating ideal sensed readings of the analog hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIGS. 14 or 23 when the battery and control module is coupled with a handpiece.
  • FIG. 49 is a graph illustrating sensed readings of the analog hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIGS. 14 or 23 when the battery and control module is coupled with the charging module of FIG. 36.
  • FIG. 50 is a graph illustrating sensed readings of the analog hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIGS. 14 or 23 when the battery and control module is coupled with the programming fixture of FIGS. 42 and 43.
  • FIG. 51 schematically illustrates an exemplary battery and control module in a front perspective view.
  • FIG. 52 schematically illustrates the battery and control module of FIG. 51 in a rear perspective view.
  • FIG. 53 schematically illustrates in side view an attachment or surgical handpiece configured for attachment to the battery and control module of FIG. 51 .
  • FIG. 54 schematically illustrates in cross sectional view the surgical handpiece of FIG. 53, including a sealing plug and a seal, in combination, configured to seal an interior of the surgical handpiece and prevent liquid from entering the interior.
  • FIG. 55 shows an implementation of a powered surgical tool in which a device housing of a battery and control module is designed to provide improved ergonomics and usability.
  • FIG. 56 illustrates in side perspective view internal components of the battery and control module including a pair of trigger sensors corresponding to the triggers of FIG. 55.
  • FIG. 57 illustrates in rear perspective view a front housing configured to be assembled, welded, laser-process attached, or otherwise affixed to a handle portion of the mid housing of FIG. 56.
  • FIG. 58 illustrates in side perspective view a sealed housing assembly including the front housing welded, laser-process attached, adhered, fastened, or otherwise attached to the mid housing in a sealing manner.
  • FIG. 59 illustrates in side perspective view the sealed housing assembly of FIG.
  • FIG. 60 illustrates the sealed housing assembly and the triggers of FIG. 59 in a disassembled state.
  • FIG. 61 illustrates in side cross-sectional view a portion of the sealed housing assembly and the triggers.
  • FIG. 62 illustrates in front cross-sectional view a portion of the sealed housing assembly and the triggers.
  • FIG. 63 illustrates in front perspective view a portion of the sealed housing assembly including a plurality of trigger vent cutouts.
  • FIG. 64 illustrates in front cross-sectional view a portion of the sealed housing assembly including the stem portions and the respective trigger vent cutouts.
  • FIG. 65 is a flowchart illustrating an example of a method for operating a powered surgical tool.
  • FIG. 66 is a flowchart illustrating an example of a method for repairing a powered surgical tool.
  • FIG. 1 shows an implementations of a powered surgical tool 20 in which a device housing 22 of a battery and control module 21 is designed to provide improved ergonomics and usability.
  • the powered surgical tool 20 includes a handpiece 24 configured to be removably coupled with the battery and control module 21.
  • the handpiece 24 may include a motor and a drivetrain (not identified), and also includes additional subcomponents such as electrical sockets, a gearbox, and geometries to removably receive a cutting accessory including a head.
  • additional subcomponents such as electrical sockets, a gearbox, and geometries to removably receive a cutting accessory including a head.
  • the handpiece 24 may take a form disclosed in commonly-owned International Publication No. WO 2013/177423, published
  • the cutting accessory assembly may be unique to complementary versions of the motor and the drivetrain so as to provide a set of handpieces configured to be selectively and interchangeably coupled with the battery and control module 21.
  • the powered surgical tool 20 is shown with a coupler 26 for attaching to the cutting accessory, such as a sagittal saw blade.
  • the medical professional may use the sagittal saw blade for cutting bones, for example small bones of a hand or foot of a patient, ligaments or other tissue.
  • Any device or accessory which is applied to the surgical site, whether it be a sagittal saw blade or drill bit, may generally be referred to as an energy applicator throughout.
  • the powered surgical tool 20 may be a rotary drill, reamer, wire driver, oscillating or reciprocating saw, ultrasonic device or photonic device.
  • the energy applicator may be a drill bit, bur, saw, reamer, grinding disc, ultrasonic cutting or catheterization tip, laser, etc.
  • the type of tool used is not intended to limit the present invention.
  • the motor may be a universal motor which may interchangeably receive more than one cutting accessory as described below.
  • the set of handpieces may be interchangeably coupled with the battery and control module 21 providing for a pencil grip configuration (FIGS. 1-13), and the battery and control modules 221, 421 providing for apistol grip configuration (FIGS. 14-23 and 23-25).
  • the powered surgical tool 20 of the present disclosure may be particularly well suited for orthopedic procedures involving the arm, hand, leg, foot, mandible, and skull, but other small bone orthopedic and soft tissues procedures are contemplated.
  • FIG. 2 shows the battery and control module 21 with the handpiece removed.
  • FIG. 3 shows a side view of the battery and control module 21.
  • the battery and control module 21 includes at least one battery 28, and a main controller 31 that is coupled to a printed circuit board assembly 33 as will be discussed in greater detail below.
  • the main controller 31 is in communication with the battery 28, which may be part of a battery assembly 30, a motor control sensor 32, and a handswitch sensor 34, and further configured to be arranged in communication with the motor when the handpiece 24 is removably coupled with the battery and control module 21.
  • the main controller 31 may also be in communication with memory device 95 (shown in FIG. 8).
  • the battery and control module 21 may include a handswitch assembly 36 optionally coupled to the device housing 22 and configured to receive an input from a user to operate the powered surgical tool 20.
  • the handswitch assembly 36 may be spring-loaded and include a handswitch magnet such that, when the handswitch assembly 36 is actuated, the handswitch magnet is moved towards a handswitch sensor 34. While the example is provided that the handswitch assembly 36 is coupled to the battery and control module 21, the handswitch assembly 36 may be detachable and attached to any portion of the battery and control module 21 and/or handpiece 24. Further, the handswitch assembly 36 may be part or attached to the handpiece 24.
  • the main controller 31 receives a signal from the handswitch sensor 34, and causes power to be drawn from at least one battery cell 28 to be supplied to the motor.
  • the main controller 31 is configured to determine a rotational position of the rotor of the motor, and control the motor based on the rotary position of the rotor as sensed by the motor control sensor 32.
  • one or more handswitch sensors 34 may not be included and the motor may be controlled through other means.
  • An operating speed of the powered surgical tool 20 may be increased incrementally as the handswitch assembly 36 is actuated between a default position and fully engaged position. Additional features of the main controller 31, the handswitch assembly 36, and other electronic subcomponents of the powered surgical tool 20 may be disclosed in the aforementioned International Publication No. WO 2013/177423.
  • the main controller 31 may be configured to regulate power drawn from the rechargeable module based on movement of the lever 66.
  • the main controller 31 may also receive a signal from a handswitch sensor 34.
  • the handswitch sensor 34 is further defined as two handswitch sensors.
  • the controller may be configured to receive signals from both sensors and regulate power drawn from the rechargeable battery module based on the both of the sensor signals.
  • Both the first handswitch sensor and the second handswitch sensor 34 both mounted to the same surface of the printed circuit board 87 or on opposite sides of the printed circuit board
  • the lever 66 may thus be configured to receive an input from a user to cause power to be drawn from the rechargeable battery module and supplied to the motor of the handpiece.
  • the device housing 22 defines a recess 40 sized to removably receive the handpiece
  • the device housing 22 includes a front surface 42 defining an opening 44 that extends proximally to define the recess 40.
  • the recess 40 may be at least substantially cylindrical to be contoured to a hub 46 of the handpiece 24.
  • the hub 46 of the handpiece 24 is disposed within the recess 40 to establish communication between the motor of the handpiece 24 and the battery and control module 21.
  • Several subcomponents of the device housing 22 may be disposed within or adjacent to the recess 40 to releasably secure the handpiece 24 to the device housing 22 and establish the communication between the motor and the main controller 31.
  • the subcomponents may include one or more motor pins 48 (shown in FIG. 4), or other terminal configuration, that provide the connection for the battery and control module 21 to the handpiece
  • Such subcomponents may also include a latch and sensors as discussed in greater detail below.
  • 20 may also include a light guide 63 for directing light from one or more light sources on the printed circuit board assembly to the user.
  • module housing 22 of the battery and control module 21 receives the handpiece 24 in the instance of FIG. 1, in other instances, the handpiece
  • the handpiece 24 may be configured to receive a component of the battery and control module 21.
  • the handpiece 24 may define a recess sized to removably receive the module housing 22 of the battery and control module 21.
  • the device housing 22 may further define a recess for positioning of a latch assembly 52.
  • the latch assembly 52 may include a locking member 54 and a biasing member.
  • the handswitch assembly 36 may be coupled to the device housing 22.
  • the device housing 22 may define a mounting base
  • the mounting base 56 may be integral with the device housing. Furthermore, the device housing 22 and the integral mounting base 56 may both be formed from a plastic material. The mounting base 56 may define apertures 58 adjacent to and on each side of the handswitch recess
  • the handswitch assembly 36 may be partially seated within the handswitch recess 50 or channel.
  • the handswitch assembly 36 may be adjustable in length relative to the device housing 22.
  • the handswitch assembly 36 may further include a pressing pin 60 and a receiving pin 62.
  • Each of the pins 60, 62 extend through one of the apertures 58.
  • the pressing pin 60 during assembly, is pressed into a bore defined by the receiving pin 62. Once the pins are pressed into each other, the receiving pin defines a pivot axis 64 and the pivot surface.
  • the pressing pin 60 and the receiving pin 62 thus define a press-fit engagement with one another.
  • the handswitch assembly may be adjustable in length relative to the device housing 22.
  • the handswitch assembly 36 may further include a pressing pin 60 and a receiving pin 62.
  • Each of the pins 60, 62 extend through one of the apertures 58.
  • the pressing pin 60 is pressed into a bore defined by the receiving pin 62. Once the pins are pressed into each other, the receiving pin defines a pivot axis 64 and the pivot surface.
  • the 36 further includes a lever 66 pivotably coupled to the pivot surface of the receiving pin 62.
  • the lever 66 may define apertures to receive the receiving pin such that the lever 66 pivots about the receiving pin 62.
  • the lever 66 is pivotable about the receiving pin 62 between a first fully depressed position and a second non-depressed position, and wherein the lever 66 is at least partially disposed within the handswitch recess 50 or channel in both the first fully depressed position and the second non-depressed position.
  • the device housing 22 defines a recess 68.
  • the recess 68 is positioned adjacent the aperture 58, with the recess 68 including a flat surface 70, with the receiving pin 62 optionally including a head 72 and a shaft 74 extending from the head 72.
  • the head 72 including a flat pin surface 76, the receiving pin 62 positioned within the aperture 58 such that the flat pin surface 76 of the head 72 engages the flat surface 70 of the recess
  • the pressing pin may include similar features with respect to the head and shaft and flat surfaces, and the other of the apertures 58 may include a similar recess with a similar flat surface.
  • the handswitch assembly 36 may further include a biasing member, such as a torsion spring 78.
  • the torsion spring 78 includes a coil 80, and two legs 82, with the legs 82 extending from opposite ends of the coil 80.
  • the coil 80 is positioned to surround the pivot surface of the receiving pin 62.
  • the lever 66 may further comprise a run-safe switch 84 slidably mounted to the lever 66, a switch magnet being mounted to the run-safe switch, a lever extension movably coupled to the lever 66. When the run/safe switch 84 is in the “run” position and the user presses the lever that magnet moves up and down.
  • the hall sensor voltage of the handswitch sensor changes in response to the magnet being closer or further away from it. That voltage change is what is used to control speed.
  • the run/safe switch is in “safe” position, the magnet is moved forward, it’s almost as if the magnet is out of range. Therefore, ensuring that even if the user presses the lever, the handswitch sensors will not see a meaningful voltage change. So, the handpiece will not run.
  • the printed circuit board assembly 33 may include a board mount 86 and a rigid printed circuit board 87. While a single printed circuit board is shown in these figures, it is contemplated that alternative configurations could split the electrical components, such as the motor control sensors and the microcontroller and MOSFETs in two or more circuits, including two or more rigid circuit boards or a combination of rigid circuit boards and flexible circuit boards.
  • the board mount 86 may include a set of protrusions 88 shaped to align with a plurality of notches 90 defined by the device housing 22.
  • the set of protrusions 88 engages the set of notches 90 to prevent the board mount 86 from moving relative to the device housing 22 in a plurality of degrees of freedom, such as at least two degrees of freedom.
  • Each of the protrusions 88 may further define a receptacle 92 to fix position of the motor control sensor 32 relative to the board mount 86.
  • the motor control sensors 32 may be inserted within the receptacles
  • One or more motor control sensors 32 may also be mounted on the surface of the printed circuit board 87 instead of being mounted in the receptacle of the board mount 86.
  • the one or more or motor control sensors may be implemented as analog hall-effect sensors.
  • the board mount 86 may be secured to the device housing 22 using a plurality of mount fasteners 96.
  • the mount fasteners 96 may extend through the board mount 86 and engage apertures of the device housing 22 to fix the position of the printed circuit board assembly 33 in an additional degree of freedom.
  • the set of protrusions 88 may be positioned about an arcuate arrangement relative one another.
  • the set of protrusions 88 may engage the set of notches 90 on the device housing 22 such that relative movement between printed circuit board assembly 33 and the device housing 22 is prevented in a plurality of degrees of freedom.
  • the printed circuit assembly 33 is further secured in its position with the device housing 22 by a plurality of mounting feet 94 are located on the opposite side of the rigid printed circuit board 87 from the set of protrusions 88.
  • the plurality of mounting feet 94 are positioned to engage an internal surface of the device housing 22 when the printed circuit board assembly 33 is inserted into the device housing 22.
  • the board mount by coupling the board mount to the printed circuit board including the motor control sensors, the position of the motor control sensors may be tightly controlled.
  • the board mount only engaging one major side of the circuit board the circuit board can expand during thermal cycling without compromising the resiliency of the device.
  • the board mount only engaging the face of the smaller circuit board the larger circuit board is provided with additional flexibility and thus is resistant to breakage imparted by torque during use of the powered surgical tool.
  • the motor of the handpiece 24 includes a plurality of magnets.
  • the aforementioned set of notches 90 may define a series of notch peaks 97 and notch valleys 98, wherein an innermost surface of the notch peak 97 is farther from magnets of the motor of the handpiece than an innermost surface of the notch valleys 98 when the handpiece 24 is inserted into the device housing
  • the motor control sensors 32 are closer to the magnets of the handpiece than if the motor control sensors were aligned with the notch peaks 97.
  • the device housing 22 is formed to include a vent opening
  • the void space may be vented during sterilization.
  • a cap 101 is coupled to the device housing 22 to cover the vent opening 100.
  • a pressure relief valve 102 is at least partially inserted into the vent opening 100 for facilitating venting of the void space during sterilization.
  • the cap 101 covers the pressure relief valve 102 and may protect the pressure relief valve 102, e.g. from being damaged/hit, by jets from washer during washing.
  • the pressure relief valve 102 may be configured to open at a predetermined pressure. When the valve opens, the is clearance between the pressure relief valve 102 and the cap 101.
  • the cap 101 may include one or more cuts adjacent or proximal to the position of the pressure relief valve 102. The cuts allow the gas/air to be released.
  • the battery and control module 21 includes at least three motor pins 48 spaced apart from one another to define an array of motor pins 48 that extends through the housing and out of the void for establishing an electrical connection between the circuit board and the electric motor of the handpiece 24. It is contemplated that the battery and control module 21 includes at least six motor pins 48, with a plurality of the motor pins 48 being positioned equidistant from a center of the array. A hermetically-sealed housing-terminal interface is defined by the device housing 22 and the at least three motor pins 48.
  • the battery and control module 21 may further include a plurality of pin wires 104, such as at least three wires, with of the wires 104 including a wire terminal 106 connected to a first wire end of the at least three pin wires
  • the 110 of the wire terminals 106 may define a cylindrical void 120, the cylindrical void 120 sized to being disposed about the motor pins 48.
  • the second end portion 110 may be soldered to the motor pins 48.
  • the battery and control module 21 further includes a routing feature 112 disposed within the void of the housing and disposed about the at least three motor pins 48, the routing feature 112 defining a plurality of channels 114.
  • the routing feature 112 may be integral with the device housing 22 or may be a separate component that is affixed to the device housing
  • Each of the wire terminals 106 are positioned within one of the channels 114 of the routing feature 112.
  • the plurality of channels 114 may include a first channel 114 and a second channel
  • the plurality of channels 114 to secure the different radial positions of the wire terminals
  • the routing feature 112 includes a rim 116 disposed about the circumference of the routing feature 112 and surrounding the motor pins 48.
  • the rim 116 may define the plurality of channels 114. In instances where the routing feature 112 includes the rim
  • the handpiece 24 includes a motor 122, such as a brushless motor.
  • the handpiece 24 may be configured to generate a magnetic field.
  • the motor 122 may include a plurality of motor magnets 124 surrounding a motor shaft 126 or a rotor.
  • the motor 122 may include a first rotor magnet 123 and a second rotor magnet 125 forming a rotor magnet pair 123,
  • the battery and control module As described with reference to FIGS. 5-6 and 22, the battery and control module
  • the 21 may include one or more motor control sensors 32 which may define a set of motor control sensors 32.
  • the motor control sensor 32 of the battery and control module 21, shown in FIGS. 5-6 and 22, may be one or more analog hall effect sensors 32 that are coupled to the control module controller 31 and are configured to sense a magnetic field.
  • FIG. 5-6 and 22 the motor control sensor 32 of the battery and control module 21, shown in FIGS. 5-6 and 22, may be one or more analog hall effect sensors 32 that are coupled to the control module controller 31 and are configured to sense a magnetic field.
  • the battery and control module 21 includes a first, second, and third analog hall effect sensor
  • the one or more motor control sensors 32 may be coupled to the printed circuit board assembly 33 by being mounted to a surface of the rigid printed circuit board 87, as shown in FIG. 5.
  • the battery and control module 21 may further include one or more wake-up sensors 134 which may define a set of wake-up sensors
  • the set of wake-up sensors 134 may be defined as at least three wake-up sensors 134.
  • the one or more wake-up sensors 134 may be positioned distally of the motor control sensors 32 on the rigid printed circuit board 87 and may be fixed on the board mount 86 in a manner similar to as described with respect to the motor control sensors 32. Additionally, or alternatively, the one or more wake-up sensors 134 may be mounted directly to the surface of the printed circuit board
  • the set of three or more wake-up sensors may be positioned to partially surround the handpiece
  • This arrangement of three or more wake-up sensors 134 provide for enhanced accuracy as it accounts for the possibility that one or more of the wake-up sensors 134 may be aligned with a gap between the plurality of motor magnets.
  • Three wake-up sensors 134 essentially guarantees that at least one of the wakeup sensors will detect a strong magnetic field no matter the rotation of the motor 122.
  • the one or more wake-up sensors 134 may be positioned to partially surround the handpiece 24, a component of the charging module 1100, or a component of the programming fixture 1200 when one of the handpiece 24, the charging module 1100, or the programming fixture 1200 is coupled with the battery and control module 21.
  • This arrangement of the one or more wake-up sensors 134 provides for enhanced accuracy by ensuring that the one or more wake-up sensors 134 sense a magnetic field generated by the rotor magnet pair 123, 125 when the handpiece 24 is coupled with the module housing 22, a magnetic field generated by a charger module magnet M (shown in FIG.
  • the wakeup sensors 134 may be positioned to surround the plurality of motor magnets 124 when the handpiece 24 is coupled with the battery and control module 21.
  • the set of motor control sensors 32 may be aligned with one another in a direction perpendicular to the axis of the motor 122.
  • the set of wake-up sensors 134 may be aligned with one another in a direction perpendicular to the to the axis of the motor 122.
  • the set of wake-up sensors 134 may be arranged parallel to the set of motor control sensors 32.
  • the control module controller 31 may include any suitable number of motor control sensors 32 for sensing the magnetic field generated by the motor 122.
  • the motor 122 may any suitable number of rotor magnets for forming any suitable number of corresponding rotor magnet pairs.
  • the motor 122 may include six rotor magnets forming three rotor magnet pairs.
  • the control module controller 31 may include three motor control sensors 32 for sensing the magnetic field generated by each of the rotor magnet pairs.
  • the control module controller 31 may include any suitable number of wake-up sensors 134.
  • the control module controller 31 may include a set of three or more wake-up sensors 134.
  • the main controller 31 may be configured to regulate power supplied to the one or more motor pins 48 of the battery and control module 21 based on the sensor signal provided by the wake-up sensor 134. More specifically, the main controller 31 may provide power to one or more motor pins 48 based on the sensor signal provided by the wake-up sensor 134. In such an implementation, the main controller 31 is configured to energize one or more motor terminals based on the output of the one or more wake- up sensors 134 and the main controller 31 is configured to commutate the motor 122 based on the one or more motor control sensors 32.
  • the wake-up sensors 134 could be omitted and the main controller 31 may be configured to regulate power supplied to the one or more motor pins 48 based on the sensor signal provided by the motor control sensors 32. In this case, the main controller 31 would both commutate the motor 122 based on the output of the motor control sensors
  • the one or more wake-up sensors 134 may be implemented as digital hall effect sensors and the one or more motor control sensors 32 may be implemented as analog hall effect sensors.
  • the wake-up sensors 134 may be referred to as digital hall effect sensors 134 and the motor control sensors 32 may be referred to as analog hall effect sensors 32.
  • Digital hall effect sensors are ideal for wake-up functions as they have a lower current draw (less than 5 uA each) than the analog hall effect sensors (greater than 5 mA each).
  • Analog hall effect sensors are ideal for the motor control function as they possess a higher acquisition rate than the digital hall effect sensors.
  • the main controller 31 may be implemented to transition or switch between a sleep state and an active state based on the sensor signal from the wake-up sensors 134.
  • the main controller 31 may stop performing certain functions, such as powering the motor 122 of the handpiece 24. In certain implementations, the controller 31 may also stop powering the motor control sensors 32 when in the sleep state.
  • the main controller 31 may stop performing certain functions, such as powering the motor 122 of the handpiece 24. In certain implementations, the controller 31 may also stop powering the motor control sensors 32 when in the sleep state.
  • the main controller 31 may still drain some energy from the battery assembly 30 while in the sleep state such that the main controller 31 remains able to power the wake-up sensors 134.
  • the main controller 31 may also still power one or more of the motor pins 48 while in the sleep state, specifically referred to as a data pin 48’.
  • the data pin 48’ may be energized while the main controller 31 is in the sleep state.
  • the data pin 48’ may also be energized while in the active state. While the main controller 31 is in the sleep state, the powered surgical tool has current draw less than 5 mA from the battery assembly 30.
  • the main controller 31 is configured to cause the main controller 31 to transition from the sleep state to the active state based on the sensor signal of the wake-up sensor in one implementation.
  • a switching module 159 including a plurality of MOSFETs 159 may also be coupled to the printed circuit board 87. Although the disclosure contemplates MOSFETs as the switching components that are coupled to the printed circuit board 87, other suitable transistors or switching components may be used.
  • the switching module 159 may be used in controlling the direction of operation of the motor of the handpiece 24, for example, in a forward direction or in a reverse direction.
  • FIGS. 14—21 depict another implementation of the powered surgical tool 220 shown in a pistol configuration.
  • a battery and control module 221 of the pistol configuration includes a barrel 200 and a handle 201.
  • the handle 201 extends downwardly from the barrel 200.
  • the handpiece 224 may be inserted to a recess 240 of the barrel 200.
  • Battery and control module 221 may have has two triggers 202, 203 or switches that are spring-loaded. Both triggers 202, 203 extend forward from the distally directed portion of the handle 201. The practitioner may actuate triggers 202, 203 to control the operation of the tool unit.
  • the triggers 202, 203 may each include a magnet which gets moved when the triggers 202,
  • the battery and control module 203 are actuated by the user as discussed in greater detail below.
  • the battery and control module 221 may include a pressure relief valve and a cap that function substantially similar to the pressure relief valve and cap discussed with respect to the pencil configuration.
  • the battery and control module 221 includes at least one battery 28 in a battery assembly 230, and a main controller 231 that is coupled to a printed circuit board assembly 233 as will be discussed in greater detail below.
  • the main controller 231 is in communication with the battery 228, which may be part of a battery assembly
  • the main controller 231 may also be in communication with memory device 295 on the board assembly, and both may be positioned on the first printed circuit board
  • the main controller 231 may receive a signal from the trigger sensor 235, and the main controller 231 may provide for power to be drawn from at least one battery cell 228 to be supplied to the motor of the handpiece 224. During operation, the main controller 231 is configured to determine a rotational position of the motor, and control the motor based on the rotary position of the motor as sensed by the one or more motor control sensors 232.
  • the device housing 222 of the battery and control module 221 defines a recess 240 sized to removably receive the handpiece 224. More particularly, the device housing 222 includes a front surface 242 defining an opening 244 that extends proximally to define the recess 240.
  • the recess 240 may be at least substantially cylindrical to be contoured to the handpiece 224. Alternatively, the recess may be shaped in other ways, such as that which is described with expect to battery and control module
  • a first printed circuit board 249, a second printed circuit board 251, and a fourth printed circuit board 255 may be disposed in the barrel 200 while a third printed circuit board 253 is disposed in the handle 201.
  • the first printed circuit board 249 is interconnected with the second printed circuit board 251 by a board header 257
  • the first printed circuit board 249 is connected to the third printed circuit board 25 by a flexible circuit
  • the first printed circuit board 249 is connected to the fourth printed circuit board 255 by a flexible circuit.
  • a plurality of motor control sensors 232 may be coupled to the second printed circuit board 251.
  • the motor control sensors 232 may be Hall-effect sensors and may be similar to the previously described motor control sensors 32.
  • a switching module 259 including a plurality of MOSFETs 270 may also be coupled to the second printed circuit board 251. Although the disclosure contemplates MOSFETs as the switching components that are coupled to the second printed circuit board 251, other suitable transistors or switching components may be used.
  • the switching module 259 may be used in controlling the direction of operation of the motor of the handpiece 224, for example, in a forward direction or in a reverse direction.
  • the fourth printed circuit board 255 may include a plurality of motor pins 248.
  • the plurality of motor pins 248 may be soldered to the fourth printed circuit board 255.
  • One or more of the motor pins 248 may be connected to the switching module 259.
  • the fourth printed circuit board 255 may also include one or more light sources 261, such as LEDs.
  • the light source(s) 261 may be controlled by the main controller 231
  • the battery and control module 221 may include a light guide 263 aligned with the one or more light sources 261 of the third printed circuit board.
  • the motor pins 248 may have form factors other than a pin, and may be more generally referred to as motor terminals.
  • the trigger sensors 235 may be disposed on the third printed circuit board 253.
  • the trigger sensors 235 may be Hall-effect sensors and may be similar to the previously described handswitch sensors 34.
  • the third printed circuit board 253 is disposed inside the handle 201. In particular, the third printed circuit board 253 is disposed in close proximity to the triggers 202, 203 so that the plurality of trigger sensors 235 may sense a state of the triggers 202, 203, such as when the triggers 202, 203 have been actuated by the user.
  • the first printed circuit board 249 and the second printed circuit board 251 may each be rigid boards, with the second printed circuit board 251 and the first printed circuit board
  • the main controller 231 may be mounted to the second printed circuit board 251.
  • the second printed circuit board 251 may also include a plurality of wake-up sensors 334, which function as described with respect to battery and control module 21.
  • the first printed circuit board 249 has greater surface area than the second printed circuit board
  • the first printed circuit boaid 249 is also farther from handpiece and the motor than the second printed circuit board 251 when the handpiece 224 is coupled with the battery and control module
  • the device housing 222 may include one or more mounting posts 265 to facilitate positioning of the third printed circuit board 253 within the device housing
  • the third printed circuit board 253 abuts the mounting post 256 such that an axial position of the third printed circuit board 253 is controlled within the battery and control module 221.
  • the axial positioning of the third printed circuit board 253 is important as it includes a plurality of light sources and these light sources need to be aligned with the light guide 263.
  • the board mount 286 indirectly ensures alignment of the third printed circuit board in the housing by locking all degrees of freedom of the first and second printed circuit boards.
  • the fasteners that engage the third printed circuit board only fix one degree of freedom.
  • the device housing 222 may further include a plurality of support ribs 267 and the tool may further include a board mount 286.
  • the board mount 286 may include a plurality of wings 269 for engaging the support ribs 267.
  • the second printed circuit board 251 includes two major sides 271, wherein the board mount 286 contacts only one of the two major sides 271.
  • the second printed circuit board 251 includes at least four minor sides 273, wherein the board mount
  • the second printed circuit board 251 includes at least four minor sides 273, wherein the board mount 286 contacts no minor sides 273. This configuration may be advantageous in that the printed circuit board 87 may expand during exposure to elevated temperatures in the latitudinal direction without being constrained by the board mount.
  • the board mount 286 comprises a body portion 275 and a flange 277, the flange
  • the flange 277 defining a bore for insertion of a fastener, the flange 277 extending perpendicularly from the body portion 275.
  • the flange 277 is configured to partially secure the position of the fourth printed circuit board 255. Together, the flange 277 and the mounting posts 265 fix the position of the fourth printed circuit board 255.
  • the battery and control module 221 further comprises a plurality of spacers
  • the board mount 286 may define a plurality of mount bores, each of the plurality of mount bores include a threaded insert 283. [00173] Similar to the battery and control module 21, battery and control module 221 may include a set of protrusions 288, and the device housing defines the other of the set of notches
  • set of protrusions 288 engages the set of notches 290 to prevent the board mount 286 from moving relative to the device housing 222 in a plurality of degrees of freedom.
  • the set of notches 290 and/or set of protrusions 288 are positioned in an arcuate arrangement relative to one another.
  • Each of the set of protrusions 288 define a receptacle 292 for securing one of the plurality of motor control sensors 232.
  • the notches 290 defining a series of notch peaks 297 and notch valleys 298, wherein an innermost surface of the notch peak 297 is farther from magnets of the motor than an innermost surface of the notch valleys
  • the first printed circuit board 249 may be longer and wider than the second printed circuit board 251 and thus, has a larger surface area than the second printed circuit board
  • the surface area of the first printed circuit board 249 may be at least 30, 40, or
  • the first printed circuit board 249 and the second printed circuit board 251 are arranged in a stacked configuration which helps to minimize the footprint of the powered surgical tool 220, in particular, a small footprint of the battery and control module.
  • the first printed circuit board 249 may have a first longitudinal axis and the second printed circuit board 251 may have a second longitudinal axis, with the first and second longitudinal axes being in alignment.
  • the first and second printed circuit board 249, 251 may each have rigid back layers and are thus rigid printed circuit boards.
  • the first printed circuit board 249 is longer than the second printed circuit board 251, a distal end of the first printed circuit board 249 extends beyond a distal end of the second printed circuit board 251. Furthermore, the second printed circuit board 251 may be positioned such that it does not extend beyond the first printed circuit board 249 in any direction beyond being spaced apart from the first circuit board as described above.
  • FIGS. 23-25 depict another implementation of the powered surgical tool 420 shown in an open-top pistol configuration.
  • a battery and control module 421 of the pistol configuration includes a receiver surface 404 and a handle 401.
  • the handle 401 extends downwardly from the receiver surface 404.
  • the handpiece 424 may be inserted to a receiver surface 404.
  • the battery and control module 421 may include any of the features described with respect to battery and control modules 21 and 221. However, the battery and control module 421 provides for an open-top configuration with respect to the handpiece 424 that provides for certain ergonomic and construction advantages.
  • the handpiece 424 may include a rail 405 and the
  • the rail 405 and the slot 406 being configured such that the rail is slidable within the slot 406 to allow coupling between the handpiece
  • the battery and control module 421 may further include a latch assembly with a locking member in a construction similar to as described above with respect to battery and control module 21.
  • the handpiece 424 may include a receiver surface 404 similar to the handpiece 24.
  • the battery and control module 421 may feature a device housing 422 the defines a void space that receives a rechargeable battery module disposed in that void space.
  • the battery and control module 21 may further include a printed circuit board including a controller configured to regulate power drawn from the rechargeable battery module based on user input.
  • the printed circuit board may further include a motor sensor configured to output a motor sensor signal representative of a state of the motor of the handpiece 424.
  • the battery and control module 421 may further include motor pins 448 at that extend through the device housing for establishing an electrical connection between the printed circuit board and the motor of the handpiece 424.
  • the motor pins 448 can take other form factors, such as other shapes of electrical terminals.
  • 421 may include a safety vent as described above with respect to battery and control module 21.
  • the battery and control module 421 may also include one or more motor control sensors as described above with respect to battery and control module 221, which may be implemented as hall-effect sensors.
  • the handpiece 424 may take the form of a pin or wire driver that defines a cannula 408.
  • This cannula 408 allows fixation pins and fixation wires to be pass through the proximal end of the handpiece 424, extending through the body of the handpiece, and extend out through the distal end of the handpiece.
  • the handpiece 424 may include the features of U.S. Patent Pub. 20210220035, which is hereby incorporated by reference in its entirety.
  • the battery and control module 421 may be free from cannulation, let allow a wire or pin to enter the proximal end of the handpiece. 424.
  • the proximal end of the battery and control module 421 may be shaped to allow the wire or pin to enter the handpiece 424 from the proximal end of the tool 420.
  • the control module 421 may define a groove 410 to accommodate the wire or pin as the wire or pin enters the proximal end of the handpiece 424.
  • the battery and control module 421 may be free of additional welding locations in the device housing 422 to defined such cannulation. The avoidance of these additional welding location simplifies the design of the battery and control module 421, and eliminates a location of possible ingress of sterilants during the sterilization process.
  • the powered surgical tool 420 may be constructed such that a distal end face 411 of the handpiece is exposed when the handpiece 424 is coupled with the battery and control module 421. In addition, a portion of the proximal end face 412 of the handpiece 424 is exposed when the handpiece 424 is coupled with the battery and control module
  • the battery and control module 421 may be relatively smaller as the battery and control module
  • the battery and control module 421 no longer features a cylindrical profile that leads to a relatively larger device.
  • This in turn also allows for the diameter of the motor to increase without becoming too large for the user. The increased diameter allows for a reduced length of the motor, thus reducing the size of the tool.
  • the handpiece 424 features a motor 522 featuring motor magnets 524 and a motor shaft 526.
  • the motor 522 may include a lamination element 228 surrounding the motor shaft 526.
  • the handpiece 424 may further include a handpiece circuit 530, such as a rigid circuit board that includes a handpiece memory 532 and conductive terminals to receive the motor pins, one of which being a data terminal 533.
  • the motor shaft 526 may define a cannula 536.
  • the handpiece 424 may further include a gearbox 538 for altering an output parameter of the motor shaft output to the tool coupler, such as the speed, torque or direction of the output to the tool coupler.
  • the surgical handpiece 424 may define an axis and the cannula 536 may surround the axis.
  • the motor shaft 526 or rotor may define an axis.
  • the rigid circuit board 530 may be defined as a rigid circuit board including a controller.
  • the rigid circuit board 530 may be oriented perpendicular to the axis of the rotor.
  • the rigid circuit board 530 may also be cannulated via cannulation aperture 540.
  • the cannulation aperture 540 may be coaxial with the cannula 536
  • the plurality of terminals, including data terminal 533 may be soldered to the rigid circuit board, and may be shaped to engage the motor pins 448 when the handpiece 424 is coupled with the battery and control module 421. This arrangement of the rigid circuit board 530 may lead to a relatively shorter handpiece 424, which allows the tool 420 to be relatively shorter and more compact than designs where the circuit board is oriented parallel to the axis of the motor shaft.
  • the handpiece 624 features a motor 722 featuring motor magnets 724 and a motor shaft 726.
  • the motor 722 features motor magnets 724 and a motor shaft 726.
  • the handpiece 624 may further include a handpiece circuit 730 that includes a handpiece memory 732 and conductive terminals to receive the motor pins, one of which being a data terminal 733.
  • the other motor pins may function as power terminals, and may operate at higher voltages than the data terminal.
  • the handpiece 624 may further include a gearbox 738 for altering an output parameter of the motor shaft output to the tool coupler, such as the speed, torque or direction of the output to the tool coupler.
  • the handpiece circuit 730 may be defined as a rigid circuit board including a controller.
  • the controller may be integrated with the memory device 732, and is not shown separately.
  • the handpiece circuit 730 may be oriented perpendicular to the axis of the motor shaft
  • the plurality of terminals may be soldered to the rigid circuit board, and may be shaped to engage the motor pins 248 when the handpiece 624 is coupled with the battery and control module 221.
  • This arrangement of the handpiece circuit 730 may lead to a relatively shorter handpiece 624, which allows the tool 220 to be relatively shorter and more compact.
  • This handpiece may also be coupled with other control modules, such as control module
  • the handpiece 824 features a motor 822 featuring motor magnets 924 and a motor shaft 926.
  • the motor 822 features motor magnets 924 and a motor shaft 926.
  • the handpiece 922 may include a lamination element 928 surrounding the motor shaft 926.
  • the handpiece 824 may further include a handpiece circuit 930 that includes a handpiece memory 932 and conductive terminals to receive the motor pins, one of which being a data terminal 933.
  • the handpiece 824 may further include a gearbox 938 for altering an output parameter of the motor shaft output to the tool coupler 826, such as the speed, torque or direction of the output to the tool coupler 826.
  • the handpiece circuit 930 may be defined as a flex-rigid board that includes a flexible portion 942 and a rigid portion 944.
  • the rigid portion 944 may be oriented parallel to the axis of the motor shaft 926.
  • the plurality of terminals, including data terminal 933, may be soldered to the flexible portion 942, and may be shaped to engage the motor pins 248 when the handpiece 824 is coupled with the battery and control module 221.
  • This particular arrangement of the rigid portion and the flexible portion advantageously provides for a compact design, while also providing room for the electrical components of in the handpiece, including, but not limited to the controller and memory device of the handpiece.
  • the controller and memory device may be integrated into a single unit. In either case, these electrical components may be onboard the rigid portion of the circuit board. It is also contemplated that this handpiece may be configured to operate with battery and control module 421, as all described handpieces in this disclosure are.
  • the pins 48 of the battery and control module 21 may establish an electrical connection between the control module controller 31 and a device coupled with the battery and control module 21. Two instances of an example pin 48 are shown in FIGS. 34 and 35.
  • FIG. 34 A first instance of a pin 48 for establishing an electrical connection between the control module controller 31 and a device coupled with the battery and control module 21 is shown in FIG. 34.
  • the pin 48 includes a first end 1050 and a second end 1052. Either the first or second end 1050, 1052 may be configured to electrically connect with the control module controller 31 and either the first or second end 1050, 1052 may be configured to electrically connect with electrical components of a device coupled with the battery and control module 21, such as the handpiece 24.
  • the pin 48 of FIG. 34 is geometrically symmetrical, the pin 48 is unable to be loaded into an injection mold incorrectly when the pin 48 is injection molded to the module housing 22 of the battery and control module 21.
  • the pin 48 includes abutments 1054 defining a groove 1056.
  • the abutments 1054 interact with the module housing 22 to provide a seal configured to prevent steam and liquid from entering into the battery and control module 21.
  • plastic flows into the groove 1056 to affix the pins 1048 to the module housing 22.
  • the abutments 1054 are also configured to aid in securing the pin 48 to the battery and control module 21 once the pin 48 is injection molded to the battery and control module 21.
  • FIG. 35 A second instance of a pin 48 for establishing an electrical connection between the control module controller 31 and a device coupled with the battery and control module 21 is shown in FIG. 35.
  • the pin 48 includes a first end 1058 and a second end 1060.
  • the first end 1058 may be configured to electrically connect with the control module controller 31 and the second end 1060 may be configured to electrically connect with electrical components of a device coupled with the battery and control module 21, such as the handpiece 24.
  • the pin 48 includes a half groove 1062 defined by an abutment 1064.
  • the half groove 1062 is configured to receive an O-ring such that the O-ring is proximate to the abutment 1064.
  • the Oring is configured to be sandwiched between against the abutment 64 and the module housing 22 of the battery and control module 21 to provide a seal configured to prevent steam and liquid from entering into the battery and control module 21.
  • the pin 48 includes a barb 1065 configured to aid in securing the pin 48 to the battery and control module 21, while providing a seal configured to prevent steam and liquid from entering into the battery and control module 21.
  • the module housing 22 of the battery and control module 21 may be configured to be received by a charging module 1100.
  • the charging module 1100 includes a charging adapter 1102, and the module housing 22 of the battery and control module 21 couples with the charging module 1100 via a charging adapter 1102.
  • the recess 40 of the module housing 22 receives the charging adapter 1102 and, as indicated by the dotted arrow, the rechargeable battery module 28 receives charging power from the charging module 1100.
  • the charging module 1100 is further shown in FIG. 37. As shown in FIG. 37, the charging module 1100 may include a recess 1104. The charging module 1100 may be configured to provide charging power to devices received by the recess 1104.
  • a rechargeable battery may be received by the recess 1104 and the rechargeable battery may be configured to receive charging power from the charging module 1100 in response to the rechargeable battery contacting the charging module 1100.
  • the charging module 1100 may include any suitable number of recesses 1104 arranged in any suitable manner. For example, in
  • the charging module 1100 includes six recesses 1104.
  • the six recesses 1104 are arranged in a two-row by three-column configuration with each row including three recesses 1104 arranged along a direction of a first charger axis AX1 and with each column including two recesses 1104 arranged along a direction of a second charger axis AX2 perpendicular to the first charger axis
  • the charging adapter 1102 is configured alter the form factor of the charging module 1100.
  • the charging adapter 1102 is configured to be received by the charging module 1100 and coupled with devices not shaped to be received by the recess 1104, allowing the charging module 1100 to provide charging power to such devices.
  • the charging adapter 1102 is configured to be received by the charging module 1100 and coupled with devices not shaped to be received by the recess 1104, allowing the charging module 1100 to provide charging power to such devices.
  • the powered surgical tool 20 is not shaped to be received by the recess 1104.
  • the charging adapter 1102 is configured to be received by the charging module 1100 and coupled with the module housing 22 such that the charging module 1100 may provide charging power to the rechargeable battery module 28 of the powered surgical tool 20 via the charging adapter 1102.
  • the charging adapter 1102 includes a charger protrusion 1108 configured to be received by the recess 1104 of the charging module 1100 and a module protrusion
  • module housing 22 of a battery and control module 21 configured to be received by a module housing 22 of a battery and control module 21.
  • the module protrusion 1110 is received by the module housing 22 to allow the charging module 1100 to provide power to the rechargeable battery module 28 via the charging adapter 1102.
  • the charging adapter 1102 alters a form factor of the charging module 1100 such that devices coupled with the charging adapter 1102 extend along a direction of the module protrusions 1110.
  • the recesses 1104 include a surface 1106 facing a surface direction D1.
  • devices received by the recesses 1104 of the charging module 1100 extend along the surface direction D1.
  • the module protrusions are shown in FIG. 37.
  • the multiple devices may be aligned for ease of access by a user.
  • the charging adapter 1102 may be configured to couple with any implementation of the powered surgical tool described herein.
  • the charging adapter may be configured to couple with any implementation of the powered surgical tool described herein.
  • the charging adapter may be configured to couple with any implementation of the powered surgical tool described herein.
  • FIG. 36 is coupled with a powered surgical tool of a pencil grip type, powered surgical tool 20, as well as a powered surgical tool of a pistol grip type, powered surgical tool 220.
  • the charging adapter 1102 is configured to couple with the module housing 22 of the battery and control module 21 and with the module housing 222 of the battery and control module
  • the module housing 22, 222 of the corresponding battery and control module 21, 221 couples with the charging module 1100 via the charging adapter 1102 and the corresponding rechargeable battery module 28, 228 receives charging power from the charging module 1100.
  • the charging module 1100 may be configured to couple with any other implementation of the powered surgical tool, such as powered surgical tool 420.
  • the charging adapter 1102 may include components that allow the charging adapter 1102 to couple with various implementations of the powered surgical tool. Referring to
  • the module protrusion 1110 may include a first portion 1112 shaped to be received by the module housing 22 of the powered surgical tool 20, and a second portion 1114 shaped to be received by the module housing 222 of the powered surgical tool 220.
  • the first portion 1112 is shown receiving the module housing 22 of the powered surgical tool 20 and the second portion 1114 is shown receiving the module housing 222 of the powered surgical tool
  • the recess 40 of the module housing 22 may include a first radius and the recess 240 of the module housing 222 (shown in FIG. 15) may include a second radius different than the first radius.
  • the first portion 1112 may include a cylindrical shape sized to be received by the recess 40 of the module housing 22 and the second portion 1114 may include a cylindrical shape sized to be received by the recess 240 of the module housing 222.
  • the charging adapter 1102 may also include components to ensure proper reception of the module protrusion 1110 by various implementations of the powered surgical tool.
  • the charging adapter 1102 may include an alignment feature 1116 configured to ensure that the module protrusion 1110 is properly received by the module housing 22, and an alignment feature 1116’ configured to ensure that the protrusion 1104 is properly received by the module housing 222.
  • the corresponding alignment feature 1116, 1116’ is configured to engage the module housing 22, 222 prior to pins 48, 248 of the battery and control module 21, 221 electrically connecting to the charging adapter 1102.
  • the alignment features 1116, 1116’ protect the pins 48 by ensuring that the pins 48 of the battery and control module 21 are received by the pin receptacles 1112 of the charging adapter 1102.
  • the alignment features 1116, 1116’ may be configured to ensure that the module housing 22, 222 is prevented from rotating after receiving the module protrusion 1110.
  • the charging adapter 1102 may include additional features configured to prevent a module housing 22, 222 from rotating after receiving the module protrusion 1110.
  • the charging adapter 1102 may also include a latch L1 configured to configured to engage an interface of the module housing 22 of the powered surgical tool 20 to ensure that the module protrusion 1110 is secured to the module housing 22 after the module housing 22 receives the module protrusion 1110.
  • the charging adapter 1102 may also include a latch L2 configured to engage an interface of the module housing 222 of the powered surgical tool 220 to ensure that the module protrusion 1110 is secured to the module housing 222 after the module housing 222 receives the module protrusion 1110.
  • the charging adapter 1102 may be configured to generate a magnetic field.
  • the charging adapter 1102 includes a magnet M disposed on the module protrusion 1110 configured to generate a magnetic field.
  • the magnet M is located proximate to the latch L1.
  • the magnet M may be disposed on any other suitable location of the charging adapter 1102 or charging module
  • the wake-up sensors 134 of the battery and control module 21 may be configured to sense the magnetic field generated by the magnet M in response to the module housing 22 receiving the module protrusion 1110; and the wake-up sensors 334 of the battery and control module 221 may be configured to sense the magnetic field generated by the magnet M in response to the module housing 222 receiving the module protrusion 1110.
  • the controller 31, 231 may be configured to transition from a sleep state to an active state based on the wake-up sensors
  • controller 31, 231 sensing the magnetic field generated by the magnet M, wherein the controller 31, 231 is configured to communicate with the charger when the controller is in the active state.
  • each charger protrusion 1108 of the charging adapter 1102 may include adapter contacts 1119.
  • the adapter contacts 1119 include an adapter ground contact 1120, an adapter communication contact 1122, and an adapter power contact 1124.
  • Each recess 1104 of the charging module 1100 may include a charger ground terminal 1126, a charger communication terminal 1128, and a charger power terminal 1130, as shown in FIG. 41. In instances where the charger protrusions 1108 are received by the recesses
  • the adapter ground contact 1120 contacts the charger ground terminal 1126
  • the adapter communication contact 1112 contacts the charger communication terminal 1128
  • the adapter power contact 1124 contacts the charger power terminal 1130.
  • each module protrusion 1110 of the charging adapter 1102 include adapter terminals 1121.
  • the adapter terminals 1121 include an adapter ground terminal 1132, a first adapter communication terminal 1134, a second adapter communication terminal 1136, and an adapter power terminal 1138.
  • the module protrusions include an adapter ground terminal 1132, a first adapter communication terminal 1134, a second adapter communication terminal 1136, and an adapter power terminal 1138.
  • the adapter terminals 1121 contact the pins 48, 48’ such that the charging adapter 1102 may facilitate communication between the charging module 1100 and the battery and control module 21 , 221 , and such that the charging module 1100 may provide charging power to the rechargeable battery of the battery and control module 21, 221.
  • the charging adapter 1102 may instead be configured to receive a component of the battery and control modules 21, 221.
  • the charging adapter 1102 may define a recess sized to removably receive the module housing 22, 222 of a battery and control module 21, 221.
  • the charging adapter 1102 and components of the charging adapter 1102 may include any suitable structure and any suitable dimensions. Refening to FIG. 37, the charging adapter 1102 includes two charger protrusions 1108 arranged along the direction of the first charger axis AX1 such that, when the charging adapter 1102 is received by the charging module
  • the charging adapter 1102 is received by two recesses 1104 of the charging module 1100 and occupies a single column of recesses 1104. Additionally, the charging adapter 1102 may include two module protrusions 1110 arranged along the direction of the second charger axis AX2.
  • Each module protrusion 1110 may include a width w a along the second charger axis AX2 such that a sum of the widths w a is less than a width w c of a recess 1104 along the second charger axis
  • the charging adapter 1102 is received by two recesses 1104 of the charging module 1100 and occupies a single column of recesses 1104, the charging module 1100 is able to provide charging power to two powered surgical tools coupled with the module protrusions 1110 of the charging adapter 1102. As such, the charging adapter 1102 preserves the ability of the charging module 1100 to provide charging power to a number of devices corresponding to a number of recesses 1104.
  • the charging adapter 1102 may include any suitable number of charger protrusions 1108 and module protrusions 1110.
  • the charging adapter may include any suitable number of charger protrusions 1108 and module protrusions 1110.
  • the charging adapter may include any suitable number of charger protrusions 1108 and module protrusions 1110.
  • first and second charger protrusion 1108(1), 1108(2) includes a first and second charger protrusion 1108(1), 1108(2) and a first and second module protrusion 1110(1), 1110(2).
  • the first and second charger protrusions 1108(1), 1108(2) are configured to be received by a first and second recess 1104(1), 1104(2) of the charging module
  • 1110(1), 1110(2) may be received by a module housing 22 of a battery and control module 21.
  • the module protrusions 1110 are shown being received by the module housings 22, 222 of the battery and control modules 21, 221.
  • charging adapters 1102 may be received by the charging module 1100.
  • the charging module 1100 of FIGS.36 and 37 include six recesses 1104 arranged in a two-by-three grid and each charging adapter 1102 includes two charger protrusions 1108 configured to be received by two recesses 1104 along the direction of the first charger axis AX1.
  • the charging module 1100 of FIGS. 36 and 37 is configured to receive three charging modules 1102(1), 1102(2), 1102(3). In other instances, the charging module
  • 1100 may include a different arrangement or different number of recesses 1104.
  • the module housing 22 of the battery and control module 21 may be configured to couple with a programming fixture 1200 shown in FIGS. 42 and 43.
  • a programming fixture 1200 shown in FIGS. 42 and 43 For example, the recess
  • a computing system coupled with the programming fixture 1200 may update, repair, or run diagnostics on the control module controller 31 of the battery and control module 21.
  • the programming fixture 1200 may be configured to couple with any implementation of the battery and control module 21.
  • the module housing 222 of the battery and control module 221 may also be configured to couple with the programming fixture
  • the programming fixture 1200 is configured to receive the programming fixture 1200 in the instance of FIGS. 42 and 43, in other instances, the programming fixture 1200 may be configured to receive a component of the battery and control module 21.
  • the programming fixture 1200 may define a recess sized to removably receive the module housing 22 of the battery and control module 21.
  • FIGS. 42 and 43 Various features of the programming fixture 1200 are shown in FIGS. 42 and 44.
  • the programming fixture 1200 includes an alignment feature 1202 configured to ensure that the programming fixture 1200 is properly received by the battery and control module 21, and an alignment feature 1202’ configured to ensure that the programming fixture 1200 is properly received by the battery and control module 221.
  • alignment features 1202, 1202’ may be configured to ensure that the battery and control modules 21, 221 are prevented from rotating after receiving the programming fixture 1200.
  • the alignment features 1202, 1202’ are configured to engage the module housings 22, 222 prior to pins 48 of the battery and control module 21 electrically connecting to the programming fixture
  • the alignment features 1202, 1202’ protect the pins 48 by ensuring that the pins 48 of the battery and control module 21 are received by the pin receptacles 1206 of the programming fixture 1200.
  • the programming fixture 1200 may be configured to generate a magnetic field.
  • the programming fixture 1200 includes a magnet
  • the magnet 1204 configured to generate a magnetic field.
  • the magnet 1204 may be located at any suitable location of the programming fixture 1200.
  • FIG. 44 illustrates a system 10 for identifying a device coupled with a powered surgical tool 20.
  • the powered surgical tool 20 includes a battery and control module 21.
  • the battery and control module 21 includes a module housing 22, which is configured to couple with a handpiece 24 (shown in FIG. 2), a charging module 1100 (shown in
  • the handpiece 100 includes a motor 122 including a first rotor magnet 123 and a second rotor magnet
  • the battery and control module 21 includes a control module controller 31 configured to determine whether the module housing 22 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 based on sensing a magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204.
  • FIG. 44 illustrates the system 10 as including the battery control module 21
  • the system 10 may include any implementation of the battery and control module described herein.
  • the system 10 may include the pencil grip configuration of the battery and control module 21 of FIGS. 1-13 and the pistol grip configuration of the battery and control modules 221, 421 of FIGS. 14-23 and 23-35.
  • the pencil grip configuration of the battery and control module 21 of FIGS. 1-13 and the pistol grip configuration of the battery and control modules 221, 421 of FIGS. 14-23 and 23-35 may be coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200.
  • the control module controller 31 may sense a magnetic field generated proximate the battery and control module 21.
  • 5-6 and 22 may be configured to sense a magnetic field generated by the rotor magnet pair 123,
  • the analog hall effect sensors 32 may also be configured to sense a magnetic field generated by the magnet M of the charging adapter 1102 (shown in FIG. 37) and the magnet 1204 (shown in FIGS. 42 and 43) of the programming fixture 1200.
  • the analog hall effect sensors 32 may also be configured to sense a magnetic field generated by the magnet M of the charging adapter 1102 (shown in FIG. 37) and the magnet 1204 (shown in FIGS. 42 and 43) of the programming fixture 1200.
  • the 32 may sense the magnetic field generated by the rotor magnet pair 123, 125 when the handpiece
  • the control module controller 31 may also include one or more digital hall effect sensors 134, shown in FIGS. 5-6 and 22, that are coupled to the control module controller
  • the digital hall effect sensors 134 may be coupled to the printed circuit board assembly 33 by being mounted to a surface of the rigid printed circuit board 87, as shown in FIG. 5.
  • the digital hall effect sensors 134 may be configured to sense a magnetic field generated by the rotor magnet pair 123, 125 of the motor 122.
  • the digital hall effect sensors 134 may also be configured to sense a magnetic field generated by the magnet M of the charging adapter 1102 (shown in FIG. 37) and the magnet 1204 (shown in FIGS. 42 and 43) of the programming fixture 1200.
  • the digital hall effect sensors 134 may sense the magnetic field generated by the rotor magnet pair 123, 125 when the handpiece 24 is coupled with the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is coupled with the module housing 22, or magnetic field generated by the programming fixture magnet 1204 when the programming fixture 1200 is coupled with the module housing 22.
  • control module controller 31 is configured to determine whether the module housing 22 has coupled with the handpiece 24, the charging module
  • the programming fixture 1200 based on the digital hall effect sensors 134 sensing a magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204.
  • the digital hall effect sensors 134 sensing a magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204.
  • control module controller 31 is configured to operate in a sleep state and transition from the sleep state to an active state.
  • the main controller 31 may be similarly configured to determine whether the module housing 222 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 based on the digital hall effect sensors 334 sensing a magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204. Descriptions herein of the main controller 31 should be understood to apply to the main controller 231.
  • the digital hall effect sensors 134 are active and the analog hall effect sensors 32 are inactive.
  • the digital hall effect sensors 134 are configured to sense a magnetic field, such as the magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204, while the analog hall effect sensors 32 are unable to sense a magnetic field.
  • the digital hall effect sensors 134 are configured to receive power from the rechargeable battery module 28, while the analog hall effect sensors 32 do not receive power from the rechargeable battery module 28.
  • the control module controller 31 transitions to an active state.
  • the digital hall effect sensors 134 may sense the magnetic field generated by the rotor magnet pair 123, 125 when the handpiece 24 is coupled with the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is coupled with the module housing
  • the control module controller 31 transitions to the active state.
  • the analog hall effect sensors 32 are configured to sense a magnetic field and receive power from the rechargeable battery module 28.
  • the digital hall effect sensors 134 are inactive during the active state and do not receive power from the rechargeable battery module 28. In alternative instances, the digital hall effect sensors 134 are also active during the active state and receive power from the rechargeable battery module 28.
  • the digital hall effect sensors 134 function as wake-up sensors.
  • the analog hall effect sensors 32 receive a greater amount of power from the rechargeable battery module 28 in the active state than the digital hall effect sensors 134 receive in the sleep state.
  • power provided to the sensors 134, 32 is conserved as the analog hall effect sensors 32 are inactive during the sleep state and do not receive power.
  • the control module controller 31 is able to detect whether the handpiece 24, the charging module 1100, or the programming fixture 1200 is coupled with the battery and control module 21 while minimizing power provided by the rechargeable battery module 28.
  • the digital hall effect sensors 134 are ideal for detecting magnetic fields during the sleep state as they have a lower current draw (less than 5 uA each) than the analog hall effect sensors (greater than 5 mA each). Additionally, the analog hall effect sensors are ideal for the motor control function as they possess a higher acquisition rate than the digital hall effect sensors.
  • the control module controller 31 may then be configured to determine whether the module housing 22 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 based on sensing a magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet
  • the control module controller 31 may determine whether the module housing 22 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 based on sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3), where the sensed readings SR1,
  • SR2, SR3 correspond to a magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3).
  • FIG. 46 illustrates example sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) while the control module controller 31 is in the sleep state. As shown, the first, second, and third analog hall effect sensor
  • 32(1), 32(2), 32(3) merely provide an offset voltage of the body and control module 21, as none of the handpiece 24, the charging module 1100, or the programming fixture 1200 are coupled with the module housing 22 and the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) do not sense a magnetic field generated by the handpiece 24, the charging module 1100, or the programming fixture 1200.
  • FIG. 47 illustrates example sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) while the control module controller 31 is in the active state, and while the handpiece 24 is coupled with the module housing
  • FIG. 48 illustrates an ideal representation of the example sensed readings SR1, SR2, SR3.
  • the sensed readings SR1, SR2, SR3 are sinusoidal and have a phase difference of 120 degrees, corresponding to a location of the rotor magnet pairs on the motor 122. Accordingly, a magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) varies in a sinusoidal manner when the handpiece 24 is coupled with the module housing 22.
  • FIG. 49 illustrates example sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) while the control module controller 31 is in the active state, and while the charging module 1100 is coupled with the module housing 22.
  • the magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) is a relatively constant value when the charging module 1100 is coupled with the module housing 22.
  • FIG. 50 illustrates example sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) while the control module controller 31 is in the active state, and while the programming fixture 1200 is coupled with the module housing 22.
  • the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) while the control module controller 31 is in the active state, and while the programming fixture 1200 is coupled with the module housing 22.
  • 32(1), 32(2), 32(3) sense the magnet 1204 of the programming fixture 1200. However, as the programming fixture 1200 does not rotate while coupled with the module housing 22, the magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor
  • the control module controller 31 may determine whether the module housing
  • the control module controller 31 may determine that the handpiece 24 is coupled with the module housing 22. In instances where a magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) is relatively constant, the control module controller 31 may determine that either the charging module 1100 or the programming fixture 1200 is coupled with the module housing 22.
  • the control module controller 31 may use a variety of methods to determine whether the charging module 1100 or the programming fixture 1200 is coupled with the module housing 22. For example, the control module controller 31 may determine that the charging module 1100 or the programming fixture 1200 is coupled with the module housing 22 by comparing the constant values of the sensed readings SR1, SR2, SR3. In instances where the first sensed reading SR1 is greater than the third sensed reading SR3, such as in the instance of FIG. 49, the control module controller 31 may determine that the charging module 1100 is coupled with the module housing 22. In instances where the first sensed reading SR1 is less than the third sensed reading SR3, such as in the instance of FIG. 50, the control module controller 31 may determine that the programming fixture 1200 is coupled with the module housing 22.
  • a position of the magnets 310, 404 may be selected to allow the control module controller 31 to determine whether the charging module 1100 or the programming fixture 1200 is coupled with the module housing 22.
  • a position of the magnet 1204 of the programming fixture 1200 and a position of the magnet M of the charging module 1100 may be selected such that the magnitude of the magnetic field generated by the magnet 1204 and sensed by the analog hall effect sensors 32 is different than the magnitude of the magnetic field generated by the magnet M and sensed by the analog hall effect sensors 32.
  • the magnet 1204 may be placed in a location about the programming fixture 1200 and the magnet M may be placed in a location about the protrusion 1104 such that the magnet 1204 aligns with the first analog hall effect sensor 32(1) when the programming fixture 1200 is coupled with the module housing 22 and the magnet M aligns with the third analog hall effect sensor 32(3) when the charging module
  • a polarity of the magnets M, 1204 may be selected to allow the control module controller 31 to determine whether the charging module 1100 or the programming fixture 1200 is coupled with the module housing 22.
  • a polarity of the magnet 1204 of the programming fixture 1200 and a polarity of the magnet M of the charging module 1100 may be selected such that the magnitude of the magnetic field generated by the magnet 1204 and sensed by the analog hall effect sensors 32 is different than the magnitude of the magnetic field generated by the magnet M and sensed by the analog hall effect sensors 32.
  • the 310 may be polarized such that the first analog hall effect sensor 32(1) senses a magnetic field of a positive polarity when the programming fixture 1200 is coupled with the module housing 22 and the first analog hall effect sensor 32(1) senses a magnetic field of a negative polarity when the charging module 1100 is coupled with the module housing 22.
  • the control module controller 31 may determine whether the module housing
  • the charging module 22 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 in order to properly communicate with the handpiece 24, the charging module 1100, or the programming fixture 1200.
  • the charging module 1100 or the programming fixture 1200.
  • the charging module 1100 or the programming fixture 1200.
  • the programming fixture 1200 may be configured to communicate with the control module controller 31 using a different communication protocol, and communication may be initiated using a different method.
  • control module controller 31 may be configured to communicate with the handpiece 24, the charging module 1100, or the programming fixture 1200 using different communication protocols.
  • control module controller 31 may be configured to communicate with the handpiece 24 using a first communication protocol in response to determining that the module housing 22 has been coupled with the handpiece 24, and the control module controller 31 may be configured to communicate with the charging module
  • the control module controller 31 may be configured to communicate using the first and second communication protocol by communicating at different transmission speed.
  • the control module controller 31 may be configured to communicate using the first communication protocol by communicating at a first transmission speed
  • the control module controller 31 may be configured to communicate using the second communication protocol by communicating at a second transmission speed.
  • the control module controller 31 may be configured to communicate at different Baud rates.
  • the control module controller 31 may be configured to communicate using the first communication protocol by communicating at 460kBaud, while being configured to communicate using the second communication protocol by communicating at 19.2kBaud. It should be noted that the control module controller 31 may be configured to communicate with the handpiece 24, the charging module 1100, and the programming fixture 1200 using any suitable Baud rate.
  • the control module controller 31 may be configured to communicate using the first and second communication protocol by communicating using different transmission modes.
  • control module controller 31 may be configured to communicate using the first communication protocol by communicating using full duplex transmission, and the control module controller 31 may be configured to communicate using the second communication protocol by communicating using half duplex transmission. It should be noted that the control module controller 31 may be configured to communicate with the handpiece 24, the charging module 1100, and the programming fixture 1200 using any suitable transmission mode, such as full duplex transmission, half duplex transmission, and/or simplex transmission.
  • the charging adapter 1102 may be configured to translate the communication protocol used by the charging module 1100 into the communication protocol used by the control module controller 31 such that the control module controller 31 may be configured to communicate with the charging module 1100 via the adapter 1102.
  • the charging adapter 1102 may be configured to translate the communication protocol used by the control module controller 31 into the communication protocol used by the charging device 1100 such that the control module controller 31 may be configured to communicate with the charging module 1100 via the adapter 1102.
  • the first and second adapter communication terminals 1134, 1136 are shorted to one another within the charging adapter 1102 to allow translation of the communication protocol used by the charging module 1100 and/or the communication protocol used by the control module controller 31.
  • the charging adapter 1102 may be configured to translate the second communication protocol into the first communication protocol by translating a half duplex transmission into a full duplex transmission.
  • control module controller 31 communication between the control module controller 31 and the handpiece 24, charging module 1100, or programming fixture 1200 coupled with the module housing 22 may be initiated by either the control module controller 31 or by the handpiece
  • control module controller 31 may be configured to initiate communication between the control module controller 31 and the charging module 1100 and the programming fixture 1200 may be configured to initiate communication between the control module controller
  • control module controller 31 may initiate communication by transmitting a communication signal to the charging module 1100 based on determining that the module housing 22 has been coupled with the charging module 1100, and the control module controller 31 may be configured to receive a communication signal from the programming fixture 1200 based on determining that the module housing 22 has been coupled with the programming fixture 1200.
  • the control module controller 31 may return to the sleep mode. For example, the analog hall effect sensors 32 may no longer detect the magnetic field generated by the handpiece
  • charging module 1100 or programming fixture 1200 when the handpiece 24, charging module
  • control module controller 31 may return to the sleep mode once the digital hall effect sensors 134 no longer detect the magnetic field generated by the handpiece 24, charging module 1100, or programming fixture 1200.
  • Powered surgical tools may include a motor or a motor body configured for receiving power, for example, including electrical power or pressurized air, and transforming that power into an output torque which is transmitted through an output shaft.
  • the powered surgical tool may further include a cannula or may be cannulated.
  • the output shaft of the motor may include a lumen or include a hollow center, for example extending through a center line of the output shaft.
  • the lumen may include a first opening on one end of the output shaft and may include a second opening on the second end of the output shaft.
  • the cannula may include a tube at least partially contained within the lumen extending down the center line of the output shaft.
  • the cannula may be open at both ends, for example, to permit passage of a device through the cannula.
  • a distal portion or direction of a device or component refers to a direction towards the patient.
  • the motor may include electronic components, such as electric magnets in the rotor and the stator, wires electrically connecting portions of the motor to other portions of the motor or to terminals extending out of the motor,
  • a powered surgical tool including a motor including a cannula disposed therewithin, wherein the powered surgical tool further includes a housing, a sealing plug, and a shaft seal, wherein the sealing plug and the shaft seal are configured to prevent liquids utilized in an autoclave process from entering an interior of the powered surgical tool while enabling the cannula to allow passage of surgical devices, such as k-wires or pins through the cannula.
  • an attachment to a powered surgical tool may be described as a surgical handpiece or a handpiece.
  • a pistol grip (or a wand or a tool handle) may include a battery and a control module and may be described as a battery and control module (BMC) as described throughout this disclosure.
  • BMC battery and control module
  • FIG. 51 shows an exemplary battery and control module 1300 configured as a pistol grip in a front perspective view.
  • the battery and control module 1300 includes a module lumen 1301 or hollow cavity portion configured to receive a surgical handpiece or attachment.
  • the module lumen 1301 may be described as a module lumen.
  • FIG. 52 shows the battery and control module 1300 of FIG. 51 in a rear perspective view.
  • the battery and control module 1300 includes a cannula access point 1302 configured to enable external access to a cannula disposed within the surgical handpiece which may be loaded into the module lumen 1301 of FIG. 51.
  • FIG. 53 shows a surgical handpiece 1310 configured to be disposed within the module lumen 1301 of the battery and control module 1300 of FIG. 51.
  • the surgical handpiece 1310 includes a housing 1320 configured to contain and physically protect components contained therewithin and features 1312 for making physical connections to the battery and control module
  • a powered surgical tool may be described as including the battery and control module 1300 including the module lumen 1301 of FIG. 51 with the surgical handpiece 10 of FIG. 53 inserted within the module lumen 1301.
  • FIG. 54 shows in cross-section the surgical handpiece 1310 of FIG. 53.
  • the surgical handpiece 1310 is illustrated including the housing 1320, an internal structure insert 1322, a circuit board 1350, a motor 1330, a cannula 1340, and terminals 1352, 1353 projected into the surgical handpiece 1310.
  • the internal structure insert 1322 may be metallic, plastic, or some other similar material and holds a number of illustrated components in place relative to the housing
  • the internal structure insert 1322 may be considered a part of the housing 1320.
  • the internal structure insert 1322 may be configured to provide distinct locations and act as a locating fixture for the circuit board 1350, the cannula 1340, the output shaft 1332 and other portions of the illustrated surgical handpiece 1310.
  • the internal structure insert 1322 includes an inner diameter at a first proximal end of the surgical handpiece 1310.
  • the terminals 1352, 1353 electronically connect the circuit board 1350 to outside electronic components, such as a connector within the battery and control module 1300 of FIG. 51. Electrical power may be supplied to the circuit board 1350 and the motor 1330 through the terminals 1352, 1353.
  • the motor 1330 includes an output shaft 1332 which is mechanically connected to a motor rotor structure 1336 and is configured to provide an output torque from the motor 1330.
  • the motor further includes connector board 1338 including exemplary layers of copper configured to provide electrical connections to portions of the motor 1330.
  • the output shaft 1332 is hollow and includes a lumen 1334 into which the cannula 1340 is disposed.
  • the cannula includes a cannula lumen 1344 at a first proximal end and a second end 1342 which may extend outwardly from a front or a distal end of the surgical handpiece 1310.
  • the cannula 1340 further includes a cannula flange 1346 which aids in positioning the cannula 1340 and interacting with sealing components of the surgical handpiece, sealing plug 1360 and seal 1370.
  • the sealing plug 1360 and the seal 1370 are configured to prevent liquid from entering the interior of the surgical handpiece 1310.
  • the sealing plug 1360 may be constructed with plastic or a rigid polymer.
  • the sealing plug 1360 may be press fit within the inner diameter of the internal structure insert 1322, with friction and compression between a sidewall 1362 of the sealing plug 1360 retaining the sealing plug 1360 within the surgical handpiece 1310.
  • the sealing plug 1360 may include terminal pass-through points 1364 configured to enable terminals 1352, 1353 to enter the internal portion of the surgical handpiece
  • the cannula 1340 passes through the sealing plug 1360.
  • the seal 1370 is provided to enable the cannula 1340 to seal against the sealing plug 1360.
  • the seal 1370 is illustrated including a cylinder shape exterior and including a hollow center or a seal lumen configured to receive the cannula 1340 in the hollow center.
  • the cylinder shape of the rubberized seal 1370 may include a same longitudinal axis as the cannula 1340.
  • a first sealing surface 1372 is provided upon an end surface of the cylinder shape of the seal 1370, resulting in a seal between the seal 1370 against an opposite face or mating surface of the sealing plug 1360.
  • a second sealing surface 1374 is provided as an annular ring-shaped surface upon an inner diameter of the seal 1370 configured to seal to an outer radial surface of the cannula 1340.
  • the seal 1370 may be disposed in contact with the cannula flange 1346.
  • a tool coupler may be attached to the output shaft 1332.
  • a socket stopper 1380 is disposed around an outside of the internal structure insert 1322 and the sealing plug 1360.
  • the socket stopper 1380 may be configured to retain the sealing plug 1360 within the inner diameter of the internal structure insert 1322 if the press-fitting between the sealing plug 1360 and the internal structure insert 1322 does not hold or loosens.
  • FIG. 55 shows an implementation of a powered surgical tool 1400 in which a device housing 1420 of a battery and control module 1410 is designed to provide improved ergonomics and usability.
  • the powered surgical tool 1400 additionally includes a handpiece configured to be removably coupled with the battery and control module 1410 within a handpiece lumen 1430.
  • the battery and control module 1410 may include a battery 1415 contained therewithin and may further contain a circuit board configured for providing functionality of the powered surgical tool 1400, such as selectively supplying power from the battery 1415 to a handpiece or unit installed to the handpiece lumen 1430.
  • the battery 1415 may include one battery cell or a plurality of battery cells.
  • the handpiece may include a modular motor and a drivetrain
  • the handpiece may include the modular motor and may be configured to provide energy to a surgical end effector, such as a burr, a saw, a drill, or other similar device.
  • a surgical end effector such as a burr, a saw, a drill, or other similar device.
  • the handpiece may take a form disclosed in commonly-owned International Publication No. WO 2013/177423, published November 28, 2013, the entire contents of which have previously been incorporated by reference herein.
  • the cutting accessory assembly may be unique to complementary versions of the motor and the drivetrain so as to provide a set of handpieces configured to be selectively and interchangeably coupled with the battery and control module 1410. Any device or accessory which is applied to the surgical site, whether it be a sagittal saw blade or drill bit, may generally be referred to as an energy applicator throughout. In other implementations, the powered surgical tool
  • the powered surgical tool 1400 may be particularly well suited for orthopedic procedures involving the arm, hand, leg, foot, mandible, and skull, but other small bone orthopedic and soft tissue procedures are contemplated.
  • the battery and control module 1410 includes at least one battery and a main controller that is coupled to a printed circuit board assembly as will be discussed in greater detail below.
  • the main controller is in communication with the battery, which may be part of a battery assembly, a motor control sensor, and a handswitch sensor, and further configured to be arranged in communication with the motor when the handpiece is removably coupled with the battery and control module 1410.
  • the main controller may also be in communication with a memory device.
  • the battery and control module 1410 may include a handswitch assembly optionally coupled to the device housing 1420 and configured to receive an input from a user to operate the powered surgical tool 1400.
  • the handswitch assembly may be spring-loaded and include a handswitch magnet such that, when the handswitch assembly is actuated, the handswitch magnet is moved towards a handswitch sensor. While the example is provided that the handswitch assembly is coupled to the battery and control module 1410, the handswitch assembly may be detachable and attached to any portion of the battery and control module 1410 and/or handpiece.
  • the handswitch assembly may be part of or attached to the handpiece.
  • the battery and control module 1410 includes a barrel 1440 and a handle 1450.
  • the handle 1450 extends downwardly from the barrel 1440.
  • the battery and control module
  • the 1410 may have two triggers 1460, 1470 or switches that are spring-loaded and installed externally upon or to the battery and control module 1410. Both triggers 1460, 1470 extend forward from the distally directed portion of the handle 1450. The practitioner may actuate the triggers 1460, 1470 to control the operation of the tool unit.
  • the triggers 1460, 1470 may each include a magnet which gets moved when the triggers 1460, 1470 are actuated by the user as discussed in greater detail below.
  • the battery and control module 1410 may include a pressure relief valve and a cap.
  • FIG. 56 illustrates in side perspective view internal components of the battery and control module 1410 including a pair of trigger sensors 1520, 1530 corresponding to the triggers 1460, 1470 of FIG. 55.
  • the trigger sensors 1520, 1530 may be configured to monitor or detect presence of or proximity to a magnetic field created by a permanent magnet, which may be detected through a housing wall.
  • a mid housing 1500 of the device housing 1420 of FIG. 55 is illustrated.
  • the trigger sensors 1520, 1530 may be disposed on or included in a printed circuit board 1510.
  • the trigger sensors 1520, 1530 may be Hall-effect sensors.
  • the printed circuit board 1510 is disposed inside the handle 1450.
  • the printed circuit board 1510 is disposed in close proximity to the triggers 1460, 1470 so that the plurality of trigger sensors 1520, 1530 may sense a state of the triggers 1460, 1470, such as when the triggers 1460, 1470 have been actuated by the user.
  • a plurality of motor control sensors may be coupled to another or a second printed circuit board coupled with the battery and control module 1410.
  • the motor control sensors may be Hall-effect.
  • a switching module including a plurality of metal-oxide semiconductor field- effect transistors (MOSFETs) may also be coupled to the second printed circuit board.
  • MOSFETs metal-oxide semiconductor field- effect transistors
  • the switching module may be used in controlling the direction of operation of the motor of the handpiece, for example, in a forward direction or in a reverse direction.
  • FIG. 57 illustrates in rear perspective view a front housing 1600 configured to be assembled, welded, laser-process attached, or otherwise affixed to a handle portion of the mid housing 1500 of FIG. 56.
  • the front housing 1600 is illustrated including structures 1620, 1630 configured for containing portions of the triggers 1460, 1470 of FIG. 55 and springs and other hardware configured for aligning and enabling actuation of the triggers 1460, 1470. Additionally, a pocket 1640 or cutout region is illustrated configured for containing the trigger sensors 1520,
  • the pocket 1640 may include space in which the trigger sensors 1520, 1530 may be disposed, while a wall of the front housing 1600 is disposed between the trigger sensors 1520,
  • the battery and control module 1410 may be sealed to prevent liquids from entering the interior of the battery and control module 1410 while enabling signal interaction between the triggers 1460, 1470 and the corresponding trigger sensors 1520,
  • the front housing 1600 may be intact without any through-holes in the area of the structures 1620, 1630 and the pocket 1640. Magnetic interaction between the triggers 1460, 1470, and the corresponding trigger sensors 1520, 1530 enables recognition or signal generation corresponding to depression of the triggers 1460, 1470 while maintaining a sealed housing between the triggers
  • FIG. 58 illustrates in side perspective view a sealed housing assembly 1610 including the front housing 1600 welded, laser-process attached, adhered, fastened, or otherwise attached to the mid housing 1500 in a sealing manner.
  • the sealed housing assembly 1610 may include a plurality of housings sealingly joined together and configured to encase components therewith. Wherein housings of the disclosed battery and control module 1410 may be constructed with polymers, welding may refer to a joining process such as a vibration welding process wherein contacting surfaces of the housings are heated locally and joined.
  • the sealed housing assembly may include a plurality of housings sealingly joined together and configured to encase components therewith. Wherein housings of the disclosed battery and control module 1410 may be constructed with polymers, welding may refer to a joining process such as a vibration welding process wherein contacting surfaces of the housings are heated locally and joined.
  • FIG. 59 illustrates in side perspective view the sealed housing assembly 1610 of FIG. 58 with the triggers 1460, 1470 installed thereto.
  • the trigger 1460 is illustrated in an at least partially not-depressed state and the trigger 1470 is illustrated in an at least partially depressed state.
  • FIG. 60 illustrates the sealed housing assembly 1610 and the triggers 1460
  • Trigger hardware components 1700 are illustrated including springs, a trigger lock translating plate, and alignment hardware configured for enabling assembly and selective actuation of the triggers 1460, 1470.
  • 1700 may include a front plate 1710 and a screw 1720 configured for installation and removal, permitting one to easily install and later replace the triggers 1460, 1470.
  • the triggers 1460, 1470 may be retained in place by the front plate 1710 and the screw 1720.
  • Each of the triggers 1460, 1470 may be retained in place by the front plate 1710 and the screw 1720.
  • the sealed housing assembly 1610 is illustrated including a pair of trigger lumens 1612, 1614 configured respectively for receiving the stem portions 1462, 1472.
  • the stem portions 1462, 1472 may be described as being configured to be engaged with the trigger lumens 1612, 1614.
  • FIG. 61 illustrates in side cross-sectional view a portion of the sealed housing assembly 1610 and the triggers 1460, 1470.
  • the circuit board 1510 is additionally illustrated.
  • the triggers may each include magnets 1730, 1732 useful for providing control signals to the trigger sensors 1520, 1530 of FIG. 56.
  • FIG. 62 illustrates in front cross-sectional view a portion of the sealed housing assembly 1610 and the trigger 1470.
  • the trigger 1470 is illustrated including magnet 1730.
  • the corresponding trigger sensor 1530 of FIG. 56 is additionally illustrated.
  • a screw boss feature 1618 is illustrated configured for receiving the screw 1720 of FIG. 60.
  • the triggers 1460, 1470 may be selectively depressed for actuation of the surgical tool 1400 of FIG. 55.
  • the triggers 1460, 1470 of FIG. 60 may include stem portions 1462,
  • triggers 1460, 1470 configured to be installed to corresponding trigger lumens 1612, 1614.
  • air trapped between the triggers 1460, 1470 and the walls of the trigger lumens 1612, 1614 may inhibit free movement of the triggers 1460, 1470 relative to the sealed housing assembly 1610.
  • FIG. 63 illustrates in front perspective view a portion of the sealed housing assembly 1610 including a plurality of trigger vent cutouts 1660, 1670.
  • Each of the trigger vent cutouts 1660, 1670 may include a channel formed in a wall of the sealed housing assembly 1610 configured to release air from behind each of the triggers 1460, 1470 of FIG. 60 as each are installed or depressed.
  • the trigger vent cutouts 1660, 1670 enable air to be released from behind each of the triggers 1460, 1470 while maintaining the sealed housing assembly 1610 as a sealed unit.
  • FIG. 64 illustrates in front cross-sectional view a portion of the sealed housing assembly 1610 including the stem portions 1462, 1472 and the respective trigger vent cutouts
  • the stem portions 1462, 1472 may fit tightly with the surfaces of the respective trigger lumens 1612, 1614, while the trigger vent cutouts 260A, 260B provide paths for air to flow from behind the triggers 1460, 1470 of FIG. 60.
  • FIG. 65 is a flowchart illustrating a method 1800 for operating a powered surgical tool. The method 1800 is provided utilizing the battery and control module 1410 of FIG.
  • the method 1800 starts at step 1802.
  • the method 1800 includes providing a battery and control module 1410 including a sealed housing assembly 1610.
  • the sealed housing assembly
  • the method 1800 continues, including installing at least one trigger 1460 into the trigger lumen 1612, the trigger 1460 including a stem portion 1462 with at least one magnet 1530 configured to interact with the trigger sensor 1520 without compromising the seal of the sealed housing assembly 1610.
  • the method 1800 ends.
  • a number of additional and/or alternative method steps are envisioned, and the method 1800 is not intended to be limited to the examples provided herein.
  • FIG. 66 is a flowchart illustrating a method 1900 for repairing a powered surgical tool. The method 1900 is provided utilizing the battery and control module 1410 of FIG.
  • the method 1900 starts at step 1902.
  • the method 1900 includes providing a battery and control module 1410 including a sealed housing assembly 1610.
  • the sealed housing assembly
  • the 1610 encapsulates a printed circuit board 1510 that includes at least one trigger sensor 1520.
  • the battery and control module 1410 includes at least one trigger 1460 including a magnet 1530.
  • the method 1900 continues, including removing the trigger 1460 from the battery and control module 1410 without compromising the seal of the sealed housing assembly 1610.
  • the method 1900 ends.
  • a number of additional and/or alternative method steps are envisioned, and the method 1900 is not intended to be limited to the examples provided herein.
  • first and second elements are described in the above disclosure, that relationship can be a direct relationship where no other intervening elements are present between the first and second elements, but can also be an indirect relationship where one or more intervening elements are present (either spatially or functionally) between the first and second elements.
  • the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
  • the term subset does not necessarily require a proper subset. In other words, a first subset of a first set may be coextensive with (equal to) the first set.
  • the direction of an arrow generally demonstrates the flow of information (such as data or instructions) that is of interest to the illustration.
  • information such as data or instructions
  • the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is transmitted from element B to element A.
  • element B may send requests for, or receipt acknowledgements of, the information to element A.
  • controller In this application, including the definitions below, the term “controller” or
  • module may be replaced with the term “circuit.”
  • controller may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a programmable system on a chip
  • PSoC a digital, analog, or mixed analog/digital discrete circuit
  • a digital, analog, or mixed analog/digital integrated circuit a combinational logic circuit
  • a field programmable gate array a digital, analog, or mixed analog/digital discrete circuit
  • a digital, analog, or mixed analog/digital integrated circuit a digital, analog, or mixed analog/digital integrated circuit
  • a combinational logic circuit a field programmable gate array
  • FPGA field-programmable gate array
  • the controller may include one or more interface circuits with one or more transceivers.
  • the interface circuit(s) may implement wired or wireless interfaces that connect to a local area network (LAN) or a wireless personal area network (WPAN).
  • LAN local area network
  • WPAN wireless personal area network
  • IEEE Institute of Electrical and Electronics Engineers
  • 802.11-2016 also known as the WIFI wireless networking standard
  • IEEE Standard 802.3-2015 also known as the ETHERNET wired networking standard
  • Examples of a WPAN arc the BLUETOOTH wireless networking standard from the Bluetooth Special Interest Group and IEEE Standard
  • the controller may communicate with other controllers using the interface circuit(s). Although the controller may be depicted in the present disclosure as logically communicating directly with other controllers, in various implementations the controller may actually communicate via a communications system.
  • the communications system may include physical and/or virtual networking equipment such as hubs, switches, routers, gateways and transceivers.
  • the communications system connects to or traverses a wide area network (WAN) such as the Internet.
  • WAN wide area network
  • the communications system may include multiple LANs connected to each other over the Internet or point-to-point leased lines using technologies including Multiprotocol Label Switching (MPLS) and virtual private networks
  • MPLS Multiprotocol Label Switching
  • the functionality of the controller may be distributed among multiple controllers that are connected via the communications system.
  • multiple controllers may implement the same functionality distributed by a load balancing system.
  • the functionality of the controller may be split between a server (also known as remote, or cloud) controller and a client (or user) controller.
  • Some or all hardware features of a controller may be defined using a language for hardware description, such as IEEE Standard 1364-2005 (commonly called “Verilog”) and
  • IEEE Standard 1076-2008 (commonly called “VHDL”).
  • the hardware description language may be used to manufacture and/or program a hardware circuit.
  • some or all features of a controller may be defined by a language, such as IEEE 1666-2005 (commonly called
  • code may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, data structures, and/or objects.
  • the term shared processor circuit encompasses a single processor circuit that executes some or all code from multiple controllers.
  • the term group processor circuit encompasses a processor circuit that, in combination with additional processor circuits, executes some or all code from one or more controllers. References to multiple processor circuits encompass multiple processor circuits on discrete dies, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above.
  • the term shared memory circuit encompasses a single memory circuit that stores some or all code from multiple controllers.
  • the term group memory circuit encompasses a memory circuit that, in combination with additional memories, stores some or all code from one or more controllers.
  • memory circuit is a subset of the term computer-readable medium.
  • Non-limiting examples of a non-transitory computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only memory circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray
  • the apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general purpose computer to execute one or more particular functions embodied in computer programs.
  • the functional blocks and flowchart elements described above may serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer.
  • the computer programs include processor-executable instructions that are stored on at least one non-transitory computer-readable medium.
  • the computer programs may also include or rely on stored data.
  • the computer programs may encompass a basic input/output system
  • BIOS that interacts with hardware of the special purpose computer
  • device drivers that interact with particular devices of the special purpose computer
  • one or more operating systems one or more operating systems, user applications, background services, background applications, etc.
  • the computer programs may include: (i) descriptive text to be parsed, such as
  • HTML hypertext markup language
  • XML extensible markup language
  • JSON JavaScript
  • source code for execution by an interpreter
  • source code for compilation and execution by a just-in-time compiler
  • source code may be written using syntax from languages including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran,
  • ASP Active Server Pages
  • PHP PHP
  • Scala Eiffel, Smalltalk, Erlang

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  • Health & Medical Sciences (AREA)
  • Surgery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Biomedical Technology (AREA)
  • Medical Informatics (AREA)
  • Orthopedic Medicine & Surgery (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Engineering & Computer Science (AREA)
  • Dentistry (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Nuclear Medicine, Radiotherapy & Molecular Imaging (AREA)
  • Molecular Biology (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Surgical Instruments (AREA)
EP24710328.6A 2023-02-15 2024-02-15 Chirurgisches system mit einer batterie und steuermodul Pending EP4665248A2 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202363445896P 2023-02-15 2023-02-15
PCT/US2024/015957 WO2024173660A2 (en) 2023-02-15 2024-02-15 Surgical system including a battery and control module

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EP4665248A2 true EP4665248A2 (de) 2025-12-24

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JP (1) JP2026507595A (de)
CN (1) CN120936306A (de)
AU (1) AU2024221906A1 (de)
WO (1) WO2024173660A2 (de)

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EP4740832A1 (de) * 2024-11-06 2026-05-13 Olympus Surgical Technologies Europe Elektronikmodul zur integration in einen handgriff eines medizinischen instruments, handgriff und medizinisches instrument

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JP6047498B2 (ja) * 2010-12-21 2016-12-21 ストライカー・コーポレイション 内部構成部品を殺菌の影響から保護するための能動シールを有する密封ハウジング内に収容された制御モジュールを有する電動外科工具
CA2873788C (en) * 2012-05-23 2022-03-29 Krishnamurthy Belagali Powered surgical tool assembly including a tool unit and a separate battery and control module that energizes and controls the tool unit
WO2016081604A2 (en) 2014-11-19 2016-05-26 Stryker Corporation Surgical wire driver capable of automatically adjusting for the diameter of the wire or pin being driven
US10159483B2 (en) * 2015-02-27 2018-12-25 Ethicon Llc Surgical apparatus configured to track an end-of-life parameter
US12207975B2 (en) * 2016-01-04 2025-01-28 Peleton Surgical, Llc Portable device and method of supplying power to a portable device

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JP2026507595A (ja) 2026-03-04
AU2024221906A1 (en) 2025-08-28
WO2024173660A2 (en) 2024-08-22
CN120936306A (zh) 2025-11-11

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