Contaminant-resistant motors for surgical instruments

1. A contaminant-resistant motor for surgical applications comprising:

a housing including a housing wall defining a housing interior;

a front endbell;

a rear endbell, having a first side facing the housing interior and a second side, opposite the first side, defining a control module cavity;

a stator;

a rotor;

a control module within the control module cavity of the rear end bell, wherein the control module is hermetically sealed within the control module cavity and isolated from the housing interior.

2. The motor of claim 1 , further comprising at least one stator lead extending through a stator lead passage in the rear endbell from the control module in the control module cavity on the second side of the rear endbell to the first side of the rear endbell, the at least one stator lead being sealed against contaminants at least partially by encapsulation within the control module cavity.

3. The motor of claim 2 , wherein the at least one stator lead includes a stator lead having an exterior section that extends outside of the control module cavity through the rear endbell to the first side of the rear endbell and wherein the stator lead exterior section extends through a seal disposed in the rear endbell between the first and second sides of the rear endbell for sealing the stator lead exterior section from contaminants.

4. The motor of claim 3 , wherein the seal is a glass seal.

5. The motor of claim 1 , wherein the control module is hermetically sealed by a first encapsulation in the control module cavity.

6. The motor of claim 5 , further comprising at least one sensor in electrical communication with the control module, the at least one sensor being hermetically sealed by the first encapsulation in the control module cavity with the control module.

7. The motor of claim 5 , wherein the stator is encapsulated to an interior surface of the housing cavity by a second encapsulation that is separate from the first encapsulation.

8. The motor of claim 7 , further comprising a stator lead extending through a stator lead passage in the rear endbell from the control module in the control module cavity on the second side of the rear endbell to the first side of the rear endbell, a first end of the stator lead encapsulated by the first encapsulation, a second end of the stator lead encapsulated by the second encapsulation and the stator lead passing through a seal in the stator lead passage in the rear endbell between the first and second encapsulations.

9. The motor of claim 1 , further comprising a bearing pocket formed in a front portion of the housing, wherein an encapsulation of the stator has an inner diameter that is smaller than the diameter of the bearing pocket.

10. The motor of claim 1 , further comprising at least one Hall magnet on a motor shaft supporting the rotor that is disposed on the first side of the rear endbell and hermetically isolated from the control module cavity.

11. The motor of claim 1 , further comprising a rear bearing disposed within the rear endbell on the first side of the rear endbell, and at least one motor rotation sensor located rearward of the rear bearing on the second side of the rear endbell in the control module cavity.

12. The motor of claim 1 , wherein the rear endbell has an exterior surface that is continuous with an exterior surface of the housing.

13. The motor of claim 1 , wherein the rear endbell includes a shoulder formed therein for engaging a wall of the housing.

14. The motor of claim 1 wherein the rear endbell defines a rotor end cap on the first side of the rear endbell having a first diameter and configured to receive one end of the rotor and a magnet on a motor shaft supporting the rotor and defines a bearing housing on the first side of the rear endbell forward of the rotor end cap having a second diameter greater than the first diameter and configured to receive a rear bearing supporting the rotor for rotation within the housing.

15. The motor of claim 1 wherein an outer wall of the rear endbell defines an arcuate recessed portion on the second side of the rear endbell axially aligned with a stator lead passage in the rear endbell and configured to receive a stator lead that extends from the control module through the stator lead passage in the rear endbell.

16. A method of making a motor for a surgical device comprising:

providing a motor housing having a housing wall defining a housing interior and an integrally formed front end bell;

arranging a stator within the housing interior;

securing a rear endbell to the housing, the rear endbell having a first side facing the housing interior and a second side, opposite the first side, defining a control module cavity in which a control module is hermetically sealed and isolated from the housing interior;

and

placing a rotor within the stator.

17. The method of claim 16 , further comprising the step of encapsulating the control module within the control module cavity on the second side of the rear endbell.

18. The method of claim 16 , further comprising the step of rotating the rear endbell relative to the housing to orient sensors within the control module cavity relative to the stator.

19. The method of claim 16 , further comprising the step of positioning a rear bearing within the rear endbell on the first side of the rear endbell and providing sensors in a location that is rearward of the rear bearing on the second side of the rear endbell in the control module cavity.

20. The method of claim 16 , further comprising the steps of aligning a fixture within the housing to align the stator, housing and rear endbell, and encapsulating the stator within the housing.