Surgical instruments and switch assemblies thereof

1. A switch assembly for actuating functions of a hand-held surgical instrument, comprising:

a switch housing defining a channel therethrough, the switch housing defining a first longitudinal axis;

a first switch subassembly including:

a shaft disposed within the channel of the switch housing and having a proximal end portion and a distal end portion, the proximal end portion of the shaft including a magnet, the shaft being pivotable relative to the switch housing about a first pivot axis to actuate a first function of a surgical instrument and a second pivot axis to actuate a second function of the surgical instrument; and

a toggle button non-rotatably connected to the distal end portion of the shaft; and

a second switch subassembly including:

a safety bar extending through the switch housing, transverse to the first longitudinal axis, and being axially movable therein, the safety bar defining a second longitudinal axis and having a first end and a second end; and

a post extending through the safety bar, transversely thereto, such that movement of the safety bar along the second longitudinal axis moves the post between a firing position and a non-firing position.

2. The switch assembly according to claim 1 , wherein the first switch subassembly further includes:

an outer member disposed within the channel of the switch housing, the outer member being prevented from moving distally relative to the switch housing; and

an inner member non-rotatably disposed within the outer member, the shaft of the first switch subassembly extending through the outer and inner members, the outer and inner members defining a cavity therein having a substantially spherical configuration, wherein the proximal end portion of the shaft has a spherical portion disposed in the spherical cavity.

3. The switch assembly according to claim 2 , wherein the first switch subassembly further includes:

a first keyed member rotatably connected to the spherical portion of the shaft; and

a second keyed member rotatably connected to the spherical portion of the shaft such that the keyed members resist rotation of the shaft about a third longitudinal axis defined by the shaft.

4. The switch assembly according to claim 2 , wherein the first switch subassembly further includes:

a pivoting member having a cone-shaped proximal end in abutment with a concave face of the outer member; and

a biasing member disposed between the cone-shaped proximal end of the pivoting member and the toggle button to center the toggle button within the channel.

5. The switch assembly according to claim 1 , wherein a proximal end of the post of the second switch subassembly includes a magnet configured to communicate with a hall effect sensor of a surgical instrument.

6. The switch assembly according to claim 1 , further comprising a third switch subassembly including an annular switch rotatably disposed within the switch housing to actuate at least one function of a surgical instrument.

7. A handle assembly of a hand-held surgical instrument, comprising:

a handle housing;

a plurality of motors disposed within the handle housing;

a plurality of hall effect sensors disposed within the handle housing and in communication with the plurality of motors to actuate at least one of the plurality of motors; and

a switch assembly supported on the handle housing and including:

a switch housing defining a channel therethrough, the switch housing defining a first longitudinal axis;

a first switch subassembly including:

a shaft disposed within the channel of the switch housing and having a proximal end portion and a distal end portion, the proximal end portion including a magnet disposed adjacent a first hall effect sensor of the plurality of hall effect sensors, the shaft being pivotable relative to the switch housing about a first pivot axis to signal the first hall effect sensor to actuate a first function of a surgical instrument and a second pivot axis to signal a second hall effect sensor of the plurality of hall effect sensors to actuate a second function of the surgical instrument; and

a toggle button non-rotatably connected to the distal end portion of the shaft; and

a second switch subassembly including:

a safety bar extending through the switch housing, transverse to the first longitudinal axis, and being axially movable therein, the safety bar defining a second longitudinal axis and having a first end and a second end; and

a post extending through the safety bar, transversely thereto, the post having a proximal end including a magnet in communication with the second hall effect sensor such that movement of the safety bar along the second longitudinal axis moves the post between a firing position, in which a first motor of the plurality of motors is actuatable by the first switch subassembly, and a non-firing position, in which the first motor of the plurality of motors is prevented from actuation by the first switch subassembly.

8. The handle assembly according to claim 7 , wherein the first switch subassembly of the switch assembly further includes:

an outer member disposed within the channel of the switch housing, the outer member being prevented from moving distally relative to the switch housing; and

an inner member non-rotatably disposed within the outer member, the shaft of the first switch subassembly extending through the outer and inner members, the outer and inner members defining a cavity therein having a substantially spherical configuration, wherein the proximal end portion of the shaft has a spherical portion disposed in the spherical cavity.

9. The handle assembly according to claim 8 , wherein the first switch subassembly of the switch assembly further includes:

a first keyed member rotatably connected to the spherical portion of the shaft; and

a second keyed member rotatably connected to the spherical portion of the shaft such that the keyed members resist rotation of the shaft about a third longitudinal axis defined by the shaft.

10. The handle assembly according to claim 8 , wherein the first switch subassembly of the switch assembly further includes:

a pivoting member having a cone-shaped proximal end in abutment with a concave face of the outer member; and

a biasing member disposed between the cone-shaped proximal end of the pivoting member and the toggle button to center the toggle button within the channel.

11. The handle assembly according to claim 8 , wherein the switch assembly further includes a third switch subassembly including an annular switch rotatably disposed within the switch housing, the annular switch having a magnet in communication with a third hall effect sensor of the plurality of hall effect sensors to actuate a second motor of the plurality of motors.

12. The handle assembly according to claim 8 , further comprising a printed circuit board disposed within the handle housing and having the plurality of hall effect sensors arranged therealong.

13. The handle assembly according to claim 12 , further comprising a battery coupled to the printed circuit board and electrically coupled to the plurality of motors.

14. The handle assembly according to claim 12 , further comprising a battery removably received within the handle housing and electrically coupled to the plurality of motors.

15. The handle assembly according to claim 12 , further comprising an electrical cord electrically coupled to the plurality of motors.

16. The handle assembly according to claim 7 , wherein the handle housing includes:

a distal half-section having the switch assembly secured thereto; and

a proximal half-section pivotably connected to the distal half section, wherein the proximal half-section has at least a portion of the plurality of motors disposed therein.

17. A hand-held surgical instrument, comprising:

a handle assembly including:

a handle housing;

a plurality of motors disposed within the handle housing;

a plurality of hall effect sensors disposed within the handle housing and in communication with the plurality of motors to actuate at least one of the plurality of motors; and

a switch assembly supported on the handle housing and including:

a switch housing defining a channel therethrough, the switch housing defining a first longitudinal axis;

a first switch subassembly including:

a shaft disposed within the channel of the switch housing and having a proximal end portion and a distal end portion, the proximal end portion including a magnet disposed adjacent a first hall effect sensor of the plurality of hall effect sensors, the shaft being pivotable relative to the switch housing about a first pivot axis to signal the first hall effect sensor and a second pivot axis to signal a second hall effect sensor of the plurality of hall effect sensors to move an end effector; and

a toggle button non-rotatably connected to the distal end portion of the shaft; and

a second switch subassembly including:

a safety bar extending through the switch housing, transverse to the first longitudinal axis, and being axially movable therein, the safety bar defining a second longitudinal axis and having a first end and a second end; and

a post extending through the safety bar, transversely thereto, the post having a proximal end including a magnet in communication with the second hall effect sensor such that movement of the safety bar along the second longitudinal axis moves the post between a firing position, in which a first motor of the plurality of motors is actuatable by the first switch subassembly, and a non-firing position, in which the first motor is prevented from being actuated by the first switch subassembly; and

an adapter assembly including:

a proximal end having a plurality of rotatable shafts configured to be coupled to and driven by respective motors of the plurality of motors of the handle assembly; and

a distal end configured to be operatively coupled to the end effector.

18. The surgical instrument according to claim 17 , wherein the first switch subassembly of the switch assembly further includes:

an outer member disposed within the channel of the switch housing, the outer member being prevented from moving distally relative to the switch housing; and

an inner member non-rotatably disposed within the outer member, the shaft of the first switch subassembly extending through the outer and inner members, the outer and inner members defining a cavity therein having a substantially spherical configuration, wherein the proximal end portion of the second switch subassembly has a spherical portion disposed in the spherical cavity.

19. The surgical instrument according to claim 18 , wherein the first switch subassembly of the switch assembly further includes:

a first keyed member rotatably connected to the spherical portion of the shaft; and

a second keyed member rotatably connected to the spherical portion of the shaft such that the keyed members resist rotation of the shaft about a third longitudinal axis defined by the shaft.

20. The surgical instrument according to claim 18 , wherein the first switch subassembly of the switch assembly further includes:

a pivoting member having a cone-shaped proximal end in abutment with a concave face of the outer member; and

a biasing member disposed between the cone-shaped proximal end of the pivoting member and the toggle button to center the toggle button within the channel.

21. The surgical instrument according to claim 17 , wherein the switch assembly further includes a third switch subassembly including an annular switch rotatably disposed within the switch housing, the annular switch having a magnet in communication with a third hall effect sensor of the plurality of hall effect sensors to actuate a second motor of the plurality of motors.

22. The surgical instrument according to claim 17 , further comprising a printed circuit board disposed within the handle housing and having the plurality of hall effect sensors arranged therealong.

23. A switch assembly for actuating functions of a hand-held surgical instrument, comprising:

a switch housing defining a channel therethrough, the switch housing defining a first longitudinal axis;

a first switch subassembly including:

a shaft disposed within the channel of the switch housing and having a proximal end portion and a distal end portion, the shaft being pivotable relative to the switch housing about at least one pivot axis to actuate at least one function of a surgical instrument, the proximal end portion of the shaft including a magnet;

a toggle button non-rotatably connected to the distal end portion of the shaft;

an outer member disposed within the channel of the switch housing, the outer member being prevented from moving distally relative to the switch housing; and

an inner member non-rotatably disposed within the outer member, the shaft of the first switch subassembly extending through the outer and inner members, the outer and inner members defining a cavity therein having a substantially spherical configuration, wherein the proximal end portion of the shaft has a spherical portion disposed in the spherical cavity; and

a second switch subassembly including:

a safety bar extending through the switch housing, transverse to the first longitudinal axis, and being axially movable therein, the safety bar defining a second longitudinal axis and having a first end and a second end; and

a post extending through the safety bar, transversely thereto, such that movement of the safety bar along the second longitudinal axis moves the post between a firing position and a non-firing position.