Surgical attachment instrument and method

A surgical instrument comprising:

• a housing sized and shaped to be coupled to a motor;
• a tubular member coupled to the housing so that a distal portion of the tubular member extends from the housing a predetermined distance, the tubular member extending generally along a longitudinal axis and comprising:
• a first positioning detent formed in an outer surface of the tubular member;
• a second positioning detent formed in the outer surface of the tubular member and spaced along the longitudinal axis from the first positioning detent;
• a positioning channel formed in the outer surface of the tubular member and extending between the first and second positioning detents;
• a first locking detent formed in the outer surface of the tubular member and substantially aligned with the first positioning detent;
• a second locking detent formed in the outer surface of the tubular member and substantially aligned with the second positioning detent;
• a first locking channel extending between the first positioning detent and the first locking detent in a direction substantially transverse to the longitudinal axis;
• and
• a second locking channel extending between the second positioning detent and the second locking detent in a direction substantially transverse to the longitudinal axis;
• and
• a coupling connecting the tubular member to the housing, the coupling comprising:
• a bore extending along its length and receiving a proximal portion tubular member;
• an opening extending from an outer surface of the coupling to the bore in a direction substantially transverse to the bore;
• a ball extending at least partially through the opening and engaging at least one of first and second positioning detents;
• and
• a spring engaged with the ball for applying an inwardly-directed radial force to the ball;
• wherein the ball is movable between the first and second positioning detents to adjust the predetermined distance that the tubular member extends from the housing between a first predetermined distance associated with the first positioning detent and a second predetermined distance associated with the second detent, and wherein application of a longitudinally-directed force to the tubular member overcomes the inwardly-directed radial force so that the ball disengages from one of the first and second positioning detents and engages the positioning channel and wherein continued application of the longitudinally-directed force causes the ball to travel along the positioning channel and engage the other of the first and second positioning detents.

A method of assembling a surgical attachment instrument, comprising:

• obtaining a housing adapted to be coupled to a motor;
• obtaining a tubular member comprising at least two positioning detents formed in an outer surface of the tubular member and longitudinally spaced along the tubular member at a fixed interval, the tubular member further comprising a positioning channel formed in the outer surface of the tubular member and extending between the at least two positioning detents;
• coupling the tubular member to the housing with a coupling element so that a distal end portion of the tubular member extends from the housing, the coupling element comprising a through-opening with a ball extending at least partially through the through-opening and a spring engaged with the housing and the ball for applying an inwardly-directed radial force to the ball, wherein coupling the tubular member to the housing comprises engaging the ball with one of the at least two positioning detents;
• and
• selectively adjusting how far the distal end portion of the tubular member extends from the housing by applying a longitudinally-directed force to overcome the inwardly-directed radial force so that the ball disengages from the one of the two positioning detents and engages the positioning channel during the longitudinal movement of the tubular member and wherein continued application of the longitudinally-directed force causes the ball to travel along the positioning channel and engage the other of the at least two positioning detents.

A method of assembling a surgical attachment instrument comprising:

• providing a housing sized and shaped to be coupled to a motor, the housing comprising an inner surface defining a bore, the inner surface having a recess formed therein;
• providing a coupling element having an external threaded portion and a groove;
• positioning an arcuate member around an outer portion of a coupling element such that an inner projection of the arcuate member engages the groove of the coupling element;
• and
• threadingly engaging the coupling element with the housing such that, as the coupling element advances longitudinally into the bore of the housing, a portion of the arcuate member is forcibly deformed into the recess of housing, the engagement between the deformed portion of the arcuate member and the recess resisting disengagement of the coupling element from the housing.