Articulating surgical instruments and method of deploying the same

• US 10,016,187 B2
• Filed: 11/14/2016
• Issued: 07/10/2018
• Est. Priority Date: 05/20/2013
• Status: Expired due to Fees

• Current Assignee: Endobotics, LLC
• Original Assignee: Medrobotics Corp.
• Inventors: Castro, Michael Salvatore
• Primary Examiner(s): Houston, Elizabeth
• Assistant Examiner(s): GABR, MOHAMED GAMIL
• Application Number:
  US15/350,549
• Publication Number:
  US 20170119364A1
• Time in Patent Office: 603 Days
• CPC Class Codes: A61B 17/00234 for minimally invasive surgery A61B17/0218, A61B17/0469, A61B17/12013, A61B17/1285, A61B17/29, A61B17/320016 take precedence
• CPC Class Codes: A61B 17/29 Forceps for use in minimally invasive surgery
• CPC Class Codes: A61B 17/2909 Handles
• CPC Class Codes: A61B 18/1442 Probes having pivoting end effectors, e.g. forceps
• CPC Class Codes: A61B 18/1445 at the distal end of a shaft, e.g. forceps or scissors at the end of a rigid rod
• CPC Class Codes: A61B 2017/00314 Separate linked members
• CPC Class Codes: A61B 2017/00327 with actuating members moving in opposite directions
• CPC Class Codes: A61B 2017/291 the position of the handle being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2923 Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/2929 with a head rotatable about the longitudinal axis of the shaft
• CPC Class Codes: A61B 2017/2946 Locking means

Abstract

A surgical instrument comprises a steering mechanism. The steering mechanism comprises a handle at a proximal end of the surgical instrument. The handle includes a plurality of controls for controlling a movement of the surgical instrument. The steering mechanism also comprises a hub that rotatably mates with the handle and a housing positioned about the hub. The handle, the housing, and the hub communicate with each other to provide at least a first degree of freedom and a second degree of freedom. An articulation region is at a distal end of the surgical instrument. A movement of the steering mechanism handle in one and only one of the first or second degrees of freedom relative to at least one of the housing or the hub translates to a movement of the articulation region in a single plane of motion.

Claims

1. A surgical instrument comprising:

a steering mechanism, comprising;

a handle at a proximal end of the surgical instrument, the handle including a plurality of controls for controlling a movement of the surgical instrument;

a hub that rotatably mates with the handle;

a housing positioned about the hub, wherein the handle, the housing, and the hub communicate with each other to provide at least a first degree of freedom and a second degree of freedom, the surgical instrument further comprising an articulation region at a distal end of the surgical instrument, wherein a movement of the steering mechanism handle in one and only one of the first or second degrees of freedom relative to at least one of the housing or the hub translates to a movement of the articulation region in a single plane of motion; and

a U-joint comprising elements of the handle, the hub, and the housing, the U-joint providing the first and second degrees of freedom between a combination of the handle, the hub, and the housing; and

a plurality of steering cables between the housing and the articulation region, wherein articulation of the handle relative to the housing advances and retracts the plurality of steering cables, which move the articulation region in the single plane of motion or in multiple planes of motion, wherein the plurality of steering cables comprises;

first and second steering cables that extend from the hub to the articulation region, the first and second steering cables constructed and arranged to move the articulation region relative to a first axis about the single plane of motion when the handle articulates at the first degree of freedom relative to the housing; and

third and fourth steering cables that extend from the handle to the articulation region, the third and fourth steering cables constructed and arranged to move the articulation region about a second axis orthogonal to the first axis,

wherein the hub includes first and second cable pass-through holes and the handle includes first and second cable fastening locations, wherein the third and fourth steering cables extend through the first and second pass-through holes, respectively, and wherein proximal ends of the third and fourth steering cables are coupled to the handle.

2. The surgical instrument of claim 1, wherein the U-joint comprises a first hinge along the first axis, the first hinge providing the first degree of freedom between the handle and the housing about the first axis, a region of the housing and the hub in communication with each other at the first hinge.

3. The surgical instrument of claim 2, wherein the U-joint comprises a second hinge along the second axis orthogonal to the first axis, the second hinge providing the second degree of freedom between the hub and the handle about the second axis.

4. The surgical instrument of claim 1, wherein the instrument comprises an end effector coupled to the articulation region, and wherein an articulation of the handle in accordance with two degrees of freedom permits the articulation region to be manipulated to reach anywhere on a surface of at least a partial sphere.

5. The surgical instrument of claim 4, wherein the plurality of controls at the handle includes a ratcheting trigger for incrementally ratcheting the end effector at the distal end of the instrument.

6. The surgical instrument of claim 1, wherein the articulation region moves in the single plane of motion in response to a movement of at least one of the first or second steering cables in an axial direction between the handle and the articulation region.

7. The surgical instrument of claim 6, wherein the movement of the at least one of the first or second steering cables in the axial direction is in response to a movement by the handle relative to the housing at the first degree of freedom.

8. The surgical instrument of claim 1, wherein the hub includes third and fourth cable fastening locations that couple proximal ends of the first and second steering cables to the hub.

9. The surgical instrument of claim 1, wherein the articulation region moves in the single plane of motion in response to a movement of at least one of the third or fourth steering cables in an axial direction between the handle and the articulation region.

10. The surgical instrument of claim 9, wherein the movement of the at least one of the third or fourth steering cables in the axial direction is in response to a movement by the handle relative to the hub in the second degree of freedom orthogonal to the first degree of freedom.

11. The surgical instrument of claim 1, wherein the handle includes a cable tensioner that adjusts a tension of the third and fourth steering cables at proximal ends of the third and fourth steering cables.

12. The surgical instrument of claim 11, wherein the cable tensioner comprises a set screw movably positioned in a threaded socket in the handle, the set screw including an opening for receiving an end of at least one of the third or fourth steering cables, which is secured to the set screw.

13. The surgical instrument of claim 12, wherein the cable tensioner further comprising a tightening tool that adjusts the position of the set screw relative to the socket to achieve a desired tension of the at least one of the third or fourth steering cables.

14. The surgical instrument of claim 1, wherein the steering mechanism further comprises a ratchet mechanism, a gearing mechanism, a trigger assembly, and a translating assembly, wherein the ratchet mechanism is configured to maintain the translating assembly in a series of linear positions.

15. The surgical instrument of claim 1, further comprising an end effector coupled to the articulation region at the distal end of the surgical instrument.

16. The surgical instrument of claim 15, wherein the end effector includes a housing and at least one tool.

17. The surgical instrument of claim 16, wherein the at least one tool comprises at least one of:

a grasper;

a scissor;

a cutter;

a claw;

or a knife.

18. The surgical instrument of claim 16, wherein the at least one tool comprises at least one of:

an ablator, a drug delivery apparatus, a radiation source, an EKG electrode, a pressure sensor, a blood sensor, a camera, a magnet, a heating element, an energy delivery element, and a cryogenic element.

19. The surgical instrument of claim 16, further comprising a support element that extends along at least a portion of the instrument, through a central working channel of the articulation region, and terminates at the end effector housing.

20. A surgical instrument comprising:

a steering mechanism, comprising;

a handle at a proximal end of the surgical instrument, the handle including a plurality of controls for controlling a movement of the surgical instrument;

a hub that rotatably mates with the handle;

a housing positioned about the hub, wherein the handle, the housing, and the hub communicate with each other to provide at least a first degree of freedom and a second degree of freedom, the surgical instrument further comprising an articulation region at a distal end of the surgical instrument, wherein a movement of the steering mechanism handle in one and only one of the first or second degrees of freedom relative to at least one of the housing or the hub translates to a movement of the articulation region in a single plane of motion; and

a U-joint comprising elements of the handle, the hub, and the housing, the U-joint providing the first and second degrees of freedom between a combination of the handle, the hub, and the housing; and

a plurality of steering cables between the housing and the articulation region, wherein articulation of the handle relative to the housing advances and retracts the plurality of steering cables, which move the articulation region in the single plane of motion or in multiple planes of motion, wherein the plurality of steering cables comprises;

first and second steering cables that extend from the hub to the articulation region, the first and second steering cables constructed and arranged to move the articulation region relative to a first axis about the single plane of motion when the handle articulates at the first degree of freedom relative to the housing; and

third and fourth steering cables that extend from the handle to the articulation region, the third and fourth steering cables constructed and arranged to move the articulation region about a second axis orthogonal to the first axis,

wherein the handle includes a cable tensioner that adjusts a tension of the steering cables at proximal ends of the steering cables, and wherein the cable tensioner comprises a first set screw movably positioned in a threaded socket in the hub, the first set screw including an opening for receiving an end of at least one of the first or second steering cables, which is secured to the first set screw in the hub, and wherein the cable tensioner comprises a second set screw movably positioned in a threaded socket in the handle, the second set screw including an opening for receiving an end of at least one of the third or fourth steering cables in the handle.

21. The surgical instrument of claim 20, wherein the cable tensioner further comprises a tightening tool that adjusts the position of the first or second set screw relative to the threaded socket in the hub or handle to achieve a desired tension of at least one of the steering cables.