Highly articulated robotic probes and methods of production and use of such probes

• US 10,238,460 B2
• Filed: 12/31/2014
• Issued: 03/26/2019
• Est. Priority Date: 10/22/2010
• Status: Expired due to Fees

• Current Assignee: Endobotics, LLC
• Original Assignee: Medrobotics Corp.
• Inventors: Stand, Joseph A., Didomenico, Robert A., Zubiate, Brett, Darisse, Ian J., Flaherty, J. Christopher
• Primary Examiner(s): Kasztejna, Matthew J
• Application Number:
  US14/587,166
• Publication Number:
  US 20150313449A1
• Time in Patent Office: 1,546 Days
• Field of Search: 600139-142
• CPC Class Codes: A61B 1/0055 Constructional details of insertion parts, e.g. vertebral elements
• CPC Class Codes: A61B 1/0057 Constructional details of force transmission elements, e.g. control wires
• CPC Class Codes: A61B 1/018 for receiving instruments
• CPC Class Codes: A61B 2034/306 Wrists with multiple vertebrae
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms

Abstract

A highly articulated robotic probe comprises an outer sleeve and an inner core. The outer sleeve and inner core include a plurality of links. The links of the outer sleeve and inner core are configured to pivot relative to one another. Various characteristics of the links determine the overall pivot angle of the articulated probe. Each of the plurality of links may have one or more channels. The channels form a semi-continuous passage from link to link and are configured to receive an elongated member such as an inner core, tool or cable. One or more cables may be used to control the outer links of the outer sleeve and the inner links of the inner core. Various characteristics of the cables determine the overall performance of the articulated probe.

Claims

1. An articulated probe comprising:

a plurality of outer links configured to pivot relative to one another through a first maximum pivot angle; and

an elongated member,

wherein at least two of the plurality of outer links each includes an outer link first portion, an outer link second portion, and a first channel extending through the outer link first and second portions of the outer links,

wherein a first portion of the first channel in the outer link first portion of each of the at least two of the plurality of outer links is tapered in an amount that permits the plurality of outer links to pivot at the first maximum pivot angle while providing a substantially continuous surface between the first channels of the outer links, respectively,

wherein the first portion of the first channel of a first outer link of the at least two of the plurality of outer links is positioned in a second portion of the first channel in the outer link second portion of an adjacent second outer link so that an outer surface of the first outer link abuts the second portion of the first channel of the second outer link, and remains only in the second portion of the first channel at the first maximum pivot angle, and

wherein a greatest width of the tapered first portion of the first channel in the first outer link is greater than a width of an uppermost region of the second portion of the first channel in the second outer link to form a portion of the substantially continuous surface between the first channels of the first and second outer links, respectively, the articulated probe further comprising a plurality of inner links that are structurally different than the outer links and configured to pivot relative to one another through a second maximum pivot angle, the plurality of inner links each comprising a second channel for receiving an elongated member therein, wherein the second channel in each of the inner links is tapered in an amount that permits the inner links to pivot through the second maximum pivot angle while providing a substantially continuous surface between the second channels of the inner links,

wherein the second maximum pivot angle of the inner links is greater than the first maximum pivot angle of the outer links,

wherein only the outer links of the inner and outer links have outwardly extending flanges,

wherein the outer links include at least one distal outer link, and

wherein a width of the outwardly extending flange of the at least one distal outer link is greater than a width of outwardly extending flanges of other outer links of the outer links.

2. The articulated probe of claim 1, further comprising an inner core comprising the plurality of inner links.

3. The articulated probe of claim 1, further comprising an outer sleeve comprising the plurality of outer links, and wherein the first channel is positioned within at least two of the plurality of outer links.

4. The articulated probe of claim 1, wherein the at least two of the plurality of outer links comprises a side port and a channel is positioned within the side port.

5. The articulated probe of claim 1, wherein the first or second channel comprises a recess in the at least two of the plurality of outer links or inner links.

6. The articulated probe of claim 1, wherein an

angle of the tapered first portion of the first channel of the first outer link is approximately twice the first maximum pivot angle, and wherein an angle of the tapered second channel of the inner link is approximately twice the second maximum pivot angle.

7. The articulated probe of claim 6, wherein the angle of the tapered first portion of the first channel or the angle of the tapered second channel of the inner link is approximately 26 degrees and the first or second maximum pivot angle is approximately 13 degrees.

8. The articulated probe of claim 1, wherein a diameter of the elongated member is less than a diameter of the first or second channels.

9. The articulated probe of claim 1, wherein the elongated member includes at least one of a tool or a cable.

10. The articulated probe of claim 1, wherein the elongated member comprises another plurality of links that extend through at least one of the inner links or the outer links.

11. The articulated probe of claim 1, wherein the articulated probe has a probe central axis, and comprises:

an inner core having the plurality of inner links configured to pivot relative to one another and the probe central axis through an inner maximum pivot angle of the second maximum pivot angle; and

an outer sleeve having the plurality of outer links configured to pivot relative to one another and the probe central axis through an outer maximum pivot angle of the first maximum pivot angle,

wherein the inner maximum pivot angle is greater than the outer maximum pivot angle.

12. The articulated probe of claim 11, wherein the plurality of outer links in the outer sleeve includes:

a first outer link with a first central axis that aligns with the probe central axis, the first outer link including an outwardly extending first flange with a first engagement surface extending radially outward relative to the first central axis; and

a second outer link with a second central axis that can align with the probe central axis, the second outer link including an outwardly extending second flange with a second engagement surface extending radially outward relative to the second central axis,

wherein the first outer link and second outer link are configured to permit the first and second outer links to pivot relative to one another and the probe central axis at the outer maximum pivot angle until the first engagement surface engages the second engagement surface.

13. The articulated probe of claim 12, wherein the first engagement surface tapers relative to a line perpendicular to the first central axis.

14. The articulated probe of claim 12, wherein the second engagement surface tapers relative to a line perpendicular to the second central axis.

15. The articulated probe of claim 12, wherein the first engagement surface tapers approximately 6.5°

degrees relative to a line perpendicular to the first central axis and the second engagement surface tapers approximately 6.5°

degrees relative to a line perpendicular to the second central axis.

16. The articulated probe of claim 11, wherein the outer maximum pivot angle is no greater than approximately 13 degrees.

17. The articulated probe of claim 11, wherein at least one of the plurality of inner links or the plurality of outer links includes channels configured to receive an elongated member therein, wherein the channels are tapered in an amount that permits pivoting at the outer maximum pivot angle while providing a substantially continuous surface between the channels for the elongated member.

18. The articulated probe of claim 1, wherein the second outer link includes a third portion between the first and second portions of the first channel of the second outer link, wherein the first channel further extends through an inner sidewall of the third portion, and wherein the tapered first portion of the first outer link abuts the inner sidewall of the third portion to form the portion of the substantially continuous surface between the channels of the first and second outer links.

19. The articulated probe of claim 1, wherein the inner links have a concave portion, a convex portion, and a uniform linear sidewall extending from the concave portion to the convex portion.

20. An articulated probe with a probe central axis, comprising:

an inner core having a plurality of inner links configured to pivot relative to one another and the probe central axis through an inner maximum pivot angle, wherein the plurality of inner links comprise an inner link channel for receiving an elongated member therein, wherein the inner link channel in each of the inner links is tapered in an amount that permits the inner links to pivot through the inner maximum pivot angle while providing a substantially continuous surface between the inner link channels of the inner links; and

an outer sleeve having a plurality of outer links configured to pivot relative to one another and the probe central axis through an outer maximum pivot angle, wherein the inner links are structurally different than the outer links, wherein only the outer links of the inner and outer links include an outwardly extending flange;

wherein the inner maximum pivot angle of the inner links of the inner core is greater than the outer maximum pivot angle of the outer links of the outer sleeve, wherein at least two links of the outer links each includes a tapered first channel for receiving the inner links and that permits the at least one of the inner links or outer links to pivot at the inner maximum pivot angle or outer maximum pivot angle, respectively, while providing the substantially continuous surface between the tapered first channels of the at least two outer links,

wherein the at least two links of the outer links each includes a plurality of second channels peripheral to the first tapered channel,

wherein the outer links include at least one distal outer link, and

wherein a width of the outwardly extending flange of the at least one distal outer link is greater than a width of outwardly extending flanges of other outer links of the outer links.

21. The articulated probe of claim 20, wherein the plurality of outer links in the outer sleeve includes:

a first outer link with a first central axis that can align with the probe central axis, the first outer link including an outwardly extending first flange with a first engagement surface extending radically outward relative to the first central axis; and

a second outer link with a second central axis that can align with the probe central axis, the second outer link including an outwardly extending second flange with a second engagement surface extending radically outward relative to the second central axis,

wherein the first outer link and second outer link are configured to permit the first and second outer links to pivot relative to one another and the probe central axis at the outer maximum pivot angle until the first engagement surface engages the second engagement surface.

22. The articulated probe according to claim 21, wherein the first engagement surface tapers relative to a line perpendicular to the first central axis.

23. The articulated probe according to claim 21, wherein the second engagement surface tapers relative to a line perpendicular to the second central axis.

24. The articulated probe according to claim 21, wherein the first engagement surface tapers approximately 6.5°

degrees relative to a line perpendicular to

the first central axis and the second engagement surface tapers approximately 6.5°

degrees relative to a line perpendicular to the second central axis.

25. The articulated probe according to claim 20, wherein the outer maximum pivot angle is no greater than approximately 13 degrees.

26. The articulated probe according to claim 20, wherein the second channels are tapered in an amount that permits pivoting the outer maximum pivot angle while providing a substantially continuous surface between the second channels for the elongated member.

27. An articulated probe comprising:

a plurality of outer links configured to pivot relative to one another through a first maximum pivot angle; and

an elongated member,

wherein at least two of the plurality of outer links each includes an outer link first portion, an outer link second portion, and a first channel extending through the outer link first and second portions of the outer links,

wherein a first portion of the first channel in the outer link first portion of each of the at least two of the plurality of outer links is tapered in an amount that permits the plurality of outer links to pivot at the first maximum pivot angle while providing a substantially continuous surface between the first channels of the outer links, wherein the probe in an articulating state has a first radius of curvature relative to a central axis and a second radius of curvature relative to the central axis that is greater than the first radius of curvature, and wherein the substantially continuous surface includes the tapered first portions of the first channels of the outer links extending along the first radius of curvature, the articulated probe further comprising a plurality of inner links that are structurally different than the outer links and configured to pivot relative to one another through a second maximum pivot angle, the plurality of inner links comprising a second channel for receiving an elongated member therein,

wherein the second channel in each of the inner links is tapered in an amount that permits the inner links to pivot through the second maximum pivot angle while providing a substantially continuous surface between the second channels of the inner links,

wherein the second maximum pivot angle of the inner links is greater than the first maximum pivot angle of the outer links; and

wherein only the outer links of the inner and outer links have outwardly extending flanges of the outer link second portions,

wherein the outer links include at least one distal outer link, and

wherein a width of the outwardly extending flange of the at least one distal outer link is greater than a width of outwardly extending flanges of other outer links of the outer links.